epa+608+technician+training+show 1
TRANSCRIPT
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DESIGN AIRIn cooperation with
The Esco Institute
presents . . .
Click the mouse orPage Up orPageDown key to advance through the program.
Click this button to exit the program . . . or Enter to keep going!
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EPA CERTIFICATION
TRAINING
for
AirConditioning& Refrigeration Technicians
Federal Clean Air Act - 608
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This presentation is designed to help technicians
prepare for the EPA 608 Certification Exam.
This exam is offered regularly by DESIGN AIR
UNIVERSITY at locations throughout Wisconsin
and Michigan's U.P.
You must pre-register for this exam.
When you pre-register, you will receive a study
guide that will help you prepare for the exam. To receive information about the date & site of
the next exam in your area as well as the exam fee,
call 800-569-3389 and ask for Mike Mills.
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Section 608 of the Federal Clean Air Act
REQUIRES
All persons who maintain, service, repair, or dispose
of appliances that contain regulated refrigerants, be
certified in proper refrigerant handling techniques.
If EPA regulations change after a technician becomes
certified, it is the responsibility of the technician to
comply with any future changes.
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There are Four (4) Categories of
Technician Certification
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TYPEI
Persons who maintain, service or repair
small appliances must be certified asType I technicians.
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TYPEII
Persons, who maintain, service, repair
or dispose of high or very high-pressureappliances, except small appliances and
motor vehicle air conditioning systems,
must be certified as Type II technicians.
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TYPEIII
Persons, who maintain, service, repair,
or dispose of low-pressure appliances
must be certified as Type III technicians.
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UNIVERSAL
Persons, who maintain, service or repairboth low and high-pressure equipment, as
well as small appliances, must be certified
as Universal technicians.
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TESTFORMAT
The test contains four sections, Core (A), I, II, III.
Each section contains twenty five (25) multiple-choice
questions.
A technician MUST achieve a minimum passing score of70 percent on the CORE and in each group in which they
are to be certified. ie: 18 out of 25 questions in each
section.
If a technician fails one or more of the Sections on the
first try, they may retake the failed Section(s) without
retaking the Section(s) on which they earned a passing
score. In the meantime the technician will be certified in
the Type for which they received a passing score.
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Choose thesection you want tostudy.
Core click here:
Type I click here:
Type II click here:
Type III click here:
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WHATISREFRIGERATION
Heat is a form of energy. Refrigeration is
the movement of heat from an area where itis not wanted to an area where it is less
objectionable. For example, a refrigerator
removes heat from the inside of the cabinet
and transfers it to the outside.
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GAUGEMANIFOLDSET
One of the most important tools to the HVAC&R
technician is the gauge manifold set. The compound
gauge (BL
UE) and the high pressure gauge (RED)are connected to the manifold, and the manifold is
then connected by hoses to access ports to measure
system pressures. The compound gauge measures
low pressure (psig) and vacuum (inches Hg.). The
high pressure gauge measures high side (discharge)
pressure. The manifold is also equipped with a center
port, (usually a YELLOW hose), that can be
connected to a recovery device, evacuation vacuum
pump, or charging device. EPA regulations require
that hoses be equipped with low loss fittings that will
minimize refrigerant loss when hoses are
disconnected.
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PRESSURE/VACUUM
Pressure is defined as the force per
unit area, most often described as
pounds per square inch (U.S.).
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ATMOSPERIC PRESSURE
Our atmosphere extends about 50 miles above the earth
and consists of approximately 78% nitrogen, 21% oxygen,
the remaining 1% is composed of other gasses. Eventhough the gas molecules are very small, they have weight.
The atmosphere exerts a pressure of 14.7 lbs. per square
inch at sea level. At higher altitudes, the atmospheric
pressure will be significantly less.
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The most common method of measuring
atmospheric pressure is the mercury
barometer. Normal atmospheric pressure at sea
level (14.7 psia) will support a column of
mercury 29.92 inches high.
Mercury barometer
Atmospheric pressure
will support a column of
mercury 29.92 inches in
the sealed tube.
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GAUGEPRESSURE
The pressure reading we most often use
is called gauge pressure. Atmosphericpressure is shown as 0 psi or psig
(pound per square inchgauge).
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Compound gauges that are
used to measure low side
pressures in air conditioningsystems can measure
pressures both above and
below 0 psig. Gauge readings
are relative to atmosphericpressure. It will be necessary
to adjust a compound gauge
periodically to compensate
for changes in atmospheric
pressure.
COMPOUND GAUGES
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VACUUM
Pressures below atmospheric are usually read in inches of
mercury (in. Hg) or in millimeters of mercury (mm Hg).
A thorough understanding of vacuum principles is an
absolute necessity for the air conditioning technician.
Since an increase in pressure will increase the boiling
point of a liquid, the opposite is also true. Lower pressure
will result in a lower boiling point. Any pressure below
atmospheric is considered a partial vacuum. A perfect
vacuum would be the removal of all atmospheric pressure.
For reading deep vacuum, a micron gauge is used. A
micron is 1/1000th of a millimeter.
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ABSOLUTEPRESSURE
The absolute pressure scale allows measurement of
both vacuum and pressure to be made using the same
units. Absolute pressure measurements are indicated as
psia (pounds per square inch absolute). 0 psia is a
pressure that cannot be further reduced.
Since atmospheric pressure will measure 14.7 psia atsea level, gauge pressure can be converted to absolute
pressure by adding 14.7 to the gauge pressure reading.
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CORE
SECTIONAGeneral Knowledge
Passing the CORE is a prerequisite
to achieving certification
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STRATOSPHERICOZONE
DEPLETION
The stratosphere is the Earth's security blanket. It is
located between 10 and 30 miles above sea level and iscomprised of, among other things, Ozone.
An Ozone molecule consists of three oxygen atoms (03).
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2=21(3527(&7686)520+$50)8/8/75$ 9,2/(7
5$',$7,21$1'+(/36720$,17$,167$%/(($57+
7(03(5$785(6
StratosphericOzone Depletion is a
GLOBAL PROBLEM
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DepletionofOzone in the
Stratosphere Causes . . .
Crop Loss
Increase In Eye Diseases
Skin Cancer
Reduced Marine Life
Deforestation
Increased Ground Level Ozone
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CFCs & HCFCs
in theSTRATOSPHERE
CFC's and HCFC's, when released into the atmosphere
deplete the Ozone layer.
