EPA 608 Type III

 Certification Requirements

• Technicians handling low-pressure appliances (such as chillers) must be Type III certified or hold Universal certification.

• Low-pressure systems operate under a vacuum, increasing the risk of air and moisture infiltration.

Leak Detection for Low-Pressure Systems

• Purge Units: Essential for removing non-condensables that leak into the system, often indicated by high head pressure or frequent purge operation.

• Hydrostatic Tube Testing: Used to test for leaks; a maximum test pressure of 10 psig is applied.

• Moisture Prevention: Moisture commonly enters low-pressure systems through gaskets or fittings; leak detection should be frequent.

• Air Accumulation Prevention: Maintain slightly positive pressure during system downtime to avoid air entry.

Leak Repair Requirements

• Leak Thresholds:

• Comfort Cooling: 10% per year.

• Commercial Refrigeration: 20% per year.

• Industrial Process Refrigeration (IPR): 30% per year.

• Repair or Retirement: If leak thresholds exceed these values, repairs, retrofitting, or retirement of the appliance are mandatory.

Repair Deadlines

• 30 Days: For appliances exceeding the threshold leak rate, repairs must reduce leaks below the threshold within 30 days.

• 18 Months: If the leak rate exceeds 50 pounds, 18 months is allowed to retrofit or retire the appliance if using a refrigerant exempt from venting prohibition.

System Mothballing

• Does not require removal of the appliance. If refrigerant is recovered, storing the appliance at atmospheric pressure can extend deadlines.

Recovery Techniques for Low-Pressure Systems

• High-Pressure Cut-Out: The cut-out level for low-pressure recovery units is set at 10 psig.

• Recovery Process:

• Begin with liquid refrigerant removal followed by vapor recovery.

• Large systems like 350-ton R-123 chillers may retain about 100 pounds of refrigerant in the vapor state at 0 psig.

• Dehydration with Nitrogen: For moisture-heavy systems, use nitrogen to prevent water from freezing during evacuation.

Recovery Equipment and Requirements

• Water-Cooled Recovery: Recommended for faster recovery and to prevent freezing.

• Oil Heating: Before replacing refrigerant oil, heat to 130°F to release refrigerant trapped in oil.

• Evacuation Levels: Recover refrigerants to an absolute pressure of 25 mm Hg. Disposal of low-pressure appliances requires records for three years.

Recharging Techniques

• Oil Sampling: Before recharging, take an oil sample if the unit has had a compressor burn-out.

• Prevent Freezing: For systems charged in a vacuum, avoid freezing by referencing the pressure-temperature (P-T) chart.

• Pressure Adjustments: Charge refrigerant vapor into the system to avoid freezing; liquid refrigerant is added through the evaporator charging valve.

Safety Protocols

• TLV-TWA Standard: When exposure limits are exceeded, ASHRAE Standard 15-2013 mandates alarms and mechanical ventilation.

• Room Sensors: Required to detect refrigerant leaks for all safety groups due to the asphyxiation risk of refrigerants.

• Pressure Relief Valve: Relief valves must be vented outdoors and installed in parallel, not in series.

• Protective Equipment: Technicians should wear gloves and safety goggles when handling liquid refrigerants.

General Handling and Precautions

• Rupture Discs: Located on evaporators, rupture at 15 psig to release pressure.

• Refrigerant Charging: Avoid over-pressurizing the system when charging through the evaporator.

• Sight Glass Maintenance: Use isopropyl alcohol to remove ice from sight glasses and other components.

EPA 608 Type II

Type II Certification

• Required for technicians handling medium, high, and very high-pressure appliances (excluding small appliances and MVAC systems).

• Applies to commercial refrigeration, comfort cooling, and industrial process refrigeration.

System Classifications

• Comfort Cooling: Used to control temperature and humidity in occupied spaces (e.g., residential, office buildings).

• Commercial Refrigeration: Preserves products, used in sectors like retail food and cold storage.

