Troubleshooting Window-Type Air-conditioning / domestic refrigeration systems

7. If leak found, rectify.
8. If clog found, recover/recycle the

refrigerant from the system and
replace the clogged accessories.
9. Pressurize the system with 150 psig
nitrogen and check for leak.
10. If no leaks, evacuate and charge the
system.
11. Observe the operation (record
operating pressures, temperatures and
ampere reading. Low side pressure is
vacuumed at 25 in Hg. and the high
side pressure is increasing.

12. Have your instructor check your work.
13. Perform housekeeping

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PERFORM REFRIGERANT RECOVERY / RECYCLING AND RETROFITTING
/ CONVERSION ON DOMESTIC REFRIGERATION AND AIR CONDITIONING

Introduction

Recognizing the problems caused by ozone depletion makes everyone aware on the
importance of preventing ozone-depleting substances (ODS) emission to atmosphere. One-
way of doing this is through the use of recycling and recovery machine in the refrigeration and
air-conditioning (RAC) and mobile air-conditioning (MAC) industry.

Recovery and recycling is the heart of the refrigerant issue. We can reduce the need
to handle refrigerant by understanding the refrigeration theory, systems, applications and
good service practices, but we will have failed in our mission of reducing unnecessary
refrigerant releases if we don’t train every technician in the art of refrigerant handling.

This module covers the knowledge, skills, and attitudes in recovery and recycling of
refrigerants in refrigeration and air-conditioning system, and mobile refrigeration and air-
conditioning system. This also includes awareness in environmental protection and good
servicing practices.

Summary of Learning Outcomes

On completion of this module you should be able to:
1. Recognize the importance of recovery/recycling of refrigerants
2. Set-up the recovery/recycling equipment
3. Perform recovery/recycling of refrigerants

Performance Criteria

After completion of the lessons in this module, the student must be able to:
• Explain the prevention of ozone layer depletion
• Explain the Montreal Protocol
• Discuss the effects of ODS emission
• Identify refrigerants using refrigerant identifier
• Identify accessories, parts and functions of recovery/recycling equipment
• Familiarize with the operations of recovery/recycling equipment in
accordance with manufacturer’s specifications
• Prepare tools, materials and instruments for recovery/recycling equipment
• Set-up recovery/recycling equipment in accordance with manufacturer’s
manual
• Perform recovery/recycling in accordance with manufacturer’s manual

• Recover 100% of the refrigerants from the system
• Recover refrigerant from the tank and must be labeled prior to recycling of

refrigerants
• Practice safety measures in recovery/recycling of refrigerant.

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Conditions

The trainee must be provided with the following:

1. Learning Materials
• Module1: Recovery/Recycling

Refrigerants
• Service Manual
• PT Chart
• Video tapes:
• Payong ng Kalikasan

2. Training Facilities
• Computer
• TV Monitor
• VHS/VCD player
• Flip Chart
• Blackboard/Whiteboard

3. Equipment
• Recovery/recycling machine
• Weighing scale
• Actual equipment
• Vacuum pump

4. Instruments
• System analyzer
• Leak detector
• Refrigerant identifier
• Thermometer

5. Tools
• Spanner
• Ratchet/wrench
• Piercing valve
• Screw drivers
• Set of pliers

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6. Personal protective equipment
• Apron
• Safety shoes
• Goggles
• Gloves
• Gas mask

7. Supplies and materials
• Refrigerants
• Teflon
• Madden rubber
• Soap solution
• Rags
• Bucket
• Pen/marker

Prerequisite

Before starting this module, you should have already completed the manual on:
• Code of Practice in Refrigeration and Air Conditioning

Reference

A. Books Good Practices in Refrigeration Training Manual. UNEP, December 1994
•
• Recovery and Recycling System: Guidelines, UNEP, 1999
•
National Regulations and Import Licensing System for Phase-out of
• Ozone Depleting Substances in the Philippine, Country Handbook, DENR

Modern Refrigeration and Air-conditioning. Althouse/Turnquist/
Brancciano. Copyright 2002

B. Curriculum guides
• HVAC Competency Standard
• HVAC Competency-Based Curriculum

C. Manuals
• Service Manual
• Code of Practice in Refrigeration and Air Conditioining

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Information Sheet 16

The Importance of Recovery/Recycling of Refrigerants

I. How Refrigerants Affect Ozone Layer and Global Warming

Some refrigerants, especially
chlorofluorocarbons (CFCs), contribute to
the reduction of the earth’s ozone layer.
The ozone layer is a vital part of the earth’s
atmosphere and protect life from the
harmful effects of excessive ultraviolet
(UV) radiation, which come from the sun.

1. UV-B radiation -- On land, ultraviolet
radiation endangers all living forms. The
danger of Ultraviolet Radiation are:
• Harmful to human health
• Causes skin cancer
• Causes eye cataracts
• Suppresses man’s immune system
• Arrest the growth of crops and trees
• Practically destroy all life on earth

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2. What is Ozone Layer?

Ozone layer is a thin, fragile shield of kind
oxygen in the stratosphere. It envelops the
entire earth and blocks off most of the
harmful UV rays from the sun from
reaching the earth’s surface.