The chlorine in these compounds is the culprit.When a chlorine atom meets with an Ozone molecule, it
takes one Oxygen atom from the Ozone. This forms a
compound called Chlorine Monoxide (ClO) and leaves an
O2molecule.
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CHLORINEISTHECULPRIT
Chlorine Monoxide will collide withanotherOzone molecule, release its Oxygenatom, forming two O
2molecules, and leave
the chlorine free to attack anotherOzone
molecule.
A single Chlorine atom can destroy100,000 Ozone molecules!!!
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SOURCEof CHLORINE
in the
STRATOSPHERE
Some believe that the Chlorine found in the stratosphere comes
from natural sources such as volcanic eruptions. However, air
samples taken over erupting volcanoes show that volcanoes
contribute only a small quantity of Chlorine as compared to CFC's.
In addition, the rise in the amount of Chlorine measured in thestratosphere over the past two decades matches the rise in the
amount of Fluorine, which has different natural sources than
Chlorine, over the same period. Also, the rise in the amount of
Chlorine measured in the stratosphere over the past twenty years,
matches the rise in CFC emissions over the same period.
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Chlorine in CFCs
vs.Naturally Occurring Chlorine
The chlorine in CFC's will neither dissolve inwater nor break down into compounds that dissolve
in water, so they do not rain out of theatmosphere and return to earth.
Naturally occurring chlorine will dissolve in water
(humidity) and rain out of the atmosphere.
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OZONEDEPLETIONPOTENTIAL
Ozone Depletion Potential (ODP) is a
measurement of CFC's and HCFC's ability todestroy ozone. CFC's have the highest ODP.
HFC's (R-134A) do not contain chlorine and
have no Ozone Depletion Potential.
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The Three (3) Primary Types
of
REFRIGERANTS
TYPE EXAMPLE ELEMENTS
CFC R-11 R-12 R-500 Chlorine-Fluorine-Carbon
HCFC R-22 R-123 Hydrogen-Chlorine-Fluorine-Carbon
HFC R-134a R-410A Hydrogen-Fluorine-Carbon
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THREE PRIMARY REFRIGERANT TYPES:
CFC = CHLORINE - FLUORINE - CARBON
EXAMPLE: R-11, R-12, R-500
HCFC = HYDROGEN - CHLORINE - FLUORINE - CARBON
EXAMPLE: R-22, R-123
HFC = HYDROGEN - FLUORINE - CARBON
EXAMPLE: R-134a
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CLEANAIR ACT
The United States Environmental Protection Agency (EPA) regulates
section 608 of the Federal Clean Air Act. Failure to comply could
cost you and your company as much as $27,500. per day, per violationand there is a bounty of up to $10,000 to lure your competitors,
customers and fellow workers to turn you in. Service technicians who
violate Clean Air Act provisions may be fined, lose their certification,
and may be required to appear in Federal court.
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It isa Violationof
Section 608 to:
Falsify or fail to keep required records;
Fail to reach required evacuation rates prior to openingor disposing of appliances;
Knowingly release (vent) CFC's, HCFC's or HFCswhile repairing appliances, with the exception of de-minimus releases;
Knowingly release (vent) CFC's, HCFC's or HFCswhile repairing appliances, with the exception of de-minimus releases;
Vent CFC's or HCFC's since July 1, 1992; continued . . .
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It isa Violationof
Section 608 to:
Vent HFC's since November 15, 1995;
Fail to recover CFC's, HCFC's or HFCs before opening ordisposing of an appliance;
Fail to have an EPA approved recovery device, equippedwith low loss fittings, and register the device with the EPA;
Add nitrogen to a fully charged system, for the purpose ofleak detection, and thereby cause a release of the mixture;
Dispose of a disposable cylinder without first recovering anyremaining refrigerant (to 0 psig.) and then rendering the
cylinder useless, then recycling the metal;
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STATE& LOCALREGULATIONS
State & local governments may not pass regulations
that are less strict than those contained in Section 608.They may pass regulations that are as strict or stricter
than Federal regulations.
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THEMONTREAL PROTOCOL
The Montreal Protocol is an internationaltreaty.
It regulates the production and use of CFCs,HCFCs, halons, methyl chloroform and carbontetrachloride.
CFC's were phased out of production on
December 31, 1995. HCFC refrigerants arescheduled of phase out in the future.
When virgin supplies of CFC's are depleted, futuresupplies will come from recovered, recycled, or
reclaimed refrigerants.
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RECOVERY
To remove refrigerant in any
condition from an applianceand store it in an
EXTERNAL CONTAINER
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RECOVERY& REUSE
Refrigerant that has been recovered from a unit
(if it is not contaminated) may be reused in the
unit from which it was removed.
It may be reused in another unit so long as the equipment
that it was removed from and the unit to which it is being
introduced is owned by the same owner. This requirement
is designed to prevent excessive cross-contamination.
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RECYCLE
To clean refrigerant for reuse by
separating the oil from the refrigerant
and removing moisture by passing it
through one or more filter driers
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RECLAIM
To process refrigerant to a level equal to
new product standards as determined by
chemical analysis. Reclaimed refrigerantmust meet standards set forth in ARI 700
before it can be resold.
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RECOVERYDEVICESRefrigerantRecovery and/orRecycling equipment manufactured
afterNovember 15, 1993, must be certified and labeled by an
EPA approved equipment testing organization to meetEPA
standards. There are two basic types of recovery devices.
1) System-dependentwhich captures refrigerant with theassistance of components in the appliance from which
refrigerant is being recovered.
2) "Self-contained which has its own means to draw therefrigerant out of the appliance (a compressor).
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SALESRESTRICTION
As of November 14, 1994, the sale of CFC and
HCFC refrigerants was restricted to certified
technicians.
Only technicians certified under Clean Air Act Section
609 (Motor Vehicle Air Conditioning) are allowed to
purchase R-12 in containers smaller than 20 lbs.
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SUBSTITUTE
REFRIGERANTS& OILS
HFCs are considered Ozone friendly. R-134A is the leading
candidate for CFC R-12 retrofit, but it is not a drop-in
substitute. Actually, there is not a drop-in alternative, but R-
134A can be used in most R-12 systems by following
appropriate retrofit procedures.
