Keep this book! You may need it for your retest. Revised 01/2015 Certification Training Manual Approved by the U.S. EPA for technician training requirements under Section 609 of the Clean Air Act.
Certification Training Manual Important Notes! Do not mix up tests or exchange tests with other individuals at your place of business. All tests are coded with names matching assigned numbers. Please review your test upon completion. Any questions marked with more than one answer will be scored as incorrect. Any question not marked will be scored as incorrect. Completely fill in the block ( ) to the left of the correct answer. Do not mark with a check (4) or an “x” (7).
Certification Training Manual This publication is protected under the copyright laws of the United States and all other applicable international laws and treaties. All rights are reserved, including resale rights. No part of this publication may be reproduced or transmitted in any form, by any means (electronic, photocopying, recording, or otherwise) without the prior written permission of Mobile Air Conditioning Society Worldwide (MACS Worldwide).
Certification Training Manual Foreword World vehicle manufacturers are currently required to meet international regulatory requirements to use lower global warming potential (GWP) refrigerants in new vehicle A/C systems. This MACS Technician Training Program conforms to and complies with the SAE International standard J2845, “HFO-1234yf Technician Training for Service and Containment of Refrigerants Used in Mobile A/C Systems.
Certification Training Manual Table of Contents The Switch to Climate-Friendly Refrigerants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Servicing of Future Mobile Air Conditioning Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Federal Regulations Affecting Mobile A/C System Service. . . .
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Certification Training Manual THE SWITCH TO CLIMATE-FRIENDLY REFRIGERANTS INTRODUCTION Before the early 1990s, mobile air conditioning systems used CFC-12 refrigerant, a substance that destroys the stratospheric ozone layer that shields the earth from the sun’s harmful ultraviolet radiation. Some heat-trapping gases occur naturally in the atmosphere: water vapor, carbon dioxide, methane, ozone and others. Natural processes within the atmosphere keep the gasses and the heat exchange in balance.
Certification Training Manual The Switch to HFC-134a Refrigerant Starting with some 1992 models, and completed by the 1995 model year, HFC-134a replaced CFC-12 in vehicles sold in the U.S. Changes in system designs were required to assure that HFC-134a systems performed equal to CFC12 systems. Some of these changes included new hose and seal materials compatible with HFC-134a, and the lubricants used with it. New hose and seal designs also reduced leakage.
Certification Training Manual SERVICING OF FUTURE MOBILE AIR CONDITIONING SYSTEMS Concern about the environment has, and continues to spur changes in the type and amount of refrigerant used in mobile air conditioning systems. This has resulted in system design updates, new service procedures and equipment to reduce lifetime emissions. The global automotive industry and the U.S. EPA are evaluating new replacement refrigerants that will affect the service of future systems.
Certification Training Manual R-744 (Carbon Dioxide) Systems To meet the European low GWP refrigerant requirements, vehicle manufacturers have worked to develop mobile air conditioning systems that use carbon dioxide (R-744) as a refrigerant. R-744 has the lowest GWP value of new refrigerants being considered. Carbon dioxide systems will require different types of components compared to HFC134a systems. R-744 systems operate at pressures 5 to 10 times higher than HFC-134a and HFC-152a systems.
Certification Training Manual FEDERAL REGULATIONS AFFECTING MOBILE A/C SYSTEM SERVICE Section 609 of the Clean Air Act gives the EPA authority to establish standards and requirements regarding servicing of mobile A/C systems.
Certification Training Manual Section 609 of the Clean Air Act establishes standards specifically for the service of MVACs. MVACs are included in the definition of appliances under the stipulations put forth in Section 608; however, since their service and repair are regulated under Section 609, they are not subject to the servicing requirements put forth in Section 608. Both regulations require that technicians become certified.
