Recovery-Recycling of Refrigerants

Module 4
RECOVERY/RECYCLING OF
REFRIGERANTS

Unit of Competency:
Recovery/Recycling of Refrigerants from
Refrigeration and Air-conditioning
System

A Joint Project of:
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
Environmental Management Bureau
Philippine Ozone Desk
and
TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY
National Institute for Technical Vocational Education and Training

1

Table of Contents

How to use this Learning Guide ............................................................................................ 3
Symbols ................................................................................................................................ 4
Introduction ........................................................................................................................... 5

Element 1: Recognize the Importance of Recovery/Recycling of Refrigerants ............. 8
Information Sheet No. 1: The Importance of Recovery/Recycling of Refrigerants .............. 11
Self Check No. 1 ................................................................................................................ 18
Answer Key 1 ...................................................................................................................... 19
Information Sheet No. 2: I dentify Refrigerants ................................................................... 20
Information Sheet No. 3: Identify Refrigerants Using Identifier ........................................... 26
Operation Sheet no. 1: Portable Refrigerant Diagnostic Tool: Operation Procedures ........ 30
Self Check No. 2 ................................................................................................................ 31
Answer Key ......................................................................................................................... 33
Job Sheet 1: Identify Refrigerant Using Identifier ............................................................... 34
Job Sheet 2: Identify Refrigerant Using Pressure Temperature Method ............................ 35

Element No. 2: Set up Recovery/Recycling Equipment ................................................. 37
Information Sheet No. 4: Set up Recovery/Recycling System ............................................ 39
Self Check No. 3 ................................................................................................................ 47
Answer Key No. 3................................................................................................................ 48
Job Sheet No. 3 Set up Recovery/Recycling Machine ........................................................ 50

Element 3: Perform Recovery/Recycling of Refrigerants .............................................. 52
Information Sheet No. 5: Application of Recovery and Recycling ....................................... 54
Operation Sheet No. 2: Perform Recovery/Recycling Operation Using Van Steenburgh

Recovery/Recycling Machine ........................................................................................ 58
Operation Sheet No.3: Troubleshooting Guide: Recovery Operation ................................. 62
Job Sheet No. 4: Recover/Recycle Refrigerant Using Van Steenburgh Recycling Machine

in Domestic Refrigeration and Window Type Air Conditioner ....................................... 65
Job Sheet No. 5: Recover/Recycle Refrigerant Using Van Steenburgh Recycling Machine

in Automotive Air-conditioning Vehicle ........................................................................... 68

Competency Assessment ................................................................................................. 71

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Introduction Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

How to use this Learning Guide

; Read through the learning guide carefully .It is divided into element that covers all the

skill and knowledge you need to successfully complete this module.

; Talk to your trainer and agree on how you will both organize the training of this unit.
; Work through all the information and complete the activities in each element. Use the

multi-media and other training aids that came with the learning package.

; Most probably your trainer will also be your supervisor or manager. He/she is there to

support you and show you the correct way to do thing. Ask for help.

; Your trainer will tell you about the important things you need to consider when you are

completing activities and it is important that you listen and take notes.

; You will be given plenty of opportunity to ask questions and practice using the Assignment

Sheet or Job Sheet. Make sure you practice your new skills during regular work shifts.
This way you will improve both your speed and memory and also your confidence.

; Talk to more experience workmates and ask for their guidance.
; Use the self-check questions at the end of each information sheet to test your own

progress.

; When you are ready, ask your trainer to watch you perform the activities outline in the

learning guide.

; As you work through the activities, ask for written feedback on your progress check.

Your trainer keeps feedback/pre-assessment reports for this reason. When you have
successfully completed each element, ask your trainer to mark on the reports that you
are ready for assessment.

; When you have completed this module (or several module), and feel confident that you

have had sufficient practice, your trainer will arrange an appointment with registered
assessor to assess you. The results of your assessment will be recorded in your
competency Achievement Record.