3. What is “0zone hole”

Ozone hole refers to the loss of the
blocking effect of ozone against ultraviolet
rays. This is the consequence when the
ozone layer is severely depleted, in effect
allowing the entry of greater
concentrations of UV-B imperiling all living
things on earth.

Note:

Joe Farman, a British Antarctic survey
scientist, discovered the “ozone hole” over
the Antarctic area.
A similar “hole”, but not as damaging as
the one over the Antarctic, has been found
over the Arctic region.

The discovery of the ozone hole in
Antarctic shocked the world. It has come
to be regarded as one of this century’s
major environmental disaster.

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4. What is ozone depletion?

Ozone depletion is the loss of the blocking
effect of the ozone layer against UV rays
from the sun. The continuous use of ozone
depleting substances(ODS) like CFC and
halons destroy the ozone layer.

These ozone depleting substances are
used in the wide range of household
and industrial uses as follows:
• As refrigerants for refrigerators and

airconditioners
• As blowing agents in the production of

foams
• As propellant in aerosol sprays
• As firefighting agent in fire

extinguishers
• As industrial solvent for cleaning and

dry cleaning

The ozone layer can be saved only by
stopping the use of CFC’s halons and

other ozone depleting substances:

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OZONE DEPLETING SUBSTANCES
• Chloroflourocarbons (CFCs)
• Halons
• Hydrochloroflourocarbons (HCFCs)
• Other mine chemicals
• Methyl Bromide

Note:

Dubbed as a miracle chemical, CFCs
were utilized in many industries—first as the
working fluid for refrigerators; then propellants
in aerosol cans; and more recently as solvents
in computers where it cleans the delicate
circuit without the plastic mountings; or used
as blowing agent in foams for various uses
from buildings and cars to fast food containers

Where are CFC and halons used?.
• Aerosols used in sprays
• Refrigeration and air-conditioning
• Industrial Solvent
• Foam for insulation and padding
• Fire extinguishers
• Tobacco fluffing and expansion
• Semi-conductor and electronics

Note:

By 1994, refrigeration and air-
conditioning service industry as well as foam
manufacturing in the solvent sectors are the
only remaining users of CFC in the country.

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5. What is Greenhouse Effect and Global
Warming— Another environmental effect
of refrigerants is their possible contribution
to globalwarming.The theory of global
warming states that, due to mankind’s
activities, the concentration of certain heat-
trapping gases is increasing in the
atmosphere. This is believed to be causing
the mean temperature of earth’s
atmosphere to increase slowly.

Refrigerants may contribute to global
warming by way of a phenomenon called
the greenhouse effect.

Although the greenhouse effect is essential
for life, enhance global warming may have
severe consequences. Some other effect
that have been speculated include:

• Rising mean level of the seas. It has
been predicted that increase
temperatures will cause some ice that
is currently stored (e.g., in glaciers)
above sea level, to melt and flow into
the oceans, raising sea level globally.

• Climate. Models that are currently
used give average global estimates.
But changes in temperatures, rain,
sunshine, etc., vary enormously from
one point to another.

• Harvests. The larger CO2
concentration could benefit harvests of
certain crops, but the uncertainty
regarding the regional climate changes
does not allow us to predict which crops
will be able to adapt to the changes in
each zone.

• Eco-systems. Local ecosystems are
very sensitive to changes in
temperature, precipitation and ground
humidity. The increase in CO2, favors
plant growth. Some plant species and
animals may disappear in certain

regions if they are unable to adapt to

the new conditions or to migrate fast

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enough to more favorable ecosystems.

II. What is NCPP Phase-out Plan?

The Montreal Protocol on substances that
deplete the ozone layer is an agreement
among 129 countries, including the
Philippines, that limits the production,
application and use of the most common
ozone depleting substances, like CFCs
and provides for the phase-out of these
chemicals.

Under the Montreal Protocol, the National CFC Phase-Out Plan

Philippines is committed to phase out the Year Percentage
country’s CFC consumption by:

2005 50%

2007 85%

2010 100%

Through the Philippine Ozone Desk Department of
(POD) of the Environmental Environment
Management Bureau (EMB) the National and Natural
CFC Phase Out Plan(NCPP) was Resources
established.
Environmental
The NCPP aims to phase-out CFC in the Management
country as stipulated under the Montreal Bureau
Protocol without creating adverse effect
in the economy. PHILIPPINE OZONE DESK

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The focus of the NCPP is to phase out the
remaining CFC consumption in the country
specifically in the following sectors:

Manufacturing Sectors:

1. Foam manufacturers

2. Tear gas producers

3. Refrigeration equipment manufacturers

Service Sectors;

1. Mobile air conditioners

2. Domestic refrigeration and
air conditioners

In order to achieve this target, the DENR S
in cooperation with TESDA will train/certify
at least 5000 service technicians
nationwide in order for them to recover/
recycle refrigerants.

Republic Act No. 6969 otherwise known
as the “Toxic Substances and

Hazardous and Nuclear Waste Control
Act of 1990”. Its main objective is to
monitor, regulate and keep an inventory
of imported, manufactured, or used
chemicals that presents unreasonable risk
or injury to health or to environment in
accordance with the national policies and
international commitments.