Certification Training Manual Purity of Recycled CFC-12 The SAE J1991 standard of purity for on-site recycled CFC-12 states that the refrigerant shall not exceed the following levels of contaminants: Moisture: 15 Parts Per Million (PPM) by weight Oil: 4000 PPM by weight Air (non-condensable gases): 330 PPM by weight EPA regulations require that certified CFC-12 recovery/ recycling equipment must conform to the specifications listed in SAE standard J1990.
Certification Training Manual Service Equipment Hoses Hoses used with mobile A/C system service equipment must be equipped with shut-off valves. The valves may be either manual or automatic. The shut-off valves must be located within 12 inches (30 cm) of the “vehicle end” of the service hose, and most equipment manufacturers incorporate the shut-off valve in their quick-couplers. These automatically shut off the flow of refrigerant when the hoses are disconnected.
Certification Training Manual sell containers of Class I and Class II refrigerant to any person who is not properly trained and certified to operate approved refrigerant recovery/recycling equipment.” Section 608 of the Clean Air Act requires that all persons who sell CFC and HCFC refrigerants must retain invoices that list the name of the purchaser, the date of the sale, and the quantity of refrigerant purchased.
Certification Training Manual A Further Word on Recovery-only Equipment The operation of recovery-only equipment is similar to the recovery feature of recovery/recycling equipment. However, recovery-only equipment is designed for the sole purpose of removing refrigerant from a system; it does not recycle refrigerant for reuse.
Certification Training Manual SERVICE PROCEDURES FOR MOBILE AIR CONDITIONING SYSTEMS Caution: When using recovery/recycling/recharge equipment, while it is very important to follow the general service procedures outlined in this manual, it is also very important to follow your equipment manufac- turer’s instructions. Failure to follow these instructions could result in personal injury, damage to the equipment or A/C systems, or improper or inadequate refrigerant recovery, recycling and containment.
Certification Training Manual Maintaining Your Refrigerant Recovery/ Recycling/Recharge Equipment Recovery/recycling/recharge equipment should be checked frequently to ensure that no leaks exist within the internal refrigerant flow circuits, as well as the external hoses and seals. Filters/driers must also be replaced in accordance with the machine manufacturer’s specifications (check the equipment manual for filter location).
Certification Training Manual Refrigerant Recovery and Recycling Procedures Before You Begin . . . Refrigerant Identifiers A refrigerant identifier can help alert you to air conditioning system refrigerant contamination problems. The service industry and EPA strongly recommend, but do not require the use of this equipment. You can also use an identifier to help confirm what type of refrigerant is in a container.
Certification Training Manual connecting a pressure gauge to a system service port before starting a recovery process. If a system contains no pressure, it is a safe assumption that the refrigerant has leaked out, and one of your first steps in service should be trying to track down a leak or leaks in the system. If a system has some pressure but contains an unknown amount of refrigerant, additional refrigerant can be added to check the system’s operation.
Certification Training Manual Engine Pre-Heat for Refrigerant Removal Procedure The following procedure will aid in refrigerant removal when the work area is cool and J2210 and J1732 recovery equipment is being used. In general if the work area is warmer than 90° F (32° C) this procedure is not required. Recovery equipment certified to J2788 and J2810 does not require this pre-warming procedure. Removal Procedure 1.
Certification Training Manual System Lubricants CFC-12 systems use mineral-based lubricants. HFC-134a systems use polyalkylene glycol (PAG) lubricants. Hybrid vehicles with electrically driven compressors use special A/C system lubricants. formance. The excess oil can heavily coat the interior surfaces of the heat exchangers, insulating the refrigerant from those surfaces. Do not mix lubricants. Use only the type of lubricant specified by the system manufacturer.
Certification Training Manual Best Service Practices for Mobile A/C Systems Sources of Refrigerant Emissions Motor vehicle air conditioning systems can release refrigerant into the atmosphere in a number of ways: Leaks from system part failures and seepage, which occur when a leak is not repaired and the system is recharged or “topped off.” Refrigerant released during various service procedures. Refrigerant released from service equipment, manifold gauges and equipment hoses.
