C2 Split Systems Learning Resource Book V17

Brown tip is all that is required although blue tip is still appropriate for this type of join (keep in mind that is actually silver)! SILVER SOLDERING COPPER TO DISSIMILAR METALS Copper to other metals requires even more careful preparation with the application of flux needed to ensure a proper seal using Blue tip solder. Otherwise preparation is the same as Copper to Copper. Less heat is needed to melt silver solder so hold the heat source slightly further away to avoid the solder simply pouring off. ANNEALING COPPER TUBE The reasons for annealing have been covered in earlier chapters. The method is to heat the copper to cherry red (using dry nitrogen) then allowing to cool. That easy! Hard drawn copper pipe is used in commercial refrigeration and air conditioning systems and is ideal for long pipe runs and being hard it requires few pipe supports. The maximum pipe diameter for refrigeration applications is 100mm and lines above this size should be steel. COMMON PIPE SIZES D mm Wall OD mm Wall Inche (mm) Inche (mm) s s ¼” 6.35 0.81 ¾” 19.05 1.14 5/16 7.937 0.81 7/8” 22.22 1.63 ”5 5 3/8” 9.525 0.81 1” 25.4 1.63 ½” 12.7 0.81 1 28.57 1.83 1/8” 5 5/8” 15.87 1.02 5 PAIR COIL “Pair coil‟ is pre-insulated soft drawn copper tube ideal for rapid, cost effective split air- conditioning installations. Pair sizes are matched to standard split air conditioning pipe sizes. Drawn or annealed tube is available in various standard sizes and roll lengths ranging from 4.76 mm up to a maximum of 22 mm nominal outside diameter (OD), and 15 or 30 metre roll lengths. The Building Code of Australia stipulates that the insulation on air-conditioning gas lines used in class 2-9 buildings must comply with specification C.10 and C10a. ©Industry Development Training Pty Ltd 51 of 267

• Pre-insulated Aluminum Tube is carefully designed using a high-quality material that is best suited for split air- conditioning installation and has the following benefits: • Flexibility & Strength • Higher wall thickness ( G18) provides better tensile strength • Lightweight & Durable Swaging & Expanding • 30% expansion from original OD • Using the same set of swaging tools as copper BURST PRESSURE • PSB TUV (Singapore) tested to meet ASTM B75 @ 1000PSI BRAZING & REPAIR • Armor Braze Rods allows up to 45-50 joints per rod ( 50cm rod) • No additional flux is required • Joints are stronger than main material • Fast & secures joints in less than 15s, 4 times faster than to braze copper • Uses the same method to braze copper • No argon gas, wire spool, gloves, shield or electricity required LENGTH & PACKAGING • Design to 50 meters length per coil • Longer length, less wastage • Offers more flexibility and does not kink easily • Able to withstand burst pressure of more than 1000psi without sign of leakage • Requires less strength to bend • Using the same set of bending tools as copper • Manufactured up to 1.5mm wall thickness providing superior rigidity CORROSION RESISTANCE • 48 hours salt water test before shipment • Corrosion rate is very much lesser than copper • Oxidisation rate is also lower making pipes clean and bright when exposed ©Industry Development Training Pty Ltd 52 of 267

THERMAL CONDUCTIVITY • Lower than copper by almost 50% which means lesser rate of condensation STEEL PIPE Steel pipe is available in various types including black steel, stainless steel and galvanized steel. Steel pipe is cheaper and stronger compared to other pipe materials but does suffer from rusting and corrosion. Stainless steel pipe is widely used in refrigeration systems where there is a need to refrigerate process and or distribute food products directly such as ice cream, milk and beverages beer and soft drink are good examples. The advantage of using stainless pipe is its resistance to corrosion and can be easily joined with pipe of different material using common fittings and brazing alloys. Galvanized steel tube has been used on condensers on medium to large refrigeration and air conditioning systems and usually, but not always, involve evaporative (water and air cooling). Galvanizing is an electrochemical process which protects the steel tube with a bonded coating of zinc. FLEXIBLE THERMOPLASTIC PIPE Thermoplastic flexible pipe is used in a number of industry sectors in applications such as hydraulics. The refrigeration industry is now employing more of this material in uses such as pressure control lines oil return lines and compressor unloader control lines to name a few. The material is compatible with all refrigerants (with steel fittings) including hydrocarbon refrigerants. This material is resistant to corrosion and very tolerant to vibration. Tube joining is easily done with crimping tools and fittings and in turn the fittings are connectable to standardized flare fittings. PIPE INSTALLATION Pipe insulation is necessary to prevent heat gain or loss depending upon what is being carried inside the pipe. The two types of protection for refrigerant piping are steel trucking and plastic pipe duct. If the pipe is a cold pipe the insulation prevents condensation, (water dripping), and causing damage such as ceilings and creating a workplace hazard. If the pipe is a hot pipe heat lost can be energy inefficient. Insulation can lock in the heat to wherever it is needed for example, hot water systems. ©Industry Development Training Pty Ltd 53 of 267

When slipping insulation over pipe ends leave pipe end caps in place to prevent powder from entering pipe. Tube insulation (copper & drains) Sheet insulation (tanks etc.) Running the Pipe Once the inside and outside units have been fitted. You may now run the pipe. Remember pipe cost money, save money by saving pipe. When planning layout, take into consideration length of run, minimize number of bends, and overall appearance The main fitting you will use is the flare and nut. This is easy and quick. There may be situations where you will need to use other forms of jointing. COMMON SILVER BRAZING RODS USED IN THE REFRIGERATION / AIR CONDITIONING INDUSTRY ARE: Yellow Tip Is used for flux free brazing of copper. Yellow tip is free flowing than brown tip and is only suitable for copper to copper joints. As it has a free-flowing capillary action, tight fit-ups are necessary. Because of its lower silver content, a yellow tip joint is less costly but not as strong as a brown tip joint, therefore its use in vibration situations should be avoided. Brown Tip is used for high shear strength flux free brazing of copper. Brown tip is used for joining copper tubing and other copper to copper applications without flux where a strong joint is required, e.g. vibration situations. Because of its medium capillary flow, fit-ups should be from 0.05mm – 0.15mm. Blue Tip is a low temperature, general purpose alloy. Blue tip is used where a very strong joint is required between dissimilar metals, e.g. joining copper, steel or brass pipe and fittings. The correct flux must be used on all applications. ©Industry Development Training Pty Ltd 54 of 267

SILVER SOLDER BRAZING ALLOYS % SILVER ALLOY MELTING COLOUR NAME RANGE °C CODE 2 AMFOS 644 – 740 Yellow 15 SIL-FOS 644 – 700 Brown 45 EASY-FLO 607 – 620 Blue BRAZING (GENERALLY THE BEST METHOD OF CONNECTING PIPEWORK) The technique for brazing is very similar to soldering, the difference being the heat and the filling rod. Brazing also requires flux (more than silver soldering). Flux stops moisture and contaminants from entering the weld. No matter if it’s soldering or brazing, it is important to clean the weld after, as any left-over flux can trap moisture on the weld causing failure. Brazing temperature is generally 3200 degrees C ©Industry Development Training Pty Ltd 55 of 267

©Industry Development Training Pty Ltd 56 of 267

OXY ACETYLENE If map gas is not available or you choose to use oxy acetylene. Although the method of soldering or brazing is the same, the oxy acetylene system has to be set up for the job. The torch has a mixing chamber on the bottom. This is to allow the user to vary the heat output of the flame. The flame used for soldering is called the “neutral flame”. SETUP To set up the oxy acetylene for soldering or brazing, there are a few safety steps that must be taken: 1. Both cylinders should be upright and secured. The acetylene cylinder must be upright at all times. If found on its side, the cylinder must be left upright for a few hours before use. This will allow the acetone in the cylinder to settle away from the valve. 2. Both cylinder valves should be clear. This is done by opening and shutting to valve very quickly. NEVER use oil on the regulators. 3. Flash back arrestors MUST be fitted to both the oxygen and acetylene lines and both ends. This stops back firing from entering the cylinders. 4. Flint gun should be used to ignite the flame, NOT a lighter. 5. The oxygen cylinder is black and has a right hand thread onit. 6. The acetylene cylinder is maroon and has a left hand thread on it. The regulator nut will have small notched cut in it to indicate left hand thread. FLAME SETUP Once the cylinders are connected, you are ready to start the flame. There are a few simple steps to get this done safely: 1. Turn on the acetylene torch first. Use the flint gun to light the flame. This flame is called the “carbon flame”, it’s yellow and has a lot of black smoke on it. 2. Slowly open the oxygen side of the torch. You will notice the flame will go from yellow to a blue colour. This flame is called the “neutral flame” 3. Proceed to solder or brazing using the same method as the map gas. FINISHED It is very important that when finished using the oxy/acetylene set, it is safely stored in the work shop or service vehicle. The following procedure is recommended before storing the oxy set: 1. Turn the oxygen off at the bottle, 2. Turn the acetylene off at the bottle, 3. Open the oxy and acetylene valves at the torch and bleed all gas from the lines, 4. Set the regulated oxy gauge to zero (turn anti-clockwise all the way out), 5. Set the regulated acetylene gauge to zero (turn anti-clockwise all the way out), 6. Ensure all gauges are reading zero pressure. Remove regulators and hoses from the bottles. Neatly coil the hoses and store where they will not be damaged. ©Industry Development Training Pty Ltd 57 of 267