Republic Act No. 8749, known as the
“Clean Air Act of 1999”, RA 8749 is
intended to formulate a holistic national
program on air pollution. DENR is the lead
agency but cooperates with other
government agencies as well as with
industry and related non-governmental
organizations. The Clean Air Act’s primary
focus is on ambient air quality but it is
applicable to all other pollutants including
ODS.

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Self-Check 11

The Importance of Recovery/Recycling of Refrigerants

QUESTIONS Satisfactory
response
The student trainee should answer the following questions
1. Refrigerants are believed to contribute to two major global YES NO
environmental phenomena. Name them:
1.
2.
2. Describe two methods by which ozone is converted into oxygen.
1.
2.
3. Name some possible effects of ozone depletion.

4. What is the name of the international treaty, which controls the
production of certain refrigerants due to their ability to reduce the
ozone layer?

5. Define ozone layer?

The student’s underpinning knowledge was: Not Satisfactory
Satisfactory

Feedback to student/trainee:

Candidate Signature: Date:
Instructor Signature: Date:

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1. Ozone depletion and global warming

2. Ozone is naturally converted to oxygen (and vice-versa) by the sun’s UV
rays. Also, chlorine and bromine can act as a catalyst in the presence of
UV rays, converting ozone to oxygen.

3. Increase in skin cancer and cataracts; impaired immune systems;
decrease crops yields; decreased phytoplankton growth.

4. Montreal Protocol

5. Ozone layer —is a thin, fragile shield of kind oxygen in the stratosphere. It
envelops the entire earth and blocks off most of the harmful UV rays from
the sun from reaching the earth’s surface.

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Information Sheet 17
Identify Refrigerants

I. Refrigerants Methane Ethane
Propane
A refrigerant is a fluid (liquid and gas)
which transfer heat away from one point
to another. In a typical vapor compression
system, the refrigerant changes phase.
That is, it changes from a liquid to a gas
when it absorbs heat and changes back to
a liquid when it gives up heat. Most
chemicals have the ability to change from
a liquid to a gas, but only a few chemicals
do so in a manner that makes them good
refrigerants.

Most refrigerants used today for vapor
compression air conditioning are called
halocarbons. A halocarbon is a
hydrocarbon molecule containing one or
more halogens. The halogen elements
most commonly used in refrigerants are
chlorine (CI) and fluorine (F). Refrigerants
used in centrifugal chillers are halocarbons
based on methane, ethane and propane
molecules.

• A halocarbon can contain chlorine and
fluorine in place of hydrogen, in which
case it is a chlorofluorocarbon (CFC):

CFC-11 CFC-12

• It can contain hydrogen in addition to
chlorine and fluorine, in which case it
is a hydrochlorofluorocarbon (HCFC).

HCFC-22 HCFC-123

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• Or, it can contain only hydrogen and
fluorine (no chlorine), in which case it
is a hydro fluorocarbon (HFC)

HFC-32 HFC-134a

Refrigerant Nomenclature—single component refrigerants have an “R-” designation of
two or three numbers, which reflect its chemical composition.
• The first digit (of a refrigerants with three numbers) is one unit lower than the number

of carbon atoms, the first digit is omitted.
• The second digit is one unit greater than the number of hydrogen atoms in molecule.

• The third digit is equal to the number of fluorine atoms in the molecule.

One less than the number of carbon
atoms (i.e., there are 1 + 1 = 2 carbon
atoms)

More than the number of hydrogen atoms (i.e.
there are 3 - 1 = 2 hydrogen atoms)

Number of fluorine atoms (i.e. there are 4
fluorine atoms)

R - 134a The ‘a” indicates an isomer (i.e. a different
arrangement of the same atoms) of R - 134

Physical and Environment Properties of Some Common Refrigerants

Even small changes in the makeup of these refrigerants can make a large difference in
their physical and environmental properties as shown in table below:

R - 11 Boiling Heat of ODP GWP Atmospheric
R - 12 Point (Co) Vaporization Life (years)
R - 22 (kJ/kg-mol) 1.000 3400
R - 123 23.82 1.000 7100 60
R - 134a -29.79 24768 0.055 1600 130
-40.76 0.020 15
27.87 19982 90
-26.16 0 1200 2
20207 16

26005

22160

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Health and safety consideration— TOXICITY
Another consideration for an acceptable
refrigerants is its effect on human health Class A: refrigerants with low
and safety. Many chemical, including toxicity, with a weighted TLV over time
refrigerants, can be dangerous if used higher than 400 ppm. That is, only
improperly. Two important categories of concentrations over 400 ppm over
health and safety concerns are toxicity and sustained period of time are concern.
flammability. Most toxic and flammable
refrigerants gives off pungent odor. Class B: refrigerants with higher
toxicity with a weighted TLV over time
lower than 400 ppm.

