OVERVIEW OF THE CLEAN AIR ACT AMENDMENTS OF 1990

Transcription

1 OVERVIEW OF THE CLEAN AIR ACT AMENDMENTS OF 1990 In response to increase scientific evidence of significant ozone depletion, the land mark international environmental agreement, the Montreal Protocol on Substances that Delete the Ozone Layer, was signed in September The original Protocol called for 50 percent reduction in CFC s by the year The discovery of seasonal ozone hole over Antarctica highlighted the need for more stringent measures. In June 1990, the Protocol was amended to comply phaseout production CFC s halons (used in fire extinguisher by the year In November 1992, in response to scientific findings indicted that ozone depletion was more severe than anticipated, the parties to the Montreal Protocol voted to accelerate the phaseout to the end of Currently, 132 nations, representing over 95 percent of the worlds consumption of CFC s are parties to the Protocol. In addition to the phase out of ozone-depleting substances, title VI includes provisions to reduce emissions of all ozone-depleting substances. Section 608 contains requirements for a lowest achievable level of emissions of the controlled substances during use and disposal of appliances and industrial process refrigeration and bans on intentional venting at services and disposal. The requirements for auto technicians and the regulations they must follow when servicing an A/C unit are in Section 609 of the Act. Section 609 of the Clean Air Act of 1990 establishes an important new statutory structure to control the release of refrigerants from motor vehicle air conditioners into the atmosphere. After January 1, 1992, any person repairing or servicing motor vehicle air conditioners for consideration must properly use refrigerant recycling equipment that has been approved by the EPA. All such persons must be properly trained and certified. To obtain your certification, you must read and study the following booklet, including completing the test at the end of the booklet. The test will consist of 25 questions, and will be on the material covered in the booklet. You cannot miss more than five questions to pass. Should you have questions about the booklet, please call the Greater Cleveland Automobile Dealers' Association ( ).

2 WHAT IS THE OZONE Ozone is formed when ultraviolet radiation from the sun reacts with oxygen molecules which causes them to split apart into two oxygen atoms. These separated atoms then combine with other oxygen molecules (O2) to form ozone (O3), which contains a total of three oxygen atoms. Ozone is a pungent gas that has a close chemical relationship to molecular oxygen. About 90 percent of the earth s ozone is located in a layer far above the earth s surface in a region known as the stratosphere. This natural layer acts as a shield against ultraviolet radiation. Concern about possible depletion of the ozone layer from CFC s was first raised in 1974 with publication of research which theorized that chlorine released from CFC s could migrate to the stratosphere and destroy ozone molecules. (Molina and Rowland, 1974). Some of the CFC s have an atmospheric lifetime of more than 120 years and as a result, they rise slowly to the stratosphere where the Suns radiation strikes them, releasing chlorine. Once freed, the chlorine acts as a catalyst repeatedly combining with and breaking apart ozone molecules. If ozone depletion occurs, more UV radiation penetrates the earth s surface. Moreover, because of the long atmospheric lifetimes of CFC s, it would take many decades for the ozone layer to return to past concentrations. HOW IT EFFECTS THE ENVIRONMENT The ozone layer shielding the earth from much of the damaging part of the sun s radiation and is a critical resource safeguarding life on this planet. Should the ozone layer be depleted, more of the sun s damaging rays would penetrate to the earth s surface. It is believed that for each one percent depletion exposure to damaging ultraviolet radiation would increase by 1.5 to 2 percent. The Environmental Protection Agency s (EPA) assessment of the risks from ozone depletion focused on the following areas: *Increases in skin cancers *Suppression of the human immune response system *Increases in cataracts *Damage to crops *Damage to aquatic organisms *Increases in ground level ozone *Increased global warming

3 HOW IT EFFECTS THE HUMAN HEALTH Under current atmospheric conditions, the greater the distance from the equator, the greater the effectiveness of the ozone layer as a shield. As a result, people who live further north are exposed to less damaging UV radiation than those residing closer to the equator. Not surprisingly, the chances of getting skin cancer follow the same gradient; the closer to the equator, the greater the risk. Three distinct types of the skin cancer would increase if the ozone layer is depleted. Basal and squamous cell skin cancers, the two most common types, affect about 500,000 people annually in the United States alone. If detected early, these cancers are treatable. Even so, approximately 1 percent of cases result in premature deaths. Malignant melanoma is far less common but substantially more harmful. About 25,000 cases now occur annually resulting in 5,000 deaths. Cataracts cloud the lens of the eye, thus limiting vision. Although cataracts develop for a variety of reasons, scientific evidence supports the conclusion that increased exposure to UV radiation would increase the number of people experiencing this eye disorder. Based on epidemiological studies, if current trends in the use of ozone depleting gases continued, the number of cataract cases would increase by 16 million (for the population alive today or born before 2075). Suppression of the immune system is another possible threat to human health resulting from ozone depletion. HOW IT EFFECTS PLANT & MARINE LIFE Crop and other land based ecosystems could also be adversely affected by increased exposure to UV radiation. In studies of the greenhouse effect, approximately 65 percent of the crops exposed to elevated levels of UV radiation proved sensitive. Certain marine organisms, particularly phytoplankton, may be sensitive to increased exposure to UV radiation because they spend much their existence near the surface of the water. Other Considerations: Ground Level Ozone - Ozone depletion in the stratosphere would increase the rate of formation of ground level (tropospheric) ozone, due to higher levels of UV radiation, a major component of what is commonly called smog. Degradation of Polymers - Ozone depletion would accelerate the breakdown (i.e. chalking, yellowing, and cracking) of plastics used in outdoor applications. Climatic Changes - CFC s are greenhouse gases and thus would contribute to global warming and rising sea levels.

