Lo 3 Retrofit

PERFORM REFRIGERANT RECOVERY / RECYCLING AND RETROFITTING /
CONVERSION ON DOMESTIC REFRIGERATION AND AIR CONDITIONING
Introduction
Recognizing the problems caused by ozone depletion makes everyone aware
on the importance of preventing ozone-depleting substances (ODS) emission to
atmosphere. One- way of doing this is through the use of recycling and recovery
machine in the refrigeration and air-conditioning (RAC) and mobile air-
conditioning (MAC) industry.
Recovery and recycling is the heart of the refrigerant issue. We can reduce
the need to handle refrigerant by understanding the refrigeration theory, systems,
applications and good service practices, but we will have failed in our mission of
reducing unnecessary refrigerant releases if we don’t train every technician in the
art of refrigerant handling.
This module covers the knowledge, skills, and attitudes in recovery and
recycling of refrigerants in refrigeration and air-conditioning system, and mobile
refrigeration and air- conditioning system. This also includes awareness in
environmental protection and good servicing practices.
Summary of Learning Outcomes
On completion of this module you should be able to:
1. Recognize the importance of recovery/recycling of refrigerants
2. Set-up the recovery/recycling equipment
3. Perform recovery/recycling of refrigerants
Performance Criteria
After completion of the lessons in this module, the student must be able to:
• Explain the prevention of ozone layer depletion
• Explain the Montreal Protocol
• Discuss the effects of ODS emission
• Identify refrigerants using refrigerant identifier
• Identify accessories, parts and functions of recovery/recycling
equipment
• Familiarize with the operations of recovery/recycling
equipment in accordance with manufacturer’s
Date Developed: Document No.

Issued by:
December 20, 2011
Troubleshooting RAC Developed by: Revision #
Mr. Eugene R. Valdez Page | 1
TESDA-
CCNTS CCNTS – Region XI
specifications
• Prepare tools, materials and instruments for recovery/recycling
equipment
• Set-up recovery/recycling equipment in accordance with
manufacturer’s manual
• Perform recovery/recycling in accordance with manufacturer’s
manual
• Recover 100% of the refrigerants from the system
• Recover refrigerant from the tank and must be labeled prior to
recycling of refrigerants
• Practice safety measures in recovery/recycling of refrigerant.
Conditions
The trainee must be provided with the following:
1. Learning Materials
• Module1: Recovery/Recycling
Refrigerants
• Service Manual
• PT Chart
• Video tapes:
• Payong ng Kalikasan
2. Training Facilities
• Computer
• TV Monitor
• VHS/VCD player
• Flip Chart
• Blackboard/Whiteboard
3. Equipment

Issued by:
December 20, 2011
TESDA-
• Recovery/recycling machine
• Weighing scale
• Actual equipment
• Vacuum pump
4. Instruments
• System analyzer
• Leak detector
• Refrigerant identifier
• Thermometer
5. Tools
• Spanner
• Ratchet/wrench
• Piercing valve
• Screw drivers
• Set of pliers

Issued by:
December 20, 2011
TESDA-
6. Personal protective equipment
• Apron
• Safety shoes
• Goggles
• Gloves
• Gas mask
7. Supplies and materials
• Refrigerants
• Teflon
• Madden rubber
• Soap solution
• Rags
• Bucket
• Pen/marker
Prerequisite
Before starting this module, you should have already completed the manual
on:
• Code of Practice in Refrigeration and Air Conditioning
Reference
A. Books
• Good Practices in Refrigeration Training Manual. UNEP, December
1994
• Recovery and Recycling System: Guidelines, UNEP, 1999
• National Regulations and Import Licensing System for Phase-out of
Ozone Depleting Substances in the Philippine, Country Handbook,
DENR
• Modern Refrigeration and Air-conditioning.
Althouse/Turnquist/ Brancciano. Copyright 2002
B. Curriculum guides
• HVAC Competency Standard

Issued by:
December 20, 2011
TESDA-
• HVAC Competency-Based Curriculum
C. Manuals
• Service Manual
• Code of Practice in Refrigeration and Air Conditioining

Issued by:
December 20, 2011
TESDA-
Information Sheet 16
The Importance of Recovery/Recycling of Refrigerants
I. How Refrigerants Affect Ozone Layer and Global Warming
Some refrigerants,
especially
chlorofluorocarbons (CFCs),
contribute to the reduction of the
earth’s ozone layer. The ozone layer
is a vital part of the earth’s
atmosphere and protect life from
the harmful effects of excessive
ultraviolet (UV) radiation, which
come from the sun.
1. UV-B radiation -- On land,

ultraviolet radiation endangers all
living forms. The danger of Ultraviolet
Radiation are:
• Harmful to human
health
• Causes skin
cancer
• Causes eye
cataracts
• Suppresses man’s immune
system
• Arrest the growth of crops and

Issued by:
December 20, 2011
TESDA-
trees
• Practically destroy all life on
earth
2. What is Ozone Layer?
Ozone layer is a thin, fragile shield

of kind oxygen in the stratosphere. It
envelops the entire earth and blocks
off most of the harmful UV rays
from the sun from reaching the
earth’s surface.
3. What is “0zone hole”
Ozone hole refers to the loss of the

blocking effect of ozone against
ultraviolet rays. This is the
consequence when the ozone layer is
severely depleted, in effect allowing
the entry of greater
concentrations of UV-B imperiling all
living things on earth.
Note:
Joe Farman, a British Antarctic

survey scientist, discovered the
“ozone hole” over the Antarctic area.
A similar “hole”, but not as damaging

as the one over the Antarctic, has
been found over the Arctic region.

Issued by:
December 20, 2011
TESDA-
The discovery of the ozone hole
in Antarctic shocked the world. It
has come to be regarded as one of
this century’s major environmental
disaster.
4. What is ozone depletion?
Ozone depletion is the loss of the

blocking effect of the ozone layer
against UV rays from the sun. The
continuous use of ozone depleting
substances(ODS) like CFC and
halons destroy the ozone layer.
These ozone depleting substances

are used in the wide range of
household and industrial uses as
follows:
• As refrigerants for refrigerators
and airconditioners
• As blowing agents in the
production of foams
• As propellant in aerosol
sprays
• As firefighting agent in fire
extinguishers
• As industrial solvent for cleaning
and dry cleaning

Issued by:
December 20, 2011
TESDA-
The ozone layer can be saved only by
stopping the use of CFC’s halons and
other ozone depleting substances:
OZONE DEPLETING
SUBSTANCES
• Chloroflourocarbons
(CFCs)
•
Halons
• Hydrochloroflourocarbons
(HCFCs)
• Other mine
chemicals
• Methyl
Bromide

Issued by:
December 20, 2011
TESDA-
Note:
Dubbed as a miracle chemical, CFCs

were utilized in many industries—first
as the working fluid for refrigerators;
then propellants in aerosol cans; and
more recently as solvents in computers
where it cleans the delicate circuit
without the plastic mountings; or used
as blowing agent in foams for various
uses from buildings and cars to fast food
containers
Where are CFC and halons used?.

• Aerosols used in sprays
• Refrigeration and air-conditioning
• Industrial Solvent
• Foam for insulation and padding
• Fire extinguishers
• Tobacco fluffing and expansion
• Semi-conductor and electronics
Note:
By 1994, refrigeration and air-
conditioning service industry as well as
foam manufacturing in the solvent
sectors are the only remaining users of
CFC in the country.

Issued by:
December 20, 2011
Page | 10
TESDA- Mr. Eugene R. Valdez
5. What is Greenhouse Effect and
Global Warming— Another
environmental effect of refrigerants is
their possible contribution to
globalwarming.The theory of global
warming states that, due to
mankind’s activities, the
concentration of certain heat-
trapping gases is increasing in the
atmosphere. This is believed to be
causing the mean
temperature of
earth’s atmosphere to increase
slowly.
Refrigerants may contribute to

global warming by way of a
phenomenon called the greenhouse
effect.
Although the greenhouse effect is

essential for life, enhance global
warming may have severe
consequences. Some other effect that
have been speculated include:
• Rising mean level of the seas. It
has been predictedthat
increase temperatures
will cause some ice that is
currently stored (e.g., in glaciers)
above sea level, to melt and flow
into the oceans, raising sea level
globally.
• Climate. Models that are
currently used give average
global estimates. But changes in
temperatures, rain, sunshine,
etc., vary enormously from one
point to another.
• Harvests. The larger CO2
concentration could benefit
harvests of certain crops, but the
uncertainty regarding the
regional climate changes does not
allow us to predict which crops
will be able to adapt to the
changes in each zone.
• Eco-systems. Local ecosystems
are very sensitive to
changes in temperature,
precipitation and ground
humidity. The increase in CO2,
favors plant growth. Some plant
species and animals may
disappear in certain
regions if they are unable to
adapt to
the new conditions or to migrate
fast
enough to more favorable
ecosystems.
II. What is NCPP Phase-out Plan?
The Montreal Protocol on

substances that deplete the ozone
layer is an agreement among 129
countries, including the
Philippines, that limits the
production, application and use of
the most common ozone depleting
substances, like CFCs and provides
for the phase-out of these chemicals.
Under the Montreal Protocol, the National CFC Phase-Out Plan

Philippines is committed to phase out
the country’s CFC consumption by: Year Percentage
2005 50%
2007 85%
2010 100%
Through the
Philippine De
Ozone Desk rtm
nt
(POD) of
En
the
onm
nt
Environment
and
al
Na
Management
ral
Bureau (EMB) Re
the National ur
CFC Phase
Out En
Plan(NCPP) onm
was nt
established. Ma
gem
The NCPP aims nt
to phase-out Bu
CFC in the au
country as
stipulated PHILIPPINE
under the OZONE DESK
Montreal
Protocol
without
creating
adverse effect
in the
economy.
The focus of the NCPP is to phase out
the remaining CFC consumption in
the country specifically in the
following sectors:
Manufacturing
Sectors:
1. Foam
manufacturers
2. Tear gas
producers
3. Refrigeration equipment
manufacturers
Service
Sectors;
1. Mobile air
conditioners
2. Domestic refrigeration and
air conditioners
In order to achieve this target, the

DENR
in cooperation with TESDA will train/certify S
at least 5000 service
technicians
nationwide in order for them to
recover/
recycle
refrigerants.
Republic Act No. 6969 otherwise
known as the
“Toxic Substances
and Hazardous and Nuclear
Waste Control Act of 1990”. Its
main objective is to monitor,
regulate and keep an inventory of
imported, manufactured, or used
chemicals that presents
unreasonable risk or injury to health
or to environment in accordance with
the national policies and
international commitments.
Republic Act No. 8749, known as
the “Clean Air Act of 1999”, RA
8749 is intended to formulate a
holistic national program on air
pollution. DENR is the lead agency
but cooperates with other
government agencies as well as
with industry and related non-
governmental organizations. The
Clean Air Act’s primary focus is on
ambient air quality but it is
applicable to all other pollutants
including ODS.
Self-Check 11
QUESTIO Satisfact
NS ory
respons
The student trainee should answer the following questions YES NO
1. Refrigerants are believed to contribute to
two major global environmental phenomena.
Name them:
1.
2.
2. Describe two methods by which ozone is converted
into oxygen.
1.
2.
3. Name some possible effects of ozone depletion.
4. What is the name of the international treaty,

which controls the production of certain
refrigerants due to their ability to reduce the
ozone layer?
5. Define ozone layer?