FLAMMABILITY
Group 1: No flammability
Group 2: Low flammability
Group 3: High flammability

1. Refrigerants are identified through a
consistent numbering system.

a. So me common CFC are:
• R-11 or CFC-11
• R-12 or CFC-12
• R-114 or CFC-114
• R-115 or CFC-115

b. Common HCFC’s include:
• R-22 or HCFC-22
• R-123 or HCFC-123
• R-124 or HCFC-124

c. HF C’ s include:
• R-134a or HFC-134a
• R-125 or HFC-125
• R-32 or HFC-32

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d. Some non-halocarbon refrigerants
that have been used include:
• Ammonia (NH3), designated as R-
717
• Water (H 02 ), designated as R-718
Propane (C3H8) designated as R-
290

 Isobutene (C4H10) designated as
R-600a

• Carbon Dioxide (CO2), designated
as R-44

e. So me Common Refrigerants and
their Uses
• CFC-11 low pressure centrifugal
chillers; (also for foam blowing)
• CFC-12 high pressure centrifugal
chiller; domestic and commercial
refrigeration; automobiles
• HCFC-22 Unitary air conditioning;
mid-temperature refrigeration
• HCFC-124 low pressure centrifugal
chillers
• HFC-134a high pressure centrifugal
chillers;domestic and commercial
refrigeration;automobiles.

2. Standing Pressure

The temperature/pressure relationship
of refrigerants. The pressure exerted by
a refrigerant gas is related to the
temperature of the refrigerant. Using
gauge manifold, thermometer, and
pressure temperature chart, you can
identify an unknown refrigerant. With many
type of refrigerant at present, PT chart is
not as reliable as before in identifying
refrigerants as shown:

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3. Color Code —Refrigerant manufacturers • R-11 Orange
have voluntarily established a color code • R-12 Grey/White
system to identify their products, with both • R-22 Medium Green
disposable and reusable cylinders painted • R-502 Orchid
or otherwise distinguished by the following • R-500 Yellow R- 13 Pale Blue
common refrigerant colors and • R-503 Aquamarine
identification: • R-114 Dark Blue
• R-113 Purple
4. Portable Refrigerant Identifier • R-717 (NH3) Silver

The instrument is housed in a rugged
portable high-density polyethylene case.
The case will store the instrument itself as
well as required hose assemblies, power
cord and adapter fitting. This type of
refrigerant identifier can identify R-12, R-
22,R-134a HC and air.

5. Refrigerant Stamped on Data Plate

a. Ref r i ger a nt can be identified on
the back label of refrigerant unit

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b. Stamped can also be found on
compressor label, or

c. On a soldered steel plate in the
Compressor.

6. TEV/TXV for specific refrigerant.

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Information Sheet 18

Identify Refrigerants Using Identifier

1. The Refrigerant Identifier

Power Cord Sample Hose
Control Panel

Sample Inlet
Port

Air Intake Port System Pressure Gauge
Sample Filter Printer Port

Back View of the Identifier

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2. Tools and Personal Protective Goggles
Equipment needed when using refrigerant Gloves
identifier:
• Goggles
• Gloves
• Rachet wrench
• Adjustable wrench

Adjustable
Wrench

Rachet
Wrench

3. When using the identifier, the following should be considered:
• Always wear eye and skin protection when working with refrigerants.
• Always work in a well-ventilated area, avoid contact with refrigerant. It can cause
frostbite and blindness.
• If working with hydrocarbon, extreme care must be considered because of its
flammability.

4. Before proceeding in identifying refrigerant, the following should be considered:
• Always place the identifier on a flat and sturdy surface
• Do not utilize other hose than those supplied with the instrument
• Always verify that the refrigerant to be tested does not contain or will emit heavy loads
of oil or liquid
• Never admit any sample into the instrument in excess of 30 psig.

Pre-Operational Procedure

1. Open the case and inspect the sample filter for signs of red spots or discoloration
anywhere on the white outside diameter of the element. If any red spots or discoloration
are noticed, REPLACE THE FILTER BEFORE USING THE INSTRUMENT!

Warning: When red spots or discoloration begin to appear on the white outside diameter
of the filter element, THE FILTER MUST BE REPLACED. Failure to properly
maintain the sample filter may result in severe instrument damage that will
not be covered under warranty repairs.

2. Select the R12 or R13a sample hose for use in the specification. Inspect the hose for
signs of wear and as cracking, frying or kinks. Verify that the hose is not obstructed
and that no oil is present internal to the hose. If the hose shows signs of wear, obstruction
or oil IT MUST BE REPLACED (OR CLEANED) BEFORE USING THE INSTRUMENT!

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3. Install the selected sample hose into the inlet of the instrument. The hose connector
needs only to be tightened to achieve a gas-tight seal.

4. Inspect the air intake port, sample exhaust port and case vent ports of the instrument
to verify they are clear and unobstructed.

5. Inspect the sample port of the refrigerant storage cylinder or vehicle air conditioning
system to be tested. Verify that the port is the LOW SIDE or VAPOR port.

Procedure:

Step 1. Plug the power cord of the instrument into a SUITABLE RECEPTACLE. The instrument
will display various parameters of the instrument and begin the warm up period.

