Proklima,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, User manual

Proklima International
Good Practices in Refrigeration
Proklima International
Good Practices in Refrigeration
Published by
Deutsche Gesellschaft für
Internationale Zusammenarbeit (GIZ) GmbH
Registered Offices
Bonn and Eschborn
Proklima
Dag-Hammarskjöld-Weg 1-5
65760 Eschborn, Germany
Telephone: +49 6196 79-1022
Fax: +49 6196 79-80 1022
www.giz.de/proklima
[email protected]
Programm manager: Bernhard Siegele,
[email protected]
On behalf of
Federal Ministry for Economic Cooperation and Development (BMZ)
Environment and Sustainable Use of Natural Resources Division
Dahlmannstr. 4
53113 Bonn, Germany
Telephone: +49 228 99 535-0
Fax: +49 228 99 535-3500
www.bmz.de
Editors
Dr. Volkmar Hasse, GIZ, [email protected]
Linda Ederberg, Proklima, [email protected]
Rebecca Kirch, Proklima
Design
Bloomoon – Silke Rabung; Revision: Jeanette Geppert, Frankfurt
Typesetting
Jeanette Geppert, Frankfurt
Print
Wolf, Ingelheim
1st edition: Eschborn, March/April 2010
Reprint: Eschborn, September 2012
Note: Except for the company details on this page and on the following page, this book is an unmodified reprint of the 2010 edition published by GTZ Proklima.
Since 1 January 2011, GIZ has brought together under one roof the capacities and long-standing experience of three organisations: the Deutscher Entwicklungsdienst (DED) GmbH (German Development
Service), the Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH (German technical
cooperation) and InWEnt – Capacity Building International, Germany. As a federal enterprise, we support
the German Government in achieving its objectives in the field of international cooperation for sustainable development. We are also engaged in international education work around the globe. GIZ operates
in more than 130 countries worldwide.
PROKLIMA is a programme of the Deutsche Gesellschaft für Internationale
Zusammenarbeit (GIZ) GmbH, commissioned by the German Federal
Ministry for Economic Cooperation and Development (BMZ). PROKLIMA has
been providing technical and financial support for developing countries since
1996 to implement the provisions of the Montreal Protocol on Substances
that Deplete the Ozone Layer.
Preface ....................................................................... 1
Part I
TOOLS AND EQUIPMENT
Introduction to Part I .................................................. 3
Chapter
Chapter
Chapter
Chapter
Part II
1: Tools for Tubing (TT) ............................. 5
2: Tools for Refrigerant Handling
and Containment (RHC)...................... 18
3: Equipment for Recovery, Recycling,
Reclamation and Evacuation (RRRE).... 32
4: Measuring Instruments (MI) ................. 41
SKILLS AND OPERATION
Introduction to Part II ............................................... 53
Chapter 5: Assembling a Refrigeration System ..... 55
Chapter 6: Bending, the Process .......................... 77
Chapter 7: Brazing, the Process ........................... 81
Chapter 8: Flaring, the Process ............................ 90
Chapter 9: Domestic Refrigeration ....................... 95
Chapter 10: Domestic Refrigeration HC ................. 104
Chapter 11: Pressing, the Process ..........................121
Chapter 12: Refrigerant, Recovery, Recycling
and Containment in the Field ............ 129
Chapter 13: Retrofit ............................................. 148
Chapter 14: Safety ...............................................164
Annex
Glossary ..................................................................170
Acronyms and Abbreviations ................................... 175
Index ......................................................................176
CONTENT
Good Practices in Refrigeration
Acknowledgements
We thank the author Rolf Huehren for his thorough compilation and detailed demonstration of
how to service and maintain refrigeration systems and Daniel Colbourne for technical advice.
Furthermore, we thank the following companies for their kind provision of picture material:
Agramkow Fluid Systems A/S and RTI Technologies Inc., Appion Inc., Peter M. Börsch KG,
Danfoss GmbH, Fluke Deutschland GmbH, GEA Kueba GmbH, Harris Calorific GmbH, IKET –
Institut für Kälte-, Klima- und Energietechnik GmbH, ITE N.V., Ixkes Industrieverpackung e.K.,
Manchester Tank, Mastercool Europe, Moeller GmbH, Ntron Ltd., Panimex, Parker Hannifin GmbH
& Co. KG, Perkeo-Werk GmbH & Co. KG, Refco Manufacturing Ltd., Rotarex, Sanwa Tsusho Co.
Ltd., Georg Schmerler GmbH & Co. KG, Testboy GmbH, Van Steenburgh Engineering Labs Inc.,
Vulkan Lokring Rohrverbindungen GmbH & Co. KG, Worthington Cylinders.
Volkmar Hasse, Linda Ederberg and Rebecca Kirch
Preface
The phase-out of HCFCs and the introduction of various alternative refrigerants confronts both
the servicing technicians and vocational trainers in the refrigeration and air-conditioning sector
with specific problems. Refrigeration technicians are not yet sufficiently prepared to deal with
the new technologies which will have to be introduced in the near future.
The manual ‘GOOD PRACTICES IN REFRIGERATION’ is the second edition of a booklet jointly
published by the PROKLIMA Programme of the ‘Deutsche Gesellschaft für Technische
Zusammenarbeit’ (GTZ) GmbH, the Brazilian ‘Servico Nacional de Aprendizagem Industrial’ (SENAI)
and the ‘Ministério do Meio Ambiente do Brazil’ (MMA) in 2004, which had been widely used as
part of the training courses on ‘Best practices in refrigeration servicing and CFC conservation’,
which were implemented by PROKLIMA as part of the national CFC phase-out plan in Brazil.
This manual has now been updated to provide professional guidance on how to service and
maintain refrigeration systems operating with new technology, e.g. ozone-friendly alternative
refrigerants to CFCs and HCFCs. It addresses essential know-how on containment of HFC refrigerants which have a high Global Warming Potential (GWP) and are already widely applied. It
also provides extensive information on the safe use of natural refrigerants, such as CO2, Ammonia
or Hydrocarbons, which are much more environmentally-friendly with zero or negligible GWP.These
efficient but still relatively little used refrigerants are in fact suitable replacements for HCFCs in
all applications of refrigeration and air-conditioning equipment.
Part I of this picture book addresses important tools and equipment for tubing; refrigerant handling and containment; for recovery, recycling, reclamation and evacuation, as well as measuring
instruments. Part II focuses on the handling of servicing and maintenance of refrigeration systems,
such as brazing, flaring, recovery, retrofit and recycling.
Illustrations should help the technicians to easily remember, identify and communicate elements
of best practices in refrigeration.
1
Background
Ozone depletion and Montreal Protocol
In the 1970s, scientists discovered the dangerous impact CFCs have in the earth’s atmosphere.
CFCs were used as foam blowing agents, refrigerants and solvents. It was found that they destroy
the ozone layer, so that aggressive UV-B radiation can reach directly the Earth’s surface causing
genetic damage in the cells of people, plants and animals. Therefore, in 1987, an international
treaty was concluded at Montreal, Canada (the so called Montreal Protocol on Substances that
Deplete the Ozone Layer), to prevent the ozone layer from further destruction and begin the phaseout of the use of CFCs and other ozone-depleting substances (ODS). Until November 2009, all
states worldwide had signed the Protocol.They have worked effectively and successfully towards
a substitution of CFCs which have been banned since1 January 2010. In 2007, the treaty was
adjusted to address the phase-out of HCFCs which are the last group of ODS. The refrigeration
and air-conditioning sector, especially in many Article-5 countries, uses very large quantities of
HCFCs and is therefore particularly relevant in the imminent HCFC phase-out.
2
Part I
INTRODUCTION TO PART I
TOOLS AND EQUIPMENT
Part I Tools and Equipment
Introduction to Part I
Proper and environmentally responsible servicing and maintenance of refrigeration systems requires special equipment, e.g. instruments for refrigerant
leak detection, tools to measure gas pressure and temperature, as well as
special equipment for the general handling and recycling of refrigerants.
The following chapters review various kinds of tools and equipment needed
in modern workshops when working on refrigeration and air-conditioning
systems.
3
Part I
4
Part I
TOOLS FOR TUBING (TT)
TOOLS AND EQUIPMENT
Chapter 1: Tools for Tubing
Preface
In the following chapter we will describe tools and equipment for the handling of tubing.
Tools for Tubing
Figure 1: Tube cutter (wheel cutter)
Cuts copper, brass and aluminium tubing
Cutter for 6 to 35 mm tubes diameter
Cutter for 3 to 16 mm tubes diameter
Figure 2: Capillary tube cutter
For cutting capillary tubes without collapsing the tubes inside diameter
Cuts all sizes of capillary tubes
5
TOOLS FOR TUBING (TT)
Part I
TOOLS AND EQUIPMENT
Figure 3: Reamer and deburrer
Inner and outer reamer for copper tubing burr removal
Inner-outer reamer for copper tubing
Handy deburrer, blade can be swivelled
Figure 4: Scouring pad and brush
Inner and outer cleaning and finishing with a
6
Plastic scouring pad
Fitting brush
Part I
TOOLS FOR TUBING (TT)
TOOLS AND EQUIPMENT
Figure 5: Steel brush
Outside cleaning of copper, steel, brass, aluminium tubes
Steel wires
Figure 6: Pinch-off plier
Pinches off copper tubes up to 12 mm diameter
7
TOOLS AND EQUIPMENT
TOOLS FOR TUBING (TT)
Part I
Figure 7: Extended copper tube with access valve (Schrader)
8
Straight solder with tube and service valve 1/4“ male flare SAE
Valve core
If improperly installed a potential refrigerant leak source!
Not recommended for Hydrocarbon applications!
Part I
TOOLS FOR TUBING (TT)
TOOLS AND EQUIPMENT
Figure 8: Quick couplers ‘Hansen’
Assembly of quick coupler from tube to refrigerant hose
Clamps directly on straight tubes with diameter from 2 to 10 mm
Same as , but for screwing
Working pressure from 13 mbar to 45 bar
9
TOOLS FOR TUBING (TT)
Part I
TOOLS AND EQUIPMENT
ø6mm
ø6mm
ø2mm
Figure 9: Press system components for tubing
Tool set with fittings, connectors and adapters
Straight copper tube press connector
Elbow press connector
Press connector for suction pipe with capillary tube (domestic)
Figure 10: Telescope inspection mirror
Visual inspection of brazing joints
10
TOOLS AND EQUIPMENT
TOOLS FOR TUBING (TT)
Part I
Figure 11: Flaring tool
Faceted flaring bar (holding tool) 6-8-10-12-15 and 16 mm (or inch size)
with flaring cone
Iris-diaphragm flaring bar (holding tool) 5 to 16 mm with flaring cone
Clamp tool with flaring cone
Flaring bars to admit tubes with different diameter
Figure 12: Tube bender
Swivel handle tube bender for one specific tube size (available from 6 to 18 mm
or inch sizes)
Triple head tube bender for tubes 6, 8 and 10 mm (or inch sizes)
Mechanical tube bender assembly with shoes and counter formers (different sizes)
11
TOOLS AND EQUIPMENT
TOOLS FOR TUBING (TT)
Part I
Figure 13: Tube expander
12
Tube expander for annealed copper with replaceable
expanding heads (10 to 42 mm or inch sizes)
Example of an expanded copper tube
Expander and headset
Part I
TOOLS FOR TUBING (TT)
TOOLS AND EQUIPMENT
Figure 14: Brazing equipment
Propane/Oxygen brazing unit
Oxygen pressure regulator with hose assembly
Propane (only) brazing unit
Acetylene (only) brazing unit
Acetylene pressure regulator with hose assembly
Burner (torch)
Figure 15: Torch (burner) and tips for Propane-Oxygen
Brazing of copper, brass and aluminium tubing
Torch handle with gas regulators
Twin-flame fork torch
Torch attachments different sizes with tips made of hard copper
13
TOOLS AND EQUIPMENT
TOOLS FOR TUBING (TT)
Part I
Figure 16: Lighters
Igniter with spark flint (binder form)
Igniter with spark flint and tips cleaner (binder form)
Igniter with spark flint (pistol form)
‘Cigarette’-lighters are dangerous to use
with brazing equipment
Figure 17: Example of fittings
Various design and diameter
Material: brass or copper
14
Rod
CP 203
CP 105
AO 106
AO 104
AO 203
Cu
Ag
Zn
Sn
P
Rest
Rest
35–37
26–28
29–31
–
1.5–2.5
33–35
44–46
43–45
–
–
Rest
Rest
Rest
–
–
2.5–3.5
2.5–3.5
–
5.9–6.5
5.9–6.7
–
–
–
Melting
Range °C
710–890
645–825
630–730
640–680
675–735
Part I
TOOLS FOR TUBING (TT)
TOOLS AND EQUIPMENT
Figure 18: Brazing rods examples (solder)
Recommended (solder) for copper/copper brazing
Recommended (solder) for copper/brass brazing
Figure 19: Nitrogen cylinder
Nitrogen cylinder
Nitrogen pressure regulator
Nitrogen transfer hose with 1/4” female flare SAE connection
15
TOOLS AND EQUIPMENT
TOOLS FOR TUBING (TT)
Part I
Figure 20: Cylinder and accessories for technical gases
16
Cylinder various sizes
Cylinder valve with safety valve
Standard guards (tulip shaped)
Standard guard (open-closed shaped)
Part I
TOOLS FOR TUBING (TT)
TOOLS AND EQUIPMENT
Figure 21: Fire extinguisher
Powder – 2 kg
17
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Chapter 2: Tools for Refrigerant Handling and
Containment (RHC)
Preface
For the measurements of refrigeration or AC operation pressures and temperatures, for the
purpose of refrigerant transfer and for system evacuation, a service gauge manifold is used.
In the following we would like to describe different gauges and gauge sets and important
tools for refrigerant handling and containment.
The Service Gauge Manifold
Figure 1: The pressure gauge
18
The pressure gauge body with
transparent removal protection cap
Scale with graduation
Temperature scale (in °F or °C)
Pressure scale (in bar, PSI, kPa…)
Pointer
Calibration screw
Refrigerant indication
Brass connection with thread
We have three different pressure gauges!
• The low pressure gauge
• The high pressure gauge
• The vacuum gauge
For easy handling the pressure (low/high) gauges are assembled together with a brass or
aluminium body and valves.
We differentiate 2, 3, 4 and 5-valve service gauge manifold sets.
Schematic view
of the above 4-valve
service gauge manifold
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
Figure 2: Example of a 4-valve service gauge manifold
Support bar
Manifold body
Sight glass for refrigerant flow
Low pressure valve
Vacuum pump valve
High pressure valve
Valve connection for
charging cylinder or recovery unit
Hose connection 1/4”male flare SAE
Vacuum hose connection 1/4” and 3/8”
19
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Figure 3: Manifold gauge set for HC refrigerant R600a
Low pressure gauge for refrigerant HC-R600a
Vacuum gauge
Support bar
Valves
Sight glass for refrigerant flow
A perfect service gauge manifold set should have a vacuum gauge
Vacuum gauges are installed regularly at a 4 or 5-valve service gauge manifold
20
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
Figure 4: The vacuum gauge
5-valve service gauge manifold with vacuum gauge
Relative vacuum pressure gauge – measuring range 0 to 1000 mbar
Maximum reading pointer (adjustable)
Calibration screw
Pressure scale
Absolute vacuum pressure gauge – measuring range 0 to150 mbar
21
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Figure 5: Refrigerant transfer hoses and accessories
22
Refrigerant standard hose with 2 x 1/4” SAE female flare connection
Adjustable and replaceable core-depressor (valve opener) ‘schematic’
Refrigerant hose with inline ball valve, 2 x 1/4” SAE female flare connection
Refrigerant hose with ‘end-mounted’ ball valve for minimal refrigerant emission
Ball valve adapter for standard hose 1/4” SAE male/female connection
Vacuum hose 2 x 3/8” female flare SAE connection
Ball valve - 1/4” SAE male x 1/4” SAE female
Spare gaskets and core-depressors
Figure 6: Service port quick coupler
Straight coupler for refrigerant hose 1/4” SAE flare male x 1/4” SAE flare female
Elbow coupler for refrigerant hose 1/4” SAE flare male x 1/4” SAE flare female
Core-depressor (valve opener)
A
B
C
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
D
Figure 7: Core removal tools
Easy and quick core removal without refrigerant emission
Valve
Magnetic core holder
23
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Figure 8: Core valve removal tool
For removing and replacing valve cores in ‘Schrader’-valves and charging hoses
Tools contain spare valve cores
Figure 9: Piercing plier (adjustable)
Enables immediate piercing/access on any refrigerant tubing from 5 to 22 mm
24
Piercing plier for different diameter/with hand operated valve
Piercing plier/adjustable
Spare needle
Figure 10: Piercing valve
Enables piercing/access to any refrigerant tubing from 5 to 16 mm
ONLY for temporary system installation
otherwise a potential refrigerant leak source!
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
Figure 11: Charging hose and cylinder connectors
Can valve/extracting of refrigerants out of small disposable refrigerant cylinders
21.8 mm adapter and gasket for connecting a charging hose with 1/4” SAE thread
Stand for liquid charge, disposable cylinder connection to ensure a firm standing
of the cylinder on the charging scale
25
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Figure 12: Automotive (MAC) manual quick service couplers for HFC-134a
26
Low pressure service valve 1/4” male flare x 13 mm quick coupler
Low pressure service quick coupler 14 mm female x 13 mm quick coupler
High pressure service valve 1/4” male flare x 16 mm quick coupler
High pressure service valve quick coupler 14 mm female x 16 mm quick coupler
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
Figure 13: Refrigerant recovery cylinder
Refrigerant recovery cylinder DOT standard (US) without OFP (overfill protection)
Liquid level float switch for recovery unit connection (cylinder installation kit)
Refrigerant recovery cylinder DOT standard (US) with OFP (overfill protection)
Refrigerant recovery cylinder EN standard (Europe) according ADR regulation
(Transport of dangerous goods on roads)
Virtual cylinder cut
Liquid/vapour valve (double valve) with internal safety valve
Transfer line for gaseous refrigerant
Transfer line for liquid refrigerant (dip-tube)
27
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Figure 14: Heating belt with thermostat
Speeds up refrigerant recharge time
Enables efficient refrigerant discharge
Working temperature 55°C/125°F – 300 W capacity
Figure 15: Refrigerant and oil contamination test kit
‘Checkmate’ test kit for field use
Quick and accurate determination of contaminant levels in oil and refrigerant
28
Figure 16: Oil test kit for mineral and alkylbenzene lubricant
The test kit is a single bottle test kit designed to give visual indication as to the acid
content of both mineral and alkylbenzene lubricants. Simply place a sample of oil in the
bottle, shake and look at the colour. If it remains purple, the oil is safe. If it turns orange,
the oil is marginal and steps may need to be taken. If it turns yellow, the oil is acidic and
needs to be changed or other steps need to be taken. Always read the manufacturer’s
instructions before use.
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
Figure 17: Oil test kit for polyol ester (POE) lubricants
The test kit is a single bottle test kit designed to give visual indication as to the acid
content of polyol ester (POE) lubricants. Simply place a sample of oil in the bottle, shake
and look at the colour. If it remains purple, the oil is safe. If it turns orange, the oil is
marginal and steps may need to be taken. If it turns yellow, the oil is acidic and needs to
be changed or other steps need to be taken. Always read the manufacturer’s instructions before use.