Certification Training Manual The SAE J1628 procedure does not require a fully charged A/C system. If the system has only a few ounces of refrigerant and at least 50 psig pressure (at approximately 55° F), that is sufficient to check for a leak. Static pressure will be higher with the same amount of refrigerant if the working area temperature is warmer. For example, with HFC-134a, the pressure will be about 125 psig at 100° F.
Certification Training Manual Another (Big) Reason to Find and Fix Refrigerant Leaks Loss of refrigerant can reduce oil circulation – even before the low pressure switch or other sensor cuts power to the compressor clutch. Clutchless compressors may operate until a catastrophic failure occurs. If a vehicle comes into your shop with a failed compressor and the system is low on refrigerant, just replacing the compressor is not going to fix the apparent leak.
Certification Training Manual Another Tip on Using Electronic Leak Detectors To isolate a suspected leak site in an area where air currents could dissipate leaking refrigerant, if possible, tape a piece of aluminum foil or plastic wrap around the connection or component. Allow some time for possible leaking refrigerant to collect in the plastic wrap or foil. Then, make a small hole in the foil or wrap at the lowest area possible and place the leak detector probe at the hole to check for the leak.
Certification Training Manual How Much Dye Is Too Much? It is important that dyes be safely and properly used. Excessive dye can result in compressor damage. Check the manufacturer’s recommendation; the basic rule of thumb is 1/4 oz. per conventional system. Lamps & Goggles Most manufacturers design their UV lamps to work best with their own dyes (so the dye particles fluoresce with their lamp for the best wavelength), and use a reflector and lens to direct and filter the light properly.
Certification Training Manual In cases where a leak does not become readily apparent, you might want to consider instructing the customer to drive the car and use the A/C for a week or so, then bring it back so you can look for visual evidence of leakage. Do not let the customer run the car for months before coming back for their inspection and expect to see dye traces. Some of these dyes will wash off or lose their fluorescence over time.
Certification Training Manual A/C System Evacuation Before a system is recharged, it must be evacuated to remove air and any remaining refrigerant. It is necessary to use a quality, well-maintained vacuum pump to perform a worthwhile evacuation. But there’s a lot more to evacuation than that.
Certification Training Manual So the bottom line is, even the best vacuum pump or recovery/recycling machine may not remove moisture through evacuation. The best assurance for control of excess moisture in the A/C system is to replace the desiccant. Desiccant Failure When the refrigerant fittings (lines and components) are left un-capped and open to the atmosphere for an extended period of time, moisture can enter the system and result in the desiccant becoming saturated.
Certification Training Manual Incorrect System Charges – Some Reasons Why Following are several more reasons that A/C systems end up getting charged with the incorrect amount of refrigerant. Making an Unintentional Mistake While Determining the Charge Amount One reason for incorrect charge is making an unintentional mistake while determining the recharge amount.
Certification Training Manual Volkswagen uses grams, so if you’re converting to ounces, divide by 28.4. Example: 750 grams equals 26.4 ounces (just under 26-1/2 ounces) and the tolerance is plus (no minus) 50 grams, which equals 1.76 ounces (just over 1-3/4 ounces). So the precise range is 26.4 to 28.16 ounces. Nissan uses pounds and kilograms, and if your machine is calibrated in pounds, please notice that the plus/minus tolerance is just 0.055 lb., which is 0.88 ounces, less than the 0.1 lb.
Certification Training Manual Equipment Inaccuracy The accuracy of shop equipment is a major issue. You might be using an old recovery/recycling/recharge machine. Its accuracy was never great in its best days. For example, the GM ACR-4, the first dealer recovery/recycling/recharge machine for HFC-134a systems, had a tolerance that was later discovered could go as high as plus/minus six ounces – a 19% variation in a two-pound system. At one time, that might have been close to acceptable.