HFCs will not mix with most refrigerant oils used with CFCs
& HCFCs. The oils used in most HFC systems are ESTERS.
Esters cannot be mixed with other oils. It is also important to
remember that when leak testing an HFC system to use
pressurized nitrogen.
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REFRIGERANTBLENDS
There are several refrigerant blends commonly in use.
Some of the blends are called Ternary, which means theyare a three-part blend. Ternary blends are used with a
synthetic alkylbenzene oil.
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REFRIGERANTBLEND
CHARGING
The components of a blended refrigerant will leakfrom a
system at uneven rates due to different vapor pressures.
Therefore, the propercharging method for blended
refrigerants is to weigh into the high side of the system as
a liquid.
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TEMPERATUREGLIDE
Temperature glide refers to a refrigerant blend that hasa range of boiling points and / or condensing points
throughout the evaporator and condenser respectively.
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AZEOTROPIC
REFRIGERANTS
An azeotropic mixture acts like a single component
refrigerant over its entire temperature / pressure range. Anazeotrope does not have a temperature glide.
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HYGROSCOPICOIL
Most refrigerant oils are hygroscopic.
A Hygroscopic oil is one that easily absorbs &releases moisture (has a high affinity for water).
An oil sample should be taken and analyzed if a system
has had a major component failure.
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RECOVERY
andCUSTOMER
RELATIONS
Some customers have complained about
the increased cost of service. To justify
the increase, simply explain that you are
duty bound and required by law to
recover refrigerants in order to protect
the environment and human health.
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EPA REQUIREMENTOF
EQUIPMENTMANUFACTURERS
EPA regulations require a service
aperture or process stub on all
appliances that use a Class I or Class II
refrigerant in order to make it easier to
recover refrigerant.
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MIXED REFRIGERANTRECOVERY
Do not mix refrigerants in a recovery cylinder.
A refrigerant mix may be impossible to reclaim.
If you discover that two or more refrigerants have beenmixed in a system, you must recover the mixture into a
separate tank.
Badly contaminated and mixed refrigerants must be destroyed.
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with a
COMPRESSOR BURN-OUT
A strong odor is an
excellent indicator of a
compressor burn-out .
If you suspect a
compressor burn-out,
flush the system &
watch for signs of
contamination in the
oil.
If nitrogen is used to
flush debris out of the
system, the nitrogen
may be vented.
A suction line filter
drier should be
installed to trap any
debris that may damage
the new compressor.
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RECOVERYSPEED
Long hoses will reduce pressure resulting in
increased recovery time.
Since all refrigerants have a pressure
temperature relationship, lower ambient
temperatures, result in slower recovery rate.
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DEH
YRATIONTo remove water and water vapor from a refrigeration system
If moisture is allowed to remain in an operating
refrigeration system, hydrochloric & hydrofluoric acids
may form.Evacuation of a system is the suggested method of
dehydration.
It is not possible to over evacuate a system.
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EVACUATION
Never evacuate a system to the air without first
following proper recovery procedures andattaining the mandated vacuum level.
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EVACUATIONESSENTIALS
forAccurate Readings & Speed
Vacuum lines should be equal to or larger than the
pump intake connection.
The piping connection to the pump should be as short alength as possible and as large in diameter as possible.
The system vacuum gauge should be connected as far as
possible from the vacuum pump.
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EVACUATION
SPEED &EFFICIENCY
FACTORS
Size of equipment being evacuated
Ambient temperatureAmount of moisture in the system
The size of the vacuum pump and suction line
Heating the refrigeration system will decrease dehydration time
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The use of a large vacuum pump could cause trapped
water to freeze.
During evacuation of systems with large amounts of
water, it may be necessary to increase pressure by
introducing nitrogen to counteract freezing.
EVACUATION
Precautions
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COMPLETING
THE
DEHYRATIONPROCESS
Measuring a system's vacuum should be done with the
system isolated and the vacuum pump turned off.
A system that will not hold a vacuum probably has a
leak.
Dehydration is complete when the vacuum gauge shows
that you have reached and held the required finished
vacuum.
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MEASURING DEHYDRATION
EFFECTIVENESS
It is impossible to determine dehydration
effectiveness using a compound gauge that
reads in inches of Hg (MERCURY)
The use of a Micron Gauge & achieving 500
microns of vacuum assures proper dehydration.
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MICRONS INCHESOF Hg Vaporization Temp of Water
at each Pressure
0 29.921 ------
20 29.92 -50100 29.92 -40
150 29.92 -33
200 29.91 -28
300 29.91 -21
500 29.90 -12
1,000 29.88 1
4,000 29.76 29
10,000 29.53 52
20,000 29.13 72
50,000 27.95 101
100,000 25.98 125
200,000 22.05 152
500,000 10.24 192
760,000 0 212
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RECOVERY CYLINDERSRecovery cylinders are designed to be refilled.
Recovery cylinders have 2 ports, one liquid and one vapor.
They must not be overfilled or heated.
Overfilling or heating can cause an explosion.NEVER heat a refrigerant cylinder with an open flame
The EPA requires that refillable refrigerant cylinders MUST
NOT BE FILLED ABOVE 80% of their capacity by weight, and
that the safe filling level can be controlled by either mechanical
float devices, electronic shut off devices (thermistors), or weight.
Refillable cylinders must be hydrostatically tested and date
stamped every 5 years.
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Refillable cylinders used for transporting recovered pressurized
refrigerant must be DOT (Department of Transportation)
approved. Approved refrigerant recovery cylinders can easily beidentified by their colors, YELLOW TOPS and GRAY BODIES.
All refrigerant recovery cylinders should be inspected for RUST. If
they show signs of rust or appear to not be secure they should be
reduced to 0 psig and discarded.
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DISPOSABLECYLINDERS
Disposable cylinders are used with
virgin refrigerant and mayNEVER be used for recovery.
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SCHRADERVALVES
It is necessary to inspect Schrader valve cores
for leaks, bends and breakage, & replace
damaged valve cores to prevent leakage.
Always cap Schrader ports to prevent
accidental depression of the valve core.
