HC HFO Manual
HC HFO Manual
HC HFO Manual
Safe Handling of
Flammable Hydrocarbon and
Hydrofluoroolefin Refrigerants
Written by
Kay Rettich
Julia Setlak
Robert P. Scaringe, Ph.D., P.E.
Second Edition
February 2017
© Copyright 2017
ALL RIGHTS RESERVED
iii
Covered End Uses ................................................................................................................24
Household Refrigeration ....................................................................................................24
Retail Food Refrigerators and Freezers .............................................................................24
Other Use Conditions ............................................................................................................25
Charge Size Limitations ........................................................................................................25
Color-Coded Hoses and Piping .............................................................................................26
Labeling ................................................................................................................................27
Refrigerant Containers ..........................................................................................................27
Refrigerant Container Colors .................................................................................................27
Unique Fittings ......................................................................................................................28
Training Requirements ..........................................................................................................28
Recovery and Recycling Equipment ......................................................................................29
Chapter 5. What are the Safety Classifications of HC and HFO Refrigerants? ....................30
ASHRAE Safety Classifications.............................................................................................30
Toxicity ..............................................................................................................................30
Flammability ......................................................................................................................32
Flammability Limits of Hydrocarbon Refrigerants ..................................................................32
Use Conditions......................................................................................................................33
Asphyxiation..........................................................................................................................34
Chapter 6. What are the HC and HFO Safe Handling Practices? ........................................36
Charge Limitations ................................................................................................................36
Household Refrigeration ....................................................................................................36
Retail Food Refrigeration...................................................................................................37
HC and HFO Refrigerant Recovery .......................................................................................37
Recovery Techniques ........................................................................................................37
Identifying the Refrigerant .................................................................................................37
Evacuation Requirements .................................................................................................39
Proper Recovery/Recycling Equipment .............................................................................40
Pressure Decay Leak Test ................................................................................................44
Triple Evacuation...............................................................................................................46
Triple Evacuation Procedure .............................................................................................47
Leak Repairs .........................................................................................................................52
Brazing..................................................................................................................................52
Pipe Connections ..............................................................................................................52
Charging ...............................................................................................................................53
Liquid Charge ....................................................................................................................53
Recharging the System with Recovered Refrigerant..........................................................53
Venting..................................................................................................................................54
Static Electricity Concerns.....................................................................................................55
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Handling ................................................................................................................................55
Sales Restrictions .................................................................................................................56
MVAC Self-sealing Valve Specifications ...............................................................................58
Shipping ................................................................................................................................58
Department of Transportation Regulations ........................................................................58
Shipping Labels .................................................................................................................58
Cylinder Loading ...............................................................................................................59
Storage .................................................................................................................................59
Risk Assessment ...............................................................................................................59
Major Accident Prevention Policy ......................................................................................60
Procedures for Damaged Equipment.................................................................................60
Record Keeping Procedures .................................................................................................61
References ...............................................................................................................................80
Index .........................................................................................................................................83
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vi
Preface
The information in this course is intended for educational purposes only.
Procedures described in this manual are for use only by qualified air conditioning
and refrigeration service technicians who already hold EPA Section 608 Type II,
Type III, or Universal Certification. This training course is not a substitute for
the operator manual of any equipment manufacturer.
Safety Precautions
Take safety precautions when using all HVAC equipment. Improper use of
HVAC equipment can cause explosion and serious personal injury.
Always read the entire manufacturer’s operator manual before turning on any
equipment for the first time. Never turn on any equipment if you do not
understand its operation. Where procedures described in this manual differ
from those of a specific equipment manufacturer, you should follow the
equipment manufacturer’s instructions.
Use caution when working with hydrocarbon refrigerants; hoses could contain
liquid flammable refrigerant under pressure. Use only approved refillable storage
cylinders. Do not overfill any storage cylinder beyond its rated capacity.
Always wear safety glasses. Protect the skin from flash freezing.
EPA Regulations
Technical and legislative information presented in this book is current as of the
date of the manual’s latest publication. Because of rapidly advancing technology
and changing regulations in the hydrocarbon refrigerant area, no representation
can be made for the future accuracy of the information. Visit the EPA’s Internet
home page at http://www.epa.gov for the latest details.
Liability
Mainstream Engineering Corporation assumes no liability for the use of
information presented in this publication. This information is presented for
educational purposes only.
vii
Manufacturer’s operator manuals must be consulted for the proper operation of
any piece of equipment.
The content of this course is limited to information and service practices needed
to contain, conserve, and re-use flammable refrigerants, and to prevent their
escape into the atmosphere.
viii
Document Conventions
The following helpful information appears throughout this document:
Caution
Cautions indicate the possibility of bodily harm or damage to your
equipment.
Note
Notes contain related information.
Tip
Tips are designed to provide hints or shortcuts.
Example
Examples provide practical applications of a concept.
ix
Chapter 1. What Are Hydrocarbon
Refrigerants?
A hydrocarbon is an organic compound consisting only of carbon and hydrogen
atoms. A halocarbon is any compound derived from a hydrocarbon by replacing
at least one hydrogen atom with a halogen. For halocarbon hydrofluorocarbon
(HFC) refrigerants, some of the hydrogen atoms are replaced with fluorine atoms.
Although the fluorine atoms reduce the flammability of the refrigerants, the
fluorine is harmful to the environment. The hydrocarbon refrigerants are therefore
flammable (because the hydrogen atom has not been replaced with a halogen such
as fluorine).
1
Physical Properties of Hydrocarbons
Hydrocarbon refrigerants are components of oil and natural gas that are found in
nature. Although hydrocarbon refrigerants have excellent environmental,
thermodynamic, and thermo-physical properties, these refrigerants are highly
flammable. Table 1 summarizes the physical properties of hydrocarbons
[ACRIB, 2001].
HC Refrigerant Types
R-600a (Isobutane)
Isobutane, also called 2-methylpropane, has four carbon atoms, the chemical
formula C4H10, and a branched structure. Isobutane is often written as
CH(CH3)2-CH3 to distinguish it from butane, which is a straight-chain
hydrocarbon with the same chemical formula.
The Chemical Abstracts Service (CAS) registry number for isobutane is 75-28-5.
As a refrigerant, isobutane is designated as R-600a by the ASHRAE
Standard 34-2010 “Designation and Safety Classification of Refrigerants”
[ASHRAE, 2010]. Isobutane is also referred to as HC-600a and iso-C4H10.
2
Refrigerant R-600a, which was used in residential refrigerators up to the 1940s, has
again found acceptance in domestic refrigerators and freezers in Europe where most of
today’s refrigerators using R-600a refrigerant are manufactured. Isobutane R-600a is a
well-suited refrigerant for household applications with good energy efficiency, but this
refrigerant has very different characteristics when compared to R-134a, which means
it is not a drop-in replacement for R-134a, especially because R-600a is flammable.
One significant difference between R-600a and R-134a is the normal operating
pressure, which is much lower for R-600a. For example, as shown in Table 2,
R-600a at 20 °F is barely above atmospheric pressure. In addition, R-600a has
roughly half the volumetric capacity of R-134a, which means the swept volume of
the compressor must be about twice as large to move the same mass of
refrigerant. However, the volumetric cooling capacity, which is a value calculated
from suction gas density and latent heat of evaporation at the suction gas pressure,
is only slightly lower, so less refrigerant mass flow is required.
3
R-290 (Propane)
Propane has three carbon atoms, the chemical formula C3H8, and the CAS
Number 74-98-6. As a refrigerant, propane has ASHRAE designation R-290.
Propane is also referred to as HC-290 and CH3CH2CH3.
Refrigerant R-290 was used in refrigeration plants in the past and is still used in
industrial plants in Europe. For residential heat pumps and air conditioners, R-290
has been used in Germany and Sweden for some time.
The pressure difference between R-290 and R-22 or R-404A is very little.
Evaporator and condenser designs are similar to R-22 or R-404A, but special care
has to be taken because of the flammability of these HC refrigerants.
Using pure R-290 as a substitute for R-22 results in approximately a 7–10% lower
cooling capacity. The larger 10% capacity decrease is associated with higher
operating conditions. However, the coefficient of performance for cooling (COPc)
is approximately 2–8% higher when using R-290 to replace R-22. In this case, the
higher 8% COPc occurs at the lower operating temperatures.
In addition, the compressor discharge pressure when using R-290 is about 14–
18% lower than the R-22 discharge pressure. Using R-290 instead of R-22 also
results in approximately 12–14% lower power consumption and lower pressure
drops in the heat exchanger coils.
If R-290 were charged into an unchanged refrigeration system that was designed
for R-22, the charge in terms of mass (weight) would be much lower, but the
charge in terms of volume would be about the same. Because liquid volume in the
evaporator and condenser determine optimum charge (not the mass of
refrigerant), the R-290 charge would be about 40% of the charge by mass of an
R-22 system. The charge size limitation for flammable refrigerants is 57 g
(0.13 lb) for household refrigerators and 150 g (0.35 lb) for retail food
refrigeration, which equates to a R-22 charge of about 0.31 pounds for household
refrigerators and 0.83 pounds for retail food refrigerators.
R-441a
R-441a, also known as HCR188C, was the first hydrocarbon refrigerant to be
approved for sale in the United States by the Environmental Protection Agency
(EPA). This refrigerant is a blend of four hydrocarbons and has ASHRAE
certification as being non-toxic. R441a was designed to replace R-134.
4
R-1270
Other HC Blends
An HC blend of 50% (by weight) of R-290 and 50% of R-600a has been used to
replace R-134a in refrigeration applications. For this replacement, energy
consumption drops by approximately 5% and the refrigerant charge is reduced by
35–40%.
Materials Compatibility
Lubricants
Caution
Never use lubricants containing silicone or silicate, which
are often used as anti-foaming additives, because these
lubricants are not compatible with HC refrigerants.
Never use any leak-sealing or moisture-drying compounds
with HC refrigerants because these compounds all contain
silicates.
5
Caution
If you are changing or selecting a lubricant for a
hydrocarbon refrigerant application, always consult the
compressor manufacturer for recommendations.
Desiccants
Desiccants are used in filter dryers. Most of the commonly used desiccants are
compatible with HC refrigerants. Acceptable types are XH-5, XH-6, or the
equivalent. You can use molecular sieve desiccant types such as XH5, XH6, XH7,
and XH9, and the universal filter drier MS 594.
Materials
Almost all common elastomer and plastic refrigeration materials that are used as
O rings, valve seats, seals, and gaskets are compatible with HC refrigerants. These
include neoprene, Viton™, nitrile rubber, hydrogenated nitrile butadiene rubber
(HNBR), polytetrafluoroethylene (PTFE aka Teflon™), and nylon. Ethylene
propylene diene terpolymer (EPDM), natural rubbers, or silicone rubbers are not
compatible.
Caution
Do not use EPDM, natural rubbers, and silicone rubbers in HC
refrigerant systems. These materials are not compatible.
6
Tip
Although a number of materials have been tested with hydrocarbons,
many different grades are available in the market. Always check
compatibility with the manufacturer or supplier of the component.