4 THE GLOBAL CONCERN ON THE OZONE Unlike other environmental issues, stratospheric ozone protection is a global concern. CFC s and halons are used by most industrialized nations, and, given their long atmospheric lifetimes, they become widely distributed over time. As a result, the release of these chemicals in one country could adversely affect the stratosphere and therefore the health and welfare of other countries. Many developed and developing countries produce CFC s and halons. Most use the chemicals in a variety of different products. The United States is one of the largest consumers of the world s CFC s. Other nations are also significant users. Therefore, to protect the ozone layer from the damages that may be caused by CFC s and halons, an international solution is critical. OPTIONS OF TOPPING OFF LEAKING SYSTEM Since Section 609 of the Federal Clean Air Act of 1990 came into affect, their has been some confusion on whether it is legal to top of a leaking air conditioning system. Although the EPA encourages, but does not mandate, leak detection and repair of air conditioners systems, it is essential that consumers realize that, in most states and localities, they have the option to top off their air conditioning systems with freon. THE RECYCLING CONCEPT FIELD STUDY: Due to the serious nature of the ozone depletion issue, industry efforts were immediately directed toward determining if CFC s used in the mobile air conditioning service industry could be recycled. During the summer of 1988, the EPA, with the support of the Mobile Air Conditioning Society (MACS) initiated a sampling program of used refrigerant from 227 vehicles from 4 regions of the country. These vehicles included properly operating systems, failed compressors, low mileage vehicles, and vehicles with over 100,000 miles. The chemical analysis of the removed refrigerant indicated a low amount of contamination. From the field study results, the task force established specifications for recycled refrigerant and requested the world auto manufacturers to approve the level of purity in December, Many automobile and truck manufacturers have accepted recycled CFC-12 for service and warranty repairs.

5 SYSTEM CONTAMINANTS: Data gleaned from the field study of CFC-12 from mobile air conditioning systems identified moisture, refrigerant oil and non-condensable gases (air) as contaminants in used refrigerant that could affect system performance and life. A consensus was achieved establishing the standard of purity for recycled R-12 refrigerant. Recycled refrigerant may not contain impurities that exceed the level specified by SAE J1991: *Moisture: 15 PPM by weight, *Refrigerant oil: 4000 PPM by weight, *Non-condensable gases (air): 330 PPM by weight. STANDARDS DEVELOPED: Based on the field study, the Society of Automotive Engineer s R-12 task force published three documents to cover the mobile air conditioning industry use of CFC s. The documents include: *SAE J1989: Service Procedures. (On Page 9) *SAE J1990: Specifications for Recycling Equipment. (On Page 12) *SAE J1991: Purity Requirement of Recycled Refrigerant. (On Page 15) WHY WE MUST RECYCLE: With over 65.8% of the CFC-12 used in the mobile air conditioning industry being used for service, current practices that involve venting to atmosphere can no longer be considered acceptable. This includes the addition of CFC s to systems that have leaks and are not repaired prior to recharge, and charging equipment that requires venting to fill the measuring device. Proper procedures for containment of CFC s during service and proper disposal of residual from containers prior to disposal are covered in SAE J1989. From limited information presently available, service facilities that have used recycling equipment during the summer of 1989 have realized approximately a 50% reduction in CFC-12 usage. If the sale of CFC s were limited to facilities that have trained personnel and certified recycling equipment, a major reduction of CFC usage could be attained. It is important that CFC-12 be available beyond the year 2000 to assure that vehicles produced with CFC-12 can be serviced for the life expectancy of the vehicle. Without CFC-12 for service in the time period, conversion or obsolescence of vehicles will result in a major economic impact for the owners. Although the mobile air conditioning industry is scheduled to phase in HFC-134a in the mid-1990 s, CFC-12 systems will still be produced before then. With a 5 to 10 year vehicle life expectancy, CFC-12 will be required for service well beyond the year If CFC-12 is not available for service, the consumer will have to choose whether to convert to a new refrigerant, to

6 purchase a new vehicle with HFC-134a, or to do without air conditioning. Controlled sale of CFC s, proper repair of leaking systems, and recycling of existing CFC s are required to assure consumers the use of their air conditioning systems beyond the year With elective controls of CFC supplies and mandatory recycling at all servicing levels, the auto industry can effect a major reduction of new CFC-12 production requirements in the mid-1990 s. SAE J1989 Issued October 1989 RECOMMENDED SERVICE PROCEDURE FOR THE CONTAINMENT OF R-12 A. SCOPE: During service of mobile air-conditioning systems, containment of the refrigerant is important. This procedure provides service guidelines for technicians when repairing vehicles and operating equipment defined in SAE J1990. B. REFERENCES: SAE J1990, Extraction and Recycle Equipment for Mobile Automotive Air-Conditioning Systems C. REFRIGERANT RECOVERY PROCEDURE: a- Connect the recovery unit service hoses, which shall have shut off valves within 12 inches (30 cm) of the service ends, to the vehicle air-conditioning system service ports. b- Operate the recovery equipment as covered by the equipment manufacturers recommended procedure. 1- Start the recovery process and remove the refrigerant from the vehicle AC system. Operate the recovery unit until the vehicle system has been reduced from a pressure to a vacuum. With the recovery unit shut off for at least 5 minutes, determine that there is no refrigerant remaining in the vehicle AC system. If the vehicle system has pressure, additional recovery operation is required to remove the remaining refrigerant. Repeat the operation until the vehicle AC system vacuum level remains stable for 2 minutes. c- Close the valves in the service lines and then remove the service lines from the vehicle system. Proceed with the repair/service. If the recovery equipment has automatic closing valves, be sure they are properly operating.