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PERSONAL SAFETY- WEAR
When handling and filling refrigerant cylinders, or
operating recovery or recycling equipment, you should
wear
SAFETY GLASSES
PROTECTIVE GLOVES
NITROGEN
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NITROGEN
PRESSURETESTINGSAFETY
When pressurizing a system with nitrogen, you should:
1. Charge through a pressure regulator
2. Insert a relief valve in the downstream line fromthe pressure regulator
3. NEVER install relief valves in series
4. Replace the relief valve if corrosion is found within
the body of a relief valve
To determine the safe pressure for leak testing, check
the data plate for the low-side test pressure value
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OXYGEN& COMPRESSED AIR
When leak checking a system, NEVERpressurize
the system with oxygen or compressed air.
When mixed with refrigerants, oxygen or
compressed air can cause an explosion.
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SAFETY & LARGE
REFRIGERANTLEAKS
If a large release of refrigerant in a confined area occurs;
S
elf ContainedB
reathing Apparatus (S
CB
A) is required.IfSCBA is not available, IMMEDIATELY VACATE AND
VENTILATE the area.
In large quantities, refrigerants can cause suffocation
because they are heavier than air and displace oxygen.
Inhaling refrigerant vapors or mist may cause heart
irregularities, unconsciousness, and oxygen deprivation
leading to death (asphyxia).
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REFRIGERANTSAFETY
&
OPENFLAMES
NEVER expose R-12 or R-22 to open flames or
glowing hot metal surfaces. At high temperatures,
R-12 and R-22 decompose to form Hydrochloric acid,Hydrofluoric acid, and Phosgene gas.
Always review the material safety data sheets, when
working with any solvents, chemicals, or refrigerants.
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SHIPPING& TRANSPORTATION
Before shipping used refrigerant cylinders, complete the
shipping paperwork include the number of cylinders of each
refrigerant, and properly label each cylinder with the type
and amount of refrigerant.
Cylinders should be transported in an upright position.
Each cylinder must have a DOT classification tag indicating
it is a 2.2 non-flammable gas.
Some states may require special shipping procedures to befollowed based on their classification of used refrigerants.
Check with the DOT in the state of origin.
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Sample Core Questions & Answers
Here are ten sample Core questions for youto practice with.
None of these are actual questions from the
Core section of the test. They do not cover all of the subject material
that you will be tested on.
T
hey do help you to practice multiplechoice type questions by reading carefully,reviewing what you have read and justrelaxing and doing your best.
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Sorry. Try again!
Click here to try again.
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Sample Core Question #1
1. The chemicals that have been identified
as contributing to ozone depletion are:
a. CFCs and HCFCs
b. CFCs and HFCs
c. HFCs and HCFCs
d. all of the above
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Sample Core Question #2
2. Why should technicians get EPA
certification?
a. to make more money
b. to qualify for the G.I. Bill
c. to avoid large fines
d. to attain R.S.E.S. membership
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Sample Core Question #3
3. Ozone depletion occurs in the . . .
a. ionosphere
b. stratosphere
c. hemisphere
d. biosphere
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Sample Core Question #4
4. A refrigerants Ozone Depletion
Potential (ODP) is directly related to the
presence of . . .
a. ozone molecules
b. oxygen molecules
c. fluorine atoms
d. chlorine atoms
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Sample Core Question #5
5. It is against the law to use a vacuum
pump on a system until first . . .
a. replacing the driers
b. following recovery procedures to
mandated levels
c. verifying the compression ratio
d. All of the above.
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Sample Core Question #6
6. To reclaim refrigerant one must . . .
a. Appear in a court of law
b. Process recovered refrigerant to alevel of purity equal to new refrigerant
c. Clean recovered refrigerant for reuse
by passing it through a series of driers d. Recover refrigerant from a system and
then putting it right back in the samesystem
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Sample Core Question #7
7. Only technicians certified under Section
609 (Motor Vehicle Air Conditioning) are
allowed to purchase refrigerants incontainers smaller than . . .
a. 16 oz.
b. 2 lbs.
c. 10 lbs.
d. 20 lbs.
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Sample Core Question #8
8. R-134A is a drop-in replacement for . . .
a. R-12
b. R-22
c. R-11
d. None of the above
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Sample Core Question #9
9. If a customer complains about the increased
costs associated with refrigerant recovery
practices, the serviceperson should . . . a. Offer them a service contract
b. Tell them to get another bid
c. Offer them a discount after checking with
your office
d. Explain that the law requires that you
follow these procedures
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Sample Core Question #10
10. Every five years, technicians must . . .
a. get re-certified
b. take a refresher course
c. have their recovery cylinders tested
d. pay a users fee
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Choose thesection you want tostudy.
Core (return) click here:
Type I click here:
Type II click here:
Type III click here:
Click this button to exit the program . . . or keep going!
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TYPEI
Technicians servicing small appliances must be certified
in refrigerant recovery if they perform sealed system
service.
The EPA definition of a small appliance includes
products manufactured, charged, and hermetically sealed
in a factory with five pounds of refrigerant or less.
Persons handling refrigerant during maintenance, service
or repair of small appliances must be certified as either a
Type I Technician or as a Universal Technician.
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RECOVERYEQUIPMENT
MANUFACTUREDBEFORE
NOVEMBER 15, 1993
Must be capable of removing 80% of the
refrigerant, whether or not the compressor
is operating, or achieve 4 inch vacuumunder the conditions of ARI 740.
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RECOVERYEQUIPMENT
MANUFACTUREDAFTERNOVEMBER 15, 1993
Must be certified by an EPA approved testing
laboratory, (example, U.L. or E.T.L) as capable of
recovering 90% of the refrigerant if the compressoris operating, 80% of the refrigerant if the
compressor is not operating, or achieving a 4 inch
vacuum under the conditions of ARI 740.
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It's as simple as ABC
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RECOVERYEQUIPMENT
All equipment must be equipped with low loss
fittings that can be manually closed, or closeautomatically, when hoses are disconnected to
minimize the refrigerant loss.
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LEAKREPAIRREQUIREMENTS
Although leaks should be repaired
whenever possible, the EPA does notrequire leak repair for small appliances.
RECOVERY TECHNIQUES
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RECOVERYTECHNIQUESSelf-Contained (Active)
Equipment
Active recovery equipment stores refrigerant in a pressurized
recovery tank. Before operating a self-contained recovery machine,
open the tank inlet valve, and remove excessive noncondensables
(air) from the recovery tank.