The student’s underpinning knowledge was:
Satisfactory Not Satisfactory
Feedback to student/trainee:
Candidate Signature: Date:

Instructor Signature: Date:
1. Ozone depletion and global warming
2. Ozone is naturally converted to oxygen (and vice-versa) by the

sun’s UV rays. Also, chlorine and bromine can act as a catalyst
in the presence of UV rays, converting ozone to oxygen.
3. Increase in skin cancer and cataracts; impaired immune systems;

decrease crops yields; decreased phytoplankton growth.
4. Montreal Protocol
5. Ozone layer —is a thin, fragile shield of kind oxygen in the

stratosphere. It envelops the entire earth and blocks off most of the
harmful UV rays from the sun from reaching the earth’s surface.
Identify Refrigerants
I. Refrigerants
A refrigerant is a fluid (liquid and
gas) which transfer heat away from
one point to another. In a typical
vapor compression system, the
refrigerant changes phase. That is, it
changes from a liquid to a gas when Methan
it absorbs heat and changes back to e
a liquid when it gives up heat. Most
chemicals have the ability to change
from a liquid to a gas, but only a few
chemicals do so in a manner that Ethane
makes them good refrigerants.
Most refrigerants used today for

vapor compression air conditioning
are called halocarbons. A
halocarbon is a
hydrocarbon molecule containing one
or more halogens. The halogen
elements most commonly used in
refrigerants are chlorine (CI) and
fluorine (F). Refrigerants used in Propane
centrifugal chillers are halocarbons
based on methane, ethane and
propane molecules.
• A halocarbon can contain chlorine

and fluorine in place of hydrogen,
in which case it is a
chlorofluorocarbon (CFC):
CFC-11
• It can contain hydrogen in
addition to chlorine and fluorine,
in which case it is a
hydrochlorofluorocarbon (HCFC).
CFC-12
HCFC-22 HCFC-123
• Or, it can contain only hydrogen
and fluorine (no chlorine), in
which case it is a hydro
fluorocarbon (HFC)
HFC-32
HFC-134a
Refrigerant Nomenclature—single component refrigerants have an “R-”

designation of two or three numbers, which reflect its chemical composition.
• The first digit (of a refrigerants with three numbers) is one unit lower than
the number of carbon atoms, the first digit is omitted.
• The second digit is one unit greater than the number of hydrogen atoms in
molecule.
• The third digit is equal to the number of fluorine atoms in the molecule.
One less than the number of
carbon atoms (i.e., there are
1 + 1 = 2 carbon atoms)
More than the number of
hydrogen atoms (i.e. there are 3 -
1 = 2 hydrogen atoms)
Number of fluorine atoms (i.e.
there are 4 fluorine atoms)
The ‘a” indicates an isomer (i.e.

R - 134a a different arrangement of the
same atoms) of R - 134
Physical and Environment Properties of Some Common Refrigerants
Even small changes in the makeup of these refrigerants can make a large
difference in their physical and environmental properties as shown in table
below:
Boili Heat of Atmospher

Vaporiza ODP GWP
ng ic
Point tion Life
R - 11 23.82 24768 1.000 3400 60
R - 12 -29.79 19982 1.000 7100 130
R - 22 -40.76 20207 0.055 1600 15
R - 123 27.87 26005 0.020 90 2
R - 134a -26.16 22160 0 1200 16
Health and safety consideration
— Another consideration for an TOXICITY
acceptable refrigerants is its effect on Class A: refrigerants with
human health and safety. Many low toxicity, with a weighted TLV
chemical, including refrigerants, over time higher than 400 ppm.
can be dangerous if used That is, only concentrations over
improperly. Two important 400 ppm over sustained period of
categories of health and safety time are concern.
concerns are toxicity and
flammability. Most toxic and Class B: refrigerants with
flammable refrigerants gives off higher toxicity with a weighted TLV
pungent odor. over time lower than 400 ppm.
FLAMMABILIT
Y Group 1: No
flammability Group 2:
Low flammability
Group 3: High flammability
1. Refrigerants are identified

through a consistent numbering
system.
a. So me common CFC
are:
• R-11 or CFC-11
• R-12 or CFC-12
• R-114 or CFC-114
• R-115 or CFC-115
b. Common HCFC’s
include:
• R-22 or HCFC-22
• R-123 or HCFC-123
• R-124 or HCFC-124
c. H F C ’s include:
• R-134a or HFC-134a
• R-125 or HFC-125
• R-32 or HFC-32
d. Some non-halocarbon
refrigerants that have been used
include:
• Ammonia (NH),
3
designated as
R-717
• Water (H2 0), designated as R-
718
Propane (C3H8) designated as R-
290
 Isobutene (C4H10) designated as
R-600a
• Carbon Dioxide (CO ), designated
2
as R-44
e. So me Common Refrigerants
and their Uses
• CFC-11 low pressure
centrifugal chillers; (also for
foam blowing)
• CFC-12 high pressure
centrifugal chiller; domestic
and commercial refrigeration;
automobiles
• HCFC-22 Unitary air
conditioning;
mid-temperature
refrigeration
• HCFC-124 low pressure
centrifugal chillers
• HFC-134a high pressure
centrifugal chillers;domestic
and commercial
refrigeration;automobiles.
2. Standing Pressure
The temperature/pressure
relationship of refrigerants. The
pressure exerted by a refrigerant
gas is related to the temperature
of the refrigerant. Using gauge
manifold, thermometer, and
pressure temperature chart, you
can identify an unknown refrigerant.
With many type of refrigerant at
present, PT chart is not as reliable as
before in identifying refrigerants as
shown:
3. Color Code —Refrigerant • R-11 Orange
manufacturers have voluntarily • R-12 Grey/White
established a color code system to
• R-22 Medium Green
identify their products, with both
disposable and reusable cylinders • R-502 Orchid
painted
commonor otherwise
refrigerantdistinguished
colors andby • R-500 Yellow R- 13 Pale Blue
the following
identificati n: • R-503 Aquamarine
o
• R-114 Dark Blue
• R-113 Purple
• R-717 (NH3) Silver
4. Portable Refrigerant Identifier
The instrument is housed in a

rugged portable high-density
polyethylene case. The case will store
the instrument itself as well as
required hose assemblies, power cord
and adapter fitting. This type of
refrigerant identifier can identify R-
12, R-
22,R-134a HC and
air.
5. Refrigerant Stamped on Data Plate

a. R ef r i g e r a nt can be identified
on the back label of refrigerant
unit
b. Stamped can also be found
on compressor label, or
c. On a soldered steel plate in the
Compressor.
6. TEV/TXV for specific refrigerant.

Identify Refrigerants Using Identifier
1. The Refrigerant Identifier
Sample Hose
Control Panel
Power
Cord
Sample Inlet
Port
Air Intake Port

System Pressure Gauge
Sample Filter
Printer Port
Back View of the Identifier

Goggles
2. Tools and Personal
Protective Equipment Gloves
needed when using refrigerant
identifier:
• Goggles
• Gloves
• Rachet wrench
• Adjustable wrench
Adjustable
Wrench
Rachet
Wrench
3. When using the identifier, the following should be considered:
• Always wear eye and skin protection when working with refrigerants.
• Always work in a well-ventilated area, avoid contact with refrigerant. It
can cause
frostbite and blindness.
• If working with hydrocarbon, extreme care must be considered because
of its
flammability.
4. Before proceeding in identifying refrigerant, the following should be