7 D. SERVICE WITH MANIFOLD GAGE SET: a- Service hoses must have shut off valves in the high, low, and center service hoses within 12 inches (30 cm) of the service ends. Valves must be closed prior to hose removal from the air-conditioning system. This will reduce the volume of refrigerant contained in the service hose that would otherwise be vented to atmosphere. b- During all service operations, the valves should be closed until connected to the vehicle air conditioning system or the charging source to avoid introduction of air and to contain the refrigerant rather than vent open to atmosphere. c- When the manifold gage set is disconnected from the air conditioning system, or when the center hose is moved to another device which cannot accept refrigerant pressure, the gage set hoses should first be attached to the reclaim equipment to recover the refrigerant from the hoses. TABLE 1 TEMP F PSIG TEMP F PSIG TEMP F PSIG TEMP F PSIG TEMP F PSIG

8 TABLE 1 (Metric) TEMP C PRES TEMP C PRES TEMP C PRES TEMP C PRES TEMP C PRES PRES kg/sq cm e- If the container pressure is less than the Table 1 values and has been recycled, limits of noncondensable gases (air) have not been exceeded and the refrigerant may be used. f- If the pressure is greater than the range and the container contains recycled material, slowly vent from the top of the container a small amount of vapor into the recycle equipment until the pressure is less than the pressure shown on Table 1. g- If the container still exceeds the pressure shown on Table 1, the entire contents of the container shall be recycled. F. CONTAINERS FOR STORAGE OF RECYCLED REFRIGERANT: a- Recycled refrigerant should not be salvaged or stored in disposable refrigerant containers. This is the type of container in which virgin refrigerant is sold. Use only DOT CFR Title 49 or UL approved storage containers for recycled refrigerant. b- Any container of recycled refrigerant that has been stored or transferred must be checked prior to use as defined in Section E.

9 G. TRANSFER OF RECYCLED REFRIGERANT: a- When external portable containers are used for transfer, the container must be evacuated to at least 27 inches of vacuum (75 mm Hg absolute pressure) prior to transfer of the recycled refrigerant. External portable containers must meet DOT and UL standards. b- To prevent on-site over filling when transferring to external containers, the safe filling level must be controlled by weight and must not exceed 60% of container gross weight rating. H. DISPOSAL OF EMPTY/NEAR EMPTY CONTAINERS: a- Since all the refrigerant may not be removed from disposable refrigerant containers during normal system charging procedures, empty/near empty container contents should be reclaimed prior to disposal of the container. b- Attach the container to the recovery unit and remove the remaining refrigerant. When the container has been reduced from a pressure to a vacuum, the container valve can be closed. The container should be marked empty and is ready for disposal.

10 APPLICATION: During service of mobile air-conditioning systems, containment of the refrigerant is important. This procedure provides service guidelines for technicians when repairing vehicles and operating equipment defined in SAE J1990. Overview of SAE J1990 EXTRACTION AND RECYCLE EQUIPMENT FOR MOBILE AUTOMOTIVE AIR-CONDITIONING SYSTEMS A. SCOPE: The purpose of this document is to provide equipment specifications for CFC-12 (R-12) recycling and/or recovery, and recharging systems. This information applies to equipment used to service automobiles, light trucks, and other vehicles with similar CFC-12 systems. Systems used on mobile vehicles for refrigerated cargo that have hermetically sealed systems are not covered in this document. B. REFERENCES: SAE J51, Automotive Air-Conditioning Hose SAE J1991, Standard of Purity for Use in Mobile Air-Conditioning Systems UL 1963 Section 40 Tests Service Hoses for Refrigerant-12 (Underwriters Laboratories) Pressure Relief Device Standard Part 1 - Cylinders for Compressed Gases, LGA Pamphlet S-1.1 C. SPECIFICATION AND GENERAL DESCRIPTION a- The equipment must be able to extract and process R-12 from mobile airconditioning systems to purity levels specified in SAE J1991 b- The equipment shall be suitable for use in an automotive service garage environment as defined in 7.8. c- The equipment must be certified by Underwriters Laboratories or an equivalent certifying laboratory. D. REFRIGERATION RECYCLE EQUIPMENT REQUIREMENTS:

11 a- Moisture and Acid: The equipment shall incorporate a desiccant package that must be replaced before saturated with moisture and whose acid capacity is at least 5% by weight of total system dry desiccant. 1- The equipment shall be provided with a moisture detection means that will reliably indicate when moisture in the R-12 exceeds the allowable level and requires the filter/dryer replacement. b- Filter: The equipment shall incorporate an in-line filter that will trap particulates of 15 um spherical diameter or greater c- Noncondensable Gas: 1- If the equipment has a self-contained recovery tank, a device is required to alert the operator that the noncondensable level has been exceeded. 2- Transfer of Recycled Refrigerant: Recycled refrigerant, for recharging and transfer shall be taken from the liquid phase only. E. SAFETY REQUIREMENTS: a- The equipment must comply with applicable federal, state and local requirements on equipment related to the handling of R-12 material. Safety precautions or notices related to the safe operation of the equipment shall be prominently displayed on the equipment and should also state Caution Should Be Operated By Qualified Personnel. F. OPERATING INSTRUCTIONS: a- The equipment manufacturer must provide operating instructions, necessary maintenance procedures, and source information for replacement parts and repair. b- The equipment must prominently display the manufacturer s name, address and any items that require maintenance or replacement that affect the proper operation of the equipment. Operation manuals must cover information for complete maintenance of the equipment to assure proper operation.

