Cert 2 Split Systems Procedures Step by Step AUTC

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 51

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. 52

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 orgrease • Ensure all valves are closed • Fit tip to suit task 53

• 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 begone) • Gradually open the Oxygen until the desired flame is achieved as shown below • The Neutral Flame is suitable for mostSilver Soldering • Oxidising is the name for excessive Oxygen and • Carburising is the name for excess Acetylene 54

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 55

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. 56

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 or brazing is the preferred method and best method for joining copper. It 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 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. 57

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 58

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. 59

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 (2-5% silver) is free flowing than brown tip that 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 (15% silver) is used for high shear strength flux free brazing of copper. It is the best brazing rod used for split system 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 (45% silver) 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 together. The correct flux must be used on all applications. Process should be as follows. Clean both metal surfaces, apply flux, use blue tip filler rod (45% with oxidising flame to heat both metals and ensure good even flow of filler rod 60

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 corrosion and failure. 15 percent silver content is used due to the use of high pressures in the refrigerant pipework. Not brazing the pipe incorrectly can cause cracking and weakening the joints Brazing temperature isgenerally3200 degrees C 61

1. Cut tne tube ends square, de-burr, and if soi tedl or excessive oxidehas bt.Jilt up, clean the surface wi th a [ight grade emery tape or wirebrush. 2. IPush the tube tightly into the fitting oc the eJCpanded endl or the other tube and apply heat. Brazing torches fueled with air-acetylene, µc-opane- o�gen or ox•(acetylene torch.es are aII suitabte 3. Apply heat uniformly to both tube and fitting, by moving the tord-i around to ensure even heating before adding the sitver solder. 4. As the heated ar ea gradualty changes corour to a bright red, apply silver solder by [ightly brushing the t•p of the stick into the sho1.1lder of the fitting. If sufficient heat is bein,g applied, the solder should! melt on contact andl fl.ow into the capi[lary :space between the tube and the fitting. Keep a crierry red colour, not a bright red. As the heat is app[ied evenly around the joint.. tne molten br212ing alfoy will be automatic;i[ly dra11m in b•, \"c;ipi[lary action\". Care shou!dl be taken not to overneat �he tube. S. To complete the joint, an even buil�up, of so!der should be justt visible around ttie shoufder o:f the \"itting. IRemo•,e the heat (takin,g care not to cfist•urb the joint) until the molten brazing alloy so[icfifies to a ten black color !approx. 10-15 secondsj.. After brazing is: completed, the joints are normaD•( left to cool in the air. 1-{o wever, if ne:::es_sary the joints m,;,y be quendled in water or cooled! with a wet rag. 6. To braze an U1pi.-.·ard<S vertical joint follow the same pro:ed1.1res, although moce heat should! be con:::entrated on the fitting than the tube. This wi[I draw the molten brazing allo•; 1.1pwards into the ca pill ar)•gap. 62

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 mapgas. 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. 63

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 64

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 65

• 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 66

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SPLIT SYSTEM INSTALL 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. 68

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 Read all manufacturers specifications as they show safe working and correct installation procedures Prior to starting the job you should have the following. Work order, Plans and diagrams, Instruction manuals, Installation manuals, Checklists, OHS documents. 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. All policies and procedures for the workplace should be written by Employers and Employees jointly together. Using social media, must always be followed in the companies policies and procedures document and should be adhered to in the workplace and on site. WARNING: Alwayscheck for electrical,gasor water 69

Split System Installation Procedures STEP BY STEP 70

MANIFOLD GAUGES Blue hose always goes on the RHS (Low pressure) Yellow hose goes on the middle (Common ) Red hose goes on LHS (High pressure) 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 on the inside - the chemical process of forming black copper oxide (scale) when heating copper in the presence air. Scale can form also on the outside. PERSONAL SAFETY Nitrogen is supplied in cylinders that may have an internal pressure as high as twenty thousand kilopascals (20,000 KPA-2900 PSI). A regulator must be used to regulate the cylinder pressure through refrigeration gauges into a system. Applying Dry Nitrogen to a Piping Circuit You must attach a regulator to the nitrogen bottle, and a set of refrigeration gauges. Attach the common line (yellow) to the regulated (outlet), and the blue hose to the high side gauge on the manifold which is (red), the other end of the blue hose goes to the air-conditioner system service valve. Open the bottle and ensure the pressure is sufficient for the task. Open the high side gauge on the cylinder 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). For field testing use 550 PSI (3700 kPa) 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. When using a regulator always before starting remember safety 1 Check cylinder is closed (valve righty tighty lefty loosey ) 2 Check regulator is closed (regulator valve opposite direction - lefty tighty righty loosey) When using a regulator always after finishing remember safety 1 Check cylinder is closed (valve righty tighty lefty loosey ) 2 Check regulator is closed (regulator valve opposite direction - lefty tighty righty loosey) 71

