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Code of Practice for Refrigeration and Air Conditioning
NOTICE ON THE DOCUMENT This Code of Practice for Refrigeration and Air Conditioning was made possible using funding from the Multilateral Fund (MLF) through the World Bank (WB) and the Government of Sweden, granted to the Philippine Government through the Department of Environment and Natural Resources (DENR) as implementing agency and Land Bank of the Philippines (LBP) as the financial intermediary. This handbook was developed to generally reduce the emission of Ozone Depleting Substances (ODS), in Refrigeration and Air Conditioning Sector. There are three (3) sections under the sector, namely: Domestic Refrigeration and Window Type Air Conditioner, Commercial and Industrial Refrigeration and Air Conditioning, Transport Refrigeration and Air Conditioning. The original document was drafted by Engr. Ariel D. Delicana, the Project Component Coordinator for the Code of Practice, Reclamation and Trade Communication (PCCCPRTC) of the Project Management Unit (PMU) - National CFC Phase-out Plan (NCPP) under the Philippine Ozone Desk (POD) of the Environmental Management Bureau (EMB), Department of Environment and Natural Resources (DENR). This was then presented to the members of the Technical Working Group (TWG) for the Code of Practice for Refrigeration and Air Conditioning, who are composed of representatives from concerned industry organizations and stakeholders directly or indirectly involved in the field of refrigeration and air conditioning. The finalization was attained through a series of discussions with the group and consultations meetings conducted with different sectors in the refrigeration and air conditioning industry. Technicians will also use this Code as reference on good practices in handling and working with refrigerants, including regulations and legislations concerning with the trade. Each technician will be made to fully understand the contents of this material in line with their training on recovery, recycling and retrofitting procedures prior to their certification from TESDA. This Code will be a living document and therefore subject to change or revision. It is expected that those concerned sectors with areas not fully covered by this Code shall be responsible to present additional inclusions to be included in the next revision and reproduction. Any comment or suggestion will be highly appreciated for the improvement of the contents of this Code and should be addressed to: The Technical Working Group (TWG) Code of Practice for Refrigeration and Air Conditioning C/o National CFC Phaseout Plan- Project Management Unit (NCPP-PMU) Philippine Ozone Desk-Environmental Management Bureau (POD-EMB) Department of Environment and Natural Resources (DENR) DENR Compound, Visayas Avenue, Quezon City Tel. No.: 63-02-4264338/ 63-02-9284578/ 63-02-9284589 E-mail: [email protected]
NCCP-Project Management Unit
REVISION # 1st Revision 2nd Revision 3rd Revision 4th Revision 5th Revision 6th Revision 7th Revision 8th Revision 9th Revision 10th Revision 11th Revision 12th Revision
DATE Sept. 20, ‘03 Dec. 2, ‘03 Jan. 15, ‘04 Feb. 20, ‘04 Mar. 26, ‘04 May 14, ‘04 Jun. 17, ‘04 Jul. 6, ‘04 Aug. 20, ‘04 Oct. 26, ‘04 Nov. 12, ‘04 Jan. 28, ‘05
THE 2004 TECHNICAL WORKING GROUP FOR CODE OF PRACTICE This Code of Practice for Refrigeration and Air Conditioning was signed this 18th day of June 2004 at Discovery Suites, Ortigas Center, Pasig City by all Technical Working Group Members and personalities as follows:
______________________ Engr. Rosendo C. Perez Jr. Immediate Past President, PSVARE
_________________ Engr. Alex Pamplona Immediate Past President, HEAP
__________________ Engr. Ernesto J. Casis President, MAPHIL
___________________ Ms. Remma B. Tenoso White Lines Committee Chairman PAIA
__________________ Engr. Aurelio Mones Past President, HEAP
___________________ Mr. Ramon Elias F. Ortiz Ex-Officio Director, MAPHIL
__________________ Mr. Romel Y. Dimaano PARII/ Delsa Chemicals
_________________ Mr. Kenneth Tan President, KST Auto Aircon
___________________ Engr. Miracle C. Dungo Technical Coordinator, FTK
__________________ Engr. Genaro Moron Jr. Sales Engr., Unity Marketing
________________ Mr. Patricio Ilada Technical Manager, KST Auto A/C
___________________ Ms. Bess B. Llenaresas STIDS, DTI-BTRCP
___________________ Mr. Manuel P. Azucena Sr. TESD Specialist, TESDA
__________________ Engr. Jake M. Velasco STIDS, DTI-BPS
_______________________ Ms. Westphalia D. Dimalanta TIDS, DTI-BTRCP
________________ Engr. Ariel D. Delicana PCCCPRTC, NCPP PMU DENR EMB POD
__________________ Engr. Klas Berglof International Consultant Swedish International Development Cooperation Agency (Sida)
With the support and in witness hereof:
_________________ Ms. Elvira S. Pausing Project Manager, NCPP PMU DENR EMB POD
_____________________ Mr. Prudencio E. Calado III Program Manager, POD DENR EMB
___________________ Engr. Julian D. Amador Director Environmental Management Bureau Department of Environment and Natural Resources
TABLE OF CONTENTS Background A. The Ozone Issue and the Montreal Protocol -------------------------------B. Kyoto Protocol ---------------------------------------------------------------------C. The Country’s Specific Program ----------------------------------------------Introduction A. Purpose and Scope --------------------------------------------------------------B. References -------------------------------------------------------------------------C. Definition of Terms ---------------------------------------------------------------Part 1 - General Requirements Section 1 - TESDA Certification on Technicians ----------------------------Section 2 - DTI Accreditation on Service Shops ----------------------------Section 3 - DENR Registration --------------------------------------------------Section 4 - On Practices ----------------------------------------------------------Part 2 – Refrigeration and Air Conditioning Sector Part 2-1 – Domestic Refrigeration and Window Type Air Conditioners -----Section 1 – Installation--------------------------------------------------------------Section 2 – Operation and Maintenance ---------------------------------------2.1 Refrigerators -----------------------------------------------------------------2.2 Window Type Air Conditioners ------------------------------------------Section 3 – Servicing and Repair ------------------------------------------------Part 2-2 – Commercial and Industrial Refrigeration and Air Conditioning Section 1 – Upgrading of Existing System -------------------------------------Section 2 – Installation of Equipment --------------------------------------------Section 3 – Operation and Maintenance ---------------------------------------Section 4 – Preventive Maintenance --------------------------------------------Section 5 – Record Keeping and Documentation ----------------------------Section 6 – Procedures -------------------------------------------------------------6.1 Leak Testing, Evacuation and Charging Procedure ---------------6.2 Retrofitting Procedure -----------------------------------------------------6.3 Retrofitting Process Flow -------------------------------------------------Part 2-3 – Transport Refrigeration and Air Conditioning Section 1 – Marine Refrigeration and Air Conditioning----------------------1.1 Marine Refrigeration--------------------------------------------------------1.1.1 Operation--------------------------------------------------------------1.1.2 Maintenance----------------------------------------------------------1.1.3 Servicing and Repair------------------------------------------------1.2 Marine Air Conditioning---------------------------------------------------1.2.1 Installation-------------------------------------------------------------1.2.2 Operation and Maintenance--------------------------------------1.1.3 Servicing and Repair------------------------------------------------Section 2 – Land Refrigeration and Air Conditioning------------------------2.1 Mobile Air Conditioning---------------------------------------------------2.1.1 General Classification----------------------------------------------A. Engine Driven--------------------------------------------------------1. System Operation----------------------------------------------2. Maintenance-----------------------------------------------------3. Servicing and Repairs-----------------------------------------B. Dedicated Engine---------------------------------------------------1. Inspection, Operation and Maintenance ------------------
4 4 5 5 5 6 10 10 10 10 11 11 11 11 11 12 12 12 14 15 16 16 16 17 18 18 18 18 19 19 19 19 19 20 20 20 20 20 20 20 21 22 22
2.1.2 Procedures 2.1.2.1 Retrofitting Procedure -----------------------------------------2.1.2.2 Cleaning of Evaporators --------------------------------------1. For Single A/C System-----------------------------------------2. For Dual A/C System--------------------------------------------2.1.2.3 Cleaning of Solenoid Valves ---------------------------------2.1.2.4 Compressor Oil Change -------------------------------------2.1.2.5 Replenishing or Adding Compressor Oil -----------------2.1.2.6 Leak Testing ----------------------------------------------------2.1.2.7 Evacuation ------------------------------------------------------2.1.2.8 Charging ---------------------------------------------------------2.1.3 Retrofitting---------------------------------------------------------------2.1.3.1 Retrofitting From CFC-12 To HFC 134a ------------------2.1.3.2 Pointers for Retrofitting-----------------------------------------2.1.3.3 Recommended Refrigerant and Lubricant Charges-----2.1.3.4 Retrofitting Label-------------------------------------------------2.1.4 Record Keeping and Documentation------------------------------2.2 Mobile Refrigeration---------------------------------------------------------2.2.1 General Classification-------------------------------------------------2.2.2 Inspection, Operation and Maintenance--------------------------2.2.3 Servicing and Repairs-------------------------------------------------Part 3 - Retrofitting and Alternatives Section 1 – Retrofitting ---------------------------------------------------------------1.1 General Guidelines ----------------------------------------------------------1.2 Use of Drop-in Refrigerants -----------------------------------------------Part 4 – Refrigerant Handling and Storage Section 1 – Handling and Storage--------------------------------- ----------Part 5 – Recovery, Recycling, Reclamation and Disposal Section 1 – Recovery ----------------------------------------------------------------Section 2 - Recycling -----------------------------------------------------------------Section 3 – Reclamation ------------------------------------------------------------3.1 Reclamation Scheme--------------------------------------------------------3.2 Reclamation Process Flow-------------------------------------------------Section 4 – Disposal-------------------------------------------------------------------Part 6 – Safety Aspect Section 1 – Safety Requirement----------------------------------------------------Part 7 – Legislation and Regulation Section 1 – DENR Administrative Order No. 2004-08------------------------Section 2 – Phil. National Standards for MAC Systems----------------------Part 8 - ANNEXES AND TABLES ------------------------------------------------------Annex 1- Service Record ------------------------------------------------------------Annex 2 – Retrofitting Data Sheet ------------------------------------------------Annex 3 – Equipment Label --------------------------------------------------------Annex 4 – User Specific Data ------------------------------------------------------Annex 5 – Service Report -----------------------------------------------------------Annex 6 – Retrofit Label ------------------------------------------------------------Annex 7 – Start-Up Data Sheet ---------------------------------------------------Annex 8 – Inspection Checklist ---------------------------------------------------Table 1 - ARI Refrigerant Container Color Assignment ---------------------Table 2 – Maximum Allowable Container Pressure for R-12 --------------Table 3 – Maximum Allowable Container Pressure for R-134a -----------Table 4 – Useful Tables and Charts ---------------------------------------------The Technical Working Group for Code of Practice-------------------------------Acknowledgement--------------------------------------------------------------------------Ang Code of Practice…Baw --------------------------------------------------------------
23 24 24 25 25 25 26 26 26 27 28 28 28 28 28 28 28 29 29 29 30 30 30 30 32 32 32 33 34 35 35 36 40 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 56
BACKGROUND A. THE OZONE ISSUE AND THE MONTREAL PROTOCOL The ozone layer is a thin veil of molecules in the stratosphere, located between troposphere and ionosphere, which is about between 11-48 km from the earth’s surface. It blocks most of the Ultraviolet B or UV-B range from reaching the earth’s surface. Harmful effect of the UV-B rays in humans include skin cancer, eye disorders, weakening of body’s immune system and damage to plants and aquatic organisms. The stratospheric ozone depletion became a worldwide issue upon the discovery of the Antarctic “ozone hole” in 1985. Scientific evidence confirms that ozone damaged are caused by manmade compounds containing chlorine and bromine-such as chlorofluorocarbons (CFCs) and halons released in the were considered as “miracle compounds” in the chemical atmosphere. CFCs industry, but later were identified as the leading cause of ozone depletion. These are widely used in the industry like refrigeration and air conditioning (household, commercial, stationary and mobile), foam production (building insulation, flexible and rigid) and tobacco expansion. This global problem which alerted the international community, led to the adoption of the Montreal Protocol in September 1987 and was entered into force on January 1,1989 by 73 countries including the Philippines and the EEC. The Montreal Protocol on Substances that Deplete the Ozone Layer was created to restore the ozone layer by implementing programs to reduce production and consumption and eventual phase-out of Ozone Depleting Substances (ODS). The Philippines, being considered as Article 5 country (those that consume less than 0.3kg. of CFCs per capita), is legally bound to comply with the subsequent obligations; 50% consumption reduction by 2005, 85% by 2007 and complete phase out by 2010, of Annex A Group 1 chemicals. Those chemicals include: CFC 11, CFC 12, CFC 113, CFC 114, CFC 115, Halon 1211 and Halon 1301. Implementing agencies of the Multilateral Fund actively involved in assisting the Philippines with its effort to phase out ODS are the United Nations Development Program (UNDP), the World Bank (WB), the United Nations Environment Programme (UNEP) and the Swedish International Development Cooperation Agency (Sida).
B. KYOTO PROTOCOL The Kyoto Protocol is a pact agreed on by governments at a United Nations conference in Kyoto, Japan in 1997 to reduce the amount of greenhouse gases emitted by developed countries by 5.2 percent of 1990 levels during the five-year period 2008-2012. Eighty-four countries have signed the pact and 40 have already ratified it, with Romania as the only country with emissions target who have ratified to date. Greenhouse gases are gases that trap heat in the earth’s atmosphere. The main one is Carbon Dioxide (CO2), most of which comes from burning fuel. The protocol also covers Methane (CH4), much of which comes from agriculture and waste dumps, and Nitrous Oxide, mostly as a result of fertilizer use. Three industrial gases used in various applications, such as refrigerants, heat conductors and insulators, are also included – they are Hydrofluorocarbons (HFCs), Perfluorocarbons (PFCs) and Sulfur Hexafluoride (SF6) and also Chlorofluorocarbons (CFCs).
C. THE COUNTRY’S SPECIFIC PROGRAM In the Philippines, the Department of Environment and Natural Resources (DENR) - Environmental Management Bureau (EMB), act as the national coordinator for the implementation of programs under the Montreal Protocol, through the Refrigeration Management Plan (RMP) that created the Philippine Ozone Desk which develop a wide range of policy and support services. In order to concentrate further in the implementation stages, the Project Management Unit (PMU) was created under DENR Special Order No. 2003-43. Its main task is for the detailed planning, monitoring, coordination and implementation of specific projects in Refrigeration and Air Conditioning (RAC) and Mobile Air Conditioning (MAC) sector, service, foam, aerosol, Metered-Dose Inhaler (MDI) sectors.