An accurate pressure reading of refrigerant inside a recovery
cylinder is required to detect excessive non-condensables. The only
way to read refrigerant pressure accurately is at a stable, known
temperature. Air in a refrigeration system will cause higher
discharge pressures. Follow the operating instructions supplied by
the recovery equipment manufacturer regarding purging of non-
condensables. All refrigerant recovery equipment should be
checked for oil level and refrigerant leaks on a daily basis.
RECOVERY TECHNIQUES
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RECOVERYTECHNIQUESSystem-Dependent (Passive)
Equipment
System-dependent recovery process for small appliances
captures refrigerant into a non-pressurized container. These
are special charcoal activated plastic bag containers.
System-dependent equipment captures refrigerant with the
assistance of the appliance compressor, an external heat
source, or a vacuum pump.
A standard vacuum pump can only be used as a recovery
device in combination with a non-pressurized container
When using a system dependent recovery process on
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When using a system dependent recovery process on
an appliance with an operatingcompressor, run the
compressor and recover from the high side of thesystem. Usually, one access fitting on the high side will
be sufficient to reach the required recovery rate, as
the appliance compressor should be capable of
pushing the refrigerant to the high side.
Appliances with a non-operatingcompressor, access to
both the low and high side of the system is necessary.
In order to achieve the required recovery efficiency, it
will be necessary to take measures to help release
trapped refrigerant from the compressor oil, (heat
and tap the compressor several times and/or use a
vacuum pump).
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Because appliances with non-operating compressors
can not always achieve desired evacuation rates
utilizing system-dependent recovery equipment, the
EPA requires technicians to have at least one self-
contained recovery device available at the shop to
recover refrigerant from systems with non-operating
compressors. The exception to this rule is technicians
working on small appliances only.
System dependent devices may only be used on
appliances containing 15 lbs. of refrigerant or less.
INSTALLING PIERCING
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INSTALLING PIERCING
TYPE ACCESS FITTINGS
Fittings should be leak tested before proceeding
with recovery. It is generally recommendedthat solderless piercing type valves only be usedon copper or aluminum tubing material.
Fittings tend to leak over time and should notbe left on an appliance as a permanent serviceport. After installing a fitting, if you find thatthe system pressure is 0 psig, do not begin therecovery process.
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DEFROSTHEATERS
If the appliance is equipped with a defrost
heater, such as in a domestic frost-freerefrigerator, operating the defrost heater will
help to vaporize any trapped liquid refrigerant
and will speed the recovery process.
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DONOTRECOVER
Refrigerators built before 1950 may have used
Methyl Formate, Methyl Chloride, or SulfurDioxide as refrigerant and should not berecovered with current recovery devices.
Small appliances used in campers or otherrecreational vehicles may use refrigerants suchas Ammonia, Hydrogen, or Water, andtherefore should not be recovered usingcurrent recovery equipment.
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CHARGING CYLINDERS
When filling a graduated charging
cylinder with a regulatedrefrigerant, the refrigerant vapor
that is vented off the top of the
cylinder must be recovered.
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101
S l T I Q ti & A
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102
Sample Type I Questions & Answers
Here are ten sample Type I questions for you to
practice with.
None of these are actual questions from the Type Isection of the test.
They do not cover all of the subject material that
you will be tested on.
They do help you to practice multiple choice type
questions by reading carefully, reviewing what
you have read and just relaxing and doing your
best.
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103
Sample Type I Question #1
1. Type I Certification applies to . . .
a. small appliances.
b. appliances with 5lbs. or less of
refrigerant.
c. appliances charged and hermetically
sealed in a factory.
d. All of the above.
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Sample Type I Question #2
2. All recovery equipment must be
equipped with . . .
a. temperature relief valves.
b. glycerin filled gauges.
c. low-loss hose fittings.
d. thermistors.
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105
Sample Type I Question #3
3. The leak requirement for small appliances is . . .
a. all leaks must be repaired.
b. leaks should be repaired whenever possible.
c. leaks of one or more pounds per month must
be repaired.
d.T
here is no leak repair policy stated by the EPA.
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Sample Type I Question #4
4. Sending a recovery cylinder to a reclamationfacility with more than one type of refrigerant in
it . . . a. saves storage space.
b. require that a contents tag be filled out.
c. may result in the cylinder being returnedunprocessed at the owners expense.
d. may lead to the technicians arrest
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Sample Type I Question #5
5. The EPA requires technicians to . . .
a. have at least one self-contained recovery
device.
b. display a Underwriters Laboratories
(UL) label on their uniform.
c. evacuate the systems to 250 microns.
d. check for leaks 30 days after any repair.
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108
Sample Type I Question #6
6. Systems using Ammonia, Hydrogen orWater should not be . . .
a. allowed to remain in service. b. recovered using current recovery
equipment.
c. compared to modern systems.
d. considered covered by the UniformDwelling Code.
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109
Sample Type I Question #7
7. When leak checking a system use . . .
a. compressed air.
b. oxygen.
c. R-11.
d. nitrogen.
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110
Sample Type I Question #8
8. When exposed to a torch flame, R-12 and R-22
will decompose to form . . .
a. hydrochloric acid.
b. hydrofluoric acid.
c. phosgene gas.
d. all of the above.
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111
Sample Type I Question #9
9. The sale of CFCs and HCFCs is restricted to
a. certified technicians
b. licensed technicians
c. experienced technicians
4. trained technicians
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112
Sample Type I Question #10
10. Recovery cylinders must not be filled more
than . . .
a. disposable cylinders.
b. 80% of its capacity by weight.
c. 90% of its capacity to allow for thermal.
expansion
d. 75% by volume.
Choose the section you want to study
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113
Choose thesection you want tostudy.
Core click here:
Type I (return) click here:
Type II click here:
Type III click here:
Click this button to exit the program . . . or keep going!
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114
TYPE II
Technicians maintaining, servicing, repairing or
disposing of high pressure or very high-pressure
appliances, except small appliances and motor
vehicle air conditioning systems, must be certified
as a Type II Technician or a Universal Technician.
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LE AK DETECTION
After installation of a system, pressurize
the unit with nitrogen and leak check.
In order to determine the general area of
a leak use an electronic or ultrasonic leakdetector.
To pinpoint the leak use soap bubbles.
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LeakingSystems
A refrigeration unit using an open compressorthat has not been used in several months islikely to leak from the shaft seal.
During a visual inspection of any type ofsystem, traces of oil are an indicator of arefrigerant leak.