considered:
• Always place the identifier on a flat and sturdy surface
• Do not utilize other hose than those supplied with the instrument
• Always verify that the refrigerant to be tested does not contain or will emit
heavy loads of oil or liquid
• Never admit any sample into the instrument in excess of 30 psig.
Pre-Operational Procedure
1. Open the case and inspect the sample filter for signs of red spots or
discoloration anywhere on the white outside diameter of the element. If any
red spots or discoloration are noticed, REPLACE THE FILTER BEFORE
USING THE INSTRUMENT!
Warning: When red spots or discoloration begin to appear on the white outside
diameter of the filter element, THE FILTER MUST BE REPLACED.
Failure to properly maintain the sample filter may result in severe
instrument damage that will not be covered under warranty repairs.
2. Select the R12 or R13a sample hose for use in the specification. Inspect the
hose for signs of wear and as cracking, frying or kinks. Verify that the hose
is not obstructed and that no oil is present internal to the hose. If the hose
shows signs of wear, obstruction or oil IT MUST BE REPLACED (OR
CLEANED) BEFORE USING THE INSTRUMENT!
3. Install the selected sample hose into the inlet of the instrument. The hose
connector needs only to be tightened to achieve a gas-tight seal.
4. Inspect the air intake port, sample exhaust port and case vent ports of the
instrument to verify they are clear and unobstructed.
5. Inspect the sample port of the refrigerant storage cylinder or vehicle air
conditioning system to be tested. Verify that the port is the LOW SIDE or
VAPOR port.
Procedure:
Step 1. Plug the power cord of the instrument into a SUITABLE RECEPTACLE.
The instrument will display various parameters of the instrument and
begin the warm up period.
During the warm up period the user has the option to enter the local elevation
above sea level into the instrument memory. The instrument is sensitive to
elevation changes of 500 feet (152 meters) and the local elevation must be
entered into the instrument memory upon initial use. Normal barometric
variations will not effect the performance of the instrument. After the local
elevation has been entered into the instrument memory there is no need to
enter it again unless the instrument is moved to a new elevation. To enter the
elevation into the memory, follow the procedure presented by the instrument
display as stated below:
a. During the warm up period depress and hold the “A” and “B” buttons
simultaneously until the display reads, ‘USAGE ELEVATION, 400 FEET”.
This is the factory setting of
400 feet fee (122-meters) elevation.
b. Use the “A” and “B” buttons to adjust the elevation to the nearest 100-foot
(30-meter) increment. Pushing the “A” button will increase the elevation
setting by 100-foot (30 meter) increments. Pressing the “B” button will
decrease the elevation setting by 100- foot (30 meter) increments. The setting
is adjustable from 0-9000 feet (0-2743 meters) and will be displayed while
adjusting.
c. When the correct setting of local elevation has been achieved, allow the
instrument to sit for approximately 20 seconds while not pushing either of
the buttons. The instrument will automatically return to the warm up period
and the elevation setting will be stored in the memory.
Step 2: Calibration. A buzzing sound

will be heard during the self
calibration of the
instrument. When it is
already calibrated the control
panel display reads “READY:
CON. HOSE PRESS A to
START” as shown in the
illustration.
Step 2: Connect the sample hose to the
vapor port of the tank or unit
and the other end of the
sample hose to the identifier.
Note: When connecting the sample

hose to the cylinder and
identifier, make sure that it is
finger tight only.
Sample hose
connected to the vapor
port of the tank.
The other end of the

sample hose connected
to the identifier.
Step 3: Open the cylinder slowly and
allow approx. 9-15 psi of
refrigerant to enter the
instrument, then close the
cylinder and press “A” as
indicated in the control panel.
The instrument will read

“SAMPLING IN PROGRESS”
while a small refrigerant
sample is analyzed to determine
the concentrations of R12,
R134a, R22, hydrocarbons and
air.
Step 4: Check the type of refrigerant
based on the display result
screen.
Note: In case error occurs, unplug and

re- plug the identifier to reset it.
Warning: Disconnect the service end of

the sample hose from the
refrigerant source immediately
when so directed by the
instrument. The instrument is not
equipped with an automatic shut
off device and refrigerant will
continue to flow through the
sample hose as long as it is
connected to the source. Failure
to immediately disconnect the
sample hose from the
refrigerant source when directed
will result in excess refrigerant
loss to the atmosphere.
Step 5: Unplug and return the

instrument to its proper
arrangement.
Self-Check 12
QUESTIO Satisfact
NS ory
respons
The student trainee should answer the following questions YES NO
1. What is the family name for the common
refrigerant based on methane, ethane and
propane?
2. What are the methods of identifying refrigerants?

1.
2.
3.
3. What is the best method of identifying refrigerants?
4. What is the cylinder color code for R-22?
5. What are the personal protective equipment

required when using refrigerant identifier?
The student’s underpinning knowledge was:


Instructor Signature: Date:
Part II : Part of portable identifier:
Instructions: Identify the different parts of the refrigerant identifier. Write

your answer on the numbered blank lines below.
7
1
2
5
3
4
1. 5.
2. 6.
3. 7.
4. 8.
Part I.
1. Halocarbons
2. Different methods of identifying refrigerants
• Refrigerants stamped on unit data plate
• TEV for specific refrigerant (Thermostatic Expansion Valve)
• Standing pressure
• Refrigerant identifier
3. Use refrigerant identifier
4. Medium Green
5. Gloves and goggles
Part II.
1. Power cord
2. Air intake port
3. Sample filter
4. Printer port
5. Sample hoses
6. Control panel
7. Sample inlet port
8. System pressure gauges
Job Sheet 13
Identify Refrigerant Using Identifier

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

content • Gloves
• Labeled Refrigerant tank with • Goggles
content
• Safety clothes
Ob servatio n
Pro ced u Ch ecklist
re Yes No N/A
1. Prepare identifier. (Set up instrument correctly)
2. Apply safety measure (Safety measure were applied)
3. Warming up and calibrate
4. Connect the sample to the vapor port of the tank or

unit.
5. Open the cylinder slowly and allow approx. 9 -
15 psi of refrigerant to enter the instrument.
6. Close the cylinder and press "A" as indicated in
the control panel.
7. Check the type of refrigerant based on the
display result screen.
8. Unplug and return the instrument to its proper

arrangement.
9. Perform housekeeping
Job Sheet 13
Identify Refrigerant Using Pressure
Temperature Method
Equipment/Instrument: Materials:
• System analyzer • Unlabeled refrigerant tank with
content
Tools:
• Labeled Refrigerant tank with
• Service valve ratchet content
wrench
• PT Chart
• Tap line valve
• Adjustable wrench Safety Protective Devices:
• Gloves
• Goggles
• Safety clothes
Observation
Proedu re n
Ch
Yes No N/A
1. Instruments, materials were prepared in accordance

with job requirements (Set up instrument correctly)
2. Apply safety measure (Safety measure were applied)

3. Gauge manifold was connected to the refrigerant
cylinder correctly
4. Ambient temperature was taken using
thermometer( Refrigerant was identified correctly
according to pressure and temperature chart)
Set up Recovery/Recycling System
I. Good Service Practices
1. The following list of service practices may be helpful in establishing your

own service practices:
DO:
• Think CFC conservation and safety
• Follow and use recommended procedures and equipment for
handling refrigerants.
• Replace, tighten, and seal caps on all valves after servicing.
• Shut down system and make repairs when leaks exist.
• Use close loop refrigerant transfer equipment when removing,
charging, and storing refrigerants.
• Recover vapor and liquid refrigerant from charging hoses.
• Maintain refrigerant use logs for all equipment.
• Leak tests all charging hoses and refrigerant handling equipment.
• Install service isolation valves to limit refrigerant losses during
servicing and purge operation.
• Eliminate unnecessary mechanical joints. Use welded or brazed
joints.
• Establish proper leak testing routine.
• Follow the published leak test procedures.
• Use industry-accepted tools/equipment for leak testing.
• Confirm overall leak tightness by using a standing vacuum test.
• After major service, evacuate and dehydrate to a minimum 757 mm
using a deep vacuum or triple evacuating method.
• Use only approved cylinder/drums/tank for storing refrigerant.
• Install charging valve quick connects.
• Recover all refrigerants for recycling/reclaiming.
• Use non-CFC gas as tracer gas when conducting leak tests.
• Add refrigerant carefully to avoid overcharging.
• Dispose used refrigerant container properly.
• Use refrigerants as cleaning solvent.
• Open the refrigerant side of system unless absolutely necessary.
• Use CFC for leak testing.
• Operate equipment with Vent/blow off (noncondensable
• gasses/refrigerant) to the atmosphere.
DON’T• Blow off refrigerant “empty” tanks, drum, or containers.
• Throw away any refrigerant.
• Contaminate recovered refrigerants with other refrigerants,
solvents, oils, or other materials.
• Exceed manufacturer’s recommend pressure when leak testing.
• Overfill refrigerant containers, tank, drum, recovery units, and
receivers.
Etc.
• Refill disposable cylinders.
• Substitute alternative refrigerants into old system without approval.
II. Recovery/Recycling Equipment
1. Two types of recycling equipment are on the market. The first is referred to as
single pass.
The other is a multiple pass.
Contr
A/C ol
System
Condenser
Evaporator
Control
A/C System
Condenser
Evaporator
Single pass
2. Typical equipment available in the

market in the Philippines is as
shown
• Recovery/recycling machine—this
type of machine can service
both the refrigeration and
airconditioning and mobile air-
conditioning equipment.
• Recovery/recyclingmachine for
domestic refrigeration and mobile
air- conditioning. It can onlybe
used for R-
12 running equipment.
III. Identifying Recovery/Recycling Equipment Parts and Functions
1. Part of a typical recovery/recycling equipment is as shown:

Pressure Gauge O o
i r
l t
R
O e
u f
Recovery Tank r
t i
l g
e e
t r
a
n
P t
o
r O
u
t t
l
O e
i t
l
P
o
I r
n t
l
e
t
P
o
r
t
R
e
f
r
i
g
e
r
a
n
t
I
n
l
e
t
P
2. Major parts and functions:
• Pressure gauges — indicators of refrigerant pressure from the unit and to

the recovery tank.
• Recovery tank — a cylinder for recovery/recycling of refrigerants.
• Oil outlet port— is where foreign particles and acids are drained out
• Oil inlet port -- is where refrigerant oil is pumped in to add the
lubricants of the compressor.
• Refrigerant inlet port -- is where the refrigerants passes from the
refrigeration and air-conditioning equipment being recovered.
• Refrigerant outlet port -- is where refrigerants comes out from the
refrigeration and air-conditioning equipment being recovered.
IV. Prepare the right tools, supplies and materials

When setting recovery/recycling equipment you must prepare the
following tools, supplies and materials, instrument:
1. Safety protective devices

• Gloves
• Goggles
2. Hand
tools
• Adjustable wrench
 Ratchet wrench
3. Supplies and materials
• Rugs
• Tape
• Pen
4.
Instruments
• Gauge manifold
• Weight scale
• Thermometer
V. General procedure in setting recovery/recycling equipment