Store the cylinders upright and secure correctly. Always refer to the manufacturer’s recommendations and MSDS for more detailed information. ADHESIVES AND TAPES The three types of accessories that may be fixed with adhesives are: • Ductwork • Plastic pipe connections • Insulation Some hazards from using adhesives include: • Fumes • Cutting • Physical contact • Ingestion WORKING WITH METALS & NON-METALS Some of the types of accessories that may be fixed to metal are: • Saddle clips • Conduits • Brackets • Switches • Cable and pipe support The types of sheet metal commonly used in electrical work are: 1. 0.4mm – 1.2mm galvanized sheet metal – for ductwork fabrication 2. 0.6 colour bond steel for pipework trunking The types of tools that may be used with sheet metals (and non-metals) include: FIXINGS • Hacksaw • Tinsnips • Guillotines • Punches • Notching tools • Folding machines MULTI GRIPS • Vice grips • Pliers • Chisels • Files • Wood saws • Grinders ©Industry Development Training Pty Ltd 58 of 267

Some common devices for solid and hollow wall fixings include wood screws, coach bolts, hollow wall anchors, behind plaster brackets, plasterboard devices, toggle devices and wall mates. • Accurate marking out contributes to sustainable practices by reducing waste. This can be achieved through the use of a Vernier Caliper and Micrometer. • A Vernier Caliper is a precision instrument that is used to measure internal and external distances up to 20cm. • A Micrometer is a precision instrument which can measure thickness of an object up to 5cm. USE PPE GLOVES, GLASSES, BOOTS AND EARMUFFS DRAWINGS AND DIAGRAMS The purpose of using an electrical diagram is to identify wires, labelling and specifications related to a system. There are four types of electrical drawings: • Block – a flow chart providing a quick, high level view of a system • Circuit – a visual display of an electrical circuit • Wiring – the simple visual representations of the physical connections and layout of circuit • Ladder diagram – specialized schematics commonly used in industrial control logic systems. The diagrams look like a ladder with each vertical ring representing the power supply and each horizontal rung representing control circuits There will be five main types of plans you will be expected to interpret: • Electrical floor plan (power lighting communications) • Mechanical • Floor or building plan • Installation or fabrication drawing • Architectural These and everything else on a drawing is set and governed by a government body. In Australia, this is the codes and practices board. AS1102 is the standard that all Australian drawings are based on. This standard covers things like what lines mean what, how thick and which colour they will be. No matter how complex the drawing is. All drawing must show certain information: • Scale to which the drawing is done ©Industry Development Training Pty Ltd 59 of 267

• Unit of measurement used (Metric or Imperial) • Material list • Legend to help the reader identify components. Almost every drawing will have a scale to it. This allows the reader to get an idea on the size of the project and also allows the drawing to be smaller. Like everything else, though, even these scales have standards to control their size. These scales are usually what the measurements are based on. However, if the drawing has a dimension written on it, this dimension takes precedence over the scale. This exception allows for the physical change o components for better accuracy in measurements of key components An example on standards that govern scales size: • Floor Plane 1:50 or 1:100 • Elevations 1:10 • Sections 1:10 • Site Plans 1:200 larger 1:1500 • Details 1:10 ©Industry Development Training Pty Ltd 60 of 267

©Industry Development Training Pty Ltd 61 of 267

SPLIT SYSTEM ISTALL PROCESS 1. Prior to supplying and installing an air conditioner the client’s needs must be understood. Client needs may include: • Client expectations • Desired temperatures in cooling and heating modes • Construction of house • Orientation • Area to be conditioned • Budget • Availability/access • Environmental/ power usage • Materials required 2. Identify the size of the unit needed. There are a few tools on the market that will help you with this. Danfoss has a number of phone Apps that can aid you. Danfoss “Fitters app”, Danfoss “Kool codes” and Danfoss “Ref Slide” are the most common apps on the market. a. You can calculate yourself with the following: X every m2 by 160 Watts, 180 Watts or 200 Watts depending on heat load. An example of this is a room - 3m Long X 4m Wide = 12m2 12m2 x 0.160Kw/m2 = 1.92Kw, you will round up to the closest size 2KW b. If the location of the unit has a high heat load, such as Kitchen, Lounge room or large windows, you may want to use a larger refrigeration capacity (200w/m2 for kitchens and 180w/m2 for lounge rooms). Over size is better. c. Contact wholesalers for current price and availability of parts and materials to enable you to put together a quotation or tender. To obtain a quote or tender, wholesalers will usually require a purchase order or an accurate list of required materials or equipment. d. A customer quotation is required to provide an accurate costing of the job prior to the commencement of the installation. For a commercial job, you will need to enter a tender detailing the items required and a due date for response. The supplier will then respond in writing. Tender responses are reviewed by management. The successful tenderer is appointed, and the contract is signed. e. During the installation process, ensure that the right materials are delivered on time and keep record of the delivery docket or invoice received. f. Plan your work and only make one trip where possible to reduce wastage of time and fuel on your vehicle. g. Work more sustainably when using materials, creating less wastage by measuring correctly. ©Industry Development Training Pty Ltd 62 of 267

LOCATION Once the size is determined you must talk to the customer about its location. Use the following check list: • Is the indoor unit being mounted on an external or internal wall? If it’s internal, you may have to install a condensate pump. • Where will the outside unit sit? (Ground level, wall mounted on brackets, on thereof) • Is there a place to run the condensate? • Will the pipe run be longer than the manufacturers specification? • Is there a place for the isolator switch near the outside unit? Remember the isolator switch can NOT be mounted to the unit itself. • Can you get access to the electrical feed? • How much piping and electrical can be kept out of site? You are trying to impress the customer and looks are everything. • Can the outside unit get air flow needed? • Is it in a well-ventilated area? • Will the inside unit be easy to access for maintenance or repairs? • If you have to come back for extra work will the unit be easy to work on. INSTALLATION PROCESS OF A SPLIT SYSTEM FROM START TO FINISH First fixing occurs by prewiring and pre pipework. Second Fixing occurs by final fit off at completion of construction. You must co-operate with all other trades and supervisors when installing into a new construction. WARNING: Always check for electrical, gas or water ©Industry Development Training Pty Ltd 63 of 267

DRY NITROGEN SAFETY INFORMATION • Nitrogen is a non-toxic and non-reactive except at high temperatures. • If insufficient oxygen is present, high nitrogen concentrations cause asphyxiation and death. • There are no physiological warning signs to nitrogen enrichment. • Nitrogen does not support combustion. • Liquid nitrogen has the capacity to inflict dangerous cold burns. • Used in the refrigeration industry as a process of purging to displace or dilute unwanted gas or vapour, to reduce oxygen concentration or remove air, flammable or toxic vapour. • Used in the refrigeration industry to pressure test systems and components. • Purging nitrogen through the pipework during brazing displaces the oxygen and prevents oxidation – the chemical process of forming black copper oxide (scale) when heating copper in the presence fair. PERSONAL SAFETY 2 Cu(s ) + O2(g ) --> 2 CuO(s ) Nitrogen is supplied in cylinders that may have an internal pressure as high as twenty thousand kilopascals (20,000 kPa). A regulator must be used to regulate the cylinder pressure through refrigeration gauges into a system. Applying Dry Nitrogen to a Piping Circuit Attach a regulator to the nitrogen bottle, and a set of refrigeration gauges. Attach the common line (yellow) to the regulated (outlet), and the high side line (red) to the system. Open the bottle and ensure the pressure is sufficient for the task. Open the high side gauge and then wind in the regulator handle until the desired pressure is achieved. (Regulator valves work opposite to water taps – wind in for more pressure, and wind all the way out for zero pressure). When using nitrogen for brazing, a low pressure is required – approximately 5 - 10 PSI or 50 - 70 kPa. Ensure there is an open end in the system to stop pressurization of the system, and prevent holes being blown in the solder. ©Industry Development Training Pty Ltd 64 of 267

