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Maytag Services

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Some refrigerants (R-12, R-134a) have value on the reclaim market. ... Samsung 4 drawer side by side. Refrigerator technicians will need to turn in their vacuum pumps ... – PowerPoint PPT presentation

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Title: Maytag Services


1
  • Maytag Services
  • Refrigerant Handling
  • Standard Operating Procedures

1
2
  • Federal EPA Refrigerant Recovery Guidelines

3
Licensing Requirements
  • Under section 608(c) of the 1990 Clean Air Act
    Amendments, ( It is )unlawful for any person,
    in the course of maintaining, servicing,
    repairing or disposing of an appliance. to
    knowingly vent or otherwise knowingly release or
    dispose of any Class I or Class II substance used
    as a refrigerant in such an appliance in a manner
    which permits such substance to enter the
    environment
  • The Act further establishes that any technician
    that can be reasonably expected to enter a sealed
    system during the course of repair of a
    refrigeration appliance must be certified in
    refrigerant handling by a Federal EPA approved
    certification organization.

4
EPA Penalties
  • A willful release of refrigerants or failure to
    follow EPA recovery guidelines carries stiff
    penalties for the technician
  • 30,000 per occurrence
  • Up to 5 years jail time
  • EPA offers a 10,000 reward to anyone reporting a
    violation

5
Certification Classifications
  • There are 4 certification classifications
  • Type I- Allows technicians to perform service on
    refrigeration equipment containing less than 5
    lbs. of refrigerant.
  • Type II- Allows technicians to work on
    refrigeration equipment containing more than 5
    lbs. but less than 50 lbs. of refrigerant.
  • Type III-Allows a technician to work on
    refrigeration equipment containing more than 50
    lbs. of refrigerant
  • Universal- Allows a technician to work on any
    refrigeration equipment, regardless of the amount
    of refrigerant.

6
Certification Guidelines
  • Type I or Universal certification is required to
    work on residential refrigeration appliances.
    Type II and Type III certifications do not permit
    working on small appliances.
  • Technicians are required to have valid
    certification cards on their person anytime that
    they are performing repairs on a refrigeration
    system.

7
EPA Restrictions
  • Purchase of refrigerant is restricted to
    certified technicians and Section 608(c)
    certified technicians can only purchase
    refrigerant in 30 lb. (minimum) containers.
  • Recovery of refrigerants must be accomplished
    with an EPA approved recovery device. Two types
    of recovery devices are allowed.
  • Active- a recovery pump that is able to pull a
    system into a minimum 4 vacuum.
  • Passive- a non powered device capable of
    capturing 80 of the system charge (such Recovery
    bag)

8
EPA Restrictions
  • Use of refrigerant recovery bags, such as the
    Whirlpool Ozone Saver Bag, is regulated by the
    EPA. Compliance requires
  • The technician must recover a minimum of 80 of
    the system charge. On a non working compressor,
    the base of the compressor must be heated and
    struck sharply with a hammer to free any
    refrigerant trapped in the compressor oil.
  • Recovery bags are designed as temporary
    refrigerant storage devices and should be removed
    from vans each night.
  • The bag can only be used 4 times before it is
    discarded.
  • The bag must be emptied within 48 hours
  • Torn or damaged bags must be discarded.

9
Recovered Refrigerant
  • All Refrigerants must be recovered and reclaimed
  • Mixed refrigerants cannot be reclaimed and must
    be destroyed
  • Some refrigerants (R-12, R-134a) have value on
    the reclaim market.
  • Every pound we have to destroy not only costs us
    3-4 per pound to dispose of but we miss out on
    the reclaim income that would have been generated

10
Other EPA Recommendations
  • All leaks should be located and repaired
  • All hoses and manifold gauge sets must utilize
    low loss fittings

11
  • US Department Of Transportation (DOT) Guidelines

12
Material Safety Data Sheets (MSDS)
  • Technicians are required to carry MSD Sheets for
    every type of chemical in their truck, including
    acetylene, oxygen, glues, cleaners and
    refrigerants.
  • Technicians should read and follow all
    recommended safety guidelines when handling
    refrigerants and other chemicals.