1. Procedure:
• Prepare required materials,
equipment, tools and
personal protective
equipment.
• Ask for Manufacturer’s Manual
of a recovery/recycling machine.
• Evacuate recovery/recycling machine
• Evacuate recovery tank
• Connect recovery/recycling
machine to the unit to be
recovered
• Perform housekeeping
2. Shown below is the recovery/recycling equipment connected to a

refrigeration unit.
Refrigeration
System
Recovery/Recycling
Equipment
Recovery
Cylinder
V. Procedure in setting recovery/recycling equipment
1. Prepare required materials,

equipment, tools and personal
protective equipment.
Gloves
Goggles
Adjustable Wrench Adjustable

Wrench
2. Evacuate recovery/recycling machine
Getting Started Recovery/Recycling
• Make sure recovery/recycling Machine
machine is connected to proper
Pressure Gauge
voltage.
• Hook vacuum pump to both inlet
end outlet fitting of
recovery/recycling machine
and pull a vacuum for
approximate 5-7 minutes. Make
sure that the inlet and outlet valve
are open. The center switch must
be in the pump out position.
• After evacuation of the recovery/ recycling machine, close inlet and
outlet valves, unplug the machine and place the center switch to recycle
position.
3. Evacuate recovery tank

• Evacuate the recovery tank for 5 minutes by connecting a vacuum pump
to the vapor and liquid valve of the cylinder.
• The recovery tank is now ready to accept refrigerants.
Turn off the machine

• Clean machine
• Return tools, instruments and supplies to proper place.
Set up Recovery/Recycling Equipment
QUESTION Satisfacto
S ry
response
The student/trainee should answ er the follow ing YES NO
questions
1. Before operating any equipment a new technicians must first
read the
Manufacturer's Manual. Why?
2. Identify at least two types of recovery/recycling equipment
3. Before set-up of equipment, it is good practice to prepare

the right
tools, supplies and materials needed, instruments
requirement. List the most important tools, supplies,
4. Enumerate at least three good service practices.
5. Enumerate at least three don'ts in good service practices.
The student's underpinning know ledge w as:

Candidate Siganture: Date:
Instructor's Signature: Date:

Identify Parts of Recovery/Recycle Equipment and
Accessories
Instructions: Label the illustration below by writing the right description

of the parts numbered blank space.
Part II : Part of recovery/recycling equipment
1 3
2
5
1. 4.
2. 5.
3. 6.
Identify Parts of Recovery/Recycle Equipment and
Accessories
Part I.
1 Specific technical instructions, setting guide, on how to use the
equipment can be found in the manual. Therefore it is a good practice that
before operating a machine one has to read the manual.
2 Types of recovery/recycling equipment:
• Multiple-pass
• Single-pass
3 Tools, supplies and materials, instruments:
Tools:
• Valve key/service wrench
• Tap line valve/piercing valve
Personal Protective Equipment:
• Goggles
• Gloves
• Safety shoes
• Working clothes
Instrument:
• Gauge manifold
• Electronic weighing scale
• Electronic leak detector
4. Good practices (at leat 3 items)
• Shut down system and make repairs when leaks exist.
• Use close loop refrigerant transfer equipment when removing,
charging, and storing refrigerants.
• Recover vapor and liquid refrigerant from charging hoses.
• Maintain refrigerant use logs for all equipment.
5. Don’ts in good safety practices (at least 3 items)
• Use CFC as tracer gas for leak testing.
• Operate equipment with leaks.
• Refill disposable cylinder.
• Vent/blow off air (non-condensable gasses/refrigerant) to the
atmosphere.
Part II
1. Pressure gauges
2. Recovery Tank
3. Oil outlet port
4. Oil inlet port
5. Refrigerant inlet port
6. Refrigerant outlet port
Set up Recovery/Recycling Machine
A. Equipment: C. Tools:
• Vacuum pump • Valve key/service wrench
• Recovery & recycling machine • Tap line valve/piercing valve
set
• Recovery tank D. Personal Protective Equipment:
• Refrigerant tank • Goggles
• Gloves
B. Instrument:
• Safety shoes
• Gauge manifold
• Working clothes
• Electronic weighing scale
Ob servatio
Pro ced u re:
n
Ch
YES NO N/A
1. Ask for Manufacturer's Manual of a recovery/recycling

machine
2. Prepare required materials, equipment, tool and personal
protective equipment.
3. Evacuate recovery/recycling machine
4. Evacuate recovery tank
5. Connect recovery/recycling machine to the unit to be

recovered
6. Apply safety measure
Application of Recovery/Recycling
I. Recover/recycling refrigerant of different systems
1. Recover/Recycling Refrigerant from a Refrigeration and Window

Type Air- conditioning Unit. It is possible to recover refrigerant from a
hermetically sealed system, which has no service valves. A line-tap valve
(piercing valve) should be fitted to the system.
Procedure:
• Following the manufacturer’s instructions, and a recovery unit used to
remove the refrigerant from the unit via the line-tap as with the larger
system.
• Line-tap valves should never be lea permanently in place, but removed
after use if placed on the process tube.
• It is recommended to install tap-valves on both high and low pressure side.
Note: Figure below shows a recovery unit is connected to a refrigerator with a

typical tap-valve (piercing valve). Because of the small charge of
refrigerant, only vapor recovery is needed.
Piercing
Tube
Evaporator
Valve
Core
Pierced
Tube
Nut
Refrigerant
Outlet Port Recovery
/
Recovery Recyclin
Tank g
Machine
2. Recover from air-conditioning system(Liquid transfer)
Procedure
• Discharge side recovery unit to the suction pipe on the air-conditioning
system
If there are available valves on the systems receiver (high pressure side) the
recovery discharge side could be connected here as well. Liquid flows now
from the liquid side of the air-conditioning system and into the cylinder.
• The recovery unit will keep the pressure inside the cylinder lower than in
the air- conditioning system and keep up the liquid flow.
Figure below shows a typical condensing unit for air-conditioning installations
OUT
Perform Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine
Equipment: 4. uncoded tank/cylinder
1. refrigerant identifier 5. thermometer
2. refrigerant 6. PT chart
3. unlabeled 7. Operator Manual
tank/cylinder
CAUTION: Never mix refrigerants. Be sure unit is set up for the

refrigerant you are about to recover.
WARNING: Use only authorized refillable refrigerant tanks. Use of other

tanks could cause personal injury and void the warranty.
Getting started:
1 Make sure that the R/R machine is connected to proper voltage.

2 Hook the vacuum pump to both inlet and outlet fitting of R/R machine and
pull a vacuum for approximately 5-7 minutes. Make sure that the inlet and
outlet valves are open. The center switch must be in the pump out position.
3 After the evacuation of the R/R machine, unplug the machine and place
the center switch to recycle position and close inlet and outlet valves.
4 Evacuate the recovery tank for 5 minutes by hooking a vacuum pump to the
vapor and liquid valves of the cylinder.
5 The R/R machine and recovery tank is now ready to accept refrigerant.
Note: Always evacuate R/R machine and recovery tank if you will
recover/recycle another type of refrigerant
Operational procedure:
1 Plug in R/R machine to proper to proper voltage.
2 Connect hose to inlet valve of the machine and the other end to the
source. Use a gauge at the source as this will show when source is empty.
3 Attach the yellow cable to recovery tank. Connect other hose to outlet valve of
the R/R
machine and the other end of the hose to the vapor port of the recovery tank.
4 Turn compressor and recycle switch on and open inlet valve half turn. If
recycling liquid regulate suction gauge pressure to 20-25 psi for 2-3
minutes, open the inlet valve fully.
5 Open outlet valve of R/R machine. Open vapor valve of recovery tank.
When source is empty of liquid, turn vapor switch on. Leave on until source and
R/R
machine have equalized at 3-4 psi.
7 When equalized, turn vapor switch off and unit will pump down to
approximately 5" vacuum. If additional vacuum is required, use the
compressor momentary contact.
8 Pump out to clear unit by closing inlet valve, center switch to pump out
and vapor switch on and outlet valve open. Unit will pump down to 5"
vacuum and shut off.
9 Turn compressor off and use the compressor momentary switch to pull R/R
machine into 10" vacuum.
10 Close the outlet valve, put center switch to recycle and turn vapor switch on.
Unit will equalize. If positive pressure remains after equalize, repeat pump
out procedure.
Perform oil out procedure:

The oil out procedure is very important. By performing oil out frequently, you
will keep the separated oil below the level of the chamber entry point and assure
that the oil/moisture will be purged out of the R/R machine.
1. Close inlet valve and let machine pump down and shut off.
2. Turn compressor switch off and by using the recycle/pump out switch, add
2-3 psi to suction gauge. Do this by flipping switch to pump out position and
returning to recycle position.
3. Put a container under the oil out valve and slowly open valve.
4. When oil stops draining, close the oil out valve.
Method of Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine
Liquid Recovery Method
ALTERNATIVE
CONNECTION FOR
“PUSH - PULL”
OUT
OUT
Troubleshooting Guide: Recovery Operation
SYMPTOM CAUSE REMEDY
1. Recovery • Power cord not • Plug in cord, check

compressor does plugged in or no circuit for power
not start power at plug Recycle
• Be sure recycle switch
switch is on or main
is off and main power
power switch is off
is on
• Tank full light is on • Change tank

• Recalibrate
weight platform
• High pressure light is
on • Check valves on tank
to be sure they are
• Bad components— open
start switch, relay,
compressor, etc. • Check scale calibration
• Call factory
2. Runs a short time, • Tank valves not open • Open both tank valves
but does not
complete recovery • Low oil level • Call factory
in
compressor
• Call factory
• Bad components,
compressor, relay,
3. Runs but won’t • Leak In vehicle system • Pressure must be
shut off present in manifold
gauges before starting
• Oil drain valve recovery
not closed operation
• Bad components,
vacuum switch, • Close both valves
etc.
• Call factory
RECYCLING OPERATION
SYMPTOM CAUSE REMEDY
1. Refrigerant • Power cord not • Plug in cord, check

pump does not plugged in or no circuit for power
appear to be power at plug
running • Turn on
• Main power switch off
• Open valves
• Tank valves not open
• Call factory
• Faulty
components,
2. Bubbles will not • Tank valves not open • Open valves

clear in moisture • Not enough • Recover more
indicator refrigerant in tank— refrigerant before
must have 15 recycling
Ibs. minimum
3. Moisture indicator • Wet or plugged • Remove and replace

wilt not turn green filter cartridge filter cartridge. Be sure
after 3 hours of to pull
• Not enough a vacuum
recycling
refrigerant in tank—
must have 15 • Recover more
Ibs. minimum refrigerant before
recycling
• Faulty
moisture • Remove and
indicator replace moisture
Troubleshooting (VAN Steenburg Recycling Machine)
PROBLEM SOLUTION
1. Unit won’t accept refrigerant • Check inlet ball valve

• Check that cable is attached to
recycle cylinder
• Make sure recycle cylinder is not
full
• Check valves in hoses
2. System “Pulls Slowly” • Checked to ensure you are hooked
to liquid side of source
• Low ambient temperature, apply
heat to source
• Check hoses for restrictions
• Connecting hose to source to long
3. Oil in lines • Oil out operation has not been

completed on a regular basis.
Separator chamber is full and oil
has migrated though system
Recovery/Recycle Refrigerant Using Van Steenburgh Recycling Machine
in Domestic Refrigeration and Window
Air Conditioner
I. Equipment, instruments, tools and material needed.

