C2 Split Systems Learning Resource Book V17

UEE20111 Certificate II in Split Air-conditioning and Heat Pump Systems Resource Book V10

CONTENTS 3 3 Scope of this Qualification 5 Units included in the course 5 INTRODUCTION 6 APPLYING FOR YOUR LICENSE 7 THE AUSTRALIAN REFRIGERATION COUNCIL 8 OCCUPATIONAL HEALTH AND SAFETY 8 HAZARDS 9 WORKING WITH ADHESIVES AND CHEMICALS 11 GUIDELINES FOR THE SAFE HANDLING OF REFRIGERANTS 12 ENVIRONMENTAL ISSUES 13 RISK ASSESSMENT 17 AIR CONDITIONING AND HEAT PUMP SYSTEMS 20 REFRIGERANT LEAKAGE 24 REFRIGERATION & WATER GRADE COPPER TUBE 29 TUBE QUALITIES 29 PIPE INSULATION 30 OTHER TUBE MATERIALS 32 CUTTING 34 BENDING 42 JOINING 67 SOLDERING AND BRAZING EQUIPMENT 87 Split System Install Process 88 Ozone Depletion Potential 88 Suppliers, products and materials use 91 What is ‘Matter’? 99 REFRIGERANT CONDITIONS 124 Overview of R32 146 Australia and New Zealand Refrigerant handling code of practice 2007 151 VBA Technical Solution Sheet 7.08 Split System Air Conditioning 200 The Plumbers Handbook BOC Guidelines for Gas Cylinder Safety 2 of 267 ©Industry Development Training Pty Ltd

SCOPE OF THIS QUALIFICATION The installation, commissioning and de-commissioning of single head, split air conditioning and heat pumps systems to a prescribed routine where the maximum plant capacity for each system does not exceed 18 kWr. This includes wall hung, floor and ceiling suspended, cassette and ducted fan coil split systems and water heating heat pump systems. This qualification excludes competencies required for service, repair, maintenance, diagnostic/fault finding and electrical work or the safe and proper installation of commercial refrigeration, air conditioning and heat pump plant and equipment. Notes: 1.The letter “r” denotes “refrigeration” or cooling capacity, not electrical input power. 2.The Ozone Protection and Synthetic Greenhouse Gas Legislation Amendment Bill 2003 and the Ozone Protection and Synthetic Gas Management Regulations apply to this qualification. Prior to planning the delivery of any training and/or assessment activities all legislative and regulatory requirements shall be identified and included. UNITS INCLUDED IN THE COURSE UEENEEE038B PARTICIPATE IN DEVELOPMENT AND FOLLOW A PERSONAL COMPETENCY DEVELOPMENT PLAN. This unit covers the application of skills and knowledge in taking responsibility for one's own competency development. It encompasses understanding the structure of a competency development plan, participating the development of a personal competency development plan, understanding responsibilities and obligation under competency development plan, following activities for developing competency, self-monitoring competency development and meeting trainee obligations for periodic reporting of competency development activities. UEENEEE101A APPLY OCCUPATIONAL HEALTH AND SAFETY REGULATIONS, CODES AND PRACTICES IN THE WORKPLACE. This unit specifies the mandatory requirements of occupational health and safety and how they apply to the various electro technology work functions. It encompasses responsibilities for health and safety, risk management processes at all operative levels and adherence to safety practices as part of the normal way of doing work. UEENEEE102A FABRICATE, ASSEMBLE AND DISMANTLE UTILITIES INDUSTRY COMPONENT. This unit covers basic fitting and fabrication techniques as they apply in the various utilities industry work functions. It encompasses the safe use of hand, fixed and portable power tools; cutting, shaping joining and fixing using metallic and non-metallic materials; dismantling and assembling equipment; basic mechanical measurement and marking-out and reading drawings/diagrams. UEENEEE105A FIX AND SECURE ELECTRO TECHNOLOGY EQUIPMENT. This unit covers fixing, securing and mounting techniques as apply in the various electro technology work functions. It encompasses the safe use of hand and portable power tools, ©Industry Development Training Pty Ltd 3 of 267

safe lifting techniques, safe use of ladders and elevated platforms and the selection and safe application of fixing devices and supporting accessories/equipment. UEENEEE107A USE DRAWINGS, DIAGRAMS, SCHEDULES, STANDARDS, CODES AND SPECIFICATIONS. This unit covers the use of drawings, diagrams, cable schedules, standards, codes and specifications as they apply to the various electro technology work functions. It encompasses the rudiments for communicating with schematic, wiring and mechanical diagrams and equipment and cable/connection schedules, manuals, site and architectural drawings and plans showing the location of services, apparatus, plant and machinery and understanding the use and format of compliance standards and job specifications. UEENEEE137A DOCUMENT AND APPLY MEASURES TO CONTROL OHS RISKS ASSOCIATED WITH ELECTRO TECHNOLOGY WORK. This unit covers identifying occupational health and safety hazard and risks and documenting control measures. It encompasses identifying workplace hazards, assigning levels of risk, developing control measures to eliminate and/or mitigate risks, reviewing risk control measures and maintaining documentation of hazards, risk control measures and their application in accordance with compliance procedures. UEENEEJ102A PREPARE AND CONNECT REFRIGERANT TUBING AND FITTINGS. This unit covers the basic connection of refrigeration and air conditioning piping/tubing and fittings. It encompasses the safe use of hand, fixed and portable power tools for cutting, flaring, bending, swaging, silver brazing copper tube to copper tube, bundy tube and brass and steel fittings, measurement and reading drawings and diagrams. UEENEEJ105A POSITION, ASSEMBLE AND START UP SINGLE HEAD SPLIT AIR CONDITIONING AND WATER HEATING HEAT PUMP SYSTEMS. This unit covers the assembly, installation and starting up and de-commissioning of single head split air conditioning systems and split water heating heat pump systems up to a maximum of 18kWr refrigeration capacity. It encompasses working safely and to standards, following routine procedures to install equipment, connecting pipe work, pressure testing, evacuating, perform functional checks and complete installation / regulatory documentation. UEENEEJ172A RECOVER, PRESSURE TEST, EVACUATE, CHARGE AND LEAK TEST REFRIGERANTS - SPLIT SYSTEMS. This competency standard unit covers the recovery of refrigerant, pressure and leak testing, evacuation and refrigerant charging in split air conditioning and heat pump systems. It encompasses working safely and to standards, following regulations and industry practices for handling refrigerants and completing the necessary documentation. ©Industry Development Training Pty Ltd 4 of 267

UEENEEK142A APPLY ENVIRONMENTALLY AND SUSTAINABLE PROCEDURES IN THE ENERGY SECTOR. This competency standard unit requires the worker to undertake methods of work practice that minimises energy and material usage and to seek energy reduction strategies in the energy sector workplace. The unit seeks to minimise negative impacts on the environment. UEENEEC001B MAINTAIN DOCUMENTATION This unit covers the maintenance of the variety of documentation required to record work activities, purchases and expenses and compliance obligations. It encompasses documentation typically required in an electrotechnology enterprise, work instructions and procedures and time management. INTRODUCTION ENVIRONMENTAL ISSUES In 1989 the government released the Ozone Protection and Synthetic Greenhouse Gas Management Act making it an offence to discharge fluorocarbon refrigerant into the atmosphere. 1kg of fluorocarbon refrigerant emissions has the same greenhouse effect as running your car for 6 months. The Ozone Protection and Synthetic Greenhouse Gas Management Regulations 1995 outlined the recovery process which needs to be undertaken to safely dispose of the gas. A technician licensed with a 'Restricted Refrigerant Recovery License' (RRRL) can recover, store and then pass on the gas to an authorised business. Waste refrigerant needs to be taken back to supplier for them to dispose or reclaim property. The fluorocarbon gas is forwarded to the national collection point and destroyed using an Australian developed plasma-arc process which transforms the gas to harmless salty water. You should also determine whether parts can be recycled, such as the compressor, fan or motor etc., or if you need take the unit to the tip where you could get money for the copper etc. Refrigerants can also damage the environment if handled improperly. In the mid-1970s it was suggested that Freon and other CFCs were, by chemical reaction, destroying the ozone present in the stratosphere. Depletion of the ozone could create a threat to animal life on the Earth because the ozone absorbs ultraviolet radiation that can induce skin cancer. The use of Freon in aerosol-spray containers was banned in the United States in the late 1970s. By the early 1990s, accumulating evidence of ozone depletion in the Polar Regions had heightened worldwide public alarm over the problem, and in 1992 most of the developed nations agreed to end their production of Freon and other CFCs by 1996. The EPBC Act protects and manages national and international flora, fauna, ecological communities and heritage places of national environmental significance. Refrigerants can cause environmental issues if not disposed of properly. You should ensure there are no sharp edges on or near bottles, no chemicals, gases or fuels left inside bottles, and the refrigerant and any removed components are appropriately stored with labels. Ensure that all refrigeration components are placed in clean bags and stored in a container which is free from dust and contaminants. ©Industry Development Training Pty Ltd 5 of 267