COMMISSIONING The process of commissioning has a few steps. In order to do this you will need the following tools: • Vacuum pump • Vacuum gauge • Gauge manifold • Nitrogen and Regulator • Bubble up • Mirror • On startup check Pressures and Temperatures LEAK TESTING After the unit has been fitted and all piping run. You must check the system has no leaks before the release of refrigerant. The most common method is to use nitrogen. This method is simple with just a few steps: START WITH ALL GUAGES CLOSED 1. Connect the “BLUE” hose from the gauge group to the port on the vapor side (large pipe) 2. Connect the “YELLOW” hose from the gauge to the nitrogen cylinder. Ensure all valves on the gauge are closed and the gauge is secure. 3. Open the nitrogen cylinder and open the regulator to the pressure of 350 PSI to 2500kpa. 4. Open the “BLUE” valve on the gauge and allow system to charge with nitrogen 5. Leave \"BLUE\" valve open, and nitrogen cylinder valve open for 15 minutes 6. Squirt all joints with liquid detergent and check for bubbles. Take your time and look closely the leak maybe very small 7. Close the nitrogen cylinder and the “BLUE” valve on the gauge group. 8. With all gauges and valves closed let sit for 15 minutes and make sure the pressure reading does not go lower than original position (it shouldn't move) 9. Once the system passes the leak test. You can remove the “YELLOW” hose from the nitrogen bottle very very slowly to release the nitrogen from the system. Remember this has to be done slowly as there is high pressure in the system or open the \"RED\" valve on the gauge group slowly. This will allow the nitrogen to leave the system. 10. Proceed with the next step to vacuum the system to remove air and moisture VACUUM Once the system has been leak tested, you can now vac down the system. This will remove all moisture from the system and allow the refrigerant to perform at its best. 1. “BLUE” hose already connected to gauge and unit 2. Connect the \"YELLOW\" hose from the gauge group to the vacuum pump. 3. Make sure all gauges are closed 4. Turn the vacuum pump on and listen for a quiet sound ©Industry Development Training Pty Ltd 65 of 267

5. If the vacuum pump is gurgling, then check all connections are tight or the pump oil may require replacing 6. Then open the \"BLUE\" valve on the gauge group and watch the gauge go from 0 to - 30. A change of noise will happen for a short time 7. Let it run for 15 minutes while at -30, the vacuum noise should be quite again. 8. Close the \"BLUE\" gauge and the vacuum will remain at -30 9. Open up the 2 service ports to release the gas into the system, you will hear gas be released and the pressure will now show on the gauges 10.Remove the vacuum pump and turn power onto the unit 11.Go inside and turn the unit on and after 2 minutes it should start to cool 12.Remove the gauge while the unit is running 13.Pack up tools PUMP DOWN Pump down is the act of getting all the refrigerant from the system back into the outside unit. It is a simple process and is most commonly used were the customer would like the air con moved. It is important to note that pump down can NOT be used at the end of life or decommission of a unit. 1. With the system “ON” turn the mode to “COOL” 2. Connect the “BLUE” hose of your gauge group onto the large pipe. 3. Close the large pipe valve. Then open it up two turns (this will limit the time the compressor runs dry) 4. Close the small pipe valve. 5. Watch the “BLUE” gauge. When it reaches 0 or just a bit lower. Shut the large pipe valve. 6. Once the valves are closed turn the unit “OFF” via the outside isolation switch. 7. Now you have pumped down you can remove pipe work. Please remember that all the gas is now in the outside unit. Work can NOT be done on any components inside this unit RECLAIM Reclaim is the act of safely removing the refrigerant from a unit into a storage cylinder. This refrigerant can now be taken away for disposal. This is needed when you are decommissioning or at the end of life of a unit. The reclaim MUST be done on site and NOT back at the workshop. Turn the unit “OFF” at the isolation point on the wall. 1. Remove the “RED” hose of the gauge group. 2. Connect one end of the “RED” hose to the reclaim cylinder. 3. Connect the other end of the “RED” hose to the outlet port of the reclaim unit. 4. Connect the “Yellow” hose from the gauge group to the inlet port on the reclaim unit. 5. Connect the “BLUE” hose from the gauge group to the large pipe service port. ©Industry Development Training Pty Ltd 66 of 267

6. Turn the reclaim unit “ON” and open the “BLUE” gauge valve. Then open the reclaim cylinder. 7. Once the “BLUE” gauge has gone into a partial vacuum. Turn of the “BLUE” valve on the gauge group. 8. Once the gauge valves are shut. Shut the reclaim cylinder. Turn of the reclaim unit. 9. Clean up site and close hoses off. RELEASE THE REFRIGERANT Now the vacuum is completed, the system can now have the gas introduced: 1. With the gauge group still connected, open the large pipe valve. This only needs to be opened as mall amount. 2. Watch the “BLUE” gauge pressure rises to 0 kpa or a little bit over. 3. Shut the large pipe valve. 4. Remove the gauge group. Do this quickly to avoid gas leak and injury. 5. Open the small pipe valve all the way and back seat it. 6. Open the large pipe valve all the way and back seat it. 7. Turn the system on and activate cool mode set the air con to the lowest temperature. 8. Using a thermostat, measure the air temperature at the top of the inside unit (above the filters). 9. Then measure the air temperature coming out of the vents (don’t poke the thermostat into the vent you will contact the fan). You should get a minimum of 12 degrees centigrade from top to bottom. HAND OVER Once the system is turned on and running, you have the most important job left. • Talk to the customer and explain the operation of the unit. • Explain the maintenance requirements. • Fill out the warranty form. • Leave a clean job site and make sure you get paid. ADDING GAS Gas should NEVER be added to a system before leak testing has been done. If you find yourself in the situation where you must add gas, there are a few things you need to do to ensure there is a limited amount of release. This step will involve some release this is called “un-preventable release” and should be kept at a minimum. To do this you will need the following tools: • Gauge group • Accurate scales • Bottle of gas • Pressure temperature chart ©Industry Development Training Pty Ltd 67 of 267

All top up are done with the system “ON” and in cool mode. If adding gas due to pipe run and you know how much is needed, it is done after the vacuum and before the release of the outside unit. 1. Turn the unit “ON” and have it on “COOL” mode. 2. Connect the “YELLOW” hose from the gauge group to the refrigerant bottle. 3. Place the bottle on the scales. Zero the scales. Secure the gauge group. 4. Open the gas bottle “LIQUID” side. 5. Place the “blue” hose from the gauge onto the large service port. DON’T tighten it all the way. 6. Open the “BLUE” gauge valve. A very small amount. 7. Watch the “BLUE” hose at the air con fitting. When you see a small amount of liquid escape. Using gloves tighten up the valve. Don’t turn the bottle of at this time. You have now “PURGED” the line. This is the unpreventable escape of gas. 8. Close the “BLUE” gauge valve. 9. Now you will be charging the vapor side of the compressor with liquid. You will have to “THROTTLE” the charge. This is done by opening and closing the “BLUE” gauge valve. 10.Keep throttling the liquid until you reach the scale weight you want or pressure on your chart. Remember that there will be about 20 to 60 grams of liquid in the lines depending on length. Take this into account. 11.Once you have reached the desired amount of charge. Turn the bottle off. Leave all hoses connected. 12.Open the “BLUE” valve on the gauge. This will allow any leftover liquid in the lines to get sucked into the unit. 13.Close the “BLUE” gauge valve. 14.Remove all lines and cap them. 15.Clean up ©Industry Development Training Pty Ltd 68 of 267