1. Equipment: 3. Tools:
• Domestic refrigeration unit • Tap line valve/piercing valve
• Window air-conditioning • Access valve
unit • Tubing tools
• VS recovery machine (VS-
220) 4. Materials:
• Vacuum pump • Appropriate refrigerant cylinder
• Oxy acetylene equipment • Appropriate recovery tank
2. Instruments:
• Weighing scale
• Gauge manifold
Observation
A. Recovery and Recycling Procedures: Checklist
YES NO N/A
1. Prepare the required materials, equipment,
instruments, tools and personal protective equipment.
2. Set-up recovery and recycling machine
Note: Pls. Refer manual of recovery and recycling machine.
3. Connect recycler to proper voltage
4. Attach hose to ¼” flare fitting labeled inlet.
5. Attach other end to the source and purge. Note: Use a
gauge at the source as this will show when source is
empty.
6. Attach cable to recycle cylinder and one end of hose to
¼” flare fitting labeled outlet. Attach other end of hose to
vapor part on cylinder.
Observation
A. Recovery and Recycling Procedures: Checklist
YES NO N/A
7. Attach cable to recycle cylinder and one end of hose to
¼” flare fitting labeled outlet. Attach other end of hose to
vapor part on cylinder.
8. Turn compressor switch and recycle switch on and open
inlet valve. If recycling liquid regulate suction gauge
pressure to 20-
25 psi, 2-3 minutes before opening the valve fully.
9. Open outlet valve and purge hose. Open vapor
valve on recycle cylinder.
10. When source is empty of liquid, turn vapor switch on.
Note: Leave on until source and recycler have equalized
at 3-4 psi.
11. When equalized turn vapor switch off and unit will
pump down to approximately 5” vacuum. If additional
vacuum is required use the compressor momentary
switch.
12. Pump out to clear unit by closing inlet valve, counter
switch to pump out and vapor switch on and outlet
valve open. Note: Unit will pump down to 5” vacuum
and shut-off.
13. Turn compressor off and use the compressor
momentary switch to pull recycler into 10” vacuum.
14. Then close outlet valve, put center switch to recycle
and turn vapor switch on. Unit will then equalize.
Note: If positive pressures remains after equalize repeat
pump out procedure.
15. Then close outlet valve, put center switch to recycle
and turn vapor switch on. Unit will then equalize.
Note: If positive pressures remains after equalize repeat
pump out procedure.
16. Fill-up the worksheet form to complete the job.
17. Perform housekeeping.
Observation
Checklist
YES NO N/A
B Maintenance (Van Steen Burgh Recycling Machine)Oil

Compressor
Note:Recycle must be of “0” psi to check oil level and to
add oil to the compressor. If oil level is below bottom of
sight glass of oil must be added.
18. Locate the valve on the front of unit labeled comp. oil
19. Attach one end of hose to fitting and other end to oil
supply
20. Hold compressor momentarily switch down until
a small vacuum is indicated on suction gage.
21. By opening comp. Oil valve oil will be pulled into
compressor.
Proper oil level is from bottom of the sight glass to
NAME: Date:
COMPETENCY: Recovery/Recycling of Refrigerants TEST ATTEMPT

1ST 2ND 3RD
OVERALL EVALUATION
DIRECTIONS LEV
EL PERFORMA
• Ask instructor to CAN PERFORM THIS SKILL
4 WIITHOUT SUPERVISION AND
assess your CAN PERFORM THIS SKILL
competencies of the 3 SATISFACTORILY WITHOUT
ASSISTANCE
CAN OR SUPERVISION.
PERFORM THIS SKILL
critical performance 2 SATISFACTORILY WITH
CAN PERFORM PARTS OF THIS
criteria listed below. 1 SKILL SATISFACTORILY WITH
FULL
• You will be 0 CANNOT PERFORM THIS SKILL
INSTRUCTOR WILL INITIAL LEVEL
evaluated using the
guide on the other
PERFORMANCE
PERFROMANCE STANDARD LEVEL
YES NO N/A
1. Identify refrigerants using identifier

• Relevant data is gathered on unit to be recovered recycled
• Unit is determined whether to be subjected to refrigerant
recovery/recycle.
• Apply safety measure
2. Set up equipment for recover/recycling
• Prepare, instruments, tools and accessories based on job
requirements
• Set up equipment, instruments and tools according
to manufacturer’s recommendations
3. Recover/recycling refrigerants
• Observe safety measures in recovering/recycling of
refrigerants
• Achieve optimum recovery/recycling of refrigerants
• Identify and label recovered refrigerant in the tank prior to
recycling
• Perform refrigerant recovery/recycling according
to manufacturer’s recommendations
• Remove contaminants from the system as a result of
recycling based on instrument readings
• Operate and maintain recovery/recycling machine
in accordance with manufacturer’s
Introduction
Retrofitting is the replacement of the refrigerant towards alternatives. It may
require replacing specific parts of the equipment. For older refrigeration and air-
conditioning systems, it may be more cost-effective to replace rather than retrofit.
In addition, new equipment will be more energy and cost efficient.
This module covers the knowledge, skills and attitudes in retrofitting process
of preparing refrigeration and air-conditioning system for use with a replacement
refrigerant and lubricant.
This also includes the selection of alternative refrigerant, lubricant
components and accessories, basic principles of retrofitting, costing your work and
good servicing practices.
Learning Outcomes
On completion of this module you should be able to:

; Asses unit for retrofit
; Retrofit the unit
; Test performance of retrofitted unit.
Performance Criteria
After completion of the lessons in this unit, the student should beable
to:
• Explain the advantages, disadvantages and procedures of
retrofitting to customer in layman’s terms
• Estimate the cost of retrofitting based on manufacturer’s
recommendations
• Select alternative refrigerants & lubricants according to
manufacturer’s recommendations
• Select system components and accessories for retrofitting
according to application
• Perform retrofitting according to manufacturer’s recommendations
• Observe safety measures during retrofitting
• Monitor and check operating pressures, current,
temperatures for conformance with manufacturer’s
operating manual
• Analyze and interpret recorded data based on
manufacturer’s recommendations
• Perform adjustment of controls and devices on pressures,
current and temperature in accordance with manufacturer’s
recommendations
Conditions
The trainee must be provided with the following:
1. Learning materials
• Module 2: Retrofitting RAC & MAC Systems
• Operators Manual
2. Equipment and Materials
• Recovery/recycling machine
• Vacuum pump
• Standard tools and devices
• Adequate supplies and materials.
3. Learning Environment
• RAC or MAC unit for servicing
• Workshop or workplace
• Training facilities
Prerequisite
Before commencing this module, you should have already completed the
following module:
• Module 1: Recover/Recycling Refrigerants
• Module 2 : Perform Processing of RAC System
• Good Practice in Servicing R & R System
References
A. Books
• Good Practices in Refrigeration Training Manual. UNEP, December
1994
• Modern Refrigeration and Air-conditioning.
Althouse/Turnquist/Brancciano.
Copyright 1992
B. Curriculum guides
• HVAC Competency Standard
• HVAC Competency-based Curriculum
C. Manuals
• Service Manual
Assess Unit for Retrofit

I. Basic Consideration for
Retrofitting
1. Retrofitting is the process of
preparing a refrigeration and air
conditioning system for use with Materials
a replacement refrigerant and Compatibility Capacity
lubricant. The basic idea of retrofit
is to replace the refrigerant and
refrigerating machine oil.
2. Retrofitting would appear to be a
simple matter since it involves Cost
replacing an old refrigerant with a Power
new one in an existing system. Requirement
However, because many other
factors are involved, it is not
generally a simple process.
3. Other economic factors must be

considered. These factors include:
Hermetic
Open or
• The estimated equipment life,
• Current performance,
• operating requirement, and
• The cost of equipment and 60 - 80%
equipment room
Open Only w/ gea r
40 - 60% Simp le
Drive line
modification, maintenance,
or imp eller
retrofit
refrigerant and electrical
20 - 30%
Saving s
power. Comparison of cost of

chiller upgrade is as shown.
Repla c ement with insta lla
% of Replacement Cost
tion c ost total

