EPA 608 & 609 CERTIFICATION TEST RESULTS

Transcription

1 EPA 608 & 609 CERTIFICATION TEST RESULTS Attention: Testing results can now be retrieved on the web. Get your test results quickly. Avoid retest delays. Results posted 1 st & 15 th of each month and periodically between. If you ve recently taken the 608 or 609 Certification Exam, you may retrieve your test results at You will be required to enter your social security number as your User ID, and your last name. A certification card containing your results will be mailed to you, regardless of whether you logon to this site. Q & A Q: Are the results found on the website actual proof of my certification? A: Results are for information only and not actual proof of certification. Q: Can I gain employment or purchase products with the information obtained on the website? A: This information cannot be used to gain employment or purchase products. Q: When will I receive my actual certification results? A: Actual certification results will be mailed to the address you provided on your test. You should receive them within 30 days of your test date. There is no need to call or logon to the website for this to happen. Q: What does void mean? A: You did not pass a portion or your entire test. You must have a score of at least 18 to pass all 608 sections and you must pass core to become certified in any section. If you scored less than 18 in any section, you only have to retest that section. For EPA 609 you must have at least an 90% to pass. Questions or concerns? Call (623) or (800) ext

2 DO YOU NEED YOUR EPA CERTIFICATION CARD REPLACED? In order to get a replacement card you must write a letter stating the card was lost, stolen, or damaged. The letter must contain the following student information: Name Social security number Which test you took; 608 (HVAC) or 609 (Automotive) Mailing address and current phone number There is a $10.00 fee that must be included. We accept Visa or MasterCard with the expiration date. Make money orders payable to UTI. WE DO NOT ACCEPT PERSONAL CHECKS Mail to: UTI ATTN: CTG/ (If you are requesting a 608 HVAC residential card send your information to CTG/608; 609 Automotive send it to CTG/609) W. Pierce St. Avondale, AZ If you have any further questions please contact us at: or Extension 10853

3 Mobile Air Conditioning Certification Training Manual (Effective 3/98) Universal Technical Institute W. Pierce St. Avondale, AZ

4 Table of Contents Introduction... 1 The Ozone Layer and Chlorine... 2 Ozone Layer... 2 Chlorine and the Ozone Layer... 2 Destruction of the Ozone Layer by CFCs... 2 Myth... 4 Refrigerants... 5 Chemicals... 5 CFCs - Chlorofluorocarbons... 5 HCFCs - Hydrochlorofluorocarbons... 6 HFCs - Hydrofluorocarbons... 6 Blends... 6 Ozone Depletion Potential... 7 Legislation... 8 Taxation... 8 Clean Air Act... 9 Section Recovery Recycle Reclaim Refrigerant Recovery Procedure Checking for Noncondensables Containers for Storage of Recycled Refrigerant Transfer of Recycled Refrigerant SAE Standard J SAE Standard J SAE Standard J SAE Standard J SAE Standard J SAE Standard J SAE Standard J SAE Standard J ARI Standard Handling Other Refrigerants That Substitute for CFC Significant New Alternatives Policy (SNAP)... 18

5 What We Can Do Service Requirement Retrofit Safety About the Test Scoring Certification Card No Renewal... 26

6 1 Introduction Why are we required to have laws pertaining to the air conditioning our vehicles use? There are many reasons, but the most important is the protection of our environment, most particularly our atmosphere. For years we have released chemicals containing substances, such as chlorine, into the air without realizing that the releases could be harmful. The release to the atmosphere of chemicals that are used in vehicle air conditioning and refrigeration equipment has been established as a cause of ozone destruction. The primary refrigerant used in most mobile air conditioners is CFC-12, also known as Freon. This chemical is composed of chlorofluorocarbons (CFCs). Studies determined that the release of CFC s would harm the ozone layer. The Clean Air Act passed by Congress established standards for the production, sale, use and handling of certain refrigerants. Under these standards, technicians servicing mobile air conditioning systems must be certified. The certification requirement can be met by taking and passing a test. All of the knowledge that you must have to pass the test is in this manual. Study the manual and understand its contents and you will have no difficulty becoming a certified technician under Section 609 of the Clean Air Act. In addition to becoming certified you will gain understanding of what the ozone problem is all about. Universal Technical Institute 1 Mobile Air Conditioning Certification Training

7 2 The Ozone Layer and Chlorine Ozone Layer The ozone layer plays an important role in our daily lives. It filters out much of the ultraviolet (UV-B) radiation from the sun s rays before they reach the earth. Ozone is a bluish gas containing three oxygen (O ) atoms linked together instead 3 of the usual two (O ). Ozone can be formed when UV radiation from the sun splits 2 apart ordinary oxygen molecules (O ) into single oxygen atoms and they recombine in 2 three parts to form O. Ozone at ground level is considered a pollutant, but when it 3 is in the upper atmosphere it serves as a protection layer for the earth from the sun s rays. Chlorine and the Ozone Layer The ozone layer is found in the stratosphere above the earth s surface. Scientists believe that chlorine atoms released into the atmosphere are destroying the ozone layer. A major portion of the chlorine that reaches the ozone layer was released by industry venting certain refrigerants to the air. Chlorine has been used in other applications, such as:! propellant for aerosol cans, which was banned 17 years ago! solvents for cleaning electronic parts! plastic foam production. Destruction of the Ozone Layer by CFCs In the past the ozone layer was stable, however, studies have found that holes are occurring in the layer. The presence of the holes and the thinning of the layer itself can have bad effects on our planet by allowing increased ultraviolet radiation to reach our planet. Increased UV radiation reaching us will result in: 2 Mobile Air Conditioning Certification Training