INTRODUCTION A. PURPOSE AND SCOPE The RAC and MAC sector plays a vital role in the implementation of the Montreal Protocol to phase out the ozone depleting substances and to improve the service level in the refrigeration trade. Refrigeration and air-conditioning systems are large users of electrical energy and represent huge capital investments. To maintain these systems according to this Code of Practice (CoP) should ensure low leaks of refrigerants and lowest possible energy consumption resulting to lowest possible impact of the environment from Ozone Depleting Substances and on Global Warming from direct emissions of refrigerants as well as from indirect effects from Carbon Dioxide (CO2) emissions caused by energy consumption. This CoP will also act as reference document for the training of service technicians, to set minimum standards for good practices in servicing refrigeration and air conditioning systems and initiate communication between relevant stakeholders and other concerned trades. As a result, upon implementation of this code, it is expected that CFC consumption will be reduced in a cost effective manner, without requiring major capital investment. It will also help in the smooth transition of technology from CFC to non-CFC and will improve quality, safety and the health aspects. This CoP establishes the minimum acceptable standards of services in refrigeration and air-conditioning systems. If alternative methods are used they should ensure lower environmental impact, higher reliability and better energy performance.
B. REFERENCES UNEP Good Practices in Refrigeration Training Manual Guidebook for Implementation of Codes of Good Practice Updated Philippine Country Program for Ozone Layer Protection Carrier Refrigerant Handbook Carrier Refrigerant Transition and Recovery Certification Program UNEP National Training on Good Practices in Refrigeration Toyota HFC134a Air conditioning Fundamentals and Repairs ARI Coolnet at http://www.ari.org/er/guide-n.html TESDA TR HVAC/R SECTOR (RAC Service Technician)
C. DEFINITION OF TERMS Accredited Service Shops - service enterprises performing refrigeration and air conditioning related activities that passed the qualification requirements and was issued accreditation certificate by DTI. Air Pressure Switch - a device that triggers defrosting when the difference of the air pressures between inlet and outlet of the evaporator rises above the preset value. Alternative Refrigerant - replacement for ODS with zero ODP. Article 5-country - a developing country that is a party to the Montreal Protocol, and whose annual consumption is less than 0.3 kg per capita and operate under article 5 of the Montreal Protocol. Azeotrope - a mixture of two or more liquids, which when mixed in a precise proportions, behave like a compound when phase changing from liquid to gas (evaporating) and gas to liquid (condensing). These blends do not change volumetric composition or saturation temperature as they evaporate or condense at constant pressures. The boiling point of the mixture will be either below or above the boiling point of the individual liquids. ARI - Air Conditioning and Refrigeration Institute ARI 700 - standard used as basis for the quality of reclaimed refrigerant. ASHRAE - American Society of Heating, Refrigerating and Air Conditioning Engineers Back Conversion - means an act of charging with CFC a system designed for and/ or using non-CFC. Blend - a refrigerant mixture of two or more chemical compounds mixed in a specific ratio which can be separated by distillation. Regular blends may have up to 10 degrees C or more temperature glide Brix - a hydrometer scale usually used for sugar solutions (that is also used for refrigerant oil) so graduated that its readings at a specified temperature represent percentages by weight of that sample compared to the solution. Certified Technician - a technician who has successfully completed and passed the competency or assessment testing given by TESDA or its accredited institutions and was issued certification by TESDA itself. Chlorofluorocarbon (CFC )- a stable chemical containing only chlorine, fluorine and carbon atoms, known to be ozone-depleting substances (ODS). Commercial and Industrial Refrigeration and Air Conditioning - refers to refrigeration and air conditioning units other than domestic appliances and window type unitary units. Container/Cylinder - drum or tank intended to contain ODS or non-ODS. Contaminants - dirt, moisture or any other substance that is foreign to a refrigerant. Disposable Container/Cylinder - drum or tank designed to be used only once for the transport and storage of a virgin substance, oftentimes termed as “one trip” cylinder; made of common steel that oxidize, therefore weakens when rust occurs on walls, with a single-acting plastic valve that makes it non-refillable. Domestic Refrigeration and Window Type Air Conditioner – refers to refrigeration and window type units used for household application.
Drop-in Refrigerant – substance that is claimed to be direct replacement for ODS refrigerant, without changing existing mineral oil in the system. Dual Pressure Switch - a device with two settings; both high and low, that trips-off compressor when operating pressures go above or below the preset high or low pressure setting. Elastomers - any of various elastic substances resembling to rubber. Equipment/Unit - refers to a set of refrigeration and/or air conditioning components assembled into one packaged. It may be a fan coil assembly, a condenser-compressor assembly or combination of both. Evacuation - the process of removing air (gas) and moisture from a refrigeration and air conditioning system. Firestat - a device that controls electric defrost heaters to prevent overheating based on preset temperature setting. Flushing - an act of cleaning a contaminated refrigeration/air conditioning system or system with burnt compressor by pumping a solvent or pushing it through a system with a gas (Nitrogen) then releasing the compounds to the atmosphere or a system openly exposed or in contact with the atmosphere. Fractionation - a condition wherein one or more refrigerants in a blend leak at a rate faster than the other refrigerants in that blend. Frangible/Rupture Disk - a circular (round and dished) device used on some refrigeration equipment to provide pressure release for safety purposes. This disc suddenly breaks when a certain pressure is reached. Global Warming Potential (GWP) - is the time integrated change in “radiative forcing” due to the instantaneous release of 1kg of a trace gas expressed relative to the radiative forcing from the release of 1kg carbon dioxide. CO2 is assigned a GWP=1. Holding Charge - a charge of an inert or a refrigerant gas put into a system or equipment to ensure that there is a positive pressure to prevent air or moisture from entering into the system or equipment. Hydrocarbon - a chemical compound containing only hydrogen and carbon. These are not damaging to the ozone layer and have a minimal global-warming potential but are flammable and appropriate measures to avoid the flammability hazard should be taken. Hydrochlorofluorocarbon (HCFC) - a chemical compound containing only hydrogen, chlorine, fluorine and carbon, known to be less damaging to the ozone layer and are considered interim replacement for CFCs. Hydrofluorocarbon (HFC) - a chemical compound containing hydrogen, fluorine, and carbon, which has zero ozone depletion potential but have a global-warming potential. Hygroscopic - characteristic of a substance that readily absorb and retain moisture. Initial Charge - partial charge of refrigerant to ensure positive pressure in a system prior to final charging. Installation - refers to any permanent mounting or setting-up of system; or transfer of equipment from one location to another, which involve disconnection and reconnection of refrigerant piping and/or electrical interconnections between indoor and outdoor units. MSDS - Material Safety and Data Sheet Mobile Air Conditioning (MAC) - refers to the air conditioning system of motor vehicles. They are usually directly driven by the vehicles’ engine while for some bigger units, they are driven by another or separate engine.
Mixture - a refrigerant that contains oil and contaminants including other refrigerants. National Certificate I (NC I) - a technician certification wherein workers in this level perform routine and predictable tasks involving little or no latitude for judgment. Work involves adherence to appropriate standards or specifications while assignments are usually made by a supervisor or a worker at a higher level who gives simple instructions and makes clarifications or suggestions when necessary. National Certification II (NC II) - a technician certification wherein workers in this level prescribed range of functions involving known routines and procedures, where clearly identified choices and limited complexity applies. Work involves some accountability for the quality of outputs while applications at this level may involve individual responsibility or autonomy or working with others as part of a team or group. National Certification III (NC III) - a technician certification wherein workers on this level perform a wide range of skilled operations at a high level of competence involving known routines and procedures. The work context involves some complexity in the extent and choice of options available, understanding the work processes, equipment to and material to be used. Applications at this level may involve individual responsibility or autonomy and/or may involve some responsibility for others. Participation in teams including team or group coordination may be involved. National Certification IV (NC IV) - a technician certification wherein workers in this level perform a wide range of applications in a variety of context most of which are complex and non-routine. Work involves some leadership and guidance when organizing activities of self and others as well as contributing to technical solutions of a non-routine or contingency nature. Work at this level also requires evaluation and analysis of current practices and the development of new criteria and procedures. Application involves responsibility for the organization and performance of others. Non-condensables - gases that do not change to liquid state at operating temperature and pressure of the refrigerant. Oil Pressure Switch - a device that trips-off compressor when suction and oil pressure difference does not meet manufacturer’s recommendation. Original Equipment Manufacturer (OEM) - manufacturers of complete refrigeration/air-conditioning units. Ozone-depletion Potential (ODP) - a measure of the relative capability of a particular chemical to destroy ozone. The ODP is measured against CFC-11 which has an assigned ODP of 1.0. Ozone Depleting Substances (ODS) - a chemical compound that is sufficiently stable to reach the stratosphere and is capable of reacting with stratospheric ozone, leading to ozone depletion. Philippine National Standard (PNS) - standards developed by the Department of Trade and Industry-Bureau of Product Standards (DTI-BPS) that will be used as basis for the certification of certain products or practices. Polyalkylene Glycols (PAGs) - a very hygroscopic refrigeration lubricant that is used for HFC refrigerants for automotive air conditioning systems and have very high molecular weights. Polyolester - a popular synthetic lubricant for use with HFC refrigerants.
Pump-down system - a term used wherein the refrigerant content of a refrigeration system is isolated and temporarily stored in the condenser/liquid receiver. RAC - Refrigeration and Air Conditioning Large RAC System – capacity of more than 300kg refrigerant charge Medium RAC System – capacity of 30kg up to 300kg refrigerant charge Small RAC System – capacity of less than 30kg refrigerant charge Reclamation - means re-processing of recovered/used refrigerant to a quality/degree or specification the same as that of new refrigerant. Reclaimed material should meet the specification defined by ARI 700. Recovery - means removal of a refrigerant in any condition (vapor, liquid or mixed with other substance) from a system and to store it in an external container. Recovery Machine - a machine/equipment used to extract refrigerant. Recovery & Recycling Machine - a machine/equipment used to extract refrigerant and subject to a process to clean it in accordance with acceptable standards (e.g. SAE, ISO and PNS). Recycling - reduction of contaminants in used refrigerants by separating oil, removing non-condensables, moisture, acid and particulate matters. Refillable Container/Cylinder - re-usable drum or tank intended to contain ODS and non-ODS. Refractometer - an instrument used to measure Brix (%) of the sample solution (refrigerant oil) being checked. Refrigerant Identifier – a portable unit that allow the reliable identification or detection of percentage composition (not all) of CFCs, HCFCs, HFCs, Hydrocarbons and air content of a substance. Relief Valve - a calibrated spring-operated pressure release device that is designed to relieve pressure for safety purposes. Retrofit - process by which the equipment currently using an ODS refrigerant is made to run on a non-ODS refrigerant. SAE - Society of Automotive Engineers Servicing - means any act of repair, maintenance, testing and trouble shooting of parts, including mechanical and electrical components of an existing refrigeration and air conditioning equipment. Specified Refillable Container/Cylinder - a recyclable container that is properly color-coded or tagged for the substance it contains. System - refers to refrigeration and air conditioning components assembled/installed into a closed circuit structure isolated from outside air or surroundings. System Analyzer – gauge manifold with at least high and low pressure gauge and valves to allow control and service on RAC system. Temperature Glide - range of condensing or evaporating temperatures for one pressure. Thermistor – an electrical resistor made of a semi-conductor whose resistance varies with certain temperature. Venting - means intentional release and/or purging of substances to the atmosphere. Zeotrope - refrigerant blends that change volumetric composition and saturation temperatures as they evaporate or condense at constant pressures. They have a temperature glide as they evaporate and condense.
PART 1 - GENERAL REQUIREMENTS SECTION 1 - TESDA Certification on Technicians 1.1
Only service technicians who have passed the assessment by TESDA will be given certification.
Each Certified Technician shall be assigned with a certification number and their list will be maintained in a database at TESDA.
Only Certified Technicians will be allowed to perform service/repair works on RAC equipment/system. Only Certified Technicians will be allowed to purchase refrigerants listed under the Montreal Protocol Controlled Substances (refer to Annex II of the revised Chemical Control Order for ODS). Only Certified Technicians will be allowed to operate a Recovery and Recycling Machine.
SECTION 2 - DTI Accreditation on Service Shops 2.1 2.2 2.3
All service and repair enterprises must be registered with appropriate government agencies and accredited by DTI. Only Accredited Service Shops will be allowed to perform RAC-related services. Only Accredited Service Shops will be allowed to purchase refrigerants listed under the Montreal Protocol Controlled Substances (refer to Annex II of the revised CCO). All technicians of a certain service shop actively involve in the service of RAC system shall be certified.
SECTION 3 - DENR Registration on ODS Importers, Distributors, Dealers, and Retailers 3.1 3.2
Only DENR-registered enterprises shall be allowed to import ODS refrigerants. Only enterprises (dealers, retailers, re-sellers) registered by DENR shall be allowed to purchase, re-sell or distribute ODS refrigerants.
SECTION 4 - Practices 4.1 4.2 4.3 4.4
Never use ODS as cleaning solvent for the system. Never mix different types of refrigerant in one cylinder. Always recover refrigerant before servicing a system. Never vent ODS/ HFCs refrigerant in the atmosphere.
PART 2 – REFRIGERATION AND AIR CONDITIONING SECTOR PART 2-1 – DOMESTIC REFRIGERATION AND WINDOW TYPE AIR CONDITIONER SECTION 1 - INSTALLATION 1.1 Refer to the manufacturer’s recommended installation instruction when installing window type air conditioning unit. 1.2 As much as possible, avoid installation wherein the condenser coil is exposed to direct sunlight. 1.3 Seal-off all possible air leakages within the conditioned area to prevent infiltration of outside air. 1.4 Seal-off air gap between unit’s housing and wall. 1.5 Unit should be installed in such a way that the water condensate is prevented from dripping back inside the room. 1.6 Make sure that available electrical power supply is in accordance with the unit’s specification. 1.7 Unit should be secured using approved brackets or fabricated frames.
SECTION 2 - OPERATION AND MAINTENANCE 2.1 Refrigerators 2.1.1 Refer to manufacturer’s recommended operation manual. 2.1.2 Excessive ice build-up on the evaporator should be avoided. 2.1.3 Observe regular defrosting interval and procedure in accordance with manufacturer’s recommendation. 2.1.4 Maintain a time delay interval of at least 3 minutes when turning the compressor on after shut off or during power failures. 2.1.5 Minimize frequent opening of the refrigerator door. 2.1.6 Provide adequate flow of air on the condenser section of the refrigerator. 2.1.7 Freezer/refrigerator doors/compartments should be locked air tight to avoid migration of humid and warm air that will become additional load to the unit.