100%
Best Efficiency
Open Only
4. In the refrigeration sector, often
times ODS-based equipment can Original CFC Possible Retrofit
be replaced with transitional Refrigerants Refrigerant*
refrigerant such as HCFCs, or CFC - 11 HCFC - 123
alternative substances. The most
commonly used non-ozone CFC - 12 HFC - 134a
depleting refrigerants are
HFC(which have zero ODP, but CFC - 114 ???
contribute to global warming) and
HCs (which have zero ODP and R - 500 HFC - 134a
zero global warming potential, but * Approved by the U.S. Environment
are flammable and require specific Protection
safety precautions). Agency
5. Replacement of end-of-live
ODS equipment may be the most Advantages Disadvantages
economical option taking into
account the energy saving which Alternate May reduced
may be realized by modern refrigerant is system
technology. The advantage and ozone friendly efficiency
disadvantage of retrofitting are can be more
as shown. expensive in case
System is
overhauled compressor and
other components
needs
Commercial
Toxicity
availability at
and
reasonable
flammabilit
cost
6. A retrofit can usually performed
at the same time as a system
overhaul. An overhaul ordinarily
consists of:
• Repair leaks
• Cleaning system tubing
• Charging t h e r e f r i g e r a n t
a n d lubricant to the proper
levels,
• Adjusting controls.
7. Finally, the decision for
retrofitting is the end-user, but as
technicians you can advice the
owner on the best option. Guide in
making your advice is shown
below.
BASIC CONSIDERATION FOR RETROFITTING

• Consider the expected energy efficiency, performance and operating costs
of the retrofitted system in addition to the direct retrofit costs.
• Consider the properties of the alternative refrigerant such as flammability,
toxicity and its global warming potential; some of these properties may
require additional safety measures.
• Consider retrofitting when major damage of the existing system requires
expensive repair work.
• Consult the system manufacturer for the appropriate alternative
refrigerant/lubricant system and the necessary replacement of system
components, such as compressor, filters, drier etc., before retrofitting.
• Consult the system manufacturer for the appropriate retrofitting procedure,
which is, in general, equipment-specific.
• Investigate the operating parameters and performance data of the existing
system before retrofitting.
• Investigate the operating parameters and performance data of the system
and control settings after completion of the retrofit.
• Re-label the retrofitted system and components to reflect the refrigerant and
lubricant change and to indicate future service needs.
• Record the retrofitting procedure in the service logbook.
Note: Observe local regulations concerning the collection, transport,

storage and. destruction of hazardous waste; contact
refrigerant suppliers, refrigeration associations or appropriate
government institutions.
II. Retrofit rofi n equi
Factor and when d re
Costing comp l flus
resso y hin
1. The
r has g
decision
failed H the
to replace
and F min Effi
or convert
existing
will C era V cien
be s oil cy
equipment
repla fro
should be
ced ( m
made only
is i the
after
muc . syst xpe
carefully
h e ems cte
considerin
more . and d
g the total
cost 1 repl lif
costs of
ef 3 acin of
both exis
ive 4 g
scenarios. tin
a with
To 2. equ
synt
minimize M ipm
e heti
the cost, if a ent.
t c •
timing n c este E •
permits, it y . r
is best to ai ) lubr
undertake r- r ican
a retrofit co e ts.
operation n f To
around a di r be
major ti i able
maintenan o g to
ce period. ni e perf
Many of n r orm
the g a suc
component a n h a
s would n t tas
normally d s the
be replace re . serv
during a fri T ice
major ge h cont
maintenan ra i ract
ce ti s or
overhaul. o need
Note: n w s to
sy i be
R st l well
e e l awa
t m r re of
4. As a service technician, it is your
work to advice equipment owner
the best way to minimized cost,
and at the same time maximizes
the efficiency of the equipment.
Example on costing is shown
below:
Example of costing retrofit
No. Measur Unit Cost/Uni Hours Cost/Hou Cost

e t r
1 Assessment 1 100 100
No Recovery to change oil -
3 Change oil 3x1L 800 3x2 100 3000
1 Recovery to change 2 100 200

refrigerant
1 New refrigerant 3 kg 300 1 100 1000
1 New filter 1 pc. 500 500
1 Commissioning 1 100 100
Total cost of retrofit 4900
III. Alternative Refrigerants and

Lubrication
1. In selecting ozone-
compatible alternatives for
CFCs, two molecular concepts are
to be used:
• Eliminate (or at least
minimize) C- Cl bonds, and
• Include C-H bonds
This is in addition to
maintaining the desirable physical and
physiological properties already
ascribed to the CFCs.
2. With these criteria set forth, the

major CFCs producers, such as
DuPont, Solvay, and ICI,
searched the tables of known
fluorocarbons in an attempt to
match these properties. From
these tables, which are extensive
only a few compounds
approximate the physical
properties of the existing
CFCs.The following table
identifies these
compounds:
List of Alternative Refrigerants
Replaceme Alternative
ODP Main Application
nt for Refrigerant
R - 11 R - 123 0.02 Water chillers
R - 12 R - 134a 0 Domestic and Commercial

Refrigeration(medium
temperature), fixed and vehicle
air-con, water chiller
R - 409A 0.0
5 Commercial and transport
R - 404A 0 Commercial and transport
R - 502
R - 408A 0.02 refrigeration
R - 22 6
0.05 Retrofit of existing R - 502
Air-conditioning
5
R - 407C Stationary air-conditioning
R - 22 0
R - 410A Stationary air-conditioning
0
R - Refrigeration
R - 500 Blends
404A Commercial and Industrial
R - 114 HCFC 124 Chiller application, marine
R - 115 HFC 125 0 Low temperature
R - 12/ R - Hydrocarbo 0 Domestic/Air-conditioners

22 ns
R - 114 HCFC - Refrigeration
142b
3. The factors that have to be considered in choosing an alternative refrigerant
are:
• The refrigerant’s atmospheric lifetime
• The ozone depletion potential (ODP)
• The total equivalent warming index (TEWI) in the intended application
• The refrigerant toxicity and flammability
• The pressure under which the refrigerant operates
• Its heat transfer characteristics
• Its compatibility with materials used in the system
• Miscibility and compatibility with lubricants
IV. Oils for Alternative Refrigerants
1. An important consideration in the development of hydro chlorofluorocarbon
(HCFCs) and hydro fluorocarbons (HFCs) as alternative refrigerants is the
testing of oils for solubility, stability, lubricity with the refrigerant, and
compatibility with materials of construction. Testing will determine which
lubricants can be used in current systems and what changes are required.
2. In general the ternary blends and HCFCs can be used with oils that are
commercially available; however, some development work may be required to
optimized performance. Applications with HFCs require the development of
new oils. The desirable properties for developmental use are:
• Acceptable solubility with the refrigerant (ideally, single phase over a
broad temperature range);
• Acceptable lubricity;
• Good thermal stability for the refrigerant/lubricant combination;
• Acceptable compatibility with system materials (elastomers, metals and
plastics);
• Low toxicity; and
• Commercial availability at a reasonable cost.
3. Listed below are the refrigeration lubricating oils and their characteristics:
Mineral Oil (MO)
• Designed for and miscible in CFC/HCFC
• Very soluble in HC (higher viscosity/superheat can be required
Alkylbenzene (AB)
• Designed for and miscible in CFC/HCFC
• Low viscosity AB is also used in rotary compressors for R-407C
Polyol ester oil (POE)
• Designed for HFC compatibility
• Soluble in CFC/HCFC/HFC/HC
• High solubility in CFC/HCFC/HC must be considered
Polyalkylene glycol (PAG)
• Designed for HFC compatibility
• Not considered suitable with CFC/HCFC
HFC Oils
Polyol esters (POE) and Poly alkylene Glycol (PAG)
PAG oils are developed for Mobile air conditioning (MAC).

• These oils are extremely sensitive to humidity and will absorb moisture
from air if exposed to ambient
• Should always be kept in well-sealed cans
• PAG oil in cans that have opened and not protected with dry nitrogen
should not be used in system
• Humidity will drastically reduce stability and reduce lifetime of system
• Careful evacuation and use of nitrogen are essential for long term
reliability
POE oils are developed for stationary refrigeration and air conditioning
(RAC) systems but are also used by some auto manufacturers for retrofit as they
are more tolerant to contaminations than PAG.
• POE oils are sensitive to humidity and will absorb moisture from
ambient air if exposed
• Humidity will drastically reduce stability and reduce lifetime of system
• Careful evacuation and use of nitrogen are essential for long term
reliability
Low viscosities Alkylene Benzene (AB) are used in rotaries for R407C and
R410A.
Self-Check 14
Satisfactor
QUESTIONS
y
Response
The student/trainee should answer all the following YES NO
questions
1. What is the importance of retrofitting?
2. What are the advantages and disadvantages of

retrofitting?
3. What lubricants are suited for HFC refrigerants?
4. What are the alternative refrigerants for R - 12?
5. In selecting ozone-compatible alternatives for CFCs,

two molecular concepts are to be used. What are they?
6. What are the factors to be considered when

approaching refrigerant retrofit?
7. Define retrofitting
The students underpinning knowledge was:

Date:
Instructor Signature:
1. The unit will be ozone-friendly.
2. A. Advantages
a. a lt er na t i ve refrigerant is ozone
friendly b. System is overhauled
c. c o m m e r c i a l availability at reasonable cost
B. Disadvantages
a. m a y reduced system efficiency
b. c a n be more expensive in case
compressor and other components needs
replacements
c. T o x i c i t y and flammability (in case of hydrocarbons)
3. Polyolester oil, Polyalkylene oil
4. R – 134a, R- 409A, Hydrocarbon
5. a. Eliminate (or at least, minimize) C-Cl bonds,

b. Include C-H bonds
6. 1. Alternative refrigerant cost

2. Availability of alternative refrigerant, in the present and
3. future.
Expected life of existing equipment.
4. Refrigerant leak history of equipment.
7. Retrofitting is the process of preparing a refrigeration and air