OZONE DEPLETION POTENTIAL The Ozone Depletion Potential (ODP) is the measurement of depletion a gas will do to the ozone layer when released. The Ozone layer is a layer of gas in the upper atmosphere. That has a number of functions: • Prevent the majority of dangerous radiation from the sun from damaging the earth. • Help to regulate the temperature of the earth. This is important to maintain the “Life zone” as this is the optimal temperature and radiation that life on earth needs to survive. The Montreal and Kyoto protocol were introduced to stop and phase out the gases that are ozone depletes. 1992 saw the last of these gases R12. RENEWABLE ENERGY Renewable energy is energy which can be obtained from natural resources that can be constantly replenished. Renewable energy technologies include technologies that use, or enable the use of, one or more renewable energy sources. Types of renewable energy technologies include: • Bioenergy – Energy that is obtained through organic matter • Geothermal Energy – Energy that is produced via using the earth’s surface • Hydropower – Energy produced by moving water • Ocean Energy – Using the ocean’s tides to produce energy • Solar Energy – Converting the Sun’s rays into energy • Wind Energy – Using the wind to produce energy Renewable energy technologies also include hybrid and related technologies. For more information about renewable energy, please visit: http://arena.gov.au/about-renewable-energy/ http://www.altenergy.org/renewables/renewables.html ©Industry Development Training Pty Ltd 69 of 267

GLOBAL WARMING POTENTIAL Global Warming Potential (GWP) is the measurement of greenhouse gases a gas will hold in the atmosphere once released. The base unit for this measurement is C02 (carbon Dioxide). Current gases used can have a GWP of 1400 this means that for every molecules of this gas released into the atmosphere. It will have the same greenhouse effect as 1400 molecules of C02. R22 is in the process of being phased out due to its potential for ODP and high GWP. Energy, greenhouse gas emissions and ozone ENVIRONMENT AND SUSTAINABILITY CONTEXT ENERGY USE The demand for energy and environmental impacts are closely linked. The extraction, transport and use of fuels, and generation and transmission of electricity affects the environment on a global, regional, and local level. The sustainable use of energy and energy security is becoming an increasing issue for countries seeking social cohesion and economic prosperity. In Australia, as demand for energy increases there will be a greater emphasis in optimising energy efficiency. GREENHOUSE GAS (GHG) EMISSIONS Human activities over the past 200 years, such as burning of fossil fuels and land clearing, have led to an increased concentration of greenhouse gases in the lower atmosphere – increasing the average global temperature. The 1997 Kyoto Protocol has defined the most prominent greenhouse gases as carbon dioxide, methane, nitrous oxide, and sulphur hexafluoride, hydrofluorocarbons and perfluorocarbons.1 Emission limits under the Protocol do not include emissions by international aviation and shipping, but are in addition to the industrial gases, chlorofluorocarbons, or CFCs, which are dealt with under the 1987 Montreal Protocol on Substances that Deplete the Ozone Layer. OZONE DEPLETING SUBSTANCES (ODSS) The evidence of damage to the ozone layer has prompted a decisive international response through the 1987 international treaty – Montreal Protocol on Substances ©Industry Development Training Pty Ltd 70 of 267

that Deplete the Ozone Layer. Substances implicated in ozone layer destruction include the chemical families known as chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs) and halons, which have uses in refrigeration, fire suppression, fumigation, laboratory operations and chemical processes.2 There has been significant progress made toward phasing out the use of these substances through legislation, regulations and other legal instruments. LEGISLATIVE AND POLICY AUTHORITY This section outlines government legislation and policies that are relevant to energy use, greenhouse gas emissions and ozone depleting substances. These are: • Environment Protection and Biodiversity Conservation Act 1999 (Cth) • Building Energy Efficiency Disclosure (BEED) Act 2010 (Cth) • Ozone Protection and Synthetic Greenhouse Gas Management Amendment Act 2010 (Cth) • Energy Efficiency in Government Operations (EEGO) Policy (2006) • Australian Government ICT Sustainability Plan (ICTSP) 2010-2015 • Australian Government Data Centre Strategy 2010-2025 and Data Centre Optimisation Policy • State Government Environment Protection Legislation and Regulations, such as the Protection of Environment Operations Act 1997 (NSW) It should be noted that the Australian Government has an overall commitment to reduce greenhouse gas emissions by 5 per cent from 2000 levels by 2020. 1 Kyoto Protocol, 1997, Annex A – Greenhouse gases, http://unfccc.int/essential_background/kyoto_protocol/items/1678.php SUPPLIERS, PRODUCTS AND MATERIALS USE ENVIRONMENT AND SUSTAINABILITY CONTEXT Meeting consumer demand for goods and services requires the extraction of raw materials from the environment. To develop raw materials into a saleable product requires production, manufacturing and distribution processes. Producers can use materials more efficiently through strategies such as light weighting, using recovered resources as inputs, and enhancing the recyclability of their products. These approaches increase the service intensity, or value, from each unit of raw material.3 As the department is a major consumer of products and services in the Australian Government, the application of environmental standards in procurements for sustainable products and services will provide a catalyst for improving environmental performance in supply chains – driving resource efficiency and innovation.4 In addition, managing demand, avoiding unnecessary consumption and maximising product utilization are organisational strategies that provide opportunities to control and reduce costs, and improve environmental performance. Since 2013 Air-conditioners and Heat Pumps have been regulated for energy efficiency in Australia under the Greenhouse and Energy Minimum Standards (Air- conditioners and Heat Pumps) Determination 2013. On the 1st April 2019 a replacement determination the Greenhouse and Energy Minimum Standards (Air- conditioners up to 65Kw) Determination 2019 was introduced. ©Industry Development Training Pty Ltd 71 of 267

The new energy rating label indicates the difference in energy efficiency depending on the climate zone in which it is used. For example some models are much less efficient in frosty conditions. The climate zone performance information helps customers to purchase air conditioners best suited for their location. It also enables retailers to promote air conditioners better suited to different regions. The new label also shows annual energy consumption across air conditioner models in a consistent way. This brings the label for air conditioners into line with many of the other energy rating labels, such as those for fridges, washing machines and televisions, which already display an annual consumption figure. A new energy rating icon is also introduced in this Determination. The icon is a simpler image than the energy rating label, only recording the star rating of the product across the three climate zones. The simplicity of the icon will allow it to be reproduced legibly at a range of scales making it more flexible for use in advertising and on-line media than the energy rating label. Australia/New Zealand specific efficiency rating method The Energy Rating Label shown in Figure 4 above rates energy efficiency performance based on the Australian/New Zealand test standard AS/NZS 3823.2 Performance of electrical appliances – Air conditioners and heat pumps. The tests are performed at ‘full load’ (100 per cent of rated capacity) conditions at the two test points of 35 °C for cooling and 7 °C for heating. These temperature points have been the international rating points for air conditioners since the 1970s, with residential air conditioners first required to carry a label in Australia in 1987 (based on these rating points). Replace Energy Rating Label with Zoned Label Remove the existing Energy Rating Label and replace it with a Zoned Energy Rating Label that provides energy efficiency information for three distinct climate zones across Australia and New Zealand as per the existing scope of mandatory energy efficiency labelling. Adoption of the SEER test standard provides the opportunity to improve the provision of energy efficiency information to consumers and installers using the proposed Zoned Label Energy labels incorporating maps and climate specific information are in use internationally. The EU introduced their SEER label for air conditioners in January 201345 and for all space heating46 and water heating47 products in September 2015. In January 2015, the USA implemented a map-based label to display SEER ratings, as well as their regional performance standards48. This international adoption ©Industry Development Training Pty Ltd 72 of 267

acknowledges the importance of displaying the effect climate can have on the energy efficiency and performance of air conditioners. The Zoned Label is intended to provide consumers, retailers and installers with information provided by the adoption of the SEER standard. To read the full standards go to https://www.legislation.gov.au/Details/F2019L00490 Or click on the link to watch the video. https://youtu.be/MIBDUJ3-VZ8 WHAT IS ‘MATTER’? To understand how a vapour compression system operates, the effect of adding or removing heat energy to matter needs to be understood. To understand this, it is necessary to have a basic knowledge of what “matter” is. Matter is anything that has mass and occupies space. Matter can exist in any of three states: solids, liquids or gases. The smallest particle of a piece of matter is an atom. ATOM The atom consists of a nucleus at its Centre, made up of protons (+ charge) and neutrons (no charge) with electrons (- charge) orbiting the nucleus in much the same way as the planets orbit the sun. MOLECULES Atoms usually are bonded into groups called Molecules. Molecules with the same types of atoms are calls Elements. Molecules with two or more different types of atoms are called Compounds. Molecules of all matter vibrate. The rate at which they ©Industry Development Training Pty Ltd 73 of 267