During the warm up period the user has the option to enter the local elevation above sea
level into the instrument memory. The instrument is sensitive to elevation changes of 500
feet (152 meters) and the local elevation must be entered into the instrument memory
upon initial use. Normal barometric variations will not effect the performance of the
instrument. After the local elevation has been entered into the instrument memory there is
no need to enter it again unless the instrument is moved to a new elevation. To enter the
elevation into the memory, follow the procedure presented by the instrument display as
stated below:
a. During the warm up period depress and hold the “A” and “B” buttons simultaneously

until the display reads, ‘USAGE ELEVATION, 400 FEET”. This is the factory setting of
400 feet fee (122-meters) elevation.
b. Use the “A” and “B” buttons to adjust the elevation to the nearest 100-foot (30-meter)
increment. Pushing the “A” button will increase the elevation setting by 100-foot (30
meter) increments. Pressing the “B” button will decrease the elevation setting by 100-
foot (30 meter) increments. The setting is adjustable from 0-9000 feet (0-2743 meters)
and will be displayed while adjusting.

c. When the correct setting of local elevation has been achieved, allow the instrument to
sit for approximately 20 seconds while not pushing either of the buttons. The instrument
will automatically return to the warm up period and the elevation setting will be stored
in the memory.

Step 2: Calibration. A buzzing sound will be
heard during the self calibration of the
instrument. When it is already
calibrated the control panel display
reads “READY: CON. HOSE PRESS
A to START” as shown in the
illustration.

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Step 2: Connect the sample hose to the vapor
port of the tank or unit and the other
end of the sample hose to the
identifier.

Note: When connecting the sample hose
to the cylinder and identifier, make
sure that it is finger tight only.

Sample hose connected to
the vapor port of the tank.

The other end of the sample
hose connected to the identifier.

Step 3: Open the cylinder slowly and allow
approx. 9-15 psi of refrigerant to enter
the instrument, then close the cylinder
and press “A” as indicated in the
control panel.

The instrument will read “SAMPLING
IN PROGRESS” while a small
refrigerant sample is analyzed to
determine the concentrations of R12,
R134a, R22, hydrocarbons and air.

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Step 4: Check the type of refrigerant based
on the display result screen.

Note: In case error occurs, unplug and re-
plug the identifier to reset it.

Warning: Disconnect the service end of the
sample hose from the refrigerant
source immediately when so directed
by the instrument. The instrument is
not equipped with an automatic shut
off device and refrigerant will continue
to flow through the sample hose as
long as it is connected to the source.
Failure to immediately disconnect the
sample hose from the refrigerant
source when directed will result in
excess refrigerant loss to the
atmosphere.

Step 5: Unplug and return the instrument to
its proper arrangement.

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Self-Check 12

The Importance of Recovery/Recycling of Refrigerants

QUESTIONS Satisfactory
response
The student trainee should answer the following questions
1. What is the family name for the common refrigerant based on YES NO
methane, ethane and propane?

2. What are the methods of identifying refrigerants?
1.
2.
3.

3. What is the best method of identifying refrigerants?

4. What is the cylinder color code for R-22?

5. What are the personal protective equipment required when using
refrigerant identifier?

The student’s underpinning knowledge was: Not Satisfactory
Satisfactory

Feedback to student/trainee:

Candidate Signature: Date:
Instructor Signature: Date:

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Part II : Part of portable identifier:
Instructions: Identify the different parts of the refrigerant identifier. Write your answer

on the numbered blank lines below.

8
7

1
6

2 5
3 4

1. 5.
2. 6.
3. 7.
4. 8.

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Part I.
1. Halocarbons
2. Different methods of identifying refrigerants
• Refrigerants stamped on unit data plate
• TEV for specific refrigerant (Thermostatic Expansion Valve)
• Standing pressure
• Refrigerant identifier
3. Use refrigerant identifier
4. Medium Green
5. Gloves and goggles

Part II.
1. Power cord
2. Air intake port
3. Sample filter
4. Printer port
5. Sample hoses
6. Control panel
7. Sample inlet port
8. System pressure gauges

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Job Sheet 13

Identify Refrigerant Using Identifier

Equipment/Instrument: Tools:
• Refrigerant identifier • Service valve ratchet wrench
• Tap line valve
• System analyzer • Adjustable wrench

Materials: Safety Protective Devices:
• Unlabeled refrigerant tank with content • Gloves
• Labeled Refrigerant tank with content • Goggles
• Safety clothes

Procedure Ob s erv atio n
C h ec k l is t

Yes No N/A

1. Prepare identifier. (Set up instrument correctly)

2. Apply safety measure (Safety measure were applied)

3. Warming up and calibrate

4. Connect the sample to the vapor port of the tank or unit.

5. Open the cylinder slowly and allow approx. 9 - 15 psi of
refrigerant to enter the instrument.
6. Close the cylinder and press "A" as indicated in the control
panel.
7. Check the type of refrigerant based on the display result
screen.

8. Unplug and return the instrument to its proper arrangement.

9. Perform housekeeping

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Job Sheet 13

Identify Refrigerant Using Pressure
Temperature Method

Equipment/Instrument: Materials:
• System analyzer • Unlabeled refrigerant tank with content
• Labeled Refrigerant tank with content
Tools: • PT Chart
• Service valve ratchet wrench
• Tap line valve Safety Protective Devices:
• Adjustable wrench • Gloves
• Goggles
• Safety clothes

Pr oc ed u r e Obs er v ati o n
Checklist
1. Instruments, materials were prepared in accordance with job
requirements (Set up instrument correctly) Yes No N/A

2. Apply safety measure (Safety measure were applied)

3. Gauge manifold was connected to the refrigerant cylinder
correctly

4. Ambient temperature was taken using thermometer(
Refrigerant was identified correctly according to pressure and
temperature chart)