conditioning system for use with a replacement refrigerant and
lubricant. The basic idea of retrofit is to replace the refrigerant and
refrigerating machine oil.
Retrofit the Unit
I. Retrofit Systems
1. After all refrigerant decisions have been made, the implementation of a
refrigerant retrofit program is best accomplished in a methodical, organized
manner. Every system has unique operating conditions. It is important to
remember that all current practices for refrigeration system services still
apply with the alternative refrigerants. The basic refrigeration cycle still
applies, and changes that accompany the alternative refrigerants involve
additional service practices that must be followed. The accompanying
retrofit checklist may be used as a guide during the preliminary assessment
of an existing system. Remember that a successful retrofit begins with a
thorough analysis of the existing system. This is done before any retrofit
procedures.
2. Generally, a successful retrofit should be prefaced by the following steps:
• Assess existing equipment and examine the system for potential problem
areas
(low point, poor piping, etc.)
• Determine the service and operational history of the equipment.
• Carefully record all information regarding the existing system
components (i.e., compressor, valves, heat transfer surfaces, piping, etc.).
• Establish existing system operating conditions (pressures, temperatures,
amperage, etc.) to determine the baseline operation. This step is essential
in determining whether or not the existing system is actually producing
the desired refrigeration effect.
• Cross-reference all existing components to the intended alternative
refrigerant. Many components are likely to be acceptable; however, some
system components may need to be changed.
• Material compatibility is best determined by the OEM. Be sure to consult
the OEM
recommendation for retrofits—this is especially important for older
systems.
• Once the equipment selections have been made and all preliminary
investigation is complete, a thorough leak-check of the system should be
performed. Remember that the genesis of this CFC problem is in a large
part of result of excessive leakage.
• Further, the leak characteristics of some of the alternatives mandate the
need for
“very tight” systems.
• After all preliminary work is complete, the retrofit procedure
II. Safety requirements:
Low- and high-pressure refrigerants need to be handled as compressed
gases, and refrigerant containers are pressure vessels, which require particular
safety considerations.
Specific Safety
Practices: DOs:
• Use specific colors for containers for different refrigerant types (see
document 14 in
Annex G).
• Comply with mandatory safety precautions for systems retrofitted with
alternative refrigerants, such as hydrocarbons or ammonia, which might be
flammable or toxic (these are beyond the scope of this Guidebook).
• Properly label all cylinders using country-approved hazard labels where
applicable.
• Use proper protective caps over refrigerant valves to prevent damage to the
valve on top of the cylinder.
• Recover refrigerant prior to servicing.
• Use nitrogen in cleaning refrigeration piping.
• Use non-CFC as gas tracer.
• Thoroughly leak test system before changing.
DON’Ts
• Do not substitute refrigerant with drop-in alternatives without consulting
the system manufacturer.
• Do not exceed the manufacturer’s recommended pressure or system
strength test pressure when leak testing.
• Do not overfill refrigerant containers, tanks, drums, recovery units, receivers,
etc.
• Do not refill disposable cylinders.
• Do not use an open flame on any refrigeration system that has not been
properly evacuated for servicing.
• Do not service refrigeration systems unless wearing protective clothing,
including goggles and gloves.
• Do not attempt to service equipment unless fully trained in the safe
handling of refrigerants.
• Do not work with refrigerants in a confined space lacking ventilation.
• Do not blow off a piping system with air or oxygen to remove welding,
brazing or cutting debris, because this may cause contamination and the risk
of explosion; only dry nitrogen should be used for this task.
• Do not pressurize refrigeration or piping systems with air or oxygen.
• Do not use CFC as gas tracer.
III. Retrofitting Procedure
1. Ensure that the system is leak tight
2. Recover the refrigerant into a clean cylinder.
3. Drain the mineral oil from the system and replace it with correct
quantity of appropriate polyolester lubricant.
4. Recharge the system with the previously recovered refrigerant.
5. Run the system for long enough to “flush” the system mineral oil
residues.
6. Stop system and recover the CFC refrigerant again into the clean recovery
cylinder.
7. Drain the oil mixture and recharge the system with fresh polyolester
lubricant.
8. Recharge the system with recovered CFC refrigerant.
9. Run the system for long enough to “flush” the system mineral oil
residues.
cylinder.
11. Drain the polyolester mineral oil mixture and test it with an appropriate
test kit. The target mineral oil/polyolester lubricant concentration is 5%
mineral oil 95% polyolester lubricant. (Preferably less than 5% mineral
oil.)
12. If the mineral oil residue is higher than 5% then repeat the flushing
procedure until its lower.
13. Once the mineral oil concentration is below 5% then recharge the system
with fresh polyolester, change the drier, test for leak, and if system is free
from leak, evacuate the system.
14. Now charge the system with alternative refrigerant in accordance
with the manufacturer’s instructions/recommendation.
15. Run the system and make any adjustment as required.
16. Thoroughly leak test system and ensure that all valve caps are in place
and tight.
Note: Although HFC refrigerant will give acceptable performance in the

CFC/ HCFC system, some of the materials may not be compatible
and this can lead to component failure and leakage. It is advisable
to consult with the manufacturer before changing system
refrigerant.
II. Alternative refrigerants

Replacement refrigerants are gradually becoming available, but the earliest
ones are either blends of HCFC-22, and thus have a limited life expectancy, or
consist of blends of new “ozone friendly” (non-ODS) refrigerants that are
undergoing the the last stages of toxicity testing. However, several blends are now
available, that are based upon HFCs only, such as R-404 and R-410.
There are three categories into which replacement fluids can fall. These are:
• DROP-INS — fluids that can be substituted into an existing system
without any work being required apart from very minor servicing such as
the replacement of a refrigerant filter dryer.
• RETROBITTABLE FLUID —fluids that can be substituted into an
existing plant but only after certain changes are made, such as
substitution of new type of lubricating oil or a modification of compressor
speed.
• NON-RETROFITTABLE FLUID — fluids that cannot be used in existing
equipment even with major modifications, because of different operating
pressures materials incompatibility and other potential problems.
Retrofitting Using “Drop in” Replacement
Another type of retrofitting is the use of “drop in” replacements. “Drop in”
replacements need no change of lubricants and other accessories of the unit except
for the filter drier which is mandatory practice in servicing.
There are number of “drop in” replacements available now. It must be noted
that if you will use “hydrocarbons” drop in replacement, outmost care must be
taken into consideration. A technician should possess a special training when
dealing with hydrocarbon because of its flammability and explosiveness.
Procedure to retrofit a system with “drop in” replacement

1. Check system for leaks
2. Recover CFC refrigerant into appropriate containers and label it.
3. Record weight of recovered CFC
4. Change liquid line drier
5. Evacuate system to 500 microns (If you will use hydrocarbons, all spark
producing mechanical and electrical components must be replaced,
repositioned or enclosed)
6. Charge the replacement “drop in” into system in accordance with
manufacturer’s instruction (i.e. for weight in liquid phase from the cylinder)
7. Start system and observe the operation of the unit, make adjustment if
necessary to expansion valve, Hi switch pressure and Lo pressure switch cut
outs etc.
8. Leak test the system
9. Label the system with the new refrigerant type and remove the old labels to
prevent confusion in the future.
Note: Wear personal protective equipment and work in a well ventilated

area.
The general procedure used to retrofit a system from CFC to HFC
refrigerant is as follows:
1. Check the system for leaks
2. Recover/recycle the CFC refrigerant into a clean cylinder
3. Drain the mineral oil from the system and replace it with the correct quantity
of appropriate polyolester lubricant.
4. Recharge the system with the previously recovered CFC refrigerant
5. Run the system for long enough to flush the system mineral oil residues.
cylinder.
7. Drain the oil mixture and recharge the system with fresh polyolester
lubricant.
8. Recharge the system with recovered CFC refrigerant.
9. Run the system for long enough to flush the system mineral oil residues.
cylinder.
11. Drain the polyolester/mineral oil mixture and test it with appropriate
test kit or refractrometer. The target mineral oil/polyolester lubricant
concentration is 5% mineral oil 95% polyolester lubricant. (Preferably less
than 5% mineral oil).
12. If the mineral oil residue is higher than 5% then repeat the flushing
procedure until it is lower.
13. Once the mineral oil concentration is below 5% then, recharge system
with fresh polyolester lubricant, change drier and evacuate the system
thoroughly.
14. Now charge system with HFC refrigerant in accordance with the
manufacturers instruction.
15. Run system and make any adjustment as required.
16. Thoroughly leak test system and ensure that all valve caps are in place and
tight.
NOTE: Although HFC refrigerant will give acceptable performance in

CFC/HFC system, some of the materials may not be compatible and
this can lead to component failure and leakage. It is advisable to
consent with the manufacturer before changing system refrigerant.
Wear personal protective equipment.
Satisfactor
QUESTION
y
S
Response
The student/trainee should answer all the following YES NO
questions
1. How do you apply safety measure in retrofitting the
system?
2. What precautions must you take in handling refrigerants?
3. What would you do if something in the system

malfunction? What action should you take?
4. What should we not leave lubricant uncovered?
5. What are the three categories in which replacement fluids

can fall?
6. Give the standing pressure and temperature of the
following refrigerant.
Refrigerant Pressure
Temperature a) R - 12
b) R - 22
c) R - 134a
The students underpinning knowledge was:

Date:
Candidate Signature:
Date:
Instructor Signature:
1. a. always wears protective clothing
a. a lw a y s work in a ventilated area
b. n ev er apply heat to a system with
pressure in it. c. N e v e r use air or oxygen in
cleaning the system.
2. a. always wears gloves and goggles in handling

refrigerants b. always cover the valve spindle of
refrigerant cylinder
c. a l w a y s secure refrigerant cylinder.
d. D o not vent refrigerant in the atmosphere
3. Stop retrofitting. Troubleshoot the unit. Recover refrigerant , if necessary.
4. It will absorb moisture from the atmosphere.