vibrate (their kinetic energy) depends on how much heat energy is added to or removed from the matter and how much matter there is in a body or its Mass. In gases, the molecules are comparatively far apart and can move freely within the space they occupy. In liquids, the molecules are more closely crowded together, they cannot move so freely and collide more often. In solids, the molecules occupy fixed positions but still vibrate. The force exerted by a: • Solid – is downward • Liquid – is downwards and sideways • Gas – is in all directions ENTHALPY Enthalpy is the thermodynamic potential (H) consisting of the internal energy of the system (U) plus the product of pressure (p) and volume (V). H = U + pV RELATIVE HUMIDITY Relative Humidity refers to the amount of water vapour in the air compared to the maximum amount that the air could hold at a given temperature. Relative humidity changes with temperature so when the volume of air is heated, the relative humidity decreases. In the same manner, when the volume of air is cooled, the relative humidity decreases. HEAT Heat is a form of energy. ENERGY Energy is used to do work. Some other forms of energy are: • Mechanical energy • Electrical energy • Light energy • Chemical energy Energy can be converted from one form to another. UNIT The S.I. unit for work and energy is the “Joule” (J)”. The rate at which work is done or energy expended or moved is Power. POWER is work or energy over time(J/sec) or Watts (W). As more heat energy is added to a substance, the rate o f more curial movement increases. HEAT TRANSFER Heat can only transfer from a hotter body to a colder body. There must be a Temperature Difference for heat to transfer. The greater the temperature difference (td) the greater the rate of heat transfer. ©Industry Development Training Pty Ltd 74 of 267

There are 3 methods of heat transfer: • Conduction – by physical contact in solids, liquids and gasses. • Convection – by currents forming in fluids (liquids and gases). • Radiation – by heat rays through gases or a vacuum. This is the only method that transfers heat through vacuums. EFFECTS OF HEAT TRANSFER Adding of removing heat energy to or from matter will either change the temperature or the state of the matter. KINDS OF HEAT used to change temperature of matter, without a change in state is called Sensible Heat. HEAT USED to change the state of matter. Without a change in temperature is called Latent Heat. TYPES OF LATENT HEAT • Condensation – changing steam (vapour) to water (liquor) • Vaporisation – changing water (liquid) to steam (vapour) • Fusion – changing water (liquid) to ice (solid) • Sublimation – changing dry ice (solid) to CO2 (gas) HEAT CALCULATION The amount of heat added to or removed from a body cannot be measured, it has to be calculated. SENSIBLE HEAT CALCULATIONS To calculate Sensible heat quantities, the following information is required: • The mass of matter • The ‘specific heat capacity’ for that matter • Temperature change of the matter The formula used is: Where Q = Quantity of heat in kilojoules(kJ) M = Mass in kilograms (kg) C = specific heat capacity in kilojoules per kilogram Kelvin (kJ/kgK) = change in temperature of the mass in Kelvins (K) Latent heat calculations ©Industry Development Training Pty Ltd 75 of 267

To calculate Latent heat quantities, the following information is required: • The mass of matter • Latent heat value The formula is: Q = mLH Where Q = Quantity of heat in kilojoules(kJ) M = Mass in kilograms (kg) LH = latent heat value in kilojoules per kilogram (Kj/kg) REFRIGERANT CONDITIONS SATURATION TEMPERATURE Saturation temperature is the temperature at which a liquid will boil or a vapour will condense. It is the point at which a change of state will occur for a liquid or a vapour. A refrigerant is in a Saturated condition when it is going through a change of state (i.e., both liquid and vapour states are present). While in this condition, it has a pressure/temperature relationship. SATURATED LIQUID Saturated Vapour is a vapour at its condensing point (temperature) and if any heat is removed, it will cause it to change state back into a liquid. A refrigerant is known as a Saturated Liquid when enough heat has been removed from a vapour to cause a change of state (into a liquid). In an operating system, saturated vapour is present in the evaporator and the condenser. SUPERHEATED VAPOUR A superheated vapour is produced if any extra heat is added to a saturated vapour without a change of pressure occurring. A refrigerant is in a superheated condition when it is in a Vapour state and its temperature is above its saturation temperature. (Note: This condition can only occur with a vapour). In an operating system, superheated vapour is present in the end of the evaporator in the suction line, compressor, and discharge line and at the start of the condenser. ©Industry Development Training Pty Ltd 76 of 267

SUBCOOLED LIQUID Sub cooled Liquid is a liquid at any temperature below saturation. If any heat has to be added to a liquid to raise its temperature to saturation temperature, it is a sub cooled liquid. A refrigerant is in a Sub cooled condition when it is in a liquid state and its temperature is below its saturation temperature (Note: this condition can only occur with a liquid). In an operating system, sub cooled liquid is present in the end of the condenser, the receiver (if fitted) and the liquid line. REFRIGERANTS Refrigerant is a term given to any gas that is used within a sealed air conditioning system. The better the thermodynamic properties of the gas, the better it’s cooling or heating potential. There are two main types of refrigerants used: • Natural Refrigerants, such as Hydrocarbons, Carbon Dioxide and Ammonia • Synthetic Refrigerant such as R410a, R134a and R404a Natural refrigerants have a lower GWP and are becoming increasingly popular, therefore becoming more environmentally sustainable. There are many different types of refrigerants. No matter what the refrigerant is, they come under one of the following categories. BLENDS A blend is a combination of two or more refrigerants in a defined ratio which forms a refrigerant with specified thermodynamic properties. (RH COP 2007 Part 2). A blend MUST be charged as a liquid. Failure to do this will allow the different gases to boil of at different times which may give poor system performance. PURE REFRIGERANTS Pure refrigerants consist of one chemical compound. Pure refrigerants may be charged as a gas and a liquid as they can’t separate. Examples of pure refrigerants include: • R134a (Tetrafluoroethene) • R22 (Chlorodifluoromethane) • R123 (Dichlorodifluoromethane) Table representing the properties of the refrigerants commonly used. Refrigerant Refrigerant T Chemical Band Number Name y Formula Colour p e R717 Ammonia N NH3 Slate a t u r ©Industry Development Training Pty Ltd 77 of 267

a l R22 Chlorodifluo H CHICIF2 Moss romethane C Green F C R404a R125 + 143a H Ternary Orange + R134a 44% F Blend of HFC C refrigerants 52% 4% R134a Tetrafluoroe H CF3CH2F Light Blue thene F C R410A R125 + R32 H Binary Blend Pink 50% 50% F of HFC C refrigerants PRESSURE TEMPERATURE Any gas in a confined space will increase its pressure as heat is applied. This is due to the gas expanding. We can use this relationship to determine if a system is correctly charged or not. PRESSURE Pressure is force per unit of area, ie, Newton’s per square metre (N/m2) is a Pascal (Pa). UNITS The S.I. unit for pressure is the Pascal (Pa). The common multiple used is the kilopascal (kPa). Scales Pressure is measured in two scales in the S.I. system: • Gauge Scale - the everyday scale used is the ‘gauge pressure scale. This scaled has the same size graduations as the absolute scale i.e. Pascals or kiloPascals. The zero point on this scale is at atmospheric pressure (101.325kPa absolute, usually rounded to 100 kPa). • Absolute scale – the absolute scale is used for scientific calculations. The zero point on the absolute scale is at no pressure at all (a perfect vacuum). A container at zero absolute pressure contains no gas molecules. Absolute values for temperature and pressure are used for Gas Law calculations. PASCALS LAW Pressure applied in a confined fluid is transmitted undiminished in all directions and acts with equal force on equal areas and at right angles to them. GAS LAWS General Gas Laws relate to Pressure – Temperature – Volume. All gas laws are based on “absolute” values. ©Industry Development Training Pty Ltd 78 of 267

CHARLES’ LAW For a constant pressure process, Charles’ Law states that when the pressure of a gas remains constant, the volume of the gas varies directly with the absolute temperature. BOYLE’S LAW For a constant temperature process, Boyle’s Law states that if the temperature remains constant, the absolute pressure varies inversely to the volume. For situations where the pressure, volume and temperatures can all change, the general gas law equation (Gay- Lussac’s Law) combines all three formulae of Charles’ and Boyle’s Laws: P1V1 = P2V2 T1 T2 Where P1 = Pressure 1 P2 = Pressure 2 V1 = Volume 1 V2 = Volume 2 T1 = Temperature 1 T2 = Temperature 2 DALTON’S LAW Dalton’s law of Partial Pressures states that in any mechanical mixture of gases, not chemically combined: 1. Each gas in the mixture exerts an individual partial pressure that is equal to the pressure that the gas alone would exert if it occupied the space alone. 2. The total pressure of the gaseous mixture is equal to the sum of the partial pressures exerted by the individual gases. PRESSURE MEASUREMENT & GAUGES Pressure Measurement Instruments measure the condition of a liquid or gas or the force that the fluid would exert when at rest. Types of gauges used with installing split system units are: • Pressure measures the condition of a liquid or gas and the force that the fluid would exert wheat rest • Compound measures both pressure above and below atmospheric ©Industry Development Training Pty Ltd 79 of 267