2.2 Window Type Air Conditioners 2.2.1 2.2.2 2.2.3
Refer to manufacturer’s recommended operation manual. Regularly clean air filter. Maintain a clean condenser, evaporator, blower and other accessories through periodic cleaning. 2.2.4 Ensure that the condenser airflow is not blocked. 2.2.5 Re-start the unit only after at least 3 minutes from compressor shut-off or power breakdown/failure. 2.2.6 Check for traces of oil on refrigerant lines as signs of possible leaks. 2.2.7 Provide periodic checks on the operating amperages and temperatures. 2.2.8 Use appropriate cleaning agents when cleaning the evaporator and condenser coils. 2.2.9 Use pressurized water or compressed air when cleaning coils. 2.2.10 Use fin comb in straightening fins.
SECTION 3 – SERVICING AND REPAIR 3.1 3.2 3.3
Assess condition of unit to determine whether it is practical to repair or not. If beyond repair, the technician shall exert utmost effort to recover the refrigerant content of the unit, if there is any. If repairable, perform procedures in accordance with acceptable industry practices
PART 2-2 – COMMERCIAL AND INDUSTRIAL REFRIGERATION AND AIR CONDITIONING SECTION 1 – UPGRADING OF EXISTING UNIT This section covers the improvement of existing system set-up, particularly for larger units with sufficient remaining lifetime. This does not cover system design. Modification of the system including installation of additional parameters mentioned herein shall be done only during major repair, in order not to hamper its continuous operation, and should not be effected while the unit is normally operating. The following guidelines should be followed as well as those given by the manufacturer, if available: 1.1 Pump down system and/or recover refrigerant before opening the refrigeration system. 1.2 Recovered refrigerants shall be properly labeled to avoid being charged to other system. 1.3 Technicians shall exert all efforts to prevent leaks of refrigerant during recovery operation. 1.4 Ensure that the existing equipment is set-up to a pump down system. If not, install the necessary refrigerant service valves, replace if found defective. 1.5 If found necessary, modify refrigerant piping installation to the standard and acceptable industry practice (refer to applicable ASHRAE/ARI or manufacturer’s standard). 1.6 Whenever possible, convert flared or screwed connections into brazed type refrigerant piping and fittings. 1.7 Ensure that gauges for monitoring system condition and refrigerant charge are installed and operational. 1.8 Ensure that vibration eliminators installed on suction and discharge lines as per manufacturer’s standard. 1.9 Ensure setting of pressure-limiting devices such as high/low and oil-failure pressure switches according to manufacturer’s standard.. 1.10 Ensure pressure relief valve setting is in accordance with manufacturer’s standard.
SECTION 2 - INSTALLATION OF EQUIPMENT The following should be observed for all refrigeration and air conditioning installations: 2.1 Refer to the manufacturer’s recommended installation instruction and procedure. 2.2 Exposed pipe ends shall be sealed-off to prevent it from being exposed to moisture and foreign materials. 2.3 All units shall be installed free from hazards to person, property and the environment. 2.4 All installation works shall be closely monitored and supervised by a competent and responsible person. 2.5 Always observe safety procedures during installations.
2.18 2.19 2.20 2.21 2.22
Provide adequate ventilation at refrigeration equipment room or adequate space as per acceptable industry standards (ASHRAE, ARI, and other standard ventilation handbook). Sufficient service space shall be provided to individual equipment, as recommended by its manufacturer. Use tube or pipe cutter when cutting copper tube or pipes. Ensure that pipes and fittings to be used are clean before installation. Provide oil trap for refrigerant riser pipelines as per manufacturer’s standard. Refrigerant piping shall be properly clamped and secured. Refrigerant piping shall be kept properly insulated with the correct insulation size all throughout its piping length. Insulation shall be properly joined. Provide rubber pad between unit and its base to prevent transmission of vibration that may cause noise. Do not over-tighten bolt & nuts/fasteners. Secure unit frame to a firm hold to prevent vibration. Whenever possible, avoid installation of condensing unit with its coil directly exposed to sunlight. Fan Coil Unit (FCU) / Air Handling Unit (AHU) shall be installed ensuring positive condensate drain. Refrigerant piping should be done according to acceptable industry/manufacturer’s standard. As much as possible, avoid imbedded piping installation. Introduce dry nitrogen into the pipe while brazing or soldering to prevent metal oxidation. Use dry nitrogen or with any acceptable non-CFC/HCFC agent to flush out debris from brazing or cutting. Never use oxygen for flushing. CFC refrigerant shall not be used as cleaning agent nor shall it be used for flushing dirt out of the system. Always check holding charge content of the condensing unit before connecting to the installed refrigerant piping. Piping installation shall be leak tested at150 psig for low side and300psig at high side using dry nitrogen (as per manufacturer’s recommendation) to ensure that the system is free from leaks. Evacuation of the system shall be at least 1000 microns (1 mBar, 29.87in Hg) or below. Always provide exclusive power supply and circuit breakers for each unit as per manufacturer’s standards. When using polyethylene tapes on refrigerant piping insulation, do not wrap too tightly to avoid decreasing the insulation property. Safety related component shall be checked if functioning properly (e.g. high and low pressure switches, time delay, solenoid valves, pressure relief valves and the like). The settings and results of tests should be documented for future reference. The refrigeration system component shall be labeled. Equipment specification and technical data (MSDS, technical bulletin, etc.) shall readily be available, to include type and amount of refrigerant and lubricant used in the system. A Start-Up Data Sheet shall be accomplished right after installation.
SECTION 3 - OPERATION AND MAINTENANCE This section includes activities performed on a regular basis: 3.1 General 3.1.1 Inspect panels (insulated cabinet, control panel, etc.); schedule repair, if necessary. 3.1.2 Inspect unit switches for unusual or abnormal condition. 3.1.3 Check bearings for any unusual sound and vibration. Apply grease or oil, if necessary. 3.1.4 Check tightness of all bolts and screws; tighten, if necessary. 3.1.5 Check fan and fan housing for dirt accumulation; clean, if necessary. 3.2 Refrigerant/oil system 3.2.1 Inspect condition of refrigerant piping insulation, and schedule repair or replacement, if necessary. 3.2.2 Inspect sight glass (if present) for refrigerant flow/quality. 3.2.3 Visually inspect for refrigerant leaks as indicated by oily spots and use appropriate leak detector to accurately locate the leak. 3.2.4 Check schrader/access valves, packing glands, O-rings and service caps for tightness. 3.2.5 Check compressor oil level (if applicable). If it is low, report for further analysis. 3.2.6 Check oil for discoloration indicating oil that needs to be replaced and system checked. If it is discolored, report for further analysis. 3.2.7 Check oil pressure (if applicable). It should read higher than the suction pressure or as recommended by the manufacturer. If below the manufacturer’s recommended pressure, report. 3.2.8 Check Oil Failure Pressure Switch (if applicable). 3.2.9 Check operating pressures: 3.2.9.1 Suction 3.2.9.2 Discharge 3.2.9.3 Oil Pressure (if applicable) 3.3 Secondary warm side 3.3.1 Check condenser coils for dirt accumulation; clean, if necessary. 3.3.2 Check condenser water supply (if applicable) 3.3.3 Check condenser water return (if applicable) 3.3.4 Check operating temperatures: 3.3.4.1 Condenser water supply (if applicable) 3.3.4.2 Condenser water return (if applicable) 3.3.4.3 Condenser supply air (if applicable) 3.3.4.4 Condenser return air (if applicable) 3.3.5 Check condenser water pumps’ operating parameters (if applicable): 3.3.5.1 Suction pressure 3.3.5.2 Discharge pressure 3.3.6 Check motor current draw. 3.3.7 Check cooling tower’s water level, make-up water and other operating parameters and abnormalities. 3.4 Secondary Cold side 3.4.1 Check evaporator coils for dirt accumulation; clean, if necessary. 3.4.2 Check drain pan for any dirt accumulation; clean, if necessary. 3.4.3 Check drain line to ensure continues condensate flow; de-clog, if necessary. 3.4.4 Check chilled water expansion tank’s water level and float valve. 3.4.5 Conduct regular bleed-off as per manufacturer’s recommendation. 3.4.6 Check operating temperatures:
3.4.6.1 Evaporator water supply (if applicable) 3.4.6.2 Evaporator water return (if applicable) 3.4.6.3 Evaporator supply air (if applicable) 3.4.6.4 Evaporator return air (if applicable) 3.4.6.5 Chilled water supply pressure (if applicable) 3.4.6.6 Chilled water return pressure (if applicable) Electrical/control system 3.5.1 Check and clean all electrical contacts and terminals. Tighten loose terminals. 3.5.2 Check quality of power supply. Ensure that power supply is within ±10% of the rated voltage requirement of the equipment. 3.5.3 Take reading of compressor motor current draw. 3.5.4 Check overload relays. 3.5.5 Check belt tensions and alignment of pulley; adjust, if necessary. 3.5.6 Check belt for any abnormal wear. Determine its cause and make necessary correction. 3.5.7 Take reading of fan and pump motor current draw. 3.5.8 Check all electrical controls; calibrate, if necessary: 3.5.8.1 High and Low Pressure switch 3.5.8.2 Timers 3.5.8.3 Thermostat 3.5.8.4 All other electrically and electronically controlled devices.
SECTION 4 - PREVENTIVE MAINTENANCE This section includes planned activities that must be done on specific intervals. 4.1 Preventive maintenance procedures shall be aimed to: 4.1.1 Promote safety: 4.1.1.1 Avoid accidents to personnel 4.1.1.2 Prevent damage to goods and properties 4.1.2 Maintain continuous operation of the system 4.1.3 Identify system leaks the earliest possible time 4.1.4 Ensure good working condition of all components and parts 4.1.5 Minimize energy consumption and peak loads. 4.2 Establish a Preventive Maintenance Schedule (PMS) to ensure efficient equipment performance to avoid breakdown. 4.3 All moving parts shall be given extra attention since these are subject to wear and tear. 4.4 Signs of abnormal vibration shall be checked and corrected. 4.5 Avoid electrical lines to come in contact with the discharge line. Hot pipe surface can melt the wire insulation that may result to short circuit. 4.6 Regular bearing lubrication is needed for efficient performance. 4.7 Use appropriate leak detector or other leak detection method to accurately locate leak (e.g. refrigerant, air and water). 4.8 Use appropriate cleaning agent when cleaning evaporator and condenser coils. 4.9 Check evaporator superheat. 4.10 Establish the quality (e.g. acidity level) and type of lubricating oil in the system before adding or changing new oil.
SECTION 5 - RECORD KEEPING AND DOCUMENTATION NCCP-Project Management Unit
Detailed and regular documentation of operating parameters is very important in maintaining a refrigeration or air conditioning system. If properly implemented, this will serve as the system history and would be the basis in the diagnosis of abnormal conditions that will happen in the future. The following should be implemented: 5.1 Provision of a daily log sheet report (for large refrigeration and air conditioning system) where all operating parameters like suction and discharge pressures, amperages, temperatures, and the like, will be recorded by the technician in-charge. 5.2 Daily log sheet should be compiled and placed inside the machine room or near the unit for future references. 5.3 A service logbook should also be provided and located in a place accessible for service technicians and in close proximity to the refrigeration system. It should contain the following: 5.3.1 Service Record (Annex 1) 5.3.2 Retrofitting Data Sheet (Annex 2) 5.4 Locate and maintain an equipment manual in a place near the service logbook. The manual should contain the following: 5.4.1 Equipment Label (Annex 3) 5.4.2 User Specific Data (Annex 4) 5.4.3 Manufacturer’s instruction/ operating manual
SECTION 6 - PROCEDURES 6.1 LEAK TESTING, EVACUATION AND CHARGING PROCEDURE If the system is suspected to have leaks and needs repair (except for leaks on fittings which can be corrected through proper tightening), the following procedure should be undertaken: 6.1.1 6.1.2
Locate the leak through visual inspection. Run the system and check for leaks using appropriate leak detector. If the system has no charge, proceed with step 1.1.4. 6.1.2.1 If leak is located on the low side, pump down the system. 6.1.2.2 If the leak is located on the high side, proceed with 1.1.3. 6.1.3 Recover refrigerant charge of the system using recovery machine. 6.1.4 Charge system with dry nitrogen (150 psig on low side, 300 psig on high side) for leak testing. 6.1.5 Repair leaks found and double check by performing 1.1.4 again until system is sure to be free from leaks. 6.1.6 Evacuate the system to at least 1000 microns (1 mBar, 29.87 in Hg) using an appropriate vacuum pump and an electronic/vacuum meter. 6.1.7 Initially charge the system, run the unit and add refrigerant until fully charged. 6.1.8 Refrigerant charge should be based on manufacturer’s data by weight or pressure temperature chart until proper operating conditions are attained (e.g. proper sub-cooling).
6.2 RETROFITTING PROCEDURE (e.g. CFC 12 to HFC 134a and R502 to 404A/R507) 6.2.1 Pump down system and recover refrigerant before opening the refrigeration 6.2.2 6.2.3 6.2.4 6.2.5
6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14
6.2.15 6.2.16
system. Recovered refrigerant shall be stored only in a specified refillable container or cylinder and properly labeled. Recovery of refrigerant shall be done using recovery machine or a recovery and recycling machine to be operated only by a certified technician. Technician should exert all efforts to ensure the prevention of refrigerant emissions during recovery operation. Drain and recover existing mineral oil charge, measure the quantity and compare with the recommended oil charge to determine approximately the quantity of oil left in the system. Replace all equipment components and accessories that will be affected by the new alternative refrigerant and its alternative refrigerant oil (e.g., expansion valve, gaskets, filter drier, etc., as recommended by the manufacturer.) Charge the system with new and correct amount of alternative refrigerant oil as recommended by compressor/system manufacturer. Run the system while performing oil change procedure as many times as necessary until mineral oil in the system does not exceed the recommended 5 percent acceptable level. Leak test the system with dry nitrogen and observe a 24-hour standing pressure. Make corrections if deemed necessary. Evacuate system to at least 1000 microns (1 mBar, 29.87 in Hg) using appropriate vacuum pump and an electronic vacuum meter. Charge the system with initial amount of alternative refrigerant (50 psig for refrigeration, 70 psig for air conditioning systems). Run the system and charge additional refrigerant if needed until full-charged. Monitor the system operation and performance for at least 48 hours or longer and make necessary adjustment. Check remaining content of mineral oil with a refractometer or oil test kit. Follow system and/or compressor manufacturer recommendations as tolerance are dependent on system and operating conditions. Label the system (see Annex 7).