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Introduction Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Symbols

These symbols are located in the left margin of the module. These illustrate actions
which should be taken or resource to be used at the particular stage in the module.

Learning Optional Activity
Outcome

Resources Practice

Reading Activity Self Check

Use Computer Answer Key

View Video Competency
Assessment
Listen to
Audio Tape Safety

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Introduction Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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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Introduction Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Conditions

The trainee must be provided with the following:

1. Learning Materials 6. Personal protective equipment
• Module1: Recovery/Recycling • Apron
Refrigerants • Safety shoes
• Service Manual • Goggles
• PT Chart • Gloves
• Video tapes: • Gas mask
• Payong ng Kalikasan
7. Supplies and materials
2. Training Facilities • Refrigerants
• Computer • Teflon
• TV Monitor • Madden rubber
• VHS/VCD player • Soap solution
• Flip Chart • Rags
• Blackboard/Whiteboard • Bucket
• Pen/marker
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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Introduction Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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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Learning Element 1

Recognize the Importance of Recovery/
Recycling of Refrigerants

Learning Outcome

On completion of this Element you should be able to:

; Explain the importance of recovery/recycling of refrigerants
; Identify refrigerants
; Identify refrigerant using identifier instrument

Resources

To undertake this Element you are required to have on hands the following
resources:
• Information Sheets 1: The Importance of Recovery/Recycling of

Refrigerants
• Self Checks 1
• Answer Sheet 1
• Information Sheet 2: Identify Refrigerants
• Self Check 2
• Answer Sheet 2
• Information Sheet 3: Identify Refrigerant Using Identifier
• Self Check 3
• Answer Sheet 3
• CD: Payong ng Kalikasan
• User’s Instruction Manual: Portable Refrigerant Diagnostic Tool

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Learning Activity 1 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Reading Activity 1

Read: Learning Outcome
Information Sheet 1: The Importance of Recovery/Recycling of Refrigerants

Viewing Video CD Program

View: Ask instructor for the VCD
• Payong ng KaliKasan

Self Check 1

Do: Self-Check.
• Check your work with the Answer Sheet

Reading Activity 2

Read: Information Sheet 1: Identify refrigerants

Self Check 2

Do: Self-Check.
• Check your work with the Answer Sheet

Reading Activity 3

Read: Information Sheet 3: Identify refrigerant using identifier

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Learning Activity 1 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Self Check 3

Do: Self-Check.
• Check your work with the Answer Sheet

Optional Activity

Call Instructor: Discuss other options to attain objectives
• Ask instructor for short lecture and demonstration using portable

refrigerant identifier.

Practice Activity

Practice: Job Sheet 1 - Identify Refrigerant Using Portable Identifier
• Ask permission from instructor
• Prepare equipment, tools and materials
• Observe safety practices
• Maintain cleanliness
Practice: Job Sheet 2 - Identify Refrigerant Using Pressure Temperature

Method
• Ask permission from instructor
• Prepare equipment, tools and materials
• Observe safety practices
• Maintain cleanliness

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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

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

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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

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

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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

5. What is Greenhouse Effect and Global
Warming— Another environmental effect
of refrigerants is their possible contribution
to global warming.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

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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

regions if they are unable to adapt to
the new conditions or to migrate fast
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
country’s CFC consumption by: Year Percentage

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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

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
airconditioners

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 Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

The Importance of Recovery/Recycling of Refrigerants

QUESTIONS Satisfactory
response
The student trainee should answer the following questions
YES NO

1. Refrigerants are believed to contribute to two major global
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:

Satisfactory Not Satisfactory

Feedback to student/trainee:

Candidate Signature: Date:
Instructor Signature: Date:

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Answer Key 1 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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 Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

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 flourine (F). Refrigerants
used in centrifugal chillers are halocarbons
based on methane, ethane and propane
molecules.