8 < increased number of cases of skin cancer < a weakening of our body s immune system < decreased crop yields < damage to our ecosystem. The destruction of the layer occurs when the chlorine atoms of CFC-12, or other CFC-based refrigerants, interacts with the ozone. Each detached chlorine atom attacks an ozone molecule, breaking it down to a free oxygen atom and a stable molecule of chlorine monoxide. The reduction of ozone, which blocks ultraviolet rays, allows additional ultraviolet radiation to reach the earth. When these rays reach the lower atmosphere the ill effects described earlier occur. The first step in attempting to reverse the destruction of the ozone layer is banning the venting that has been done in the past. In addition, regulations covering refrigerant usage, manufacture and production were established to slow the release of CFC based refrigerants to the atmosphere. HOW CFC's DESTROY THE OZONE Chlorine atom UV Light... Chlorine monoxide.. Ozone molecule Oxygen molecule CFC molecule A free oxygen atom can then break the chlorine away from the chlorine monoxide molecule. The chlorine atom then attacks and destroys another ozone molecule. This process then repeats thousands more times. 3 Mobile Air Conditioning Certification Training

9 Myth The link between ozone depletion and the use of CFCs has been a continuing controversy. Stratospheric ozone concentrations vary normally with seasonal changes and at different latitudes. Studies, which began in 1965 and continue to this day, have shown that global ozone depletion continues. Critics argue that CFCs can t be a source of ozone depletion because they are heavier than air. While true, wind carries CFCs into the upper atmosphere. Studies have found CFCs in the stratosphere since CFC molecules, while harmless at lower levels, break down under high levels of UV rays in the upper atmosphere. CFCs decompose and free chlorine atoms attach to and destroy ozone molecules. Depletion of the ozone layer is in itself not harmful, but the increased level of UV radiation now allowed to reach the earth s surface is the real cause for concern. Volcanoes have been cited as another source of the ozone-destroying chlorine. What of this claim? Volcanoes pour out tons of hydrochloric acid when they erupt. This form of chlorine tends to break down before it ever reaches the upper atmosphere. Their molecules are not as stable as CFC molecules and dissolve in rain and return to the earth. Another claimed source are the oceans - they are full of chlorine atoms. Don t these chlorine molecules contribute to the depletion of the ozone layer as they evaporate? Because they are similar to the chlorine atoms discharged during a volcanic eruption, they are also returned to the earth by rain fall. Studies state that CFC molecules are extremely stable and do not break down until they reach the upper atmosphere. It is because of this fact that you are taking this test. In December 1994, after a three-year study, NASA confirmed that CFCs are the main source for upper atmosphere chlorine. Their research was based on the fact that fluorine was also found in the stratosphere. Fluorine is not a natural element in the upper atmosphere, but is part of the CFC molecule. The scientists who proposed the original theory have won the Nobel Prize for their research, even though the scientific community continues to argue. Whether you agree or disagree with the theory of chlorine contributing to the destruction of the ozone layer is not important. The laws and standards are in place. What is important is that you conform with all of the regulations and requirements that affect your use of refrigerant when servicing mobile air conditioning systems. 4 Mobile Air Conditioning Certification Training

10 3 Refrigerants Chemicals The handling of refrigerant is a primary focus of the attempt to help resolve the ozone crisis. CFC-12 has been the primary target, but there are other refrigerants that also deplete the ozone layer. Certain refrigerants are now classified by their potential to deplete the ozone layer. Some refrigerants have been used for cleaning, flushing and other commercial purposes. They, too, are to be eliminated from the market place. Service procedures must change to compensate for the unavailability of these products. Because venting refrigerants has been determined to be a cause of ozone depletion, it is our responsibility to comply with all the new requirements. Let s look at the different classes of refrigerant and their depletion rates. CFCs - Chlorofluorocarbons Some typical CFC refrigerants are: R-11, -12, -113, -114, -115 and As an automotive technician, the primary refrigerant to be concerned about is CFC-12, since that is the refrigerant that will still be found in the majority of automotive applications. CFC-12 contains chlorine and is designated a Class 1 refrigerant. Class 1 refrigerants are fully halogenated chlorofluorocarbons and do not contain any hydrogen atoms as other refrigerants can. It is CFCs that are of prime concern in ozone destruction. CFC refrigerants are very stable and if they reach the atmosphere can stay there for as long as 120 years doing damage. As of January 1, 1996, R-12 is no longer produced. While some believe that a shortage of CFC-12 5 Mobile Air Conditioning Certification Training