An EPA SNAP (Significant New Alternatives Policy) rule allows the use of
isobutane and propane with charge limit restrictions (up to 57 g for household
refrigerators and up to 150 g for commercial refrigerators). Underwriters
Laboratory (UL) has approved the use of propane in window air-conditioning
applications with charge limits.
The EPA SNAP ruling published in December 2016 allows the following:
• Use of R-600a (isobutane) and R-441A in retail food refrigeration
• Use of R-170 (ethane) in very low temperature refrigeration and non-
mechanical heat transfer
• Use of R-290 (propane) in household refrigerators
• Use of R-290, R-600a, and R-441A in vending machine
• Use of HFC-32, R-290, and R-441A in self-contained room air
conditioners, packaged terminal air conditioners, packaged terminal heat
pumps, windows AC units, and portable AC units designed for use in a
single room
7
Chapter 2. What Are Hydrofluoroolefin
Refrigerants?
Hydrofluoroolefins (HFO) refrigerants are unsaturated hydrofluorocarbons
(HFCs) that are heavily promoted as the next generation of refrigerants because of
their environmental friendliness, although they are not as green as the HC
refrigerants. They are less flammable, but they are still flammable.
The HFO blends under development are designed to offer higher capacities with
tradeoffs in either GWP or flammability. The GWP values of these blends range
from less than 150 to around 600, which are still significantly lower than the
GWP values of the HFCs they would replace but are significantly higher than the
HC refrigerants. Therefore, these HFO blends are being proposed for use to
replace HFC refrigerants, but they are flammable, and this could impede
acceptance. HFOs have no chlorine, and they have zero ozone depletion
potential (ODP).
HFC refrigerants, such as R-134a, R-125, R-1434a, and R-152a, and HFC blends,
such as R-407A, R-407B, R-410A, and R-5078, are all composed of hydrogen,
fluorine, and carbon connected by single bonds. Although HFOs are also
8
composed of hydrogen, fluorine, and carbon, they contain at least one double
bond between the carbon atoms.
Because HFO refrigerants like the HFC refrigerants contain fluorine atoms, these
fluorine atoms reduce the flammability, which is the reason the HFO refrigerants
are classified as slightly flammable and HC refrigerants (which by definition
never contain fluorine) are flammable. Table 4 summarizes the physical
properties of HFOs.
Normal Boiling
Point or
Bubble/Dew Critical Critical
ASHRAE ASHRAE Molecular Points Temp Pressure
Number Classification Formula (°F) at 1atm (°F) (psig)
R-1234yf A2L CF₃CF = CH₂ –14.8 215.6 602.7
R-1234zd A1 65.0 330.1 518.2
R-1234ze(E) A2L CF₃CH = CHF –2.1 229.0 534.5
R-1336mzz(Z) A1 CF3CH=CHCF3(Z) 59.2 309.2 531.2
Cost is a major concern with HFOs and HFO blends. Although actual costs under
the conditions of full-scale production are unknown, current HFO-based
refrigerants will almost certainly have a higher cost than the refrigerants they
would replace. Additionally, with HFO systems, the efficiency tends to decrease
as the GWP of the refrigerant decreases. Therefore, implementing HFOs as a
replacement for HFCs requires a tradeoff between GWP and system efficiency.
As a rule of thumb, the efficiency of HC refrigerants typically outperforms the
efficiency of HFO refrigerants.
R-1234yf
9
The new refrigerant is patented and manufactured in a joint venture between
Honeywell and DuPont. Other manufacturers have also been licensed to produce
the refrigerant. Honeywell markets the new refrigerant under the trademark
Solstice® YF [Honeywell, 2017]. DuPont and European manufacturer Chemours
are selling R1234yf under the trademark Opteon™ YF [Chemours, 2017]. Figure
2 shows a photo of an R-1234yf refrigerant cylinder.
R-1234zd
R-1234zd, also referred to as HFO-1234zd, is another a fluorinated gas from the
HFO family with a low GWP and low pressure. This refrigerant is suitable for
new industrial air conditioning applications and the cooling of buildings where
cooling water or intermediate fluids are used in large systems with centrifugal
compressors (one or more stages) and where R-123 might have been used in the
past. Linde and Honeywell market this refrigerant as Solstice® ZD and as a
replacement for R-123 in new chiller applications [Honeywell, 2017].
However, compressors using this new refrigerant would require larger impeller
diameters for the same cooling capacity because of the substantially lower
volumetric cooling capacity and the higher required compression ratio.
R-1234ze
R-1234ze, also referred to as HFO-1234ze, has a chemical name of trans-
1,3,3,3-tetrafluoroprop-1-ene and is an HFO with the formula CF3 CH=CHF.
10
R-1234ze has two isomers, R-1234ze(Z) and R-1234ze(E) with different
properties. R-1234ze(Z) has a higher boiling point (50.0 °F) associated with a
higher critical temperature (308.7 °F) and a volumetric capacity roughly 50%
lower than R-1234ze(E).
R-1234ze(E) is the isomer that is typically sold for use and is marketed as
Solstice ZE. Because there is currently no HVAC/R application for R-1234ze(Z),
the R-1234ze that is typically sold is the (E) isomer. Currently, R-1234ze(E) is
being used as a replacement for R-22.
Caution
Do not use R-1234ze to retrofit any existing system including
existing R-22 systems.
11
Figure 4. Saturation pressure–temperature plot for R-1234zd
12
Temperature Pressure (psig)
(°F) R-1234yf R-1234ze(E )
45.0 43.5 26.2
50.0 48.8 30.1
55.0 54.5 34.7
60.0 60.6 39.3
65.0 67.1 44.4
70.0 74.0 49.8
75.0 81.3 55.6
80.0 89.0 61.8
85.0 97.3 68.1
90.0 106.0 75.2
95.0 115.2 82.5
100.0 124.9 90.5
105.0 135.1 98.7
110.0 146.0 107.5
115.0 157.3 116.7
120.0 169.2 126.5
125.0 181.8 136.9
130.0 195.0 147.7
Temperature Vacuum
(°F) in-Hg
–94.0 29.7
–90.4 29.7
–86.8 29.7
–83.2 29.6
–79.6 29.6
–76.0 29.5
–72.4 29.4
–68.8 29.4
–65.2 29.3
–61.6 29.2
–58.0 29.0
–54.4 28.9
–50.8 28.8
–47.2 28.6
13
Temperature Vacuum
(°F) in-Hg
–43.6 28.4
–40.0 28.2
–36.4 28.0
–32.8 27.8
–29.2 27.5
–25.6 27.2
–22.0 26.8
–18.4 26.5
–14.8 26.0
–11.2 25.6
–7.6 25.1
–4.0 24.5
–0.4 23.9
3.2 23.3
6.8 22.6
10.4 21.8
14.0 21.0
17.6 20.1
21.2 19.1
24.8 18.1
28.4 17.0
32.0 15.8
35.6 14.5
39.2 13.1
42.8 11.6
46.4 10.0
50.0 8.3
53.6 6.5
R-449B
R-449B is an HFO/HFC blend classified by ASHRAE as a non-flammable, non-
ozone-depleting class A1 refrigerant with a global warming potential (GWP) of 1296.
Arkema, Inc. manufactures this new refrigerant as Forane® 449B [Arkema, 2016].
EPA’s approval allows R-449B refrigerant to be installed in new and retrofit R-22
and R-404A commercial refrigeration supermarket systems, remote condensing units,
low-temperature standalone equipment, refrigerated food processing and dispensing
equipment, commercial ice machines, and refrigerated transport.
14
Materials Compatibility
Lubricants
HFOs are miscible (soluble) in POE (polyolester) oils but are not miscible (not
soluble) in mineral or AB (alkyl benzene) oils. Therefore, mineral and AB oils
cannot be used with HFO refrigerants.
POE oil is recommended for using R-1234yf, R-1234ze, and R-1234zd. However,
because of the higher miscibility of the R-1234 refrigerants with oils, a higher
viscosity lubricant is probably required. Use the lubricants recommended by
compressor manufacturers to avoid potential problems with lowered viscosity of
the refrigerant–lubricant mixture.
Desiccants
Desiccants are used in filter dryers. Most of the commonly used desiccants
are compatible with HFO refrigerants. Acceptable types are XH-5, XH-6, or
the equivalent.
Materials
In general, fluorocarbon and silicone elastomers exhibit significant swelling in the
presence of HFO refrigerants. EPDM and neoprene show signs of one or more
components of the elastomer being separated from the material formulation as a
result of interaction with the HFO refrigerants as well as a reduction in the volume of
these elastomers, which is the consequence of this separation. Clearly, you should
only use materials specifically approved for use with HFO refrigerants.
Caution
Do not use EPDM, neoprene, fluorocarbon, or silicone rubbers in
HFO refrigerant systems. These materials are not compatible.
15
Example
Material compatibility with R-1234yf does not assure compatibility
with R-1234ze or R-1234ze(E).
Tip
Always check compatibility with the manufacturer or supplier
of the component.
16
Chapter 3. Environmental Comparison of HC,
HFO, and HFC Refrigerants
Both hydrocarbon (HC) and hydrofluoroolefin (HFO) refrigerants have zero ozone
depletion potential (ODP) and lower global warming potential (GWP) compared to
hydrofluorocarbon (HFC) refrigerants. The HC refrigerants have GWPs that are
lower than the HFOs and are less expensive, but they are more flammable.
The overall climate impacts from the use of these refrigerants also depend on the
energy use by the appliances in which they are used because the indirect climate
impacts associated with electricity consumption usually exceed the impact from
the refrigerants themselves over the full life cycle of refrigerant-containing
products [ORNL, 1997]. When a hydrocarbon or HFO appliance is more energy
efficient than the appliance it replaces, greenhouse gas emissions are reduced
beyond those attributable to the substitute refrigerant alone. Conversely, the
greenhouse gas benefits of a substitute refrigerant in a replacement hydrocarbon
appliance would be offset if that appliance had lower energy efficiency than the
appliance it replaced.
EPA did not find any detailed life-cycle analysis addressing greenhouse gas
emissions associated with substituting traditional ozone-depleting refrigerants
with hydrocarbons. Energy efficiency of these refrigerants is likely to be
comparable to or higher than that of ozone-depleting refrigerants and of HFC
refrigerants that are sometimes used (e.g., HFC-134a) [Ben & Jerry’s, 2008; A.S.
Trust & Holdings, 2007, 2009; GE, 2008].
Hydrocarbons are regulated as VOCs under sections of the Clean Air Act that
address plans to attain and maintain air quality standards for ground-level ozone,
which is a respiratory irritant. EPA’s 1994 risk screen document (EPA, 1994)
describes the potential emissions of VOCs from all substitutes for all end-uses in
the refrigeration and air-conditioning sector as likely to be insignificant relative
to VOCs from all other sources (i.e., other industries, mobile sources, and
biogenic sources).