COMMISSIONING 1. Hang indoor bracket and mount indoor unit 2. Locate and secure outdoor unit 3. Connect pipework (flare, use Nylog, use digital torque wrench) The process of commissioning has a few steps. In order to do this you will need the following tools: • Nitrogen Bottle and Regulator • Gauge manifold (Gauge Group) • Bubble up (Soapy water and sponge) • Mirror (To check behind pipes) • Vacuum pump • Thermometer On startup check Pressures and Temperatures and do a drain test LEAK TESTING (Pressure test with Nitrogen) After the unit has been fitted and all piping run completed, you must check the system has no leaks before the release of refrigerant from the condenser into your pipework. The most common method is to use nitrogen. This method is simple with just a few steps: START WITH ALL GUAGES CLOSED 1. Attach \"BLUE' and YELLOW hoses to manifold. 2. Move the \"BLUE\" hose from the manifold to the high pressure side \"RED\" on the manifold. (this will ensure when testing with nitrogen you don't accidentally blow up your gauge with high pressure from the nitrogen) 3. Connect the other end of the \"BLUE\" hose from the manifold to the unit shraeder valve (service port). Ensure all valves on the manifold are closed. 4. Connect the other end of the \"YELLOW\" hose from the manifold to the nitrogen cylinder regulator. Ensure the nitrogen cylinder vave and regulator are closed 5. Open the nitrogen cylinder and open the regulator slowly to the pressure of 550 PSI (3700kpa). 6. Open the \"Red\" valve on the manifold and allow system to charge with nitrogen 7. Leave \"Red\" valve open on the manifold and nitrogen cylinder valve open for 15 minutes. You may have to feather in more nitrogen to get the required pressure to a set point as the regulator is never accurate. 8. Squirt all joints with liquid detergent and check for bubbles. Take your time and look closely the leak maybe very small 9. Close the nitrogen cylinder and the \"Red\" valve on the manifold. 72

9. With all gauges and valves closed let sit for 15 minutes and make sure the pressure reading does not go lower than original position 550psi it shouldn't move) 10.If the gauge reading drops repeat step 4 onwards. If it passes the pressure test proceed to the next step. 11.Release the nitrogen from the system by opening the Red valve first, followed by the slowly opening the blue valve until all nitrogen is released 12.Once the system passes the leak test. You can remove the \"Blue\" hose from the \"Red\" side of the manifold and relocate it back to the \"Blue\" side of the manifold 13.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 and non condensables from the system and allow the refrigerant to perform at its best. Note that all the refrigerant is in the condensing unit and the service valves are closed. 1. \"BLUE\" hose already connected to manifold unit and should be on the Blue side of the manifold. 2. Connect the \"YELLOW\" hose from the center of the gauge group to the vacuum pump. 3. Make sure both manifold valves are closed 4. Turn the vacuum pump on and listen for a quiet sound 5. If the vacuum pump is gurgling (indicates a lose hose connection), 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 to minus 30. A change of noise will happen after a short time. There should be no gurgling sound and it should be back to being quiet 7. Let it run for 15 minutes while at minus 30, the vacuum noise should be quite 8. Close the \"BLUE\" gauge valve, turn the vac pump off, and the vacuum will remain at minus 30 9. If the gauge moves and is not holding minus 30, check all hoses are tight and start the vacuum process again. 10. Remove the caps from the 2 service ports with an allen key to release the gas into the system, you will hear gas being released and the pressure will now show on the gauges. There is no set order for opening the two service valves 11. Remove the vacuum pump and turn power on to the unit at the isolator 12. Go inside and turn the unit on and after 2 minutes approximately it should start to cool. Leave the unit running in cooling and perform your commissioning check list 13. Remove the \"Blue\" hose from unit while it is running in cooling mode. *Note never remove the \"Blue\" hose from the unit if it is running in heating due to high pressure(500 psi or 3600 kPa) 14. Pack up tools 73