11 may occur, methods to help alleviate this shortage are to recover, recycle and reclaim refrigerants. This can ensure an ongoing supply. Vehicles that use CFC-12 can also be retrofitted to the new alternative refrigerants. This will help reduce the demand for CFC-12. While the production of CFC-12 has ceased, use of HFC- 134a will reduce the demand for CFC-12. Newer cars contain an alternative refrigerant (HFC-134a) that contains no chlorine. HCFCs - Hydrochlorofluorocarbons The chemical structure of an HCFC is composed of methane or ethane molecules, chlorine and fluorine, with some hydrogen atoms present. An HCFC refrigerant is called a partially halogenated refrigerant. A partially halogenated refrigerant is less stable than a fully halogenated refrigerant. The lower stability lessens the ozone destruction potential, hence HCFCs are still used. Refrigerants in this category are HCFC-22, -123 and The primary HCFC refrigerant is HCFC-22 which is used for residential and commercial comfort cooling. HCFC-22 is also used in some buses and transportation refrigeration equipment. HFCs - Hydrofluorocarbons Two refrigerants in this group are HFC-134a and HFC-152a. The base molecule is halogenated by a fluorine atom only. There are no chlorine atoms in the molecule. This type of refrigerant has an ozone depletion potential of zero. HFC-134a has been chosen as the replacement for CFC-12 in the automotive industry. This refrigerant was introduced in the automotive line as a factory replacement during the early 1990's. To retrofit a vehicle to HFC-134a from CFC- 12, some changes will have to be made to the system. The heat carrying capacity and the lubrication oils used with HFC-134a are different than CFC-12. Manufacturers are providing kits to insure that a CFC-12 to HFC-134a changeover is successful. Blends Other refrigerants are being developed as a replacement for CFC-12. These refrigerants must be approved by the Environmental Protection Agency (EPA) before they become available to the market place. Certain standards must be met, such as safety, and most importantly, a very low or zero ozone depletion rate. These standards and approvals are set by SNAP (See Chapter 7). 6 Mobile Air Conditioning Certification Training

12 Ozone Depletion Potential Almost every refrigerant has a potential to destroy ozone but not equally. A relative measure of a refrigerant s potential to destroy the ozone layer is its Ozone Depletion Potential. CFC-12 (R-12) was used as the baseline and has been designated as having an ODP of 1. The values shown in the chart are relative to the CFC-12 value. REFRIGERANT CHART Refrigerant ODP (Ozone Depletion Potential) Primary Use R Plastic, foam, refrigerant & flush R Auto A/C, plastic, foam, refrigerant R Stationary A/C R Solvent R Refrigerant R Refrigerant FR Refrigerant R-134a 0.0 Refrigerant 7 Mobile Air Conditioning Certification Training

13 4 Legislation Due to the concerns of destroying our atmosphere, CFCs that were considered harmful were banned from being used in certain products in As the concern became larger a group of countries gathered in Montreal, Canada to sign an agreement, known as the Montreal Protocol, setting limits on the production of ozone depleting chemicals. The United States and other countries in the group agreed to limit, and eventually cease, the production of CFCs and halons. In July 1989 the first step was taken by restricting the production of CFCs to 1986 production levels. It was agreed that production levels could be modified as information was gathered that warranted a reduction in production. Studies showed the ozone layer continuing to thin, and in June 1990 another meeting was held in London, England. At that time, the Protocol nations agreed to step up the phase out and more quickly reduce production of certain refrigerants than was previously proposed. They also agreed to end CFC production by the year In the US, CFC-12 is no longer manufactured. Taxation Congress passed legislation to impose an excise tax on certain CFCs shown to be detrimental to our atmosphere. This law became effective on January 1, The tax served as an incentive to reduce the production of ozone depleting CFCs and encourage the development and production of refrigerants that are safe for our environment. The amount of tax to be assessed was determined by a base tax multiplied by the ozone depletion level of the refrigerant. The tax levied against the depleting refrigerants increases every year. Clean Air Act 8 Mobile Air Conditioning Certification Training

14 On November 15, 1990 the Federal Clean Air Act Amendments were signed by President Bush as a method to protect the stratospheric ozone layer. The amendments established a national policy to reduce the production and eliminate chemicals that deplete the ozone layer. The final rule became effective on August 13, Section 608 of the Clean Air Act pertains primarily to the servicing of appliances and stationary refrigeration systems, but also includes some mobile air conditioning systems such as: Transit or coach air conditioning, farm or implement air conditioning and container refrigeration using R-22 refrigerant. There are three areas of certification in Section 608, each dealing with capacity or pressures. Section 609 of the 1990 Clean Air Act pertains to the servicing of motor vehicle air conditioning. A motor vehicle is defined as any vehicle which is self-propelled and designed for transporting persons or property on a street or highway. The term motor vehicle air conditioning represents a mechanical vapor compression refrigeration equipment used to cool the driver s or passenger s compartment of a motor vehicle. This section addresses standards for technician certification and service equipment used in the servicing of mobile air conditioning systems. 5 Section 609 As of November 15, 1992, the sale of refrigerants used in motor vehicle air conditioners was restricted to 20 pound containers and became available only to trained certified technicians. Only certified technicians may purchase any size container of refrigerant. Service equipment used for mobile air conditioning systems must have EPA approval. This equipment must meet specific performance standards as detailed in the Clean Air Act. EPA approved independent testing laboratories must test the 9 Mobile Air Conditioning Certification Training