29
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
Part I
TOOLS AND EQUIPMENT
Figure 18: Retrofit test kit
The retrofit process requires the removal of mineral based oil and replacement with
polyol ester based lubricants.
When this is required, it is necessary to reduce the mineral based oils to acceptable levels
to assure proper system operation.
The RTK (retrofit test kit) provides a simple method of determining the level of residual
mineral oil in a system. It is ideal for field use as it provides a visual indication of three
levels of mineral oil concentration: Greater than 5%, between 1% and 5% and equal to
or less than 1%. Always read the manufacturer’s instructions before use.
Figure 19: Refractometer
A precise optical instrument that allows the rapid and accurate determination of the
refractive index of liquid solutions. It will specifically assist in determining the percentage
of residual oil remaining in a refrigeration system when converting it to a new refrigeration oil.
30
Figure 20: Oil pump
Part I
TOOLS FOR REFRIGERANT HANDLING AND CONTAINMENT (RHC)
TOOLS AND EQUIPMENT
Suction connection
Suction hose
Pump outlet with hose connection 1/4“ SAE
Hand pump body
31
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
Part I
32
TOOLS AND EQUIPMENT
Chapter 3: Equipment for Recovery, Recycling,
Reclamation and Evacuation (RRRE)
Preface
The following chapter gives an overview about important equipment used in the field of
recovery, recycling, reclamation and evacuation of refrigeration systems.
Recovery Equipment
Figure 1: Refrigerant recovery unit
Recovery unit ‘oil less’ for commercial refrigeration and air-conditioning
Condenser and ventilator
High and low pressure gauges
Refrigerant inlet and outlet valves
Inline filter-drier
Recovery unit ‘oil based’ for small
commercial, AC and domestic
Access cord for overfill protection (OFP)
Recovery cylinder
Recovery unit ‘oil less’ for all
refrigerants including CFC-R11
+
+
Figure 2: Refrigerant recovery and recycling unit
Recovery unit ‘oil less’ for commercial
refrigeration and air-conditioning
equipped with connective facilities
for refrigerant recycling
Refrigerant cleaning module for
recovery unit
Oil separator with oil drainage valve
Filter-drier with sight glass
Recovery unit ‘oil based’ for small
commercial, AC and domestic
Refrigerant cleaning module for
recovery unit
Cleaning module for all recovery units
Oil separator with oil drainage valve
Manifold gauge set with high and low
pressure gauges
Filter-drier with sight glass
Part I
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
TOOLS AND EQUIPMENT
33
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
Part I
34
TOOLS AND EQUIPMENT
Figure 3: Recovery, recycling, evacuation and charging unit
Semiautomatic unit for refrigerant
recycling and MAC application
Dual recycling MAC unit (for two
different refrigerants use)
Internal and external high and low
pressure gauges with hoses and
quick couplers
Internal and external refrigerant
cylinder with OFP and heating device
Automatic refrigerant service station
for MAC, truck and bus
Automatic refrigerant service station
for MAC
Semiautomatic service unit for
MAC, commercial etc.
Figure 4: Refrigerant reclaim machine
Refrigerant reclaim machine for high refrigerant processing capacity and purity results
High and low pressure gauges
Control board with refrigerant selector handles up to three different refrigerants
Refrigerant reclaim machine small sized
Figure 5: Refrigerant recovery bag
Recovery bag for refrigerant CFC-R12 and/or HFC-R134a,
refrigerant capacity up to 250 gr (R12) and 200 gr (R134a),
maximum working temperature 60°C,
maximum overpressure 0.1 bar
Accessories (hose and piercing pliers)
Part I
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
TOOLS AND EQUIPMENT
35
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
Part I
36
TOOLS AND EQUIPMENT
Figure 6: Refrigerant recovery hand pump
Recovery hand pump with handle,
maximum overpressure 15 bar, piston
stroke 20/300 mm, output at
frequency with 30 strokes/min and
constant suction pressure of 5 bar
0.14 kg/min vapour and 0.8 kg/min
liquid, weight 1.9 kg, for using with
CFC-R12 and HFC-R134a
Pump body with piston
Inlet pressure suction gauge
In- and outlet port connection
1/4” SAE male
Inline filter-drier size 032
Refrigerant transfer hose with
ball valve for 1/4” SAE female
Figure 7: Vacuum pump
Double stage vacuum pump 40 L/min (1.44 CFM) to 280 L/min (9.64 CFM),
ultimate vacuum down to 0.16 mbar (12 micron), gas-balast valve equipped
Solenoid valve
Handle with exhaust of purged air
Vacuum gauge (relative)
Oil level sight glass
Oil mist filter
3/8” hose connection
Vacuum pump 198 L/min (7 CFM)
Vacuum pump oil container (different sizes)
Part I
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
TOOLS AND EQUIPMENT
37
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
Part I
38
TOOLS AND EQUIPMENT
Charging Equipment
Figure 8: Refrigerant charging and evacuation unit
Vacuum pump (double stage) with vacuum gauge
Manifold gauge set with high/low pressure gauge
Thermometer for charging cylinder
Charging cylinder with refrigerant scale and graduation
Figure 9: HC-R600a and HFC-R134a charging and evacuation unit
Vacuum pump (double stage)
Manifold gauge set with R600a / R134a low pressure gauges and vacuum gauge
Electronic charging scale
Refrigerant can support
Figure 10: Metric refrigerant charging cylinder
Thermometer or pressure gauge for refrigerant temperature/
pressure indication
Valves for liquid/gas
Transparent scale with refrigerant graduation
Internal refrigerant cylinder
Refrigerant level indication glass pipe
Charging cylinder stand with refrigerant heater element
Figure 11: Charging arrangement for HCs
HC refrigerant drainage hose (min. 5 m long)
Refrigerant container for HCs 450 gr
Charging hose with adapters and valves
Electronic charging scale
Part I
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
TOOLS AND EQUIPMENT
39
EQUIPMENT FOR RECOVERY, RECYCLING, RECLAMATION AND EVACUATION (RRRE)
Part I
40
TOOLS AND EQUIPMENT
Figure 12: Compressor lubricant charging/draining cup
1/4” female
SAE connection
Valve
Charging graduation oz/ml
PVC bottle
Figure 13: Non-condensable gases (NCGs) remover
Indicates and removes e.g. excess air (NCG) from refrigerant
(CFC-R12 and HFC-R134a) containing cylinders
Chapter 4: Measuring Instruments (MI)
Preface
The following chapter will describe several instruments for the identification of leaks in
refrigeration systems and different measuring tools for refrigerant charging, electrical values
measurement and compressor capacity test. In addition, we like to present instruments for
refrigerant identification and vacuum control.
Leak Detecting Instruments
Part I
MEASURING INSTRUMENTS (MI)
TOOLS AND EQUIPMENT
Figure 1: Electronic leak detector
Detects all halogenated refrigerants. Points leaks as small as 3 gr per year.
Variable frequency audible alarm. Visual leak indication.
Mechanical pump and flexible metal probe.
Flexible metal probe with sensor
Keypad
Additional spot lighting
41
TOOLS AND EQUIPMENT
MEASURING INSTRUMENTS (MI)
Part I
Figure 2: Electronic leak detector for HC refrigerants
Sensitivity less than 50 ppm (Propane, Iso-Butane, Methane)
Flexible metal probe with sensor
Keypad
Figure 3: Halide leak detector (banned use in EU)
Portable halide leak detector kit Propane operated
42
Propane cylinder, valve and flame head
Sniffle hose
Blue flame (no refrigerant detection)
Green flame (refrigerant detection)
Part I
MEASURING INSTRUMENTS (MI)
TOOLS AND EQUIPMENT
Figure 4: UV leak detector
Transportable ultra violet (UV) leak detection kit indicates leaks about 3.5 gr per year
for all common refrigerants in AC and refrigeration systems
High intensity UV/blue lamp (100 Watt)
Dye for refrigerant cycle injection
Fluorescence enhancing glasses
Hose with adapter and connections
Injection pump
Figure 5: Leak detection spray
Non-corrosive, high viscosity and non-freezing leak detector spray
43
MEASURING INSTRUMENTS (MI)
Part I
TOOLS AND EQUIPMENT
Measuring Instruments
Figure 6: Refrigerant identifier
Infrared refrigerant identifier determining weight concentration of:
A) CFC-R12, HFC-R134a, HCFC-R22, HCs and air
B) HFC blends, e.g. R404, R407, R410, etc.
44
LCD display
Inlet filter
Printer
Connection hose with adapter
Figure 7: Refrigerant identifier for HCFC-R22
Identifier to verify presence and quality of HCFC-R22 refrigerant
Pass / fails indication of 95% pure refrigerant
Confirms the refrigeration system / cylinder content in less than five minutes
Part I
MEASURING INSTRUMENTS (MI)
TOOLS AND EQUIPMENT
Figure 8: Electronic vacuum gauges (commonly used) examples
Electronic vacuum gauge, measuring range 50 to 5000 microns
Digital vacuum gauge, range 0 to 12,000 microns (different units selectable)
LED display
LCD display
Hose connections
45
MEASURING INSTRUMENTS (MI)
Part I
TOOLS AND EQUIPMENT
Figure 9: Refrigerant charging scale
Electronic charging scale for cylinder and refrigeration system
charging, capacity 50 kg, accuracy +/–0.5%, resolution 2 gr
Electronic charging scale for small hermetic refrigeration
systems (domestic), capacity up to 5 kg, resolution 1 gr
LCD display
Figure 10: Spring-type charging scale
46
Fixture
Graduation for weight
Adjustment kit for maximum filling amount
Feeder hook
Connection cord for overfill protection (OFP)
Part I
MEASURING INSTRUMENTS (MI)
TOOLS AND EQUIPMENT
Figure 11: Electronic thermometer
Electronic thermometer for up to two probes, measuring range –50°C to 1150°C
Electronic thermometer equipped with three probes
Electronic hand thermometer with one probe, measuring range –50°C to 150°C
Refrigerator and freezer thermometer, range –50°C to 50°C
47
MEASURING INSTRUMENTS (MI)
Part I
TOOLS AND EQUIPMENT
Figure 12: Digital clamp on meter
Noncontact ampere measurement, voltage and resistance measurement
LCD display and holding function for easy reading
Ampere measuring clamp
Measurement selector
LCD display
Test leads
Figure 13: Rotating field meter
Rotating field identification for e.g. scroll-compressors
48
Rotating field to the right
Connection clamps for three phases
Rotating field (wrong) direction (left)
Figure 14: Auto range digital multimeter
Part I
MEASURING INSTRUMENTS (MI)
TOOLS AND EQUIPMENT
Tests batteries, capacitors and resistors components
Measurement selector
Test leads
Figure 15: Anemometer and thermometer
Air velocity measurement for AC systems
Vane sensor with integrated thermometer
Measuring device for temperature and air velocity
49
MEASURING INSTRUMENTS (MI)
Part I
TOOLS AND EQUIPMENT
Figure 16: Sound level meter
Measuring of sound level on refrigeration and AC equipment
Measuring range 40 to 140 dB
Sensor
Digital display
Key pad
Figure 17: Mains tester
Electrical tester, DC Voltage 6 to 220 Volts, AC Voltage 24 to 480 Volts
50
Mains tester with lead
LED display
Part I
MEASURING INSTRUMENTS (MI)
TOOLS AND EQUIPMENT
Figure 18: Hermetic compressor tester
Easy to use tool for testing the compressor’s capacity
Use with dry Nitrogen only!
Quick coupler
Pressure gauge
Adjustable safety valve
Pressure tank
Refrigerant charging hose
51
Part I
52
Part II Skills and Operation
Introduction to Part II
Part II provides detailed know-how on professional state-of-the-art service
and maintenance of refrigeration systems, including system assembling and
commissioning. In addition, expertise is provided on skills such as bending,
flaring, brazing and pressing of pipe work needed in the repair of domestic
refrigeration and air-conditioning systems. This is especially important for
systems containing flammable Hydrocarbon refrigerants which have to be
treated with extra care.
Part II
INTRODUCTION TO PART II
SKILLS AND OPERATION
53
Part II
54
Chapter 5: Assembling a Refrigeration System
Preface
Beside the installation of the main refrigeration system components, the refrigerant pipe
work has to be carried out in a perfect clean and proper manner.
The most common pipe work you will find on refrigeration systems is made of copper. It is
sized by the actual outside diameter and comes in lengths of 5 to 6 m (16 to 20 feet) in
hard copper and coils of 15 to 50 m (50 to 165 feet) in soft copper.
There are two common types of copper piping:
• Hard Copper (rigid copper)
• Soft Copper (annealed copper)
Specially designed and prepared copper pipes are used in refrigeration as they can be used
for higher pressures. They arrive from the producer sealed at both ends to prevent contamination by moisture or dust etc ...
Soft Copper
Soft, flexible copper tube is really more versatile than a rigid copper pipe. It comes in much
longer lengths which are rolled and requires fewer joints which reduce leak potential. Due
to its fairly flexible nature it can be positioned and shaped easily which saves time.
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Hard Copper
Hard Copper piping is rigid and is identified by size and name. This type of piping makes a
neater installation, but it is more time consuming and difficult to install than soft tubing. It
needs very little mechanical support to keep it in position, compared to soft copper.
Figure 1: Soft and hard copper comparison
55
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
The table below shows common pipe sizes:
European Standard
Copper Coils (annealed)
Copper Coils (annealed)
INCH
METRIC
Diameter
3/16”
1/4”
5/16”
3/8”
1/2”
5/8”
3/4”
7/8”
Length (m)
50
30
50
30
30
30
15
15
Wall (mm)
1
1
1
1
1
1
1
1
Length (m)
25
25
25
25
25
25
25
25
25
Table 1: Soft copper (annealed) European standard
US Standard
Copper Coils (annealed)
INCH
Diameter
1/8”
3/16”
1/4”
5/16”
3/8”
1/2”
5/8”
3/4”
7/8”
11/8”
13/8”
15/8”
Length (Ft)
50
50
50
50
50
50
50
50
50
50
50
50
Table 2: Soft copper (annealed) US standard
56
Diameter
4 mm
6 mm
8 mm
10 mm
12 mm
15 mm
16 mm
18 mm
22 mm
Wall (mm)
0.76
0.76
0.76
0.81
0.81
0.81
0.89
0.89
1.14
1.21
1.40
1.52
Wall (mm)
1
1
1
1
1
1
1
1
1
European Standard
Rigid Copper Straight Length Rigid Copper Straight Length
INCH
METRIC
Diameter
1/4”
3/8”
1/2”
5/8”
3/4”
7/8”
1”
11/8”
13/8”
15/8”
21/8”
25/8”
31/8”
35/8”
41/8”
Length (m)
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4 or 5
4
4
Wall (mm)
1
1
1
1
1
1
1
1
1.24
1.24
1.65
2.10
2.50
2.50
2.50
Diameter
6 mm
8 mm
10 mm
12 mm
15 mm
16 mm
18 mm
22 mm
28 mm
35 mm
42 mm
54 mm
64 mm
76 mm
89 mm
108 mm
Length (m)
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
Wall (mm)
1
1
1
1
1
1
1
1
1.5
1.5
1.5
2
2
2
2
2.5
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Table 3: Rigid copper (hard) European standard - inch/metric
US Standard
Rigid Copper Straight Length
INCH
Diameter
3/8”
1/2”
5/8”
3/4”
7/8”
11/8”
13/8”
Length (Ft)
16.4
16.4
16.4
16.4
16.4
16.4
16.4
Wall (mm)
0.76
0.89
1.02
1.07
1.14
1.21
1.40
Diameter
15/8”
21/8”
25/8”
31/8”
35/8”
41/8”
Length (Ft)
16.4
16.4
16.4
16.4
16.4
16.4
Wall (mm)
1.53
1.78
2.03
2.29
2.54
2.79
Table 4: Rigid copper (hard) US standard
57
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
The refrigeration capacity of the system is influenced by pressure drops in the pipe work.
Such pressure loss not only results in a decrease in cooling capacity but also in an increase
in the compressor’s power consumption.