5. Perform housekeeping

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Set up Recovery/Recycling System

I. Good Service Practices

1. The following list of service practices may be helpful in establishing your own service
practices:

DO:

• Think CFC conservation and safety
• Follow and use recommended procedures and equipment for handling

refrigerants.
• Replace, tighten, and seal caps on all valves after servicing.
• Shut down system and make repairs when leaks exist.
• Use close loop refrigerant transfer equipment when removing, charging,

and storing refrigerants.
• Recover vapor and liquid refrigerant from charging hoses.
• Maintain refrigerant use logs for all equipment.
• Leak tests all charging hoses and refrigerant handling equipment.
• Install service isolation valves to limit refrigerant losses during servicing

and purge operation.
• Eliminate unnecessary mechanical joints. Use welded or brazed joints.
• Establish proper leak testing routine.
• Follow the published leak test procedures.
• Use industry-accepted tools/equipment for leak testing.
• Confirm overall leak tightness by using a standing vacuum test.
• After major service, evacuate and dehydrate to a minimum 757 mm using a

deep vacuum or triple evacuating method.
• Use only approved cylinder/drums/tank for storing refrigerant.
• Install charging valve quick connects.
• Recover all refrigerants for recycling/reclaiming.
• Use non-CFC gas as tracer gas when conducting leak tests.
• Add refrigerant carefully to avoid overcharging.
• Dispose used refrigerant container properly.

DON’T • Use refrigerants as cleaning solvent.
•
• Open the refrigerant side of system unless absolutely necessary.
•
Use CFC for leak testing.

Operate equipment with Vent/blow off (noncondensable

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• gasses/refrigerant) to the atmosphere.
• Blow off refrigerant “empty” tanks, drum, or containers.
• Throw away any refrigerant.
• Contaminate recovered refrigerants with other refrigerants, solvents, oils, or

other materials.
• Exceed manufacturer’s recommend pressure when leak testing.
• Overfill refrigerant containers, tank, drum, recovery units, and receivers.

Etc.
• Refill disposable cylinders.
• Substitute alternative refrigerants into old system without approval.

II. Recovery/Recycling Equipment

1. Two types of recycling equipment are on the market. The first is referred to as single pass.
The other is a multiple pass.

Control Condenser
A/C System

Evaporator

Multiple pass

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Control

A/C System Condenser

Evaporator

Single pass

2. Typical equipment available in the market
in the Philippines is as shown
• Recovery/recycling machine—this type
of machine can service both the
refrigeration and airconditioning and
mobile air-conditioning equipment.

• Recovery/recycling machine for
domestic refrigeration and mobile air-
conditioning. It can onlybe used for R-
12 running equipment.

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III. Identifying Recovery/Recycling Equipment Parts and Functions
1. Part of a typical recovery/recycling equipment is as shown:

Pressure Gauge Oil Outlet Port
Oil Inlet Port

Recovery Tank Refrigerant Inlet Port
Refrigerant Outlet Port

2. Major parts and functions:

• Pressure gauges — indicators of refrigerant pressure from the unit and to the recovery
tank.

• Recovery tank — a cylinder for recovery/recycling of refrigerants.
• Oil outlet port— is where foreign particles and acids are drained out
• Oil inlet port -- is where refrigerant oil is pumped in to add the lubricants of the

compressor.
• Refrigerant inlet port -- is where the refrigerants passes from the refrigeration and

air-conditioning equipment being recovered.
• Refrigerant outlet port -- is where refrigerants comes out from the refrigeration and

air-conditioning equipment being recovered.

IV. Prepare the right tools, supplies and materials

When setting recovery/recycling equipment you must prepare the following tools,
supplies and materials, instrument:

1. Safety protective devices
• Gloves
• Goggles

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2. Hand tools
• Adjustable wrench
• Ratchet wrench

3. Supplies and materials
• Rugs
• Tape
• Pen

4. Instruments
• Gauge manifold
• Weight scale
• Thermometer

V. General procedure in setting recovery/recycling equipment

1. Procedure:
• Prepare required materials, equipment,
tools and personal protective
equipment.
• Ask for Manufacturer’s Manual of a
recovery/recycling machine.
• Evacuate recovery/recycling machine
• Evacuate recovery tank
• Connect recovery/recycling machine to
the unit to be recovered
• Perform housekeeping

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2. Shown below is the recovery/recycling equipment connected to a refrigeration unit.

Refrigeration
System

Recovery/Recycling
Equipment

Recovery
Cylinder

V. Procedure in setting recovery/recycling equipment

1. Prepare required materials, equipment,
tools and personal protective
equipment.

Gloves

Goggles

Adjustable Wrench Adjustable Wrench

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2. Evacuate recovery/recycling machine Recovery/Recycling Machine
Pressure Gauge
Getting Started
• Make sure recovery/recycling machine Vacuum Pump
is connected to proper voltage. Pressure Gauge
• Hook vacuum pump to both inlet end
outlet fitting of recovery/recycling
machine and pull a vacuum for
approximate 5-7 minutes. Make sure
that the inlet and outlet valve are open.
The center switch must be in the pump
out position.

• After evacuation of the recovery/
recycling machine, close inlet and
outlet valves, unplug the machine and
place the center switch to recycle
position.