15 service equipment to see that it meets the legal standards. Underwriters Laboratories (UL) or ETL Testing Labs must certify the equipment. Recovery A/C System SINGLE PASS REFRIGERANT RECOVERY SYSTEM Recovery/Recharge Solenoid Valve Recycling Equipment Hook-up Liquid/Oil Separator and Primary Filter Compressor REFRIGERANT CIRCUITRY, IF APPLICABLE Moisture Indicator Automatic Air Purge Oil Return Line Storage Tank Master Drier Condenser Oil Separator The extraction of refrigerant from a mobile air conditioning system for the purpose of repairs or replacement of parts. Recovered refrigerant is normally sent to a reclaimer for purification. Recycle The processing of refrigerant on-site to a condition acceptable for reuse in the same vehicle, without need to send it off-site for reclamation. The refrigerant is filtered through a replacement filter and dried using a desiccant as part of the equipment standards required. 10 Mobile Air Conditioning Certification Training

16 A/C System MULTI-PASS REFRIGERANT RECOVERY SYSTEM (TYPE A SYSTEM) Recycling Equipment Hook-up Recovery Solenoid Valve Liquid/Oil Separator Compressor Oil Return line Moisture Indicator Filter Drier Air Purge Storage Tank Oil Separator Recycle Solenoid Valve High Pressure Switch A/C System MULTI-PASS REFRIGERANT RECOVERY SYSTEM (TYPE B SYSTEM) Recycling Equipment Hook-up Recovery Solenoid Valve Liquid/Oil Separator Filter Drier Compressor Moisture Indicator Air Purge Oil Return Line Storage Tank Oil Separator Recycle Solenoid Valve High Pressure Switch 11 Mobile Air Conditioning Certification Training

17 Reclaim Refrigerant sent to a reclamation center for distillation to a higher standard of purity. Reclaimed refrigerant must meet ARI standards which compares to virgin refrigerant. Technician training standards are also specified in Section 609. Technicians must study and be tested on material pertaining to: C the destruction of the ozone layer C service procedures to minimize loss of refrigerant into the atmosphere C safety C equipment requirements and purity standards involved on the servicing of mobile air conditioning units. This certification will verify the technician s skills to properly service, repair and handle refrigerants when repairing mobile air conditioning units. Future technological developments are addressed and the requirements imposed by Section 609 of the Clean Air Act are also in the test taken by the technician. Since January 1, 1993, repair facilities are required to show that they are using certified equipment and employ trained and certified technicians to perform A/C service. The owner must sign a statement as to: C the equipment manufacturer s name C model number C date of manufacture C serial number. The statement must also include names of the individuals certified and trained to use the equipment. This statement should be sent to: MVACs Recycling Program Manager, Stratospheric Ozone Protection Branch (6205-J), US Environmental Protection Agency, 401 M Street SW, Washington, DC The refrigerant recycling equipment must meet the requirements of SAE Standard J1990 (for CFC-12 equipment) or SAE Standard J2211 (for HFC-134a equipment) to meet requirements of the EPA. The requirements include: C a desiccant to remove moisture and a moisture detection device C C a filter to trap particulates automatic purge capability of noncondensables (NCGs) or a device to alert the operator that the NCG limit has been exceeded. The equipment must be capable of reducing system pressure to a minimum of 102mm of mercury. Overcharge protection for the storage tank must be installed with a shutoff device and a mechanical pressure relief valve. 12 Mobile Air Conditioning Certification Training

18 Portable refillable tanks or containers used with the equipment must meet Department of Transportation (DOT) or Underwriters Laboratories (UL) Standards and be adaptable to existing refrigerant service and charging equipment. Each storage tank must be marked to indicate the first retest date, required 5 years after the date of manufacture. All flexible hoses must meet SAE J2196 hose specifications, effective January 1, Service hoses must have shutoff devices located within 12 inches from the connection point to the system being serviced. The equipment must also be capable of separating lubricant from the recovered refrigerant and accurately indicate the amount of oil removed during the process. 6 Refrigerant Recovery Procedure The following are the necessary steps to recover refrigerant from a vehicle A/C system: 1. Connect the recovery unit service hoses to the vehicle air conditioning system service ports. 2. Start the recovery process. Operate the unit until the system has been reduced from a pressure to a vacuum. 3. With the unit shut off for 5 minutes, observe whether there is refrigerant left in the system. Pressure indicates further recovery is necessary. Repeat the procedure until the system remains in a vacuum for 2 minutes. 4. Close the valves in the service lines and remove the lines from the system. Proceed with the necessary repairs to the system. Checking for Noncondensables All recovered refrigerant must be checked for noncondensables. To determine if the recovered refrigerant contains noncondensables, the container must be stored at a temperature of 65EF or above for 12 hours and be protected from the sun. 13 Mobile Air Conditioning Certification Training

19 Install a calibrated pressure gauge, with 1 psig divisions, to the container and determine the container pressure. Next, measure the ambient air temperature within 4 inches of the container. Compare the observed container pressure and air temperature reading to the chart to see if the refrigerant contains noncondensables. Example: at 70EF the container pressure should not exceed 80 psig. Standard Temperature/Pressure Chart (R-12) EF PSIG EF PSIG EF PSIG EF PSIG EF PSIG Metric Pressure/Temperature Chart (R-12) EC Pres. EC Pres. EC Pres. EC Pres. EC Pres Mobile Air Conditioning Certification Training