• Vacuum Gauge measures lower than atmospheric pressure • Manometer a digital pressure instrument that uses microprocessor- based electronics to measure, record and store differential pressures and air velocity • Magnahelic displays pressure differences in cylinders • Barometer measures atmospheric pressure • Micron one thousandth of a millimeter ©Industry Development Training Pty Ltd 80 of 267

• Thermometers measures the temperature THERMOMETERS There are six types of thermometers: 1. Digital – detects temperatures over a greater range (reads from -50 °C and 260°C)Stem – contains a red liquid that rises as temperature increases (reads from -35 °C to 49 °C) 2. Dial – operates by a bi metallic strip with a volatile liquid (reads from -40 °C to 70 °C) 3. Max/Min – has various hands which indicate highest temperature reached, present temperature and lowest temperature reached 4. Non-Contact – uses infrared/laser to measure temperature from a distance 5. Data Loggers – a portable instrument that can record temperature over a period of time PRESSURE TEMPERATURE CHART ©Industry Development Training Pty Ltd 81 of 267

PT CHARTS HAVE 3 PURPOSES: 1. To set a coil pressure so that the refrigerant produces the desired temperature 2. To check the amount of superheat above the saturated vapour condition at the outlet of the evaporator 3. To check the amount of sub cooling below the saturated liquid condition at the end of the condenser. PRESSURE TEMPERATURE The Refrigeration/Air Conditioning Industry is made up of many different applications that operate at vastly different temperature ranges (e.g. Air conditioning, cool rooms and freezers etc.). By using different refrigerants, we can achieve these temperature ranges and still permit each of the systems to operate within an acceptable pressure range. This occurs because each refrigerant has a unique pressure/temperature relationship. PRESSURE TEMPERATURE RELATIONSHIP OF REFRIGERANT The relationship that exists between pressure and temperature for various liquids is used to provide the effects known as refrigeration and air conditioning. ©Industry Development Training Pty Ltd 82 of 267

Pressure Temperature Relationship of Water The boiling point for any liquid is governed by the amount of pressure places upon its surface. At sea level, the pressure exerted upon the surface of any open pan of water is 101kPa (abs) or ‘atmospheric’ pressure. Under this pressure, the water will boil off to a vapour once its temperature has been raised to 100◦C. If the pressure on the water is increased, so too will the boiling temperature of the water. For example, water will not boil until it reaches a temperature of 125◦C if the pressure over it is increased to 300kPa (abs). However, lowering the pressure over the water, will also decrease its boiling point. For example, water will begin to boil when it reaches a temperature of 80◦C if the pressure over it is reduced to 50kPa (abs). By reducing the pressure to a sufficiently low enough value, it is possible to drop the boiling temperature of the water to a value that is cooler than the surrounding ambient air temperature, thus resulting in the process known as refrigeration. However, using water for this process presents a number of problems so scientists have created new liquids that are much more efficient and provide a wide range of pressure/temperature relationship. The relationship that exists between the temperature and pressure is so consistent that tables have been created that accurately shows the boiling point of the liquid for any desired pressure. Which is why we use refrigerants in refrigeration systems instead of water. One refrigerant that has become popular and is becoming more and more popular each day are the hydrocarbon refrigerants especially the R32. Interest in and application of hydrocarbon (HC) refrigerants is growing, especially now that the global warming impact of refrigerants is becoming an increasingly important aspect for the refrigeration and air conditioning industry. The accelerated phase-out of HCFCs under the Montreal Protocol in September 2007 and a foreseen regulation of fluorinated gas emissions under a future climate change agreement – within the Montreal and Kyoto area – heighten the need to substitute widely used fluorinated substances in favour of climate friendly refrigerants. Hydrofluorocarbon (HFC) refrigerants with their typically high GWP as well as environmentally friendly natural refrigerants (such as HCs, ammonia and carbon dioxide) are all available as mature technologies for most applications, both in industrialised and developing countries. If HFCs continue to replace HCFCs in a substantial manner, the climate benefits of the Montreal Protocol may be lost within a short period of time. Despite their superior properties, natural refrigerants continue to remain in the shadows, largely because of exaggerated safety concerns which are rarely properly addressed. It is widely known that HCs are excellent refrigerants in terms of performance and because of their negligible environmental impact aspects. ©Industry Development Training Pty Ltd 83 of 267

Overview of R32-Using Systems There is no major difference in specifications between the R32 and R410A units, but there is a difference in pressure and refrigerant oil used between the R32 and R22 units. Refrigerant name HFC units HFC units HCFC units Composing R22 substances R32 R410A Single-component Standard design Single-component Quasi-azeotropic refrigerant pressure refrigerant Mixture (R32:R125 = 50:50 wt%) 2.75 MPa G Refrigerant oil RA：4.17 MPa G PA：4.0 MPa G or RA: 4.17 MPa G Mineral oil 3.6MPa PA: 4.0 MPa G (suniso) Synthetic oil or 3.8 MPa G (ether) Synthetic oil (ether) Refrigerant piping consists of copper/steel pipes, joints, and other fittings. All components must be selected and installed in conformity with the standards pertaining to the Refrigeration Safety Regulation. Same piping as for R410A can be used. ©Industry Development Training Pty Ltd 84 of 267

■ R32-related Regulations <As of March, 2019> ISO5419, ISO817 & EN378 Field International Europe US Refrigerant Classification ISO817 -NA- ASHRAE 34 (based on ISO) UL 2182 Usage ISO5149 Restriction for EN378 ASHRAE 15 IEC60335-2-40 Under revision UL 207 Safety Under revision UL 250 EN60335-2-40 UL 471 Based on IEC UL 474 UL 484 UL 984 UL 1995 UL 60335-2-40 UnderASHRAE 34 and draft ISO 817, R32 is a slightly flammable gas, it will only burn when concentration is between lower & upper flammable limits (LFL & UFL). Lower flammable limit Upper flammable limit R32 concentration 13,3% 29,3% CERI + Kayak Japan 2011 R32 is rated A2L, meaning slightly flammable since the burning velocity is rather low and non toxic or which toxicity has not been identified at concentrations less than or equal to 400 ppm R1234yf/ze R600a Propane, R32 iso-butane Class A: Non Class B: High Class 3: High Flammability Toxicity* Toxicity Class 2: Lower Flammability Class 1: Non Flammability A3 B3 R410A / R22 A2 B2 ©Indu*stry Development Training Pty Ltd A2L B2L A1 B1 SAFETY GROUP Ammonia 85 of 267

Properties of Refrigerants ■Refrigerant Properties of R32 Major refrigerant properties of R32 are summarized in the chart below. Formula R32 R410A R22 CH2F2 CH2F2 /CHF2CF3 CHCLF2 Composition Single component R32/R125 Single (Mixture ratio: wt%) (50/50 wt%) component - 51.7 Boiling temperature (ºC) 3.14 - 51.5 - 40.8 Pressure (physical property) *1 160 3.07 1.94 Capacity (physical property) *2 95 141 100 COP (physical property) *3 91 100 Ozone depletion potential (ODP) 0 0.055 Global warming potential (GWP) *4 675 0 1810 Flammability Slightly flammable 2090 (Ashrae 34 & draft ISO817) (A2L) No flammable No Not flammable (A1) (A1) Toxicity No No *1: Physical property value under a temperature condition of 50ºC *2: Temperature condition: 0/50ºC; the values are relative values based on R22 as 100 *3: Te/Tc/SC/SH = 5/50/3/0ºC *4: GWP = Global warming potential; values are specified in IPCC 4th Assessment Report ©Industry Development Training Pty Ltd 86 of 267