6.3 RETROFITTING PROCESS FLOW: Existing CFC systems
Isolate Compressor Fill Alternate Refrigerant
Drain Mineral Oil
Remove CFC Refrigerant
Refill with Alternative Oil
Check Oil Contamination
If > 5.0 % If < 5.0 %
PART 2-3 – TRANSPORT REFRIGERATION AND AIR CONDITIONING SECTION 1 – MARINE REFRIGERATION AND AIR CONDITIONING 1.1 MARINE REFRIGERATION 1.1.1 OPERATION Before unit is set to operate, make sure that the following are strictly observed: 1. Power supply (circuit breaker or On-Off switch) is off before performing preoperational check-up. 2. Voltage selector switch set to the right supply voltage. 3. Dry element battery is checked. 4. Control box cover tightly closed after circuit breaker is turned-on. 5. Temperature recorder is functioning. 6. Recording paper is in placed, time and date is set. 7. Cooling water piping properly connected and air is purged. 8. All refrigerant valves opened. 9. Oil pressure protection switch is checked if reset is needed (other unit may not start unless this switch is reset).
1.1.2 MAINTENANCE 1. Always refer to the manufacturer’s recommendation when maintaining a refrigeration system. 2. Check for unusual noise and vibration. 3. Check suction and discharge pressures of the compressor. 4. Check oil level of compressor. 5. Check refrigerant and content thru the sight glass (if applicable). 6. Check moisture content of the refrigerant thru the sight glass. 7. Check if temperature recorder operates according to inside temperature. 8. Check solenoid valves. 9. Check switches and pilot lights. 10. Check voltage indicator of dry battery for temperature recorder. 11. Check temperature recorder quartz motor if functioning. 12. Check dual pressure switch. 13. Check oil pressure protection switch. 14. Check water pressure switch. 15. Check defrost timer. 16. Check heaters. 17. Check air pressure switch. 18. Check defrost thermostat. 19. Check firestat. 20. Power cable plug should be positioned facing downward to prevent water from entering. 21. Perform defrosting after every operation. 1.1.3 SERVICING AND REPAIR 1. Always follow manufacturer’s standard procedures when replacing parts and accessories of a system. 2. Check cause of melted fusible safety plug before replacement. 3. Refer to manufacturer’s diagnostic chart for remedies when trouble shooting mechanical and refrigeration mal-functions. 4. Perform servicing and repair of the system in reference to manufacturer’s servicing manual.
1.2 MARINE AIR CONDITIONING 1.2.1 INSTALLATION 1. Always follow manufacturer’s recommended installation procedure. 2. Install only units designed for marine application. 3. Evaporator and condensing unit shall be properly secured and fixed. 4. Refrigerant piping, electrical control lines and ducting (if applicable) shall be properly installed and secured. 5. Install drain line to effect immediate flow of condensate and prevent from accumulation on the drain pan. 6. Electrical connectors shall be thoroughly checked for tightness. 7. Refrigerant piping shall be thoroughly checked, leak tested and dehydrated. 8. Control box cover shall be properly sealed after commissioning. 1.2.2 OPERATION AND MAINTENACE 1. Always refer to the manufacturer’s recommendation when maintaining a refrigeration system. 2. Check for correct voltage before starting the unit. 3. Check for unusual noise and vibration. 4. Check suction and discharge pressures of the compressor. 5. Check oil level of compressor (if applicable).
6. Check refrigerant and content thru the sight glass (if applicable). 7. Check moisture content of the refrigerant thru the sight glass. 8. Check if temperature recorder operates according to inside temperature. 9. Check solenoid valves (if applicable). 10. Check switches and pilot lights. 11. Check dual pressure switch (if applicable). 12. Check oil pressure protection switch (if applicable). 13. Check fans, motors and water pumps (if applicable). 14. Check condition of coils and fins. 15. Check sump tank/drain pan of FCU/AHU including drain lines. 1.2.3 SERVICING AND REPAIR 1. Always follow manufacturer’s standard procedures when replacing parts and accessories of a system. 2. Ensure that faults and are corrected before replacing defective parts. 3. Seal-off exposed pipe ends and fittings. 4. Always replace filter drier after every repair. 5. Always follow standard procedure for servicing and repair of the system.
SECTION 2 – LAND REFRIGERATION AND AIR CONDITIONING 2.1 MOBILE AIR CONDITIONING 2.1.1 GENERAL CLASSIFICATION A. ENGINE DRIVEN 1. SYSTEM OPERATION Purpose: To inform the technician the basics in operating a MAC System. Background: It is important that the mechanic is well informed of the basic Standard Operating Procedure of the MAC system. The mechanic should consider the effect of the air conditioner to the vehicle and vice-versa. Guidelines: 1.1 Make sure that the air conditioner switch is off when starting the engine. 1.2 Make sure that the engine is properly warmed-up before starting the MAC system. 1.3 Make sure that the air vent is set at the re-circulation mode. 1.4 Set air conditioner blower and thermostat switches to maximum and adjust to desired setting as the cabin reaches comfortable temperature. 1.5 Avoid prolonged opening of windows and doors when the air conditioner is in operation. 1.6 Always keep the car interior clean, especially the carpets. 1.7 Turn off the air conditioner/blower switch before shutting off the engine. 2. MAINTENANCE Purpose: To serve as reference for technician in the proper maintenance of a working MAC system to prevent or detect breakdown/failure to happen. Background: Maintenance servicing of the MAC system should be done every two years or 25,000 km whichever comes first. Guidelines: 2.1 Check for signs of leak on the systems’ fittings and component parts that are readily accessible. 2.2 Check for any refrigerant lines that are not properly secured.
2.3 Check for any air conditioner electrical wirings and components that are not properly secured. 2.4 Check belt tension. 2.5 Check magnetic clutch gap. 2.6 Check for unusual sounds e.g. belt noise, bearing noise, vibrations. 2.7 Check refrigerant content of the system through the sight glass. 2.8 Attach gauge manifold to check for systems’ low and high pressures. 2.9 Check condition of condenser. 2.10 Check condition of auxiliary fan. 2.11 Check function of air conditioner switch. 2.12 Check function of safety pressure switches. 2.13 Check function of thermostat. 2.14 Check systems performance that should run at normal operating pressures: 0.15-0.25MPa (22-36psig) for low side and 1.37-1.57MPa (200-228psig) for high side. 2.15 Ensure that the refrigerant charging ports (suction & discharge) are properly capped. 2.16 Keep the condenser clean as often as possible. 3. SERVICING AND REPAIRS Purpose: To serve as guide/reference for technicians on the general conditions, precautions and procedures for the service and repair of MAC systems. Guidelines: 3.1 Before attempting any service or repair, identify first the type of system. The most common means of identification of HFC-134a system are as follows: a. Vehicle identification through air conditioning labels and fittings. b. Compressor identification through the labels and stickers. c. Line identification through the groove at the connectors and marks at refrigerant lines. 3.2 Remove wristwatches, rings, bracelets, necklaces, keys and other personal items that may inflict personal injuries. These may also damage the exterior and interior parts of the vehicle. 3.3 Use proper and complete set of tools before starting a job. 3.4 Ensure that gauge manifold set used for charging CFC system shall not be used for charging HFC system to prevent refrigerant contamination. 3.5 Use lubricating oil compatible to the refrigerant used in the system. 3.6 Never convert an HFC 134a system to a CFC-12 system. 3.7 Always use fender covers. 3.8 Always cover open or exposed pipes and fittings. 3.9 Never re-use O-rings. 3.10 Use quick connectors (with check valve) for HFC 134a system. 3.11 Always tighten all fittings. 3.12 Never use hose clamp in place of crimped connectors. 3.13 Never use Carbon Tetrachloride as a cleaning agent. 3.14 Always use vacuum pump to evacuate the system. 3.15 Containers of excess HFC oils shall be sealed-off to prevent the oils from absorbing moisture. 3.16 Factory protective caps shall not be removed from the fittings until ready for connection particularly for receiver drier or compressor. 3.17 When connecting two pipes with fittings, observe the following: a. Apply compressor oil to O-ring surfaces. b. Check O-ring position if correctly seated on the groove. c. Insert the pipe with the O-ring straightly to the other pipe and tighten by hand. If pipe with O-ring is inserted un-aligned, pipe sealing surface may get damaged.
d. Use two wrenches when tightening/loosening fittings to avoid twisting or bending the pipes. Observe the following: i. Excessive tightening torque may cause gas leak. ii. Visually inspect/check for cracks on fittings as a result of over-tightening or over-turn. iii. Make sure that the surface of the fitting seat is corrosion free and not deformed. Both high and low-pressure side of the system should be connected to the vacuum pump when evacuating the system. Extra care should be observed not to damage the line when replacing Orings. Oil cans should have their individual labels in order not to contaminate a system. Evaporator shall be properly cleaned following a standard procedure (see section 2.1.2.2 under Procedures) or as recommended by the manufacturer. Ensure that wire/wire connectors are properly labeled during dismantling/pulling-down of evaporator for repair or cleaning, to avoid misconnections upon re-installation. Make sure all operating parameters like system pressures or temperatures are recorded to serve as reference data for after-service reading. Always use Personal Protective Equipment (PPE). Always add refrigerant oil to the system (see section 2.1.2.3 under Procedures).
B.DEDICATED ENGINE (SUB-ENGINE) 1. INSPECTION, OPERATION AND MAINTENANCE It is advisable to follow manufacturer’s recommended inspection, operation and maintenance procedure. Otherwise, the following should be considered before and during the operation of a MAC system with a dedicated engine to drive its compressor: 1. For Drive Engine 1.1 Check engine’s oil condition and level, replace if necessary. 1.2 Check cooling water’s condition in the radiator, replace if necessary. 1.3 Check belt tension, replace if necessary. 1.4 Check level of fuel at tank, re-charge if needed. 1.5 Check bolts and nuts for tightness. 1.6 Check air cleaner element, clean or replace as needed. 1.7 Check intake air hose, clean or replace as needed. 1.8 Check radiator hose, clean or replace as needed. 1.9 Check fuel filter, clean or replace if needed. 1.10 Check rubber cushion and mounting bolts, replace if needed. 2. For Compressor 2.1 Check oil level at sight glass and add/replace if needed. 2.2 Check installation of mounting brackets, clamps and bolt tightness. 2.3 Check abnormal noise and vibration, correct if needed. 2.4 Check shaft seal for oil leaks, replace if necessary. 2.5 Check other parts of compressor for possible oil leaks, repair if needed. 3. For Condenser 3.1 Check condenser coil, clean if needed. 3.2 Check for leaks, repair if found.
Check condition of condenser motor and fan, repair/replace if needed. 4. For Cooling Unit 4.1 Check Cooling coil, clean if needed. 4.2 Check air inlet packing for restriction, replace if needed. 4.3 Check air filter, clean if needed. 4.4 Check condition of evaporator blower and motor, repair/replace if needed. 4.5 Check for leaks, repair if found. 4.6 Lubricate bearings as needed. 5. Other Accessories 5.1 Check for leaks on refrigerant piping, fittings and hoses, repair/replace if needed. 5.2 Check strainers/driers, replace if needed. 5.3 Check piping clamps, fix or replace if needed. 5.4 Check for any damage to flange couplings, replace if needed. 5.5 Check loose electrical wirings and connections, tighten or replace if needed. 2.1.2 PROCEDURES
2.1.2.1 RETROFITTING PROCEDURE The following are recommended procedures in retrofitting CFC 12 MAC systems to HFC 134a system (refer also to PNS SAE J1661: 2003 and manufacturer retrofit procedures whenever available.): 1. Leak check using hand held leak detector (refer also to PNS SAE J1628: 2003) set to detect CFC 12 and/or the soap bubble test. Make repairs if necessary. 2. Run the vehicle to obtain (suction/discharge pressures) and check again for leaks. 3. Recover all refrigerant from the system following standard procedure for CFC refrigerant recovery and store in a specified refillable container properly labeled. 4. Remove compressor from its mounting bracket and drain its lubricating oil. 5. Rinse the internal parts by pouring alternative oil for new refrigerant into the compressor and manually rotating the compressor shaft. Amount of oil for rinsing is about 50% of the recommended factory oil charged. 6. Repeat oil rinsing procedure as necessary. 7. Pour proper amount of alternative refrigerant oil into the compressor as per Original Equipment Manufacturer (OEM) and cap suction and discharge lines until the system is ready for re-assembly. 8. Flush the entire system with Nitrogen and any environmental friendly cleaning agent. 9. Pressure test each component for leaks. Repair or replace if necessary. 10. Replace expansion device and filter drier compatible to the alternative refrigerant. 11. Change all flare type to o-ring type fittings. 12. Replace all O-ring seals on pipes and hoses with those approved for HFC 134a and PAG oils. 13. Re-install and assemble system components.
14. Modify access valves/fittings to accept only the new alternative refrigerant fittings. 15. Evacuate system to at least 1000 microns(1 mBar, 29.87in Hg) using appropriate vacuum pump and an electronic vacuum meter. Make corrections if necessary. 16. Charge the system with alternative refrigerant (PNS SAE J1657 : 2003, Annex 5) as recommended by manufacturer whenever possible. Notice that optimum charge will change when systems are retrofitted. 17. Observe system operation and check again for leaks. 18. Compare obtained new set of data to that obtained when the system was still using CFC. 19. Label system clearly.
CLEANING OF EVAPORATORS
If it is determined that the job would require to pull-down the evaporator as for checking of leaks, replacement of expansion valve, fixing of mal-functioned air vent that resulted to the coming in of outside air into the vent assembly due to damaged foam insulation, or plainly because of too much dirt; proceed with utmost care as it is always a good service management to prevent dashboard, seat covers and other interior part of the vehicle from getting dirty or stained when removing the evaporator assembly. The following steps are recommended when cleaning the evaporator:
1. FOR SINGLE A/C SYSTEM 1.1
When the evaporator is removed from the system, cap or cover the refrigerant lines from which it was disconnected as well as its fittings. This will prevent dirt from entering the system. 1.2 Remove the evaporator coil from its housing. 1.3 Remove the thermistor or sensor of the thermostat, taking note of its location so that it can be returned to the same place after cleaning the evaporator. 1.4 Using the pressure washer, wash-off dirt from the evaporator fins by directing the pressurized stream of water thru the fins on the opposite side where all dirt is accumulated. This should dislodge the dirt clinging to the fins of the evaporator. 1.5 Directing the pressurized water to the area on the other side will further force the dirt deeper into the fins. Extra should be observed not to damage the fins when subjected to a very high water pressure that will fold back the fins and will subsequently hamper the air speed from flowing thru it. Adjust the pressure washer nozzle as necessary. 1.6 Leak test the coil. 1.7 If there is no leak, check condition of the expansion valve. When removing the expansion valve, take note of the location and position of its sensing bulb and shall be fixed exactly the same after servicing. 1.8 Check whether the expansion valve is still clean, dirty or clogged-up, replace if necessary. Car air conditioner manufacturers suggest that drier and expansion valve shall be replaced after every two (2) years or 50,000 km, whichever comes first. 1.9 If evaporator coil has leak/s, repair or replace if necessary. 1.10 Flush the evaporator coil with Nitrogen to remove excess oil. Install back the expansion valve to its original. Change the o-ring, apply Teflon tape if necessary on the thread and connect its fittings with care (initially by hand before using wrenches) to prevent damage to the threads. 1.11 Leak test the assembly one more time for verification.