12 G. FUNCTIONAL DESCRIPTION: a- The equipment must be capable of ensuring recovery of the R-12 from the system being serviced, by reducing the system to a vacuum. b- To prevent overcharge, the equipment must be equipped to protect the tank used to store the recycled refrigerant with a shut off device and a mechanical pressure relief valve. c- Portable refillable tanks or containers used in conjunction with this equipment must meet applicable Department of Transportation (DOT) or Underwriters laboratories (UL) Standards and be adaptable to existing refrigerant service and charging equipment. d- During the recovery and/or recycle, the equipment must provide over fill protection to assure that during filling or transfer, the tank or storage container cannot exceed 80% of volume at 70 F (21.1 C) of its maximum rating as defined by DOT standards, CFR Title 49 Part/Section and American Society of Mechanical Engineers. 1- Additional Storage Tank Requirements: a- The cylinder valve shall comply with the standard for cylinder valves, UL b- The pressure relief device shall comply with the Pressure Relief Device Standard Part c- The tank assembly shall be marked to indicate the first retest date, which shall be 5 years after date of manufacture. The marking shall indicate that retest must be performed every subsequent 5 years. The marking shall be in letters at least 1/4 in. high. e- All flexible hoses must meet SAE J51 or UL 1963 Section 40. f- Service hoses must have shut off devices located within 12 inches (30 cm) of the connection point to the system being serviced to minimize introduction of noncondensable gases into the recovery equipment and the release of the refrigerant when being disconnected. g- The equipment must be able to separate the lubricant from recovered refrigerant and accurately indicate in 1 oz units (28 grams).

13 h- The equipment must be capable of continuous operation in ambient of 50 to 120 F (10 to 49 C). j- The equipment must be compatible with leak detection material that may be present in the mobile AC system. H. TESTING This test procedure and the requirements are used for evaluation of the equipment for its ability to clean the contaminated R-12 refrigerant. a- The equipment shall clean the contaminated R-12 refrigerant to the minimum purity level as defined in SAE J1991, when tested in accordance with the following conditions: b- For test validation, the equipment is to be operated according to the manufacturer s instructions. c- The equipment must be preconditioned. d- Contaminated R-12 Samples: 1- Standard contaminated R-12 refrigerant shall consist of liquid R-12 with 100 ppm (by weight) moisture at 70 F and 45,000 ppm (by weight) mineral oil 525 suspension viscosity nominal and 770 ppm by weight of noncondensable gases (air). 2- High moisture contaminated sample shall consist of R-12 vapor with 1,000 ppm (by weight) moisture. 3- High oil contaminated sample shall consist of R-12 with 200,000 ppm (by weight) mineral oil 525 suspension viscosity nominal. e- Test Cycle: 1- After preconditioning as stated in H.c, the test cycle is started, processing the following contaminated samples through the equipment: f- Equipment Operating Ambient: g- Sample Analysis: h- Quantitative Determination of Moisture: j- Determination of Percent Oil:

14 k- Noncondensable Gas: l- Sample Requirements: J. DATE OF EFFECTIVENESS: This recommended practice will become a standard after one year. APPLICATION: The purpose of this document is to provide equipment specifications for CFC-12 (R-12) recycling and/or recovery, and recharging systems. This information applies to equipment used to service automobiles, light trucks and other vehicles with similar CFC-12 systems. Systems used on mobile vehicles for refrigerated cargo which have hermetically sealed systems are not covered in this document. Overview of SAE J1991 STANDARD OF PURITY FOR USE IN MOBILE AIR-CONDITIONING SYSTEMS A. SCOPE: This information applies to refrigerant used to service automobiles, light trucks, and other vehicles with similar CFC-12 systems. Systems used on mobile vehicles for refrigerated cargo that have hermetically sealed, rigid pipe are not covered in this document. B. REFERENCES: SAE J1989, Recommended Service procedure for the Containment of R-12 SAE J1990, Extraction and Recycle Equipment for Mobile Automotive Air- Conditioning Systems ARI Standard

15 C. PURITY SPECIFICATION: The refrigerant in this document shall have been directly removed from, and intended to be returned to, a mobile air-conditioning system. The contaminants in this recycled refrigerant 12 shall be limited to moisture, refrigerant oil, and noncondensable gases, which shall not exceed the following level: a- Moisture: 15 ppm by weight. b- Refrigerant Oil: 4000 ppm by weight. c- Noncondensable Gases (Air): 330 ppm by weight. D. REFRIGERATION RECYCLE EQUIPMENT USED IN DIRECT MOBILE AIR-CONDITIONING SERVICE OPERATIONS REQUIREMENT: a- The equipment shall meet SAE J1990, which covers additional moisture, acid, and filter requirements. b- The equipment shall have a label indicating that it is certified to meet this document. E. PURITY SPECIFICATION OF RECYCLED R-12 REFRIGERANT SUPPLIED IN CONTAINERS FROM OTHER RECYCLE SOURCES: Purity specification of recycled R-12 refrigerant supplied in container from other recycle sources, for service of mobile air-conditioning systems, shall meet ARI Standard (Air Conditioning and Refrigeration Institute). F. OPERATION OF THE RECYCLE EQUIPMENT: This shall be done in accordance with SAE J1989. APPLICATION: This information applies to refrigerant used to service automobiles, light trucks, and other vehicles with similar CFC-12 systems. Systems used on mobile vehicles for refrigerated cargo that have hermetically sealed, rigid pipe are not covered in this document.