Sizing of the piping system is determined by the following factors:
• Pressure drops
• Flow velocity
• Oil return
For the assembling of the selected refrigeration system (demo unit) the following pipe
diameters are selected:
• Suction pipe 10 mm
• Liquid pipe 6 mm
System Design and Selection Criteria
Item Qty. Unity
58
Part
Reference
DANFOSS SC 15 GXT2
Refrigerant HFC-R134a
Ref. capacity –5°C/830W
Power input 600W
230V/1Ph/50Hz
KUEBA DFA 031
Refrigerant HFC-R134a
Ref. capacity –5°C/900W
Surface 4.9 m2
Fan 230V/1Ph/50Hz/29W
DANFOSS TN 2
1
1
Piece
Hermetic
condensing unit
2
1
Piece
Evaporator
3
1
Piece
4
1
Piece
5
1
Piece
Th. expansion
valve
Th. expansion
valve with inlet
strainer
Filter-drier
6
1
Piece
Sight glass
7
1
Piece
Solenoid valve
8
1
Piece
Capillary tube
thermostat
Dimensions/
Range
HxWxD/mm
296x333x451
Weight 21.6 kg
HxWxD/mm
165x580x510
Weight 10 kg
/
3 8” Inlet
/
1 2” Outlet
DANFOSS
Size 01
DANFOSS
DML
DANFOSS
SGN
DANFOSS
EVR 3
DANFOSS
KP 62
6 mm/ 1/4” flared male
x 6 mm/ 1/4” flared male
6 mm/ 1/4” flared male
x 6 mm/ 1/4” flared female
6 mm/ 1/4” flared male
x 6 mm/ 1/4” flared male
Temperature range
– 40°C to +65°C
Item Qty. Unity
9
1
Piece
10
11
12
5
5
3
m
m
Piece
13
6
Piece
14
1
Piece
15
1
Piece
16
2
Piece
17
2
Piece
18
1
Piece
19
1
Piece
20
21
22
1
1
1
Piece
Piece
Piece
23
6
m
24
25
26
27
40
10
10
1
Piece
Piece
Piece
Piece
28
29
30
31
32
33
50
8
2
4
2
18
Piece
m
Piece
Piece
Piece
Piece
Part
Reference
Dual pressure
switch
Soft copper pipe
Soft copper pipe
Brass union
coupling
Brass SAE nut
for union coupling
Brass SAE nut
Expansion valve outlet
Brass SAE Nut
Expansion valve inlet
Brass SAE nut/
filter-drier and
sight glass
Brass SAE nut/
solenoid valve
Forged brass
tee with valve
core/evaporator
measurements
Master switch
with housing
Indicator light
Indicator light
Cable
connection box
Electrical cable
flexible
Cable fastener
Copper pipe clips
Copper pipe clips
Perforated plate
(metal)
Sheet screws
Hollow punch
Floor stands
Angel 45°
Frame angel 90°
Screw set
frame
DANFOSS
KP15
Liquid pipe
Suction pipe
Dimensions/
Range
LP – 0.7 to 4 bar
HP – 8 to 32 bar
6 x 1 mm/ 1/4”
10 x 1 mm/ 3/8”
10 mm/ 3/8”
5/8” UNF
10 mm/ 3/8”
5/8” UNF
1/2”/10 mm hole
3/4” UNF
3/8”/6 mm hole
5/8” UNF
1/4”/6 mm hole
7/16” UNF
/
1 4”/6
mm hole
/
7 16” UNF
/
3 8” Pipe
– 7/16” UNF
MOELLER – SVB
230V/1Ph/50Hz
green
red
HENSEL D9045
5 Openings
230V/1Ph/50Hz
230V/1Ph/50Hz
98x98x58 mm
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
3 x 1.5 mm2
6 mm/ 1/4”
10 mm/ 3/8”
500 x 800 mm
36 x 36 mm
36 x 36 mm
M8 x 40 mm
Table 5: Complete list of material (parts as selected or similar)
59
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
Hermetic compressor
Discharge pipe
Refrigerant condenser
Refrigerant receiver
Service connection
Shut-off valve
Refrigerant liquid pipe
Filter-drier
Refrigerant sight glass
Solenoid valve
Thermostatic expansion valve
Capillary tube with sensor
Refrigerant evaporator
Service connection
Suction pipe
Shut-off valve
Service connection
Figure 2: The refrigeration system layout (refrigerant flow schematic)
60
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
230V/1Ph/50Hz
L
N
S1
TC
Y1
LP
HP
M1
M2
OP
Electr. connection ‘phase’
Electr. connection ‘neutral wire’
Main switch (on-off)
Thermostat
Solenoid valve
Low pressure switch
High pressure cut-off
Condenser fan motor
Evaporator fan motor
Overload protection (compressor)
RW
SW
M3
SR
UR
C1
C2
H1
H2
Running winding (compressor)
Start winding (compressor)
Refrigerant compressor
Start relay
Unload resistor (C1)
Start capacitor
Running capacitor
Indicator light ‘operation’ green
Indicator light ‘high pressure’ red
Figure 3: The electrical wiring diagram (pump-out/pump-down)
61
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
Main Components for System Assembling
Condensing unit
Hermetic
Refrigerant HFC-R134a
Voltage 230V/1Ph/50Hz
Refrigeration capacity 875W
to –5°C/amb.temp. 32°C
Maximal amb.temp 43°C
Figure 4: Condensing unit
Evaporator
Air forced
Refrigerant HFC-R134a
Voltage 230V/1Ph/50Hz
Refrigeration capacity 950W
to –5°C
1 Ventilator/29W
Surface 4.9 m3
Lamella spacing 4.2 mm
Figure 5: Evaporator
Figure 6: Evaporator air circulation (schematic)
62
Thermostatic
expansion valve
with internal equalization
Refrigerant HFC-R134a
flare/flare connection
inlet size 1/4” (6 mm),
outlet 1/2” (12 mm)
Figure 7: Thermostatic expansion valve
Solenoid valve
Normally closed (NC)
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Refrigerants: CFC, HCFC, HFC
Inlet/Outlet 1/4”/6 mm
Min. opening differential
pressure 0.0 bar
Brazing or flaring connections
Figure 8: Solenoid valve
Filter-drier
Optimized for HFC refrigerant
Brazing or flaring connections
Inlet/Outlet 1/4”/6 mm SAE
Figure 9: Filter-drier
63
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
Sight glass
with colour indicator for
moisture content in refrigerant
Ambient temperature:
–50°C to +80°C
Max. working pressure: 35 bar
Inlet/Outlet 1/4”/6 mm SAE
Figure 10: Sight glass
Thermostat
with capillary tube
Ambient temperature:
–40 to +65°C
Figure 11: Thermostat
Dual pressure switch
LP – 0.7 to 4 bar
HP – 8 to 32 bar
Figure 12: Dual pressure switch
64
Master switch
with Housing
230V/1Ph/50Hz
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Figure 13: Master switch (photo courtesy of Moeller GmbH)
Front view of the
refrigeration system
• Cut hollow punch and
assemble frame
• Install stand and angle
• Place evaporator
• Place condensing unit
Figure 14: Refrigeration system (front view)
65
SKILLS AND OPERATION
ASSEMBLING A REFRIGERATION SYSTEM
Part II
Rear view of the
refrigeration system
• Evaporator section
• Install perforated metal plate
Figure 15: Refrigeration system (rear view)
Detail evaporator
• Expansion valve with nozzle
installation
• Inserted nozzle and fix flare-nut
• Temperature sensor with
capillary tube
• Brass tee with valve core
connection at suction line
(outlet evaporator)
Figure 16: Evaporator in detail
66
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Install dual pressure
switch for high and
low pressure control
• Dual pressure switch
Figure 17: Dual pressure switch in detail
References
Install refrigerant
circuit components
including piping
• Solenoid valve
• Flare-nut (example)
Bending
of copper
tubes
Brazing
• Sight glass
Flaring
• Filter-drier
Figure 18: Refrigerant circuit components
67
SKILLS AND OPERATION
ASSEMBLING A REFRIGERATION SYSTEM
Part II
Install electrical
components
• Thermostat
• Master switch
• Cable connection box
• Install and fix electric cable
Figure 19: Electrical components
References
Install remaining
pipe work
• Suction line
• Liquid line
Bending
of copper
tubes
Brazing
Flaring
• Process pipes for
dual pressure switch
Figure 20: Pipe work installation
68
Commissioning
The operational reliability and service life of a refrigeration system primarily depends on the
degree of contamination, the moisture and non-condensable gases (e.g. air) contained in
the refrigeration cycle and the hermetic design and construction (leak tightness).
Improved hermetisation of the refrigeration cycles enables a reduction of substances entering and escaping from the system during operation. All these facts and backgrounds enable
the operation in an environmentally protective and energy-efficient manner.
The previously assembled refrigeration system provides for system commissioning several
service connections. These service connections are located as follows:
References
Service port at liquid line
(outlet receiver)
A
Service port at suction
line (inlet compressor)
Service port at the
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Tools RHC
Page 23
Figure
6+7
evaporator
B
Figure 21: Service connections overview
Service port
suction line
Service port
liquid line
A
B
Figure 22: Service connections in detail
69
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
Pressure Leak Test
This leak test provides information on the overall leak tightness of the refrigerated system.
Only dry Nitrogen must be introduced into the refrigerated system.
Transferring the dry Nitrogen gas from both, the high and low pressure side up to a system
pressure of a maximum of 10 bar.
NEVER USE OXYGEN (e.g. shop-air) FOR PRESSURIZING A REFRIGERATION SYSTEM.
References
Connect the Nitrogen
cylinder’s pressure
regulator to the manifold
gauge set centre port.
Connect the high pressure
gauge to the system’s high
side service port.
Connect the low pressure
gauge to the system’s low
side service port.
Figure 23: Pressure leak test
70
Tools RHC
Page 18
to 22
TT
Page 15
Figure 19
MI
Page 43
Figure 5
• Pressurize the refrigeration system up to a
maximum of 10 bar dry Nitrogen.
• Close the pressure regulator and hold the
pressure in the system.
• Observe the pressure at gauges. If leaks exist,
pressure will drop. Some leaks are audible and
can be identified by the sound of discharging gas.
• Check all connections, flares and joints with
soap water solution. Identify leaks by bubbles
formed by discharging Nitrogen.
• Repair leaks.
• If necessary repeat leak test.
Figure 23a: Example of a leaky connection (see bubbles)
Evacuation
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Most importantly, the evacuation of a refrigeration system is a matter of reducing the content
of non-condensable gases such as air and Nitrogen. Additionally, introduced humidity during
the assembling process must be removed before system operation.
The pressure measured finally with the vacuum process should be about 0.5 mbar (50 Pa,
375 micron) or better.
If possible, a system should be evacuated on both, high and low pressure sides. To be able
to ensure the specified vacuum, it is therefore necessary (if possible) to measure the pressure
with a vacuum gauge in the system and not directly at the vacuum pump.
Short hoses with large diameter (e.g. 3/8”) are best for evacuating and greatly reduce the
time required for evacuation. Most manufacturers recommend evacuating down to at least
250 microns. You may even come across specifications requiring a 50 micron evacuation. To
achieve vacuums that are so low, you would have to use large diameter and very short connections between the vacuum pump and the system. Standard flexible hoses (1/4”) just don’t
seal enough and also present too much restriction flow to achieve those types of vacuum.
71
SKILLS AND OPERATION
References
ASSEMBLING A REFRIGERATION SYSTEM
Part II
Connect the vacuum
pump to the manifold
gauge set to the centre
port.
Connect the vacuum
gauge to the service port
at the evaporator’s outlet
service port.
Figure 24: Evacuation
of a refrigeration system
Run the vacuum pump and
read the vacuum indicated
at the vacuum gauge.
RRRE
Page 37
Figure 7
MI
Page 45
Figure 8
Charging
The compressor must never be operated without refrigerant or under vacuum. A damage
of the compressor would result.
If the filling capacity of the plant is known, liquid charging of the refrigerant into the
high side of the system can be carried out with the plant at rest, against vacuum, using a
charging cylinder or scales.
72
Be extremely careful when charging liquid refrigerant to the low side of the system. Liquid
(in large amounts) must never enter the compressor. For this reason prevent the compressor
from the so called ‘liquid hammer’ while charging refrigerant. R134a is a single substance
refrigerant and may therefore be charged into the system from the refrigerant cylinder in
vapour or liquid form.
If the charging amount is yet to be determined, first fill in refrigerant until the low pressure
switch responds and the compressor can be started. In general, it is sufficient to charge half
of the rated quantity to be able to operate the compressor during the charging operation
without compressor damage. Measure the charged amount of refrigerant.
References
Connect the refrigerant
charging cylinder on
scale to the manifold
gauge centre port.
Purge the air out of
the charging hose.
MI
Page 46
Figure 9
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
Figure 25: Charging of a refrigerant system
73
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
System Check and Final Leak Test
After the charging process the adjustment and functioning of the safety devices and other
control devices must be checked. The system must be operated until sufficient system conditions are visible. Meanwhile temperature and pressure values should be recorded and the
system must receive a label showing actual figures e.g. type and amount of refrigerant
charged. After disconnection of gauges and hoses a final leak test has to be performed.
References
MI
Page 41
Figure 1
Page 42
Figure 2
Figure 26: Overview of a refrigerant system
Once again use soap water and/or an electronic leak-detector and you will find that there
are common places to check. The following lists some very common leak locations:
• Flare-nuts
• Service valve: packing, access fitting, mounting
• Cracked brazed joint in piping
• Rotted evaporator end bends
• Pipes rubbing together
• Cracked ferrous brazed in accessory
74
T3
T5
P2
T2
T6
T4
T1
T7
P1
T11
Part II
ASSEMBLING A REFRIGERATION SYSTEM
SKILLS AND OPERATION
T9
T10
P3
T8
Figure 27: Measuring spots for temperature and pressure
References MI Page 47-Figure 11, Page 48-Figure 12, Page 50-Figure 17
75
ASSEMBLING A REFRIGERATION SYSTEM
Part II
SKILLS AND OPERATION
Start-Up Data Sheet
Technician name
Address
Telephone & fax no.
Registration no.
Installation/Appliance DATA
Type of installation
Date started
Model and no.
Date finished
Operating Data
Refrigerant type
Type of lubricant
Suction pressure P1
Suction pressure evap. P3
Discharge temp. T1
Air temp. ent. cond. T3
Temp. ref. leav. cond. T5
Temp. ref. leav. filter T7
Air temp. leav. evap. T9
Temp. gas ent. comp. T11
LP-switch cut-off
Refrigerant charge
Lubricant charge
Condensing pressure P2
Hotgas temp. T2
Air temp. leav. cond. T4
Temp. liquid ent. filter T6
Air temp. ent. evap. T8
Temp. gas leav. evap. T10
HP-switch cut-off
Electrical Data
Power supply (voltage)
Overall ampere reading
Current draw compressor
Current draw fan evapor.
Current draw fan cond.
L1
L1
L1
L2
L2
L2
Other Installation Data
Discharge line diameter
Liquid line diameter
Suction line diameter
Insulation suction line
Type of condenser
Type of filter-drier
Remarks:
Signature technician
Date
Table 6: Start-up data sheet
76
Discharge line length
Liquid line length
Suction line length
Altitude diff. compr./evap.
Type of evaporator
Type and size of receiver
L3
L3
L3
Chapter 6: Bending, the Process
Preface
Because of its exceptional formability, copper can be formed as desired at the job site.
Copper tube, properly bent, will not collapse on the outside of the bend and will not buckle
on the inside of the bend.
Because copper is readily formed, expansion loops and other bends necessary in an assembly
are quickly and simply made if the proper method and equipment are used.
Simple hand tools employing mandrels, dies, forms and fillers, or power-operated bending
machines can be used.
Part II
BENDING, THE PROCESS
SKILLS AND OPERATION
Both annealed tube and hard drawn tube can be bent with the appropriate benders. The
proper size of bender for each tube size must be used.
Always follow specific safety regulations!
(see also chapter safety)
Portable bending machines, suitable for bending tubes up to and including 54 mm outside
diameter (OD) are available, indeed some smaller benders up to 22 mm can be carried in
a tool kit. For tube sizes larger than 54 mm, fixed power benders are the only satisfactory
option. All bending machines work on the principle that the tubing is bent between
matched formers and back guides, which support the OD of the tubing, thus eliminating
the risk of collapse of the tube wall.
77
BENDING, THE PROCESS
Part II
SKILLS AND OPERATION
Bending Process Steps
References
Only the use of sealed and
interiorly clean and dry copper
tubes is permitted.
This bad example shows
an inappropriately treated
and stored copper tube.
Collapsed tube
Figure 1: Inappropriately
treated copper tube
No seal plug for tube inside
protection.
Positioning
The bending tool diameter must
match the copper tube diameter.
With the handles at 180° and
the tube holding clip raised out
of the way, insert the tube in the
forming wheel groove.
TT
Page 11
Figure 12
Figure 2: Tube-holding
Bending start position
Place the tube-holding clip over
the tube and bring the handle
into an approximately right angle
position, engaging the forming
shoe over the tube.
The zero mark on the forming
wheel should then be even with
the front edge of the forming shoe.
Figure 3: Tube-holding position
78
TT
Page 11
Figure 12
References
Bending the tube
Bend by pulling the handles
towards each other in a
smooth, continuous motion.
TT
Page 11
Figure 12
The desired angle of the
bend will be indicated by the
calibrations on the forming
wheel.
Part II
BENDING, THE PROCESS
SKILLS AND OPERATION
Figure 4: Bending of the tube
Tool removal
Remove the bent tube by
pivoting the handle to a
right angle with the tube,
disengaging the forming
shoe.
TT
Page 11
Figure 12
Then release the tubeholding clip.
Figure 5: Removing of the bent tube
Bending copper
and tool example
TT
Page 11
Figure
12 (1)
Figure 6: Bending process
79
SKILLS AND OPERATION
References
BENDING, THE PROCESS
Part II
Bending copper
and tool example
TT
Page 11
Figure
12 (3)
Bending copper
and tool example
TT
Page 11
Figure
12 (2)
Figure 7: Example of bent copper
Figure 8: Bending copper tool
Piping should be designed to use a minimum number of bends and fittings. It is most important to minimize pressure drop in the suction line so plan your piping layout around the
optimum route for the suction line.
If you are manually bending some soft copper and you accidentally kink the pipe, cut out
and discard the kinked section and try again. It is much easier to correct the problem now
than it is after the system is in operation. There is no excuse for allowing unnecessary pressure drop to affect a system for its entire operational life.
80
Chapter 7: Brazing, the Process
Preface
Brazing and soldering techniques are the most common methods of joining copper tubes
and fittings.
Since modern technologies and best practices have been introduced and regulations have
been developed for the sectors of refrigeration and air-conditioning, the only technical
standard in this field is BRAZING.
Good brazing joints are strong, durable and stay tight! Brazing is necessary to provide joints
that can withstand vibration, temperature and thermal cycling stress.
Part II
BRAZING, THE PROCESS
SKILLS AND OPERATION
The basic theory and techniques of soldering and brazing are the same for all diameters of
copper tubes. The only variables are the filler metal and the amount of time and heat required to complete a given joint.
Soldering is the joining process that takes place below 450°C (840°F) and brazing as a
process that takes place above 450°C (840°F), but below the melting point of the base
metals. Most brazing is done at temperatures ranging from 600°C to 815°C (1100°F to
1500°F).
Brazing carried out while using copper-phosphorus (CP) filler metals is the preferred method
for making non-detachable joints. No flux is needed as the vaporised phosphorus will remove
the copper oxide film. Flux used for brazing may also contaminate the environment inside
tubing and must be removed after the brazing process. Nitrogen introduction as protective gas (very low flow rate inside the pipe assembly during brazing process)
is a common method to avoid oxidation.
Purging refrigerant pipelines whilst brazing with dry Nitrogen.
When heat is applied to copper in the presence of air (oxygen), oxides form on the surfaces of
the tube. This is very harmful for a durable functioning of the refrigeration system in general
but primarily for the compressor’s lubricating system. Oxide scale on the inside of refrigerant pipelines can lead to problems once the refrigerant and the lubricant is circulating in
the system. Refrigerants have a scouring effect that will lift the scale from the tubing and
this can be carried through the system and lead to form sludge.
The formation of oxides when brazing can be easily prevented: this is achieved by slowly
passing Nitrogen through the pipework whilst the heat is being applied.
81
BRAZING, THE PROCESS
Part II
SKILLS AND OPERATION
The previously mentioned brazing techniques are approved and accepted standards for
brazing in the refrigeration and air-conditioning sector.
Basic steps for brazing and joining copper tubes and fittings:
1. Measuring and cutting
2. Reaming
3. Cleaning
4. Assembly and support
5. Nitrogen introduction
6. Heating
7. Applying the filler metal
8. Cooling and cleaning
82
Always follow specific safety regulations!
(see also chapter safety)
Brazing Process Steps
References
Cutting tube
Use a wheel cutter rather
than a hacksaw in order to
prevent swarf entering the
tube.
TT
Page 5
Figure 1
Part II
BRAZING, THE PROCESS
SKILLS AND OPERATION
Figure 1: Cutting tube
Removing internal
burrs
A deburrer, reamer or round
file can be used to remove
internal burrs.
TT
Page 6
Figure 3
Figure 2: Removing of burrs
Prevent the entering of
swarfs into the tube and
fitting arrangement.
Figure 3: Further processing with file
83
SKILLS AND OPERATION
References
BRAZING, THE PROCESS
Part II
Cleaning the surfaces
For surface cleaning use a
abrasive plastic scouring pad.
Prevent cleaning particles
or swarf from entering the tube.
TT
Page 6
Figure 4
Figure 4: Cleaning of surfaces
Cleaning the fitting
For interior fitting cleaning
use a properly sized fitting
brush.
Figure 5: Fitting cleaning with brush
Assembly
Put the pipe and fitting or
expanded pipes together and
make sure you maintain the
right joint depth.
Figure 6: Assembly of pipe and fitting
84
TT
Page 6
Figure 4
(2)
References
Purge tubes
Purge residues out of the tubes before brazing. Use dry Nitrogen for purging.
TT
Page 15
Figure 19
Apply Nitrogen flow
Prevent oxide formation on the
inner surface of the tubes.
Once the refrigerant is circulating
in the system, oxide scale on the
inside of the tubes can lead to
serious problems.
Part II
BRAZING, THE PROCESS
SKILLS AND OPERATION
TT
Page 15
Figure 19
Slowly pass Nitrogen through
the pipework, the far end of
the pipework to be open to the
atmosphere, without building
up a pressure.
Nitrogen transfer hose
Flow rate should be about 1 to 2
liter per minute. Flow rate sensitively can be felt easily on the
back of a moistened hand.