17
charge over the course of a year, the resulting increase in annual VOC emissions
from isobutane, propane, and R-441A as a percent of all annual VOC emissions in
the U.S. would be negligible. Therefore, the use of these hydrocarbons for
household and retail food refrigeration is sufficiently small that a switch from an
ozone-depleting substance (ODS) or from an HFC refrigerant would not have a
noticeable impact on local air quality.
The global warming potential (GWP) of a greenhouse gas quantifies its potential
to lead to global warming relative to the potential of carbon dioxide (CO2) over a
specified time. EPA reports the 100-year integrated GWPs of isobutane, propane,
and R-441A are significantly lower than the 100-year integrated GWPs of the
substances they would be replacing and are significantly lower than those of other
acceptable refrigerants in these end-uses (e.g., HFC-134a, R-404A, and R-410A).
Although the GWPs of HFOs are lower than the HFC refrigerants they are
replacing, they are not as low as the GWP of HC refrigerants.
Ozone-Depleting Potential
Temperature Glide
The 400 series refrigerant blends are known as non-azeotropic blends, which means
they experience a temperature glide during evaporation and condensation. In contract,
a pure refrigerant or an azeotropic (500 series) refrigerant blend has a single boiling
18
point temperature (no glide) at a given pressure. As shown in Table 7, R-410A is a
near azeotropic refrigerant that can be treated as an azeotropic-like refrigerant.
Why is this important? If the refrigerant has a significant glide and there is a leak
in the system, more of the more volatile refrigerant leaks out (compared to the
other refrigerants in the blend). This change in the ratio of the components
changes the properties of the blend. The performance properties could change
and/or other properties such as flammability could change. Refrigerant blends
must be charged as a liquid to assure that the ratio of the individual refrigerants in
the blend remain at the proper ratios.
The hottest temperature of the temperature glide is known as the dew point. Any
mixed refrigerant temperature above the dew point is superheated. The lowest
temperature of the temperature glide is known as the bubble point. Any mixed
refrigerant temperature below the bubble point is subcooled.
19
Example
A refrigerant with a smaller latent heat of vaporization per unit
volume requires a greater compressor displacement to provide
equivalent cooling. Likewise, a refrigerant with a smaller latent
heat per volume could require a larger evaporator. There is no
drop-in replacement for existing systems.
800.0
700.0
600.0 R-290
R-600a
500.0 R-601a
Pressure (psig)
R-441a
400.0 R-1150
R-1270
300.0 R-1234yf
R-1234ze(E)
200.0 R-134a
R-410A
R-22
100.0
0.0
0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0
Temperature (F)
20
Chapter 4. What is the EPA SNAP Program?
The Significant New Alternatives Policy (SNAP) program is EPA’s program to
evaluate and regulate substitutes for the ozone-depleting chemicals that are being
phased out under the stratospheric ozone protection provisions of the Clean Air
Act (CAA). The list of SNAP-approved refrigerants evolves as the EPA makes
decisions based on its overall understanding of the environmental and human
health impacts of various new refrigerants as well as its current knowledge about
available substitutes. Section 612 allows the EPA to prohibit the use of a
substitute refrigerant when the EPA has determined that there are other available
substitutes that pose less overall risk to human health or the environment.
Hydrocarbon refrigerants have been in use for over 15 years in countries such as
Germany, the United Kingdom, Australia, and Japan in the end-uses addressed by
21
EPA’s rule. In Europe and Asia, equipment manufacturers have designed and
tested household and commercial refrigerators and freezers to account for
flammability and safety concerns associated with hydrocarbon refrigerants.
Because hydrocarbon refrigerants have zero ODP and very low GWP compared
to other refrigerants, many companies are interested in using them in the United
States as well.
This action also lists propane (R-290) as an acceptable substitute for CFC-12,
HCFC-22, and R-502 in retail food refrigerators and freezers (standalone units
only) [EPA, 2011].
An EPA SNAP rule effective May 2012 allows the use of HFO-1234yf in motor
vehicle air conditioning systems. An EPA SNAP rule effective August 2012
allows the use of HFO-1234ze in centrifugal, reciprocating, and screw compressor
chillers and the use of HFO-1233zd in centrifugal chillers.
22
The EPA SNAP rule effective January 2017 also finalized the proposed restriction
that non-exempt substitute refrigerants can only be sold to technicians certified
under sections 608 or 609 of the CAA. In the case of MVAC refrigerants, EPA
exempted the sale of small cans of non-ODS substitutes to allow the do-it-
yourself (DIY) community to continue servicing their personal vehicles. As of
January 1, 2018, small cans of non-exempt substitute refrigerant must be outfitted
with self-sealing valves. Sales are permitted if the cans without self-sealing valves
were manufactured or imported before 2018.
23
markings to denote the system charge is a flammable refrigerant. The
color must be present at all locations through which the refrigerant is
serviced (e.g., process tubes). In addition, the red coloring must be in
place at all times and be replaced if removed.
• EPA recommends unique fittings at service apertures.
Note
EPA does not prohibit the sale of hydrocarbon refrigerants in containers
designed to contain less than 5 pounds (2.3 kg) of refrigerant.
As stated previously, the two end-uses specified by EPA are retail food
refrigerators and freezers (standalone units only), and household refrigerators,
freezers, and combination refrigerators and freezers. The HC refrigerants can only
be used in new equipment that was specifically designed and clearly identified for
the HC refrigerant.
Caution
You may not retrofit existing equipment for HC refrigerant use.
EPA did not review the substitutes isobutane or R-441A in the retail food
refrigeration end-use. Because the use profiles and handling practices for these
chemicals in these end-uses are similar to the combinations of substitutes and end-
uses that were accepted, isobutane and R-441A can be used for retail food
refrigeration and propane in household refrigeration.
Household Refrigeration
24
sale. This rule addresses the use of hydrocarbons in standalone units only. A
standalone appliance is one using a hermetically sealed compressor and for which
all refrigerant-containing components, including but not limited to at least one
compressor, condenser, and evaporator, are assembled into a single piece of
equipment before delivery to the ultimate consumer or user. Such equipment does
not require addition or removal of refrigerant when placed into initial operation.
Standalone equipment is used to store chilled beverages or frozen products.
Examples include reach-in beverage coolers and standalone ice cream cabinets.
Retail food refrigeration does not apply to large refrigeration systems such as
walk-in coolers or the direct expansion refrigeration systems typically found in
retail food stores. It also does not apply to vending machines. The refrigerant
charge in this end-use is limited to 150 g (5.3 ounces by weight) or less.
25
limit for the retail food refrigeration end-use does not reflect an additional amount of
refrigerant assumed to be solubilized in the oil.
This color is the same color specified in AHRI Guideline N-2008, Assignment of
Refrigerant Container Colors, to identify containers of flammable refrigerant,
such as propane, isobutane, and R-441A [AHRI, 2008]. The purpose of the
colored hoses and tubing in this case is to enable service technicians to identify
the use of a flammable refrigerant and to take additional precautions (e.g.,
reducing the use of sparking equipment) as appropriate to avert accidents, and
particularly if labels are no longer legible. Adding red coloring on tubing inside
the appliance provides additional assurance that technicians will be aware that a
flammable refrigerant is present.
This does not mean that the entire hose or process tube must be colored. For
process tubes, the tube must be colored for at least one inch with the red mark to
extend from the compressor. This way, if the process tube is cut for service, the
red marking still remains after the tube is welded back together.
If further servicing would leave the colored portion of the process tube less than
1 inch long, the red marking must be extended to at least 1 inch. If there is not
enough room to extend the marking at least 1 inch, you need to install a new
process tube with at least 1 inch of red marking. For other locations—for
example, if a service port or refrigerant access valve is added to the system—the
red mark must extend at least 1 inch in both directions from the port or valve.
Note
UL Standards referenced in this rule do not allow the inclusion of
service ports in finished products using flammable refrigerants;
however, service ports can be added during servicing and the red line
marking requirement would still apply.
The red coloring must always be present (not just applied initially at installation)
even when a hose or piping is replaced or removed.
26
A colored sleeve or cap can be used as long as the requirements of the use condition
(red color, location, and dimension) are met. However, to remain in compliance with
the use condition, a technician who removes a sleeve during servicing is required to
replace that sleeve on the serviced tube with another sleeve.
Labeling
Refrigerant Containers
EPA has not limited the sale of the hydrocarbon refrigerants in containers
designed to hold less than five pounds (2.3 kg).
All refrigerant containers must be painted light green gray. If the refrigerant has
flammable compounds or mixtures that could become flammable if there is a leak,
the container must also have a red band on the shoulder or top of the container. To
27
see the exact colors required for the container of each type of refrigerant, see AHRI’s
2016 Guideline for Assignment of Refrigerant Container Colors [AHRI, 2016].
Unique Fittings
Although EPA does not require unique fittings, unique fittings are recommended.
Service ports are not allowed in new household refrigerators or standalone retail
food refrigerators that use flammable refrigerants, but Clean Air Act regulations
require a process tube when a service fitting is not being used. This process tube
must have at least a one-inch-long red marking on the tube to indicate flammable
refrigerant, and if this marking is removed or shortened, it must be replaced with a
new red mark that is at least one inch long. If a service port or access valve is
installed after manufacture, it must have the red flammable marking applied at
least one inch in both directions from the valve. Such fittings, if installed, should
be designed specifically for flammable refrigerants.
Caution
Non-refrigerant-grade hydrocarbons should never be used as
refrigerants because the impurities in the lower grade can cause
serious problems. The contaminants are typically not removed by the
filter-drier and can cause the lubricant to thicken, resulting in
increased wear or passage clogging.
Training Requirements
In the ruling effective January 2017, EPA requires that technicians be certified to
handle HFCs and other non-exempt substitutes. EPA also finalized the
requirement for certifying organizations to publish lists or create online databases
of technicians that they certify [EPA, 2016b].
Training is an important way for technicians to learn about the safe handling of
flammable refrigerants and become certified. Other countries where hydrocarbon
refrigerants are currently in wide use have long-standing training programs on
flammable refrigerants. The use of hydrocarbon refrigerants, and training on such
use, is in its infancy in the United States and is generally tied directly to specific
products or applications, rather than generally to multiple types of products.
28
Since the inception of the SNAP program and the Section 608 refrigerant
management program, EPA has continued to list a variety of new refrigerants as
acceptable. EPA has not previously required that certified technicians be
recertified as a result of the listing of the additional refrigerants.
Moreover, the goals of the Section 608 technician certification program reflect the
need to reduce emissions during servicing, maintenance, repair, and disposal.
They do not substitute for the proper training that is normally provided through
trade schools, apprenticeships, or other industry mechanisms. Given the extent of
technical knowledge available within the industry, the industry is better equipped
than EPA to define the specific contents of such training.
Although EPA does not require training as a use condition for these substitutes, to
ensure that they can be used as safely as other available refrigerants, technicians
must be certified and should receive training on the safe handling of hydrocarbon
refrigerants through courses such as this one.