Certification Training Manual Not Accounting for the Refrigerant Inside the Service Hoses A typical six-foot service hose holds approximately two ounces of refrigerant. The use of very long service hoses can cause a system to receive an overcharge if procedures are not followed that take hose length into consideration. Some charging equipment is programmable to allow for different hose lengths, which should assure an accurate charge. Refer to your machine’s instruction manual for more information.
Certification Training Manual avoiding refrigerant contamination Whenever you hear the term “refrigerant contamination,” the first thing you probably think of is mixed refrigerants. However, the most prevalent contaminant, particularly in recycled refrigerant, is air. This section will provide tips on dealing with both of these problems; excessive amounts of air in refrigerant and cross-contaminated refrigerant. floor temperature can affect the tank temperature.
Certification Training Manual To obtain the refrigerant liquid temperature, measure the temperature of the lower one-half of the refrigerant container’s outer surface (make sure the thermometer is in contact with the “liquid zone” of the tank). Using only the air temperature reading in the vicinity of the refrigerant container can result in incorrect information. Compare the pressure gauge and temperature readings with the limits found in Tables 1 and 2.
Certification Training Manual will decrease. Allow the temperature to stabilize then re-perform the check to confirm if there is still excess air remaining in the tank. Remember: The information in the tables is only reliable if the tank has been kept at a stable temperature for several hours before the readings are taken, has been kept out of direct sunlight, contains some liquid refrigerant, and no refrigerant cross-contamination exists.
Certification Training Manual R-What? Counterfeit Refrigerants The potential for refrigerant cross-contamination has been a reality for many years. Initially the threat was viewed as being generated by a do-ityourselfer, or maybe even another shop, introducing a can of the blend du jour or some illegal hydrocarbon cocktail into the A/C system before eventually bringing the car to an A/C specialist for repair. But the threat is more complicated than that.
Certification Training Manual Recovery and Disposal of Contaminated Refrigerant There are currently two types of equipment that can be used to recover contaminated refrigerant: Caution: If the refrigerant contains flammable substances, such as propane and butane, a fire or explosion could occur if the refrigerant is exposed to an ignition source within the equipment.
Certification Training Manual Contaminated refrigerant must be sent off-site to an EPA certified refrigerant reclaimer for either reclamation or destruction. A list of EPA certified refrigerant reclaimers can be found on the EPA’s web site at www.epa.gov/ ozone/title6/608/reclamation/reclist.html. Used Refrigerant from Non-mobile Sources CFC-12 and HFC-134a are also used in residential and commercial refrigeration systems, such as refrigerators, water chillers and central cooling systems.
Certification Training Manual Recovering Refrigerant from Disposable Cylinders Before they are discarded, disposable refrigerant cylinders should be connected to recovery equipment and brought to a vacuum. This will ensure that all refrigerant has been removed. The cylinder should then be marked “Empty.” (Note: Some disposal facilities will not accept these cylinders unless some type of visual assurance exists that the cylinder is completely empty (such as a hole drilled in the cylinder.
Certification Training Manual The conscientious shop can do a great job when it comes to the field-assembly and repair of A/C system hoses. Measure Twice, Crimp Once Is your bulk A/C hose a quality brand and do you have a hose cutter that produces a neat end? Lube the hose end with refrigeration oil and insert the fitting. Although it won’t be a difficult force fit, it shouldn’t be drop-off loose either, even with the lubrication.
Certification Training Manual Retrofit requirements and recommendations may include the installation of new o-rings and/or seals, new desiccant, a different lubricant, replacement of refrigerant controls, increased condenser capacity and other modifications. Not following OEM recommendation may result in system damage, loss of performance and could also affect component warranties. Additional information on retrofits can be found at the following link: http://www. epa.
Certification Training Manual TABLE 3 - Substitutes in Motor Vehicle Air Conditioners NOTE: All substitutes in this sector are acceptable subject to use conditions. See SNAP Regulations for more information. Substitutes are reviewed on the basis of ozone depletion potential, global warming potential, toxicity, flammability, and exposure potential. (The list of acceptable and unacceptable substitutes are updated several times each year).