Figure 7: Application of Nitrogen flow
Torch (flame) adjustment
Adjust the torch for a slightly
reduced flame.
Blue flame
Green ‘feather’
TT
Page 13
Figure 15
Page 14
Figure16
Light torch flame only
with safe lighters!
Figure 8: Torch adjustment
85
SKILLS AND OPERATION
References
BRAZING, THE PROCESS
Part II
Apply heat
Apply heat uniformly to both,
tube and fitting, by moving
the torch around to ensure even
heating before adding the filler
material (rod).
Figure 9: Heat application
Apply filler
As the heated area gradually
changes colour to red (a cherry
red but not a bright red),
apply filler material (rod) by
lightly brushing the tip of the
stick into the shoulder of the
fitting.
Care should be taken not to
over-heat the tube!
Figure 10: Filler application
Complete joint
To complete the joint, an even
build-up of solder should
be just visible arround the
shoulder of the fitting.
Filler (rod)
Figure 11: Filler in detail
86
TT
Page 15
Figure 18
References
Remove the heat
Remove the heat until the
molten brazing alloy solidifies
to a tan black colour (approx.
10 to 15 seconds).
Part II
BRAZING, THE PROCESS
SKILLS AND OPERATION
Figure 12: Heat removal
Finnish brazing
After brazing is completed, the joints are normally left to cool in the air.
Stop the flow of Nitrogen.
However, if necessary, the joint may be cooled with a wet rag.
Brass to copper tube brazing
This combination of materials
requires the use of e.g. a water
solble flux. Apply a small amount
of flux to the end of the tube
and to the inside surface of the
fitting. Avoid spilling of flux
inside the tube and fitting, as
the residue needs to be removed
on completion.
Figure 13: Flux application
87
BRAZING, THE PROCESS
Part II
SKILLS AND OPERATION
References
Figure 14: Brass adapter
The procedure for these joints is
essentially the same as for copper
to copper brazing, only that more
heat should initially be concentrated on the brass fitting to
bring it to temperature.
Take care not to overheat the fitting. Dull red colour is sufficient.
Figure 15: Brass adapter brazing
88
Use brazing rods with higher
content of silver (Ag).
TT
Page 15
Figure 18
Improve your Skills
Cut a section of a joint with fitting to examine the penetration of solder in the fittings
capillary.
Penetration of solder (perfect)
Part II
BRAZING, THE PROCESS
SKILLS AND OPERATION
Penetration of solder (insufficient)
Figure 16: Brazed copper-T
examples/cut away
Example of Nitrogen
protective brazing
Straight brazing copper/copper
joint with Nitrogen
OXIDE FORMATION
Straight brazing copper/copper
joint without Nitrogen
Figure 17: Nitrogen protective
brazing examples
89
FLARING, THE PROCESS
Part II
SKILLS AND OPERATION
Chapter 8: Flaring, the Process
Preface
Because of its exceptional formability, copper can be formed as desired at the job site.
Flaring is a mechanical way of joining pipe work.
While a copper tube is usually joined by soldering or brazing, a mechanical joint may be
required or preferred at times. Flared fittings are an alternative when the use of an open
flame is either not desired or impractical.
Flared joints (and screwed connections) should be kept as minimal as possible. Leak prevention requires the design of a ‘sealed system’ as far as possible. Check the availability of
‘brazed in’ components and use them wherever possible!
In particular, flared joints must not be used to connect expansion valves.
90
Always follow specific safety regulations!
(see also chapter safety)
Flaring Process Steps
Cut the tube
Use a wheel cutter rather than
a hacksaw in order to prevent
swarf entering the tube.
References
TT
Page 5
Figure 1
Part II
FLARING, THE PROCESS
SKILLS AND OPERATION
Figure 1: Cutting the tube
Remove internal burrs
A deburrer or reamer can be
used to remove internal burrs.
TT:
Page 6
Figure 3
Figure 2: Removing of burrs
Clean the surfaces
Dirt, debris and foreign
substances should be
removed from the tube
end by mechanical cleaning.
TT:
Page 6
Figure 4
(1)
Figure 3: Cleaning the surface
91
SKILLS AND OPERATION
References
FLARING, THE PROCESS
Part II
The flaring tool (example)
The flaring tool consists of:
Flaring bar (holding tool)
Clamp tool
TT
Page 11
Figure 11
Flaring cone
Figure 4: Flaring tools
Holding bores different
diameters
Assemble the flaring tool
with tube and flare-nut
Place the flare-nut over the
end of the tube with the threads
close to the end being flared.
Insert the tube between the
flaring bars of the flaring tool.
Opening of the flaring bars must
match the diameter of the tube
being flared.
Figure 5: Flaring arrangement
Fabricate the flare
Align the compression cone
on the tubing’s end and tighten
the screw. As you turn the
handle, the cone flares the
tubing’s end.
Figure 6: Flare fabrication
92
TT
Page 11
Figure 11
References
Inspect your work
Inspect your work after removing
the tubing from the flaring tool.
If the tube end has splits, cut
off the flared portion and repeat
the process.
It is essential to examine the tight
position of :
Part II
FLARING, THE PROCESS
SKILLS AND OPERATION
• male flare union
• female flare-nut
• flared copper tube
Figure 7: Flare inspection
Tight and clean fitting is
requested.
Assembling
Position the flare union against the
flared end of the tubing and slide
down the nut. The fitting should be
easily tightend by hand if done
properly. Additional pipe jointing
or sealing compound (e.g. oil) is
not necessary.
Figure 8: Flared connection positioning
93
SKILLS AND OPERATION
References
FLARING, THE PROCESS
Part II
Tightening
It is now time to tighten the
joint by placing one wrench on
the union and one on the nut.
Do not ‘over-tighten’ a flare
joint!
Figure 9: Flared connection tightening
Once the parts fit by hand,
give them a half turn on each
nut/wrench to create a gas
tight join.
Final result
Figure 10: Copper tube with flare,
flare-nut and adapter
94
Chapter 9: Domestic Refrigeration
Preface
Domestic refrigerators are amongst the most common electric appliances in the world, for
instance being present in 99.5% of European and American homes. They may consist of
either a cooling compartment only (a larder refrigerator) or a freezing compartment only (a
freezer) or contain both.
Some refrigerators are now divided into four zones for the storage of different types of food:
• –18°C or 0°F (freezer)
• 0°C or 32°F (meats)
• 4°C or 40°F (refrigerator)
• 10°C or 50°F (vegetables), for the storage of different food types.
Part II
DOMESTIC REFRIGERATION
SKILLS AND OPERATION
The following chapter is about the maintenance and repair of the domestic refrigeration
systems.
First Steps
Before opening a hermetic refrigerant cycle
it is essential to have first visible, sensitive
and audible impressions which can directly
lead to fault identification.
The first system cycle evaluation consists of:
Figure 1: View of a refrigerant circuit
(1) Heat transfer at the condenser
(2) Temperature of the filter-drier
(3) Noise level of the compressor
(4) Heat emission of the compressor
(5) Situation of hoar frost at the evaporator
(6) Capacity of the compressor
• With refrigerant shortage (leak) the refrigerant entrance at
the condenser is warm, the outlet cold
• With iced-over evaporator the heat transfer is very low
• With reduced compressor capacity the heat transfer is very low
95
SKILLS AND OPERATION
References
DOMESTIC REFRIGERATION
Part II
Placing a fridge / freezer
It is very important that the fridge/
freezer is placed with sufficient
surrounding for heat transfer (air
circulation).
Pay attention that the condenser
is free of dust or dirt and that no
items obstruct the ventilation area.
Placing of a fridge/freezer close
to other heat sources must be
avoided.
Figure 2: Freezer air circulation
It is necessary to clean the
condenser regularly.
Use a common thermometer and
a glass of water for inside temperature measurements.
Figure 3: Freezer temperature
measuring
The evaporator must not be icedover. This will hinder the heat absorption in the refrigerated area.
Check that there is a sufficient
ice formation (hoar frost).
The fridge/freezers door gasket
must lie perfectly close at the
body.
Use a hair-drier to work on spots
where the gasket does not fit.
Figure 3a: Refrigerator wall
(evaporator area) with hoar frost
96
MI
Page 47
Figure
11 (4)
References
Connect the sensor of the
electronic thermometer to the
securing clip of the thermostat
sensor to measure switch-on
and switch-off temperatures.
MI
Page 47
Figure 11
Check that the lighting switches
off while you close the door.
Figure 4: Sensor positioning
Part II
DOMESTIC REFRIGERATION
SKILLS AND OPERATION
Adjust the thermostat slightly
above medium position of the
temperature adjustment range.
e.g.: Position 4 of range 7
Position 2.5 of range 4
Figure 5: Temperature adjustment range
Does the thermostat cut-off?
Compare cut-off/cut-on
temperatures with the thermostat
manufacturer’s technical
information.
Refrigerant Cycle Opening
If a hermetic refrigerating system is to function correctly and to have a reasonable long life,
it is essential that the amount of impurities present in the system, i.e. moisture, foreign gases,
dirt etc., are being kept at a minimum.
This fact must be taken into consideration when repairs are to be made and the necessary
precautions must be taken. Before commencing repairs, especially those which require the
opening of a hermetic refrigerant cycle, make sure that all other possible faults have been
eliminated and that an exact diagnosis of the problem has been made.
If the first system cycle evaluation and measurements indicate that it is necessary to open
the hermetic system, we have to proceed as follows:
97
SKILLS AND OPERATION
DOMESTIC REFRIGERATION
Part II
Figure 6: Steps when opening a refrigerant cycle
References TT Page 5-Figure 2, RHC Page 24-Figure 9
References
Figure 7: Placement of piercing
plier at process pipe
98
For gauge connection and
pressure/temperature reading,
place piercing plier connected
with refrigerant hose to the
process tube (charging tube)
at the compressor. Continue
system cycle analysis with
operating compressor.
RHC:
Page 24
Figure 9
Figure 8: Placement of an additional
piercing plier at the filter-drier
For refrigerant gas recovery, place
one additional piercing plier
directly on the filter-drier’s surface
(high pressure side). This enables
refrigerant gas recovery from
both, high and low pressure sides
of the system. Additional, if the
capillary tube is mechanically
blocked, refrigerant will remain
at the high pressure side of the
system. For further explanation
of the refrigerant gas recovery
process see also chapter ‘refrigerant recovery, recycling and
containment in the field’.
References
RHC
Page 24
Figure 9
Part II
DOMESTIC REFRIGERATION
SKILLS AND OPERATION
After entire emptying of the refrigerant cycle, cut the capillary tube
at the filter-drier outlet (distance
from filter-drier approx. 3 cm).
TT
Page 5
Figure 2
Avoid burrs and deformation of
the capillary tube.
Figure 9: Cutting of the capillary tube
Cut the filter-drier with a tubecutter if sufficient condenser
tube length (steel) is available.
This action enables you to remove
bounded humidity and residues
together with the filter-drier.
TT
Page 5
Figure 1
Figure 10: Cutting of the filter-drier
99
SKILLS AND OPERATION
References
DOMESTIC REFRIGERATION
Part II
If a sufficient tube length is not
available, proceed as follows:
For safety reason, destroy the
filter-drier with a side cable
cutter plier close to the filterdrier outlet. Unbraze the filterdrier and clean the steel tube
of the condenser’s outlet
thoroughly with a wire-brush.
Brazing torch
Filter-drier
Destroyed filter section
Side cable cutter
Figure 11: Destruction of a filter-drier
Here the capillary was
cut in figure (9)
If a reduced hermetic
compressor capacity is
assumed, complete a
capacity test.
Figure 12: Capacity test
100
MI
Page 51
Figure 18
Dry Nitrogen (N2) is connected
now to the valve on the process
pipe.
Figure 13: Nitrogen connection
to the process pipe
The pressure regulator of the
Nitrogen supply cylinder is adjusted to a maximum of 10 bar.
The Nitrogen flow will enter the
system passing the process tube,
the compressor, the evaporator
with the connected capillary tube
and the condenser.
References
RHC
Page 24
Figure 9
Part II
DOMESTIC REFRIGERATION
SKILLS AND OPERATION
Flushing the System with Nitrogen N2
Nitrogen discharges now at the open end of the condenser (previously connected to the
filter-drier inlet) and the open end of the capillary tube. Hold a rag at both open ends because remaining compressor lubricant may come with the purged Nitrogen. The Nitrogen
flushes the system and takes humidity etc. The blowing process also allows the localization
of any obstructions in the piping.
Plan the repair work so that the refrigerating system will not be open for more than 10–15
minutes.
Assemble the special equipment required for the repairs.
Assemble any spare parts required.
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DOMESTIC REFRIGERATION
Part II
SKILLS AND OPERATION
System Assembling – Create a Hermetic System
While assembling the refrigerated section, service valves (Schrader valves) must not be used
because of the high risk of leakage. Domestic appliances require a sensitive and accurate
refrigerant charge and the correct charging amount is very low compared with commercial
or air-conditioning systems. For domestic appliances only a few gram of leakage per year
will reduce the refrigerators/freezers efficiency resulting in increased electricity consumption.
Prevent intentional leaks and provide a hermetic system (refrigerant cycle) without
screwed connective service ports.
References
Figure 14: Brazing of the filter-drier
When brazing the filter-drier and the capillary tube, note that the thin capillary
cannot withstand high temperatures due to the risk of melting and the torch’s
heat must therefore be confined from the filter.
Preferably install a filter-drier with additional process tube (high pressure side)
if available.
Use copper brazing rods (solder) with approximately 1.5% to 4% of silver content and phosphorus for copper-copper connections.
Use silver brazing rods (solder) coated with flux or separate flux paste for coppersteel connections.
Clean all brazing joints thoroughly with a wire brush and check the condition
(appearance) with an inspection mirror.
102
TT
Page 15
Figure 18
TT
Page 7
Figure 5
References
Connect the quick coupler now
to the prepared refrigerant
cycle at low and high pressure
side using the service quick
coupler.
TT
Page 9
Figure 8
Figure 15: Connection of quick coupler
and refrigerant cycle
Part II
DOMESTIC REFRIGERATION
SKILLS AND OPERATION
Connect the evacuation and
charging station to the previously
connected quick coupler.
1. Low pressure side
2. High pressure side
RRRE
Page 38
Figure 8
Connect the Nitrogen cylinder
to the charging station.
Figure 16: Evacuation and charging
station
Pressurize the system with dry
Nitrogen while transferring the
gas from both, the high and low
pressure side up to a system
pressure of a maximum of 10 bar.
TT
Page 15
Figure 19
Figure 17: Nitrogen cylinder with
pressure regulator
103
DOMESTIC REFRIGERATION HC
Part II
SKILLS AND OPERATION
Chapter 10: Domestic Refrigeration HC
Preface
Hydrocarbons (HCs) are widely used in today’s modern refrigeration appliances (capillary
tube operational domestic and small commercial systems). Within the foreseeable future,
CFC, in particular for servicing purpose, will become unobtainable. In new production of
household appliances CFC-R12 is widely replaced by HFC-R134a and HC-R600a. HCs will
become more important in the future, as most fluorinated gases have a high impact on
global warming.
HC refrigerants are flammable if mixed with air and ignited, and should therefore only be
used in appliances which fulfil regulated safety requirements.
In order to carry out service and repair on HC systems, the service personnel must be properly trained to be able to handle a flammable refrigerant.This includes knowledge on tools,
refrigeration cycle components and refrigerants, and the relevant regulations and safety precautions when carrying out service and repair.
The refrigerant must be stored and transported in approved containers. Best possible in 450 g
aluminium cylinder (within two containers maximum transported in a service car). In general,
replaced compressors containing refrigerant (not only HC containing compressors) residues
must be sealed before being transported.
Pressure
regulator
Electronic
charging
scale
HC-R600a
charging
cylinder
Figure 1: HC Refrigerant charging set
104
Important Note:
For safety reasons a practical limit of 8 g / m3 of Hydrocarbon refrigerant should
not be exceeded in a closed space or room.
HCs are heavier than air. The concentration (if refrigerant is exposed) will always be highest
at floor level.
Do not release the refrigerant close to basements, canalisation etc.The working room/area
must be always sufficient ventilated.
To avoid any dangerous circumstances, open flames should be avoided. The best possible
way for domestic appliances service and repair is to use e.g. LOKRING connections and
joints.
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
The use of dry Nitrogen for system service and repair plays an important role:
• Refrigerated system flushing
• Leak test
• Removal of sectional restrictions (dirt or residues)
Abstract:
The service technician is familiar with the dangers related to flammable HC
refrigerants.
• There is no risk of sparks forming near the work area.
• Do not smoke or use naked flame or other means of heat.
Therefore, no brazing on the system is preferred.
• Electrical appliances used during the service must not produce sparks.
• Arrange good ventilation in the work area.
• Do not let the refrigerant flow into basement openings, low lying rooms,
sewer systems etc. as HCs are heavier than air.
• Safety rules for handling, storage and transport of combustible
refrigerant applicable in the various countries must be followed.
105
DOMESTIC REFRIGERATION HC
Part II
SKILLS AND OPERATION
First Steps
Before opening a hermetic refrigerant cycle
it is essential to have first visible, sensitive
and audible impressions which can directly
lead to fault identification.
The first system cycle evaluation consists of:
Figure 2: View of a refrigerant circuit
(1) Heat transfer at the condenser
(2) Temperature of the filter-drier
(3) Noise level of the compressor
(4) Heat emission of the compressor
(5) Situation of hoar frost at the evaporator
(6) Capacity of the compressor
• With refrigerant shortage (leak) the refrigerant entrance at
the condenser is warm, the outlet cold
• With iced-over evaporator the heat transfer is very low
• With reduced compressor capacity the heat transfer is very low
Placing a fridge / freezer
It is very important that the fridge/freezer
is placed with sufficient surrounding for
heat transfer (air circulation).
Pay attention that the condenser is free of
dust or dirt and that no items obstruct the
ventilation area.
Placing of a fridge/freezer close to other
heat sources must be avoided.
It is necessary to clean the condenser
regularly.
Figure 3: Freezer air circulation
106
References
Use a common thermometer
and a glass of water (as indicated
above) for inside temperature
measurements.
The evaporator must not be icedover. This will reduce the heat absorption in the refrigerated area.
Check that there is a sufficient ice
formation (hoar frost).
MI
Page 47
Figure
11 (4)
The fridge/freezers door gasket
Figure 4: Freezer temperature measuring must lie perfectly close at the body.
Use a hair-drier to work on spots
where the gasket does not fit.
Connect the sensor of the
electronic thermometer to the
securing clip of the thermostat
sensor to measure switch-on
and switch-off temperatures.
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
MI
Page 47
Figure
11 (1-2)
Check that the lighting switches
off while you close the door.
Figure 5: Sensor positioning
Adjust the thermostat slightly
above medium position of the
temperature adjustment range.
e.g.: Position 4 of range 7
Position 2.5 of range 4
Figure 6: Temperature adjustment range
Does the thermostat cut-off?
Compare cut-off/cut-on
temperatures with the thermostat
manufacturer’s technical
information.
107
DOMESTIC REFRIGERATION HC
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SKILLS AND OPERATION
Refrigerant Cycle Opening
If a hermetic refrigerating system is to function correctly and has a reasonable long life, it
is essential that the amount of impurities present in the system, i.e. moisture, foreign gases,
dirt etc., is being kept at a minimum.