16 HFC-134a (R-134a) SERVICE HOSE FITTINGS FOR AUTOMOTIVE AIR- CONDITIONING SERVICE EQUIPMENT Foreword-The purpose of this SAE Standard is to establish specific but unique fittings for service equipment used in maintaining HFC-134a (R-134a) systems. This is necessary to avoid cross mixing of refrigerant and lubricants from CFC based systems. This applies only to systems specifically designed for or retrofitted to R-134a. Hermetically sealed appliances and refrigerated cargo systems are not covered by this document. 1. Scope 1.1 This SAE Standard covers fittings intended for connecting service hoses, per SAE J2196, from Mobile Air-Conditioning Systems to service equipment such as manifold gauges, vacuum pumps and air-conditioning charging, recovery and recycling equipment. (Figure 1) 1.2 Due to similarities between English and metric thread sizes a single, unique ACME thread fitting is specified. This fitting was recommended by the Compressed Gas Association(CGA), Connection Standards Committee Task Force as one which could be qualified to meet their requirements for use and safety in a time frame consistent with the introduction of R-134a. It was selected because its unique design would reduce the likelihood of cross-treading services hoses on R-12/R-134a refrigerant storage containers and service equipment. 1.3 The high and low pressure hose in J2196 requires the charge coupling (used to connect service hoses to vehicle access ports) to be an integral part of the hose assembly. To allow removal of the hose from the coupling for hose replacement only, a two-piece construction with a wrench tight connection is permitted. Specifications covering this fitting are provided. 2. References 2.1 Applicable Documents-The following publications form a part of this specification to the extent specified herein. The latest issue of SAE Publications shall apply SAE Publications-Available from SAE, 400 Cpmmpnwealth Drive, Warrendale, PA SAE J639-Vehicle Service Coupling SAE J2196-Service Hose for Automotive Air Conditioning SAE J2210-HFC-134a Recycling Equipment fro Mobile Air-Conditioning Systems

17 2.1.2 ARI Publications-Available from Air Conditioning and Refrigeration Institute, 1501 Wilson Boulevard, Sixth Floor, Arlington, VA ARI 720-Refrigerant Access Valves and Hose Connectors SAE Technical Standards Board Rules provide that: This report is published by SAE to advance the state of technicial and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including and patent infringement arising therefrom, is the sole responsibility of the user. SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 1992 Society of Automotive Engineers, Inc. All rights reserved. Reprinted with permission from SAE J Society of Automotive Enguneers, Inc. SAE J2197 Issued JUN92 3. Specification and Application Description on x 16-2G ACME-Right Hand Thread Cylinder Valve Outlet Connection-Compressed Gas Association, Inc. Connection No (Figure 2) The Connection shall be used on all R-134a refrigerant storage containers liquid and vapor outlet connections. It will also be used for all R-134a service equipment including manifold guage hose connections, utility hose connection to the vacuum pump, and charging, recovery and recycling equipment as defined in SAE J Aoolications which will require the use of valve cores should locate the valve core in accordance with ARI M14 x 1.5-6G right hand thread, SAE Hose Barb connection. (Figure 3) Limited Standard Cylinder Valve Outlet Connection For Pressures Up To 500 PSIG (3450 kpa) For Tetrafluoroethane (R-134a) Automotive Use Figure in-16-acme-2g-rh-ext

18 3.2.1 This fitting may be used as an option to a nonserviceable connection of the charge coupling to the service hose assembly and will require a secure, wrench tight connection. 4. Functional Description 4.1 The high pressure hose assembly shall meet SAE J2196 requirements and will be terminated at one end with the in x 16-ACME threaded nut. The other end will be permanently attached to the SAE J639 service charge coupling or terminated with the optional M14 x 1.5-6G external thread/male hose barb fitting. SAE J2197 issued JUN92 Figure 3 -- SAE HOSE BARB R-134a SERVICE ADAPTER 4.2 The low pressure hose assembly shall meet SAE J2196 requirements and will be terminated at one end with the in x ACME threaded nut. The other end will be permanently attached to the SAE J639 service charge coupling or terminated with the optional M14 x 1.5-6G external thread/male hose barb fitting. 4.3 The utility hose shall meet SAE J2196 requirements and will be terminated at both ends using o.500 in x ACME threaded nut. 4.4 Manifold Gauge Assembly shall require three or four in x ACME male threaded connections. 4.5 Containers disposable or refillable shall require in x ACME male threaded connections with shut off valves. 4.6 Refrigerant recovery, charging stations and stand-alone vacuum pumps shall require in x ACME male threaded connection unless an internal, nonserviceable connection is made by the equipment manufacturer. 4.7 High and low pressure charge couplings shall be constructed with an internal, M14 x 1.5-6H right hand thread connection as an option to attaching the hose assembly with a nonserviceable connection. (Figure 4)