1.12 Clean the evaporator housing. Check foam insulation, replace if necessary. 1.13 Remove the blower assembly. Check if noisy or weak, repair if necessary. Apply lubricating oil on motor shaft/bushing. Clean the blower assembly before putting everything back into the car.
FOR DUAL A/C SYSTEM
2.1 The same procedure is followed except 20ml of new refrigerant oil is added in each of the evaporator coil before it is assembled. 2.2 Magnetic and solenoid valves of systems with separate coolers should be cleaned thoroughly by flushing with Nitrogen in the direction opposite to the refrigerant flow. Note location of the solenoid valves as follows: 2.2.1 Incorporated into the refrigerant lines 2.2.2 Incorporated into the expansion valve
CLEANING OF SOLENOID VALVES
Should the construction of the solenoid valve allow it to be dismantled and its internal parts cleaned, it would be advisable to do so to be sure that there are no debris lodged in the valve that might cause problems later on. 1. Detach/Pull-out the solenoid valve from the system. Extra care should be observed not to damage its fittings. 2. Dismantle the valve. Be careful not to loose particularly its smaller parts. 3. Remove any dirt or debris lodged on the valve seat. 4. Assemble the valve parts. 5. Test the efficiency of the valve by blowing air into it in the valve in the direction of the refrigerant flow. No air should pass through the valve. 6. Energize the valve and test again, this time air should be able to pass thru it. 2.1.2.3
REPLENISHING OR ADDING COMPRESSOR OIL
1. Remove the compressor from the bracket. 2. Immediately cap the suction and discharge ports to avoid dirt from entering the compressor. 3. Cap the hoses from which the compressor was removed. 4. Disassemble the magnetic clutch assembly from the compressor. 5. Remove the caps and drain bolt then pour out the oil in the compressor. 6. Let the compressor sit for 2-3 minutes to completely drain all the oil. 7. Measure the quantity of the oil drained. 8. Replenish the same amount of new oil into the compressor. Sixty percent (60 %) thru the drain port, approximately 20% thru the discharge port and 20% thru the suction port. 9. Cap tightly the suction and discharge ports. The caps should be removed only when the compressor is to be connected to the system.
Ideally, adding or replenishing oil into the system is always recommended through the compressor. However, because of space limitations the following may be employed:
1. Replenish or add the amount of oil needed into the part to be replaced or serviced. Pour the right amount of oil to be replenished into the part that is to be changed. 2. Replenish or add the amount of oil needed by passing it through the discharge line. This is done if no other way is available. Note that oil of R-134a is hygroscopic and shall not be exposed to outside air. The following are the basic procedures: 2.1 Connect the system analyzer to the system and the vacuum pump. 2.2 Open the suction stop valve and close the discharge stop valve analyzer. 2.3 Remove the red hose from the analyzer. 2.4 Start the vacuum pump and feel if there is suction in the red hose. 2.5 Pour the desired amount of oil into the hose slowly. 2.6 Allow the oil to enter the system. 2.7 Connect the red hose back to the analyzer to prevent further exposure of the oil to air. Do not open the analyzer discharge stop valve until such time that the oil has completely entered the system. Opening it too soon will just allow the added oil to be sucked out by the 3. Observe the following amount of oil to be replenished in the system and when replacing the following parts (if no available information given by the manufacturer): a. Evaporator 50cc b. Condenser 40cc c. Receiver 10cc d. A/C Pipes 10cc e. A/C Hoses 10cc 2.1.2.6
After the system has been assembled, leak test the system using dry Nitrogen. Make sure to use R-12 system analyzer for R-12 system and so with R-134a system. 1. Set the Nitrogen regulator to a pressure between 100-150 psig. 2. Connect the system analyzer to the regulator. Make sure that both stop valves of the analyzer are closed. 3. Open the Nitrogen tank valve. 4. Open the discharge stop valve and allow Nitrogen to flow inside the system through the high side until the gauges of the analyzer stop moving. 5. Close the discharge stop valves of the analyzer to trap the pressure inside the system. Close the tank valve. 6. Allow the set-up to stand for at least five minutes. Leak test all accessible fittings using soap solution. 7. If pressure drops, locate leak/s and repair. 8. Repeat leak testing procedure until system is leak-free. 9. Disconnect the analyzer from the Nitrogen regulator, release the pressure from the system and connect to the vacuum pump for dehydration.
1. Check the system analyzer. Make sure that fittings/quick connectors/adaptors are clean. Make sure that hoses are fitted tightly to the adaptors and gauges before starting to vacuum. 2. Attach the vacuum meter in such a way that it can read vacuum in system when valve to vacuum pump is closed (dependent on system analyzer configuration). 3. Remove the cap of the system’s charging ports and attach the quick connectors. Support the underside of the tube by hand if needed, where the charging ports are located. 4. Open the stop valves of both suction and discharge side of the system analyzer.
5. Attach the yellow hose to the vacuum pump. 6. Start vacuum pump until vacuum meter reads at least 1000 microns (1 mBar, 29.87in Hg). 7. Close the suction and discharge stop valves of the system analyzer. 8. Switch-off vacuum pump and observe vacuum meter to hold at 1000 microns (1 mBar, 29.87in Hg) for at least five minutes. 8. Check for leaks if vacuum meter reading goes up and repeat process again.
It is always recommended to charge refrigerant (non glide refrigerants such as HFC134a) to the system in gas state rather than in liquid. 1. Disconnect the yellow hose from the vacuum pump and connect it to the refrigerant tank. Make certain that it is tightly connected to the tank to avoid refrigerant leak while charging. 2. Disconnect vacuum meter to avoid damaging it with excessive pressure. 3. With the tank on its upside down position, purge air out of the yellow hose. 4. Charge initial liquid refrigerant into the system through the discharge side. Open the red stop valve of the analyzer and allow refrigerant to enter the system until both suction and discharge gauges indicate the similar pressures. 5. Allow the refrigerant to settle for about 3-5 minutes. 6. Set the following conditions before continuing to charge the gas into the system. a. Engine Speed : regulated idle running b. Aircon Switch : on c. Blower Switch : Hi position d. Vent Lever : recirculation d. Doors : close e. Windows : close 7. With the refrigerant cylinder in the upright position, close the discharge side stop valve of the analyzer, and continue to charge gas refrigerant thru the suction side stop valve. 8. When high pressure gauge indicates 180 psig, check refrigerant flow at the sight glass. Run the air conditioner for five minutes at this condition to stabilize the system before completely filling it with refrigerant. 9. The following are the average pressure reading of an air conditioning unit: R-12 System R-134a System A/C Type Lo side Hi side Lo side Hi side Single A/C 28-30 psig 200-220 psig 28-30 psig 200-220 psig Dual A/C 30-40 psig 200-220 psig 30-40 psig 200-220 psig 10. Continue to fill the system taking careful notice of the condition of the sight glass to show a stream of refrigerant with slight bubbles. Above conditions should prevail.
11. When the system is full, close the suction and discharge valve of the analyzer. Close the refrigerant tank valve. Open again the suction stop valve and charge refrigerant left on the charging hose to the system. 12. Turn-off the air conditioner and the engine.
2.1.3 RETROFITTING 2.1.3.1 RETROFITTING FROM CFC-12 TO HFC 134a Retrofitting from CFC-12 to HFC-134a will require alterations on the system’s existing parts. However, because of the difference of the physical properties of the two refrigerants (e.g. pressure of R-134a is higher than R-12 at high temperatures) there will be situations wherein replacements of some parts will be necessary. This may be determined during the initial evaluation of the R-12 system before and after retrofitting. 2.1.3.2 POINTERS FOR RETROFITTING CFC-12 TO HFC-134a SYSTEM (If no information available from the manufacturer): Component
Refrigerant Compressor Oil Piping Sealing Material Comp. Sealing Material Hose Material Receiver Desiccant *Safety Device *Pressure Switch Setting *Relief Valve Setting
CFC 12 Mineral Oil NBR O-ring NBR Gasket NBR/ Nitrite hoses Silica Gel Fusible bolt 2.65 Mpa (386psig) 3.14 Mpa (457psig)
HFC 134a Synthetic Oil/ PAG RBR/ HNBR O-ring RBR Gasket CL-IIR / Lined Nylon hoses Zeolite Pressure relief valve 3.14 Mpa (457psig) 3.43 Mpa (500psig)
NBR-Nitrile Butadiene Rubber HNBR - hydrogenated nitrile butadiene rubber
2.1.3.3 RECOMMENDED REFRIGERANT AND LUBRICANT CHARGES (Or refer to manufacturer’s recommendation) Component
Previous Charge Previous Charge
Previous Charge x 0.93 Previous Charge x 1.20
2.1.3.4 RETROFITTING LABEL FOR MAC SYSTEM (refer to Annex 7).
2.1.4 RECORD KEEPING AND DOCUMENTATION Detailed service records are very important in maintaining the MAC system. If properly implemented, this will serve as the system history and would be the basis in the diagnosis of abnormal conditions that will happen in the future. Every manufacturer of the MAC system has its own suggested maintenance check-up schedule for their product. This should be followed specially during the first year of the units operation.
1. Recording of services done to the MAC system should start on the first warranty/service check-up of the unit (refer Annex 7). 2. Record every warranty check-up done on the system as recommended by the manufacturer. 3. Review service records before any service is done on the unit. 4. Update records after each performed service.
5. Keep service records for future reference.
2.2 MOBILE REFRIGERATION 2.2.1 GENERAL CLASSIFICATION 1. ENGINE DRIVEN- unit that is directly driven by the transporter’s engine. 2. DEDICATED ENGINE- unit that is driven by a separate engine. 3. ELECTRICALLY DRIVEN- unit that is driven by an electric motor connected to an outer source. 2.2.2 INSPECTION, OPERATION AND MAINTENANCE 1. Refer to manufacturer’s inspection, operation and maintenance procedure. 2. Visually check unit for physical damage. 3. Check electrical connections, contacts, wires and cables. Tighten loose terminals in the control box. 4. Check battery charge, if low, re-charge or replace (for Dedicated Engine). 5. Check drain pan, de-clog/clean if needed. 6. Check system for leaks. 7. Check condition of evaporator and condenser coils, clean if needed. 8. Check mounting bolts on unit, compressor and fan motors, tighten if needed. 9. Install new temperature recorder chart. 10. Ensure that power selection switch is set to correct voltage setting. 11. Check condenser fan airflow direction or rotation. 12. Check evaporator blower wheel for proper rotation. 13. Unit should be operated before product loading. 14. Check compressor oil level at sight glass. 15. Check defrost control setting/adjustment. 16. Ensure temperature recorder is operational. 2.2.3 SERVICING AND REPAIRS 1. Refer to manufacturer’s manual for servicing and repairs. 2. Make sure that driers are replaced when the high side is opened or when low side is opened for an extended period. 3. Replaced clogged filter/drier. 4. Ensure that the unit power source is disconnected before performing any repair or servicing. 5. Replace the same amount of oil removed from the compressor after repair. 6. Maintain a minimum acceptable clearance between electric motor and compressor drive plates when re-installing compressor-motor assembly (Electrically Driven). 7. Tighten mounting screw based on recommended torque.
PART 3 – RETROFITTING AND ALTERNATIVES SECTION 1 – RETROFITTING
1.1 GENERAL GUIDELINES Retrofitting from an ODS-using system to an ozone-friendly refrigerant requires a thorough investigation and study of the system. Some factors that should be taken into account: 2.3 Retrofit the system if it is more cost effective than replacement. If a major repair (e.g. compressor change, etc.) or modification of an ODS using system is necessary it shall be evaluated if retrofit can be done at acceptable cost. 2.4 Upon evaluation of a system that requires major repair and is close to its technical/economical life, consider replacement if it is more cost effective than retrofitting. 2.5 The safety and environmental properties of alternative refrigerant to be used, such as flammability, toxicity, ozone depleting and global warming potential shall be considered. 2.6 Assessment of the compatibility of components and materials in the system in particular elastomers and oil. Also components like sight glasses and oil separators shall be checked for suitability. 2.7 Assess and examine the operating condition of the system and determine the service and its operational history. 2.8 If necessary, consult equipment manufacturer for the recommended alternative refrigerant and lubricant for the system.
1.2 USE OF DROP-IN REFRIGERANTS The phasing-out of ODS particularly CFCs in the refrigeration and air conditioning sector has led to the development of new refrigerants that claims to be direct replacements for ODS refrigerants. These refrigerants vary in compositions; some are single substance, others are blends and Hydrocarbons. As the manufacturer of these substances claims, existing mineral oil need not be replaced since they are compatible with the old oil in the system. These claims should be proven This Code is not against the use of these new substances, as long as health, safety and the environment aspects are addressed with. A complete literature should be provided, MSDS and other pertinent information related to the substance. Training should also be conducted to acquaint the technicians on the proper handling of these new refrigerants. Hydrocarbons are known to be flammable, although unless there are certain concentration that must be reached prior to explosion if ignition occurs. That is why education and information dissemination is very important. Blends on the other hand are composed of different refrigerants that may act independently at certain temperature and pressure. Training is also very important in the proper handling of these substances, particularly on charging processes wherein they are charged on liquid state. During system leaks, a thorough investigation of the composition of the refrigerant left is very important since fractionation may have occurred and recharging after fixing of found leaks will not make it to function normally.