Only use recovery or recycling equipment that has been tested and certified for
use with the specific HFO or HC refrigerant being recovered. These recovery
units have been specifically designed to provide additional safeguards to avoid
explosion and fire hazards.
29
Chapter 5. What are the Safety Classifications
of HC and HFO Refrigerants?
Toxicity
ASHRAE 34 divides refrigerant compounds into either low-toxicity or high-
toxicity groups. The toxicity group is assigned depending on the acceptable
exposure level (AEL) of the compound (see Figure 1 on page 1).
Refrigerants with lower toxicity have AELs of more than 400 parts per million
(ppm) and are classified as type A.
Refrigerants with higher toxicity have AELs of less than 400 ppm and are
classified as type B.
Older refrigerants, such as CFC-11 and HCFC-22, had very high safe exposure
limits, as does the alternative refrigerant HFC-134a. One popular alternative
refrigerant, HCFC-123 has a very low allowable exposure limit (30 ppm) and is
classed along with ammonia and sulfur dioxide as higher in toxicity.
To assess occupational exposure for the household refrigeration and retail food
refrigeration end-uses, EPA estimated the number of refrigerant releases during
appliance manufacture and disposal, and the refrigerant amounts released per
event. For each refrigerant, EPA used those estimates to calculate the maximum
8-hour TWA exposure, which was then compared to the corresponding workplace
guidance level (WGL). EPA found that occupational exposures to these
hydrocarbons should not pose a toxicity threat in either end-use because the
TWAs were well below the industry and government exposure limits.
30
To assess consumer and end-user exposure for the household refrigeration end-
use, EPA modeled 15- and 30-minute TWAs for catastrophic refrigerant release in
a consumer kitchen under a reasonable worst-case scenario. Even under the very
conservative modeling assumptions that were used, EPA found that exposures to
any of the three hydrocarbons would not pose a toxicity threat to end-users in the
household refrigeration end-use because the TWAs were significantly lower than
the no-observed adverse effect level (NOAEL) and/or acute exposure guideline
level (AEGL).
Likewise, to assess consumer and end-user exposure for the retail food
refrigeration end-use, EPA estimated 15- and 30-minute TWAs as acute/short-
term consumer exposures resulting from catastrophic leakage of refrigerant from
retail food refrigerators and compared the TWAs to standard toxicity limits.
Again, the EPA concluded that none of the three hydrocarbons posed a toxicity
threat in the retail end-use because the TWAs were significantly lower than the
NOAEL and/or AEGL.
Finally, EPA assessed the exposure risk to the general population for the three
hydrocarbons in their respective end-uses. To do so, EPA estimated factory and
on-site releases of each hydrocarbon and compared them to the reference
concentration (RfC) each hydrocarbon. In all cases, the modeled exposure
concentrations were significantly lower than the RfC, leading EPA to conclude
that isobutane, propane, and R-441A are unlikely to pose a toxicity risk to the
general population. These toxicity risks are lower than or comparable to those
posed by the other acceptable substitutes in these end-uses. The HC refrigerants
discussed to date are all listed as non-toxic, which is toxicity level A (see Table 4
on page 9).
Example
R-1234yf is listed as slightly flammable and non-toxic;
however, in a fire, the refrigerant would form highly poisonous
carbonyl fluoride as well as hydrogen fluoride. “It has been
known for some time now that combustion of R-1234yf results
in the production of the toxic hydrogen fluoride,” said Andreas
Kornath, Professor of Inorganic Chemistry at Munich
University. “Our analysis has now shown that 20% of the
gases produced by combustion of the compound consist of the
even more poisonous chemical carbonyl fluoride” (Green Car
Congress, 2014).
31
However, a risk assessment conducted by SAE (Society of Automotive
Engineers) stated that R-1234yf is safe for use in automotive air conditioning.
According to their analysis, although they agree that the combustion of R-1234yf
does create carbonyl fluoride, they claim it only lasts for a fraction of a second
before reacting to form another safer compound and therefore is not around in the
air long enough to put bystanders, passengers, or first responders in any danger. In
addition, because they claim carbonyl fluoride is also formed during the burning
of R-134a, R-1234yf is no worse than existing refrigerants.
Flammability
Class 3 refrigerants exhibit flame propagation at 60 °C and 101.3 kPa, and have
either a lower flammability limit (LFL) of less than or equal to 0.10 kg/m3 or a
heat of combustion greater than or equal to 19,000 kJ/kg.
Because they are flammable, isobutane, propane, and R-441A could pose a
significant safety hazard for workers and consumers if handled incorrectly.
Isobutane, propane, and R-441a have lower flammability limits (LFLs) of
18,000 ppm, 21,000 ppm, and 16,000 ppm, respectively. The ODS (ozone-
depleting substance) for which these refrigerants are substitutes—CFC-12,
HCFC-22, and R-502—and other substitutes available in this end-use are not
flammable. When the concentration of a flammable refrigerant reaches or exceeds
its LFL in the presence of an ignition source (e.g., a static electricity spark
32
resulting from closing a door, use of a torch during servicing, or a short circuit in
wiring that controls the motor of a compressor), an explosion or fire could occur.
Tip
To use these substitutes safely, minimize the presence of potential ignition
sources. Also reduce the likelihood that the levels of these refrigerants will
reach their LFLs.
Production facilities and other facilities where large quantities of the refrigerant
are stored should have proper safety precautions in place to minimize the risk of
explosion. EPA recommends that these facilities be equipped with proper
ventilation systems to minimize the risks of explosion and be designed to reduce
risks from possible ignition sources.
The worst-case scenario analysis for each of the three hydrocarbons revealed
that even if the full charge of the unit were emitted within one minute, the
concentration would not reach the LFL for that hydrocarbon. However,
because hydrocarbon refrigerants are flammable and manufacture personnel,
service personnel, and consumers in the United States might not be widely
familiar with refrigeration appliances containing flammable refrigerants,
training, certification, and restricted use are being used to safeguard personnel,
create awareness, and ensure safe handling.
Use Conditions
Restricted use conditions ensure that the flammable substitutes present risks that
are lower than or comparable to those of other substitutes that are currently or
potentially available. EPA made recommendations, such as proper ventilation and
storage practices, and use of appropriate tools and recovery equipment to mitigate
safety risks for manufacture and servicing personnel.
33
EPA’s interpretation of the risk of ignition-related failures in residential refrigerators
for internal leak events is based on information presented in Risk Assessment of
Flammable Refrigerants for Use in Home Appliances [A. D. Little, 1991].
This A. D. Little report used historical leak rate data provided by three
refrigerator manufacturers to estimate possible leakage rate failures. Failure
scenarios were based on independent, random events. For a leak to pose a
potential risk for ignition, the refrigerant had to be present in amounts that meet or
exceed the LFL.
However, the ability of a refrigerant to accumulate and reach its LFL is a function
of both the rate at which the leak occurs and the size of the enclosed spaces that
can trap the refrigerant and allow it to build up. A.D. Little distinguished
catastrophic leaks (the loss of a significant portion of refrigerant charge over a
few minutes) from slow leaks, observing that only catastrophic or fast leaks
would allow refrigerant to accumulate to a level of concern. The report goes on to
calculate the average risk that a leak is a fast leak as 0.1% and the worst-case risk
that a leak is a fast leak as 1%.
Asphyxiation
The EPA calculated the maximum charge of each refrigerant that would result in
a reduction of oxygen levels to 12% in air, which is the no-observable adverse
effect level (NOAEL) for hypoxia [ICF, 1997]. Specifically, under these worst
case conditions, EPA calculated that the charge sizes necessary to reduce the
oxygen level in air to the 12% NOAEL in the household refrigeration end-use
would be 625 grams and 535 grams (for isobutane and R-441A, respectively),
which is much larger than the 57 gram charge size limitation required in the use
conditions in their rule [ICF, 2011a and 2011c].
34
Likewise, the charge size necessary to achieve the NOAEL in the retail food
refrigeration end-use would be 904 g for propane, which is six times greater than
the 150 g charge size limitations in their rule [ICF, 2011b]. This risk is lower than
or comparable to that of other available substitutes in these end-uses.
35
Chapter 6. What are the HC and HFO Safe
Handling Practices?
In this chapter, you’ll learn about best practices for handling HC (hydrocarbon)
and HFO (hydrofluoroolefin) refrigerants safely.
Charge Limitations
Household Refrigeration
EPA stipulated that the charge size not exceed 57 g for household refrigeration.
The EPA also assumed that 7 g of refrigerant be solubilized in the oil (and
assumed not to immediately vaporize with the refrigerant in the event of a leak),
and therefore the EPA modeled a maximum refrigerant release of 50 g [ICF,
2009a and ICF, 2011a].
The 50 g allowable leak limit for household refrigerators in UL 250 differs from
the 150 g allowable leak limit for commercial refrigerators and freezers in UL 471
because of factors such as the difference in the room sizes modeled for household
versus retail appliances. Therefore, building on the UL allowance of a 50 g
allowable leak limit, EPA concluded that the maximum charge size should be
57 g for the household refrigeration end-use.
36
Retail Food Refrigeration
EPA finalized the 150 g charge size limit for the retail food refrigeration end-use.
This definition applies to any appliances produced or imported into the
United States as well as U.S. manufactured appliances that will be exported.
Again, the charge size limitation applies to each sealed system in an appliance.
After evaluating the HC refrigerants, EPA concluded that they present overall
environmental and human health risks that are lower than or comparable to other
acceptable substitutes in the household refrigeration and retail food refrigeration
end-uses. Risks can be mitigated to ensure the substitutes can be used as safely as
other available substitutes.
Flammability could pose a concern for the servicing and disposal of appliances
containing HC and HFO refrigerants. The requirements for labeling and coloring
the tubing red at access locations serve as notification to servicing or disposal
personnel that the appliance contains a flammable refrigerant.
Caution
If the refrigerant is flammable, you must use recovery equipment
designed specifically for flammable refrigerants.
Recovery Techniques
EPA regulations prohibit venting of any refrigerant including HC or HFO
refrigerants during service, maintenance, repair, and disposal. Under the Clean
Air Act, EPA established regulations that require technicians to maximize the
recovery and recycling of refrigerants when they are servicing or repairing air
conditioning and refrigeration equipment. If you are going to dispose of the
equipment, you must also follow EPA’s safe disposal requirements to ensure the
refrigerants are removed and the equipment does not enter the waste stream with
the charge intact.
Note
Before beginning a refrigerant recovery procedure, you must ALWAYS
know the type of refrigerant that is in the system.
37
Each type of refrigerant has its own recovery evacuation requirements that you
must understand before you start the recovery procedure. You should check the
nameplate on the system to identify the refrigerant used, or you can use an ARI
700 purity test to determine the type of refrigerant. You may also be able to use
the saturation pressure/temperature characteristics of the refrigerant to verify the
refrigerant type. However, the only completely reliable method of accurately
determining the refrigerant type is to take a sample of the refrigerant and send it
to a certified testing laboratory for analysis.