19 5. Testing -- This test procedure is for the qualisae J2197 issued JUN92 Figure 4 -- SAE SPUD R-134a SERVICE ADAPTER 5.1 Determine the minimum torque necessary for a gas tight shutoff between the nippie and valve body at a gas pressure equal to the maximum rated working pressure per SAE J2196. For cycling purposes, twice this shutoff torque will be used to simulate normally applied field torque. 5.2 Cycling is to be conducted at atmospheric pressure, since that is the pressure at which connections are normally made. 5.3 Before and after cycling, measurements of the connection shall be recorded (Such as threaded elements, nipple bore diameters, and any other dimensions that may be subject to change) due to repeated tightenings. 5.4 Each connection is to be cycled 500 times with tightening to the torque determined in 5.1. Once cycle consists of tightening to the predetermined torque and then loosening to, at most, finger tight. 5.5 After each 100 cycles, the torque required to achieve gas tight shutoff at test pressure shall be recorded to determine if there is any abnormal torque buildup in shutoff requirements. The measurements indicated in 5.3 shall also be recorded at this interval to determine if there is any abnormal deformation of parts. 5.6 Each connection shall be subjected to a hydrostatic test and must withstand a pressure of at least 4 times the maximum rated working pressure per SAE J2196 without structure failure. 5.7 After completion of the previous tests, the results will be recorded on a suitable test report form which will be kept on file at the Compressed Gas Association office. air- fication of new connection fir R-134a automotive conditioning system service equipment. SAE J2197 issued JUN92

20 5.7.1 Testing of either a left hand or right hand connection of identical design (except for thread direction automatically qualifies the untested connection of the opposite thread direction. (The direction of the thread does not effect the structural integrity of the design.) PREPARED BY THE SAE INTERIOR CLIMATE CONTROL STANDARDS COMMITTEE Rationale -- Not applicable. J2197 JUN92 Relationship of SAE Standard to ISO Standard -- No applicable. Application -- This specification covers fittings intended for connection service hoses, per SAE J2196, from Mobile Air-Conditioning Systems to service equipment such as manifold gauges, vacuum pumps and air conditioning charging, recovering and recycling equipment. Reference Section SAE J Vehicle Service Coupling SAE J Service Hose for Automotive Air Conditioning SAE J HFC-134a Recycling Equipment for Mobile Air- Conditioning Systems ARI Refrigerant Access Valves and Hose Connectors Committee Composition Developed by the SAE Interior Climate Control Standards Committee W. J. Atkinson, Sun Test Engineering, Scottsdale, AZ -- Chairman A. Abraham, Arlington, TX G. Ambrozaitis, Mercedes Benz of North America, Montvale, NJ H. S. Andersson, Saab Automotive AB, Sweden P. E. Anglin, ITT Higbie Baylock, Auburn Hills, MI J. A. Baker, General Motors Corporation, Lockport, NY D. J. Bateman, Dupont Company, Wilmington, DE D. W. Berry, ICI Americas Inc., Wilmington, DE D. B. Chichester, Aeroquip Corporation, Jackson, MI R. K. D Amico, Nissan R & D, Farmington Hills, MI J. G. Dodsworth, Jaguar Cars Ltd, Coventry, England

21 J. J. Elias, General Motors Corporation, Warren, MI K. J. Fouts, Acustar Chrysler Motors, Dayton, OH P. C. George, Pince Corporation, Holland, MI L. K. Gronlund, BMW of North America Inc., Montvale, NJ J. J. Hernandez, Navistar, Fort Wayne, IN S. D. Jones, Caterpillar Inc., Peoria, IL M. G. Malloy, M. G. Malloy & Associates, Ontario, Canada K. W. Manz, SPX Corporation, Montpelier, OH R. McClelland, K-Whit Tools Inc., Fishers, IN J. H. McCorkel, Freightliner Corporation, Portland, OR C. J. McLachlan, Ford Motor Company, Dearborn, MI H. L. Miner, Climate Control Inc., Decatur, IL D. J. Nelson, Dana Corporation, South Beloit, IL N. Novak, Chrysler Corporation, Detroit, MI S. Oulouhojian, Mobile Air Conditioning Society, Upper Darby, PA A. P. Patti, Chrysler Corporation, Detroit, MI Developed by the SAE Interior Climate Control Standards Committee (continued) A. N. Reginaldo, Toyota Technical Center USA, Torrance, CA S. Swerhun, Sun Electric Corporation, Crystal Lake, IL J.P. Telesz, General Motors Corporation, Lockport, NY C. Wojdyla, Paccar Technicial Center, Mount Vernon, WA RECOMMENDED SERVICE PROCEDURE FOR THE CONTAINMENT OF HFC-134a 1. Scope-Refrigerant containment is an important part of servicing mobile air-conditioning systems. This procedure provides guidelines for technicians for servicing mobile airconditioning systems and operating refrigerant recycling equipment designed for HFC-134a (described in SAE J2210). 2. References 2.1 Applicable Documents-The following publications form a part of this specification to the extent specified herein, The latest issue of SAE publications shall apply SAE Publications-Available from SAE, 400 Commwealth Drive, Warrendale, PA SAE J2196-Service Hoses for Mobile Air-Conditioning Systems SAE J2197-Service Hose Fittings for Automotive Air-Conditioning SAE J2210-Refrigerant Recycling Equipment for HFC-134a Mobile Air- Conditioning Systems