Certification Training Manual Table 4 - Unacceptable Substitute Refrigerants Substitutes are reviewed on the basis of ozone depletion potential, global warming potential, toxicity, flammability, and exposure potential. (The list of acceptable and unacceptable substitutes are updated several times each year).
Certification Training Manual Table 5 - MVAC Refrigerants Fitting Sizes (Side 1) These fittings and labels must be used with alternative refrigerants when used in motor vehicle air conditioning systems. For more details, see EPA’s fact sheet titled “Choosing and Using Alternative Refrigerants for Motor Vehicle Air Conditioning.
Certification Training Manual Table 5 - MVAC Refrigerants Fitting Sizes (Side 2) The list includes all refrigerants found acceptable subject to use conditions in motor vehicle air conditioning as of March 29, 2011. 30-lb.
Certification Training Manual Table 6 - MVAC Refrigerant Label Colors To comply with the conditions on the use of motor vehicle refrigerants, a detailed label must be applied that features a unique background color. This table summarizes the colors chosen for the refrigerants listed as of March 29, 2011. The information required for each label is listed in EPA’s fact sheet titled ”Choosing and Using Alternative Refrigerants for Motor Vehicle Air Conditioning.” (Latest EPA update - June 1, 2012).
Certification Training Manual HFO-1234yf: Specific Safety Procedures Besides following all of the GENERAL safety procedures, HFO-1234yf has additional specific safety require- ments. To work safely with this chemical, a technician must know and follow these procedures. 1. HFO-1234yf is classed by ASHRAE as A2L – Mildly Flammable. It can ignite under certain circumstances. Always follow these steps before working with this chemical: A.
Certification Training Manual Unique Properties of HFO-1234yf Systems The refrigerant HFO-1234yf is similar to, but not the same as, HFC-134a. HFO-1234yf has been listed under EPA’s SNAP as acceptable, subject to use conditions, for use in new vehicles; the refrigerant was not listed as acceptable for retrofit. The use conditions for HFO-1234yf include compliance with SAE J639, and manufacturers must conduct Failure Mode and Effect Analysis (FMEA) as provided in SAE J1739.
Certification Training Manual Purchase, storage, and Transport Vapor Pressure 3.5 All compressed gas in cylinders or portable tanks must be stored, handled and transported in accordance with the Compressed Gas Association Pamphlet P-1. Storage of multiple containers of refrigerant may be subject to local, state or federal rules or regulations. 3 R-134a R-1234yf PRESSURE, MPa 2.5 2 1.5 1 0.
Certification Training Manual Tanks, labels, and fittings Refrigerant Tanks Tanks containing HFC-134a are light blue in color. Tanks and containers of HFO-1234yf are identified by information on printed labels and by the color and design of the container itself. To prevent confusion, HFO-1234yf containers will be white with a red stripe or band. The red is used to remind users that the product is flammable.
Certification Training Manual erant and the type of lubricating oil (oil lamp symbol). Note that the amount of refrigerant may be indicated in kilograms, grams, ounces or pounds-and-ounces. Depending on your service equipment, you may have to perform mathematical conversions of the units before performing repairs and recharging. Fittings The law requires that the service fittings (“ports”) and connectors be unique for each refrigerant used.
Certification Training Manual Connect the refrigerant identifier according to instructions that came with it. You may need to allow a bit of time for the unit to perform an internal calibration. chemicals found. Identifiers that meet the SAE specification look for at least 98% concentration before reporting that the refrigerant is “pure.” If the identifier shows “Fail” or reports mixtures of refrigerants, the system must be evacuated into a “junk” tank, not the regular supply tanks of refrigerant.
Certification Training Manual Using Dyes Before adding any dye to an A/C system, you must know what its manufacturer recommends. If a dye is permitted, you must use a product that is compatible with HFO-1234yf. Read the label and make sure the dye product you choose meets SAE specification J2297. By meeting this criteria, you are assured that the dye is compatible with the refrigerant and will not harm seals or lubricants.