This fact must be taken into consideration when repairs have to be made, and the necessary precautions must be taken. Before commencing repairs, especially those which require
the opening of a hermetic refrigerant cycle, make sure that all other possible faults have
been eliminated and that an exact diagnosis of the problem has been made.
If the first system cycle evaluation and measurements indicate that it is necessary to open
the hermetic system, we have to proceed as follows:
References
RHC
Page 24
Figure 9
Figure 7: Placement of piercing plier
For gauge connection and pressure/temperature reading, place piercing plier
connected with refrigerant hose to the process tube (charging tube) at the compressor. Continue system cycle analysis with operating compressor.
108
References
To remove the refrigerant gas,
place one additional piercing plier
directly on the filter-drier’s surface
(high pressure side).
The hose (vent line) is carried outside and connected to the ‘free
ambient’, e.g. through a window
opening.
Figure 8: Placement of
additional piercing plier
RHC
Page 24
Figure 9
The vent line must have an inner
diameter of minimum 10 mm
or 3/8”.
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
The end of the hose is carried
through, e.g. an open window.
This will be a ‘vent line’ to remove
the flammable refrigerant to the
safe outside area.
RHC
Page 22
Figure
5 (6)
• Open window or door
• Vent line
Figure 9: Open window as vent line
If the compressor does not have to be replaced, the oil is degassed in the compressor
by letting the compressor run for about one minute.
Never start the compressor under vacuum; it would risk damaging of the motor.
109
SKILLS AND OPERATION
References
DOMESTIC REFRIGERATION HC
Part II
As follows, the system can be
‘blown through’ with Nitrogen.
Nitrogen will flush the system
while taking residues of refrigerant and venting to the ambient
atmosphere.
RHC
Page 24
Figure 9
TT
Page 15
Figure 19
Figure 10: Nitrogen flush
After flushing the Nitrogen, the cylinder pressure regulator is closed.The vent line at the filterdrier is dismounted.
• Connect the vent line to vacuum pump outlet on the exhaust port.
• Connect the hose of the vacuum pump suction port to the valve on the filter-drier.
110
References
• Suction hose connected to the
piercing pliers on filter-drier
• Suction hose connected to the
vacuum pump suction port
RHC
Page 24
Figure 9
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
RRRE
Page 37
Figure 7
• Vent line on exhaust port of
the vacuum pump
• Vent line to the outside area
RHC
Page 22
Figure
5 (6)
Figure 11: HC refrigerant recovery
with vacuum pump and vent line
111
DOMESTIC REFRIGERATION HC
Part II
SKILLS AND OPERATION
The refrigerating system is now ready for the first evacuation. Evacuate to a pressure of
approximately 5 mbar.
The vent line must have a minimum inner diameter of 10 mm (3/8”)!
There must not be any appreciable overpressure at the exhaust port of the vacuum
pump, as this may damage the vacuum pump!
End the first evacuation process through switching off the vacuum pump.
The Blowing Process
Open the valve on the Nitrogen tank pressure regulator and flush the total arrangement of
refrigeration system, piercing pliers, vacuum pump and vent line by less than 1 bar (low
pressure).
Regulate the working pressure with the reducing valve and equalize the pressure into the
system.
112
SKILLS AND OPERATION
➡
➡
➡
DOMESTIC REFRIGERATION HC
Part II
➡
➡
➡
➡
• Nitrogen blowing
process by low pressure
• Vent line to the outside area
Figure 12: Nitrogen blowing process
113
DOMESTIC REFRIGERATION HC
Part II
SKILLS AND OPERATION
Removing Filter-Drier /
References
Compressor Capacity Test
After the entire blowing of the
refrigerant cycle disconnect the
vacuum pump and vent line.
Cut the capillary tube at the
filter-drier outlet (distance
from filter-drier approx. 3 cm).
TT
Page 5
Figure 2
Avoid burrs and deformation
of the capillary tube.
Figure 13: Cutting of the capillary tube
Cut the filter-drier with a tubecutter if sufficient condenser tube
length (steel) is available.
This action enables you to remove
bounded humidity and residues
together with the filter-drier.
TT
Page 5
Figure 1
If a reduced hermetic compressor
capacity is assumed, complete a
capacity test.
MI
Page 51
Figure 18
Figure 14: Cutting of the filter-drier
Figure 15: Adjustment for a capacity test
114
Evaporator and Condenser Check
Dry Nitrogen (N2) is connected
now to the valve on the process
pipe.
The pressure regulator of the
Nitrogen supply cylinder is adjusted to a maximum of 10 bar.
References
RHC
Page 24
Figure 9
The Nitrogen flow will enter the
system passing the process tube,
the compressor, the evaporator
with the connected capillary tube
and the condenser.
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
TT
Page 15
Figure 19
Figure 16: Nitrogen flow adjustment
Nitrogen discharges now at the open end of the condenser (previously connected to the
filter-drier inlet) and the open end of the capillary tube. Hold a rag at both open ends
because remaining compressor lubricant may come with the purged Nitrogen. The blowing
process also allows the localization of any obstructions in the piping.
Plan the repair work in a way that the refrigerating system and new parts will not be open
for more than 10–15 minutes.
• Assemble the special equipment required for the repairs.
• Assemble any spare parts required.
• Mount a service filter, which is larger than the filter originally used and
(if possible) with additional process pipe connection. The filter-drier must
be hermetically sealed until it is mounted.
The refrigerating system is prepared for assembly using a tube joining system by pressing
connections.
115
DOMESTIC REFRIGERATION HC
Part II
SKILLS AND OPERATION
References
Leak Test
Connect the quick coupler now
to the prepared refrigerant cycle
at the low and high pressure side
using the service coupler.
TT
Page 9
Figure 8
Connect a 4-valve manifold
gauge set to the system.
Low pressure side
High pressure side
Nitrogen supply
RHC
Page 19
Figure 2
Connect the Nitrogen cylinder to
the centre port of the manifold
gauge set.
Pressurize the system with dry
Nitrogen while transferring the
gas from both, the high and low
pressure side up to a system
pressure of a maximum of 10 bar.
Figure 17: Connection system for
a leak test
116
TT
Page 15
Figure 19
Carry out a leak-test ...
References
1. By standing pressure with
closed valves and gauge for
pressure observation. For very
small leaks a pressure test may
take up to 24 hours. A pressure
drop indicates a leak.
MI
Page 43
Figure 5
and
Figure 18: Bubble indicating a leak
2. With soap water and a brush,
adding this liquid to all joints while
observing if the liquid creates
bubbles. Bubbles indicate a leak.
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
Bring all pipes carefully into the correct position (e.g. protruding tubes).
If the system is identified as leak free, blow off the Nitrogen into the atmosphere.
Evacuation and Charging the System
The system is now ready for the final evacuation and charging. To keep the content of noncondensability and humidity in the system to a minimum, the system must be evacuated to
a vacuum as low as possible before charging is carried out (0.5 mbar, 50 Pa, 375 micron).
The vacuum attained must be checked with a vacuum gauge.
General rule for evacuation time required:
1. One side evacuation at the compressor’s process tube only, minimum
time required is 30 minutes.
2. Two side evacuations at the compressor’s process tube and the filter-drier’s
process tube, minimum time required is 15 minutes.
Check for stability of the vacuum by closing the valve for the vacuum pump. If the vacuum
gauge needle falls appreciably, possible leakage in the system is indicated or hose connections of the service equipment to the refrigerator/freezer are not properly fitted.
117
SKILLS AND OPERATION
References
DOMESTIC REFRIGERATION HC
Part II
Connect the quick coupler now
to the prepared refrigerant cycle
at the low and high pressure side
using the service coupler.
• 4-valve manifold
• Vacuum pump with
vacuum gauge
• HC refrigerant charging
cylinder on scale
Figure 19: Two side system
evacuation and charging
118
TT
Page 9
Figure 8
RHC
Page 19
Figure 2
When a stable vacuum has been achieved, close the valve for the vacuum gauge and commence charging.
The amount of refrigerant to be added is specified in grams or oz on the rating plate.
Charging process:
1. Charge 1/3 of the total charging amount gaseous into the refrigerated system.
2. Switch on the compressor.
3. Add the remaining charging amount slowly into the system.
4. Observe the gauge and check the system’s operating situation.
References
Seal the System
Part II
DOMESTIC REFRIGERATION HC
SKILLS AND OPERATION
1. Pinch the process tube(s) with
pliers twice. One pinch-off in
90° to the process pipe and
one in 45° to the process pipe.
2. Remove pinch-off pliers.
3. Seal the process tubes using a
stopper device1.
TT
Page 7
Figure 6
• Stopper device
Same process at the filter-drier’s
process tube (if present).
Figure 20: Pressing equipment
for system sealing
1
Stopper device, e.g. manufactured by Lokring.
119
SKILLS AND OPERATION
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DOMESTIC REFRIGERATION HC
References
MI
Page 42
Figure 2
Figure 21: Final leak test with
electronic leak detector2
System check and final leak test
After the charging process the adjustment and functioning of control devices
must be checked. The system must be operated until sufficient system conditions are visible.
Meanwhile temperature and pressure values should be recorded. After the
disconnection of gauges and hoses a final leak test has to be performed.
Use again soap water and/or an electronic leak-detector and you will find that
there are common places to check. The following lists some very common leak
locations:
• Flare-nuts
• Service valve: packing, access fitting, mounting
• Cracked brazed joint in piping
• Rotted evaporator end bends
• Pipes rubbing together
• Cracked ferrous brazed in accessory
2
120
e.g. STARTEK from REFCO
Chapter 11: Pressing, the Process
Preface
Alternatively to brazed joints, especially in domestic refrigeration and for systems operated
with Hydrocarbons (combustible refrigerants like R-600a and R-290), and also for the use in
small and medium AC systems and MAC, pressed tube connections are a safe and reliable
solution.
The tube pressing connection technology3 represents a proven method of producing hermetically sealed metal-to-metal tube connections.
Features of the tube pressing connection technology:
•
•
•
•
Part II
PRESSING, THE PROCESS
SKILLS AND OPERATION
Permanent hermetically metal-to-metal sealing
Unproblematic connection of tubes consisting of different materials
No special preparation of the tubes necessary
Easy and fast assembly
Pressure and Temperature Area
The above mentioned tube connections are designed for a working pressure of 50 bar
(depending on the tube material) with fourfold security and for the range of temperature
from –50°C up to +150°C ( –58°F up to 302°F).
Material Affiliation
The tube connections are made of the materials aluminium and brass.
Brass connectors, both ‘00’ series, for tube diameters 3/8“ (9.53 mm) and above, and all
sizes of ‘50’ series are usually supplied with connectors (adaptors) made from steel, with
a yellow coloured zinc plate galvanization.
The affiliation of the connectors depends on the material of the tubes to be connected and
is shown in the following figure.
3
Tube connections manufactured e.g. by ‘Vulkan Lokring Rohrverbindungen GmbH’
121
PRESSING, THE PROCESS
Part II
SKILLS AND OPERATION
Tube Material Combination
Aluminium
Aluminium
Aluminium
Aluminium
Aluminium
Copper
Aluminium
Aluminium
Steel
Copper
Brass
Copper
Copper
Brass
Steel
Steel
Brass
Steel
Tube Connectors Material
Figure 1: Tube connectors material combinations
Tube connection coupling
for double sided assembly (series 00)
Figure 2: Tube connection couplings
122
Tube connection coupling
for single sided assembly (series 50)
Example of a tube connection coupling
A tube connection coupling consists of two tube connections and one tubular joint for the
acceptance of the two tube endings.
In condition of delivery, the tube connections are pre-assembled on the fitting, the bigger
end of the conical bore is pressed onto the outwards fit of the joint.
Tube
Locking
Ring
Joint
Locking
Ring
Part II
PRESSING, THE PROCESS
SKILLS AND OPERATION
Tube
Figure 3: Tube connection coupling
During assembly the tubes which are to be connected have to be pushed into the fittings
end. With the use of a ‘hand assembling tool’ the locking rings are pushed over the fitting.
Due to the special inner profile of a tube connector (e.g. Lokring), the diameter of the connection is reduced until it is in absolute close contact with the outer surface of the tube
which is to be connected, and pinches it by a tight reduction.
Tube
Locking
Ring
After Assembly
Locking
Ring
Joint
Before Assembly
Figure 4: Tube coupling
123
PRESSING, THE PROCESS
Part II
SKILLS AND OPERATION
Safety Recommendations
Despite the high metal/metal pressure it is not always possible to seal deep surface porosity
and longitudinal grooves which might have a negative effect on the tightness of the tube
connection.
In order to obtain additional safety, the surfaces of the tube ends have to be moistened
with an anaerobic liquid. It settles in the unevenness of the tube surface and hardens there.
The curing time is dependent on various factors. After the curing of the liquid, the connection
can be loaded with pressure or vacuum.
Lokprep 65G
Anaerobic filling and sealing
Medium contains methacrylic ester
Available in 15 or 50 ml
Figure 5: Lokprep, anaerobic liquid
Figure 6: Hand assembling tool
124
Figure 7: Assortment box for refrigeration
Connection Examples
Lokring connector (double sided assembly)
made of brass for joining of tubes
1.6 to 11 mm
Brass connectors for tube materials:
Cu/Cu; Cu/St; St/St
Part II
PRESSING, THE PROCESS
SKILLS AND OPERATION
Figure 8: Lokring connector brass
Lokring connector (double sided assembly)
made of aluminium for joining of tubes
2 to 11 mm
Aluminium connectors for tube materials:
Al/Al; Al/Cu; Al/St
Figure 9: Lokring connector aluminium
Lokring reduced connector (double sided
assembly) made of aluminium for joining
of tubes
Aluminium reduced connectors for tube
materials:
Al/Al; Al/Cu; Al/St
Figure 10: Lokring reducer aluminium
125
SKILLS AND OPERATION
PRESSING, THE PROCESS
Part II
Lokring tee connector (single sided
assembly) made of brass for joining
of tubes 6 to 28.6 mm
Brass tee connectors for tube materials:
Cu/Cu; Cu/St; St/St
Figure 11: Lokring tee connector
Lokring tee reduced connector
(double sided assembly) made
of brass for joining of tubes
e.g. ø 6 mm and ø 2 mm with
tee ø 6 mm: Lokring 6/6/2 NTR Ms 00
(capillary tube insertion)
Brass tee reducer for tube materials:
Cu/Cu; Cu/St; St/St
(e.g. domestic appliances)
Figure 12: Lokring tee reducer
with capillary tube insertion
Figure 13: Filter-drier with tube ends
126
Assembly of the Tubes
Surface cleaning
Before assembling the tube connection,
clean the tube ends with a scouring pad.
Figure 14: Tube cleaning in
a rotational motion
To avoid longitudinal grooves clean the
tube ends in a rotational motion (not in
longitudinal direction of the tube).
Part II
PRESSING, THE PROCESS
SKILLS AND OPERATION
Apply anaerobic liquid
The ends of the tubes have to be
coated with an anaerobic liquid.
Figure 15: Coating with Lokprep
as anaerobic liquid
Rotate connection assembly
Figure 16: Rotating connection assembly
The tube ends have to be inserted into
the tube connection until the stop.
For a better distribution of the anaerobic
liquid the tube connection has to be
rotated at 360°.
Press locking rings
Tube connector assembly with hand
assembly tool.
Figure 17: Pressing the tube connection
127
PRESSING, THE PROCESS
Part II
SKILLS AND OPERATION
Example tee connector
Tee connector assembly and quick service
connector
• Lokring tee connector
• Quick service connector
Figure 18: Example of a tee connector
Compressor assembly
Compressor assembly with Lokring couplers
Figure 19: Example of a compressor assembly
The tube locking ring has not been pushed
to the end
The tube has not been inserted to the end
The bending point is too close to the joint
ending
Figure 20: Assembly faults
Final Leak Check
After all couplers and connectors are done, check system for leaks. Use dry Nitrogen
to pressurize the system up to a maximum pressure of 10 bar.
128
Chapter 12: Refrigerant Recovery, Recycling and
Containment in the field
Preface
The transfer of any kind of refrigerants into storage and recycling cylinders is a dangerous
practice. For this reason we always have to work according to strict safety regulations. Read
carefully refrigerant manufacturer`s safety advices for the handling of refrigerants.
Think before acting!
Pressured and liquified gas may quickly create dangerous situations.Through improper use,
liquid gas can cause severe injury to skin, eyes and respiratory tracts.
This picture shows a hand affected by
contact with liquid refrigerant.
Figure 1: Affected hand
Safety Recommendations
Part II
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
There is always a strict smoking ban in all work areas. Work areas must be ventilated if refrigerant is present. Refrigerants are heavier than air and reduce the content of oxygen in the
air. Refrigerants are not visible and do not smell. Breathing refrigerants may not be noticed
and lead to a blackout and/or death.
The touch of voltage-carrying operating supplies causes life threatening situations.
129
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
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SKILLS AND OPERATION
Special care should be taken:
• Not to overfill the refrigerant cylinder.
• Not to exceed the working pressure of each cylinder. Check stamping on cylinder!
• Safety codes recommend that closed tanks are not be filled over 80%
of volume with liquid.
• Never transport an overfilled cylinder.
• Not to mix grades of refrigerant or put one grade in a cylinder labelled for another.
• To use only clean cylinders, free from contamination by oil, acid, moisture, etc.
• To visually check each cylinder before use and make sure all cylinders are regularly
pressure tested.
• Recovery cylinders have a specific indication depending on the country (yellow
mark in US, special green colour in France) in order not to be confused with
refrigerant container.
• Not to store a filled cylinder at a high ambient temperature and exposed to the sun.
References
Starting with
cylinder 80%
full by volume
RHC
Page 27
Figure 13
Starting with
cylinder 90%
full by volume
Figure 2: Cylinder temperature and
internal liquid expanding space
Refrigerant expands when it gets warm and may cause tank explosion if
overfilled.
130
The cause was for
each overfilling with
refrigerant.
Figure 3: Examples of bursted cylinders
References
Cylinder should have
separate liquid and
gas valves and be
fitted with a pressure
relief device.
RHC
Page 27
Figure 13
Part II
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
Figure 4: Cylinder with separate liquid
and gas valves
Photos courtesy of Manchester Tank & Equipment
131
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
Part II
SKILLS AND OPERATION
Purchased Refrigerants
Purchased refrigerants are packed in both disposable and returnable shipping containers.
Disposable cylinders often indicate very bad practice. CFC refrigerants even purchased today
often have a bad quality (contaminated).These containers are generally discarded after use
and a lot of refrigerant is released into the atmosphere due to disposable cylinders.
Refrigerant manufacturers have voluntarily established a colour code system to identify their
products, with both disposable and reuseable cylinders painted or otherwise distinguished
by the following common refrigerant colours and identification:
R-11 Orange
R-134a Light Blue
R-12 Grey
R-404 Orange
R-22 Medium Green
R-507 Blue Green
Table 1: Refrigerant cylinder colours
These cylinders are not recommended for refilling!
Only use DOT or TÜV standard approved refrigerant recovery
cylinder for recovery purpose!
Figure 5: Disposable refrigerant cylinder
132
R-502 Orchid
R-407C Med. Brown
References
There are three different
possibilities for overfill
protection (OFP)!
1. The cylinder is equipped with
a liquid level float switch.
Figure 6: Recovery with OFP
connection (float-switch)
Recovery unit will cut-off if 80%
of filling volume is achieved.