22 SAE J2219-Concerns to the Mobile Air-Conditioning Industry 2.2 Definitions RECOVERY/RECYCLING (R/R) UNIT-Refers to a single piece of equipment that performs both functions of recovery and recycling of refrigerants per SAE J RECOVERY-Refers to that portion of the R/R unit operation that removes the refrigerant from the mobile air-conditioning system and places it in the R/R unit storage container RECYCLING-Refers to that portion of the R/R unit operation that processes the refrigerant for reuse on the same job site to the purity specifications of SAE J Service OProcedure 3.1 Connect the recycling unit service hoses, which shall have shutoff devices (e.g., valves) within 30 cm (12 in) of the service ends, to the vehicle air-conditioning (A/C) service ports. Hoses shall conform to SAE J2196 and fittings shall conform to SAE J Operate the recycling equipment per the equipment manufacturer s recommended procedure Verify that the vehicle A/C system has refrigerant pressure. Do not attempt to recycle refrigerant from a discharged system as this will introduce air (noncondensable gas) into the recycling equipment which must later be removed by purging Begin the recycling process by removing the removing the refrigerant from the vehicle A/C system. Continue the process until the system pressure has been reduced to a minimum of 102 mm (4 in) of Mercury below atmospheric pressure (vacuum). If A/C components show evidence of icing, the component can be gently heated to facilitate refrigerant removal. With the recycling unit shut off for at least SAE Technical Standards Board Rules provide that: This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including and patent infringement arising therefrom, is the sole responsibility of the user.

23 SAE review each technical report at least every five years atwhich time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 1991 Society of Automotive Engineers, Inc. All rights reserved. Reprinted with permission from SAE J Society of Automotive Engineers, Inc. 5 min. check A/C system pressure. If this pressure has risen above vacuum (0 psig), additional recycler operation is required to remove the remaining refrigerant. Repeat the operation until the system pressure remains stable at vaccuum for 2 min. 3.3 Close the valves in the service lines and then remove the service lines from the vehicle system. If the recovery equipment has automatic closing valves, be sure they are operating properly. Proceed with the repair/service. 3.4 Upon completion of refrigerant removal from the A/C system, determine the amount of lubricant removed during the process and replenish the system with new lubricant, which is identified on the A/C system label. Used lubricant should be discarded per applicable federal, state, and local requirements. 4. Service with a Manifold Gauge Set 4.1 High-side, low-side, and center services hoses must have shutoff devices (e.g. valves) within 30cm (12 in) of the service ends. Valves must be closed prior to hose removal from the A/C system to prevent refrigerant loss to the atmosphere. 4.2 During all service operations, service hose valves should be closed until connected to the vehicle A/C system or to the charging source to exclude air and/or contain the refrigerant. 4.3 When the manifold gauge set is disconnected from the A/C system, or when the center hose is moved to another device that cannot accept refrigerant pressure, the gauge set hoses should be attached to the recycling equipment to recover the refrigerant from the hoses. 5. Supplemental Refrigerant Checking Procedure for Stored Portable Containers

24 5.1 Certified recycling equipment and the accompanying recycling procedure, when properly followed, will deliver use-ready refrigerant. In the event that the full recycling procedure was not followed or the technician is unsure about the noncondensable gas content of a given tank refrigerant, this procedure can be used to determine whether the recycled refrigerant container meets the specification for boncondensable gases (air). NOTE: The use of refrigerant with excess air will result in higher system operating pressures and may cause A/C system damage. 5.2 The container must be stored at a temperature of 18.3 C (65 F) or above for at least 12 h, protected from direct sunlight. 5.3 Install a calibrated pressure gauge, with 6.9 kpa (1 psig) divisions, on the container and read container pressure. 5.4 With a calibrated thermometer, measure the air temperature within 10 cm (4 in) of the container surface. 5.5 Compare the onserved container pressure and air temperature to the values given in Tables 1 and 2 to determine whether the container pressure is below the pressure limit given in the Table. For example, at an air temperature of 21 C (70 F), the container pressure must not exceed 524 kpa (76 psig). 5.6 If the refrigerant in the container has been recycled and the container pressure is less than the limit in Tables 1 and 2, the refrigerant may be used. 5.7 If the refrigerant in the container has been recycled and the container pressure exceeds the limit in Tables 1 and 2, slowlyvent, from the top of the container, a small amount of vapor into the recycle equipment until the pressure is less than the pressure shown in Tables 1 and 2. CFC-12 (R-12) EXTRACTION EQUIPMENT FOR MOBILE AUTOMOTIVE AIR-CONDITIONING SYSTEMS J2209 of Foreword - CFC s deplete the stratospheric ozone layer that protects the earth against harmful ultraviolet radiation. To reduce the emissions of CFC s the 1990 Clean Air Act requires recycle of CFC-12 (R-12) used in mobile air-conditioning systems to eliminate system venting during service opera- tions. SAE

25 provide service facilities with equipment to assure that venting of refrigerant will not occur. 1. Scope - The purpose of this SAE Recommended Practice is to provide equipment specifications for CFC-12 (R-12) recovery for return to a refrigerant reclamation facility that will process it to ARI standard as a minimum (Air Conditioning and Refrigerant Institute). It is not acceptable that the refrigerant removed from a mobile air-conditioning system, with this equipment, be directly returned to a mobile airconditioning system. 2. References 2.1 Applicable Documents - The following documents form a part of this specification to the extent specified herein. The latest issue of SAE publications shall apply SAE Publications - Available from SAE, 400 Commonwealth Drive, SAE J639 - Vehicle Service Coupling SAE J Extraction and Recycle Equipment for Mobile Automotive Air- Conditioning System SAE J Service Hose for Automotive Air Conditioning ARI Publications - Available from Air Conditioning and Refrigeration Institute, 1501 Wilson Boulevard, Sixth Floor, Arlington, VA ARI Specifications for Fluorocarbon Refrigerants CGA Publications - Available from CGA, Crystal Gateway #1, Suite 501, 1235 Jefferson Davis Highway, Arlington, VA CGA S Pressure Relief Device Standard Part 1 - Cylinders for Compressed Gases DOT Specifications - Available from the Superintendent of Documents, U.S. Government Print ing Office, Washington, DC CFR 49, Section Shippers - General Requirements for Shipments and Packaging UL Publications - Available from Underwriters Laboratories, 333 Pfingsten Road, Northbrook, IL UL Cylinder Valves 3. Specifications and General Description