Certification Training Manual Using Recovery, Recycling, and Recharging Equipment Basic Rules 1. Every tool or machine used to service or repair an HFO-1234yf system MUST be approved for use with that refrigerant. 2. Fittings and connectors for HFO-1234yf are different from any other refrigerant. Equipment Certification Equipment for HFO-1234yf has been designed to safely handle flammable gas, and this equipment is NOT the same as equipment for other refrigerants.
Certification Training Manual Before delivering a full system charge, equipment used to recharge R-1234yf systems will first place the system under a minimum vacuum of -0.09 MPa gauge (26.9 in of mercury). The machine will then monitor the applied vacuum, and note if it decays. If the slope of the vacuum decay exceeds 51mm Hg/min (2.0 in HG/min) in five minutes, a leak is indicated and the machine will not permit the recharge process to continue.
Certification Training Manual System Servicing Procedures Working with HFO-1234yf is not difficult, but it is different from many procedures you already know. At all times, the secrets to success are knowledge and safety. Remember the Basics: Learn and follow the safety procedures for storage and handling of HFO-1234yf. Anticipate problems and eliminate them. All refrigerant (except CO2) must be recovered.
Certification Training Manual Refrigerant Recycling and Service Procedures for Mobile Air Conditioning Technicians The historical conteXt Before the 1990s, it was common practice during the service of mobile air conditioning systems to just add refrigerant to leaking systems. It was also common practice to vent the entire refrigerant charge to the atmosphere if the refrigeration system required any type of service which involved opening the refrigerant circuit.
Certification Training Manual in mobile air conditioning systems, resulted in system design changes, and new service procedures and equipment to reduce system lifetime emissions. Until that time, increased UV levels can lead to a greater chance of overexposure to UV radiation and the health and environmental problems that result. ULTRAVIOLET LIGHT Chlorofluorocarbon molecule Chlorine atom 1) In the upper atmosphere, ultraviolet light breaks off a chlorine atom from a chlorofluorocarbon molecule.
Certification Training Manual Health and Environmental Effects Global Problem The Environmental Protection Agency’s (EPA) assessment of the risks from ozone depletion has focused on the following issues: Ozone protection is a global concern. CFCs and halons have been produced in the United States, and in other countries, and are still being used in nations around the world. Given their long atmospheric lifetimes, they have become widely dispersed over time.
Certification Training Manual Tax on CFC-12 On January 1 of each year, businesses with an inventory, or floor stock, of 400 pounds of CFC-12 or more, are required to report their inventory and pay the difference between the prior year tax rate per pound. Each year, the floor tax increases 45 cents on each pound of refrigerant in stock. (Refrigerant recycled on-site from mobile A/C systems is not taxable.
Certification Training Manual © 2015 Mobile Air Conditioning Society Worldwide 57
Certification Training Manual EPA Regional Offices Send your form to the EPA office listed under the state or territory in which the establishment is located. Connecticut, Maine, Massachusetts, New Hampshire, Rhode Island, Vermont CAA section 609 Enforcement Contact, EPA Region 1; 5 Post Office Square, Suite 100, OES04-02, Boston, MA 02109-3912.
Certification Training Manual AIR CONDITIONING & HEATING CUSTOMER QUESTIONNAIRE _______________________________________________________ CUSTOMER Name__________________________ Phone__________________ Date__________ Address________________________ City______________ State_____ Zip_______ _______________________________________________________ VEHICLE Year____________ Make____________ Model____________ Color____________ A/C System Type – Manual Auto. Temp.
Certification Training Manual 60 © 2015 Mobile Air Conditioning Society Worldwide
Note: To learn more about the EPA stratospheric protection program or to order publications, call the EPA’s Hotline at 1-800-296-1996 or check the EPA’s website, located at: http://www.epa.gov/ozone/title6/609.html. Published by: Mobile Air Conditioning Society (MACS) Worldwide No part of this publication may be produced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher. National Office P.O.