■ Flammability of R32 R32 may burn slightly when all of the following condition (gas concentration, ignition energy) are met, but pose no risk under the normal usage conditions for air-conditioning equipment and work environment. [Concentration Condition (Upper & Lower Concentration Limits)] Lower limit Upper limit Notes R32 combustion 13.3 % 29.3 % CERI + Kayak Japan (‘11) concentration If ignition energy is applied while in the gas concentration range (between upper and lower limit), R32 may burn. However, this gas concentration condition is a level at which oxygen deficiency can occur (oxygen concentration of 18% or below) and thus is not an environment in which people generally work. [Ignition Energy] ●Value for minimum energy with which the gas may ignite Min. ignition energy Notes (Unit: mJ) R32 30 – 100 With static electricity or electronic lighters (energy: (From DuPont June 2010 several mJ), minimum ignition AIChE article report) energy is not attained Ref: Propane 0.25 May ignite even with static electricity <Reference: Static electricity energy> R32 does not ignite with Static electricity Symptom of electric shock static charge generated by energy (mJ) human contact. 0.05 No sensation 0.45 Prickling sensation 1.25 Pain extending from palm to forearm ●No possibility of ignition by spark in the machine or in the magnetic switch on a power panel Even if a spark exceeding the minimum ignition energy was generated in the magnetic switch, with the actual electrical parts (electromagnetic switch with cover), there is no flame propagation in R32 (no flame spreading). - If the distance between the electrodes and the wall is within 4 mm in an enclosed space, there is test data that indicates no flame propagation. <Source: National Institute of Advanced Industrial Science and Technology (AIST) report> R32 does not ignite with actual electrical parts. ©Industry Development Training Pty Ltd 87 of 267

By way of experiment, the following shows how R32 acts when ignited and combusted when the conditions for flammability are met. [How R32 Burns (Flame Propagation)] R32 Burning Propane speed (Unit: cm/s) 6.7 46.4 When R32 is ignited When propane is ignited Even if R32 gets ignited, the risk of pressure rise (= explosive force) is low due to its slow flame propagation (slow burning). [Change of Flame When There is R32 Leakage] Before R32 leakage R32 leaking When leakage occurs, an area of (within combustion concentration forms immediately concentration range) below the leaking part and up to a certain height above the floor in the vicinity of the leak. The picture shows the change in the flames (flame propagation). Using lighters and burners commonly used at work, the experiment shows an upward spread of flames but no flame propagation in the horizontal and downward directions. When the naked pilot flames are extinguished, the upward flame propagation disappears. R32 combustion does not occur under normal usage conditions for air-conditioning equipment or in a normal work environment. However, it is important to keep away ignition source (open flame) so as to prevent generating R32 combustion concentration conditions, hence reducing the risk of combustion occurrence with the awareness that R32 is slightly flammable. ©Industry Development Training Pty Ltd 88 of 267

Therefore, ensure that the following instructions are strictly observed when handling R32 and other HFCs: ● R32 and other HFCs are heavier than air, and therefore they are inclined to settle near the floor surface. If the gas fills up the room or the bottom part of a room, it may also cause oxygen deficiency and may reach its combustion concentration. In order to prevent oxygen deficiency and R32 combustion, keep the room well- ventilated for a healthy work environment. In particular, using HFCs in a basement room or confined area creates a higher risk; be sure to furnish the room with local exhaust ventilation. If a refrigerant leak is confirmed in a room or an inadequately ventilated location, do not use a flame until the area has been ventilated appropriately and the work environment has been improved. ● The same applies in case of brazing, ensure appropriate ventilation to prevent oxygen deficiency and R32 combustion. Check that there are no dangerous or combustible items nearby, and ensure a fire extinguisher is close at hand. ● If the gas comes into contact with open flame or metal (or other material) heated to over 300 to 400ºC, it will cause thermal decomposition, possibly producing toxic gas. Do not allow the gas to come into contact with such objects. Toxic gas generation is the same with R410A, R22, etc., and not limited to R32. ● Keep a sufficient distance away from causes of fire (ignition sources) such as gas- burning equipment and electric heaters in places where installation, repairs, or similar work on air-conditioning equipment is performed. ©Industry Development Training Pty Ltd 89 of 267

Properties of Refrigerant Oils R32 lacks compatibility with mineral oil (SUNISO) and reduces oil return performance, so to ensure compatibility ether oil (a synthetic oil) has been selected as the refrigerant oil for R32 units. Ether oil is thus used as the refrigerant oil for both R32 and R410A units, but product names are different as indicated in the table below. Unit (Manufacturer) Synthetic oil Synthetic oil Mineral oil Ether oil Applicable Ether oil SUNISO 4GS refrigerant FW68DA (Japan Sun Oil (Daikin products) (Idemitsu Kosan) FVC68D FVC50K Company) R32 (Idemitsu Kosan) R22 R410A ■Contamination Control (Preventing Impurity Contamination) ● Contamination control (preventing impurity contamination) for R32 refrigerant oil (ether oil) is the same as R410A. ● Reuse of existing piping in R32 room air conditioners is the same as R410A room air conditioners, and reuse of existing piping is possible with the samemethod. For details, check the catalogs and specifications for the products. (When the inside of the existing piping is extremely dirty, you must clean the pipes or replace the dirty pipes with new ones.) ©Industry Development Training Pty Ltd 90 of 267

Explanation of Refrigerant Cylinders ■Specifications of Refrigerant Cylinders ● Red shoulder (flammable gas). ● Left thread (an adapter piece is required to connect manifold). ● Minimum test pressure = 48 bar. ● Fill rate for recovery bottles for R32 is 60%. . ■Handling of Refrigerant Cylinders ● Laws and Regulations As liquefied gas, R32 is covered in the High Pressure Gas Safety Act. Therefore, refer to the High Pressure Gas Safety Act before use. The High Pressure Gas Safety Act sets forth standards that must be followed to prevent disasters that may be caused by high-pressure gases. ● Handling of Vessels R32, being a high-pressure gas, is supplied in a pressure vessel. The vessel itself is highly safe, but handling it without proper care may damage the vessel, which may result in unexpected accidents. Take due care to protect pressure vessels from dropping, being knocked down, impacts, and rolling. ● Storage Likewise other high-pressure gases, R32 should be preserved and stored in accordance with the standards established by laws and regulations. (Cool, dark place that is well-ventilated, with a temperature of 40ºC or lower; Implementation of fall-prevention devices, etc.) ● Caution for health and hygiene Refer to the MSDS on the back of this book (Reference). ©Industry Development Training Pty Ltd 91 of 267

Service Tools for R32 [If Switching Over from R22] R32 has a higher pressure than R22 (approx. 1.6 times), and the refrigerant oil used with R32 is ether oil instead of the SUNISO oil used with R22. If inappropriate oil is mixed with the refrigerant, it might cause sludge and other problems; therefore, service tools used with R22, such as the gauge manifold and charge hose, cannot be shared with R32. Always use dedicated tools for R32. [If Switching Over from R410A] Because R32 has approximately the same pressure as R410A, the refrigerant oil is also ether oil, and it can be accommodated with the same contamination control (preventing impurity contamination) as R410A without a large difference, tools that are used with R410A can be shared with R32 after confirmation from tooling supplier. ■Tool Compatibility Tool R32 R410A R22 Gauge manifold Sharable when temperature is recalculated Charge hose Sha able Weighing instrument Sharable Pipe bender Sharable Pipe cutter Sharable Flaring tool Sharable *1 Torque wrench Sharable *2 Cylinder cap Vacuum pump Sha able Sharable *3 Refrigerant recovery system 48 bar Sharable *4 Refrigerant recovery cylinder 40 bar Electric gas leak detector Sharable *5 *1: R22 type can be used for R32 & R410A by changing the work process. *2: Dimension of width across flats of flare nut is different between R32 & R410A and R22 (4/8” and 5/8” only. Other flare nuts can be shared.) *3: When using an R22 type for R32 & R410A, use with a reverse flow preventive adapter. *4: HFC recovery systems can be shared if they have been certified by the manufacturers to be supporting the relevant HFCs. *5: Even if a detector supports R22, if the detector does not support HFC (R32, R410A), it cannot be shared. Always check with the tooling manufacturer. ©Industry Development Training Pty Ltd 92 of 267