20 Metric Pressure/Temperature Chart (R-12) EC Pres. EC Pres. EC Pres. EC Pres. EC Pres If the container of recovered refrigerant has a pressure below the chart pressure corresponding to the ambient air temperature, the limit of noncondensable gases (air) has not been exceeded and the refrigerant may be reused. If the pressure is greater than the temperature/pressure relationship of recovered refrigerant, the noncondensables must be slowly vented into the recycle equipment until the pressure is less than the chart allows. If the container still exceeds the temperature/pressure relationship, the entire contents must be recycled or reclaimed. Containers for Storage of Recycled Refrigerant Recycled refrigerant is not allowed to be stored in disposable refrigerant containers. This type of container is only used for virgin refrigerant. A DOT CFR Title 49 or UL approved storage container must be used to store recycled refrigerant. Containers are color coded gray with a yellow top and must be labeled as to the refrigerant they contain. DOT 4BA Yellow Transfer of Recycled Refrigerant Gray Prior to using a DOT or UL approved container for transfer of refrigerant, 27 inches of vacuum must be applied to the container. To prevent overfilling of the container, it must be weighed during the filling procedure. The maximum fill allowed is 60% of the container s gross weight rating or 80% of the container volume. To properly dispose of an empty or near empty container, you must first recover any remaining refrigerant left in the container. Attach the recovery unit to 15 Mobile Air Conditioning Certification Training

21 the container and reduce the container pressure to a vacuum. Then close the container valve and mark it empty. The container is now ready for disposal. SAE Standard J1770 This standard is the standard for recycling equipment intended for use with both CFC-12 and HFC-134a refrigerant in mobile air conditioning (A/C) systems. This standard only applies to dual refrigerant equipment that uses a single (common) circuit. J1770 ensures that the single-circuit equipment includes special features to prevent cross-contamination of refrigerants. SAE Standard J1732 This standard is the standard for recover-only equipment used to recover HFC-134a refrigerant in mobile air conditioning (A/C) systems. SAE Standard J1989 This standard is the recommended service procedure for containment of CFC-12. SAE Standard J1990 This standard is designed to specify standards for equipment used to recover, recycle or recharge CFC-12. SAE Standard J1991 The SAE standard of purity for reclaimed CFC-12. The moisture, oil and noncondensables standards are the same as ARI SAE Standard J2099 This standard is the standard of purity for recycled HFC-134a. When measured in the liquid phase, the following levels of contaminate should not be exceeded: Moisture = 50 ppm by weight Lubricant = 500 ppm by weight Noncondensable gases (air) = 150 ppm by weight. SAE Standard J Mobile Air Conditioning Certification Training

22 This standard is the standard for recycling equipment used to recycle HFC-134a refrigerant in mobile air conditioning (A/C) systems. The equipment must be able to purify the removed HFC-134a refrigerant to the levels specified in SAE standard J2099. SAE Standard J2211 This standard relates to the containment of HFC-134a during servicing of mobile air conditioning equipment. ARI Standard The Air conditioning & Refrigeration Institute sets the standards for purity of refrigerants. The EPA has adopted the standard and requires reclaimers to return used CFC-12 refrigerant to new manufactured specifications. The contaminants of recycled CFC-12 are limited to certain levels. The limits are as follows: Moisture: 15 ppm by weight Refrigerant oil: 4000 ppm by weight Noncondensable gases (air): 330 ppm by weight All reclaimed CFC-12 must meet these standards as set by ARI. Handling Other Refrigerants That Substitute for CFC-12 Using Older Equipment to Recover Blends - a technician may permanently dedicate an older piece of equipment he owns to recovering one or more blends; the technician may also use this equipment to recover contaminated CFC-12 and HFC-134a and other mystery mixtures which must then be shipped off-site for reclamation or destruction. Using New Equipment to Recover Blends - a technician may use a new piece of EPA-approved equipment designed to recover, but not recycle, any single, specific blend refrigerant. This new equipment must meet standards published in EPA regulations in December, Recycling Blends - EPA regulations do not currently permit the recycling of blend refrigerants, therefore, a blend refrigerant must be shipped off for reclamation or destruction after it has been recovered. 17 Mobile Air Conditioning Certification Training

23 Converting CFC-12 Recover/Recycle Equipment for Use with Blend Substitutes - EPA also currently prohibits the conversion of existing CFC-12 or HFC-134a recycling equipment for either temporary or permanent use with a blend refrigerant. 7 Significant New Alternatives Policy (SNAP) The EPA has created a policy to certify newly developed refrigerants as being acceptable alternatives, safe to the environment, service technicians and consumers. This policy has resulted in a list of EPA accepted replacement refrigerants available to OEMs, the aftermarket and the repair industry. The SNAP policy, which became effective on April 18, 1994, researches the environmental impact and safety of new refrigerants only and does not relate to performance values. There may be special procedures that have to be followed during or after the installation. All replacement refrigerants require A/C system modification (changing of the service fittings) during the installation of a replacement refrigerant. The best practice is to use manufacturer s kits and procedures. Also required is application of a label indicating the type of refrigerant installed. The following table summarizes information about refrigerants reviewed under EPA s SNAP program for use in motor vehicle air conditioning systems. Note: other refrigerants may be listed in the future. 18 Mobile Air Conditioning Certification Training