RHC
Page 27
Figure 13
Recovery cylinder
Recovery unit
Inline filter with hose (inlet)
OFP cable connection to
recovery unit
RHC
Page 27
Figure 13
Figure 7: Connection of OFP to the
socket at the recovery cylinder
Part II
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
Figure 8: Arrangement of recovery cylinder
and recovery unit with OFP connection
133
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
Part II
SKILLS AND OPERATION
References
2. Recovery cylinder is placed
on scale.
Recovery unit will turn off if
the adjusted weight amount
is achieved.
Recovery cylinder
Recovery unit
Inline filter with hose (inlet)
Weighing scale with
MI
Page 46
Figure
9 (1)
connection to the recovery
unit
Figure 9: Recovery with cylinder on
weighing scale and connected OFP
3. Recovery cylinder is placed
on scale.
MI
Page 46
Figure
9 (1)
Operator turns off the recovery
unit manually if 80% of cylinder
charge is achieved.
Figure 10: Arrangement of cylinder, scale
and recovery unit for manual observation
Warning: An 80% shut off switch does not always prevent overfilling. Any
technician using an 80% shut off switch must be aware of the liability and
safety risks that come along with their use.
Further explanation of this topic can be found in the section below
‘Methods of refrigerant recovery – push and pull-method’.
134
Refrigerant Recovery Process
Using recovery units
Recovery units are connected to the system by available service valves, or line tap valves,
or line piercing pliers. Some of them can handle refrigerants in both liquid and vapour form
and some have onboard storage vessels.
Take care not to let the compressor suck in liquid refrigerant if the compressor is not protected against liquid strokes.
Figure 11: Refrigerant flow chart example (recovery unit)
The above sketch demonstrates a recovery unit layout example with liquid stroke protection
(suction pressure regulator) and an oil based compressor.
Part II
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
There are three types of recovery apparatus available. These are self-contained, system
dependent and passive:
Self-contained:
A self-contained recovery unit has its own compressor (or other transfer mechanism) to
pump refrigerant out of the system. It requires no assistance from any component in the
system that is being recovered.
135
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
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SKILLS AND OPERATION
System-dependent:
System-dependent recovery equipment, on the other hand, relies upon the compressor in
the appliance and/or the pressure of the refrigerant in the appliance to assist in recovery
of the refrigerant. Recovery that uses only a chilled recovery tank falls under this category.
Passive:
Passive recovery refers to a deflated bag (recovery bag), e.g. for small domestic appliances,
which is used to store small amounts of refrigerant near or slightly above atmospheric pressure (0.1 bar).
Methods of Refrigerant Recovery
The methods of recovery depend upon the type of refrigerant being recovered. This is usually
divided into two general groups: High pressure, where the boiling point of the refrigerant
is between –50°C and 10°C at atmospheric pressure, and low pressure where the boiling
point is above 10°C at atmospheric pressure. High pressure refrigerants include CFC-12,
HFC-134a and HCFC-22, while low pressure refrigerants are CFC-11, CFC-113, HCFC-123
etc.
References
Gas recovery
The refrigerant charge can be
recovered in vapour recovery
mode as shown in this sketch.
On larger refrigeration systems,
this will take appreciably longer
than if liquid is transferred.
Connection hoses between
recovery units, systems and
recovery cylinders should be
kept as short as possible and
the diameter as large as
practicable.
Figure 12: Vapour recovery mode
136
MI
Page 46
Figure
9 (1)
References
Liquid & oil recovery
If the recovery unit does not
have a built-in liquid pump (system depending) or is otherwise
not designed to handle liquid,
then liquid can be removed from
a system using two recovery
cylinders and recovery unit. The
recovery cylinders must have
two ports and two valves, one
each for liquid and one each
for vapour connections.
MI
Page 46
Figure 9
This recovery set-up will also act
to separate the oil from the
cylinder connected to the inlet
port of the recovery unit.
Figure 13: Recovery system with two
cylinders for liquid and oil separation
‘Push and pull’ liquid
refrigerant recovery method
The recovery unit will pull the
liquid refrigerant from the disabled unit when decreasing the
pressure in the recovery cylinder.
Vapour pulled from the recovery
cylinder by the recovery unit will
then be pushed back to disabled
unit’s vapour side.
MI
Page 46
Figure
9 (1)
Part II
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
Figure 14: ‘Push and pull’-recovery system
137
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
Part II
SKILLS AND OPERATION
Note: Refrigerant recovery 80% shut off switches
The 80% shut off sensors were originally intended to be a safety feature for refrigerant
recovery.
On most machines these switches simply turn off the recovery machine without stopping
the flow of refrigerant.This can result in an overfilled cylinder, becoming extremely dangerous
for the technician. This is a known hazard in these common situations:
1. During push-pull procedures, once a siphon is started, merely
powering off the machine, but does not prevent the tank from overfilling.
2. When using a tank with a large amount of cold refrigerant and recovering
from a system at a higher temperature, turning the machine off will not stop
the refrigerant from migrating to the coldest point (in this case, the recovery
tank) eventually overfilling the tank even with the machine off.
Warning: An 80% shut off switch does not always prevent overfilling. Any technician
using an 80% shut off switch must be aware of the liability and safety risks that come along
with their use.
Reminder: 80% shut off switches are not ‘walk-away’ features!
No process involving temporary connections and systems under
pressure should ever be left unattended!
Test Refrigerant and Lubricant
for Contamination
To carry out refrigerant and oil tests it is necessary to remove a sample of refrigerant and
oil from the compressor or refrigeration system without undue release of refrigerant. The
procedure for this will vary depending on the arrangement of shut-off valves and access to
the refrigerant and oil available on the unit.
138
References
RHC
Page 28
Figure 15
Figure 15: Oil-test at compressor
suction line
Figure 16: Refrigerant test
at cylinder
Proprietary test kits are available which permit the refrigerant to be tested
for water contamination and acidity.
It is possible to test the oil in
some systems for acidity.
Acid in the oil indicates that
a burnout or partial burnout has
taken place, and/or that there
is moisture in the system, which
can cause a burnout.
RHC
Page
28/29
Figure
15,16,17
Figure 17: Taking oil-sample from
a hermetic compressor
RHC
Page
28/29
Figure
15,16,17
Part II
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
Figure 18: Taking oil-sample from
a semihermetic compressor
139
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
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140
SKILLS AND OPERATION
Reuse of Refrigerant
Recovered refrigerant may be reused in the same system from which it was removed or it
may be removed from the site and processed for use in another system, depending upon
the reason for its removal and its condition, i.e. the level and types of contaminants it may
contain.
Potential contaminants in a refrigerant are acids, moisture, non-condensable gases and
particulate matter. Even low levels of these contaminants can reduce the working life of a
refrigeration system.
Contaminated refrigerants (including those from a unit with a burn-out hermetic compressor)
are reusable provided they have been recovered with a recovery unit incorporating an oil
separator and filters (recycling unit).
Recycling units may be directly connected to the serviced system (e.g. MAC) or clean the
stored refrigerant from recovery or storage cylinder.
Main cleaning components of a common recycling unit are in general:
1. Compressor
2. Thermostatic expansion valve (TEV) or Constant Pressure Regulator (CPR)
3. Suction-accumulator or oil-seperator with oil-drain valve
4. Filter sections (one or more)
5. Non-condensable gases purge device (manual or automatic)
6. Condenser
7. Storage cylinder
Figure 19: Refrigerant flow chart example of a recycling unit
Removal and absorption of:
• Acid
• Moisture
• Particulate matter
Recycling filter must be regularly
changed according to manufacturers’ recommendation and
refrigerant contamination state.
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Figure 20: Example combo-filter (recycling filter)
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SKILLS AND OPERATION
Recovery from Mobile Air-Conditioning
System (MAC)
Vapour transfer
Mobile air-conditioning systems are normally equipped with service valves on the compressor’s high and low pressure side. The refrigerant charge on such a system is rather small
and therefore only vapour transfer is required.
Passenger compartment
➡
➡
➡
➡
Connect quick service couplers
to the service hoses if required.
Gauges
Low side
service port
Filter-drier
High side
service port
➡
➡
Compressor
Receiver
Front of car
Figure 21: Mobile air-conditioning system
connected to a ‘refrigerant handling’ unit
References RRRE Page 34-Figure 3
142
Connect both refrigerant hoses
from the MAC servicing unit low
and high pressure side to the
air-conditioning system’s service
ports as indicated.
Expansion device
➡
➡
REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
Part II
Automatic and/or manual
air-conditioning system service
procedure follows:
- AC system data monitoring
and evaluation
- Refrigerant recovery
- Refrigerant recycling
- AC system repair
- AC system leak test
- AC system evacuation
- AC system charging
Recovery from a Domestic Refrigerator
Domestic refrigeration appliances have to be hermetically sealed – without exception.
It is possible to recover refrigerants from a hermetically sealed system, which has no service
valves. A piercing plier or a line-tap valve should be fitted to the refrigerant cycle (in most
cases the process tube or charging tube). These valves are only for servicing purposes and
should never be left permanently in place.Always remove these temporary valves to provide
a sealed hermetically system after service and repair.
References
Because of the small charge of
refrigerant, only vapour recovery
is needed.
It is recommended to
install valves (piercing plier
or line-tap valve) on both
and low pressure side
(if possible).
RHC
Page 24
Figure 9
RHC
Page 25
Figure 10
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SKILLS AND OPERATION
Figure 22: Installation of piercing pliers
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SKILLS AND OPERATION
Various refrigerant recovery technologies for domestic appliances
For the purpose of refrigerant recovery at small capillary systems we differentiate the use
of, e.g.:
1. Recovery unit and recovery cylinder
2. Refrigerant recovery hand pump with recovery cylinder or bag
3. Refrigerant recovery with vacuum pump and recovery bag
References
Refrigerant recovery with
recovery unit
Figure 23: Placement of
recovery cylinder
Figure 24: Recovery with recovery
unit and cylinder
144
• Place the recovery cylinder
on scale.
• Connect the recovery unit
outlet port to the liquid port
of the recovery cylinder.
• Connect the center port to the
manifold gauge set to the inlet
port of the recovery unit.
Incorporate an inline filter-drier.
• Connect low and high side of
the manifold gauge set to the
refrigerator’s low side (process
tube) and high side (filter-dier).
• Recover refrigerant.
RRRE
Page 32
Figure1
RRRE
Page 33
Figure 2
References
Refrigerant recovery hand
pump with recovery cylinder
or bag
• Connect the recovery hand
pump outlet port to the
recovery cylinder or connection
port of the recovery bag.
• Connect the refrigeration
system (process tube and/or
filter-drier) to the inlet port of
the recovery hand pump.
Incorporate an inline filter-drier.
• Recover refrigerant.
Figure 25: Connecting recovery hand-pump
RRRE
Page 35
Picture 5
RRRE
Page 36
Figure 6
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REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
Figure 26: Recovery arrangement with hand-pump
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REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
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146
SKILLS AND OPERATION
References
Refrigerant recovery with
vacuum pump and recovery
bag
Step 1
Pressure equalizing
Figure 27: Connecting recovery bag
with piercing plier
• The recovery bag is equipped
with a 1/4“ SAE male connection port with valve core.
• Connect the recovery bag to
the piercing plier valve using a
refrigerant hose with ball valve
and core depressor. The ball
valve with core depressor is
placed at the recovery bag
connection port and the core
depressor opens the valve core
while connecting.
• Install the piercing plier or line
tap valve to the system and
open the valve.
• Refrigerant will be transferred
into the recovery bag.
• Close the valve (hose and
piercing device) after pressure
equalizing and remove the
refrigerant bag.
RHC
Page 24
Figure 9
RRRE
Page 35
Figure 5
References
Step 2
Vacuum pump connection
• Connect the recovery bag to
the vacuum pump outlet
(exhaust port) using a refrigerant hose with ball valve and
core depressor. The ball valve
with core depressor is placed
at the recovery bag connection
port and the core depressor
opens the valve core while
connecting.
• Mount the refrigerant hose of
the low pressure side of the
manifold set to the piercing
device and open the valve.
• Open the valves at the manifold set (low pressure and
vacuum pump valve).
• Open the ball valve at the
recovery bag inlet.
• Start evacuation.
• Evacuate the system for
approximately 10 minutes.
There must not be any appreciable overpressure in the
refrigerant bag, as this may
damage the vacuum pump!
RHC
Page 24
Figure 9
RRRE
Page 35
Picture 5
RRRE
Page 37
Figure 7
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REFRIGERANT RECOVERY, RECYCLING AND CONTAINMENT IN THE FIELD
SKILLS AND OPERATION
Figure 28: Connecting recovery bag
with vacuum pump outlet
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RETROFIT
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SKILLS AND OPERATION
Chapter 13: Retrofit
Preface
With the phase-out of CFCs and HCFCs, existing refrigeration and air-conditioning equipment
operating with CFCs and HCFCs will ultimately need to be either replaced with new equipment
or retrofitted with alternative refrigerants.
Retrofit is the process by which the equipment currently using an ODS refrigerant is made to
run on a non-ODS refrigerant, without major effects on the performance of the equipment,
and without significant modifications/changes for the equipment, ensuring that existing
equipment operates until the end of its economic life.
Unlike a replacement, only some components of the existing system may need to be replaced.
Please refer to the tables ‘refrigerant data’ at the end of this chapter.
Retrofit in General
Involved changes
Typical retrofit may involve one or many of the following changes:
•
•
•
•
•
•
•
Refrigerant
Lubricant
Desiccant filter (drier)
Expansion valve
Compressor (gearbox, speed, motor)
Insulation and seal materials, elastomers
For centrifugal chillers: purge systems, impeller/gearbox
Problems related to a CFC/HFC retrofit:
• Studies show from 1% less to 7% higher energy consumption than CFC-12.
• Problem of finding suitable lubricants: HFC-134a has very low solubility
and mineral oil does not mix well in HFC-134a.
• Poor oil returns back to the compressor, resulting in a possible
compressor failure.
• Fouling of expansion valves and heat exchanger surfaces, leading to
reduced system performance.
148
Lubricants for alternative refrigerants:
• Polyol ester (POE) oils must be used with HFC refrigerants.
• Existing systems will require an oil flushing procedure because of
chemical incompatibilities between the refrigerants and lubricants.
• System charged with retrofit refrigerant can lead to early system
failure due to chemical reaction between the chlorine from CFC and
lubricating oils.
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Polyol ester synthetic oils are backwards compatible.
Therefore, they are acceptable for use with CFC-12, HCFC-22 and CFC-502.
Important notes for the use of lubricants:
• POEs more than minerals tend to absorb water.
• Therefore, they need to be handled with care before being used
because of the increased water which may be present in the system.
• Proper evacuation is a must!
• A larger filter-drier may be required in a system which has been
retrofitted to POEs to make sure that all of the excess water is removed.
• POEs dissolve materials that CFCs or mineral oil does not. Therefore,
the filter-driers need to be frequently checked.
It is strongly recommended that the manufacturer-specified lubricant be used
to ensure that it is compatible with all the components with which it is in contact.
Residual mineral oil
Acceptable residual mineral oil content in a retrofitted system:
Evaporation temperature
Less than –15°C
–15°C up to –5°C
Above 0°C
Residual mineral oil
in the system
1 to 3%
Approx. 5%
5 to 10%
Table 1: Residual mineral oil content related to the evaporation temperature
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Retrofit categories
Drop-in retrofit:
A switch-over to an alternative refrigerant without any changes in the refrigeration system.
Some mineral lubricating oil may be required to be replaced by Polyol Ester (POE) /
Polyalkylene Glycol (PAG) after thorough flushing of the system using dry Nitrogen and
charging the required quantity of drop-in refrigerant.
Simple / economical retrofit:
A switch-over to an alternative refrigerant which only requires the change of a few incompatible parts such as gaskets, o-rings, filter-drier. Simple retrofits may result in some cases
in slight decrease in either efficiency, capacity or both.
System optimisation or engineered retrofit:
A conversion to an alternative refrigerant which includes the replacement of major system
components, such as compressor, heat exchangers, expansion device etc. with new ones
that have been redesigned specifically for the alternative refrigerant.
Conclusions and statements
• It should be noted that properly working appliances are not recommended
for retrofit until there is a need to open the refrigeration system for repair.
• Properly operating systems could just be operating without any harm
to the ozone layer.
• For older RAC systems, it may be more cost-effective to replace rather
than retrofit. In addition, new equipment will be more energy-efficient.
• Retrofitting involves two kinds of costs:
- Cost of labour
- Cost of components that need to be changed
150
• For cost calculation the problem of lubricant changing related to the
refrigerant choice may play a significant role. A refrigeration or air-conditioning
system with extensive pipe works and/or various amounts of evaporators
and accessories (e.g. oil separator or liquid accumulators) must be flushed
with the intended retrofit lubricant until certain remaining mineral oil
containment in the system is obtained.
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• A good opportunity to carry out a retrofit procedure is in connection with
the regularly scheduled maintenance of a RAC system.
• The option of retrofitting will be considered in cases where the supply of CFCs
is getting scarce due to a ban on importation of CFC by the country, and
if no CFC is available at all.
The Practical Retrofit Process
Required data information collection:
1. Type of existing refrigerant
2. Type and brand names of all system components such as e.g. compressor
(condensing unit), evaporator, condenser …
3. Size of liquid receiver
4. Type and brand names of primary control devices
5. Type and brand names of secondary control devices
6. Dimensions and length of pipe work
7. Altitude difference between compressor, evaporator and condenser
8. Specific features of the existing equipment
9. Monitored system data under functional condition like evaporation and
condensing temperatures, electrical data, intended temperature of room
or conditioned medium
10. History of system failures (in particular compressor burn-out)
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Existing CFC
system retrofit
Isolate
compressor
Fill alternative
refrigerant
Drain mineral
oil
Recover
CFC refrigerant
Refill with
alternative oil
Refill with
alternative oil
Operate
system
Drain
oil
If
> 5%
Check oil
contamination
If
< 5%
Figure 1: Retrofit process flow
Refrigerant charging
Use HFC blends to remove liquid only from charging cylinder. Once liquid is removed from
the cylinder, the refrigerant can be charged to the system as liquid or vapour as desired.
Use the manifold gauges or a throttling valve to flash the liquid to vapour if required.
The refrigerant storage cylinder must be checked for leakage, otherwise the composition of
refrigerant can be altered. Refrigeration and AC systems should be clearly labelled after
conversion to avoid future mixing of refrigerants.
152
• Charge the system with the alternative refrigerant.
Caution should be taken not to overcharge!
• 75% of the CFC charge as a starting point.
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The optimum charge will vary depending on the system design and operating conditions,
but for most systems the best charge size will be 75-90% by weight of the original charge.
Start the system and let conditions stabilise. If the system is undercharged, add refrigerant
in small amounts (still removing liquid from the charging cylinder) until the system conditions reach the desired level.
Attempting to charge until the sight glass is clear may result in overcharging
of refrigerant.
Various pressure switches may need to be adjusted to maintain proper operating conditions, e.g.:
•
•
•
•
•
•
Evaporator pressure regulators
Cut-in and cut-out pressure switches
Condenser fan cycling pressure switches
Head pressure controls
Crankcase pressure regulators
Others
Due to the higher oil miscibility of HFCs and POE, verify proper compressor oil sump levels.
Check with the compressor manufacturer for proper amperage load ratings.
For data monitoring and evaluation use the ‘refrigeration system retrofit data sheet’ provided
at the end of the chapter.