APPLYING FOR YOUR LICENSE Upon completion of this course, and receipt of your qualification and license, you will be able to: • Install Split Systems 18KW or lower (including Split Ducted) • Decommission Split Systems 18KW or lower (including Split Ducted) • Reclaim Refrigerant • Handle Refrigerant • Add additional refrigerant, in conjunction with extended pipe run • Repair pipe work (connecting inside and outside units) • Install 2 Part Hot Water Heat Pump 18KW or lower • Install 2 Part Swimming Pool Heat Pump 18KW or lower • However, you will not be able to: • Work on any system greater than 18KW • Repair, service or maintain Split System units • Add or top up any system • Add or release gas into any system that has not been correctly tested • Install Multi head split systems THE AUSTRALIAN REFRIGERATION COUNCIL RHL (REFRIGERANT HANDLING LICENSE) The Refrigerant Handling License is given to the individual and allows the holder to handle refrigerant. It does not allow the licensee to purchase refrigerant. In order to obtain a RHL, the applicant must have completed any of the acceptable courses, as outlined on the Arctick website: https://www.arctick.org/licensing/licence-types/ ©Industry Development Training Pty Ltd 6 of 267

RTA (REFRIGERANT TRADING AUTHORITY) A Refrigerant Trading Authorisation (RTA) must be held by any individual or business acquiring, possessing or disposing of fluorocarbon refrigerant. There are three types of RTAs that can be issued by ARC, dependent on how an individual or business uses and/or engages with fluorocarbon refrigerant. The most common RTA caters for an individual or business that acquires, stores and/or disposes of refrigerant (other than halon). Typically, this would suit wholesalers, RAC and automotive businesses, sole traders and contractors. The second type of RTA caters for businesses that need to acquire refrigerant (other than halon) for use in the manufacture of RAC equipment. This is titled as a ‘refrigeration and air conditioning equipment manufacturing Authorisation’ (RAEMA). The new type of RTA is the 'restricted refrigerant trading Authorisation' (RRTA) which caters for businesses that are authorised to recover refrigerant from RAC equipment, store and dispose of refrigerant. The types of businesses most likely to require an RRTA are metal recyclers, auto parts recyclers and waste management businesses. In order to obtain a RTA, the company applying must have at least one employee who holds a RHL and the following equipment: • Refrigerant Recovery Unit • Vacuum Pump • Leak Detector • Gauge Group Please see the Australian Standards relevant to the handling of refrigerants for more information: AS1677.1:1998 Refrigerating Systems. Part 1 Refrigerant classification AS1677.2:1998 Refrigerating Systems. Part 2 Safety requirements for fixed applications Once you have completed your qualification for UEE20111 Certificate II in Split Air- conditioning and Heat Pump Systems, you are able to apply for your Restricted Refrigerant Handling License (RRHL) In order to apply for this license, you need to have a copy of: Your Training License (which includes your Username and Password to log in to the Arctick website) Your Certificate II in Split Air Conditioning and Heat Pump Systems Once you have both of the above items, please follow the steps below to apply for your license. Hop online and go to the website: https://www.arctick.org/licensing/new-application/ Click YES in the box that says “Do you hold a Refrigerant License with the Australian Refrigeration Council that is still valid?” You will be redirected to the Member Login page; Using the Username and Password found on your Training License, log in to the site; Click on the heading License Reapplication; Your personal information will come up – please ensure all details are correct. From the drop- down menu, select Restricted Refrigerant Handling License (RRHL) Click NEXT when you are finished; Tick the box next to UEE20111 Certificate II Split System and Heat Pump Systems. Click NEXT when you are finished; Complete the Suitability Questionnaire. Click NEXT when you are finished; Tick the box next to I accept the terms and conditioning of this application (located at the bottom of the page) Click FINISH when you are finished; Enter your payment details and click PAY NOW. The cost of this license is $140.00; Following this, you will receive an email from: Australian Refrigeration Council [email protected]. This is your license application which YOU MUST PRINT; Attach the certified copy of your certificate to the application you printed out. Post your application to: The Australian Refrigeration Council Locked Bag 3033 Box Hill VICTORIA 3128 You should receive your license in the post directly from the ARC within a couple of weeks. If you need any support completing your application, please contact the Australian Refrigeration Council on 1300 884 483. ©Industry Development Training Pty Ltd 7 of 267

OCCUPATIONAL HEALTH AND SAFETY Refrigerant safety will be a major role in your job. These gases have been designed for cooling. Some of these gases such as the R1234yf (a new gas on the market from Europe) can give off a Sulphur acid fume if burnt. Others can give of the same fumes used in Mustard gas. So no matter what the gas is, there are a few precautions you must take: Glasses - The refrigerant may come out as a liquid. This liquid is below freezing and can cause frostbite Gloves - If any liquid does come out and gets on your hands, it may cause “cold burns” MSDS/SDS - Always know the chemical you ‘reusing Site PPE - Each site will have a level of PPE you must wear Well vented area - The gas may be deadly so use in a vented area and with proper PPE It is important for everyone to comply with the OHS Regulations 1996 to ensure that all tools, equipment and PPE are in good order and used appropriately for each task. In the event of a fire or accident, you are expected to keep calm and dial 000 for assistance. All injuries, accidents or near misses must be reported so steps can be taken to minimize or remove the risk. You should be punctual, take part in and raise safety issues during workplace meetings, which should take place at regular intervals. It is your responsibility to understand which regulations and codes apply to the work you are commencing, such as electrical isolations and working in a trench greater than 1.5m deep both require a permit or clearance HAZARDS A hazard is the act or condition that has potential to cause damage or result in injury. A hazardous substance can take many forms – gas, powder, liquid, solid or dust. The product may be pure or diluted. Some hazards you may come across whilst working within the refrigeration industry are: • Working with Adhesives and Chemicals • Split System Disposal • Refrigerants • Electrical Risk • Airborne Hazards and Contaminants • Heights • Standard Hazards within the Construction Industry • Confined Spaces • Environmental Issues • Noises • Trip Hazards WORKING WITH ADHESIVES AND CHEMICALS Exposure to chemicals commonly used in workplaces can lead to a variety of short- and long- term health effects such as poisoning, skin rashes and disorders of the lung, kidney and liver. A quarter of all Victorian employees regularly use hazardous substances such as chemicals, flammable liquids and gases in their work. Manufacturers and importers of hazardous substances are legally obliged to include warning labels and Material Safety Data Sheets (MSDS) with their products. This information offers advice on safe handling practices. ©Industry Development Training Pty Ltd 8 of 267

Health effects depend on the type of hazardous substance and the level of exposure (concentration and duration). A hazardous substance can be inhaled, splashed onto the skin or eyes, or swallowed. SOME OF THE POSSIBLE HEALTH EFFECTS CAN INCLUDE: • Poisoning • Nausea and vomiting • Headache • Skin rashes, such as dermatitis • Chemical burns • Birth defects • Disorders of the lung, kidney or liver • Nervous system disorders. SUGGESTIONS ON REDUCING EXPOSURE TO HAZARDOUS SUBSTANCES IN THE WORKPLACE INCLUDE: • Where possible, perform the task without using hazardous substances. • Where possible, substitute hazardous substances with less toxic alternatives. • Hazardous substances should be isolated from workers in separate storage areas. • Storage areas should be separately ventilated from the rest of the workplace. • Workers should be thoroughly trained in handling and safety procedures. • Personal protection equipment such as respirators, gloves and goggles should be worn. • The workplace should be regularly monitored with appropriate equipment to track the degree of hazardous substance in the air or environment. • Workers should be consulted regularly to maintain and improve existing safety and handling practices. Refrigerants used in refrigeration and air conditioning systems must be used properly to avoid potential hazards. Most refrigerants have low boiling points and present dangers of frostbite and eye damage. Refrigerant liquids with higher boiling points can cause respiratory and skin irritation. Exposure to large concentrations of fluorocarbon refrigerants can be fatal. In high concentrations, these vapors have an anesthetic effect, causing stumbling, shortness of breath, irregular or missing pulse, tremors, convulsions, and even death. HERE ARE GUIDELINES FOR THE SAFE HANDLING OF REFRIGERANTS: Employers must ensure that personnel who handle refrigerants are properly trained in their safe use and handling and have reviewed the MSDS/SDS for the refrigerant used. Wear safety goggles and gloves at all times when handling refrigerants or servicing a refrigeration system. Wear the proper respiratory protection while working with refrigerants. Check the MSDS for the proper level of protection required. ©Industry Development Training Pty Ltd 9 of 267