24 19 Mobile Air Conditioning Certification Training

25 8 What We Can Do It is our responsibility to control our destiny. We must do everything possible to prevent refrigerant from reaching the atmosphere. If we follow proper service procedures and repair air conditioning systems properly, very small or no amount of refrigerant will escape to increase the ozone depletion. A customer normally won t come in for service until his or her air conditioning is not operating properly. The usual cause of an air conditioner not working is a lack of refrigerant. We must find the leak and repair it before continuing with the repair. Most compressors today depend on a constant supply of oil for lubrication which is dependent on refrigerant flow. The small compact compressor usually lacks an oil reservoir and operates with the principle of oil being carried with the refrigerant flow. When the refrigerant charge is lost, oil flow drops to a minimum and the compressor is usually destroyed by the time you perform service. Service Requirement 1. Beginning on August 13, 1992, and continuing on, anyone servicing a motor vehicle air conditioning unit for consideration must be certified by an approved EPA technician certification program. 2. The proper equipment must be used to service the air conditioning system. This equipment must be an EPA approved type of recovery or recovery/recycle machine capable of meeting the standards set by the EPA. 3. Refrigerant must be recovered using an approved machine before any attempt is made to work on the system. 4. Effective November 15, 1995 all refrigerants must be recovered. 20 Mobile Air Conditioning Certification Training

26 5. If the system is empty, you will need to introduce a small charge to leak check the system. 6. Upon finding the leak, recover the leak test charge before opening up the system. 7. It is not mandatory that the leak be repaired, but the customer should have the benefits of repair explained. 8. The EPA allows topping off of a system, however, some states require leaks to be repaired before adding refrigerant to the system. Note: facilities that perform top-offs but no other refrigerant servicing or repair are still required to purchase approved recovery/recycling equipment. The increasing cost of refrigerant will contribute to repair of a leaking air conditioning system. At this time, depending on the amount of repairs needed, a retrofit to the system may be considered. Retrofit kits are becoming more available so that HFC-134a, which is less harmful to our environment, may be used as a replacement for the CFC-12. WARNING: In the past we were able to use CFC-11 as a flushing agent. This refrigerant is being phased out due to its ozone depletion level. Substitutes are being introduced for the purpose of flushing air conditioning systems and there is equipment designed to flush a system without loss of the refrigerant to the atmosphere. Some automotive manufacturers recommend installing an inline filter versus flushing the system. This procedure reduces service time and the possibility of releasing refrigerant into the atmosphere. After the repair is made, the system is placed in a vacuum, using equipment capable of reducing system pressure to a minimum of 102mm of mercury, to remove any moisture that may have entered the system. This prepares the system for charging. Charge the system with the correct amount of refrigerant and return it to service after a final performance check. Use the proper procedures to prevent venting or escape of refrigerant. 21 Mobile Air Conditioning Certification Training

27 9 Retrofit What will you advise the customer to do? Their air conditioning system requires a major repair which is going to cost a great deal of money. Should they stay with CFC-12, which the supply of is limited and expensive, or make the changeover to HFC-134a, which is the current standard in new cars? There are also refrigerant blends on the market that can replace CFC-12; should they use one of these? It is very important to understand that not all of the refrigerants on the market are accepted replacements and may contaminate the system. This is where SNAP comes into effect. It is your responsibility to research the latest accepted refrigerant and the procedures for installation of that refrigerant. You need to be aware of the EPA SNAP rules and list of accepted refrigerants. Each manufacturer has specific procedures for retrofitting their vehicles. Normally, the type of oil must match the refrigerant you are going to install. It is recommended that any o-rings disturbed during service be replaced to match the refrigerant to be installed. In most cases the desiccant must be changed to be compatible with the new refrigerant. Service fittings are also replaced to indicate that an alternative refrigerant has been installed. It is important not to contaminate a system with different refrigerants. There are test kits available from tool manufacturers to determine what type of refrigerant is installed in the system before using your recovery equipment. Alternative refrigerants should not be recovered or recycled using equipment that is being used to recover or recycle CFC-12 or HFC-134a. When the retrofit is complete, a label stating the type of refrigerant must be installed to inform the technician what type of refrigerant is in the system to prevent crosscontamination. Under the SNAP rule, each new refrigerant must be used in accordance with the conditions listed below. 22 Mobile Air Conditioning Certification Training

28 UNIQUE FITTINGS: Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. LABELS: The technician must apply a detailed label giving specific information about the alternative refrigerant. REMOVE ORIGINAL REFRIGERANT: The original CFC-12 must be removed from the system prior to charging with the new refrigerant. BARRIER HOSES: HCFC-22, a component in some blends, can seep out through traditional hoses. Therefore, when using these blends that include HCFC- 22, the technician must replace the non-barrier hoses with barrier hoses. COMPRESSOR SHUTOFF SWITCH: Some systems have a device that automatically releases refrigerant to the atmosphere to prevent extremely high pressures. When retrofittig this type of system with a new refrigerant, the technician must install a shutoff switch on the compressor. This switch will prevent the compressor from increasing the pressure to the point where the refrigerant is vented. 10 Safety Any time you service an air conditioning system it is important to follow certain safety procedures. The chemicals used to manufacture refrigerants are normally safe, but should be handled carefully. < The first and most important safety practice is to wear safety glasses with side shields. < The refrigerant container should not be heated above manufacturers specifications. < You should never apply direct flame to a refrigerant cylinder or container. < Do not abuse a refrigerant cylinder or container. 23 Mobile Air Conditioning Certification Training