ADDING GAS (For additional length of pipe run) 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 To do this you will need the following tools: • Gauge group • Vacuum pump • Accurate scales • Bottle of gas (Refrigerant) Once the system has been leak tested with nitrogen you can now vac down the system and add additional gas required for the extra pipe run as per manufactures specifications. 1. Connect all hoses to manifold and close all gauge valves on manifold 2. Connect \"BLUE\" hose to unit schraeder (service port) 3. Connect the \"YELLOW\" hose from to the refrigerant cylinder liquid fitting (bottom fitting). Red cylinder valve 4. Connect the \"RED\" hose the vacuum pump. 5. Turn Vacuum pump on and listen for a quiet sound 6. Open red gauge valve and then blue gauge valve. A gurgling sounds will appear then slowly disappear. Leave running for minimum 15 minutes . 7. After 15 minutes if the vacuum pump is gurgling, then check all connections are tight or the pump oil may require replacing 8. When at minus 30 and a quiet sound is achieved shut the Red valve off and turn vac pump off. *Note*Rule of thumb - Never release gas into a system unless minus 30 is showing on the blue gauge 9. Sit the refrigerant on the scales and record the weight. You may require this if your battery goes flat then you can do a correct calculation. Then zero the scales and remove your hand away from the cylinder. Open the liquid line, (bottom valve of cylinder). Weigh in the required amount listed on manufacturers specifications for adding additional charge per metre. Close the valve as quick as you can 50 grams before the required weight, then feather in the balance. 10. Remove the caps from the 2 service ports with an allen key to release the gas into the system. There is no set order for opening the two service valves 11.The blue valve onthe manifold gauge group should be still open 12.Turn the unit on at the isolator (Go inside and make sure it is in cooling mode). Go back outside and wait approx 2 minutes till the unit has been running and the gauge pressure has dropped, then close the BLUE gauge manifold valve. 74

13. After 2-10 minutes it should have started to cool. Leave the unit running in cooling and perform your commissioning check list. 14. Remove the \"Blue\" hose from the unit while it is running in cooling mode. *Note never remove the \"Blue\" hose from the unit if it is running in heating due to high pressure (500 PSI, 3600 kPa). 15. Pack up tools 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. 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. The process uses the units own compressor, so there must be power to the air conditioioing unit. 1. With the system \"ON\" turn the mode to \"COOL\" 2. Connect the \"BLUE\" hose of your gauge group onto the service port on the condenser (large pipe) if there are two service ports use the one on the large pipe. 3. Close the small pipe valve (Liquid line). 4. Watch the \"BLUE\" gauge. When it reaches O or just a bit lower. Shut the large pipe valve (Suction Pipe). 5. Once the valves are closed turn the unit \"OFF\" via the outside isolation switch. 6. 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 75

RECLAIM / RECOVERY 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. This process does not require power to the air conditioner 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. Always connect the \"Blue\" hose to the manifold first, make sure all manifold switches (valves) are in the closed position 2. Connect the other end of the \"Blue\" hose to the unit schraeder valve (service port). You will now see pressure on your blue gauge 3. Connect the \"Yellow\" hose from the manifold to the inlet port on the reclaim unit. 4. Connect one end of the \"RED\" hose to the recovery unit outlet port, and the other end to the reclaim cylinder marked vapour at the top of the cylinder (blue} do not open the valve yet. 5. Note there is air in all the lines and we don't necessarily want it to mix with the refrigerant in the recovery cylinder so use the follow instructions 6. Follow the flow 7. Open \"Blue\" manifold valve, open recovery input,(only if there is one) Switch (knob) in the middle to Recover. Open recovery output (only if there is one) 8. All the air has now been pushed to the furtherest point which is where the hose meets the cylinder. Both the the cylinder valves should be cosed closed. 9. Crack the hose and listen for a quick PSSSSSSST which means the air has been removed. Close it quickly 10.Open the top cylinder valve(Vapour) and turn the recovery unit on 11.When the \"Blue\" gauge on the manifold goes to \"O\" shut the blue valve on the gauge group. If there is a switch on the input of the recovery unit close it. 12.Change the middle switch from Recover to Purge The left hand gauge on the recovery unit will jump back up showing you pressure and should go back down to \"O\" within minutes 13.Once the left hand gauge goes back to \"O\" the second time close the cylinder and turn the recovery unit off. 14.Turn off the outlet knob on the recovery unit if it has one. 15.Slowly remove the \"Red\" hose from the recovery cylinder (there should be only one quick initial burst then a gentle hissing only 16.Disconnect everything and pack up 76