Sometimes the refrigerant used in a system can be determined by the type and age
of the equipment. You need to ensure only one type of refrigerant is in the
appliance. Mixing refrigerants is not only unsafe, it will most likely make
reclamation impossible.
Note
If you are using a replacement refrigerant, the recovery machine
must be specifically certified for the replacement refrigerant.
Just because the recovery machine is certified for the original
refrigerant does not mean you can use the machine with any
replacement refrigerant. In fact, the machine is most likely not
suitable for the replacement HC or HFO refrigerant.
If the label identifying the refrigerant is missing, or if you suspect the unit has a
different refrigerant than the one on the label, you might be able to use the
pressure–temperature method for determining the type of refrigerant.
Examples
R-134a and R-1234yf have nearly identical saturation
pressure–temperature behavior and would be impossible to tell
apart. Likewise, R-22 and R-1270 have similar behavior. Only
38
refrigerants like R-410A, R-441a, R-1150, and R-601a are
easy to distinguish in terms of their pressure–temperature
behavior.
• Non-condensable gases in the system will raise the system pressure,
making it difficult to determine the refrigerant, unless you are trying to
select the refrigerant type from two very different choices such as R-601a
and R-134a.
• Non-azeotropic blends, such as R-441a, which are the 400-series
refrigerants, have pressure–temperature characteristics that can change as
they fractionate at a leakage site. Therefore, if the system has a leak or has
been improperly charged (charged as a vapor instead of as a liquid), the
saturation pressure–temperature curve would be very different, potentially
making refrigerant identification impossible.
If you are unsure of the refrigerant but know the correct refrigerant with which to
recharge the system, the best practice would be to recover the refrigerant into a
dedicated recovery tank and return the refrigerant to a recycling facility. Then,
recharge the system with new or reclaimed refrigerant. Never use a refrigerant
recovery device that has not been specifically designed to recover the specific HC
or HFO refrigerant being recovered.
Alternatively, if you are simply trying to determine the refrigerant that should be
charged into a system that carries no name plate for reference, contact the
equipment manufacturer, or get the compressor model number from the unit and
contact the compressor manufacturer to determine the refrigerant. Major
compressor manufacturers have this information available online.
Evacuation Requirements
The recovery requirements for appliances are different depending on the
classification of the equipment. The size of the appliance, how the appliance is
used, and even the date of manufacture of the recovery unit affect the required
recovery level.
If the HC refrigerant system has leaks, you must isolate leaking components from
non-leaking components wherever possible and evacuate non-leaking components
to the specified levels (80% or 90% depending on the status of the compressor).
39
The isolated leaking components or the entire system, if the leaking components
could not be isolated, must be evacuated to at least 0 psig to be in compliance
with EPA regulations.
Before you use any recovery equipment, inspect the equipment for signs of
damage, leaks, loose or faulty electrical connections, rust, corrosion, or
deterioration. Do not use any equipment that has questionable integrity or that
could be faulty. You must check your recovery device for refrigerant leaks on a
regular basis.
If your recovery cylinders and equipment use Schrader valves, you must inspect
the Schrader valve core for bends and breakage, replace the damaged Schrader
valve core to prevent leakage, and cap the Schrader ports to prevent accidental
depression of the valve core.
If your recovery cylinders have pressure relief valves, you must also regularly
inspect the pressure relief valves. When you find corrosion build up within the
body of a relief valve, replace the valve.
40
Caution
When operating refrigerant recovery or recycling equipment, follow
these precautions:
• Maximize the ventilation to the area.
• Wear safety glasses with side shields.
• Wear protective gloves.
• Wear protective shoes.
Follow all safety precautions and user instructions for the equipment.
Tip
Have two recovery tanks for each refrigerant. You can use
one tank to store dirty refrigerant that will not be returned
to a system. You can then hold the refrigerant until you can
sell it to a refrigerant recycler. Use the second recovery
tank for the temporary storage of recovered refrigerant
while servicing a unit.
Recovery Unit
When the refrigerant is recovered as a vapor, the recovery takes longer, but you
can make the recovery quicker by ensuring the hoses and valve ports are not
restricted. Always use the shortest hoses possible, and remove any restrictions in
the hoses such as valve core depressors.
Heating the system or cooling the recovery tank speeds up recovery. When the
pressure in the system is increased by heating the system, the recovery is faster.
Caution
Never use a flame to heat the system!
In the inverse situation, when the pressure in the system is reduced, which is
possibly caused by the evaporation of the refrigerant as it is removed from the
system, the vapor becomes less dense and the recovery is slower.
41
During vapor recovery, the vapor is drawn from the appliance into the recovery
system. The vapor passes through the compressor of the recovery system and into
the condenser of the recovery unit (which cools and condenses the recovered
vapor). This is why the recovery machine must be certified for the refrigerant
being recovered and for use with flammable refrigerants.
Cooling the recovery tank lowers the pressure in the recovery tank, thus lowering
the head pressure on the recovery machine and increasing the recovery rate.
Recovery during low ambient temperatures, on the other hand, slows the recovery
process. Although the recovery tank is cooler, the system is also cooler.
Tip
The fastest recovery is with a warm system and a cool recovery tank.
The warmer the system, the warmer and more dense the vapor is. Therefore, the
compressor in the recovery unit is able to transfer more refrigerant per minute.
Hence, any method to warm the system (via heat lamps or defrost heaters, or by
raising the temperature in the equipment room, etc.) and cool the recovery tank
speeds recovery. Again, never use an open flame to warm the system!
Cautions
When recovering flammable refrigerants, always ensure that the
refrigeration system, recovery unit, and recovery tank are all properly
grounded.
Never apply an open flame to a charged system or a refrigerant
cylinder.
When using a dual-valve recovery tank, you might be able to configure a recovery
machine to clean and filter the refrigerant. Combining the recovery unit, a dual-
valve recovery tank, three hoses, and a filter drier (with ¼" flare fittings) as
shown schematically in Figure 6 allows the cleaning of refrigerant, but it does not
make your recovery machine a certified recycling machine. The setup is shown
with actual hardware in Figure 7.
42
Figure 6. Cleaning and filtering refrigerant while servicing the unit
43
Pressure Decay Leak Test
For small systems, one of the best leak-checking procedures is a pressure decay
leak test, also referred to as a static pressure decay leak test or standing pressure
test. This procedure is ideal for small systems because even a slight loss in
refrigerant results in an easily detectable pressure drop since the overall system
volume is so small.
Before you evacuate a system, you need to use a pressure decay leak test to verify
no leaks exist. Whenever you evacuate a system with a leak, you draw air,
moisture, and other contaminants into the system, making subsequent deep
evacuation much more difficult.
Mixtures of nitrogen and the HFC refrigerant used as holding charges or as leak-
test gases are not subject to the EPA venting prohibition because in these cases
the ozone-depleting compound is not used as a refrigerant. However, you may not
avoid recovering refrigerant by adding nitrogen to a charged system!
Tip
Before nitrogen is added, you MUST evacuate the system to the
required level. Otherwise, the refrigerant–nitrogen mixture is
considered a refrigerant, and its release is a violation of the EPA
regulation and subject to a fine.
The safest way to check a system for a leak is to use dry nitrogen gas or other
inert gases that you know are dry and clean. Never use compressed air because of
the risk of explosion with flammable refrigerants and the risk of system
contamination. Compressed shop air is quite wet and contains trace amounts of
oil, which can be incompatible with the system oil.
Pressurize the system to the pressure indicated on the system nameplate, record
the pressure, and watch for pressure degradation over a sufficient time period. If
no nameplate exists, use the normal operating condenser temperature and
saturation pressure–temperature table for the refrigerant to determine the normal
operating condenser pressure and use that pressure.
44
Example
How long is sufficiently long? On a small appliance with a
normal charge of 150 g (0.33 lb) or less, a sufficiently long
time is 15 minutes.
where
Pnew is the new pressure in psia at the new temperature Tnew in degrees
Rankine
Tip
To convert a temperature from degrees Fahrenheit to degrees
Rankine, add 460 to the degrees Fahrenheit to get the
temperature in degrees Rankine.
To convert a pressure from psig to psia, add 14.7 to the
pressure in psig to get the pressure in psia.
1. If you are not going to use an electronic leak detector with this test, skip to
Step 2. If you are going to use a refrigerant leak detector, put a small
amount of HFC refrigerant in the system and bring the system pressure up
to about 10 psig. Do not use mixtures of nitrogen and any other
refrigerant except HFC refrigerants as a leak test mixture. Venting CFC
or HCFC refrigerant from any appliance, hardware, or device is illegal.
The release is presumed to be a refrigerant and is a violation of the EPA
regulations and subject to a fine.
2. Use the nitrogen to increase the pressure to the maximum pressure of the
system as indicated on the manufacturer’s nameplate.
3. Isolate the system from the nitrogen source. Tap the gauge slightly to
make sure the needle is free, and record the pressure. Any drop in pressure
45
after compensating for temperature changes indicates a leak. If you see a
pressure drop, remember the manifold gauge and connections could be
leaking, not the system.
4. Check for leaks while the system is pressurized because the leaks are
easier to detect. If refrigerant was added in Step 1 before the system was
pressurized, you can use an electronic halide leak detector. Otherwise, use
soap bubbles or an ultrasonic detector.
5. When you are convinced that the system is leak free, dehydrate the system
using the Triple Evacuation Method to ensure that no trapped air,
refrigerant, and/or water is in the system.
Caution
Always use a pressure regulator on the nitrogen cylinder. Do not
pressurize any system above the working pressure of the system written
on the equipment nameplate.
Triple Evacuation
Using the Triple Evacuation Method, the eventual goal is to reach a final deep
vacuum, at least 500 microns, 0.5 mmHg absolute. The process is essentially to
accomplish the following:
• Draw a deep vacuum
• See if the vacuum can hold
• Refill the system with dry nitrogen and repeat until a deep vacuum is
achieved and held
During each vacuum decay test, isolate the system from the vacuum pump and
wait to see if the pressure rises (water is boiling off). Because the quantity of gas
trapped in the system is essentially zero, you don’t need to make any
compensation for temperature changes.
If you see an increase in pressure, the system could have a leak, but this is
unlikely for a high-pressure system because you already passed the pressure
decay leak test with the system at a much higher pressure. If the pressure
increases to a point and then stops at some point either above or below 0 psig,
water (if below 0 psig) or refrigerant (if above 0 psig) is still evaporating. Only if
the system had a leak would the pressure increase stop at 0 psig (atmospheric
pressure).
If the pressure increases above 0 psig, refrigerant is still trapped in the system.
The refrigerant could be trapped in or under any oil in the system. The trapped
refrigerant is continuing to evaporate, which causes the vapor pressure to rise
above ambient pressure.
46
If the pressure rises from the initial deep vacuum but stops at some vacuum level
below ambient pressure, water is probably trapped in the system. Table 8 provides
the saturation pressure/temperature chart for water at different evacuation levels.
Example
Refer to the following table for this example. If the pressure increase
stopped at 22,000 microns, (22 mmHg absolute), the trapped water is
evaporating at 75 °F. This evaporation further cools the remaining
water, dropping the pressure at which additional water evaporates.