13
Transportation of Refrigerants and other
Compressed Gasses
  • Refrigerant, acetylene, oxygen, nitrogen, etc.
    are all considered to be hazardous materials by
    US DOT. Shipping of these containers is highly
    regulated.
  • Before shipping any of these items by common
    carrier, check with the carrier to determine
    packaging and Bill of Lading requirements.
  • Air freighting of these items is strictly
    prohibited.
  • All compressed gasses such as refrigerant,
    acetylene, oxygen, aerosol and paint cans, etc.
    must be in DOT approved containers and secured in
    the van with chains or other significant
    restraints to prevent containers from falling
    over, rolling around in the truck, etc.

14
Transportation of Refrigerants and other
Compressed Gasses
  • All cylinder valves should be completely closed
    and OXY/Acetylene regulators removed whenever a
    cylinder is being transported
  • All cylinder must completely shut-off with no
    leaks

15
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16
Transportation of Refrigerants and other
Compressed Gasses
  • The acetylene cylinder must not have been fully
    closed and a small leak occurred
  • On the Monday morning when the van door was
    opened, a large explosion took place.
  • Tech suffered damage to his ear drums and face.

17
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18
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19
Transportation of Refrigerants and other
Compressed Gasses
  • Transporting refrigerant in charging cylinders
    (such as Dial-a-Charge) is not permitted.
    Charging cylinders must be empty of refrigerant
    before transporting.
  • Some states go as far as requiring that
    refrigerant be removed from self sealing hoses on
    compound gauges. To assure compliance,
    technicians should be sure to recover refrigerant
    from gauges before transporting.

20
Cylinder Safety
  • New refrigerant is packaged in DOT 39 disposable
    cylinders. When empty, these cylinders must be
    disposed of properly. After evacuating the
    cylinder (to 0 PSIG), the valve must be removed.
    The tank can then be disposed of with other metal
    waste.
  • Reuse of DOT 39 disposable cylinders (such as
    storing or carrying compressed air) is illegal
    and carries a penalty of 25,000 and up to 5
    years in prison.

21
Cylinder Safety
  • Recovered refrigerant can only be stored in DOT
    approved recovery cylinders (with the exception
    of temporary storage in a refrigerant recovery
    bag.)
  • US DOT regulates that recovery cylinders must not
    be filled beyond 80 capacity.
  • Many of these tanks are equipped with a ball or
    float switch that, when connected to a recovery
    pump, will shut the pump off when the 80 mark on
    the tank is reached.

22
Cylinder Safety
  • If the cylinder is not equipped with a ball or
    float switch, the tank must be weighed prior to
    each recovery to insure that it can accept
    additional refrigerant. Cylinders are marked
    with their empty or tare weight (TW) and water
    content weight (WC). This represents the total
    weight of the cylinder and contents when the
    cylinder is filled to capacity.
  • Sometimes the tank is marked with the tare weight
    and the MAX. Gross WT ___ LB. The max weight,
    again, represents the total weight of the
    cylinder when its filled to capacity.

23
Cylinder Safety
  • To insure that the recovery tank is not filled
    beyond 80, the technician must determine the max
    fill level for each tank. To do that, the
    technician must compute the WC weight (if not
    listed) and multiply by .8
  • Example
  • MAX weight 23.5 lbs, TW 10.5 lbs.
  • Max WC weight 13 lbs. (23.5-10.5)
  • Maximum refrigerant that can be put into tank
    10.4 lbs. (13 lbs. WC X 80)

24
Cylinder Safety
  • Overfilled cylinders present a serious safety
    hazard. Because liquids dont compress, any rise
    in temperature can cause an over filled tank to
    explode. Technicians must avoid overfilling or
    exposing a tank to extreme temperatures.
  • In the summer, park in the shade whenever
    possible
  • If the truck is equipped with vents, open them
  • Never use an open flame to heat a refrigerant
    cylinder

25
Hydrostatic Cylinder Testing
  • Recovery cylinders must be hydrostatically tested
    every five years. The last test date will be
    stamped or embossed on the shoulder of the
    cylinder. In most cases, the tank will clearly
    be marked with the first retest date. For
    example,
  • FIRST RETEST DATE
  • 06 07
  • RETEST EVERY FIVE YEARS
  • This means that the tank must be submitted for
    testing prior to June of 2007 and every five
    years after that (on or before the month of
    June).

26
Hydrostatic Cylinder Testing
  • Older tanks may have the date stamped on them in
    the pattern shown to the right. This stamp
    indicates the last retest date and the testing
    organization that completed the test.
  • In this example, this cylinder was last tested on
    May of 2002 by tester A253. The next retest
    date, therefore, is May of 2007.