29 < Always have proper ventilation in the area you are working. Refrigerants displace oxygen and if an open flame is used in the area toxic fumes may be developed endangering your safety. < You should never mix refrigerants. Each refrigerant operates at its own temperature and pressure ranges. Excessive pressure may cause personal injury or damage to the vehicle s air conditioning. < It is recommended not to use air pressure to pressure test a HFC-134a system. Excessive air above atmospheric pressure and 60% by volume causes HFC-134a to become explosive. < Care should be used when handling refrigerant oils. Studies have shown that some refrigerant oils may cause cancer. Care should be used when identifying, recovering, and disposing of contaminated refrigerant. < Identifying Refrigerants: Use of a refrigerant identifier unit can help pinpoint many refrigerant identification problems, and EPA strongly recommends (but does not require) that technicians obtain this equipment. < Disposing or Reclaiming of Refrigerants: If the refrigerant in your junk recovery tank is a chemical soup - either contaminated R-12 and R-134a, or a mixture of those contaminated refrigerants and some blend refrigerants that you are unfamiliar with - then the contents should be properly recovered and reclaimed or destroyed. < Not all reclaimers have the technology to handle all contaminated or mixed refrigerants. Make sure that the hauler or reclaimer explains to you how to comply with any applicable DOT, state and local requirements relating to shipping. If you have any questions about disposing of specific blend refrigerants, call the refrigerant manufacturer. 11 About the Test 24 Mobile Air Conditioning Certification Training

30 Now that you have completed studying the areas covered in this manual, you have the required knowledge to pass the test to receive certification. As you know, this certification is important for several reasons, as the laws on refrigerant handling are strictly enforced. Tests are available in two formats; a self study mail-in open book test and a proctored closed book test are available. The mail in test can be obtained by calling Universal Technical Institute at or by downloading from the UTI site at on the World Wide Web. This 800 number can also be used to receive the dates that the proctored tests will be given. Scoring The minimum passing score to receive certification is 90% for the open book mail-in test. The mail-in test has 30 questions, you can miss no more than three questions and still pass. The proctored test also has 30 questions, no more than six questions can be missed in order to obtain the required 80% score. Be sure to answer all questions as any question left blank will be scored as an incorrect answer. If you are not sure of an answer, it is still better to mark your best educated guess than to leave it blank. After you complete the test, either mail it in or return it to the proctor. In either case, if you have achieved a passing score, you will get your certification card by mail within 30 days. Certification Card The certification you receive will enable you to perform service on mobile air conditioning units. You will be able to purchase refrigerant from authorized dealers. If you are seeking employment in the mobile air conditioning field, this card may mean the difference between being hired or not. No Renewal Certification through an approved agency for Section 609 of the Clean Air Act does not expire. There is no need to renew your certification at a later date. However, you must, as a professional technician, keep up-to-date as service 25 Mobile Air Conditioning Certification Training

31 requirements change due to updates in technology and refrigerant availability. The path of knowledge has no end. 26 Mobile Air Conditioning Certification Training

32 Universal Technical Institute Mobile Air Conditioning Certification Test Directions: Multiple choice questions - read each question or statement carefully. Next, read each of the possible answers, determine which one is most correct. Then circle the answer on your answer sheet to indicate your selection. 1. The ozone layer is found in the... A. Ionosphere B. Biosphere C. Stratosphere D. None of the above 2. Technician "A" says the ozone layer is important to our daily lives. Technician "B" says the ozone layer filters out UV-B radiation. Who is correct? A. A only C. Both B. B only D. Neither 3. Destruction of the ozone layer may cause an increase in skin cancer. A. True B. False 4. Studies have shown that CFCs have been found in the stratosphere since? A B C D Technician "A" says volcanoes contribute to ozone depletion. Technician "B" says oceans contribute to ozone depletion. Who is correct? A. A only C. Both B. B only D. Neither 6. Technician "A" says CFCs contain chlorine atoms. Technician "B" says chlorine atoms destroy the ozone layer. Who is correct? A. A only C. Both B. B only D. Neither 7. Technician "A" says R-134a has an ozone depletion potential of zero. Technician "B" says R-134a contains chlorine atoms. Who is correct? A. A only C. Both B. B only D. Neither

33 8. Which of the following has one of the highest ozone depletion potentials? A. R-502 B. R-134a C. R-22 D. R Technician "A" says section 608 of the Clean Air Act pertains to the servicing of motor vehicle air conditioning. Technician "B" says section 609 of the Clean Air Act pertains to the servicing of motor vehicle air conditioning. Who is correct? A. A only C. Both B. B only D. Neither 10. Equipment used to service mobile air conditioning must be certified by... A. EPA B. UL or ETL C. ACOA D. MACS 11. Technician "A" says refrigerant recycling equipment must include desiccant to remove moisture. Technician "B" says refrigerant recycling equipment must include a moisture detection device. Who is correct? A. A only C. Both B. B only D. Neither 12. Technician "A" says you must be certified by an approved EPA technician certification program to service mobile air conditioning systems. Technician "B" says the service equipment must be approved by the EPA. Who is correct? A. A only C. Both B. B only D. Neither 13. Which of the following is true of a portable refillable tank used in mobile air conditioning service equipment? A. Must meet DOT standards B. Or be UL approved C. Must be retested every 5 years D. All of the above 14. Technician "A" says all flexible hoses must meet SAE J2196 specifications. Technician "B" says service hoses must have shutoff devices located within 12" from the connection point. Who is correct? A. A only C. Both B. B only D. Neither