ADDING GAS WHEN RE COMMISSIONING AFTER ALL THE GAS HAS BEEN REMOVED 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 To do this you will need the following tools: • Gauge group • Vacuum pump • Accurate scales • Bottle of gas NOTE The 2 service valves must be closed during your pipework pressure test. Follow the steps above for PRESSURE TESTING first before proceeding. You can now vac down the whole system. Pipework and unit with both service/access valves open. This will remove moisture and non condensibles from the system outdoor unit and indoor unit at the same time. 1. Connect all hoses to manifold and close all gauges 2. Connect \"BLUE\" hose to unit schraeder service port. 3. Connect the \"YELLOW\" hose from to the refrigerant cylinder liquid fitting (bottom fitting), to the middle port on the gauge manifold. 4. Connect the \"RED\" hose the vacuum pump, from the red valve on the gauge manifold. 5. Make sure both access valves on the unit are open 6. Turn Vacuum pump on and listen for a quiet sound 7. Open red gauge and then blue gauge. A gurgling sounds will appear then slowly disappear. Leave running for 30 minutes. 8. After 30 minutes if the vacuum pump is gurgling, then check all connections are tight or the pump oil may require replacing 9. When at minus 30 and a quiet sound is achieved shut the Red valve off and turn vac pump off. *Note*Rule of thumb - Never release gas into a system unless minus 30 is showing on the gauge 10. Sit the refrigerant on the scales and record the weight. (Then zero the scales) Open the liquid line, (bottom valve of cylinder) and remove your hand away from the cylinder. Weigh in the required amount on the side of the unit. Close the valve as quick as you can 50 grams before the required weight, then feather in the balance. 11. Turn off the cylinder valve when the correct weight is shown on the scales. 12. Turn the isolator on. Go inside and turn the unit on in cooling mode. and wait till the unit has been running foe 2minutes and the gauge pressure has dropped then close the Blue valve and disconnect everything 13. Remove the vacuum pump and turn power onto the unit at the isolator. 14. Go inside and turn the unit on and after 2 minutes it should start to cool. Leave the unit running in cooling and perform your commissioning check list 15. Remove the \"Blue\" hose from unit while it is running in cooling mode. *Note never remove the \"Blue\" hose from the unit if it is running in heating due to high pressure 16. Pack up tools 77

REFRIGERATION BASICS & PRINCIPLES 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 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 78

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. Measured in % 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. (BTU) 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. Thermometers measure temperature in Celsius, Farenheight and Kelvin 79

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 • Vaporisation – changing water (liquid) to steam • 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 80

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. Note* Saturation is the point at which if heat is added or removed from refrigerant a change in temperature will occur. 81

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 and is a natural resource. 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. 82

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 R717 p Slate Ammonia e R22 Moss Chlorodifluo N NH3 Green R404a romethane a Orange t R134a R125 + 143a u Light Blue R410A + R134a 44% r Pink 52% a 4% l Tetrafluoroe thene H CHICIF2 C R125 + R32 F 50% 50% C H Ternary F Blend of HFC C refrigerants H CF3CH2F F C H Binary Blend 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). 83

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. 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. 84

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: • Manifold Gauge (Digital) Multifunctional manifold. Pressure ,Temperature, Vacuum, can attach wireless devices and store data • Compound measures both pressure above and below atmospheric • Manifold Gauge (Bourdon) Pressure ,Temperature, Vacuum, • Manometer a digital pressure instrument that uses microprocessor- based electronics to measure, record and store differential pressures and air velocity • Micron one thousandth of a millimeter 85

• Magnahelic displays pressure differences in cylinders • Barometer measures atmospheric pressure • 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 86

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. 87

PRESSURE TEMPERATURE CHART PT CHARTS HAVE 4 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. 4. To check proper systems operation Note There is a slight variation between different manufactures pressure temperature charts, this is due to the slight variation in the chemical makeup. Pressure and temperature test results should be used on a commissioning checklist PSI (generally American) KPA (generally UK) both used in Australia The relationship between refrigerant pressure and temperature is directly proportional. 88

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. 89

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. 90

■ 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 * A2L B2L A1 B1 SAFETY GROUP Ammonia 91

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 92

■ 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. 93

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. 94

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. 95

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.) 96

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). 97

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. If it has not been certified for R32 it must be replaced. *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. 98

■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 Accurate Scales ● Used for measuring of weight, the weighing instrument can be shared with HFCs (R32, 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. Electric gas leak detector ● Inner diameter of the part that connects to the hose is 5/16” right hand thread R410A type, left hand thread for R32 ● 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. ● Can be used with R32, R410A, and conventional refrigerants (R22, etc.) - 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 be9u9sed for R32 and R410A if it does not support use with HFCs. - 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). 100