3. Evacuate recovery tank
• Evacuate the recovery tank for 5
minutes by connecting a vacuum pump
to the vapor and liquid valve of the
cylinder.
• The recovery tank is now ready to
accept refrigerants.

4. Perform housekeeping
• Turn off machine
• Clean machine
• Return tools, instruments and supplies
to proper place.

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Set up Recovery/Recycling Equipment

QU E S T ION S Satisfactory
The student/trainee should answer the following questions response

YES NO

1. Before operating any equipment a new technicians must first read the
Manufacturer's Manual. Why?

2. Identify at least two types of recovery/recycling equipment

3. Before set-up of equipment, it is good practice to prepare the right
tools, supplies and materials needed, instruments requirement. List the
most important tools, supplies, materials and instruments.

4. Enumerate at least three good service practices.

5. Enumerate at least three don'ts in good service practices.
The student's underpinning knowledge was:

Satisfactory Not Satisfactory
Feedback to student/trainee:

Candidate Siganture: D a te:
Instructor's Signature: D a te:

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Identify Parts of Recovery/Recycle Equipment and
Accessories

Instructions: Label the illustration below by writing the right description of the parts
numbered blank space.

Part II : Part of recovery/recycling equipment

13
4

25
6

1. 4.
2. 5.
3. 6.

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Identify Parts of Recovery/Recycle Equipment and
Accessories

Part I.

1 Specific technical instructions, setting guide, on how to use the equipment can be
found in the manual. Therefore it is a good practice that before operating a machine
one has to read the manual.

2 Types of recovery/recycling equipment:
• Multiple-pass
• Single-pass

3 Tools, supplies and materials, instruments:

Tools:
• Valve key/service wrench
• Tap line valve/piercing valve

Personal Protective Equipment:
• Goggles
• Gloves
• Safety shoes
• Working clothes

Instrument:
• Gauge manifold
• Electronic weighing scale
• Electronic leak detector

4. Good practices (at leat 3 items)
• Shut down system and make repairs when leaks exist.
• Use close loop refrigerant transfer equipment when removing, charging,
and storing refrigerants.
• Recover vapor and liquid refrigerant from charging hoses.
• Maintain refrigerant use logs for all equipment.

5. Don’ts in good safety practices (at least 3 items)
• Use CFC as tracer gas for leak testing.
• Operate equipment with leaks.
• Refill disposable cylinder.
• Vent/blow off air (non-condensable gasses/refrigerant) to the atmosphere.

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Part II

1. Pressure gauges
2. Recovery Tank
3. Oil outlet port
4. Oil inlet port
5. Refrigerant inlet port
6. Refrigerant outlet port

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Set up Recovery/Recycling Machine

A. Equipment: C. Tools:
• Vacuum pump • Valve key/service wrench
• Recovery & recycling machine set • Tap line valve/piercing valve
• Recovery tank
• Refrigerant tank D. Personal Protective Equipment:
• Goggles
B. Instrument: • Gloves
• Gauge manifold • Safety shoes
• Electronic weighing scale • Working clothes
• Electronic leak detector

Procedure: Observation
Checklist

YES NO N/A

1. Ask for Manufacturer's Manual of a recovery/recycling machine

2. Prepare required materials, equipment, tool and personal protective
equipment.

3. Evacuate recovery/recycling machine

4. Evacuate recovery tank

5. Connect recovery/recycling machine to the unit to be recovered

6. Apply safety measure
7. Perform housekeeping

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Application of Recovery/Recycling

I. Recover/recycling refrigerant of different systems

1. Recover/Recycling Refrigerant from a Refrigeration and Window Type Air-
conditioning Unit. It is possible to recover refrigerant from a hermetically sealed system,
which has no service valves. A line-tap valve (piercing valve) should be fitted to the system.
Procedure:
• Following the manufacturer’s instructions, and a recovery unit used to remove the
refrigerant from the unit via the line-tap as with the larger system.
• Line-tap valves should never be lea permanently in place, but removed after use if
placed on the process tube.
• It is recommended to install tap-valves on both high and low pressure side.

Note: Figure below shows a recovery unit is connected to a refrigerator with a typical
tap-valve (piercing valve). Because of the small charge of refrigerant, only vapor
recovery is needed.

Piercing Evaporator
Tube
Valve Core
Pierced Nut
Tube

Refrigerant Recovery/ Con dens er
Outlet Port Recycling Com press or
Machine
Recovery
Tank

Scale

Refrigerant
Inlet Port

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2. Recover from air-conditioning system(Liquid transfer)
Procedure

• Discharge side recovery unit to the suction pipe on the air-conditioning system
If there are available valves on the systems receiver (high pressure side) the recovery

discharge side could be connected here as well. Liquid flows now from the liquid side
of the air-conditioning system and into the cylinder.
• The recovery unit will keep the pressure inside the cylinder lower than in the air-
conditioning system and keep up the liquid flow.
Figure below shows a typical condensing unit for air-conditioning installations

OUT

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Perform Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine

Equipment: 4. uncoded tank/cylinder
1. refrigerant identifier 5. thermometer
2. refrigerant 6. PT chart
3. unlabeled tank/cylinder 7. Operator Manual

CAUTION: Never mix refrigerants. Be sure unit is set up for the refrigerant you are
about to recover.