PART 4 – REFRIGERANT HANDLING AND STORAGE NCCP-Project Management Unit
SECTION 1 – HANDLING AND STORAGE The following shall be observed when handling and working with refrigerants: 1.1 Color-coding for refrigerant cylinders shall be maintained for new refrigerants (although these are concerns of the manufacturers). Refer to Annex 10 for refrigerant cylinder color assignments. 1.2 Refrigerant manufacturer’s recommended procedures shall be followed when handling refrigerants. 1.3 Refrigerant containers/cylinders shall be stored in a cool place or under a roof to protect it from weather extremes, away from the risk of fire and direct sunlight. 1.4 Extra care shall be taken not to drop refrigerant containers/cylinders that may damage the container or its valve. 1.5 When not in use, container valves shall be closed, the valve outlet cover nut fitted, and the valve protection cover replaced. 1.6 While charging, refrigerant containers/cylinders shall not be connected to a system of higher pressure or temperature to prevent back flow of refrigerant to the container/cylinder. 1.7 Cylinders intended for a certain type of refrigerant shall not be filled with another type unless they are properly evacuated and labeled. 1.8 Strictly follow cylinder capacity when re-filling with refrigerants. 1.9 When re-filling with recovered refrigerants, only 70% of the maximum capacity in weight for a particular type of refrigerant should be filled to a cylinder (since it may contain oil with lower density). Overfilling can cause the cylinder to explode leading to fatal danger. 1.10 Calibrated weighing scale shall be used when filling a cylinder. 1.11 Leaks on refrigerant cylinder valves shall be checked and repaired before storing in a ventilated area and on a vertical position. 1.12 Establish proper leak testing routine on charging hoses and refrigerant handling equipment. 1.13 Thorough check-up of refrigerant cylinders shall be done first before refilling. 1.14 Defective refrigerant cylinders shall not be repaired and re-used. 1.15 Refrigerant cylinders shall conform to relevant PNS (when approved). 1.16 Storage tank relief valves shall be checked to ensure that they are not leaking (shall conform to relevant PNS). 1.17 Pump seals of filling machines shall be regularly checked for leaks. 1.18 Charging lines shall be kept as short as possible and be fitted with either check valves or isolation valve near the end of charging lines. 1.19 Whenever possible, use quick disconnect fittings with one-way valve in transferring or working with refrigerants. 1.20 Use Personal Protective Equipment (PPE), such as side shield glasses/goggles, gloves, jackets, and safety shoes when handling containers. 1.21 Never apply direct flame or live steam to a container or valve. 1.22 Never refill disposable cylinders. 1.23 Never use a lifting magnet or sling (rope or chain) when handling cylinders. 1.24 Never use cylinders for rollers, supports, or any purpose other than to contain the refrigerant. 1.25 Protect cylinders from any object that will result in a cut or other abrasion on the surface of the metal. 1.26 Never tamper, repair or alter the safety devices of the cylinders. 1.27 Never force connections that do not fit. 1.28 When in doubt of refrigerant type, use electronic refrigerant identifier (will be available in all Regional EMB offices and TESDA accredited training institutions nationwide) to analyze its composition.
1.29 Avoid skin contact with refrigerants as they may cause frostbite and other skin irritations. 1.30 Extra care should be given to blend refrigerants that should be charged to a system in its liquid state.
PART 5 – RECOVERY, RECYCLING, RECLAMATION AND DISPOSAL SECTION 1 – RECOVERY 1.1 1.2 1.3 1.4
Service hoses to be used for recovery must have shut-off valves (PNS SAE J2197:2003) All refrigerant content of a non-serviceable refrigeration or air conditioning system shall be recovered before it is disposed of. Recovered refrigerants shall be verified for re-use, recycling, reclaim or disposal/destruction. Recovered refrigerants shall be stored only in Specified Refillable Container/Cylinder. Recovered refrigerants shall be properly labeled.
SECTION 2 – RECYCLING 2.1 2.2
Recycled refrigerant shall be stored only in Specified Refillable Container. Recycled refrigerants shall be checked for non-condensable gases (refer to PNS SAE J2211 and PNS SAE J1989 for the procedure) to verify if it is suitable for re-use or needs re-processing (refer to Table 1 and Table 2 for R 12 and R 134a, respectively). As much as possible, use recycled refrigerant to the system where it was recovered.
SECTION 3 – RECLAMATION Importers of ODS refrigerants are obliged to establish a Reclamation capability approved by the DENR. This facility/facilities will be established to re-process recovered refrigerants. 1. Recovered refrigerant not fit for recycling shall be subjected for reclamation, if applicable. 2. Refrigerant to be reclaimed shall be identified first to check its composition before reclamation. 3. Mixed refrigerant in one cylinder shall not be reclaimed. 4. Non-mixed recovered refrigerants shall be purchased at a certain amount upon surrender to the facility. 5. Every registered refrigerant ODS dealer, retailer/reseller shall be obliged to accept recovered refrigerant surrendered to them. 6. Registered ODS refrigerant dealer, retailer/reseller shall account for every recovered refrigerant received from service shop/technicians, with corresponding paid amount if determined to be a single substance.
3.1 RECLAMATION SCHEME PHP__
PHP__
RECLAIMED REFRIGERANT PHP__ /kg
RECOVERED REFRIGERANT PHP__/kg DEALERS NEW REFRIGERANT SUPPLY FLOW
The Reclamation Scheme starts with the establishment of a Reclamation Facility. The bottom line of the system is the service shops or service technicians who will perform recovery of used refrigerants before servicing refrigeration and air conditioning equipment. Recovered refrigerants will be sold by service shops to either the dealer, importer or directly to the facility at a certain cost. The facility will then re-process those recovered refrigerants and transform into brand new ones, provided, these refrigerants are not mixed; otherwise it will not be reclaimed. Blue arrows represent flow of recovered refrigerants, red arrow represents the reclaimed one and black arrows represent the existing supply set-up. Under the Revised CCO, venting of ODS is an illegal act, thereby requiring all service technicians/shops to recover refrigerant before performing service or repair. The facility will be managed and operated by an organization or party duly approved by DENR. A fund will be generated to be collected from refrigerant importers to help finance the facility’s operational expenses. The operators on the other hand will have their investment on the physical establishments and logistical support.
3.2 RECLAMATION PROCESS FLOW FOR DISPOSAL
The process flow starts from the recovered refrigerants being checked by a Refrigerant Identifier whether mixed or a single substance. If it turned out to be mixed, then it will be stored to the facility, otherwise it will be processed by a Refrigerant Reclaimer. From the reclaimer, the refrigerant will be filled to refrigerant cylinders. A Moisture Meter and Gas Chromatograph will check the quality of reclaimed refrigerant if it meets the ARI 700 standard. Then it may be transferred to bigger storage tanks or remain in smaller cylinders using a transfer pump either for storage or reselling.
SECTION 4 – DISPOSAL 4.1 Confirmed mixed refrigerant are automatically subject for disposal.
4.2 Until suitable disposal methods are available, contaminated refrigerants should be properly labeled and stored by concerned stakeholder. 4.3 Mixed refrigerant recovered from service shops/technicians through the reclamation scheme shall be stored at the reclamation facility. 4.4 Non-reclaimable refrigerant will be stored in the facility until final means or method will be approved by concerned agency.
PART 6 – SAFETY ASPECT SECTION 1 – SAFETY REQUIREMENTS 1.1 1.2 1.3 1.4 1.5
Personal Protective Equipment (PPE) is compulsory when handling and working with refrigerants. Always ensure good ventilation while working on refrigeration systems. Ensure that refrigerant can not accumulate in low areas where they can cause fatal accidents. Specific color-coding shall be followed for cylinders/containers of different refrigerants (refer to Annex 9). Pressure safety devices (i.e. pressure relief valves, safety pressure switches) shall be installed to prevent the equipment from operating over the maximum working pressure and must be calibrated. A dual pressure-relief valve with changeover device shall be installed for larger systems to facilitate the repair/replacement without impairing system protection. Safety precautions shall be observed for systems retrofitted with hydrocarbon, which is flammable. Proper protective caps shall be used on valves of refrigerant cylinders to prevent damage to valves that will cause refrigerant leaks. Avoid contact with liquid refrigerants that can cause severe frostbite. Hydrochloric and hydrofluoric acids may be present in contaminated recovered refrigerant and oils. Utmost care must be taken to prevent contact, even with oil spills when servicing contaminated equipment. Never exceed the cylinder’s safe liquid weight level based on net weight. Maximum capacity of any cylinder is 80% by maximum gross. Appropriate wheeled device must be used to transport larger cylinders. Ensure that the cylinder is securely strapped when moving from one location to another. Never roll a cylinder on its side. Good quality hoses/manifolds should always be used with seals/gaskets in place. Never refill disposable cylinders. Open flame should not be used on a refrigeration system that has not been fully/properly evacuated for servicing and filled with inert gas (e.g. dry nitrogen). Never use “halide torch method” (flame test) for leak testing undetermined refrigerant in a system. Never use oxygen or compressed air for pressure or leak testing or when blowing-off piping to remove welding, brazing or cutting debris. Avoid inhalation or exposure to refrigerant and lubricant vapor or mist. This will irritate skin, eyes, nose, and throat. Never open refrigerant drums (for low pressure refrigerants) until it is cooled down to atmospheric pressure/temperature when replacing its cap with valves.
Electrical wirings should be kept away from contact with the system’s discharge line. This will damage the wire’s insulation that may cause short circuit. All power supply should be disconnected and disabled to any equipment requiring recovery of refrigerants. Never connect grounding wire to gas pipes, water pipes, telephone grounds, and lightning arresters. Never use new refrigerants without reading its MSDS. Use tools with insulated handles that are in good condition when working with the system’s electrical lines.
PART 7 – LEGISLATION AND REGULATION SECTION 1 - DENR ADMINISTRATIVE ORDER No. 2004-08
(REVISED CHEMICAL CONTROL ORDER (CCO) FOR OZONE DEPLETING SUBSTANCES) The following are applicable sections for the refrigeration related acts and practices under the revised CCO:
PHASE-OUT SCHEDULE AND CONTROLS OF IMPORTATION OF ODS
Beginning 01 January 2005, all importation for CFC-11 will be absolutely prohibited. Beginning 01 January 2005, all kinds of importation of substances, except essential use (alone or mixtures) under Annex A, Group I as provided under Section 5.2 will be prohibited.
REGISTRATION OF IMPORTERS AND APPLICATION OF PRE-SHIPMENT IMPORTATION CLEARANCE
Importers shall distribute these substances only to registered/accredited dealers, retailers, resellers and service providers pursuant to Section 7 hereof or those entities utilizing these substances for essential uses as duly certified by the Department through the Bureau.
REGISTRATION OF DEALERS, RETAILERS AND RESELLERS OF ODS
A certificate of Registration may be granted and renewed only upon showing proof of the following: (c) Commitment to participate in a system to re-use refrigerants under a reclamation scheme duly approved by the Department through the Bureau. Only those registered or accredited by the Department through the Bureau and by the DTI may purchase, re-sell, distribute and utilize for allowable uses the ODS listed under Section 2. The ODS may only be sold or distributed to service providers that are duly accredited and certified under Section 8.
Dealers and retailers shall also adhere to a “Good Practice” Code for Refrigeration and Air Conditioning to be developed as condition for the issuance and renewal of registration.
CERTIFICATION OF SERVICE PROVIDERS AND ACCREDITATION OF SERVICE SHOPS OF ODS-USING EQUIPMENT
Service shops shall be duly accredited by the DTI in accordance with guidelines, rules and regulations issued for the purpose. Service providers/technicians shall be certified by the Technical Education and Skills Development Authority (TESDA) based on their level of technical and skills competencies. Service providers and service shops should have capability to take effective measure, including the necessary equipment, technology, training and infrastructure, for the purpose of effectively handling ozone-depleting substances including responsible re-use of refrigerants, minimizing their emissions and ultimately phasing out their use by replacing with substitutes/alternatives duly recognized and certified by the Department and the Bureau. Service providers and service shops shall also adhere to a “Good Practice” Code for Refrigeration and Air Conditioning to be developed as a condition for the issuance and/or renewal of accreditation and/or certification.
All importers, distributors, dealers/retailers must keep records of all transactions and prepare annual report for submission to the Bureau by 31 January of the following year. Service providers shall keep records of all transactions for validation purposes. Records retained must be available for inspection at any time, upon request, by an authorized officer of the Department through the Bureau or by other authorized government agency.
Aside from the relevant provisions in section 4 to 10, the following acts shall constitute a violation of this CCO: b. Back Conversion; c. Installation of CFC-using systems; d. Sale and use of small disposable containers (less than 1kg) with CFCs; e. Importation or manufacturing or placing in the market of products or equipment containing Halons or CFCs, except metered dose inhalers; f. Use of CFCs in Mobile Air Conditioners (MACs) starting 2006 in motor vehicles manufactured and/or initially registered from 1999 onwards, and starting 2012 in all motor vehicles; g. Use of CFC-11 as blowing agent for foam manufacturing; h. Intentional release/venting of ODS when servicing equipment; and i. Flushing with ODS.
Any person, natural or juridical, who violates any provision of this CCO shall be administratively and criminally liable pursuant to Sections 43 and 44 of DAO No. 29 series of 1992 and Section 13, 14 and 15 of RA No. 6969 and other applicable laws. Such violations will also constitute grounds for cancellation of certificate of: a) registration of importers, dealers, retailers & resellers, b) accreditation of service shops, and c) competency of technicians.
This CCO shall take effect fifteen (15) days after its publication in the National Registration Center or in at least two (2) newspaper of general circulation, except for Sections 6.7 and 7.4 which will enter into force starting January 1, 2005. Note: Date Published – April 16, 2004 at Manila Times and Today.
ANNEX II (List of Controlled Substances of the Montreal Protocol) ANNEX A: CONTROLLED SUBSTANCES Group
Refrigerant Blowing agent Propellant Refrigerant Propellant Blowing agent Cleaning agent Solvent Cleaning agent Solvent Refrigerant
(halon-1211) (halon-1301) Halon-2402)
Fire Extinguishant Fire Extinguishant Fire Extinguishant
Group II CF2BrCl CF3Br C2F3Cl3
ANNEX B: CONTROLLED SUBSTANCES Group
CFC-13 CFC-111 CFC-112 CFC-211 CFC-212 CFC-213 CFC-214 CFC-215 CFC-216 CFC-217
Group I CF3Cl C2FCl5 C2F2Cl4 C3FCl7 C3F2Cl6 C3F3Cl5 C3F4Cl4 C3F5Cl3 C3F6Cl2 C3F7Cl
Group II CCl4
Cleaning Agent Solvent
1,1,1-trichloroethane/ methyl chloroform
Group III C3H3Cl3
Ozone-Depleting 1 Potential
CHFCl2 CHF2Cl CH2FCl C2HFCl4 C2HF2Cl3 C2HF3Cl2 CHCl2CF3 C2HF4Cl CHFClCF3 C2H2FCl3 C2H2F2Cl2 C2H2F3Cl C2H3FCl2 CH3CFCl2 C2H4F2Cl CH3CF2Cl C2H4FCl C3HFCl6 C3HF2Cl3 C3HF3Cl4 C3HF4Cl3 C3HF3Cl2 CF3CF2CHCl2 CF2ClCF2CHClF
HCFC-21 HCFC-22 HCFC-31 HCFC-121 HCFC-122 HCFC-123 HCFC-123 HCFC-124 HCFC-124 HCFC-131 HCFC-132 HCFC-133 HCFC-141 HCFC-141b HCFC-142 HCFC-142b HCFC-151 HCFC-221 HCFC-222 HCFC-223 HCFC-224 HCFC-225 HCFC-225ea HCFC-225eb
0.04 0.055 0.02 0.01-0.04 0.02-0.08 0.02-0.06 0.02 0.02-0.04 0.022 0.007-0.05 0.008-0.05 0.02-0.06 0.005-0.07 0.11 0.008-0.07 0.065 0.003-0.005 0.015-0.07 0.01-0.09 0.01-0.08 0.01-0.09 0.02-0.07 0.025 0.033
Fire Extinguishant Refrigerant/Blowing Agent Refrigerant/Blowing Agent
Cleaning Agent/Solvent Cleaning Agent/Solvent Cleaning Agent/Solvent
1 Where a range of ODP is indicated, the highest value in that range shall be used for the purpose of the Montreal Protocol. The ODPs listed as a single value have been determined from calculations based on laboratory measurements. Those listed as a range are based on estimates and are less certain. The range pertains to an isometric group. The upper value is the estimate of the ODP of the isomer with the highest ODP, and the lower value is the estimate of the ODP of the isomer with the lowest ODP.