Important notes:
Since all blends contain at least one flammable component, suitable measures should be
taken to avoid entry of air into the system. A critical displacement of the ignition point can
occur under high pressure when a high proportion of air is present. Besides this, pressure
tests with an air/refrigerant mixture are not allowed.
Do not use ‘shop-air’ for pressure tests!
Dry, oxygen-free Nitrogen should be used.
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Practical Issues
Oil change (drainage):
Dry Nitrogen
Compressor
6mm Copper tube
Figure 2: Oil change with dry Nitrogen
154
1. Check the system for leaks and
repair if necessary.
2. Separate compressor while using
pump down function or closing
the compressor’s shut-off valves.
3. If necessary recover remaining amounts
of refrigerant using an appropriate
refrigerant recovery technology.
4. Open the oil support connection
at the compressor’s crank-case.
5. Insert a 6 mm soft copper tube
reaching the crankcase bottom.
6. Seal the tapped hole with tape or
rubber seal and hold the copper tube.
7. Transfer a small amount of Nitrogen
with low pressure into the crankcase.
8. The oil will be transferred (pushed)
into a separate container.
9. Dispose of the oil (as contaminated
waste) in an environmentally friendly
way.
Part II
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SKILLS AND OPERATION
• Nitrogen supply and oil draining
• Contaminated oil
Figure 3: Oil changing procedure
• Example for oil support connection
Figure 4: Oil support connection
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SKILLS AND OPERATION
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Part II
Oil draining from a hermetic
compressor:
• Disassemble the compressor
• Turn compressor upside-down
• Drain the oil through suction
or process tube
• Refill small amount POE oil (150 ml)
and shake the compressor
• Drain the remaining oil
Figure 5: Oil drainage from hermetic compressor
Oil change (refill):
1. Connect a vacuum pump to the suction
shut-off valve.
2. Insert the free end of the 6 mm copper
tube/hose assembly into a POE oil can
reaching the bottom.
3. Switch on the vacuum pump.
4. The oil will be transferred (pulled) due
Compressor
to low pressure within the crankcase
into the compressor.
5. Observe the oil level in the compressor’s
sight glass but use the same volume as
removed within the draining process.
6. Stop oil flow.
7. Measure the charged amount of oil.
8. Evacuate the compressor.
9. Open the compressor’s stop-valves.
6 mm Copper tube 10. Run the compressor.
Oil sight glass
11. Check system for leaks.
Figure 6: Oil change with vacuum pump
156
Due to the readiness of the fresh POE oil to absorb humidity, it is essential to use only small
cans of fresh oil. Do not store open cans of POE for further use.
Part II
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Oil filling process (example 1)
• Vacuum pump connection to the
compressor’s suction line stop-valve
service port
• POE oil filling hose assembly
Figure 7: Oil filling process (in detail)
Oil filling process (example 2)
• Vacuum pump
• Hose assembly to crankcase
• Oil can with POE
• Weighing scale
• Recovery unit
Figure 8: Oil filling process
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Refrigeration System Retrofit Data Sheet
Service Company Name
Address
Telephone & Fax No.
Registration No.
Client Name
Address
Telephone & Fax No.
Contact Person Name
Installation/Appliance DATA
Type of Installation
Model and No.
Type of Compressor
Model and No.
Manufacturer
Serial No.
Manufacturer
Serial No.
Operating Data
Old
New
Refrigerant Type
Refrigerant Charge
Type of Lubricant
Lubricant Charge
Suction Pressure
Discharge Pressure
Suction Line Temp.
Discharge Line Temp.
Ambient Temperature
Room/Medium Temp.
LP Cut-Off
HP Cut-Off
Refrigerant Type
Refrigerant Charge
Type of Lubricant
Lubricant Charge
Suction Pressure
Discharge Pressure
Suction Line Temp.
Discharge Line Temp.
Ambient Temperature
Room/Medium Temp.
LP Cut-Off
HP Cut-Off
Electrical Data
Power Supply (Voltage)
Current Draw Compressor
Power Supply (Voltage)
Current Draw Compressor
Other Installation Data
Discharge Line Diameter
Liquid Line Diameter
Suction Line Diameter
Insulation Suction Line
Type of Condenser
Type of Filter-Drier
Signature Technician
Discharge Line Length
Liquid Line Length
Suction Line Length
Altitude diff. Compr./Evap.
Type of Evaporator
Type of Filter-Drier
Date
Signature Client
Table 2: Refrigeration system retrofit data sheet
158
Date
RETROFIT – Equipment Label
Company
Technician Name
Address
Telephone & Fax No.
Registration No.
Part II
RETROFIT
SKILLS AND OPERATION
Refitted to Refrigerant HFC-R134a
This system is only for the use with HFC-R134a
and synthetic lubricant
Refrigerant Charge
Lubricant Charge (old)
Lubricant Charge (new)
Retrofitted by:
Retrofit Date:
Signature:
Table 3: Retrofit equipment label data sheet
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Refrigerant Data
CFCs (Phased out / Montreal Protocol)
Pure HCFC Refrigerants (Being phased out / Montreal Protocol)
Pure HFC Refrigerants (controlled under Kyoto Protocol)
160
HCFCs Blends (Being phased out / Montreal Protocol)
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161
RETROFIT
Part II
162
SKILLS AND OPERATION
HFC Blends (controlled under Kyoto Protocol)
Hydrocarbons (local safety regulations apply)
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RETROFIT
SKILLS AND OPERATION
Hydrocarbon Blends (local safety regulations apply)
Natural Refrigerants (local safety regulations apply)
163
SAFETY
Part II
SKILLS AND OPERATION
Chapter 14: Safety
Preface
Work with or on refrigeration and AC equipment (RAC), machineries or material and substances is always in different ways associated with high risks to personal health.
The following chapter gives an overview of important signs and work clothing concerning
the safety of personnel working in this field.
Work must only be performed by properly trained personnel equipped with safety equipment, machineries and tools in good condition and of good quality.
Warnings
Danger! Harmful skin/eye
contact with refrigerant and oil
Danger! Flammable
refrigerant
Danger! Electricity
Danger! Inhalation
of harmful gases
Danger! Hazard area
Danger! Compressed
gas and vessel
Danger! Suspended
heavy objects
Figure 1: Warning signs
164
Danger! Hot surfaces
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SAFETY
SKILLS AND OPERATION
Bans
Smoking ban
No open fire
Only authorized persons
No bystanders
Use of machineries not in
wet areas
Figure 2: Ban signs
Rescue
Notice escape way
Provide First Aid material
Provide eye shower fluid
Notice nearest Medical Help
contact information
Figure 3: Rescue signs
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SAFETY
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Commandment
Wear suitable work clothes
Wear protective gloves
Wear ear defender
Wear safety glasses
Wear safety helmet
Wear safety shoes
Plug out equipment for service
Disconnect machineries for service
Figure 4: Commandment signs
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Work Clothing
Normal work gloves
with rubber knobs
Normal work gloves,
inside palm rubber covered
Protection grade depends on work task
Figure 5: Work gloves (example 1)
Work gloves for refrigerant
and oil handling
Thick work gloves for
welding and brazing
Protection grade depends on work task
Figure 6: Work gloves (example 2)
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SKILLS AND OPERATION
SAFETY
Part II
Normal safety glasses
with side protection
Normal safety glasses
with full cover protection
Protection grade depends on work task
Figure 7: Safety glasses
Ear defender
Respirator (dust and dirt)
Protection grade depends on work task
Figure 8: Safety devices
168
Safety helmet
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SAFETY
SKILLS AND OPERATION
Toe and heel protection (steel)
Safety shoes (high and low shaft)
Protection grade depends on work task
Figure 9: Safety shoes
Overalls
Normal work trousers
Work jacket
Protection grade depends on work task
Figure 10: Safety clothes
169
GLOSSARY
ANNEX
Glossary
Bending
Because a copper tube is so readily formable, it is often bent to adapt to the needs of a
piping system at the job site.This is a relatively simple matter to do by hand if a wide, sweeping radius is involved, but for tighter bends, it is often desirable to use a special piece of
equipment to avoid kinking the line, which would restrict flow. Such tools can range from
a simple spring-like device that prevents the collapsing of tube walls, to more sophisticated
devices that involve lever or gear arrangements.
Brazing
Brazing is a joining process whereby a filler metal or alloy is heated to a melting temperature
above 450°C (840°F) and distributed between two or more close-fitting parts by capillary
action. At its liquid temperature, the molten filler metal and flux interact with a thin layer
of the base metal, cooling to form a strong, sealed joint. In order to attain the highest
strengths for brazed joints, parts must be closely fitted and the base metals must be exceptionally clean and free of oxides.
Brazed joint: A joint obtained by the joining of metal parts with alloys which melt at temperatures in general higher than 450°C, but less than the melting temperatures of the joined
parts.
Charging
This is transferring a refrigerant from the refrigerant source (refrigerant cylinder for virgin
refrigerants or recycled refrigerant cylinder) into a system, normally according to a specified
weight, a specified amount of subcooling or evaporating pressure. Charging is normally
carried out using a dedicated charging machine (e.g. in a production area) or using a cylinder
connected to the system via manifold/hoses. The cylinder is disconnected from the refrigeration system after the refrigeration system has been completely charged with the new
refrigerant.
Containment
The application of service techniques or special equipment designed to preclude or reduce
loss of refrigerant from equipment during installation, operation, service or disposal of refrigeration and air-conditioning equipment.
Evacuation
Evacuation of a refrigeration system means the ultimate removal of rests of moisture or noncondensable gases in the system.This means the removal of all refrigerant and volatile contaminants such as moisture and air, thus leaving a near-vacuum. Evacuation is normally carried
out by a specific vacuum pump, after refrigerant recovery has been completed (if applicable),
and is ideally drawn to an absolute pressure of 0.5 mbar (50 Pa, 375 micron) or lower.
170
Flared joint
Whereas brazing is a thermal bonding process, flared joints provide a mechanical connection
between copper tubing and fittings. This is a metal-to-metal compression joint in which a
conical spread is made on the end of the tube. This is a mechanical joint and is prone to
leakage.
GLOSSARY
ANNEX
Global Warming Potential
Global Warming Potential (GWP) is a measure of how much a given mass of greenhouse
gas is estimated to contribute to global warming. It is a relative scale which compares the
contribution to global warming of the gas in question to that of the same mass of Carbon
Dioxide (whose GWP is by definition 1) over a defined time horizon. For instance, Methane is
a significant contributor to the greenhouse effect and has a GWP of 21 (100-yr time horizon).
This means Methane is approximately 21 times more heat-absorptive than Carbon Dioxide
per unit of weight.
GTZ (Deutsche Gesellschaft für Technische Zusammenarbeit GmbH/German
Technical Cooperation Agency)
As an international cooperation enterprise for sustainable development with worldwide operations, the federally owned ‘Deutsche Gesellschaft für Technische Zusammenarbeit’ (GTZ)
GmbH supports the German government in achieving its development policy objectives. It
provides viable, forward-looking solutions for political, economic, ecological and social development in a globalised world.Working under difficult conditions, GTZ promotes complex
reforms and change processes. Its corporate objective is to improve people’s living conditions on a sustainable basis.
Hermetisation
Hermetisation is to maintain a ‘sealed system’ of the refrigerant cycle in refrigeration. A
sealed system is a refrigeration system in which all refrigerant containing parts are made
tight by welding, brazing or a similar permanent connection.
MLF (Multilateral Fund) of the Montreal Protocol
The Multilateral Fund was established in 1990 as a financial mechanism for the implementation of the Montreal Protocol. By financing technology transfer and cooperation, the Fund
assists developing (so called Article-5) countries to meet their commitments under the
Montreal Protocol, that means to enable these countries to phase out and replace ODS within
an agreed time frame. Industrialised countries agreed to contribute to the Fund in order to
help Article-5 countries achieve the Protocol’s goals. Financial and technical assistance (closure of ODS production plants and industrial conversion, technical assistance, information
dissemination, training and capacity building) is provided in the form of grants or concessional loans and is delivered primarily through four implementing agencies (UNEP, UNDP,
UNIDO, World Bank).
171
GLOSSARY
ANNEX
Montreal Protocol
The international treaty ‘Montreal Protocol on Substances that Deplete the Ozone Layer’
was agreed in 1987 after scientists discovered that certain man-made substances, such as
CFCs, were contributing to the depletion of the Earth’s ozone layer.The ozone layer protects
life below from harmful UV radiation. So far it has been ratified by all countries worldwide
(November 2009 – universal ratification). The Protocol aims at protecting the ozone layer
and therefore regulates the successive phase-out of substances that could harm the ozone
layer through the restriction of production, import und use of such substances according
to a specific timetable. The phase-out of ODS will enable the ozone layer to repair itself.
Natural Refrigerants
Natural refrigerants are naturally occurring substances, such as Hydrocarbons (e.g. Propane,
Iso-Butane), Carbon Dioxide and Ammonia.These substances can be used (amongst others)
as refrigerants in various kinds of refrigeration and air-conditioning systems. The key characteristics of these refrigerants are that they don’t contribute to depletion of the ozone layer
and have no or only a negligible global warming impact.
ODS (Ozone-Depleting Substances)
These are substances that damage the ozone layer in the upper atmosphere.They are widely
used in refrigerators, air-conditioners, foam extrusion, fire extinguishers, dry cleaning,
industrial cleaning, as solvents for cleaning, electronic equipment and as agricultural fumigants. They are defined in Annex A of the Montreal Protocol. Ozone-depleting substances
include:
•
•
•
•
•
•
•
•
Chlorofluorocarbons (CFCs),
Halon,
Carbon Tetrachloride, Methyl Chloroform,
Hydrobromofluorocarbons (HBFCs),
Hydrochlorofluorocarbons (HCFCs),
Refrigerant blends containing HCFCs,
Methyl Bromide,
Bromochloromethane (BCM).
ODP (Ozone Depletion Potential)
This is a relative value that indicates the potential of a substance to destroy ozone gas (and
thereby damage the Earth’s ozone layer) as compared with the impact of a similar mass of
chlorofluorocarbon-11 (CFC-11), which is assigned a reference value of 1. Thus, for example,
a substance with an ODP of 2 is twice as harmful as CFC-11.
172
OFP (Overfill Protection)
Overfill protection is a device (switch) installed to a refrigerant recovery unit and recovery
cylinder originally intended to be a safety feature whilst transferring and storing refrigerants into a cylinder. On most machines, these switches simply turn off the recovery machine.
OFP devices do not provide any recovery machine with a ‘walk away’ feature. Any refrigerant
transfer into systems or special cylinders must be monitored by measuring the weight of the
refrigerant by the technician. Due to specific circumstances hazards can occur in following
situations:
GLOSSARY
ANNEX
1. During push-pull procedures, once a siphon is started, merely powering
off the recovery machine does not prevent the recovery cylinder from
overfilling.
2. When using a cylinder with a large amount of cold refrigerant and
recovering from a system at higher temperature, turning the recovery
machine off will not stop the refrigerant from migration to the coldest
point (in this case the recovery cylinder) eventually overfilling the tank
even when the machine is off.
Phase-Out of Ozone-Depleting Substances
In this context, phase-out means a successive limitation and production ban on substances
that deplete the ozone layer according to a defined schedule for different groups of countries
as regulated under the Montreal Protocol.
Pressing
Pressing means a method of producing hermetically sealed metal-to-metal tube connections
with the use of specific connectors, adapters and tools.
Reclamation
Reclamation is the (re-)processing of used refrigerants through mechanisms such as filtering, drying, distillation and chemical treatment to new product specifications. Note that
chemical analysis of the refrigerant determines if appropriate specifications have been met.
The identification of contaminants and required chemical analysis are both specified in
national and international standards for new product specifications.
Recovery
Recovery means removing a refrigerant in any condition from a refrigeration system and
storing it in an external container.
173
GLOSSARY
ANNEX
Recycling
This is the process of reducing contaminants in used refrigerants by separating oil, removing
non-condensables and using devices such as filters, driers or filter-driers to reduce moisture,
acidity and particulate matter. The aim of recycling is to reuse the recovered refrigerant
following a basic cleaning process such as filtering and drying.
Refrigerant
A fluid used for heat transfer in a refrigerating system which absorbs heat at a low temperature and a low pressure and rejects heat at a higher temperature and a higher pressure
usually involving changes of the state of the fluid.
Retrofit
This is where refrigeration equipment is subject to some modifications (upgrading or
adjustment) so that it can be used with a refrigerant different to the original one. This may
involve, for example, oil change, swapping of certain system components or modifications
to electrical devices.
SAE (Society of Automotive Engineers)
SAE is an international non-profit organisation with more than 90,000 members (engineers,
students, business executives, educators etc.) from all over the world who share information
and exchange ideas for advancing the engineering of mobility systems.
TÜV (Technischer Überwachungs-Verein)
TÜV is a German testing and certification organisation. Its services comprise consultancy,
testing, certification and training mainly in the field of engineering.