WARNING: Use only authorized refillable refrigerant tanks. Use of other tanks could
cause personal injury and void the warranty.

Getting started:

1 Make sure that the R/R machine is connected to proper voltage.
2 Hook the vacuum pump to both inlet and outlet fitting of R/R machine and pull a vacuum

for approximately 5-7 minutes. Make sure that the inlet and outlet valves are open. The
center switch must be in the pump out position.
3 After the evacuation of the R/R machine, unplug the machine and place the center
switch to recycle position and close inlet and outlet valves.
4 Evacuate the recovery tank for 5 minutes by hooking a vacuum pump to the vapor and
liquid valves of the cylinder.
5 The R/R machine and recovery tank is now ready to accept refrigerant.

Note: Always evacuate R/R machine and recovery tank if you will recover/recycle
another type of refrigerant

Operational procedure:
1 Plug in R/R machine to proper to proper voltage.
2 Connect hose to inlet valve of the machine and the other end to the source. Use a
gauge at the source as this will show when source is empty.
3 Attach the yellow cable to recovery tank. Connect other hose to outlet valve of the R/R
machine and the other end of the hose to the vapor port of the recovery tank.
4 Turn compressor and recycle switch on and open inlet valve half turn. If recycling
liquid regulate suction gauge pressure to 20-25 psi for 2-3 minutes, open the inlet
valve fully.
5 Open outlet valve of R/R machine. Open vapor valve of recovery tank.

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6 When source is empty of liquid, turn vapor switch on. Leave on until source and R/R
machine have equalized at 3-4 psi.

7 When equalized, turn vapor switch off and unit will pump down to approximately 5"
vacuum. If additional vacuum is required, use the compressor momentary contact.

8 Pump out to clear unit by closing inlet valve, center switch to pump out and vapor
switch on and outlet valve open. Unit will pump down to 5" vacuum and shut off.

9 Turn compressor off and use the compressor momentary switch to pull R/R machine
into 10" vacuum.

10 Close the outlet valve, put center switch to recycle and turn vapor switch on. Unit will
equalize. If positive pressure remains after equalize, repeat pump out procedure.

Perform oil out procedure:

The oil out procedure is very important. By performing oil out frequently, you will keep
the separated oil below the level of the chamber entry point and assure that the oil/moisture
will be purged out of the R/R machine.

1. Close inlet valve and let machine pump down and shut off.

2. Turn compressor switch off and by using the recycle/pump out switch, add 2-3 psi to
suction gauge. Do this by flipping switch to pump out position and returning to recycle
position.

3. Put a container under the oil out valve and slowly open valve.

4. When oil stops draining, close the oil out valve.

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Method of Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine

Liquid Recovery Method

ALTERNATIVE CONNECTION
FOR “PUSH - PULL”

OUT

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OUT

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Troubleshooting Guide: Recovery Operation

SYMPTOM CAUSE REMEDY

1. Recovery compressor • Power cord not plugged • Plug in cord, check circuit
does not start in or no power at plug for power
Recycle switch is on or
main power switch is off • Be sure recycle switch is
off and main power is on
• Tank full light is on
• Change tank
• High pressure light is on • Recalibrate weight

• Bad components—start platform
switch, relay, • Check valves on tank to
compressor, etc.
be sure they are open
• Check scale calibration
• Call factory

2. Runs a short time, but • Tank valves not open • Open both tank valves
does not complete • Call factory
recovery • Low oil level in
compressor • Call factory

• Bad components, • Pressure must be present
compressor, relay, etc. in manifold gauges before
starting recovery
3. Runs but won’t shut • Leak In vehicle system operation
off
• Close both valves
• Oil drain valve not • Call factory
closed

• Bad components,
vacuum switch, etc.

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RECYCLING OPERATION

SYMPTOM CAUSE REMEDY

1. Refrigerant pump • Power cord not plugged • Plug in cord, check circuit
does not appear to in or no power at plug for power
be running
• Main power switch off • Turn on
• Tank valves not open • Open valves
• Faulty components, • Call factory

pump, switch, etc.

2. Bubbles will not clear • Tank valves not open • Open valves
in moisture indicator
• Not enough refrigerant • Recover more refrigerant
in tank—must have 15 before recycling
Ibs. minimum

3. Moisture indicator wilt • Wet or plugged filter • Remove and replace filter
not turn green after 3 cartridge cartridge. Be sure to pull
hours of recycling a vacuum
• Not enough refrigerant
in tank—must have 15 • Recover more refrigerant
Ibs. minimum before recycling

• Faulty moisture • Remove and replace
indicator moisture indicator

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Troubleshooting (VAN Steenburg Recycling Machine)

PROBLEM SOLUTION
1. Unit won’t accept refrigerant
• Check inlet ball valve
2. System “Pulls Slowly” • Check that cable is attached to recycle

3. Oil in lines cylinder
• Make sure recycle cylinder is not full
• Check valves in hoses

• Checked to ensure you are hooked to
liquid side of source

• Low ambient temperature, apply heat
to source

• Check hoses for restrictions
• Connecting hose to source to long

• Oil out operation has not been
completed on a regular basis.
Separator chamber is full and oil has
migrated though system

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