SECTION 2 - PHILIPPINE NATIONAL STANDARDS FOR MAC SYSTEMS PNS SAE J639 APR94 -
PNS SAE 1770 OCT95 PNS SAE J1732 DEC94 PNS SAE J1628 JUN93 PNS SAE J1657 JUN93 PNS SAE J1660 JUN93 PNS SAE J1661 JUN93 PNS SAE J1662 JUN93 PNS SAE J1990 MAR92 PNS SAE J1989 OCT89 PNS SAE J2197 JUN92 PNS SAE J2209 JUN92 PNS SAE J2210 DEC91 PNS SAE J2211 DEC91 -
Safety Containment of Refrigerant for Mechanical Vapor Compression Systems Used for MAC Systems/ Vehicle Service Coupling Air Conditioning System Automotive Refrigerant Recovery/Recycling Equipment Intended for Use with both R-12 and R-134a HFC-134a Extraction Equipment for Mobile Automotive Technician Procedure for Using Electronic Refrigerant Leak Detectors for Service MAC Systems Selection Criteria for Retrofit refrigerants to Replace CFC-12 in MAC System Fittings and Labels for Retrofit of CFC-12 MAC Systems to R-134a Procedure for Retrofitting CFC-12 in MAC System Material Compatibility with Alternate Refrigerants Extraction and Recycle Equipment for R-12 MAC Systems Recommended Service Procedure for the Containment of R-12 HFC-134a Service Hose Fittings for Automotive AC System CFC-12 Extraction Equipment for MAC System Refrigerant Recycling Equipment for R-134a MAC System Recommended Service Procedure for the Containment of HFC-134a
PART 8 – ANNEXES AND TABLES SECTION 1 – ANNEXES Annexes herein are sample forms for the concerned stakeholder to adopt, although they may have option to create their own form that they think would best suit their needs as long as all the important data are indicated.
SECTION 2 – TABLES AND CHARTS Tables and Charts herein will serve as reference for technicians as well as practitioners in the refrigeration and air conditioning sector.
ANNEX 1 – SERVICE RECORD CONTRACTOR / SERVICE COMPANY Name of Company: _________________________________________________________ Address: __________________________________________________________________ Tel. No.: _____________________________Fax No.: ______________________________ Accreditation No.: _________________________Expiry Date: _______________________ Date of Service: _______________________Certification No.: _______________________ Name of technician: ___________________________________________ Time In: ________________________ Time Out: ________________________________ SERVICED COMPANY Name: ___________________________________________________________________ Address: _________________________________________________________________ Tel. No.: ______________________________________ Fax No.: ___________________ UNIT / EQUIPMENT Type of Compressor: Brand: _______________________________________  Reciprocating Capacity: ____________________________________  Scroll Area Served: __________________________________  Screw Unit No./Designation: __________________________  Rotary Type of Unit: Model No.: __________________________________  Packaged/Split Type Serial No.: __________________________________  Unitary Type  Window Type  Chiller  Others (Specify)____________________________________________ SERVICE CARRIED OUT INSPECTION Findings: _________________________________________________________________ _________________________________________________________________ Recommendations: _________________________________________________________ ___________________________________________________________ REPAIR Defect: __________________________________________________________________ Job Done: ________________________________________________________________ ________________________________________________________________ Method/Equipment Used:  Electronic  UV/Halogen  Soap Bubble  Others (Specify) _________________________ READING AFTER SERVICE BEFORE SERVICE Suction Pressure: __________________ Suction Pressure________________ Discharge Pressure: ___________ Discharge Pressure______________ Amperages: L1: _______________ Amperages: L1:_________________ L2: ______________ L2:_________________ L3: ______________ L3:_________________ REFRIGERANT Type: _____________________________________________ Total Charge (kg) ___________________________________ Quantity Recovered (kg): _____________________________ Quantity Lost (kg): __________________________________ Quantity for Recycling (kg): ___________________________ Quantity of Old Refrigerant Recharged (kg): ______________ Quantity of New Refrigerant Recharged (kg): _____________ Accredited Company In-charged for Reclaim/recycle: _____________________________________
SUPERVISING ENGINEER:_________________________TECHNICIAN’SSIGNATURE:________________________ (Name and Signature)
2 – ____________________________________ RETROFITTING DATA SHEET END USER’S NAMEANNEX & SIGNATURE: SERVICED COMPANY Name: _____________________________________________________________________________ Address: ___________________________________________________________________________ Tel. No.: ___________________________________________ Fax no.: ________________________ UNIT / EQUIPMENT Type of Compressor: Brand: ________________________________________  Reciprocating Capacity: _____________________________________  Scroll Area Served: __________________________________  Screw Unit No./Designation: ___________________________  Rotary Type of Unit: Model No.: ___________________________________  Packaged/Split Type Serial No.: ___________________________________  Unitary Type  Window Type  Chiller  Others (Specify)_________________ CONTRACTOR / SERVICE COMPANY Name of Company: ___________________________________________________________ Address: ____________________________________________________________________ Tel. No.: ________________________________ Fax No.: ____________________________ Accreditation No.: _________________________ Expiry Date: ________________________ Name of Technician: ____________________________ Certification No.: _______________ DATES Date Started: ________________________ Date Finished: ___________________________ DATA OLD A.
REFRIGERANT SPECS Type Quantity LUBRICANT/OIL Type Quantity READINGS Suction Pressure Discharge Pressure Amperages: L1 L2 L3
LEAK TEST METHOD   
Soap and bubble Electronic Others (Specify) __________________________________________ REFRIGERANT CONTAINMENT
Recovered for re-use Recovered for recycling Company In-charged for Reclaim/recycling: _____________________________________________
__________________________________________ SUPERVISING ENGINEER’S NAME & SIGNATURE
_________________________________ TECHNICIAN’S SIGNATURE
END USER’S NAME & SIGNATURE: ____________________________________
ANNEX 3 – EQUIPMENT LABEL SERVICED COMPANY Name: _______________________________________________________________________ Address: _____________________________________________________________________ Tel. No.: ______________________________________ Fax No.: ________________________ UNIT / EQUIPMENT Brand: _______________________________ Type: ________________________________ Unit No.: _____________________________ Capacity: _____________________________ Location: __________________________________________________________________ Manufacturer: ________________________________________________________ Model No.: ________________________ Serial No.: ________________________Year: __________ TECHNICAL DATA Maximum allowable pressure: ________________________ Test Pressure: ___________________________________ Max. Allowable Temp.: _____________________________ Min. Allowable Temp.: _____________________________ Low Pressure Switch Setting: _________________________ High Pressure Switch Setting: ________________________ REFRIGERANT Type: ________________________________
Quantity: __________________________ OIL / LUBRICANT
Type: __________________________Quantity: ________________
Viscosity: _________________________
Person in-charge: ________________________________
SERVICE CONTRACTOR Company Name: __________________________________________________________ Address: ________________________________________________________________ Telephone No.: _________________________ Fax No.: __________________________ Accreditation No.: ___________________________
ANNEX 4 – USER SPECIFIC DATA OWNER DATA Name: ______________________________________________________________ Address: ____________________________________________________________ Telephone No.: _________________________ Fax No.: ______________________ E-mail Address: ______________________________________________________ EQUIPMENT DATA Capacity: ________________________Type: ______________________________ Brand: ______________________________________________________________ Model No.: _______________________ Serial No.: _________________________
LOCATION Room: _____________ Floor: ________________ Name of Building: _____________________________________________________ Building Address: _____________________________________________________ RESPONSIBILITY Department: __________________________________________________________ Supervising Engineer: __________________________________________________ Telephone: ___________________________________________________________ SERVICE CONTRACT Name of Contractor: ___________________________________________________ Address: _____________________________________________________________ Telephone No.: __________________________ Fax No.: _____________________ E-mail Address: _______________________________________________________ Technician In-charge: __________________________________________________ Certification No.:______________________________________________________ Expiration of Contract: _________________________________________________ Service Interval: ______________________________________________________
ANNEX 5 – SERVICE REPORT COMPANY NAME ADDRESS CONTACT NO. ACCREDITATION NO. SERVICE REPORT Customer __________________________________________ Tel. No. _______________________ Date _____________ Address ___________________________________________________________ Car Type ________________________ JOB DONE   
PULL DOWN EVAPORATOR REPLACE PULLDOWN COMPRESSOR
ELECTRICAL REPAIR/CHANGE WIRING PULLDOWN CONDENSER/RADIATOR ( ) RETIGHT ROTOR AUXILIARY FAN REPLACE/MODIFY ( ) H-HOSE PULLDOWN PIPES ( ) REPLACE FLUSHING OF A/C SYSTEM REPLACE ( ) BELT OTHERS, PLEASE SPECIFY _________________________________________________________________________________________________________________________
) CLEANING ( ) WELDING ) EXPANSION VALV ( ) RECEIVER DRIER ) OVERHAUL ( ) SEMI-OVERHAUL ) REPLACE COMP. ( ) LEAK REPAIR ) REPLACE COMP. INCL. BRACKET FABRICATION ) SINGLE/DUAL ( ) MAJOR/MINOR ) REPLACE/REPAIR ( ) CLEANING ) REPLACE/REPAIR ( ) INSTALL ) D-HOSE ( ) S-HOSE ) REPAIR WITH BRAZING ( ) MODIFY ) SINGLE ( ) DUAL ) IDLER BEARING ( ) PULLEY
( ) REPLACEMENT ( ) CHANGE OIL ( ) REPLACE MAGNETIC COIL ( ) REPLACE CLUTCH BEARING
PARTS/CONSUMABLES ITEM
( ) RBR
( ) NBR
( ) PAG/SYNTHETIC
( ) R 134a
FLUSHING SOLUTION ( NON-CFC) OTHERS, PLEASE SPECIFY
( ) R 12
( ) Others__________
READINGS SUCTION PRESSURE: ________________________________
DISCHARGEPRESSURE:__________________________________
TECHNICIAN: _____________________________________________ Name and signature
OWNER: _____________________________________________________ Name and signature
_____________________________ No. 00000
ANNEX 6 – RETROFIT LABEL
COMPANY NAME ADDRESS CONTACT NO. ACCREDITATION NO.
NOTICE : RETROFITTED TO R 134a RETROFIT PROCEDURE CONFORMED WITH PNS SAE J1661 USE ONLY R 134a AND SYNTHETIC OIL REFRIGERANT CHARGE/AMOUNT : _________________________ LUBRICANT AMOUNT : _________________________  PAG  ESTER Retrofitted by: _________________________ Signature: _________________ Certification No.:__________________________Date:___________________
ANNEX 7 – START-UP DATA SHEET
COMPANY NAME ADDRESS TEL. NO. ACCREDITATION NO.