Temperature Pressure
°F (mmHg) Microns
35 5. 5,000
40 6. 6,000
45 8. 8,000
50 9. 9,000
55 11. 11,000
60 13. 13,000
65 16. 16,000
70 19. 19,000
75 22. 22,000
80 26. 26,000
85 31. 31,000
90 36. 36,000
95 42. 42,000
100 49. 49,000
105 57. 57,000
110 66. 66,000
115 76. 76,000
120 88 88,000
47
The nitrogen is then purged (vented), typically through the vacuum pump.
Recovery of the nitrogen is not required. This process of evacuation followed by
nitrogen pressurization is repeated (three total evacuations), and the third
evacuation should achieve a vacuum of 500 microns or less.
Triple evacuation is an effective method for dehydration because it uses the dry
nitrogen to sweep through the refrigerant lines to push out moisture. Air is 78%
nitrogen, so this process does not harm the environment. Whenever you use dry
nitrogen from a portable cylinder, you must use a pressure regulator, and for
safety reasons, you should always use a pressure relief valve (or bust disk)
inserted in the downstream line from the pressure regulator to avoid over
pressurization of the system.
Required Tools
The tools you need to perform a triple evacuation are a two-stage vacuum pump, a
gaseous nitrogen supply (nitrogen tank and regulator), and a micron vacuum gauge.
Vacuum Pump
A vacuum pump removes fluids such as air, other non-condensable gases, and
water from a system, drawing the system pressure to below atmospheric pressure,
or 0 psig. A vacuum pump can consist of a single- or two-stage design. The two-
stage vacuum pump is necessary for HVAC/R appliances.
The size of the pump is rated according to the volumetric pumping capacity,
normally measured in cubic feet per minute (cfm). Three- to six-cfm pumps are
typically used in residential applications.
The vacuum pump may also have a gas ballast valve, which helps to prevent
moisture that is being evacuated in the system from condensing into the vacuum
pump oil and reducing the vacuum level the vacuum pump can achieve.
Figure 8 shows a typical two-stage vacuum pump and the location of the gas
ballast valve (brass knob).
The gas ballast valve is used to help keep impurities (such as refrigerants and
moisture) from condensing and mixing with the vacuum pump oil. If refrigerants
or moisture condense in the vacuum pump oil, the vacuum pump won’t be able to
obtain a deep vacuum. During the first stages of evacuation, refrigerant or
moisture vapors are more highly concentrated. The gas ballast valve allows some
ambient air into the vacuum pump to dilute the impurities and reduce the
condensation of refrigerant and/or moisture into the vacuum pump oil.
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Follow these steps when using a gas ballast valve:
1. Keep the gas ballast valve closed when the vacuum pump is not being
used.
2. After connecting the vacuum pump and starting evacuation, open the
gas ballast valve (1/4 turn to fully opened) during the initial
evacuation.
3. When the vacuum pressure has dropped into a vacuum of at least 20 to
25 inches of mercury, close the gas ballast valve and continue the
evacuation procedure to reach the ultimate vacuum. If you forget to
close the gas ballast valve, a deep vacuum will not be achieved.
Vacuum pumps are also rated for the degree of vacuum they can achieve in
microns. A two-stage vacuum pump is necessary to pull the deep vacuums (below
500 microns), which is necessary for proper deep evacuation and removal of
water in systems.
The extraction of the air and non-condensables lowers the pressure inside the
system below atmospheric pressure, which causes any trapped liquid water to
evaporate and be exhausted by the vacuum pump.
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Electronic Vacuum Gauge (Micron Gauge)
An electronic vacuum gauge or micron gauge displays the vacuum level directly
in microns and is the only accurate field method to determine the evacuation level
of a deep vacuum. Figure 9 shows a typical electronic micron gauge. The micron
gauge is much more accurate at measuring very deep vacuums (very low
pressures) when compared to a manifold gauge.
Example
There are 25,000 microns between 29 inches of mercury and 30
inches of mercury. Most manufacturers recommend the system
pressure be reduced to a vacuum level of between 300 and 500
microns. A manifold gauge does not provide sufficient accuracy for
this type of measurement.
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Evacuation Process
When you evacuate a system, you need accurate readings from the micron gauge. For
the most accurate readings, connect your vacuum gauge close to the system to be
evacuated (ideally directly on a service port) and as far as possible from the vacuum
pump. Never connect the gauge in-line between the vacuum pump and the system.
Always measure the vacuum with the vacuum pump shut off and isolated.
Caution
On very large systems where the vacuum pump can operate for long periods
unattended, such as all night, you need to take precautions in case the power
fails during the procedure. Arrange solenoid valves in the vacuum pump line
that will isolate the system (normally closed) automatically and break the
vacuum (normally open) in the connecting hose. Otherwise, a large system
left unattended during a power failure could be contaminated with vacuum
pump oil.
Tips
A system is said to be dehydrated when the vacuum indicator shows
you have reached and held the required final vacuum.
Use vacuum lines (hoses) that are equal to or larger than the pump
intake connection. The piping connection to the vacuum pump should
be as large in diameter and as short in length as possible.
Remove any restrictions in the hose such as unnecessary Schrader
valve core depressors.
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A micron gauge reading between 1,000 and 5,000 microns indicates some
moisture remains in the system and requires further evacuation.
A micron gauge reading that increases to more than 5,000 microns during the
waiting period suggests the likelihood of a leak in the system. When a leak
exists, you need to disconnect the evacuation equipment to identify and repair the
system leak.
Evacuation can be a slow, tedious process. Rushing the process only leads to
improper evacuation levels that cause equipment to operate below peak efficiency
and experience premature component failure. You can’t over-evacuate a system.
Leak Repairs
Never use any leak sealing or moisture drying compounds with any HFO or HC
refrigerants because these compounds all contain silicates. Always follow proper
brazing techniques for flammable refrigerants.
Brazing
Pipe Connections
When you braze joints in an HC or HFO system, you must perform the brazing of
the joints in an area detached from the system. If this is not possible, you need to
fully evacuate the system prior to brazing.
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Charging
After a system has been installed or repaired, the system is ready to be charged
with refrigerant only after you complete all of the following:
• Ensure that the refrigeration system, the refrigerant tank, and any other
metallic component in the refrigerant flow circuit is electrically grounded
before charging the system with refrigerant.
• Install a fresh filter drier before performing any leak tests.
• Successfully complete a standing-pressure leak check at the maximum
system pressure.
• Evacuate to at least 500 microns (ideally 300 microns) by using a triple
evacuation procedure if necessary (see Triple Evacuation on page 46).
Tip
The charge being added to flammable systems is very low.
Ensure the charging scale has sufficient accuracy to meter the
proper amount of charge into the system.
Liquid Charge
Like any other blend, HFO and HC refrigerant blends should be charged as a
liquid to maintain the correct composition.
Tip
Be careful to meter the refrigerant into the system slowly to
avoid compressor knocking.
If you have any question about the refrigerant quality, the only fail-safe method is
to replace the refrigerant.
Caution
Ensure that the refrigeration system is grounded before charging the
system with refrigerant.
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Venting
Like any other refrigerant, whenever possible you should not vent any HC or
HFO refrigerant. Legally, you cannot vent HFO refrigerants, such as R-1234yf,
R-1234zd, and R-1234ze, during service, maintenance, repair, and disposal.
However, the following substitutes in the following end-uses can be vented [EPA,
2016b]:
• Carbon dioxide, nitrogen, and water in any application
• Ammonia in commercial or industrial process refrigeration or in
absorption units
• Chlorine in industrial process refrigeration (processing of chlorine and
chlorine compounds)
• Hydrocarbons in industrial process refrigeration (processing of
hydrocarbons)
• Ethane (R-170) in very low temperature refrigeration equipment and
equipment for non-mechanical heat transfer
• Propane (R-290) in retail food refrigerators and freezers (standalone units
only); household refrigerators, freezers, and combination refrigerators and
freezers, self-contained room air conditioners for residential and light
commercial air-conditioning; heat pumps; and vending machines
• Isobutane (R-600a) in retail food refrigerators and freezers (standalone
units only); household refrigerators, freezers, and combination
refrigerators and freezers; and vending machines
• R-441A in retail food refrigerators and freezers (standalone units only);
household refrigerators, freezers, and combination refrigerators and
freezers; self-contained room air conditioners for residential and light
commercial air-conditioning; heat pumps; and vending machines.
Note
The knowing release of a Class I or Class II refrigerant or a non-
exempt substitute refrigerant after its recovery from an appliance
is a violation of the venting prohibition and subject to fines.
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Static Electricity Concerns
Example
For flammable refrigerant shown in Figure 10, if the concentration
is below the lower flammability level of approximately 2%, the
concentration isn’t high enough for combustion. If the
concentration is above the upper flammability level of
approximately 10%, insufficient oxygen prohibits combustion.
Handling
HC refrigerant is available in 300 g (0.66 lb), 3.5 kg (7.7 lb), 12 kg (26.4 lb),
and 46 kg (101.4 lb) cylinders, and 420 g (0.93 lb) non-refillable cylinders.
HFO refrigerants are commonly available in 4.5 kg (10 lb) non-refillable
cylinders.
55
Tip
To avoid any static electrical spark, ensure that the
refrigeration cylinder is grounded when not in use and before
connecting to the system.
There is an automatic excess flow valve within the liquid valve. This valve
activates to stop the supply of refrigerant if the refrigerant flow out of the cylinder
is excessive. Excessive flow might be caused by a major leak in the system or a
service hose that was disconnected. To reset the automatic excess valve, close the
supply valve and then slowly reopen the valve.
Cautions
Always follow these safety precautions:
• Never apply an open flame or live steam to a refrigerant cylinder.
• Do not cut or weld any refrigerant line when refrigerant is in the unit.
• Always refit the valve cap when the cylinder is not in use.
• To avoid any static electrical spark, ensure that the refrigeration cylinder
is grounded when not in use and before connecting to the system.
• Ensure the threads are clean and undamaged.
• Store and use cylinders in dry well-ventilated areas away from any
fire risk.
• To prevent overheating, keep cylinders away from sources of heat.
• Do not modify cylinders or cylinder valves.
• Never roll cylinders along the ground.
• Weigh the cylinder to ensure the cylinder is empty.
• Only use dedicated recovery cylinders specifically designed for the
flammable refrigerant for the recovery of flammable HFO and HC
refrigerants.
Sales Restrictions
According to the EPA [EPA, 2016b], no one may sell or distribute any Class I or
Class II substance or, starting on January 1, 2018, any non-exempt substitute for
use as a refrigerant unless the one of the following conditions are met:
• The buyer has been certified as a Type I, Type II, Type III, or
Universal technician.
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• The buyer employs at least one technician who is certified as a Type I,
Type II, Type III, or Universal technician and provides proof to the seller.
• The buyer has been Section 609 MVAC certified and the refrigerant is
acceptable for use in MVACs.