Proper ventilation or respiratory protection is required for any work on equipment in an enclosed area where a leak is suspected. Always ventilate or test the atmosphere of an enclosed area before beginning work. Many refrigerants which may be undetectable by human senses are heavier than air and will replace the oxygen in an enclosed area causing loss of consciousness. Inhaling refrigerants can cause sudden death. Intentional inhalation of refrigerants to produce intoxication can cause the heart to cease functioning properly and may be fatal. Refrigerant cylinders should never be filled over 80% of their capacity (liquid expansion may cause the cylinder to burst). Check the I.C.C. cylinder stamp to ensure the cylinder is safe. Always check the refrigerant number before charging to avoid mixing refrigerants. Always check for the correct operating pressure of the refrigerant used. Use gauges to monitor the system pressure. Always charge refrigerant into the low side of the system to avoid damaging the compressor or causing the system to rupture. R-717 and R-764 are very irritating to the eyes and lungs. Avoid exposure to these refrigerants. R-717 is slightly flammable and mixed with the proper proportions of air may form an explosive mixture. Fluorocarbon refrigerants should be treated as toxic gases. In high concentrations, these vapors have an anesthetic effect, causing stumbling, shortness of breath, irregular or missing pulse, tremors, convulsions, and even death. Ammonia is a respiratory irritant in small concentrations and is a life-threatening hazard at 5,000 parts per million (ppm). Ammonia is also flammable at a concentration of 150,000-270,000 ppm. Always stand to one side when operating an ammonia valve. Ammonia can burn and damage the eyes or cause loss of consciousness. Ammonia leaks may be detected by their smell, or with a sulfur candle or sulfur spray vapor. Refrigerant oil in a hermetic compressor is often very acidic causing severe burns. Avoid skin contact with this oil. Liquid refrigerant on the skin may freeze the skin surface causing frostbite. If contact with the skin occurs, wash immediately with water, treat any damaged skin area for frostbite, and seek medical treatment. Never cut or drill into an absorption refrigeration mechanism. The high-pressure ammonia solutions are dangerous and may cause blindness if the solution contacts your eyes. Ensure that all liquid refrigerant is removed, and the pressure is at 0 psi before disassembling a system. Do not smoke, braze, or weld when refrigerant vapors are present. Vapors decompose to phosgene acid vapors and other products when exposed to an open flame or hot surface. • When soldering, brazing, or welding on refrigeration lines, the lines should be continuously purged with low pressure carbon dioxide or nitrogen. • Following work, the lines should be pressure tested with carbon dioxide or nitrogen. • If refrigerant makes contact with the eyes, immediately wash with mineral oil as this absorbs the refrigerant. Then wash your eyes with a prepared boric acid solution. • If the refrigerant is ammonia, wash with water for at least 15 minutes. Seek medical attention as soon as possible. • Purged refrigerants must not be released into the atmosphere. Federal law governs their disposal, and they must be collected and disposed of properly. • Do not allow temperatures where refrigerant cylinders are stored to reach 125 degrees F. Temperatures can easily exceed 125 degrees F in your vehicle during hot weather. • Inspect refrigerant cylinders regularly. Do not use the cylinders if they ©Industry Development Training Pty Ltd 10 of 267

show signs of rust, distortion, denting, or corrosion. Store cylinders secured and upright in an area where they will not be knocked over or damaged. AIRBORNE HAZARDS AND CONTAMINANTS The most common airborne hazards and contaminants found in Split System Air Conditioning installation are dust and fibers which can cause performance and health issues if left alone. STANDARD HAZARDS WITHIN THE CONSTRUCTION INDUSTRY Additional to the above hazards commonly experienced within the Refrigeration Industry, you will also need to be aware of and take precautions against hazards usually found in the Construction Industry such as: • Lifting and carrying heavy objects • Slipping on slippery surfaces • Falling off ladders/from a height • Injuries from hand/power tools • Loud noises (damage to hearing) • Atmospheric contaminants • Confined spaces • Demolition work Always report any injury even if it is minor ELECTRICAL RISK Electrical Risk is the risk to a person of death, shock or injury cause directly or indirectly by electricity. You can reduce the chances of injury or worse due to electrocution by ensuring you complete the following: • Identify, Isolate and tag off the circuit being worked on • Place lockout device on switch, cct breaker or panel • Identify yourself, date, time, and reason • Make sure the circuit is “dead” before being worked on • If you have to work live, then make sure that all safety precautions are taken ie, correct PPE (rubber soled boots, rubber matting to step on and rubber gloves), tools rated to correct voltage, • SWMS (Safe Work Method Statement) and JSAs are filled out and a spotter is used Types of High Voltage hazards you may incur include: • Touch Voltage – voltage appearing between simultaneously accessible conductive parts • Step Voltage – voltage received when walking on a surface where current is flowing • Creepage – surface area distance between active conductors and other conductors Always use electrically insulated and suitably rated for the application to prevent electrocution or injury. RISK ASSESSMENT Risk Assessment refers to assessing the likely severity or impact of any injury or illness resulting from the hazard and how likely it is to occur. For more information on Risk Assessment, visit www.worksafe.act.gov.au. ©Industry Development Training Pty Ltd 11 of 267

PROCESS FOR CONDUCTING A RISK ASSESSMENT The process for conducting a risk assessment is as follows: 1. Identify the task to be carried out 2. Walk through or mentally plan the work 3. Identify all risks and appropriate control measures 4. Fill in a JSA prior to commencing work HIERARCHY OF CONTROL There are 4 levels of Risk Assessment which will determine what action needs to take place to reduce or remove the hazard. The levels are: • L (Low Risk) – At this level, the hazard presents a minimal threat to the safety, health and wellbeing of the participant. This hazard would be managed by routine procedures which are reviewed when necessary. • M (Medium Risk) – This level usually reflects a marginal severity of risk resulting in minor injury, illness, property damage and financial loss. In the case of one of these risks, determine if appropriate controls are adequate or if further action is required. • H (High Risk) – At this level, it is likely for severe injury, major property damage, significant financial loss and negative publicity to occur. The risk in question needs to be given appropriate action. • E (Extreme Risk) – The worst-case scenario of death is likely to occur immediately or in a short period of time and frequently, along with all of the risks associated with High Risks. Immediate action is required. The types of actions to be taken as part of removing or reducing the risk are: • Eliminate • Substitute • Engineering Controls • Administrative Controls • PPE ©Industry Development Training Pty Ltd 12 of 267

AIR CONDITIONING AND HEAT PUMP SYSTEMS Split System Air Conditioning units are made up of two units: outside and inside units. The outside unit contains the compressor, condenser coil and capillary tubing while the indoor unit contains the cooling coil, long blower and an air filter. The two units are connecting through piping. There are 5 types of Split System Air Conditioning units: • High Wall – This type of unit is commonly used as it takes up less space in the room • Floor Mounted – The removable bass allow the units to be recessed into the wall, reducing the depth by 33% • Ceiling Mounted – This unit is very discreet and best suited if there are no walls available for a split system or limited space for ducted system • Cassette – This unit is similar to the ceiling mounted unit • Ducted – This type of unit can control multiple rooms or an entire house and take up no space on floors or walls Heat pumps use refrigerant fluid to remove or add heat to a room. It can allow heat to be carried from a lower to a higher temperature level. COMPONENTS The main components of a split water heating heat pump system are: • Compressor • Condenser • Evaporator • Metering Device & Controls • Water Tanks • Fan The main controls of a split water heating heat pump system are: • Thermostat or temp sensor – an electric switch controlled by an element that responds to temperature electronic controls – electronically operated sensors and controls The types of refrigerant typically used in split water heating heat pump systems are 134A and 410A SPLIT HEAT PUMP SYSTEM REFRIGERANT OILS There are three types of refrigerant oils used in Split Heat Pump Systems: 1. Polyester (POE) oil is a synthetic oil mainly used with hydrofluorocarbon refrigerants in compressors 2. Mineral oils are a mix of hydrocarbons selected for their excellent fluidity at low temperature 3. Alkyl Benzene oil (AB) is a type of synthetic oil that is thermally and chemically stable COMPRESSOR The job of the compressor is to extract air from the atmosphere and compress it into a dense hot gas in the holding chamber. There are many different types of compressors on the market. ©Industry Development Training Pty Ltd 13 of 267