• Industrial Process Refrigeration (IPR): If an appliance has dual uses, the higher percentage of use determines its classification.

Determining System Charge

• Use the equipment nameplate for packaged systems to determine the refrigerant charge.

• Split-systems require calculated charge values (factory charge + piping and accessory charges).

• Example: A system with an 80 lb nameplate charge requires liquid charging through the liquid-line service valve.

Type II Leak Repair Requirements

• Leak Thresholds (as of 2019):

• Comfort Cooling: 10% annual leak rate.

• Commercial Refrigeration: 20% annual leak rate.

• Industrial Process Refrigeration: 30% annual leak rate.

• Repair Requirements: Appliances with a charge ≥50 lbs and exceeding the threshold must be repaired, retrofitted, or retired.

Leak Repair Time Frames

• 30 Days: Owners/operators have 30 days to complete repairs once a leak threshold is exceeded.

• Follow-up: A verification test is required within 10 days if ≥200 lbs of refrigerant is added.

Section 608 Leak Repair Regulations

• Leak Inspections: Required for appliances exceeding the maximum allowable leak rate.

• Inspection Frequency:

• Over 500 lbs: Inspect every three months.

• 50–500 lbs: Inspect annually.

Record Keeping

• Maintain records of leak inspections, verifications, and repairs for three years.

• The equipment owner/operator is responsible for these records.

Leak Detection Methods

• Dry Nitrogen with Tracer Gas: Pressurize the system with dry nitrogen and a small amount of refrigerant for leak detection.

• Indicators: Oil traces on rotating shafts indicate possible leaks.

Recovery Techniques

• Preparation: Determine maximum system charge; systems >15 lbs require active recovery methods.

• Enhancing Recovery: Connect service hoses to the liquid line and use recovery in liquid phase when possible to speed up the process.

• Cylinder Handling: Reduce pressure in an empty cylinder before transferring refrigerant.

Evacuation Levels During Recovery

• Evacuation Levels (required for appliances with different pressure levels):

• Very High Pressure: 0 inches Hg.

• High Pressure (<200 lbs): 0 inches Hg.

• High Pressure (≥200 lbs): 10 inches Hg.

• Medium Pressure (<200 lbs): 10 inches Hg.

• Medium Pressure (≥200 lbs): 15 inches Hg.

Refrigeration System Accessories

• Liquid-Line Sight Glass: Used to check for moisture; located before the filter drier.

• Accumulator: Found on the suction line, preventing liquid refrigerant from entering the compressor.

System Evacuation

• Target: Evacuate to 500 microns to ensure all moisture and non-condensables are removed.

• Evacuation Factors: Ambient temperature, system size, and vacuum line dimensions affect evacuation speed.

Pressure-Temperature Chart

• Use in Charging: Reference P-T charts to match refrigerant pressures with temperatures and verify no non-condensables are present.

Safety Protocols

• Personal Protection: Use safety glasses, gloves, and nitrogen regulator.

• Evacuation and Recovery Precautions: Avoid energizing hermetic compressor motors in deep vacuum and follow manufacturer’s guidelines to prevent overheat or compressor damage.

• Handling High-Pressure Systems: Monitor closely for temperature changes to prevent accidents or component failure.

EPA 608 Type I

 

1. Certification Requirements for Technicians

   • Type I Technician or Universal Technician: Required for those handling refrigerants in small appliances (hermetically sealed, containing ≤5 lbs of refrigerant).
   • Small Appliances Definition: Factory-sealed products; split systems are excluded.
   • Regulation on Sales: Only EPA-certified technicians can purchase regulated refrigerants (CFC, HCFC, HFC, HFO).
   • MVAC Systems: Motor vehicle air conditioning systems are not classified as Type I appliances.

2. Retrofit and Conversion

   • EPA-Approved Substitutes Only: No “drop-in” replacements are allowed. Each substitute must be EPA-approved for retrofitting.