A2 05 02 53
27
Hydrostatic Cylinder Testing
  • Technicians carrying tanks that are beyond the
    required test date must discontinue use of the
    cylinder immediately.
  • Filling of cylinders with expired test dates is
    prohibited.
  • Any tank that has an expired test date must be
    submitted to a reclaimer for refrigerant
    processing and cylinder testing.

28
Labeling of Refrigerant Cylinders
  • All refrigerant cylinders, both new and
    recovered, must be properly labeled with their
    content.
  • If the recovery cylinder is in its original
    cardboard carton, there are boxes printed on the
    carton that allow placing an X or a v mark next
    to the type of refrigerant that is being carried.
  • If out of the carton, most refrigeration supply
    houses supply stickers and/or tags that can be
    affixed to recovery cylinders to identify the
    contents.

29
Contaminated Refrigerants
  • Normal contaminants, such as air, refrigerant oil
    and water that are mixed with refrigerants in a
    recovery cylinder are not an issue. Care should
    be taken, however, to insure that no other
    contaminants are added to the refrigerant.
  • If a reclaimer suspects that a refrigerant tank
    is contaminated with unidentified chemicals,
    regulations require that the contents of the tank
    be analyzed and the refrigerant be disposed of.
    Reclaimers charge a fee for this service.

30
Mixed Refrigerants
  • Mixing of refrigerants should be avoided.
  • Refrigerants are considered to be mixed when more
    than 3 of a second refrigerant is added to the
    base refrigerant. For example, adding 1 lb of
    R-22 to a cylinder that contains 20 lbs of R-134a
    will render the entire tank as mixed.
  • Mixed refrigerants cannot be easily or
    economically reclaimed and thus, must be
    destroyed. Instead of the usual 25 or 30
    handling fee for accepting used refrigerant, the
    price to dispose of mixed refrigerants can exceed
    100 per cylinder (3-4 per pound).

31
Tracking of Refrigerant Usage and Recovery
  • The Federal EPA has the ability to subpoena
    refrigerant usage records of an individual and/or
    a company to compare refrigerant purchases
    against recovery levels.
  • Since the minimum recovery level for any system
    is 80, a discrepancy between refrigerant
    purchased and refrigerant recovered could
    indicate that technicians are not recovering at
    mandated rates.
  • Technicians must maintain logs to track
    refrigerant usage

32
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33
  • Refrigerant Handling Process

34
Required Equipment
  • Over the next few months, each White Goods
    technician will be supplied whatever equipment
    theyre missing to insure they all have
  • Scale
  • R-134a Charging Cylinder
  • R-134a Manifold Gauge set
  • Recovery pump
  • 30 lb. recovery cylinder
  • Electronic Leak Detector
  • Hand valves (2)
  • Process tube adapter kit
  • Pinch off pliers
  • Recovery Bags (2)

35
Required Equipment
  • Over the next few months, each specialty
    technician will be supplied whatever equipment
    theyre missing to insure they all have
  • Scale
  • R-134a Charging Cylinder
  • R-134a Manifold Gauge Set
  • CFC Manifold Gauge Set
  • Micron Gauge
  • Recovery pump
  • Vacuum pump
  • 30 lb. recovery cylinder
  • Electronic Leak Detector
  • Hand valves (2)
  • Process tube adapter kit
  • Pinch off pliers
  • Recovery bags (2)

36
Required Equipment
  • Over the next few months, each PTAC technician
    will be supplied whatever equipment theyre
    missing to insure they all have
  • Scale
  • CFC/HCFC Manifold
  • Vacuum Pump
  • Micron gauge
  • Recovery pump
  • 30 lb. recovery cylinder
  • Electronic Leak Detector
  • Hand valves (2)
  • Process tube adapter kit
  • Pinch off pliers

PTAC techs who also work on White Goods will
also carry R-134a refrigerant and related tools
37
Refrigerant Handling Process
  • Virgin refrigerant
  • Technicians serviced by land based currier will
    continue to receive new refrigerant from RPDC
  • Technicians serviced by air currier must purchase
    refrigerant locally. (Use Refron facilities when
    possible to get quantity preferred pricing)

38
Refrigerant Handling Process
  • Used refrigerant
  • Technicians serviced by land based currier will
    return full cylinders to RPC
  • RPC will replace with empty, clean cylinder
  • Technicians serviced by air currier must find
    local parts supplier that is willing to accept
    used refrigerant
  • Work with virgin refrigerant supplier
  • Set up cylinder exchange program