Manufactures will use different type depending on the application. • Energy efficient. • High flow. • Continuous flow. • High or low pressure. CONDENSER The condenser removes heat from the high-pressure refrigerant gas and transforms it into a cool liquid. This cooling is one of the most important parts of the cycle. If the heat can’t leave the gas, the system cannot get cold. EVAPORATORS An evaporator vaporises the refrigerant, absorbing heat from the surrounding fluid and produces cooling. The three types of evaporators used in Split System units are: • Finned Induced – the bare tubed type evaporators covered with fins. The fins increase • contact surface with the tubing and therefore increases heat transfer • Plate Type – several turns of turns of tubing are inside which the refrigerant flows through. The plate allows the evaporators to be more rigid. The plate helps increase the heat transfer from the tubing to the substance to be chilled • Bare Tube – made up of copper tubing or steel pipes. The atmospheric air flows over the tubing, cooling the air and then used for cooling purposes METERING DEVICE & CONTROLS Metering devices provide a pressure drop point. It holds refrigerant back in a condensed state and also feeds refrigerant to the evaporator. There are many types of metering devices. Some of which include: • Capillary Tubes - designed to deliver a certain amount of refrigerant to the evaporator to maintain proper superheat. It cannot be adjusted for superheat. • Flow Restrictor – provides a constant flow for different pressures, temperatures and fluid conditions. • Thermal Expansion (TX) Valve – maintains superheat by delivering refrigerant to the evaporator for efficient heat absorption. It can adjust itself to maintain correct superheat. • Electronic Expansion Valve – regulates the flow of gases to offer different pressure applications Accretor – control the refrigerant flow rate into the evaporator due to pressure drop caused by the internal resistance of a small hole in the orifice plate REFRIGERANT LEAKAGE IS THE MAIN PROBLEM ASSOCIATED TO SERVICE PORTS AND VALVES SERVICE PORTS OR VALVES AND PROBLEMS RELATED TO THEM The main types of service ports or valves used with Split System Air Conditioning units are: ©Industry Development Training Pty Ltd 14 of 267

BALL VALVES – manually operated shut off valves suitable for bidirectional flow CHECK VALVES – prevent flow of liquid and/or vapour refrigerant in the wrong direction SCHADER VALVES – a valve that allows easy access to service and recharge with refrigerant ACCESS VALVES – used at the evaporator outlet or liquid line inlet for servicing purposes ©Industry Development Training Pty Ltd 15 of 267

REVERSING VALVE – a four-way solenoid valve used to control the flow of refrigerant in reverse cycle air conditioning systems AIR DISTRIBUTION The three types of non-ducted air distribution are: 1. Fans 2. Filters 3. Swing louvers There are seven types of ducted air distribution: 1. BTO 2. Dampers 3. Outlets 4. Grilles 5. Plenums 6. Filters 7. Ductwork THE CYCLE Once you have the main components to make a refrigeration system, let’s see how it works. First, the compressor gets the gas from the low side and compresses it into a hot high- pressure gas. In order to get a gas into a liquid it must be cooled, or we are expelling the heat. This is done through the condenser unit and fan. Once the liquid has been cooled, it is still under high pressure. We know that refrigerants will boil (change from a liquid to a gas) at low temperatures so to stop this from happening, we must keep the liquid under pressure. Once the RMD allows the high- pressure liquid into a larger pipe with no pressure or less than its signal pressure, the boiling temperature will then drop. In order for a liquid to boil, it has to absorb heat. In this case it will absorb the heat from the room you are trying to cool. ©Industry Development Training Pty Ltd 16 of 267

Once you understand the cycle, you can start doing some diagnostics. Remember to check the simple things first: 1. All pipes are insulated (this includes the drain) 2. Condenser is clean and has good airflow 3. Evaporator is clean and has good airflow This system is like a sponge. It will absorb heat from the room and expel that heat to the outside. REVERSING VALVE A heat pump reversing valve is an electro-mechanical 4-way valve that reverses the refrigerant (Freon) flow direction, using an electrical magnet. It works very similar to your washer’s water valve or solenoid valve (pictured below). When you connect electricity to a valve (energize it), it opens and lets water in and when you disconnect the electricity (de-energize it), it closes the valve and the water stops flowing. When you press the heat mode, it reverses the flow of the refrigerant and turns the evaporator into the condenser and the condenser into the evaporator. This is what makes the system a “Reverse” cycle. ©Industry Development Training Pty Ltd 17 of 267

When you energize the coil with electricity the coil becomes magnetized, pulling a pin and compressing the spring. This action opens the valve to let the water flow. When you de- energize the coil the electrical magnet loses its magnetic power, and the compressed spring expands and pushes the pin back to shut off the water. The washer’s water valve (solenoid valve) is 2-way valve, and in the Heat Pump, the reversing valve is 4-way valve. Let’s look at the image below so we can understand it better. The heat pump reversing valve has 4 large tubes (A, B, C, D) that’s why they call it a 4 way valve and it also has:- capillary tube (1), capillary tube (2), capillary tube (3), slider (4), block (5) ,electrical coil (6), electrical magnet (7), and spring (8). The compressor’s discharge port (high pressure) is always connected to tube A in the reversing valve and the return port (low pressure) in the compressor is always connected to tube B. Therefore, tube A always has higher pressure refrigerant, and tube B always has lower pressure refrigerant. The capillary (2) is always connected to tube A, thus capillary (2) also has a high pressure. When we energize the electrical coil (6) it energizes the magnet (7) that pulls the block (5) which will blocks the capillary tube (3) and compresses the spring (8). The capillary tube (3) is now blocked, and the high pressure refrigerant will flow from capillary (2) to capillary (1 ) straight to the left side of the heat pump reversing valve’s body that will push the slider to right hand side from the valve’s body which will allow the high pressure refrigerant to go from the tube A to tube D to the outdoor coil, through the metering device to drop its pressure, then to the indoor coil to cool the inside of the house ( cooling mode ) then back to tube C The slider has a top grove which allows the low pressure refrigerant to flow from tube C to tube B then back to the return port in the compressor to repeat the cycle again. The coil (6) lost its power, or de- energized, which makes the electrical magnet (7) lose its magnetic power. When this occurs, the spring (8) will decompress and push the block (5) to the left and block the capillary tube (1). The capillary tube (1) is now blocked and the high-pressure refrigerant will flow from capillary (2) to capillary (3) straight to the right side from the reversing valve’s body. This in turn will push the slider to the left-hand side of the valve’s body, which will allow the high-pressure refrigerant to go from the tube A to tube C. This allows refrigerant to flow to the indoor coil to heat the inside of the house (heating mode), then through the metering device to drop its pressure then to the outdoor ©Industry Development Training Pty Ltd 18 of 267

coil then back to tube D. Again, the slider has a top grove this will allow the low-pressure refrigerant to flow from tube D to tube B then back to the return port in the compressor to repeat the cycle again. REFRIGERATION & WATER GRADE COPPER TUBE There are significant differences between refrigeration grade tube (known as ACR) and water grade copper pipe. These are demonstrated clearly by comparing some of their properties WATER GRADE PIPE • Supplied open to atmosphere • May have a seam • Minimal wall thickness • Is measured by the internal diameter ACR GRADE TUBE • Supplied sealed with a cap • Is seamless • Has a greater wall thickness for higher pressure • Is measured by the external diameter Refrigeration grade copper tube is of a much higher quality due to its application and must be treated with respect to maintain those conditions. Refer to the Crane Copper PDF for more information. http://www.cranecopper.com.au/downloads/AS-NZS1571.pdf Also, the Refrigerant Handling Code of Practice - Part 2 5.3 The installer must ensure that all piping used is selected in accordance with AS/NZS 1571:1995 - Copper - Seamless tubes for air conditioning and refrigeration and AS4041:2006 – Pressure piping MAINTAINING CLEANLINESS (ALWAYS CAPPED, DO NOT BLOW OUT WITH MOUTH) The Plumbers Handbook Ninth Edition – MM Kembla on pages 12 & 13 give you an idea of some of the requirements manufacturers must meet to supply ACR tubing. https://www.kembla.com/assets/Uploads/general-PDFs/The-Plumbers-Handbook-9th- Edition.pdf REFRIGERANT HANDLING CODE OF PRACTICE PART 2 -SYSTEMS OTHER THAN SELF- CONTAINED LOW The Australia and New Zealand Refrigerant Handling Code of Practice 2007 clearly states in Section 5 Installation procedures: the requirements when handling and installing ACR tubing ©Industry Development Training Pty Ltd 19 of 267