Excessive superheat, caused by a lowrefrigerant charge, is also an indication of aleak in a high-pressure system.
LEAK REPAIR
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LEAKREPAIR
REQUIREMENTSComfort Cooling
EPA regulations require that all comfort
cooling appliances (airconditioners)
containing more than 50 lbs. ofrefrigerant MUST be repaired when the
annual leak rate exceeds 15%.
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118
LEAKREPAIRREQUIREMENTS
Commercial & Industrial ProcessRefrigeration
EPA regulations require that all
Commercial and Industrial Process
Refrigeration containing more than 50 lbs.of refrigerant MUST be repaired when the
annual leak rate exceeds 35%.
CommercialRefrigeration includes appliances used in
the retail food and cold storage warehouse sectors,
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119
the retail food and cold storage warehouse sectors,
including equipment found in supermarkets, convenience
stores, restaurants and other food establishments, andequipment used to store meat, produce, dairy products
and other perishable goods.
Industrial ProcessRefrigeration means complex
customized appliances used in the chemical,pharmaceutical, petrochemical and manufacturing
industries, including industrial ice machines and ice
rinks.
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RECOVERYEQUIPMENT
Recovery equipment must be certified by an
EPA approved laboratory (UL or ETL) to meet
or exceed ARI standards.
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121
RECOVERY
REQUIREMENTS
Recovered refrigerants can contain acids, moisture, and oil.
Frequently check and change both the oil and filter on a recycling
machine. Recycling and recovery equipment using hermetic
compressors have the potential to overheat when drawing a deep
vacuum because the unit relies on the flow of refrigerant throughthe compressor for cooling. Before using a recovery unit you
should always check the service valve positions, the recovery units
oil level, and evacuate and recover any remaining refrigerant
from the units receiver.
When working with multiple refrigerants, before
recovering and/or recycling a different refrigerant purge
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recovering and/or recycling a different refrigerant, purge
the recover/recycle equipment by recovering as much of
the first refrigerant as possible, change the filter, andevacuate. The only exception to this rule is for technicians
working with R-134A who must provide a special set of
hoses, gauges, vacuum pump, recovery or
recovery/recycling machine, and oil containers to be used
with R-134A only.
Recovering refrigerant in the vapor phase will minimize
the loss of oil, recovering as much as possible in the liquid
phase can reduce recovery time. The technician maychoose to speed up the recovery process by packing the
recovery cylinder in ice and/or applying heat to the
appliance. After recovering liquid refrigerant, any
remaining vapor is condensed by the recovery system.
RECOVERY
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NOTES
Refrigerant should be placed in the receiver of
units that have a receiver/storage tank.
Refrigerant should be removed from thecondenser outlet if the condenser is below thereceiver.
In a building that has an air-cooled condenseron the roof and an evaporator on the first floor,recovery should begin from the liquid lineentering the evaporator.
After recovery, refrigerant may be returned to the
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Always evacuate an empty recovery cylinder before
transferring refrigerant (recovering) to the cylinder.
y, g y
appliance from which it was removed or to another
appliance owned by the same person without beingrecycled or reclaimed, unless the appliance is an MVAC
(Motor Vehicle Air Conditioner) like appliance.
Type of Appliance Manufactured
Before 11/15/93
Manufactured
After 11/15/93
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Before 11/15/93 After 11/15/93
HCFC-22 appliances or isolated
components of such appliances
normally containing less than 200 lbs.of refrigerant.
0 0
HCFC-22 appliances or isolated
components of such appliances
normally containing more than 200
lbs. of refrigerant.4 10
Other high pressure appliances orisolated component of such appliance
normally containing less than 200 lbs.
of refrigerant.4 10
Other high pressure appliances or
isolated component of such appliancenormally containing more than 200
lbs. of refrigerant.4 15
Very high pressure appliances
There are no questions on the exam
aboutVery high pressure appliances
0 0
After reaching the desired vacuum, wait a fewminutes to see if the system pressure rises
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minutes to see if the system pressure rises,indicating that there is still refrigerant in liquid
form or in the oil.
Appliances can be evacuated to atmosphericpressure (O psig) if leaks make evacuation tothe prescribed level unattainable.
The technician must isolate a parallel compressorsystem in order to recover refrigerant. Failureto isolate a parallel compressor system willcause an open equalization connection that will
prevent refrigerant recovery.
System-dependant recovery equipment cannot beused on appliances containing more than 15pounds of refrigerant.
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127
MAJORREPAIR
Under EPA regulations, a major repair means any
maintenance, service or repair involving the removal
of any or all of the following components: thecompressor, the condenser, the evaporator or an
auxiliary heat exchanger coil.
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REFRIGERANT TYPE
To determine the type of refrigerant used
read the nameplate.
FILTER / DRIER
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FILTER / DRIER
Filter driers will remove moisture from the refrigerant
in a system, but there is a limit to their capacity.
Some systems are equipped with a moisture indicatingsight glass. When the sight glass changes color, the
system contains excessive moisture and will need to be
evacuated.
The filter-drier should be replaced anytime a system is
opened for servicing.
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CRANKCASE HEATER
A crankcase heater is used to prevent
refrigerant from migrating to the oil during
periods of low ambient temperature.
Refrigerant in the oil will cause oil foaming
in the compressor at start-up.
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WARNING
A hermetic compressor's motor winding could
be damaged if energized when under a deep
vacuum.
NEVER energize a reciprocating compressor if
the discharge service valve is closed.
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132
LIQUID CHARGING
There is a risk of freezing during liquid charging of an
R-12 refrigeration system
Begin with vapor from a vacuum level to a pressure of
approximately 33 psig. Followed by a liquid chargethrough the liquid-line service valve. This is also the
proper method to charge a system that contains a large
quantity of refrigerant.
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133
ASHRAE
STANDARD 15
Requires a refrigerant sensor that will
sound an alarm and automatically start
a ventilation system in occupiedequipment rooms where refrigerant
from a leak will concentrate.
ASHRAESAFETYCLASSIFICATION
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FORREFRIGERANTS
CFC-12 CFC-11 HFC-134a
are all categorized as A-1
HIGHER
FLAMMABILITYA3 B3
LOWER
FLAMMABILITYA2 B2
NO FLAME
PROPAGATIONA1 B1
Lower
Toxicity
Higher
Toxicity
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135
Sample Type II Questions & Answers
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136
Sample ype Questions & nswe s
Here are ten sample Type II questions for you topractice with.