39
Bag vs. Pump
  • Use recovery pump and tank on all Major Brand
    refrigeration that
  • can be swept
  • uses R-134a
  • Use the bag when servicing systems with
  • Burnouts
  • Unknown refrigerant
  • Drop-in refrigerant

40
Bag Handling Process
  • Technicians serviced by land based currier
  • Return bags to RPC with tag identifying contents
    as
  • Unknown refrigerant
  • R-134a Burnout
  • R-22, MP-39, etc
  • RPC will replace with empty, clean bag
  • Technicians serviced by air currier
  • Transfer contents of bag to a cylinder every
    night
  • R-134a burnouts to R-134a tank
  • R-22 to R-22 tank
  • If enough R-410 is encountered, R-410 to its own
    cylinder
  • All other refrigerants to mixed refrigerants
    tank

41
RPC refrigerant handling
  • Each RPC responsible to
  • Maintain supply of empty tanks on hand to
    replenish tanks when a full tank is received
  • Empty bags within 24 hours into appropriate
    recovery tank
  • R-134a
  • R-22
  • R-410
  • All other refrigerants to mixed refrigerants
    tank

42
  • Approved Sealed System Repair Process

43
Why Change to Sweep
  • Vacuum pumps require constant maintenance
  • Oil changes every 3 or 4 normal evacuations
  • After processing every burnout
  • Dirty oil renders pump incapable of pulling
    system to required vacuum levels to assure
    complete dehydration
  • Without ability to gauge dehydration level, there
    is no way to gauge how effective a vacuum was
    pulled, even with a well maintained vacuum pump
  • Properly performed sweep superior to deep
    evacuation with poorly maintained pump or without
    measuring micron levels in system

44
Why is proper dehydration important?
  • In order for water to boil at normal room
    temperatures, system pressure must be dropped
    below 27 vacuum (About 3,000 Microns or less)
  • Vacuum must be held over system until Micron
    levels drop below 300 microns
  • Depending on pump conditions, proper dehydration
    could take several minutes or several hours.

Unless system pressure is dropped to 300 microns
or less, there is still water left in the system.
45
What happens when water is left in the system?
  • Moisture and refrigerant create acids
  • Acids eat away at compressor winding insulation
  • Acids and oil create sludge which plugs cap tubes

46
Why is proper dehydration even more important
with R-134a?
  • R-134a systems do not mix well with with mineral
    oils and require the use of Ester oils
  • Ester oil are hygroscopic, meaning that they have
    a great affinity for moisture (actually pull and
    absorb moisture out of the air)
  • Ester oils are made from acids that have been
    dehydrated
  • When exposed to atmospheric moisture, the oil
    actually pulls vapor out of the air
  • The airborne moisture combines with the ester oil
    and returns it to its original acidic state
  • Acids eat away at the compressor windings
  • Acids combine with R-134a to form salts and gels
    which can plug the capillary tube.
  • Moisture in the system will eventually destroy
    the compressor (not a matter of if but when)

47
Why Change to Sweep
  • Sweep has been used in the industry for over 30
    years (Maytag, GE, Whirlpool, Sears, Montgomery
    Wards and a slew of independents)
  • Over the 30 year period, no conclusive proof has
    ever surfaced that sweep results in any more
    repeat failures than deep evacuation
  • In fact, laboratory testing has shown that a
    properly performed sweep is superior to deep evac
    that is performed with poorly maintained vacuum
    pump or without an accurate method of measuring
    dehydration levels in system

48
Processing R-134a systems
  • R-134a requires dedicated equipment to prevent
    cross contamination
  • R-134a systems should not be open to the
    atmosphere for longer than 20 minutes (max)
  • Verify compressor is nitrogen charged
  • Keep plugs in compressor until ready to make
    final connections to system tubing

49
Processing R-134a systems
  • Low side leaks
  • Find and repair leak
  • Replace compressor and dryer
  • High side leaks
  • Find and repair leak
  • Replace drier
  • Compressor burnout
  • Flush system
  • Replace compressor and drier

50
Processing R-134a systems
  • Because of the small system charges of modern
    refrigerators, accurate charging is critical
  • On a 5 oz. system, overcharging by ½ oz. results
    in 10 overcharge
  • Because of energy and cooling capacity issues,
    its better to be slightly undercharged than to
    be overcharged by any amount.