5.1 The manufacturer’s instructions for installation must be followed if the system is factory matched and the manufacturer has supplied instructions with the system, except where the instructions specify a practice that will lead to emission of refrigerant. Manufacturer’s instructions must not specify a practice which will result in the avoidable emission of refrigerant. Provided the instructions do not specify a practice that will lead to emission of refrigerant, if the manufacturer’s instructions are followed then the installation is exempt from items 5.1.3 to 5.1.24. The relevant parts of section 5 of this code must be complied with if there are any installation procedures not covered by the manufacturer’s instructions. Installation of all other systems, or systems where manufacturer’s instructions are not supplied, must comply with section 5 of this code in its entirety. 5.2 The installer must ensure that all tools and equipment used during the installation process (including but not limited to vacuum pumps, tools and gauges) are appropriately rated for the refrigerant being used in the installation and are in serviceable condition. 5.4 All pipework and fittings should be thoroughly examined for cleanliness and suitability for the system and refrigerant prior to assembling. 5.5 All unsealed tubing must be thoroughly inspected and, if necessary, cleaned before assembly to remove any copper residue and/or scale particles such as dirt or metal. 5.6 Metal filings must not be left in pipework after cutting as they can cause damage to shaft seals, compressor bearings and windings in hermetic and semi- hermetic compressors. 5.7 Pipes must be clean, burr free and not fallen in prior to assembly. TUBE QUALITIES - DIAMETER, WALL THICKNESS (GAUGE) AND PRESSURE RATINGS (R410A etc) ACR GRADE TUBING MUST MEET AS/NZ STANDARD 1571. Wall thickness starts low for soft drawn and increases for hard drawn for the same size then increases again for R410A rating as the chart on the following page shows. Inner grooved tubes can be found in some residential and commercial air conditioning units. The purpose of these tubes is to enhance heat transfer between the medium inside and outside of the tube by increasing the inner contact surface. These seamless drawn tubes increase the efficiency of heat exchangers. ©Industry Development Training Pty Ltd 20 of 267

R410A High Pressure Compatible Half Hard Temper Hard Temper ©Industry Development Training Pty Ltd 21 of 267

SOFT AND HARD DRAWN TUBE HARD DRAWN tubing typically is supplied in 6m lengths and is only designed to be used with fittings (not to be bent or flared). If hard drawn tubing is to be swaged it must first be “annealed” (see the final chapter in this guide for more information on annealing). SOFT DRAWN tubing has been annealed and is supplied as a roll. To use ACR TUBING soft drawn tubing, it must be carefully unrolled on a flat surface, prepared as described later in this guide and flared, swaged or joined. is supplied sealed and dehydrated and must be capped at all times to maintain that condition TUBING APPLICATIONS (SOFT, HARD, PAIR COIL, WATER GRADE etc) Hard drawn and Soft drawn copper tubing including pair coil is designed for refrigeration and A/C applications with the exception of Ammonia (when ammonia comes into contact with moisture it attacks copper and brass) Water grade piping is not compatible with ACR piping in any way *Note the difference between piping and tubing is how it is measured. Water Pipe is measured internally whereas Refrigerant tubing is measured externally*. SOFT DRAWN Also known as “Annealed” is copper tube that has been heated then allowed to cool. result is that it becomes flexible or “soft”. will result in hardening and likely split or crush. The Soft Overworking drawn tubing is used in most applications. HARD DRAWN Normally supplied in 6m lengths and commonly used in refrigeration installations. Hard drawn is not designed to be bent or flared ©Industry Development Training Pty Ltd 22 of 267

SOFT DRAWN Also known as “Annealed” is copper tube that has been heated then allowed to cool. result is that it becomes flexible or “soft”. will result in hardening and likely split or crush. The Soft Overworking drawn tubing is used in most applications. HARD DRAWN Normally supplied in 6m lengths and commonly used in refrigeration installations. Hard drawn is not designed to be bent or flared CAPILLARY TUBE Used as a RMD it is very small diameter copper tube. Extreme care is required when cutting. Either a capillary cutter is to be used or else a file to score the outside then gentle flexing to harden the tube until it snaps. Common applications include Small commercial Refrigeration and A/C. Often the tube will be inside or wrapped around the suction line as a heat exchanger. ©Industry Development Training Pty Ltd 23 of 267

PAIR COIL Designed for the Split A/C industry it is pre insulated soft drawn copper or now also available in aluminum. ALUMINIUM PIPE Primarily used for automotive Air Conditioning it is lightweight, cheap and reliable. WATER GRADE Only used for water supply and drains ©Industry Development Training Pty Ltd 24 of 267

FLEXIBLE THERMOPLASTIC PIPE Typically used in automotive air conditioning for its flexibility it is now being widely used for control and oil return lines for its flexibility and simplicity to install. Held on also have a product for split air conditioning. PIPE INSULATION (TYPES - TUBE, SLIT TUBE, SHEET ETC AND JOINING METHODS - GLUE, TAPE) We use insulation on our tubing to prevent heat loss or gain. For applications below dew point insulation also prevents condensation forming on the tubing. Some materials used for insulation include cork, polystyrene, fiberglass, polyolefin foam and commonly elastomeric cellular thermal insulation CORK TAPE IS PARTICULARLY USEFUL TO INSULATE T-EX VALVE BULBS Insulation needs to be cut square with a very sharp blade to provide a good surface for joining which is made using contact glue and normally taped over for protection Insulation tubing is often supplied with an internal powder coating to assist with installation (making it very important to ensure tubing is sealed before sliding insulation over) OTHER TUBE MATERIALS (BUNDY, STEEL, ALUMINIUM, BRASS) BUNDY TUBE This is a small bore steel tube used mainly in domestic refrigeration condensers. Steel tube is used in ammonia applications due to its reaction with copper and brass in the presence of moisture. ©Industry Development Training Pty Ltd 25 of 267

ALUMINUM TUBING This has always been used in the automotive industry but is also now available as pair coil for split A/C applications. When used for domestic refrigeration (evaporators) it is joined to a copper tail using epoxy compounds to allow welding a connection. BRASS This is commonly found in fittings for the added strength and the joining method needs special attention as described later in this guide. S TAINLESS STEEL This is another material used in our industry in food processing applications where tubing must be kept sterile. CUTTING CUTTING TOOLS (IMPS, NORMAL & LARGE PIPE CUTTERS, TUBE CUTTING RINGS CUTTING ACR TUBING This is a deceptively simple task. Using the wrong method will result in excessive “burring” which will cause issues once in the system. ©Industry Development Training Pty Ltd 26 of 267

MEASURE TWICE CUT ONCE It’s a very old saying. One that saves a lot of time and material. If welding the tubing its worth running over with steel wool or emery cloth first to prepare the surface while you don’t have an open tube to worry about. Next mark the length and place the tube cutter. Tension the blade and begin cutting. Apply more pressure every couple of turns making sure that the wheel stays in the original line. CAPILLARY TUBE This requires the use of special cutters or to be etched with a file then gently rocked back and forth to harden and snap the tube Tubing other than ACR such as steel and brass will need a hacksaw to cut as these harder materials tend to blunt cutting wheels rapidly. Use at least a 32 teeth blade however to give the cleanest edge possible. * DO NOT USE A HACKSAW TO CUT ACR TUBE PRECAUTIONS WHILE CUTTING (SHARP BURRS, SHARP BLADES ETC) Care must be taken due to the sharp edges left in the tube from cutting. Of course, the blade itself needs to be treated with care. Always ensure that if the tube you are cutting is still on the system, there is no pressure present. By using a sharp blade, you will reduce the risk of tracking or other damage to the tube such as flattening due to excessive pressure. ©Industry Development Training Pty Ltd 27 of 267

DEBURRING TOOLS (REAMERS, DEBURRERS ETC) Once tube has been cut a burr remains on the inside edge which must be removed. We have deburring tools for both internal and external applications. If a tube is flared without deburring it will squash the burr and leave only a thin lip for sealing. Excessive deburring will often result in scoring the inside of the tube and thinning of the wall that will again result in a flare that is likely to leak or a swage to split. BENDING BENDING TOOLS (SPRINGS, LEVERS, PRESSES ETC) Only annealed or “soft drawn” tube may be bent. See later in this guide for how to bend “hard drawn”. Once a tube has been work hardened it is no longer annealed and prone to crushing or splitting. BENDING SPRINGS Result in a larger diameter bend than mechanical. As with all benders if used correctly they prevent any damage or squashing of the tubing. Simply slide the benders over the tube and bend by hand (around the knee is common practice). To remove unwind the spring to loosen and slide off. MECHANICAL BENDERS These come as a triple block or single bender. They are usually marked with Left Hand and Right-Hand measurements for accurate bending. ©Industry Development Training Pty Ltd 28 of 267