START-UP DATA SHEET OWNER DATA Name of Owner: ___________________________________________________________________ Address: _________________________________________________________________________ Contact Person: ______________________________________ Tel. No.: _____________________ INSTALLATION DATA Technician In-charge: _________________________________ Accreditation No.: ________________ Date Started: _________________ Date Finished: _________________ Start-up Date: ________________ FCU Model No. _____________________________ ACCU Model No.: _____________________________ FCU Serial No.: _____________________________ACCU Serial No.: ______________________________ OPERATING DATA Suction Line Temperature: _________________ Suction Line Pressure: ____________________ Discharge Line Temperature: _______________ Discharge Line Pressure: __________________ FCU Intake Air Temperature: _______________ FCU Discharge Air Temp.: _________________ ACCU Intake Air Temperature: ______________ ACCU Discharge Air Temp.: _______________ Room Temperature: ______________________ Ambient Temperature: _____________________ ELECTRICAL PARAMETERS Power Supply (Voltage), L1: _______________ L2: _______________ L3: _______________ Overall Ampere Readings, L1: _______________ L2: _______________ L3: _______________ Current Draws, Compressor: ________ ACCU Fan Motor: ________ FCU Fan Motor: _________ OTHER INSTALLATION DATA Refrigerant Piping: Suction Diameter: __________________ Length: ________________ Insulation Thickness: _____________ Discharge Diameter: __________________ Length: ________________ Insulation Thickness: ____________ Drain Line: Drain Line Diameter: __________________ Length: ________________ Insulation Thickness: ____________ Electrical Lines: Feeder Line Conduit Diameter: ______________ Feeder Line Wire Size: _____________ Length: _________ Control Line Conduit Diameter: ______________ Control Line Wire Size: _____________ Length: _________ Circuit Breaker: _______________
Technician’s Signature : _____________________________ Owner’s Signature: _________________________________
ANNEX 8 – INSPECTION CHECKLIST Date Technician Signature Value/ Remarks
Value/ Ok
3.1 General 3.1.1 Inspect panels (insulated cabinet, control panel, etc.); schedule repair, if necessary. 3.1.2 Inspect unit switches for unusual or abnormal condition. 3.1.3 Check bearings for any unusual sound and vibration. Apply grease or oil, if necessary. 3.1.4 Check tightness of all bolts and screws; tighten, if necessary. 3.1.5 Check fan and fan housing for dirt accumulation; clean, if necessary. 3.2 Refrigerant/oil system 3.2.1 Inspect condition of refrigerant piping insulation, and schedule repair or replacement, if necessary. 3.2.2 Inspect sight glass (if present) for refrigerant flow/quality. 3.2.3 Visually inspect for refrigerant leaks as indicated by oily spots and use appropriate leak detector to accurately locate the leak. 3.2.4 Check schrader/access valves, packing glands, O-rings and service caps for tightness. 3.2.5 Check compressor oil level (if applicable). If it is low, report for further analysis. 3.2.6 Check oil for discoloration indicating that oil need to be replaced and system checked. If it is discolored, report for further analysis. 3.2.7 Check oil pressure (if applicable). It should read higher than the suction pressure or as recommended by the manufacturer. If below the manufacturer’s recommended pressure, report. 3.2.8 Check Oil Failure Pressure Switch (if applicable). 3.2.9 Check operating pressures: 3.2.10.1 Suction 3.2.10.2 Discharge 3.2.10.3 Oil Pressure (if applicable) 3.3 Secondary warm side 3.3.1 Check condenser coils for dirt accumulation; clean, if necessary. 3.3.2 Condenser Water Supply (if applicable) 3.3.3 Condenser Water Return (if applicable) 3.3.4 Check operating temperatures: 3.3.4.1 Condenser water supply (if applicable) 3.3.4.2 Condenser water return (if applicable) 3.3.4.3 Condenser Supply Air (if applicable) 3.3.4.4 Condenser Return Air (if applicable) 3.3.5 Check condenser water pumps’ operating parameters (if applicable): 3.3.5.1 Suction pressure 3.3.5.2 Discharge pressure 3.3.6 Check cooling tower’s water level, make-up water and other operating parameters and abnormalities. 3.4 Secondary Cold side 3.4.1 Check evaporator coils for dirt accumulation; clean, if necessary. 3.4.2 Check drain pan for any dirt accumulation; clean, if necessary. 3.4.3 Check drain line to ensure continues condensate flow; de-clog, if necessary. 3.4.4 Check chilled water expansion tank’s water level and float valve. 3.3.6 Check cooling tower’s water level, make-up water and other operating parameters and abnormalities. 3.4.5 Check operating temperatures: 3.4.5.1 Evaporator water supply (if applicable) 3.4.5.2 Evaporator water return (if applicable) 3.4.5.3 Evaporator Supply Air (if applicable) 3.4.5.4 Evaporator Return Air (if applicable) 3.4.5.5 Chilled Water Supply Pressure (if applicable) 3.4.5.6 Chilled Water Return Pressure (if applicable) 3.5 Electrical/control system 3.5.1 Check and clean all electrical contacts and terminals. Tighten loose terminals. 3.5.2 Check quality of power supply. Ensure that power supply is within ±10% of the rated voltage requirement of the equipment. 3.5.3 Take reading of compressor motor current draw. 3.5.4 Overload relays 3.5.5 Check belt tensions and alignment of pulley; adjust, if necessary. 3.5.6 Check belt for any abnormal wear. Determine its cause and make necessary correction. 3.5.7 Take reading of fan and pump motor current draw. 3.5.8 Check all electrical controls; calibrate, if necessary: 3.5.8.1 High and Low Pressure switch 3.5.8.2 Timers 3.5.8.3 Thermostat 3.5.8.4 All other electronically controlled devices
TABLE 1 – ARI REFRIGERANT CONTAINER COLOR ASSIGNMENT ASHRAE Color Assignment Number *R-11 Orange *R-12 White *R-13 Light Blue (Sky) R-13B1 Pinkish-Red (Coral) *R-14 Yellow Brown (Mustard) *R-22 Light Green R-23 Light Blue Gray *R-113 Dark Purple (Violet) *R-114 Dark Blue (Navy) *R-123 Light Blue-Grey *R-124 Deep Green (DOT Green) R-125 Medium Brown (Tan) R-134a Light Blue (Sky) *R-141b Unassigned R-401a Pinkish-Red (Coral) R-401b Yellow-Brown (Mustard) R-401c Blue-Green (Aqua) *R-402a Light Brown (Sand) *R-402b Green-Brown (Olive) R-404a Orange R-407a Lime Green R-407b Cream R-407c Medium Brown *R-408a Medium Purple *R-409a Medium Brown (Tan) R-410a Rose R-410b Maroon *R-411a Dark Purple (Violet) *R-411b Blue Green (Teal) *R-414b Medium Blue R-416a Yellow-Green (Lime) *R-500 Yellow *R-502 Light Purple (Lavender) *R-503 Blue-Green (Aqua) R-507a Blue-Green (Teal) *R-508b Dark Blue (Navy)
Note: * – Contain ODS
TABLE 2 - MAXIMUM ALLOWABLE CONTAINER PRESSURE FOR R-12 ENGLISH UNITS O
TEMP F 65 66 67 68 69 70 71 72 73 74
PSIG TEMP F 74 75 75 76 76 77 78 78 79 79 80 80 81 81 83 82 84 83 86 84
PSIG TEMP F 87 85 88 86 90 87 92 88 94 89 96 90 98 91 99 92 100 93 101 94
PSIG TEMP F 102 95 103 96 105 97 107 98 108 99 110 100 111 111 113 113 115 115 116 116
PSIG TEMP F 118 105 120 106 122 107 124 108 125 109 127 110 129 111 130 112 132 113 134 114
PSIG 136 138 140 142 144 146 148 150 152 154
PRES 9.56 9.7 9.84 9.98 10.12 10.26 10.4 10.54 10.68 10.82
METRIC UNITS O
TEMP C 18.3 18.8 19.4 20.0 20.5 21.1 21.6 22.2 22.7 23.3
PRES 5.20 5.27 5.34 5.48 5.55 5.62 5.76 5.83 5.9 6.04
TEMP C 23.9 24.4 25.0 25.5 26.1 26.6 27.2 27.7 28.3 28.9
PRES 6.11 6.18 6.32 6.46 6.6 6.74 6.88 6.95 7.03 7.1
TEMP C 29.4 30.0 30.5 31.1 31.6 32.2 32.7 33.3 33.9 34.4
PRES 7.17 7.24 7.38 7.52 7.59 7.73 7.8 7.94 8.08 8.15
TEMP C 35.0 35.5 36.1 36.6 37.2 37.7 38.3 38.8 39.4 40.0
PRES 8.29 8.43 8.57 8.71 8.78 8.92 9.06 9.13 9.27 9.42
TEMP C 40.5 41.1 41.6 42.2 42.7 43.3 43.9 44.4 45.0 45.5
Note: PRES in kg/sq.cm.
TABLE 3 - MAXIMUM ALLOWABLE CONTAINER PRESSURE FOR R-134a METRIC UNITS O
TEMP C 18 19 20 21 22 23 24 25
kPa 476 483 503 524 545 552 572 593
TEMP C 26 27 28 29 30 31 32 33
kPa 621 642 655 676 703 724 752 765
kPa 793 814 841 876 889 917 945 979
TEMP C 42 43 44 45 46 47 48 49
psig 115 117 118 120 122 125 127 129 131 133 135 137 139 142
TEMP F 107.0 108.0 109.0 110.0 111.0 112.0 113.0 114.0 115.0 116.0 117.0 118.0 119.0 120.0
TEMP C 34 35 36 37 38 39 40 41
kPa 1007 1027 1055 1089 1124 1158 1179 1214
psig 144 146 149 151 153 156 158 160 163 165 168 171 173 176
ENGLISH UNITS O
TEMP F 65.0 66.0 67.0 68.0 69.0 70.0 71.0 72.0 73.0 74.0 75.0 76.0 77.0 78.0
psig 69.00 70 71 73 74 76 77 79 80 82 83 85 86 88
TEMP F 79.0 80.0 81.0 82.0 83.0 84.0 85.0 86.0 87.0 88.0 89.0 90.0 91.0 92.0
psig 90 91 93 95 96 98 100 102 103 105 107 109 111 113
TEMP F 93.0 94.0 95.0 96.0 97.0 98.0 99.0 100.0 101.0 102.0 103.0 104.0 105.0 106.0
TABLE 4 - USEFUL TABLES AND CHARTS TABLE A- PRESSURE SCALES COMPARISON POUNDS PER SQUARE INCH PRESSURE TYPE
105 90 75 60 45 30
NEG. PRESS. OR VACUUM
INCHES MERCURY VACUUM In. Hg.
0.725 0.621 0.518 0.414 0.311 0.207
7.143 6.122 5.102 4.082 3.061 2.041 1.0
0.101 10 20 29.9
0.069 0.035 0
0.680 0.340 0
TABLE B- CONVERSION CHART Metric
645.2 0.09290
sq.mm sq.m
Area sq.cm sq.m
sq.in sq.ft
0.1550 10.76
Length mm m m
0.03937 3.281 1.094
in ft yd
25.4 0.3048 0.9144
0.03527 2.205
28.35 0.4536
3.968 0.3307
Btu/h Ton ref
1.163 0.2931 3.517
W W kw
98.07 6.895 0.006
KPa KPa MPa
Mass g kg Power kcal/h kcal/h Mcal/h Pressure kg/sq.cm kg/sq.cm Temp. Deg. C
ACKNOWLEDGEMENT This Code acknowledges the help/support/assistance from the following: Department of Environment and Natural Resources (DENR), Environmental Management Bureau (EMB), Philippine Ozone Desk (POD), National CFC Phaseout Plan (NCPP), Project Management Unit (PMU) Michael T. Defensor – Secretary, DENR Elisea G. Gozun – Former Secretary, DENR Julian D. Amador – Director, EMB Prudencio E. Calado III – Program Manager, POD Elvira S. Pausing – Project Manager, NCPP-PMU World Bank Neeraj Prasad – Senior Operations Officer Maya Villaluz – Task Team Leader and Operations Officer Cecilia Vales – Sr. Procurement Specialist Mary-Ellen Foley – ENV-Montreal Protocol Unit Preselyn Abella – Financial Management Specialist Fe Timonera – Disbursement Specialist Swedish Government Swedish International Development Cooperation Agency (Sida) Stockholm Environment Institute (SEI) Maria Delvin – Program Manager NCPP PMU Staff Katherine C. Delfin – Project Monitoring Officer Lorelei S. Bacani – Project Component Coordinator for Accreditation and Certification Cherry P. Ballesteros - Project Component Coordinator for Accreditation and Certification Ariel L. Erasga – Project Component Coordinator for MAC Inspection and Registration Helen Grace S. Olavidez – Public Awareness Officer Marianne Leny L. Mendoza – Finance Officer Grace M. Laspinas – Procurement Officer Gladys C. Cablayan - Administrative Assistant Alex C. Oriarte – Utility/Clerk Abel P. Achas – Driver POD Staff Joel U. Baun – Administrative Officer Onofre P. Escota – Project Evaluation and Monitoring Officer Denise S. Sioson – Information Officer Melody P. Santos – Finance Officer Michelle G. Longid – Coordination and Monitoring Officer Lynette A. Vera – Project Evaluation and Monitoring Officer Rommel F. Llamson – Computer Programmer Abigail R. Galguerra – Administrative Assistant Robert B. Aboy – Liaison Officer Wilfredo A. Fieldad - Driver Land Bank of the Philippines Titus Castro – Vice President, Program Lending Vilma Calderon – Head, Special Program Management Department May D. Arizabal – Accounts Management Analyst Technical Education and Skills Development Authority (TESDA) Elmer K. Talavera – Executive Director, TESDA-NITVET Ricardo Mejia – Chief, TESD, TESDA-NITVET Eugene I. Panesa – Supervising TESDS, TESDA-NITVET Department of Trade and Industry (DTI) Jaime Lasaro L. Olmos – Assistant Director, DTI-BTRCP Noecer Llenaresas – TIDA, DTI-BTRCP Jesus Motoomul – Director, DTI-BPS Norma C. Hernandez – Division Chief, SDD, DTI-BPS
With participation/cooperation from the following: Philippine Appliance Industry Association (PAIA) Concepcion Carrier Air Conditioning Robert M. Bates – Service Director Ma. Lucia Limson – Marketing Officer Daikin-Alen Air Conditioning Augusto T. Quitco – Service Manager Fedders-Koppel Inc. Rolando D. Deximo – Service Manager Panasonic Phils. Josefino C. Noche – Service Manager Henry Malantic – Service Supervisor Sanyo Phils. Rebecca M. Relucio – S&I Engineer Kolin Phils. LG Electronics Phils. Asian Durables Manufacturing, Inc. Alvan P. Garcia – Production Supervisor/Technical Trainor Philippine Society of Ventilating, Air Conditioning and Refrigerating Engineers (PSVARE) Maintenance Association of the Philippines (MAPHIL) Jig Lasquety - Director Hotel Engineers Association of the Philippines (HEAP) Filipinas Thermoking KST Auto Aircon Unity Marketing Corporation Philippine Association of Refrigerant Importers (PARII) Dupont Phils. Delia R. Belonio – Market Development Manager Dave Bateman – Technical Expert Tropical Aire Marketing Romeo C. Liwanag – Operations Manager Toyota Motors Commonwealth Oliver Y. Gonzales – In-House Instructor Reviewed by the following TESDA Lead Trainers: Gervacio J. Faustino – Lead Trainer for R-3 Francisco J. Reyes – Lead Trainer for R-4a & R-4b Porferio C. Celestial – Lead Trainer for R-6 Victor Villamor Jr. – Lead Trainer for R-7 Ben Raymundo S. Helar – Lead Trainer for R-9 Paul C. Saavedra – Lead trainer for R-9 Tomas C. Gomez – Lead Trainer for R-10 Carmelo A. Luzon – Lead Trainer for R-12 Jaime C. Mendoza – Lead Trainer for NCR Famy L. Pepito – Lead Trainer for NCR Danilo T. Roca – Lead Trainer for NCR Special thanks to the following PSVARE Board Members (also TESDA TEP/TAP members) who made th valuable recommendations that came-up with the 11 revision of the Code: Rosendo C. Perez Jr. Sabas B. Bergantinos Danilo G. Duya Eduardo M. Fernadez Ed S. Macatangay
ANG CODE OF PRACTICE…BAW Alam n’yo ba na itong Code of Practice Ay nabuo dahil sa mga TWG members Na gumugol ng dugo at pawis Na karamihan ay mechanical engineers Na balitang matitinik at matutulis Para lamang mapaganda ang service Ng mga technician sa refrigeration at air conditioning business. At ang major na dahilan Kung bakit ‘tong Code pinagkakagastusan Ay upang tayo’y magising sa katotohanan Na umpisahan nating pangalagaan Kalikasan na di natin alam Nasisira dahil sa’ting kagagawan. Kaya aking mga kaibigan Ikaw ma’y babae, lalaki o nasa kalagitnaan Maganda man o di kagwapuhan Matinik man o ‘yong mga matutulis diyan As long as you are human You should be part of our drive to save the sanlibutan. So let’s volt-in na mga kasangkayan Wag na nating hayaang madagdagan Butas ng ozone layer sa kalawakan Upang ating mga great great granddaughters and grandsons In other words ating mga kaapu-apuhan Ay meron pang earth na matitirhan In the later years to come That is safe from the harmful ultra-violet rays of the sun. Composed for the CoP TWG Members by: Ariel Demetillo Delicana, RME PCCCPRTC, NCPP-PMU DENR EMB POD
Department of Environment and Natural Resources Environmental Management Bureau Philippine Ozone Desk National CFC Phase-out Plan Project Management Unit DENR Compound Visayas Avenue, Quezon City Tel. Nos. 426-4338 / 928-4578 / 928-4589 E-mail: [email protected] Website: www.emb.gov.ph
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