26 3.1 The equipment must be able to extract R-12 from a mobile airconditioning system. 3.2 The equipment discharge or transfer fitting shall be unique to prevent the unintentional use of ex- tracted R-12 to be used for recharging auto air conditioners. 3.3 The equipment shall be suitable for use in an automotive service garage environment as defined in figure Equipment Certification - The equipment must be certified by Underwriters Laboratories or an equivalent certifying laboratory to meet SAE J Label Requirements - The equipment shall have a label Design Certified by (Company name) to meet SAE J2209 for use with R-12. The refrigerant from this equipment must be processed to ARI specification before reuse in a mobile air-conditioning system. The minimum letter size shall be bold type 3 mm in height. 4. Safety Requirements 4.1 The equipment must comply with applicable federal, state, and local requirements on equipment related to the handling of R-12 material. Safety precautions or notices, label, related to the safe operation of the equipment shall also be prominently displayed on the equipment and should also state CAUTION - SHOULD BE OPERATED BY CERTIFIED PERSONNEL. The safety identification shall be located on the front near the controls. 4.2 The equipment must comply with applicable safety standards for electrical and mechanical require ments. 5. Operating Instructions 5.1 The equipment manufacturer must provide operating instructions, necessary maintenance proce- dures, and source information for replacement parts and repair. 5.2 The equipment must prominently display the manufacturer s name, address, and any items that re- quire maintenance or replacement that affect the proper operation of the equipment. Operation manuals must cover information for complete maintenance of the equipment to assure proper operation.

27 6. Functional Description 6.1 The equipment must be capable of ensuring recovery of the R-12 from the system being serviced, by reducing the system pressure to a minimum of 102 mm of mercury below atmospheric. To pre- vent system delayed outgassing, the unit must have a device that assures that the refrigerant has been recovered from the air-conditioning system Testing laboratory certification of the equipment capability is required which shall process con- taminated refrigerant samples at specific temperatures. 6.2 The equipment must be preconditioned with 13.6 kg of the standard R-12 at an ambient of 21 degrees Celsius before starting the test cycle. Sample amounts are not to exceed 1.13 kg with sample amounts to be repeated every 5 minutes. The sample method fixture defined in SAE J1990 (Figure 1) shall be operated at 24 degrees Celsius. Contaminated R-12 samples shall be processed at ambient temperatures of 10 and 49 degrees Celsius Contaminated R-12 sample Standard contaminated R-12 refrigerant, 13.6 Kg sample size, shall consist of liquid R-12 with 100 ppm (by weight) mineral oil noncondensable gases (air). 6.3 Portable refillable containers used in conjunction with this equipment must meet appli- cable DOT standards The container color must be gray with yellow top to identify to identify that it contains used R- 12 refrigerant. It must be permanently marked on the outside surface in black print at least 20 mm high DIRTY R-12 - DO NOT USE, MUST BE REPROCESSED The portable refillable container shall have a SAE 3/8 in flare male thread connection as identified in SAE J639 CFC-12 High Pressure Charging Valve (Figure 2) During operation the equipment shall provide overfill protection to assure that the storage container liquid fill does not exceed 80% of the tank s rated volume at 21 degrees Celsius per DOT standard, CFR title 49, Section and the American Society of Mechanical Engineers. 6.4 Additional Storage Tank Requirements

28 6.4.1 The cylinder valve shall comply with the standard for cylinder valves, UL The pressure relief device shall comply with the pressure relief device standard part 1, CGA pamphlet S The container assembly shall be marked to indicate the first retest date, which shall be 5 years after date of manufacture. The marking shall indicate that retest must be performed every subsequent 5 years. The marking shall be in letters at least 6 mm high. 6.5 All flexible hoses must meet SAE J2196 for service hoses. 6.6 Service hoses must have shutoff devices located within 30 cm of the connection point to the system being serviced to minimize introduction of noncondensable gases into the recovery equip ment during connection and the release of the refrigerant during disconnection. 6.7 The equipment must be able to separate the lubricant from recovered refrigerant and accurately indicate the amount removed from the system during processing in 30 ml units The purpose of indicating the amount of lubricant removed is to ensure that a proper amount is returned to the mobile air-conditioning system for compressor lubrication Refrigerant dissolved in this lubricant must be accounted for to prevent system lubricant overcharge of the mobile air-conditioning system Only new lubricant, as identified by the system manufacturer, should be replaced in the mobile air-conditioning system Removed lubricant from the system and/or the equipment shall be disposed of in accordance with applicable federal, state, and local procedures and regulations. 6.8 The equipment must be capable of continuous operation in ambient of 10 degrees Celsius to 49 degrees Celsius and comply with The equipment should be compatible with leak detection material that may be present in the mobile air-conditioning system.