INTERNAL BENDERS While this style of bender is simple (place the bender inside the tube and bend by hand then pull the bender out) there is a high risk of contaminating the system or scoring the inside of the tube if the bending material is not maintained to a very high standard. PRECAUTIONS WHILE BENDING (WORK HARDENING, COLLAPSING ETC) Copper tubing is unforgiving when it comes to bending – after it has been bent it is no longer annealed. It becomes “work Hardened”. To soften the tubing it would need to be annealed again. Once copper tube has become work-hardened, kinks, crushing and splitting become high risks. BENDING HARD DRAWN TUBE - THE PROCESS OF ANNEALING Annealing is the process used to soften copper tube for use with flare nuts, swaging and bending. Soft Drawn (annealed) copper tube is supplied in a roll. The process involves heating the tube to cherry red and allowing it to cool. An inert gas must be used during the process to prevent Oxidising inside the tube. Hard drawn tubing must be annealed before attempting to bend. ©Industry Development Training Pty Ltd 29 of 267

JOINING FLARE NUTS (PLAIN, SHORT BARREL, FROST PROOF, REDUCING) Different style flare nuts are available to suit various applications. Standard flare nuts have a long neck for support. For low temperatures a Frost Proof nut should be used. These look the same as standard nuts except that they have holes drilled around their neck. This is to reduce the risk of ice forming in the neck and crushing the tube. Reducing flare nuts will drop up to 2 tube sizes from the flare connection to the tube size. These are used to Maintain capacity as pipe sizing is determined by a number of factors – not by the fitting size. FLARING TOOLS (FLARE BLOCK, ECCENTRIC WITH CLUTCH FOR HIGH PRESSURE TUBE) Most current Flaring Blocks now are rated for R410A tubing. Which means they have an eccentric head (it is off Centre) and use a clutch (you cannot over tighten and squash the tube wall). Setting up the height of tubing in the flare block is often described as half the height of the flare. What this means is if you look at how deep the angled (flared) part of the block is in the size you are using; you want to set the tubing half of that height above the block. Only practice is going to help you estimate this – it is not practical to measure. Another common reference is to oil the flare. Two important points. Try to use the same oil as is in the system. The oil is to be used on the BACK of the flare NOT the front. Oil is not to assist with the seal – the soft copper will squash against the hard brass to achieve a seal. The oil is to prevent the flare nut gripping the soft flare and twisting the whole pipe (or just feeling tight before there is sufficient pressure on the flare to seal) ©Industry Development Training Pty Ltd 30 of 267

PRECAUTIONS WHILE FLARING (DEBURRED, LENGTH PAST BLOCK FACE, CLEANLINESS) The large tube is cracked, has jagged edges and an inner ‘ring’ (a visible line around the flare surface). The smaller flare also has ragged edges and the tubing wall is thin. Not deburring the tube correctly causes most of these problems. Other issues are the diameter of the flare. Too small will allow movement which either wears or hardens the tube end and it will snap or slide out the back of the flare nut. Too wide will result in having to ‘thread’ the flare nut over the flare. This prevents you from being able to tighten the nut fully as the flare binds on the thread of the nut. SWAGING TOOLS (PUNCH, FLARE BLOCK, EXPANDER ETC) Swaging is a method for joining copper tube without any fittings. Soft drawn tubing will need to be cut to length and deburred before swaging. Hard drawn will also need to be annealed or it will split the tube. Punch Swaging Tool Flare Block Swaging Tool Manual & Hydraulic Expander As any task, a good swage will require practice. Common faults when swaging is • Too much tube protruding from a flare block • Off Centre flare tool in a block • Too much too fast with a mechanical expander (leaves flats around the pipe) • Hit too hard or soft with a punch PRECAUTIONS WHILE SWAGING (LENGTH PAST BLOCK FACE, TUBE SHORTENING EFFECT, CLEANLINESS ETC) ©Industry Development Training Pty Ltd 31 of 267

The correct height to have past the flaring block for swaging is the width of the tube plus approx. 1/8” (3mm). This allows for the shortening of the tube as it is stretched out. The goal when soldering a swage joint is for the solder to just reach the end of the inner tube so the internal surface is continuous for good oil and gas flow. Preparation of a tube for swaging is the same as a flare. Both the internal and external surface must be deburred. The external surface must also be cleaned, as it will then be soldered. OTHER TUBE FITTINGS (BSP TO FLARE ELBOWS, TEES, UNIONS, PLUGS, FLARE WASHERS, LOKRINGS ETC) There is a vast choice of fittings in our industry and the applications are endless. • Solder, • Flare, • Compression, • Crimp and O-Ring. Also combinations are available to join 2 different styles. ©Industry Development Training Pty Ltd 32 of 267

Mainly we use copper and brass for our fittings (with the exception of ammonia of course which uses steel). The combination of cost, cleanliness and adaptability make these materials ideal. The Code of Practice outlines the rules and regulation regarding pipes and fittings as you can see below: REFRIGERANT PIPELINES AND FITTINGS 2.5.1 All pipelines must be designed so that the number of joints is kept to the practical minimum. 2.5.2 Welding, brazing or another permanent hermetic sealing method are recommended wherever practicable for joining refrigerant pipelines since they offer increased resistance to pressure, temperature and vibration stresses. All joints mustbe hermetically sealed and not flanged. Pipelines must be designed to minimise breakage due to vibration. FLARED, SCREWED OR FLANGED CONNECTIONS SHOULD BE AVOIDED The Automotive industry particularly widely use crimped aluminum fittings and O-rings (Note – to work on automotive equipment requires an extra endorsement on your ARCTICK license) ©Industry Development Training Pty Ltd 33 of 267

Lokring have a product that will join copper tube using a crimp method with glue. The cost is similar to normal fittings however for situations where a hot permit is required or soldering is an issue then it is a viable alternative to flares. Also useful for joining Copper to Aluminum. Copper to brass seals naturally due to the different densities of the metals. Copper is soft and squashes against the brass to seal. Brass to brass (caps for example) will not seal without using copper in between which is why we use flare washers. Small, fiddly and a pain to put in place but there for a very good reason. Brass to steel has a similar problem but copper is not practical, so we use thread seals and tapes. THREAD SEALANTS (TAPES, PASTES ETC) Care must be taken when using either a liquid or a tape. They are designed to be compatible with the refrigerant and oil in the system but are still a source of contamination if used in excess. Always follow the manufacturers recommendations for use and ensure they are rated for refrigeration equipment use. Typical applications are brass to steel connections such as on the service valves as shown in the next chapter. ©Industry Development Training Pty Ltd 34 of 267

ACCESS VALVES (SCHRADER, PIERCING, CUT-AWAY OF SERVICE VALVE/S) SCHRADER VALVES are commonly used on domestic and light commercial equipment as an access to the system. They are prone to leak under extreme conditions and will not seal against negative pressure. They must always be capped. DO NOT try to remove or install a Schrader core under pressure. Gauges must be fitted and removed quickly to minimize refrigerant loss Back-seated - allows normal operation while isolating the service fitting Mid-seat - allows full access (for charging, evacuating and servicing) Front-seated - is only used to isolate the compressor from the system – not that the service fitting is only connected to the compressor and the system flow is blocked. ©Industry Development Training Pty Ltd 35 of 267

BULLET PIERCING VALVES are used to access a sealed system. Their use is very restricted. (see the next chapter) ©Industry Development Training Pty Ltd 36 of 267

SERVICE VALVES may have 1 or 2 access fittings. The one closest to the spindle is used for service gauges while a second fitting is sometimes available for pressure controls. ***Note when servicing “cracking off the backseat” is sufficient to read pressures if the gauge needles are bouncing backseat further until they read steady*** PRECAUTIONS USING ACCESS VALVES (REFRIGERANT LEAKAGE, CORE REMOVAL, LIMITATIONS ON PIERCING VALVES etc) Valves Due to the size of self-contained low charge systems, valves are not normally included in the design. Tube piercing or line tap valves and other similar devices must be used only to gain service access to the system in order to remove refrigerant. They must be removed before the completion of service. The system design must not require these valves to be left on the system after the completion of service. Round caps with an O-ring are dust caps and not designed to seal against pressure Flare nut caps with a copper washer should always be used where there is a risk of gas leaking ©Industry Development Training Pty Ltd 37 of 267