None of these are actual questions from the Type IIsection of the test.
They do not cover all of the subject material that youwill be tested on.
They do help you to practice multiple choice typequestions by reading carefully, reviewing what youhave read and just relaxing and doing your best.
S l T II Q #1
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137
Sample Type II Question #1
1. Type II Certification is required for
servicing, repairing or disposing of . . .
a. small appliances.
b. low pressure appliances.
c. high pressure appliances.
d. appliance installed since 1995.
S l T II Q i #2
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Sample Type II Question #2
2. An indication of a potential leak on a high
pressure system is . . .
a. traces of oil.
b. excessive superheat.
c. low subcooling.
d. All of the above.
S l T II Q i #3
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139
Sample Type II Question #3
3. Refrigerant leaks on comfort coolingsystems must be repaired if . . .
a. the system contains more than 50 lbs. ofrefrigerant.
b. the annual leak rate exceeds 15%.
c. the annual leak rate exceeds 35%.
d. Both A & B.
Sample Type II Question #4
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p yp Q
4. Commercial & industrial process refrigeration
systems must be repaired if . . .a. the system contains more than 50 lbs. of
refrigerant.
b. the annual leak rate exceeds 15%.
c. the annual leak rate exceeds 35%.
d. Both a & c.
Sample Type II Question #5
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p yp Q
5. Proper recovery equipment must be . . .
a. certified by an EPA approvedlaboratory.
b. Oilless.
c. HVAC approved.
d. able to be operated on dual voltages.
Sample Type II Question #6
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142
p yp Q
6. Technicians working with R-134A must
use dedicated . . .
a. hoses & gauges.
b. recovery units.
c. vacuum pumps.
d. All of the above.
Sample Type II Question #7
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143
p yp Q
7. Recovering refrigerant in the vapor phase
will minimize the loss of . . .
a. time.
b. certification.
c. oil.
d. nitrogen.
Sample Type II Question #8
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p yp Q
After recovery, refrigerant may be . . .
a. sold to future customers.
b. reused in the same appliance.
c. Put into another appliance owned by the
same customer .
d. Either b or c.
Sample Type II Question #9
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145
p yp Q
9. The R-22 in residential air conditioners
must be recovered to . . .
a. -4 inches of mercury.
b. 10 inches of mercury.
c. 15 inches of mercury.
d. 0 inches of mercury.
Sample Type II Question #10
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p yp Q
10. System-dependent recovery equipment
cannot be used on systems . . .
a. ever!
b. containing more than 15 lbs. of refrigerant.
c. containing more than 5 lbs. of refrigerant.d. containing more than 50 lbs. of refrigerant.
Choose thesection you want tostudy.
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147
y y
Core click here:
Type I click here:
Type II (return) click here:
Type III click here:
Click this button to exit the program . . . or keep going!
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148
TYPEIII
Technicians maintaining, servicing, repairing or
disposing of low-pressure appliances must be
certified as a Type III Technician or a UniversalTechnician.
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DESCRIPTION
A typical low-pressure centrifugal chiller operating
below atmospheric pressure uses a Shell style
evaporator with tubes of running water routed
through the evaporator.
The low pressure refrigerant within the shell
absorbs the heat carried by the water in the tubes.
The cold water within the tube system circulates throughout
the area where objectionable heat is to be removed
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the area where objectionable heat is to be removed.
The water then absorbs the heat from the area where it isnot wanted and transfers the heat to the refrigerant in the
shell evaporator.
The refrigerant travels through a normal vapor
compression circuit releasing its heat through a
condenser.
The system is protected from over-pressurization by a
rupture disc located at the evaporator.
A rupture disc differs from a relief valve in that when it
opens it remains open Most system rupture discs are set
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opens it remains open. Most system rupture discs are set
at 15 psig.
Low pressure equipment operates below atmospheric
pressure (in a vacuum).
The ambient air pressure surrounding gaskets & fittings is
greater than the internal pressure.
Because the internal pressure is less than the external airpressure, leaks in gaskets or fittings will cause air &
moisture to enter the system. For this reason it is
extremely important to maintain a tight system.
Low Pressure chillers are equipped with a
method of eliminating air and other non
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method of eliminating air and other non-
condensables that will leak into the system.
T
he PURGE UnitThe purge unit is located at the condenser. (Purge
units will be covered later in this section).
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LE AK DETECTION
Detecting a leak in a low pressure system is
unlike that of a high pressure appliance.
Refrigerant does not leak out of a charged low
pressure chiller air & moisture leaks in.
The systems internal pressure must be raised above the
ambient pressure before leak testing can be performed.
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ambient pressure before leak testing can be performed.
The best method of pressurizing the system is throughthe use ofControlled Hot Water (raising the
temperature of the circulating water within the tubes).
Heater blankets may also be used to aid in raising the
system pressure. When controlled hot water or heater
blankets are not feasible, use nitrogen to increase
pressure.
When pressurizing a system, do not exceed 10 psig.
Exceeding 10 psig can cause the rupture disc to fail.
L k t ti t b i li h d b
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Leak testing a water box is accomplished by
removing the water andplacing the leak detectorprobe through the drain valve.
To leak test a tube, use a hydrostatic tube test kit.
Controlled hot water can also be used to
pressurize a system for the purpose of opening thesystem for a non-major repair
MAJOR REPAIRS
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MAJORREPAIRS
The EPA defines a major repair as anymaintenance, service or repair involving the
removal of any or all of the following
components: the compressor, the condenser,
the evaporator or any auxiliary heat exchangercoil.
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LEAKREPAIRREQUIREMENTS
EPA regulations require that all comfort cooling appliances (air
conditioners) containing more than 50 lbs. of refrigerant MUST
be repaired when the annual leak rate exceeds 15%.
EPA regulations require that all Commercial and Industrial
Process Refrigeration containing more than 50 lbs. of
refrigerant MUST be repaired when the annual leak rate
exceeds 35%.
CommercialRefrigeration includes appliances used in the
retail food and cold storage warehouse sectors, including
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retail food and cold storage warehouse sectors, including
equipment found in supermarkets, convenience stores,
restaurants and other food establishments, and equipment
used to store meat, produce, dairy products and other
perishable goods.