34 15. During the recovery procedure, if a pressure is indicated after the service equipment is shut off for 5 minutes,... A. Further recovery is necessary until the system remains in a vacuum for 2 minutes B. Immediately close the service line valves and remove the lines from the vehicle C. Further recovery is necessary until the system remains in a vacuum for 5 minutes D. Leak test the system 16. Technician "A" says the storage tank can be checked at any time for noncondensables Technician "B" says the storage container must be stored at 65EF or above for 12 hours in order to check for noncondensables. Who is correct? A. A only C. Both B. B only D. Neither 17. If the storage container pressure is below the temperature pressure relationship chart for noncondensables, the refrigerant cannot be reused. A. True B. False 18. Recycled refrigerant must be stored in a DOT approved container of what color? A. Blue B. Green C. Red D. Gray/yellow top 19. Technician "A" says a storage container must be evacuated to 27" of vacuum prior to use. Technician "B" says a storage container must not be filled greater than 60% of its gross weight rating. Who is correct? A. A only C. Both B. B only D. Neither 20. Technician A says recycled HFC-134a refrigerant must meet SAE Standard J2099. Technician B says reclaimed CFC-12 refrigerant must meet ARI Standard A. A only C. Both B. B only D. Neither 21. All refrigerant must be recovered beginning on what date? A. November 15, 1995 B. August 13, 1992 C. January 1, 1992 D. January 1, Technician "A" says under the SNAP rule, when using blends that include HCFC-22, replace nonbarrier hoses with barrier hoses. Technician "B" says when retrofitting a system, that has a device to automatically release refrigerant to the atmosphere to prevent extremely high pressure, you must install a shutoff switch on the compressor. Who is correct? A. A only C. Both B. B only D. Neither

35 23. Technician "A" says the service fittings must be replaced when retrofitting a mobile air conditioning system. Technician "B" says the service fittings do not have to be replaced when retrofitting a mobile air conditioning system. Who is correct? A. A only C. Both B. B only D. Neither 24. Technician "A" says it is OK to apply direct flame to a refrigerant container. Technician "B" says it is OK to mix refrigerants in a container. Who is correct? A. A only C. Both B. B only D. Neither 25. Technician "A" says prolonged exposure to some refrigerant oils may be harmful. Technician "B" says it is OK to pressurize a R-134a system with air pressure to leak check it. Who is correct? A. A only C. Both B. B only D. Neither 26. "A" says you must be certified to purchase 20# containers of refrigerant. "B" says you must be certified to purchase any size container of refrigerant. Who is correct? A. A only C. Both B. B only D. Neither 27. SAE standard J1991 specifies that reclaimed CFC-12 should contain by weight no more than 4000ppm of oil, 15ppm of moisture and 330ppm of noncondensable gases. A. True B. False 28. "A" says you must file a statement with EPA listing the names of certified technicians in your shop. "B" says you must file a statement with EPA listing the serial number of your certified equipment. Who is correct? A. A only C. Both B. B only D. Neither 29. The process of topping-off a leaking A/C system is: A. Allowable everywhere in the U. S. B. Prohibited by the Clean Air Act C. Prohibited in all urban areas D. Allowable everywhere in the U. S., however, some states require leaks to be repaired before adding refrigerant to the system 30. What is the Standard for Automotive Refrigerant Recycling Equipment Intended for Use with Both CFC-12 and HFC-134a? A. SAE J1770 B. ARI Standard C. SAE J2099 D. SAE J1991

36 Universal Technical Institute Mobile Air Conditioning Certification Test Answer Sheet Please print legibly. The information will be used on your certification card. Social Security Number: - - Name: Last: First: MI Address: Street Apt# City State Zip Phone# ( )- - *No Personal Checks Accepted Payment Method: Money Order $15 enclosed Credit Card Visa or Master Card#: Expiration Date: I hereby acknowledge that I have read the Universal Technical Institute Mobile Air Conditioning Certification Training Manual for EPA 609 certification and have independently answered these questions. Signature: Please circle the correct answer on this answer sheet: 1. A B C D 8. A B C D 15. A B C D 22. A B C D 2. A B C D 9. A B C D 16. A B C D 23. A B C D 3. A B C D 10. A B C D 17. A B C D 24. A B C D 4. A B C D 11. A B C D 18. A B C D 25. A B C D 5. A B C D 12. A B C D 19. A B C D 26. A B C D 6. A B C D 13. A B C D 20. A B C D 27. A B C D 7. A B C D 14. A B C D 21. A B C D 28. A B C D 29. A B C D 30. A B C D Mail the answer sheet along with your money order for $15 or credit card information to: Universal Technical Institute ATTN: CTG/ W. Pierce St. Avondale, AZ Revised 1/17/2008