• The buyer employs at least one person who is Section 609 MVAC
certified, provides proof of certification to the seller, and the refrigerant is
acceptable for use in MVACs.
• The refrigerant is sold only for eventual resale to certified technicians or to
appliance manufacturers (e.g., sold by a manufacturer to a wholesaler, sold
by a technician to a reclaimer).
• The refrigerant is sold to an appliance manufacturer.
• The refrigerant is contained in an appliance (as part of the appliance) with
a fully assembled refrigerant circuit.
• The refrigerant is charged into an appliance by a certified technician or a
supervised apprentice during maintenance, service, or repair of the appliance.
• The non-exempt substitute refrigerant is intended for use in an MVAC and
is sold in a container designed to hold two pounds or less of refrigerant,
has a unique fitting, and has a self-sealing valve.
All records must be kept for three years. Electronic or paper copies of all records
must be maintained by manufacturers of containers holding two pounds or less of
non-exempt substitute refrigerant for use in an MVAC to verify self-sealing
valves meet the requirements. All records must be kept for three years after each
purchase. (See Record Keeping Procedures on page 61 for more information.)
If the refrigerant is used, no person may sell or distribute any Class I or Class II
substance or non-exempt substitute consisting wholly or in part of used refrigerant
unless the refrigerant meets one of the following requirements:
• The refrigerant was reclaimed by a certified technician.
• The refrigerant has been recycled and was used only in an MVAC or
MVAC-like appliance and is to be used only in an MVAC or MVAC-like
appliance.
• The refrigerant is contained in an appliance that is sold or offered for sale
together with a fully assembled refrigerant circuit.
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• The refrigerant is being transferred between or among a parent company
and one or more of its subsidiaries, or between or among subsidiaries
having the same parent company.
• The refrigerant is being transferred between or among a Federal agency or
department and a facility or facilities owned by the same Federal agency
or department.
Effective January 1, 2018, all containers holding two pounds or less of non-
exempt substitute refrigerant for use in an MVAC that are manufactured or
imported on or after that date must meet the following requirements for self-
sealing valves:
• Each container holding two pounds or less of non-exempt substitute
refrigerant for use in an MVAC must be equipped with a single self-
sealing valve that automatically closes and seals when not dispensing
refrigerant.
• The leakage rate from each container must not exceed 3 g per year when
the self-sealing valve is closed. This leakage rate applies to new, full
containers as well as containers that could be partially full.
• The container must be tested for leakage by an independent test laboratory
in the United States that is not owned, operated, or affiliated with the
applicant certifying equipment and/or products.
Sales are permitted if the cans without self-sealing valves were manufactured or
imported before 2018 [EPA, 2016b].
Shipping
Shipping Labels
When transporting cylinders containing used refrigerant, DOT requires that you
attach DOT classification tags. Before shipping any used refrigerant in a cylinder,
you must properly label the refrigerant container.
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The shipping paperwork provides the following:
• Vital information to first responders after an accident. This paper
identifies the materials involved so protective actions can be taken for
your own safety and the safety of the public.
• Proper shipping name of the refrigerant
• Hazard class
• 4-digit United Nations Identification number preceded by the letters UN.
• 24-hour emergency response telephone number
Cylinder Loading
When you load the cylinders into the vehicle for shipping, you MUST place the
refrigerant cylinders in an upright position and secure the cylinders so they cannot
move during transport.
Storage
When storing flammable refrigerants, you must take extra precautions because of
their potential flammability. Local fire codes often restrict the storage of
flammable materials. In addition, other federal, state, and local regulatory
agencies might have regulations related to flammable refrigerants. Check with
these authorities for more information.
Risk Assessment
Before storing any canisters with flammable HC and HFO refrigerants, you need
to assess the following risks:
• Thermal radiation from a warehouse fire
• Explosion hazards
• Quantities of flammable material being stored
• Nature and location of materials stored
• Areas set aside for segregated storage of flammable substances
• Drainage systems
• Presence of neighbors with hazard potential
• The maximum number of persons on site and their likely locations
• Total quantity of hazardous substances and the maximum
individual quantities
• Type and characteristics of the packaging
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Major Accident Prevention Policy
Move the damaged or leaking equipment to a designated area that is far away
from the main storage area, is well ventilated, is equipped with appropriate
security features, and has segregated areas to ensure compliance with the rules for
hazardous substances.
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Record Keeping Procedures
Effective January 2018, you need to keep comprehensive records that track the
flammable refrigerants being handled [EPA, 2016b]. This information should
include the following:
• Chemical names and brand names of refrigerants
• Hazard category
• Storage location or all flammable substances, not just the refrigerants
• List of other relevant equipment used to handle the flammable refrigerants
• Details of electrical installations in the region where flammable
refrigerants could be present
• All potential hazards to firefighters
All records must be kept for at least three years in electronic or paper format.
Technicians must also record the amounts of ozone depleting substances
(ODSs) and non-exempt substitute refrigerant transferred for reclamation by
refrigerant type.
EPA requires you to maintain records of all refrigerant recovered during the
disposal of any refrigerant containing appliance. You must record the total
amount of refrigerant, by type, recovered from any appliance you dispose. This
recordkeeping requirement has been developed to discourage the illegal venting
of refrigerants during disposal. The EPA requires you to keep records when
disposing of any appliance with a normal charge that is more than 5 and less than
50 pounds. These records include the following:
• Company name
• Location of the appliance
• Date of recovery
• Type of refrigerant recovered for each appliance
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Chapter 7. Summary
This chapter lists two HC end-use case and summarizes allowable substitute
refrigerants and use conditions. Additional information is also included that you
might find helpful for each end use.
End Use 1
The first approved HC refrigerant end use is household refrigerators, freezers, and
combination refrigerators and freezers (new equipment only).
Substitute Refrigerants
Isobutane (R-600a) and R-441A can be used as substitutes for CFC-12, HCFC-22,
and R-134a.
Use Conditions
These refrigerants may be used only in new equipment designed specifically and
clearly identified for the refrigerant (i.e., none of these substitutes can be used as a
conversion or ‘‘retrofit’’ refrigerant for existing equipment designed for a
different refrigerant).
The quantity of the substitute refrigerant (i.e., normal charge size) shall not
exceed 57 g (2.0 ounces) in any refrigerator, freezer, or combination refrigerator
and freezer for each circuit.
Safety Information
Applicable OSHA requirements at 29 CFR part 1910 must be followed, including
those at 29 CFR 1910.106 (flammable and combustible liquids), 1910.110
(storage and handling of liquefied petroleum gases), 1910.157 (portable fire
extinguishers), and 1910.1000 (toxic and hazardous substances).
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Maintain proper ventilation at all times during the manufacture and storage of
equipment containing hydrocarbon refrigerants through adherence to good
manufacturing practices as per 29 CFR 1910.106. If refrigerant levels in the air
surrounding the equipment rise above one-fourth of the lower flammability limit,
evacuate the space. Only allow reentry after the space has been properly
ventilated.
Tip
Take special care to avoid contact with your skin because the rapid
evaporation of refrigerants can cause freeze burns on the skin.
Only use spark-proof tools when working on refrigerators and freezers with HC
refrigerants.
Permanent Markings
DANGER
Risk of Fire or Explosion.
Flammable Refrigerant Used.
Do Not Use Mechanical Devices To Defrost Refrigerator.
Do Not Puncture Refrigerant Tubing.
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Near Machine Compartment
DANGER
Risk of Fire or Explosion.
Flammable Refrigerant Used.
To Be Repaired Only By Trained Service Personnel.
Do Not Puncture Refrigerant Tubing.
CAUTION
Risk of Fire or Explosion.
Flammable Refrigerant Used.
Consult Repair Manual/Owner’s Guide Before Attempting To Service
This Product.
All Safety Precautions Must be Followed.
Exterior of Refrigerator
CAUTION
Risk of Fire or Explosion.
Dispose of Properly In Accordance With Federal or Local
Regulations.
Flammable Refrigerant Used.
CAUTION
Risk of Fire or Explosion Due To Puncture Of Refrigerant Tubing;
Follow Handling Instructions Carefully.
Flammable Refrigerant Used.
The letters for these markings must be at least ¼ inch high. The refrigerator,
freezer, or combination refrigerator and freezer must have red (PMS #185)
marked pipes, hoses, or other devices through which the refrigerant is serviced
(typically known as the service port) to indicate the use of a flammable
refrigerant.
This red color must be present at all service ports and where service puncturing or
otherwise creating an opening from the refrigerant circuit to the atmosphere might
be expected (e.g., process tubes). The color mark must extend at least 1 inch from
any possible refrigerant service port or process tube and must be replaced if
removed.
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End Use 2
Substitute
Propane (R-290) can be used as a substitute for CFC-12, HCFC-22, and R-502.
Use Conditions
As with End Use 1, these refrigerants may be used only in new equipment
specifically designed and clearly identified for the refrigerants (i.e., none of these
substitutes may be used as a conversion or “retrofit” refrigerant for existing
equipment designed for other refrigerants).
These substitutes may only be used in equipment that meets all requirements in
Supplement SB to the 10th edition of the Underwriters Laboratories (UL)
Standard for Commercial Refrigerators and Freezers, UL 471, dated November
2010. In cases where the final rule includes requirements more stringent than
those of the 10th edition of UL 471, the appliance must meet the requirements of
the final rule in place of the requirements in the UL Standard.
The charge size for the retail food refrigerator or freezer shall not exceed 150 g
(5.3 ounces) in each circuit.
Permanent Markings
The permanent markings for this use case are the same as Use Case 1.
UL References
65
For information on the availability of this material at NARA, call (202) 741-6030,
or go to
http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locatio
ns.html.
End Use 3
Substitute Refrigerants
Although not a drop in replacement, R-1234yf is being used as a substitute for
CFC-12, HCFC-22, and R-134a. The performance of HFO-1234yf closely
matches that of HFC-134a.
Along with being adopted for motor vehicle air conditioning (MVAC) systems,
HFO-1234yf also has potential for chillers and commercial refrigeration
applications that currently use HFC-134a.
End Use 4
R-1234zd is suitable for new industrial air conditioning applications and the
cooling of buildings where cooling water or intermediate fluids are used in large
systems with centrifugal compressors (one or more stages) and where R-123
might have been used in the past. Linde and Honeywell market this refrigerant as
Solstice® ZD and as a replacement for R-123 in new chiller applications
[Honeywell, 2017].
End Use 5
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End Use 6
67
Chapter 8. Acronyms
AEGL—acute exposure guideline level
CFC—chlorofluorocarbon
CO2—carbon dioxide
DIY—do it yourself
DOT—Department of Transportation
FR—Federal Register
g—gram
HC—hydrocarbon
HCFC—hydrochlorofluorocarbon
HFC—hydrofluorocarbon
HFO—hydrofluoroolefin
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kg—kilogram
kJ—kilojoule
kPa—kilopascal
ODS—ozone-depleting substance
PAO—poly-alpha-olefin lubricant
PTFE—polytetrafluoroethylene
RfC—reference concentration
TWA—time-weighted average
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UNEP—United Nations Environment Programme
70
Chapter 9. Definitions
Adequate ventilation. According to OSHA regulations at 29 CFR 1910.110,
ventilation is adequate when the concentration of the gas in a gas–air mixture
does not exceed 25% of the lower flammable limit or subject to alternative
safety provisions.