SOLDERING AND BRAZING EQUIPMENT BAS TYPES (OXY ACETYLENE, AIR ACETYLENE, PROPANE, MAPP GAS) MAPP Gas MAPP Gas is probably the most common used now mainly for split system installations. This is very convenient and portable being a small hand held cylinder. Maximum flame temperature is just over 2900°C OXY ACETYLENE The best quality option for Silver Soldering and Brazing. It is a lot more cumbersome being 2 cylinders typically on a trolley with regulators and hoses with a handpiece. Approximate flame temperature is 3500°C ACETYLENE The same as Oxy Acetylene except rather than a cylinder of Oxygen it uses the Oxygen in the air. The result is a cooler flame at around1600° ©Industry Development Training Pty Ltd 38 of 267

PROPANE A less common option for soldering is Propane. With a flame temperature below 2000°C it uses are very limited HAZARDS ASSOCIATED WITH THEIR USE (CYLINDER TRANSPORT, REMOVE REGULATOR, OIL & OXY = BANG) There are a number of hazards associated with the storage, transport and use of the welding gasses mentioned in the previous chapter. The restrictions you will find in the Australian standards. The safety in relation to storage, handling and first aid you will find in the MSDS/SDS (mentioned in the next chapter). For all of the gasses / cylinders we use there are some basic safety rules − Always secure the cylinders, preferably upright (especially Acetylene) − Remove the regulators when not in use − Keep away from heat sources − Never lubricate a thread for a pressure cylinder with oil or grease. Refer to the PDF BOC Guideline for Gas Cylinder Safety (which can be found at the end of this book). PERSONAL SAFETY (MSDS - OXY, ACETYLENE, PROPANE, MAPP GAS) ©Industry Development Training Pty Ltd 39 of 267

Always consult the MSDS/SDS before using any hazardous substance and make sure you are familiar with the first aid requirements in case something does go wrong. Safety glasses, long sleeves and long pants when soldering should be standard. Other examples of precautions would include having a fire extinguisher nearby. It is important to know how to use a fire extinguisher, but it’s just as important to know what fire extinguisher to use on what sort of fire. FIRE EXTINGUISHER This is an active fire protection device used to extinguish or control small fires, often in emergency situations. It is not intended for use on an out-of-control fire, such as one which has reached the ceiling, endangers the user (i.e., no escape route, smoke, explosion hazard, etc.), or otherwise requires the expertise of a fire brigade. Typically, a fire extinguisher consists of a hand-held cylindrical pressure vessel containing an agent which can be discharged to extinguish a fire. Fire extinguishers manufactured with non- cylindrical pressure vessels also exist but are less common. There are different types of fire extinguishers for fighting various classes of fire. In the instance of a fire emergency, the last thing you want to be doing is reading the side of an extinguisher trying to figure out if you can use it to fight the flames. Being able to immediately distinguish them apart could make a lifesaving difference. Fires come in many forms, so you need to familiarise yourself with how to properly What are the different classes of fires? Fires must be fought carefully depending on the materials involved. That is why they have been classified in 6 different categories: • Class A – Fires that involve solid or organic materials, such as wood, plastics, paper, textiles, or coal. • Class B – Fires that involve flammable liquids, such as gasoline, petroleum oil, paint, or diesel. • Class C – Fires that involve flammable gases, such as propane, butane, or methane. • Class D – Fires that involve combustible metals, such as magnesium, lithium, sodium, potassium, titanium, or aluminum. • Class F – Fires that involve cooking oils and fats, such as vegetable oil, sunflower oil, olive oil, maize oil, lard, or butter (typically those used for deep-fat fryers). Although it is not recognised as a separate class of fire in Europe, electrical fires that involve live equipment and electrical sources are also a type you should bear in mind (think of it as an informal Class E; ‘E’ for electric to help you remember). Each type of fire extinguisher is ergonomically designed for the safe and effective discharge of its contents. They each contain different materials that make them suitable for fighting certain types of fires. The correct one must be used for the right class, otherwise they may prove ineffective or in fact aggravate the fire and swiftly extinguish whichever type of fire you face. ©Industry Development Training Pty Ltd 40 of 267

WATER WATER EXTINGUISHER These types of fire extinguishers will be solid red and will have the word ‘water’ printed across them in white text. They are your classic model: they dispense water at a high pressure to extinguish flames. Water extinguishers are only suitable for class A fires, which means they can fight fires that involve wood, cloth, paper, plastics, coal, and other similar materials. Warning: do not use on burning fat and oil fires and electrical appliances! Water spray extinguisher These types of fire extinguishers will be solid red and have ‘aqua spray’ printed across them in white text. They are more effective at fighting fires than the traditional water ones because they spray water over a wider surface area and at a higher pressure. Like its traditional counterpart, they are only suitable for class A fires. Warning: do not use on burning fat and oil fires and electrical appliances. ©Industry Development Training Pty Ltd 41 of 267

Both water and water spray extinguishers can sometimes contain chemical additives that improve their effectiveness by up to 300%. The chemicals remove the water’s natural surface tension so that it soaks into burning materials more effectively when used. DRY WATER MIST EXTINGUISHER These types of fire extinguishers will be solid red and will have the words ‘water mist’ printed within a white rectangle. Dry water mist extinguishers are unique in that they can combat almost all types of fires, including class F fires that are usually difficult to attack. The extinguisher’s supersonic nozzle converts water into ‘dry’ microscopic particles, which are then drawn into the fire and simultaneously cool and suffocate it – successfully extinguishing the flames. They are also effective for firefighting because they form a safety barrier between the user and the fire – which repels some of the heat – and leave no hard-to-clean residue behind. POWDER ABC powder extinguisher These types of extinguishers will say ‘powder’ in white text over a blue rectangle, and underneath the rectangle will be written ‘ABC powder’. As their name suggests, these are designed to combat class A, B, and C fires – those involving solids, liquids, and gases. The powder acts as a thermal blast that cools the flames so burning cannot continue. Due to their non-conductive nature, they are also suitable for fighting electrical fires. However, they do not effectively penetrate the spaces in equipment easily, so the fire could still re-ignite. Warning: do not use on domestic chip or fat pan fires (class F). FOAM These types of extinguishers are identifiable by the word ‘foam’ printed within a cream rectangle on their bodies. Foam extinguishers are primarily water based and contain a foaming agent, which has rapid flame knock-down and a blanketing effect – it smothers the flames and seals vapours so that re-ignition cannot occur. They are suitable for fighting class A and B fires. When used against class A fires, the user can simply point and spray. However, when used against class B fires – those with flammable liquids – they should not be sprayed directly into the liquid. This could cause the fire to be pushed and spread to surrounding areas. The best method of application is to spray the foam nearby so that it can build up and flow across it. Warning: these should not be used on any other fire classes, especially chip or fat pan fires. Most foam extinguishers will have had dialectical tests performed on them, so foam is less ©Industry Development Training Pty Ltd 42 of 267

hazardous than water if it is accidentally sprayed on live electrical equipment. However, they should still not be used to fight electric fires. CARBON DIOXIDE (CO2) These types of extinguishers can be identified by the text ‘CO2’ printed in white on a black rectangle. They also have a distinct type of hose unlike other extinguishers. Carbon dioxide extinguishers are used for combating class B and electrical fires – they suffocate the fire by displacing oxygen in the air. Because they do not leave any substances behind, unlike other extinguishers, they are particularly useful for offices and workshops where electrical fires may occur as they minimise damage done to equipment. Warning: they must not be used on deep fat fryers (class F fires). The strong jet from the extinguisher would propel the burning fat out of the fryer and spread the fire to surrounding areas. Also bear in mind that while carbon dioxide is effective at smothering fires, once the gas has floated away, the fire may re-ignite if the source has not been removed. WET CHEMICAL These types of fire extinguishers are identifiable by the words ‘wet chemical’ printed across a canary yellow rectangle. It also has an extended applicator. Wet chemical extinguishers are designed for combating fires that involve class F fires. They are effective because they are capable of dissipating fires that are of an extremely high temperature – namely, cooking oils and fats. The chemicals contained within the canister dispels the flames, cools the burning oil, and produces a soap-like solution that seals the surface and prevents re-ignition of the fire. They are discharged in a gentle, yet highly effective, spray – much like M28 and L2 powder extinguishers – to prevent the hot oils and fats from splashing onto the user or spreading to surrounding areas. The best method of application is to spray in slow circular motions. The user should empty the entire contents onto the oil/fat. Otherwise, the fire may re-ignite. Warning: wet chemical extinguishers are usually not recommended for class B fires – those involving liquids. Also, although they are capable of combating class A fires, they are not as effective as other extinguishers at doing so. OTHER TYPES OF FIRE EXTINGUISHERS Wheeled fire extinguishers are also available, which have a greater capacity, volume, flow rate, range, and discharge time (not to mention the added convenience of not having to carry around a heavy canister in an emergency). ©Industry Development Training Pty Ltd 43 of 267