3. Recovery Equipment

   • Certification: Recovery devices for CFCs, HCFCs, and HFCs must be EPA-certified.
   • Types of Recovery Equipment:
     • Self-contained (Active): Contains its own compressor for recovery.
     • Passive (System-dependent): Uses appliance’s compressor and is limited to systems with up to 15 lbs of refrigerant.
   • Performance Requirements: Must recover 90% of refrigerant if compressor is operational or achieve a 4-inch vacuum.

4. Maintenance of Recovery Equipment

   • Regular Checks: Ensure no leaks and maintain proper oil levels.
   • Tank Fill Monitoring: Use refrigerant scale or float devices to avoid exceeding 80% tank capacity.

5. Recovery Techniques and Requirements

   • Refrigerant Labeling: Clearly label recovered refrigerant containers to prevent cross-contamination.
   • Checking for Contaminants: Use a pressure-temperature (PT) chart after stabilization to detect impurities.
   • Handling High-Pressure Refrigerants (R-744): Recovery is typically unnecessary for CO₂ due to its high pressure.

6. Service Apertures and Access Fittings

   • Piercing Valves: Temporary access fittings should be leak-tested and removed after repairs to prevent leaks over time.
   • Multi-Access Points: For non-operational compressors, access both high and low sides to improve recovery speed.

7. Safety and Precautionary Measures

   • Safety Gear: Use safety eyewear, gloves, and follow nitrogen use guidelines (pressure regulator, relief valve).
   • Handling Large Leaks: Leave the area if a large refrigerant leak occurs; ventilate naturally. Avoid inhalation risks.
   • High-Temperature Risks: CFCs and HCFCs can decompose into toxic gases, such as phosgene, at high temperatures.

8. Leak Detection and Preventative Maintenance

   • Electronic Leak Detectors: Essential for identifying leaks. Always pressurize new systems with nitrogen for testing.
   • Regular Leak Repairs: While not mandatory, repairing leaks conserves refrigerants and improves system efficiency.

9. Safe Recovery Practices

   • Contamination Indicators: Pungent odors may signal compressor burn-outs; oil contamination requires system flushing.
   • Passive Recovery Techniques: Heating compressors and tapping them can help release refrigerants trapped in oil.

10. Safety Standards for Hydrocarbon Refrigerants

• Markings: Permanent safety labels are mandatory on HC-charged appliances (e.g., near evaporators, tubing).
• Suffocation Risk: Large refrigerant leaks in closed spaces can displace oxygen; vacate if self-contained breathing apparatus is unavailable.

EPA 608 Core

1. Stratospheric Ozone Depletion

   • Purpose of Ozone Layer: The stratospheric ozone layer shields Earth from harmful ultraviolet (UV) rays from the sun.
   • Ozone Depletion Potential (ODP): This measures how much a substance can destroy ozone in the stratosphere. CFCs (Chlorofluorocarbons) and HCFCs (Hydrochlorofluorocarbons) have high ODP due to chlorine, which is a major contributor to ozone depletion.
   • Health and Environmental Impact:
     • Human Health: Increased UV exposure leads to higher skin cancer rates and more cases of cataracts.
     • Environmental Damage: Causes lower crop yields and damages marine life, especially plankton and coral reefs.
   • Controversy: Some early theories suggested natural sources (like volcanoes) contributed to stratospheric chlorine, but studies found human-made CFCs and HCFCs are the main sources. NASA’s data shows a direct correlation between CFC/HCFC emissions and rising chlorine levels in the stratosphere.

2. How Chlorine Depletes Ozone

   • Ozone Molecule (O₃): Composed of three oxygen atoms.
   • Depletion Process:
     • A chlorine atom from CFC or HCFC molecules breaks off and attacks an ozone molecule, removing one oxygen atom to form chlorine monoxide (ClO) and leaving an O₂ molecule.
     • ClO can collide with another ozone molecule, release its oxygen atom, and continue to destroy up to 100,000 ozone molecules before becoming inactive.
   • Persistence: A single chlorine atom can stay active in the stratosphere for up to 120 years.