Appliance. Any device that contains and uses a refrigerant and is used for
household or commercial purposes, including any air conditioner, refrigerator,
chiller, or freezer. Thus a refrigerator, freezer, or combination refrigerator and
freezer, for example, could consist of two appliances provided that the refrigerant
in the first appliance (i.e., the first compressor, condenser, evaporator, and
metering device) does not mix with the refrigerant in the second appliance (e.g.,
the second compressor, condenser, evaporator, and metering device).
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establishments. Cold storage includes the equipment used to store meat, produce,
dairy products, and other perishable goods.
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Electronic vacuum gauge or micron gauge. Electronic vacuum gauge that
displays the vacuum level directly in microns and is the only accurate field
method to determine the evacuation level of a deep vacuum.
Follow-up verification test. Test that involves checking the repairs within
30 days of when the appliance returns to normal operating characteristics and
conditions. Follow-up verification tests for appliances from which the refrigerant
charge has been evacuated means a test conducted after the appliance or portion
of the appliance has resumed operation at normal operating characteristics and
conditions of temperature and pressure, except in cases where sound professional
judgment dictates that these tests would be more meaningful if performed before
the return to normal operating characteristics and conditions. A follow-up
verification test with respect to repairs conducted without evacuation of the
refrigerant charge means a reverification test conducted after the initial
verification test and usually within 30 days of normal operating conditions. Where
an appliance is not evacuated, you only need to conclude any required changes in
pressure, temperature, or other conditions to return the appliance to normal
operating characteristics and conditions.
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High-pressure appliance. An appliance that uses a refrigerant with a liquid phase
saturation pressure between 170 psia and 355 psia at 104°F. This definition
includes but is not limited to appliances using R-401A, R-409A, R-401B, R-
411A, R-22, R-411B, R-502, R-402B, R-408A, R-410A, and R-402A.
Initial verification test. Leak tests that are conducted after the repair is finished
to verify that a leak or leaks have been repaired before refrigerant is added back to
the appliance.
King valve. Combination shut-off and service valve typically used on the inlet
and outlet of a compressor, and on the inlet and outlet of packaged condensing
units.
Leak rate. The rate at which an appliance is losing refrigerant, measured between
refrigerant charges and projected over the next 12 months. The leak rate is
expressed in terms of the percentage of the full charge of the appliance that would
be lost in the next 12 months if the current rate of loss were to continue over that
period. Use the following three steps to determine the leak rate:
Step 3. Use the following formula to determine the leak rate as a percentage.
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LFL. Lower flame limit. The minimum concentration in air at which flame
propagation occurs.
Mixture. Blend of two or more components that do not have a fixed proportion to
one another and that no matter how well blended, they still retain a separate
existence (oil and water, for example).
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Non-azeotropic refrigerant. Synonym for zeotropic, which is the preferred term
though less commonly used as a descriptor. Non-azeotropic or zeotropic refers to
blends comprising multiple components of different volatilities that, when used in
refrigeration cycles, change volumetric composition and saturation temperatures
(exhibit temperature glide) as they evaporate (boil) or condense at constant
pressure. These refrigerants are given a 400-series ASHRAE designation.
Process stub or Process tube. Length of tubing that provides access to the
refrigerant inside a small appliance or room air conditioner that can be resealed at
the conclusion of repair or service. After refrigerant is added or removed, the
process tube is usually pinched to stop refrigerant flow and then could be brazed
to provide a long-lasting seal. The tube is used solely as a refrigerant access point
for service technicians and must contain a red stripe at least 1 inch long when the
system contains flammable refrigerant.
psia. Absolute pressure in pounds per square inch, where 0 psia corresponds to
29.9 inches of mercury vacuum, and 14.7 psia corresponds to atmospheric
pressure 0 psig (pounds per square inch gauge).
psig. Gauge pressure in pounds per square inch, where 0 psig corresponds to
atmospheric pressure (14.7 psia). A positive psig value indicates the pressure in
pounds per square inch above the ambient pressure.
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Recovery. To remove refrigerant in any condition from an appliance and to store
it in an external container without necessarily testing, cleaning, filtering, or
processing it in any way.
Recovery vacuum. Used to recover refrigerant in the system and prevent its
escape into the atmosphere. This evacuation, which uses an EPA-approved
recovery or recycling machine, is performed on a charged refrigeration system
before the system is opened for repair. Like any other vacuum, it is never used to
determine if the system has any leaks. Before a Recovery Evacuation is to be
performed, the required evacuation level must be determined based on the
quantity and type of charge, and the manufacture date of the recovery equipment.
If the system has a leak, you only need to recover to atmospheric pressure to
avoid ingesting air into the recovered refrigerant.
Refrigerant. The fluid used for heat transfer in a refrigeration system, which
absorbs heat during evaporation at low temperature and pressure, and releases
heat during condensation at a higher temperature and pressure. A refrigerant
is any Class I or Class II substance or its substitute that is used for cooling
or refrigeration.
Retire. When referring to an appliance, the removal of the refrigerant and the
disassembly or impairment of the refrigerant circuit such that the appliance as a
whole is rendered unusable by any person in the future.
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changes in lubricants, gaskets, filters, driers, valves, o-rings, or appliance
components.
78
are not limited to the following: attaching or detaching hoses and gauges to and
from the appliance; adding or removing refrigerant; adding or removing
components; and cutting the refrigerant line. Activities such as painting the
appliance, rewiring an external electrical circuit, replacing insulation on a length
of pipe, or tightening nuts and bolts are not reasonably expected to violate the
integrity of the refrigerant circuit. Activities conducted on appliances that have
been properly evacuated are not reasonably expected to release refrigerants unless
the activity includes adding refrigerant to the appliance. Technicians could
include but are not limited to installers, contractor employees, in-house service
personnel, and owners and/or operators of appliances.
Temperature glide. Difference between the dew point and the bubble point.
Vacuum pump. Device used to pump the air, moisture, and other non-
condensables out of a system and, hence, evacuate the system. The extraction of
the air and non-condensables lowers the pressure inside of the system (below
atmospheric pressure), which causes any trapped liquid water to evaporate and be
exhausted by the vacuum pump. Single-stage and two-stage vacuum pumps are
commonly used in the HVAC/R industry. A two-stage vacuum pump is necessary
to pull the deep vacuums (below 500 microns), which are necessary for the proper
evacuation and removal of water in systems. Both the single-stage and two-stage
vacuum pumps are rated by their volumetric capacity, typically expressed in cubic
feet per minute (cfm). Three to six cfm pumps are typically used in residential
applications.
79
References
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Conditioning Systems, Carshalton, Surrey SM5 2JR, [email protected].
Arkema. 2016. U.S. EPA approves Arkema’s Forane® 449B refrigerant for
applications under SNAP program. http://www.arkema-
americas.com/en/media/news-overview/news/U.S.-EPA-approves-Arkemas-
Forane-449B-refrigerant-for-applications-under-SNAP-program/. Accessed
29 January 2017.
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the HCR-188C Significant New Alternatives Policy Program Submission to
the United States Environmental Protection Agency. August 2009.
Ben and Jerry’s. 2008. Ben and Jerry’s/Unilever, Significant New Alternatives
Policy Program Submission to the United States Environmental Protection
Agency, October 2008.
80
EPA. 2016b. Protection of Stratospheric Ozone: Update to the Refrigerant
Management Requirements under the Clean Air Act. 40 CFR Part 82 [EPA-
HQ-OAR-2015-0453; FRL-9950-20-OAR] RIN: 2060-AS51.
Green Car Congress. 2014. LMU study finds 20% of gases from combustion of
R1234yf MAC refrigerant consist of highly toxic carbonyl fluoride.
http://www.greencarcongress.com/2014/04/20140411-lmu.html. Accessed 27
Jan 2017.
IPCC/TEAP, 2005. Safeguarding the Ozone Layer and the Global Climate
System: Special Report of the Intergovernmental Panel on Climate Change.
Edited by Bert Metz, Lambert Kuijpers, Susan Solomon, Stephen O.
81
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82
Index
accident prevention .......................................... 60 dry nitrogen .............................. 44, 46, 47, 48, 79
ARI 700 ............................................................ 38 equipment .37, 38, 39, 40, 41, 42, 46, 52, 71, 75,
77, 78
ASHRAE.....................................................71, 76
ethane ................................................................ 7
brazing.............................................................. 52
evacuation levels ................................. 47, 50, 52
bromine ............................................................ 73
extraction ................................................... 49, 79
carbon .............................................................. 74
failure ......................................................... 51, 52
certification .................................................40, 63
filter ................................................ 42, 43, 53, 77
charge size ....................................................... 37
fine ............................................................. 44, 45
charge size limitations ...................................... 23
flammability ...................................................... 32
charging............................................................ 53
flare .................................................................. 42
chiller ................................................................ 71
fluorine ............................................................. 73
chlorine ............................................................. 73
global warming potential .............................. 17, 18
Clean Air Act .................................................... 37
grounding ......................................................... 42
climate impacts.................................................. 17
hazard .............................................................. 59
cold storage warehouse ................................... 71
HC blends .......................................................... 5
compound.............................................44, 50, 74
HC refrigerants
compressed air ................................................. 44 cylinders ...................................................... 55
desiccants compatibility ................................. 6
contaminated .................................................... 51 flammability.............................................. 9, 55
lubricant compatibility .................................... 5
core ......................................................40, 51, 77 materials compatibility ................................... 6
normal operating pressure .......................... 3, 4
deep vacuum ............... 46, 47, 48, 49, 50, 73, 79 pressure–temperature formula .................... 45
pressure–temperature relationship .......... 3, 19
defrost heater ................................................... 42
HCFC ......................................................... 44, 45
dehydration ................................................48, 52
HCFC-22 .................................................... 44, 45
disposal ............................................................ 37
head pressure .................................................. 42
83
heat ......................................................42, 75, 77 leaks ................................................................. 39
84
toxicity risk ................................................... 31 replacement refrigerant .................................... 38
recycling ............................ 37, 39, 41, 75, 77, 78 use conditions ............................................ 62, 65
red markings ..............................................23, 26 vacuum46, 47, 48, 49, 50, 51, 52, 72, 73, 75, 76,
77, 79
refrigerant ......................................................... 40
vacuum pump .................... 46, 48, 49, 51, 52, 79
refrigerant quality ............................................. 53
valve core ................................................... 40, 41
refrigerant recovery ..............................37, 40, 41
vapor pressure ................................................. 46
refrigerant, ......................... 38, 39, 44, 46, 58, 74
vapor recovery ................................................. 42
relief valve ..................................................40, 48
85
ventilation ......................................................... 63 volatile organic compound (VOC) .................... 17
86