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

CFC-11 CFC-12

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

HCFC-22 HCFC-123

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Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

• Or, it can contain only hydrogen and
flourine (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 flourine 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 flourine atoms (i.e. there are 4
flourine 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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Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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. Some 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. HFC’s include:
• R-134a or HFC-134a
• R-125 or HFC-125
• R-32 or HFC-32

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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

d. Some non-halocarbon refrigerants
that have been used include:

• Ammonia (NH3), designated as R-
717

• Water (H20), designated as R-718
• Propane (C3H8) designated as R-

290

• Isobutane (C4H10), designated as R-
600a

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

e. Some 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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

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
• R-717 (NH3) Silver

4. Portable Refrigerant Identifier

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. Refrigerant can be identified on the
back label of refrigerant unit

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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

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 Unit Recover/Recycle Refrigerants of RAC Systems
No.3 Module Recovery/Recycling Refrigerants

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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 3 Module Recovery/Recycling Refrigerants

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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Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 3 Module Recovery/Recycling Refrigerants

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.

28

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 3 Module Recovery/Recycling Refrigerants

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.

29

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 1 Module Recovery/Recycling Refrigerants

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.

30

Self Check No. 2 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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:

31

Self Check No. 2 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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. _______________

32

Answer Key Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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

33

Job Sheet 1 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Identify Refrigerant Using Identifier

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

Procedure Observation
Checklist

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 aprrox. 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

34

Job Sheet 2 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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

Procedure Observation
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

35

Notes

_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________

36

Learning Element 2
Set up Recovery/Recycling Equipment

Learning Outcome

On completion of this Element you should be able to:

; Observe good service practices
; Identify parts and function of recovery/recycling equipment
; Prepare instruments, tools and accessories
; Set up recovery/recycling equipment

Resources

To undertake this Element you are required to have on hands the following
resources:
ƒ Information Sheet 3
ƒ Self Check 3
ƒ Answer Sheet 3
ƒ Operation Sheet 1
ƒ Job Sheet 3
ƒ User’s Instruction Manual: The Portable Refrigerant Diagnostic Tool

37

Learning Activity 2 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Reading Activity

Read: Learning Outcome
Information Sheet 3: Set-up Recovery/Recycling of Refrigerants

Self Check

Do: Self-Check 3
• Check your work with the Answer Sheet 3

Optional Activity

Call Instructor: Discuss other options to attain objectives
• Ask instructor for demonstration set-up recovery/recycling equipment

Practice Activity

Practice: Job Sheet 3: Set up Recovery/Recycling Equipment
• Ask permission from instructor
• Prepare equipment, tools and materials
• Observe safety practices
• Maintain cleanliness

38

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

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.

39

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

DON’T

• Use refrigerants as cleaning solvent.
• Open the refrigerant side of system unless absolutely necessary.
• Use CFC for leak testing.
• Operate equipment with leaks.
• Vent/blow off (noncondensable 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

40

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

Control Condenser
A/C System

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.

41

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

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

42

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No.4 Module Recovery/Recycling Refrigerants

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

43

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

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

44

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

2. Evacuate recovery/recycling machine Recovery/Recycling Machine
Pressure Gauge
Getting Started

• Make sure recovery/recycling machine
is connected to proper voltage.

• 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.

Vacuum Pump
Pressure Gauge

• 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.

45

Self Check No. 3 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

Set up Recovery/Recycling Equipment

46

Self Check No. 3 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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.__________________

47

Answer Key No. Unit Recover/Recycle Refrigerants of RAC Systems
3 Module Recovery/Recycling Refrigerants

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.

48

Answer Key No. Unit Recover/Recycle Refrigerants of RAC Systems
3 Module Recovery/Recycling Refrigerants

Part II

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

49

Job Sheet No. 3 Unit Recover/Recycle Refrigerants of RAC Systems
Module Recovery/Recycling Refrigerants

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: Ob s er v at io n
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

50