Industrial ProcessRefrigeration means complex
customized appliances used in the chemical,
pharmaceutical, petrochemical and manufacturingindustries, including industrial ice machines and ice rinks.
LOW-PRESSURE
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RECOVERYEQUIPMENTA recovery unit's high pressure cut-out is set for 10
psig when evacuating the refrigerant from a low-
pressure chiller and a rupture disc on a low-pressure recovery vessel relieves at 15 psig.
Most low-pressure recovery machines utilize a
water-cooled condenser that is connected to themunicipal water supply.
Recovery Techniques
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Refrigerant recovery from an R-11 or R123 system begins
with liquid removal and is followed by vapor recovery.
Water must be flowing through the tubes while refrigerant is
drained to prevent freezing. The recovery compressor and
condenser should also be operating.
Substantial vapor remains within the system even after
liquid is removed
An average 350 ton R-11 chiller after liquid recovery will
stillcontain approx. 100 lbs of refrigerant in vapor form. In an R-11 system, 10% of refrigerant can remain in the
system in vapor form even after liquid recovery.
Recovery Tips
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Recovery Tips
If a system is suspected of water tube leaks, thewater sides of the system should be drained priorto recovering the refrigerant.
When vacuum testing a system, if the absolutepressure rises from 1mm Hg to any point above2.5mm Hg, the system should be checked for leaks
(ASHRAEGuideline 3-1996)
System oil should be heated to 130F prior todraining to ensure the release of refrigerant fromthe oil.
Recharging Requirements
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RechargingRequirements
Initial charging must occur in the vapor phaseuntil the systems pressure has reached 16.9 hg
vacuum. This insures that water will not freezeand the refrigerant will not boil. R-11 at 32Fhasa saturation pressure of 18.1Hg.
The system is charged through the lowest accesspoint on the system, the evaporator charging valve
Recovery Requirements
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Recovery Requirements
Levels of evacuation for low-pressure appliances:
For Refrigeration Recovery & Recycling Equipment
manufactured or imported Before November 15th
, 1993:
25 inches Hg
For Refrigeration Recovery & Recycling Equipment
manufactured or imported on or After November 15th, 1993:
25 mm Hg absolute
Recovery Tips
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Recovery Tips
System pressure should be monitored after
evacuation for a few minutes to ensure the
maximum amount of refrigerant has been
removed. If pressure rises, recovery must be
repeated.
Systems that cannot attain or maintain stated
levels of evacuation should be evacuated to thehighest possible level prior to repair.
Refrigeration Pointers
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Refrigeration Pointers
Freezing water must be avoided. If necessary, usenitrogen to increase pressure to counteract freezingwhile evacuating a system.
Strong odors and contaminated oil are possibleindications of a compressor burn-out.
The purge unit operates with suction from the top ofthe condenser. It removes air, moisture and other non-condensables from the system and returns refrigerant at
the evaporator. If frequent purge operation occurs, orexcessive moisture is detected in the purge unit, one ofthe systems tubes may be leaking.
Rupture Disc
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Rupture Disc
Releases pressure in a low-pressure system when itexceeds 15 psig.
Protects the system from over-pressurization.
SAFETY
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Equipment rooms must be monitored for highrefrigerant levels, in which case an alarm must
sound, and a ventilation system must be
automatically activated.
-ASHRAE standard 15(for all ASHRAE refrigerant safety groups)
All refrigeration systems must be protected by a
pressure relief valve(s)
Never install relief valves in series
ASHRAESAFETYCLASSIFICATION
FORREFRIGERANTS
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HIGHERFLAMMABILITY
A3 B3
LOWER
FLAMMABILITYA2 B2
NO FLAME
PROPAGATIONA1 B1
Lower
Toxicity
Higher
Toxicity
CFC-12 CFC-11 HFC-134a are all categorized as A-1
R-123 (an HCFC) is categorized as B1
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Sample Type III Questions & Answers
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Here are ten sample Type III questions for you topractice with.
None of these are actual questions from the Type III
section of the test.
They do not cover all of the subject material that youwill be tested on.
They do help you to practice multiple choice type
questions by reading carefully, reviewing what youhave read and just relaxing and doing your best.
Sample Type III Question #1
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1. Type III Certification is required for . . .
a. high pressure systems
b. low pressure systems
c. medium pressure systems
d. ammonia-based systems
Sample Type III Question #2
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2. Low-pressure systems operate . . .
a. without lubricants
b. in a vacuum
c. between 100 & 200 PSI
d. with HCFC-22
Sample Type III Question #3
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3. Refrigerant recovery of R-11 starts . . .
a. with vapor recovery followed by liquid
recovery
b. with liquid recovery followed by vapor
recovery
c. with removal of all dryers and receivers
d. with removal of all refrigerant oil
Sample Type III Question #4
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4. When evacuating refrigerant from a R-11
chiller . . .
a. circulate water through the tubes.
b. the compressor must be operated.
c. drain all water from the system.
d. disconnect the crankcase heater.
Sample Type III Question #5
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5. If leaks in a R-11 system make evacuation
to the prescribed level unattainable, the . . .
a. system must be scrapped.
b. leaks must first be repaired.
c. system evacuation level should be aslow as possible.
d. jobsite must be reported to the EPA.
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Sample Type III Question #7
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7. The typical design burst pressure for a
rupture disc is . . .
a. 5 PSI.
b. 10 PSI.
c. 15 PSI.
d. 30 PSI.
Sample Type III Question #8
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8. R-11 is rated as . . .
a. flammable in the presence of chlorine.
b. non-flammable with high toxicity.
c. non-flammable with low toxicity.
d. highly carcinogenic.
Sample Type III Question #9
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9. All refrigeration systems must be protected by
a. crankcase heaters.
b. suction accumulators.
c. pressure relief valves.
d. heat sensitive limit controls.
Sample Type III Question #10
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10.The standards for recovery units change for
units manufactured or imported after . . .
a. November 15, 1993.
b. November 15, 1992.
c. April 15, 1988.
d. April 15, 1995
Choose thesection you want tostudy.
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Core click here:
Type I click here:
Type II click here:
Type III(return) click here:
You are almost done! keep going!
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Correct!
Click here to return to the quiz. Then click
again to answer the next question.
Conclusion:
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When is the next exam date?
How do you register?
What can you bring with you to the exam?
What MUST you bring with you?
What else can you study?
R t ti ?