51
Affect of Over/Undercharge on 950 BTU Compressor
52
Problem with using a scale to charge small systems
  • One quarter ounce resolution could undercharge or
    overcharge a system by as much as 10- 20
    (depending on system charge)
  • Unless scale is calibrated on a regular basis,
    there is no way to determine accuracy of scale
  • Movement of the cylinder during charging changes
    the reading on the scale and could cause the
    final charge to be off by as much as 50

53
Adding system charge
  • Use Dial-a-Charge for all R-134a products.
  • Charging scales should be used for
  • Drop-ins
  • R-22
  • To weigh recovery cylinders if cylinder is not
    equipped with a ball float valve

54
Approved Sealed System Process
  • Sweep charge is the only approved method of
    refrigerator and freezer system processing for
    most product lines
  • Exceptions
  • PTACS
  • Samsung 4 drawer side by side
  • Refrigerator technicians will need to turn in
    their vacuum pumps
  • Note Vacuum pumps will be re-allocated to
    commercial and specialty techs


















55


  • Sweep Charge

56
Sweep Charge Steps
  • Reconfirm need for the sealed system repair
  • Verify that new compressor is nitrogen charged
    (should hear a pop when line plug is removed from
    compressor)
  • Reinstall plugs on compressor to prevent excess
    air from entering system while old compressor is
    removed from the system
  • Attach temporary line taps to low side and drier
    process stubs
  • Attach gauges and recovery pump. Recover
    refrigerant per pump manufacturers recommended
    procedures

57
Sweep Charge Steps
  • Cut out and remove old compressor
  • Install new drier
  • Install and plumb new compressor in place (keep
    compressor tubes plugged until ready to attach to
    system. This will assure that the system does
    not stay open longer than the recommended 20
    minutes.)
  • Attach process stub adapters to new compressor
    and drier process stubs
  • Reattach gauges. High and low side hoses should
    have hand valves attached at end of each hose

58
Sweep Charge Steps
  • Fill Dial-a-Charge with system charge plus 8 oz.
    and heat refrigerant until pressure on
    Dial-a-Charge is 30 lbs. over ambient. Remember
    to capture refrigerant if bleeding of the
    cylinder is necessary (EPA reg)
  • Attach Dial-a-Charge to common hose on manifold
    gauge set.
  • Purge air out of all hoses and pre-charge high
    side hose with liquid.
  • Charge 4 oz of refrigerant into the system using
    the hand valve at the end of the high side hose
    to meter the refrigerant into system.

59
Sweep Charge Steps
  • Check all joints for leaks with a mirror and
    electronic leak detector
  • Turn compressor on and allow charge to circulate
    for 5 minutes
  • Close hand valve at drier
  • Reattach pump and recover sweep charge as a
    liquid from the drier process stub while the
    compressor is running.
  • Continue to run recovery pump until the system is
    down to the pump design pressure (usually around
    20 inch vacuum on most pumps)

60
Sweep Charge Steps
  • Close hand valve at drier and turn off compressor
    and pump
  • Recheck pressure on Dial-a-Charge to make sure it
    is still at 30 lbs. over ambient. Reheat if
    necessary
  • Disconnect pump and reattach Dial-a-Charge to
    center hose of gauge set
  • Purge hoses and pre-charge high side hose with
    liquid
  • Using the hand valve, meter system charge into
    the system Important Once the charge is added
    and the hand valve is closed, DO NOT reopen.

61
Sweep Charge Steps
  • Using pinch off pliers, pinch off the high side
    process stub.
  • Remove the hand valve and process tub adapter and
    braise the stub shut
  • Repeat process with low side process stub
  • Check for low side leaks.
  • Restart the compressor and check high side for
    leaks.
  • Check current draw and feel compressor discharge
    for heat movement. Check air supply in freezer.
    If air is cold and current draw is normal, repair
    was successful.

62

  • R-12 and Replacements

63
Processing R-12 Systems with Drop-in Refrigerants
  • MP-39 only approved R-12 substitute
  • Hot Shot should not be purchased or used due to
    safety concerns (flammable- contains 6 methane)
  • As with all blends, the sweep and final charges
    of MP39 must go into the system as a liquid
  • Requires that refrigerant be heated to 30 lb.
    over ambient
  • If no heater blanket available for MP-39 tank,
    tank can be submersed into a partially filled 5
    gallon bucket of warm water.
  • Water should be no hotter than your skin can
    tolerate (125º F)
  • Charge must go into high side to prevent slugging
    of compressor
  • Some older refrigerators have direct suction
    pumps and adding liquid to low side could dump
    refrigerant into compression chamber
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