■Explanation of Tools for R32 Tools pictured are provided for purpose of example only. For more information about specific tools, contact the air-conditioning and refrigeration service tool dealer. Tool Information Gauge manifold ● Supports R32 (R410A) pressure - If the gauge manifold supports R410A, it can also be used with R32 if the temperature is recalculated. - High-pressure gauge: -0.1 to 5.3 MPa - Low-pressure gauge: -0.1 to 3.8 MPa ● Bore of connecting portion uses 5/16” flare screw Charge hose ● Supports R32 (R410A) pressure - If the charge hose supports R410A, it can also be used with R32. ● Bore of connecting portion uses 5/16” flare screw Weighing ● Used for measuring of weight, the weighing instrument can be shared with HFCs (R32, instrument R410A) and conventional refrigerants (R22, etc.) Pipe bender ● Can be shared between R32, R410A, and conventional refrigerants (R22, etc.) Pipe cutter ● Can be shared between R32, R410A, and conventional refrigerants (R22, etc.) Flaring tool ● Supports flare size (A size) for R32 (R410A) A size Torque wrench - If the flaring tool supports R410A, it can also be used for R32. - Flare size is different between R22 and R32 (R410A) Cylinder cap Vacuum pump ● Supports flare nut width across flats (B size) for R32 (R410A) B size - If the torque wrench supports R410A, it can also be used for Refrigerant recovery R32. system - Width across flats is different between R22 and R32 (R410A) Refrigerant recovery for 4/8” and 5/8” cylinder - No change in tightening torque value. ● Inner diameter of the part that connects to the hose is 5/16” flare thread. - If the size supports R410A type, it can also be used for R32 type. ● Equipped with oil backflow prevention function (In the case of using a vacuum pump without reverse flow preventive function, use only after connecting it to a reverse flow preventive vacuum adapter.) ● Supports R32 (R410A) pressure - If the system supports R410A and has been certified for use with R32, it can also be used with R32. ● For R32 (R410A), only the recovery cylinders with pressure resistance to 48 bar can be used. Keep in mind that the bottle might have left thread. In that case, an adapter piece is necessary. Electric gas leak detector ● Can be used with R32, R410A, and conventional refrigerants (R22, etc.) ©Industry Development Training Pty Ltd - Check what types of refrigerant the detector can be used with. - Detectors that can be used with R410A can also be used for R32 if approval from tooling manufacturer. - Even if a detector supports conventional refrigerants (R22, etc.), it cannot be used for R32 and R410A if it does not support use with HFCs. 93 of 267 - Torch type models cannot be used.

R32 Unit Installation and Service 1)Three basic rules of refrigerant piping Following the Three Basic Rules of Refrigerant Piping The three basic rules of refrigerant piping must be followed when servicing and installing refrigerant piping. (1) Drying (2) Cleaning (free (3) Tightening (no moisture) of contamination) (air-tightness) There shall be no moisture in There shall be no dust in the There shall be no refrigerant the pipe. pipe. leak. Cause Item ・Water entering from outside, O・ xidized film generated during ・ Insufficient brazing such as rain. brazing. ・ Inadequate flaring or ・ Moisture due to dew ・Entering of foreign items such insufficient tightening torque. condensation occurring inside as dust, particles and oil from I・ nadequate tightening of flange the pipe. outside. connection. C・ logging of expansion valve, C・ logging of expansion valve, capillary tube, etc. capillary tube, etc. ・ Gas shortage I・ nsufficient cooling or heating. I・ nsufficient cooling or heating. I・ nsufficient cooling or heating. T・ emperature increasing of D・ egradation of refrigerant oil. ・Degradation of refrigerant oil. ・Malfunction of compressor. ・Malfunction of compressor. discharge gas. ・Degradation ofrefrigerant oil. <For reference> ・Malfunction of compressor. Problem Not clogged Clogged Compressor is corroded due to moisture. Capillary is clogged with dust. Preventive measure Pipe preparation ・Same as the items on the left. ・Follow the basic brazing Flushing procedure ・ Do not use tools or devices Vacuum drying previously used with a different ・Follow the basic flaring type of refrigerant. procedure. ・Follow the basic flange connection procedure. ・Conduct an air-tightness test (gas leak check). ©Industry Development Training Pty Ltd 94 of 267

2) Troubleshooting <Check items for service> <Relationship of operating state, pressure, and operating current of air-conditioning system> Indoor unit To dedicated breaker for electric heater Measured from 15-20 minutes or more after operation starts. Is the air filter dirty? Transmission When cooling Low High Running wiring between Pressure Pressure Current What about voltage indoor and outdoor Air-Conditioner Status Lower and current? units Lower Lower What about switch capacity? Air Filter Fouling Lower Refrigerant What about cable thickness? Short Circuit of Indoor Unit Lower Lower piping Inlet/Outlet Air Higher Drain piping To dedicated Outdoor Unit Fin Fouling Higher Higher breaker Short Circuit of Outdoor Unit Higher Inlet/Outlet Air Higher Higher Outdoor unit Higher Earth Air Mixed in Refrigerant Higher Higher Lower Water Mixed in Refrigerant *1 Lower Lower Lower *2 Lower Lower Lower Dirt Mixed in Refrigerant Lower Lower Lack of Refrigerant (Gas) Lower Lower Unsatisfactory Compression *3 Lower When heating Low High Running Pressure Pressure Current Air-Conditioner Status Higher Higher Higher Higher Air Filter Fouling Higher Higher Short Circuit of Indoor Unit Lower Inlet/Outlet Air Lower Lower Outdoor Unit Fin Fouling Lower Short Circuit of Outdoor Unit Lower Lower Inlet/Outlet Air Higher Higher Higher Lower Air Mixed in Refrigerant *1 Lower Lower Lower Water Mixed in Refrigerant *2 Lower Lower Lower Lower Lower Dirt Mixed in Refrigerant Lower Lower Lack of Refrigerant (Gas) *3 Lower Unsatisfactory Compression *1 Water in the refrigerant freezes inside the capillary tube or expansion valve, and is basically the same phenomenon as pump down. *2 Dirt in the refrigerant clogs filters inside the piping, and is basically the same phenomenon as pump down. *3 Pressure differential between high and low pressure becomes slight. <Refrigerant Properties of R32, R410A, and R22 (Pressure-Temperature Graph)> Absolute pressure (MPa) R32 R410A R22 ©Industry Development Training Pty Ltd 95 of 267 °

3) Safety Precautions: WHAT IF ● When executing a repair indoors Make sure that there is always forced (fan) ventilation (+ 500 m³/h) to guarantee the supply of fresh air and extraction of R32 out of the room to avoid concentration rise above the LFL. ● When executing a repair outdoors Forced ventilation is only required when there is a possibility of refrigerant accumulation due to the surrounding walls, or when unit is installed in a pit. ● Accidental release of R32 Ensure enough ventilation. Cut all power to the unit and try to extinguish any open flame when any accidental release of R32 should occur. Evacuate the room and wait to return to the unit until all refrigerant has evaporated and evacuated. ● Air inside the refrigerant system Air (Oxygen) must be avoided at all times inside any refrigerant circuit. ■ It is strongly advised to measure the saturated pressure/temperature when a unit has been pumped down or when there is any doubt that air might have entered the system. ■ Use the pressure/temperature graph to verify that any other gas has entered the system. ©Industry Development Training Pty Ltd 96 of 267

● R32 blocked inside the refrigerant system Always verify if refrigerant might be trapped inside the refrigerant circuit by flushing with nitrogen prior to brazing works + assure that nitrogen flow comes through. ➔Recover the refrigerant to verify the recovered quantity with the charged quantity. ➔Always cut out the parts that need to be repaired. ➔If cutting out the parts is impossible, then puncture the pipe. ● Additional precautions Precautions when performing electrical work or replacing electric components. ■ Keep a sufficient distance away from causes of fire (ignition sources) such as gas burning equipment and electric heaters in places where installation, repairs, or similar work on air-conditioning equipment is performed. ■ Check that there are no dangerous or combustible items nearby, and ensure a fire extinguisher is close at hand. ■ If the gas comes into contact with open flame or other material heated to > 300 to 400ºC, it will cause thermal decomposition, possibly producing toxicgas. ■ Toxic gas generation is the same with R410A, R22 and not limited to R32. Replace spare parts specified by manufacturer ■ Do not try to modify or to add any inductive/capacitance loads to thecircuit. ■ Replace components only with parts specified by the manufacturer. Cautions during vacuuming and charging ■ Do not overfill the refrigeration system. ■ Ensure that contamination of different refrigerants does not occur when using charging equipment. ©Industry Development Training Pty Ltd 97 of 267

Reference 1 ■ Thermodynamic Properties of R32 <R32 Saturation Chart> R32 Thermodynamic Properties (Saturation Chart) Temperature Pressure Specific volume Specific enthalpy Specific enthalpy Inserted function ©Industry Development Training Pty Ltd 98 of 267

Pressure MPa Specific enth ©Industry Development Training Pty Ltd

■Thermodynamic Properties of R32 <Pressure-Enthalpy Graph> 99 of 267 halpy kJ/kg