5. a. Drop-ins
b. r et r of it t a b le fluid
c. n o n -retrofittable fluid
6. The standing pressure of the following refrigerant:
Refrigerant Pressure Temperature
a) R – 12
b) R – 22
c) R - 134a
Retrofit with Alternative Refrigerant
Equipment:
• Gauge manifold set
• Vacuum pump of adequate size
• Alternative refrigerant
• Alternative lubricant
• Recovery and recycling machine
• Leak testing device
• Nitrogen
• Oxyacetylene set
Observatio
Procedure n
Checklis
YES NO N/A
1. Recover refrigerant
2. Drain oil
3. Perform flashing of mineral oil
4. Change unit with alternative refrigerant and oil
5. Label the unit with new refrigerant type
6. Safety measure are applied
Retrofit with a “Drop in” Replacement
Equipment:
• Gauge manifold set
• Vacuum pump of adequate size (spark free)
• Soap suds solution
• Valve key and suitable spanners/wrenches
• Appropriate hydrocarbons.
Observation
Procedure Checklist
YES NO N/A
1. Pressure test system with nitrogen
2. Soap (bubble) test joints-repair leak if appropriate
3.Release nitrogen safely
4. Evacuate and dehydrate system - prove vacuum tight
5. Retrofit with a "drop-in" replacement
6. Record operating conditions
Note: This should only be given to those with evidence of knowledge,

skills and attitude in dealing with hydrocarbons.
Test the Operating Performance of Retrofitted Unit
Equipment: Retrofitted Unit
Instrument: Thermometer, System analyzer, Clamp Tester
Ob serv atio
Pro ced u n
re Ch
YES NO N/A
Test the operating performance of retrofitted unit using
the following steps
1. Prepare the unit and instruments required for testing
retrofitted unit such as; system analyzer, clamp-on
ammeter and retrofitted.
2. Connect the unit to the analyzer.
3. Clamp the ammeter in one of the two lines of the
power supply chord.
4. Run the retrofitted unit for thirty minutes.
5. Take reading of:
P a. Suction pressure/temperature psi/kpa
oC/oF
b. Discharge pressure/temperature psi/kpa
5. Analyze and interpret the above readings based on the
recommended operating pressure, temperature and
current. Make necessary adjustments if needed until
normal operating pressure is attained.
6. For retrofitted unit (time tested/time of
operation) Time Started
Time Ended
Total Time
No te: See specifications recommended by the manufacturer.
7. Inspection form fully accomplished.
8. Make recommendations for further maintenance action.
Forms and attachments
Comparative Data between the system before and after retrofitting
*
BEFORE AFTER RECOMMEN
RETROFIT RETROFIT DED VALUE REMARKS
TING TING (RETROFITT
ED UNITS)
Suction
Pressure
(PSI/Kpa)
Suction
Temperatu
re (? F/?
C)
Discharge
Pressure
(PSI/Kpa)
Running
Temperatu
re (? F/?
C)
Running
Current
(AMP)
Cabinet
Temperatu
re (ºF/ºC)
Type of
Refrigerant
Superheat
(ºF/ºC)
Code No. Date: Developed Date: Revised Page #

Troubleshooting Window Type Air-
conditioning/Domestic Refrigeration System 114 of 120
Cabinet temperatures are fairly standard. The table below shows the
recommended fixtures (cabinet) temperatures for some common fixtures (cabinets).
Fixture (Cabinet) o o
Temp F Temp. C
Back Bar 37 - 40 3-4
Beverage Cooler 37 - 40 3-4
Beverage Pre cooler 35 - 40 2-4
Candy Case (Display) 60 - 65 16 - 18
Candy Case (Storage0 58 - 65 15 - 18
Dairy Display Case 36 - 39 2-3
Double Display Case 36 - 39 2-3
Delicatessen Case 36 - 40 2-4
Dough Retarding Refrigerator 34 - 38 1-3
Florist Display Refrigerator 40 - 50 4 - 10
Florist Storage Case 38 - 45 3-7
Frozen Food Cabinet (Closed) -10 to -5 -23 to - 21
Frozen Food Cabinet (Open) -7 to -2 -22 to - 19
Grocery Refrigerator 35 - 40 2-4
Retail Market Cooler 34 - 39 1-3
Pastry Display Case 45 - 50 7 - 10
Restaurant Service Refrigerator 36 - 40 2-4
Restaurant Storage Cooling 35 - 39 2-3
Top Display Case (Closed) 35 - 42 2-6
Vegetable Display Refrigerator (Closed) 38 - 42 3-6
Vegetable Display Refrigerator (Open) 38 - 42 3-6

Recommended fixture (Cabinet) temperature.
Application o o
Temp F Temp. C
Service 34 - 1-3
Meats 3038- -1 to 1
Bananas 6034- 16 -
Fresh Meats 2865- -218to 0
Aging Room 3032- -1 to 1
Chill Room 34-
35 2-3
Curing Room 3239- 0-2
Freezer Room 36
-15 -26
Poultry 30 - -1 to 1
Vegetables, Fresh 3634- 2-6
Ice Cream Hardening -4225 - 32
Ice Cream Storage -20 to -10 -29 to - 23
Plants and Flowers 38 - 3 - 10
Fur Storage 3350- 0-3
Locker Room 37to
-5 -21 to -18
0
Recommended temperatures for various refrigeration applications.

• Normally, the refrigerant will be 10oF (6oC) colder than the evaporator
temperature when the unit is running. The refrigerant and evaporator will
become the same temperature during the off cycle.
• The evaporator surface temperature depends on its size and the rate at
which heat is being removed from the fixture.
• The temperature of a typical frosting type evaporator (domestic type) will vary
from 0
OF to 25 OF (-18 OC to 4 OC), and the refrigerant temperature will be about
10 OF (6 OC)
lower than this or in range of -10 OF to 15 OF (-23 OC to -9 OC) while the
unit is running.
Refrigerator Temperature
• The low side pressure in a refrigerating system determines the
temperature in the evaporator.
• One must first determine the temperature that is wanted in the cabinet or
fixture, then adjust the motor control until this temperature is maintained.

However, there are many cases where both a certain evaporator
temperature and a cabinet temperature relationship should exist.

Cross Reference Table for Single Phase, 220 Volts Compressor Motor
HP NLA FLA LRA

1/2 0.1 0.3 1.0
0
1/1 0.2 0.6 4.0
2
1/1 0.6 0.9 7.0
0
1/ 0.8 1.2 10.0
8
1/ 1.4 1.8 13.0
6
1/ 1.8 2.0 15.0
5
1/ 2.0 2.5 17.4
4
1/ 2.8 3.0 21.6
2
3/ 2.0 3.1 18.0
4
1 ¾ 6.8 34.0
1¼ 3.2 6.4 38.0
1½ 3.3 7.6 45.6
1¾ 5.1 10.20 61.2
2 6.0 12.0 72.0
2½ 7.5 15.0 90.0
Legend:
HP - Horsepower
NLA - No Load Amperage FLA
- Full Load Amperage LRA -
Lack Rotor Amperage

Name Date
Test
Competency: Retrofit Refrigeration an d Air-
Attempt
Conditioning
1st 2n d 3rd
System
OVERAL L EVAL UATION
Directions: LEVEL
PERFORMANCE LEVEL
ACHIEVED
1. Ask instructor to
Can perform the skill without supervision and with
assess your 4
adaptability to problem situations
competencies of the Can perform the skills satisfactorily without assistance
3
critical performance or supervision
Can perform this skill satisfactorily with some assistance and
criteria listed below. 2
supervision
2. You will be 1 Can perform parts of this skill satisfactorily with full assistance
0 Cannot perform this skill
evaluated using the
INSTRUCTOR WILL INITIAL LEVEL ACHIEVED
guide on the other
side
PEFORMANCE
PERFORMANCE STANDARDS L EVEL
YES NO N/A
1. Assess Un it to b e Retro fitted
1.a Estimate cost of retrofitting based on
manufacturer's recommendation
1. a.1 Select alternative refrigerants and
lubricants according to manufacturer's
recommendation.
2. Perform Retrofitting Process
2.a Select system components and accessories for
retrofitting according to application;
2.b Perform retrofitting according to
manufacturer's recommendation; and
2.c Observe safety measures during retrofitting.
3. Monitor and check operating pressures, current

3.a Temperatures for conformance with
manufacturer's operating manual
3.a.1 Analyze and interpret recorded data
based on manufacturer's
recommendations
3.a.2 Perform adjustment of controls and devices
on pressures, current and temperature in
accordance with manufacturer's standards


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PERFORM REFRIGERANT RECOVERY / RECYCLING AND RETROFITTING /

CONVERSION ON DOMESTIC REFRIGERATION AND AIR CONDITIONING

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

1. UV-B radiation -- On land,

Date Developed: Document No.

2. What is Ozone Layer?

Ozone layer is a thin, fragile shield

3. What is “0zone hole”

Ozone hole refers to the loss of the

Joe Farman, a British Antarctic

A similar “hole”, but not as damaging

Date Developed: Document No.

4. What is ozone depletion?

Ozone depletion is the loss of the

These ozone depleting substances

Date Developed: Document No.

Date Developed: Document No.

Dubbed as a miracle chemical, CFCs

Where are CFC and halons used?.

Date Developed: Document No.

Refrigerants may contribute to

Although the greenhouse effect is

II. What is NCPP Phase-out Plan?

The Montreal Protocol on

Under the Montreal Protocol, the National CFC Phase-Out Plan

In order to achieve this target, the

4. What is the name of the international treaty,

5. Define ozone layer?

Candidate Signature: Date:

2. Ozone is naturally converted to oxygen (and vice-versa) by the

3. Increase in skin cancer and cataracts; impaired immune systems;

5. Ozone layer —is a thin, fragile shield of kind oxygen in the

Most refrigerants used today for

• A halocarbon can contain chlorine

Refrigerant Nomenclature—single component refrigerants have an “R-”

The ‘a” indicates an isomer (i.e.

Physical and Environment Properties of Some Common Refrigerants

Boili Heat of Atmospher

1. Refrigerants are identified

4. Portable Refrigerant Identifier

The instrument is housed in a

5. Refrigerant Stamped on Data Plate

c. On a soldered steel plate in the

6. TEV/TXV for specific refrigerant.

Identify Refrigerants Using Identifier

1. The Refrigerant Identifier

Air Intake Port

Back View of the Identifier

4. Before proceeding in identifying refrigerant, the following should be

Step 2: Calibration. A buzzing sound

Note: When connecting the sample

The other end of the

The instrument will read

Note: In case error occurs, unplug and

Warning: Disconnect the service end of

Step 5: Unplug and return the

The Importance of Recovery/Recycling of Refrigerants

2. What are the methods of identifying refrigerants?

4. What is the cylinder color code for R-22?

5. What are the personal protective equipment