AUSTRALIAN SAFETY SIGN INFORMATION THE IMPORTANCE OF SAFETY SIGNS Safety Signs are crucial in any work environment. The primary importance of displaying Safety Signs is to prevent injury and ensure staff and visitors are well aware of the possible dangers and hazards ahead in certain situations and/or environments. Without signs, many employees would lack the necessary direction in times of crisis, and employers might find themselves in significant legal difficulties if any accidents were to arise as a result. By ensuring the workplace is sufficiently well signed, you can help protect your staff and visitors to the site, particularly members of the public, against the possible dangers that may be unnoticed - leading to less industrial accidents and reduced risk to employees and passer-by's. UNDERSTANDING STANDARD AS:1319 This standard sets out the requirements for the design and use of safety signs intended for use in the occupational environment. These signs are designed to regulate and control safety related behaviour, to warn of hazards and to provide emergency information including fire protection information. Mandatory/Speciality building site Emergency Information/First Aid Signs Signs These signs specify an instruction These signs indicate the location that must be carried out. Symbols (or of, or directions to emergency pictograms) are depicted in white on related facilities (exits, first aid, a blue circular background. Sign safety equipment, etc). Feature a wording, if necessary, is in black white symbol and/or text on a lettering on a white background. green background. Prohibition Signs Danger Signs These signs that specify behavior or These signs provide warning actions which are not permitted. The when a hazard or a hazardous annulus and slash is depicted in red condition is likely to be life over the action symbol in black. Sign threatening. The word Danger is wording, if necessary, is in black featured inside a red oval inside a lettering on a white background. black rectangle. Warning/Caution Signs General Information Signs These signs warn of hazards or a These signs are not referred in hazardous condition that is not likely AS1319,however are available to be life-threatening. The hazard due to popular demand. They symbol is black on a yellow communicate information of a background and a triangle is depicted general nature and often refer to around the hazard symbol. Sign Housekeeping, Company wording, if necessary, is in black Practices and Logistics. lettering on a yellow background. Fire Signs Advise the location of fire alarms and fire fighting equipment. They contain a white symbol and/or text on a red background. ©Industry Development Training Pty Ltd 44 of 267

SAFETY SIGN VIEWING DISTANCE GUIDE Signs should be large enough to view without straining the eyes when communicating safety messages to employees and/or visitors. Therefore, choosing the size of a sign is more than fitting it to the space you have available. In order to comply with AS 1319, you must consider the environment, lighting and viewing distance – these factors will determine the size of sign required to suit your application. The recommended minimum sizes as per AS 1319 are as follow. For a pictogram and worded sign in a factory or work environment, where lighting is good and the sign will be mounted in a reasonably prominent position: • Pictogram size is to be at least 15mm per metre of viewing distance • Text size: • Upper case: 5mm per metre of viewing distance • Lower case: 4mm per metre of viewing distance ©Industry Development Training Pty Ltd 45 of 267

FLASH BACK ARRESTORS The definition of a Flashback is a flame moving back through a combustible vapour. It happens if the tip is too close to the job or the pressures are too low. The risk is the flame making its way back to the cylinder. The solution is to use Flashback Arrestors. They are a one way valve with a filter to quench the flame. The Australian Standards require that they be tested annually EQUIPMENT SAFETY FEATURES FLASHBACK ARRESTERS AND CHECK VALVES Metalworking can be seen in nearly every aspect of our everyday lives—in air- conditioning and refrigeration units, hot and cold-water pipes, electrical connections, and much more. And because the oxyfuel welding and cutting methods used to create the joints and connections on these everyday items requires an open flame at high temperatures, you must never forget the importance of protecting yourself and your materials. Practicing safe operating procedures, wearing protective equipment, and following all operation instructions are the keys to a successful and safe weld or cut at any level of expertise. When oxygen is added to fuel gas, it accelerates the burning rate of the gas. For example, acetylene and oxygen burn at about 26 feet per second (FPS) and alternate fuel gases (propane, natural gas, MAPP®, or propylene) and oxygen burn somewhere in the 14 to 16 FPS range. Two of the most common incidents in oxyfuel welding and cutting are backfire (and sustained backfire) and flashback. A backfire occurs when the velocity of fuel gas, burning at the tip with the support of oxygen, is reduced to a point where it is less than the burning rate and backfires into the tip or torch, usually to where the fuel gas and oxygen are mixed. This is often very audible, especially if you're using large multi flames. The noise is created by the flame backfiring into the mixer. Sometimes the backfire continues to burn in the mixer area, supported by the flow of fuel gas and oxygen. This event, called sustained backfire, generally is accompanied by a loud whistle noise. Flashback, on the other hand, is the ignition of mixed gases that develops in either the fuel gas or oxygen passages. This can occur if one gas reverses into the other side of the torch. Reverse flow typically occurs when the system is over pressurized for the tip size being used; the tip is plugged or dirty; the oxygen or fuel gas supply depletes; or if you have made a procedural error. ©Industry Development Training Pty Ltd 46 of 267

When fuel gas backs into the oxygen line or oxygen backs into the fuel gas line, the mixture can travel through the torch, into the hose, through the regulator, and possibly into the supply cylinder or system. This condition represents a very dangerous situation if the gases ignite. Reverse-flow check valves at the torch help reduce the possibility of reverse gas flow. However, these valves are mechanical devices and may malfunction if they are not maintained properly. Flashback arresters are not mechanical by design. They depend on a fine-sintered filter that prevents transmission of a flame through the filter itself. A flashback arrester stops the ignition of the mixed gases even if the reverse-flow check valve is not operable. This keeps the ignition from propagating into the hose, regulator supply cylinder, or system. Ignition does take place in the torch, as it does with a backfire. As a rule, the torch design will withstand the ignition. Therefore, it is recommended that both reverse- flow check valves and flashback arresters be used at the rear of the torch. Some manufacturers build these safety devices into the equipment. SETTING UP EQUIPMENT (FITTING REGULATOR, ADJUSTING PRESSURES, TIP SELECTION) MAPP and Propane Gas set up • Check cylinder and head • Screw Head on • Set Pressure on Valve • Pull Trigger / ignite • Check condition and safety of all equipment to be used • Check test date of Flashback Arrestor, hose condition, Etc • Assemble equipment according to manufacturer’s instructions • DO NOT use any type of oil or grease • Ensure all valves are closed • Fit tip to suit task ©Industry Development Training Pty Ltd 47 of 267

• Open Cylinder(s) • Set regulator Pressure(s) to suit task (approx. 50Kpa is typical for both Oxy and Acetylene for soldering using Oxy Acetylene) IGNITING AND FLAME TYPES (FLINT GUNS, OXIDISING, NEUTRAL, CARBURISING) OXY ACETYLENE KIT AND AIR ACETYLENE • Crack open the Acetylene at the handpiece • Ignite with an approved flint • Open the acetylene until the flame roars and is jagged at the tip – then reduce pressure until the tip becomes smooth (the roar will also be gone) • Gradually open the Oxygen until the desired flame is achieved as shown below • The Neutral Flame is suitable for most Silver Soldering • Oxidising is the name for excessive Oxygen and • Carburising is the name for excess Acetylene ©Industry Development Training Pty Ltd 48 of 267

DRY NITROGEN Dry Nitrogen is a high-pressure inert gas. This makes it ideal for pressure testing, as the pressure does not change with temperature to any significant degree. Being non-flammable as well makes it perfect for purging through a system to prevent oxidisation. Care must be taken however to ensure that where the dry nitrogen is connected to the system is fully sealed as any gap will result in oxygen being drawn in through the venturi effect. PERSONAL SAFETY (MSDS - NITROGEN) Dry Nitrogen is stored in the cylinder at around 15 000Kpa Two types of regulators are available – one for pressure testing and one for purging Extreme care must be taken due to the high pressures Always use in a well-ventilated area to avoid any risk of asphyxiation * Never use any high-pressure gas to blow against your skin * As low as it is there is always a risk of gas entering your bloodstream causing serious health problems ©Industry Development Training Pty Ltd 49 of 267

APPLYING DRY NITROGEN TO A PIPING CIRCUIT Using the tool shown B is a simple method for an open pipe. Through a service valve is ideal. Always ensure flow before soldering tubing. BRAZING If welding on a system or pipe ready to be used on a closed system you MUST purge the pipe with nitrogen. This will displace the oxygen in the pipe and stop carbon build up. SILVER SOLDERING COPPER TO COPPER Copper to Copper Silver Soldering requires the preparation described in earlier chapters (cutting, deburring and swaging). Always clean any surfaces to be soldered with either emery cloth or steel wool to ensure full penetration of the solder ©Industry Development Training Pty Ltd 50 of 267