174
Acronyms and Abbreviations
AC
AC
BCM
CFC
CFM
CO2
CP
CPR
DC
DOT
EN
EU
GTZ
GWP
HC
HBFC
HCFC
HFC
HP
LP
MAC
MI
MLF
MMA
Air-Conditioning
Alternating Current
Bromochloromethane
Chlorofluorocarbon
Cubic Feet per Minute
Carbon Dioxide
Copper Phosphorus
Constant Pressure Regulator
Direct Current
Department of Transportation
(USA)
European Norm
European Union
Gesellschaft für Technische
Zusammenarbeit GmbH
(German Technical
Cooperation Agency)
Global Warming Potential
Hydrocarbon
Hydrobromofluorocarbon
Hydrochlorofluorocarbon
Hydrofluorocarbon
High Pressure
Low Pressure
Mobile Air-Conditioning
Measuring Instruments
Multilateral Fund (of the
Montreal Protocol)
Ministério do Meio Ambiente
do Brazil
NCG
NPT
OD
ODP
ODS
OFP
PAG
POE
PVC
RAC
Non-Condensable Gas
National Pipe Thread
Outside Diameter
Ozone Depletion Potential
Ozone-Depleting Substances
Overfill Protection
Polyalkylene Glycol
Polyol Ester
Poly Vinyl Chloride
Refrigeration and AirConditioning
RHC
Refrigerant Handling and
Containment
R&R
Recovery & Recycling
RRRE Recovery, Recycling,
Reclamation and Evacuation
RTK
Retrofit Test Kit
SAE
Society of Automotive Engineers
SENAI Brazilian ‘Servico Nacional de
Aprendizagem Industrial’
TEV
Thermostatic Expansion Valve
TT
Tubing Tools
TÜV
Technischer ÜberwachungsVerein (German testing and
certification organisation)
UNF
Unified Fine Thread
US
United States
UV
Ultra Violet
ACRONYMS AND ABBREVIATIONS
ANNEX
175
INDEX
ANNEX
Index
----------A---------AC, see Air-Conditioning
AC, see Alternating Current
Acetylene 13
Acid 29, 130, 139, 140, 141
Air-Conditioning (AC) 1, 2, 3, 18, 32, 33, 43, 49,
50, 53, 81, 82, 102, 121, 142, 148, 151, 152,
164, 170, 172
- Mobile Air-Conditioning (MAC) 26, 34, 121,
140, 142
Alternating Current (AC) 50
Aluminium 5, 7, 19, 104, 121, 122, 125
Ammonia 1, 172
Anaerobic Liquid 124, 127
Anemometer 49
Atmosphere 2, 85, 110, 117, 132, 172
----------B---------BCM, see Bromochloromethane
Bender 11, 77
Bending 53, 67, 68, 77, 78, 79, 80, 128, 170
Blend 44, 152, 153, 161, 162, 163, 172
Blowing Agent 2
Brass 5, 7, 13, 14, 15, 18, 19, 59, 66, 87, 88, 121,
122, 125, 126
Brazil 1
Brazilian ‘Servico Nacional de Aprendizagem
Industrial’ (SENAI) 1
Brazing 1, 10, 13, 14, 15, 53, 63, 67, 68, 81, 82,
83, 84, 85, 86, 87, 88, 89, 90, 100, 102, 105,
167, 170, 171
Bromochloromethane (BCM) 172
Burner 13
----------C---------Calibration Screw 18, 21
Carbon Dioxide (CO2) 1, 171, 172
Carbon Tetrachloride 172
Capacitor 49, 61
Capacity Test 41, 100, 114
CFC, see Chlorofluorocarbon
Charging 19, 24, 25, 34, 38, 39, 40, 41, 46, 51,
72, 73, 74, 98, 102, 103, 108, 117, 118, 119,
120, 142, 143, 150, 152, 153, 170
- Scale 25, 38, 39, 46, 72, 104
Chiller 148
Chlorine 149
Chlorofluorocarbon (CFC) 1, 2, 32, 35, 36, 40,
44, 63, 104, 132, 136, 148, 149, 151, 152,
153, 160, 172
176
Clamp 9, 11, 48, 92
Cleaner 14
CO2, see Carbon Dioxide
Compression Cone 92
Compressor 40, 41, 48, 51, 58, 60, 61, 69, 72,
73, 76, 81, 95, 98, 100, 101, 104, 106, 108,
109, 114, 115, 117, 119, 128, 135, 136, 138,
139, 140, 142, 148, 150, 151, 152, 153, 154,
156, 157, 158
Condenser 32, 60, 61, 76, 95, 96, 99, 100, 101,
106, 114, 115, 140, 151, 158
Condensing 76
- Temperature 151
- Unit 58, 62, 65, 151
Connector 10, 25, 121, 122, 123, 125, 126, 127,
128, 173
Constant Pressure Regulator (CPR) 140
Containment 1, 18, 99, 129, 151, 170
Contaminant 28, 140, 170, 173, 174
Contamination 55, 69, 130, 138, 139, 141, 152
- Test Kit 28
Control 41, 67, 153
- Board 35
- Device 74, 120, 151
Conversion 150, 152, 171
Cooling Agent, see Refrigerant
Copper 5, 6, 7, 8, 10, 12, 13, 14, 15, 55, 56, 57,
59, 67, 68, 77, 78, 79, 80, 81, 82, 87, 88, 89,
90, 93, 94, 102, 122, 154, 156, 170, 171
- Phosphorus (CP) 81
Core 8, 24, 59, 66, 146, 147
- Depressor 22, 23, 146, 147
- Removal 23, 24
Coupler 9, 23, 26, 34, 51, 103, 116, 118, 128,
142
Coupling 59, 122, 123
CP, see Copper Phosphorus
CPR, see Constant Pressure Regulator
Crankcase 153, 154, 156, 157
Cylinder 15, 16, 19, 25, 27, 32, 34, 38, 39, 40,
42, 45, 46, 70, 72, 73, 101, 103, 104, 110,115,
116, 118, 129, 130, 131, 132, 133, 134, 136,
137, 138, 139, 140, 144, 145, 152, 170, 173
----------D---------DC, see Direct Current
Deburrer 6, 83, 91
Department of Transportation (USA) (DOT) 27, 132
Direct Current (DC) 50
DOT, see Department of Transportation (USA)
Drainage 33, 39, 154, 156
----------E---------Elastomer 148
Evacuation 1, 18, 32, 71, 72, 103, 112, 117, 118,
142, 147, 149, 170
- Unit 34, 38
Evaporation 149, 151
Evaporator 58, 59, 60, 61, 62, 65, 66, 69, 72, 74,
76, 95, 96, 101, 106, 107, 115, 120, 151, 153,
158
----------F---------Filter 37, 44, 76, 100, 102, 115, 133, 134, 140,
141, 174
- Drier 32, 33, 36, 58, 59, 60, 63, 67, 76, 95,
99, 100, 101, 102, 106, 109, 110, 111, 114,
115, 117, 119, 126, 142, 144, 145, 148, 149,
150, 158, 174
Flare 8, 15, 19, 22, 23, 26, 63, 71, 92, 93, 94
- Nut 66, 67, 74, 92, 93, 94, 120
Flaring 1, 11, 53, 63, 67, 68, 90, 91, 92, 93
Flux 81, 87, 102, 170
Freezer 47, 95, 96, 102, 106, 107, 117
Fridge 96, 106, 107
----------G---------Gasket 22, 25, 96, 107, 150
Gas 16, 37, 39, 40, 69, 70, 71, 76, 81, 94, 103,
104, 108, 109, 116, 129, 131, 140, 164, 170,
171, 172
- Pressure 3
- Recovery 99, 136
- Regulator 13
Gauge 18, 19, 20, 21, 33, 36, 38, 70, 71, 72, 73,
74, 116, 117, 119, 120, 142, 144, 152
- Connection 98, 108
- Pressure Gauge 18, 20, 21, 32, 34, 35, 38,
39, 51, 70
- Vacuum Gauge 18, 20, 21, 37, 38, 45, 71,
72, 117, 118, 119
Global Warming 104, 171, 172
Global Warming Potential (GWP) 1, 171
Greenhouse 171
GWP, see Global Warming Potential
----------H---------Halon 172
HBFC, see Hydrobromofluorocarbon
HC, see Hydrocarbon
HCFC, see Hydrochlorofluorocarbon
Heat 81, 86, 87, 88, 96, 102, 105, 106,
107, 171, 174
- Exchanger 148, 150
- Transfer 95, 96, 106, 174
Heating 82, 86
- Belt 28
- Device 34
Hermetisation 69, 171
HFC, see Hydrofluorocarbon
Hydrobromofluorocarbon (HBFC) 172
Hydrocarbon (HC) 1, 8, 20, 38, 39, 42, 44, 53,
104, 105, 111, 118, 121, 163, 172
Hydrochlorofluorocarbon (HCFC) 1, 2, 40, 44, 45,
63, 136, 148, 149, 160, 161, 172
Hydrofluorocarbon (HFC) 1, 26, 35, 36, 38, 44,
58, 62, 63, 104, 148, 149, 152, 153, 159, 160
INDEX
ANNEX
----------I---------Inspection
- Mirror
Installation
Iso-Butane
10, 93
10, 102
25, 27, 55, 66, 68, 76, 143, 158, 170
42, 172
----------L---------Leak 8, 25, 41, 43, 55, 69, 70, 71, 74, 90, 95, 102,
105, 106, 116, 117, 120, 128, 154, 156
- Detection/detector 3, 41, 42, 43, 74, 120
- Test 70, 71, 74, 105, 116, 117, 120, 142
Leakage 102, 117, 152, 171
Lighter 14, 85
Line 27, 76, 135, 143, 146, 158, 170
- Liquid Line 68, 69, 76, 158
- Suction Line 66, 68, 69, 76, 80, 139, 157, 158
- Vent Line 109, 110, 111, 112, 113, 114
Liquid 25, 27, 30, 36, 39, 58, 59, 60, 68, 69, 72,
73, 76, 117, 124, 127, 129, 130, 131, 133, 135,
136, 137, 144, 151, 152, 153, 158, 170
Locking Ring 123, 127, 128
Lubricant 29, 30, 40, 76, 81, 101, 115, 138, 148,
149, 151, 158, 159
- Charge 76, 158, 159
----------M--------MAC, see Mobile Air-Conditioning
Manifold 19, 73, 118, 147, 152, 170
- Gauge Set 20, 33, 38, 70, 72, 116, 144
- Service Gauge 18, 19, 20, 21
Methacrylic Ester 124
Methane 42, 171
Methyl Bromide 172
Methyl Chloroform 172
‘Ministério do Meio Ambiente do Brazil’ (MMA) 1
MLF, see Multilateral Fund of the
Montreal Protocol
MMA, see ‘Ministério do Meio Ambiente do Brazil’
Moisture 55, 64, 69, 97, 108, 130, 139, 140,
141, 170, 174
177
INDEX
ANNEX
Montreal Protocol 2, 160, 161, 171, 172, 173
Motor 61, 109, 148
Multilateral Fund of the Montreal Protocol
(MLF) 171
----------N---------Nitrogen 15, 51, 70, 71, 81, 82, 85, 89, 101,
103, 105, 110, 112, 115, 116, 117, 128, 150,
153, 154
- Blowing Process 113
- Flow 85, 87, 101, 115
- Supply 115, 116, 155
----------O---------ODP, see Ozone Depletion Potential
ODS, see Ozone-Depleting Substances
OFP, see Overfill Protection
Oil 28, 29, 30, 31, 32, 33, 37, 58, 93, 109, 130,
135, 137, 138, 139, 140, 148, 149, 150, 151,
152, 153, 154, 155, 156, 157, 164, 167, 174
- Change 154, 155, 156, 174
- Filling Process 157
- Flushing Procedure 149
- Separator 33, 140
- Test 28, 29, 138, 139
Operation 18, 30, 61, 69, 71, 73, 80, 170, 171
Overfill Protection (OFP) 27, 32, 34, 46, 133, 134,
173
Overload Protection 61
Oxide 81, 85, 170
- Formation 85, 89
Oxygen 13, 70, 81, 129, 153
Ozone 1, 2, 172
- Depleting Substances (ODS) 2, 172, 173
- Depletion Potential (ODP) 172
- Layer 2, 150, 172, 173
----------P---------PAG, see Polyalkylene Glycol
Phase-Out 1, 2, 148, 172, 173
Pipe 10, 35, 39, 55, 56, 58, 59, 60, 68, 74, 80, 81,
84, 93, 98, 101, 115, 117, 119, 120
- Work 53, 55, 58, 68, 85, 90, 151
Plier 119
- Piercing Plier 8, 35, 98, 99, 100, 108, 109,
111, 112, 135, 143, 146
- Pinch-off Plier 7, 119
POE, see Polyol Ester
Polyalkylene Glycol (PAG) 150
Polyol Ester (POE) 29, 30, 149, 150
Poly Vinyl Chloride (PVC) 40
Port 23, 36, 69, 70, 72, 73, 102, 110, 111, 112,
116, 137, 142, 144, 145, 146, 147, 157
178
Pressing 53, 115, 119, 121, 127, 173
Pressure 3, 9, 18, 19, 20, 21, 26, 32, 33, 34, 35,
36, 38, 39, 51, 55, 58, 59, 61, 63, 64, 67, 70, 71,
74, 75, 76, 80, 85, 98, 99, 102, 103, 108, 112,
113, 116, 117, 118, 120, 121, 124, 128, 130,
131, 136, 137, 138, 142, 143, 146, 147, 153,
154, 156, 158, 170, 174
- Control 67, 153
- Regulator 13, 15, 71, 101, 103, 104, 110,
112, 115, 135, 140, 153
- Switch 61, 64, 67, 68, 73, 153
Probe 41, 42, 47
Propane 13, 42, 172
Pump 19, 31, 36, 37, 38, 41, 43, 61, 71, 72, 110,
111, 112, 114, 117, 118, 135, 137, 144, 145,
146, 147, 154, 156, 157, 170
PVC, see Poly Vinyl Chloride
----------R---------Radiation 2, 172
RAC, see Refrigeration and Air-Conditioning
Reclamation 1, 32, 173
Recovery 1, 27, 32, 33, 34, 35, 36, 99, 111, 130,
132, 133, 134, 135, 136, 137, 138, 140, 142,
143, 144, 145, 146, 147, 154, 173
- Unit 19, 32, 33, 133, 134, 135, 136, 137, 140,
144, 157, 170, 173
Recycling 1, 3, 32, 33, 34, 99, 129, 141, 142, 174
- Unit 33, 140, 141
Refrigerant 1, 2, 3, 8, 9, 18, 20, 22, 24, 25, 27, 28,
32, 33, 34, 35, 36, 38, 39, 40, 41, 42, 43, 44, 45,
46, 51, 53, 55, 58, 60, 61, 62, 63, 64, 67, 72, 73,
74, 76, 81, 85, 95, 98, 99, 104, 105, 106, 108,
109, 110, 111, 118, 119, 121, 129, 130, 131,
132, 134, 135, 136, 137, 138, 139, 140, 143,
144, 145, 146, 147, 148, 149, 150, 151, 152,
153, 154, 158, 159, 160, 163, 164, 167, 170,
172, 173, 174
- Charge 76, 102, 136, 142, 158, 159
- Cycle 43, 95, 97, 98, 99, 102, 103, 106, 108,
114, 116, 118, 143, 171
- Emission 22, 23
- Flow 19, 20, 60, 105, 135, 141
- Handling and Containment (RHC) 1, 18
- Natural 1, 172
- Transfer 18, 22, 36, 173
Refrigeration and Air-Conditioning (RAC) 1, 2, 3,
32, 33, 53, 81, 82, 148, 150, 151, 164, 170, 172
Refrigeration 1, 3, 18, 30, 32, 33, 50, 55, 58, 62, 65,
81, 104, 121, 124, 143, 148, 164, 170, 171, 174
- Cycle 69, 104
- Sector 1, 2, 82
- System 1, 3, 30, 32, 41, 43, 45, 46, 53, 55, 58,
60, 65, 66, 69, 70, 71, 72, 81, 95, 112, 136, 138,
140, 145, 150, 151, 152, 153, 158, 170, 171,
172, 173
Refrigerator 47, 95, 96, 102, 117, 143, 144, 172
Retrofit 1, 30, 148, 149, 150, 151, 152, 153, 158,
159, 174
- Test Kit (RTK) 30
RHC, see Refrigerant Handling and Containment
RTK, see Retrofit Test Kit
----------S---------SAE, see Society of Automotive Engineers
Safety 16, 27, 51, 74, 77, 82, 90, 100, 104, 105,
124, 129, 130, 134, 138, 163, 164, 166, 168,
169, 173
Scale 18, 38, 72, 73, 81, 85, 118, 134, 144, 171
- Charging Scale 25, 38, 39, 46, 104
- Pressure Scale 18, 21
- Weighing Scale 134, 157
SENAI, see Brazilian ‘Servico Nacional de
Aprendizagem Industrial’ 1
Sight Glass 19, 20, 33, 37, 58, 59, 60, 64, 67,
153, 156
Siphon 138, 173
Society of Automotive Engineers (SAE) 8, 15, 19,
22, 23, 25, 31, 36, 40, 59, 63, 64, 146, 174
Solder 8, 15, 86, 89, 102
Soldering 81, 90
Strainer 58
Sustainable Development 171
System 1, 3, 10, 18, 25, 30, 32, 41, 43, 45, 46,
49, 53, 55, 58, 60, 62, 65, 69, 70, 71, 72, 73,
74, 80, 81, 85, 90, 95, 97, 99, 101, 102, 103,
104, 105, 108, 110, 112, 115, 116, 117, 118,
119, 120, 121, 128, 132, 135, 136, 137, 138,
139, 140, 142, 143, 144, 145, 146, 147, 148,
149, 150, 151, 152, 153, 154, 156, 158, 159,
170, 171, 172, 173, 174
- Cycle 95, 97, 98, 106, 108
- Failure 149, 151
Switch 27, 61, 97, 107, 133, 134, 138, 150, 173
- Master Switch 59, 65, 68
- Pressure Switch 59, 61, 64, 67, 68, 73, 76, 153
----------T---------Technischer Überwachungs-Verein
(TÜV, German testing and certification
organisation) 132, 174
Temperature 3, 18, 28, 35, 39, 49, 58, 64, 66,
74, 75, 81, 88, 95, 96, 97, 98, 102, 106, 107,
108, 120, 121, 130, 138, 149, 151, 158, 170,
173, 174
Tester 50, 51
TEV, see Thermostatic Expansion Valve
Thermometer 38, 39, 47, 49, 96, 97, 107
Thermostat 28, 58, 61, 64, 68, 97, 107
Thermostatic Expansion Valve (TEV) 60, 63, 140
Torch 13, 85, 86, 100, 102
Tube 5, 7, 8, 9, 11, 12, 27, 55, 67, 68, 77, 78, 79,
81, 82, 83, 84, 85, 86, 87, 90, 91, 92, 93, 94,
98, 99, 100, 108, 114, 115, 117, 121, 122,
123, 124, 125, 126, 127, 128, 143, 154, 156,
170, 171
- Capillary Tube 5, 10, 58, 60, 64, 66, 99, 101,
102, 104, 114, 115
- Connection 10, 121, 122, 123, 124, 127,
173
- Cutter 5, 99, 114
- Process Tube 98, 101, 102, 108, 117, 119,
143, 144, 145, 156
TÜV, see Technischer Überwachungs-Verein
(German testing and certification organisation)
INDEX
ANNEX
----------U---------Ultra Violet (UV) 2, 43, 172
UNF, see Unified Fine Thread
Unified Fine Thread (UNF) 59
United States (US) 27, 56, 57
US, see United States
UV, see Ultra Violet
----------V---------Vacuum 18, 19, 20, 21, 22, 37, 38, 41, 45, 71,
72, 109, 110, 111, 112, 114, 117, 118, 119,
124, 144, 146, 147, 156, 157, 170
Valve 8, 16, 19, 20, 21, 22, 23, 24, 25, 27, 32,
33, 37, 39, 40, 42, 59, 66, 101, 110, 112, 115,
116, 117, 118, 119, 131, 135, 137, 140, 143,
146, 147, 152, 156, 157
- Ball Valve 22, 36, 146, 147
- Expansion Valve 58, 59, 60, 63, 66, 90, 140,
148
- Safety Valve 16, 27, 51
- Schrader Valve 8, 24, 102
- Service Valve 8, 26, 74, 102, 120, 135, 142,
143
- Shut-off Valve 60, 138, 154, 156
- Solenoid Valve 37, 58, 59, 60, 61, 63, 67
Ventilator 32, 62
Voltage 48, 50, 62, 76, 129, 158
----------W---------Welding 167, 171
179
NOTES
NOTES
180
The manual GOOD PRACTICES IN REFRIGERATION is the second edition of a
booklet jointly published by the PROKLIMA Programme of the Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH (since 2011 GIZ),
the ‘Brazilian Servico Nacional de Aprendizagem Industrial’ (SENAI) and the
‘Ministerio do Meio Ambiente do Brazil’ (MMA) in 2004.
This manual has now been updated to provide professional guidance on how
to service and maintain refrigeration systems operating with new technology,
e.g. ozone- and climate-friendly alternative refrigerants to CFCs and HCFCs.
It addresses essential know-how on containment of HFC refrigerants which
have a high Global Warming Potential (GWP) and provides information on
the safe use of environmental-friendly natural refrigerants, such as CO2,
Ammonia or Hydrocarbons.
Deutsche Gesellschaft für
Internationale Zusammenarbeit (GIZ) GmbH
Registered Offices
Bonn and Eschborn
Programme Proklima
Dag-Hammarskjöld - Weg 1 – 5
65760 Eschborn / Germany
T+ 4 9 61 96 79 - 1022
F+ 4 9 61 96 79 - 80 1022
[email protected]
Iwww.giz.de/proklima
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