3. Types of Refrigerants

   • CFCs (Chlorofluorocarbons): Contain chlorine, fluorine, and carbon; have the highest ODP and severely harm ozone. Examples: R-11, R-12.
   • HCFCs (Hydrochlorofluorocarbons): Similar to CFCs but contain hydrogen, making them slightly less harmful. Examples: R-22, R-123.
   • HFCs (Hydrofluorocarbons): Contain hydrogen, fluorine, and carbon with no chlorine; do not harm the ozone but have high GWP. Examples: R-134a, R-410A.
   • HFOs (Hydrofluoroolefins): Have low GWP and no ODP, with mild flammability. They are suitable for HVACR equipment. Example: R-1234yf.
   • HCs (Hydrocarbons): Made of hydrogen and carbon; have no ODP and low GWP but are highly flammable. Examples: Isobutane (R-600a), Propane (R-290).

4. Global Warming Potential (GWP)

   • Purpose: Compares the warming impact of gases over time, with CO₂ as the baseline (GWP = 1).
   • HFCs: High GWP, impacting climate change.
   • HFOs and HCs: Low GWP; more eco-friendly refrigerant options.

5. Refrigerant Characteristics & ASHRAE Ratings

   • ASHRAE Classification: Refrigerants are categorized based on toxicity (Class A: safer; Class B: more toxic) and flammability (1 = no flammability, 2 = low, 3 = high).
   • Types of Blends:
     • Azeotropic Blends: Behave as single components with constant boiling points.
     • Zeotropic Blends: Have temperature glide, meaning they evaporate/condense at varying temperatures, affecting charging methods.

6. EPA Regulations - Montreal Protocol & Clean Air Act (Section 608)

   • Montreal Protocol: International treaty aiming to phase out substances harmful to the ozone layer.
   • Section 608: Governs refrigerant handling, requiring technicians to be certified to handle and purchase regulated refrigerants. Violations can result in hefty fines and loss of certification.
   • Prohibited Actions: Venting CFCs, HCFCs, and HFCs; topping off R-22 systems with other refrigerants (such as R-410A).

7. Refrigerant Recovery, Recycling, and Reclaiming

   • Recover: Remove refrigerant from a system to store in approved containers.
   • Recycle: Clean refrigerant for reuse within the same owner’s systems.
   • Reclaim: Process refrigerant to meet new product standards (AHRI 700), allowing for resale.

8. Leak Detection

   • Use electronic or ultrasonic detectors and soap bubbles to identify leak locations.
   • Nitrogen is recommended for pressurizing new systems during leak tests. Adding a trace of system refrigerant with nitrogen helps in detecting leaks.

9. System Dehydration

   • Purpose: Removes moisture to prevent acid formation.
   • Evacuation: Typically done to 500 microns or lower, using large-diameter, short vacuum lines to improve efficiency.
   • Indicators of Issues: Rising pressure indicates leaks or moisture; stable low pressure indicates successful dehydration.

10. Safety and Handling Procedures

    • Always wear safety glasses, gloves, and follow equipment guidelines.
    • Avoid using open flames around refrigerants; some refrigerants can release toxic gases if overheated.
    • Use proper grounding when recovering flammable refrigerants.

11. Cylinder Handling and Disposal

    • Filling: Only up to 80% of the cylinder’s capacity.
    • Disposal: Recover all refrigerant before recycling cylinders.
    • DOT Compliance: Follow Department of Transportation (DOT) regulations when transporting cylinders, including labeling and positioning upright.

12. Shipping Regulations

    • DOT requires specific tagging and labeling for cylinders containing used refrigerants.
    • Identify refrigerant type on recovery cylinders to avoid accidental mixing, ensuring safe transport and processing.