Appendix C to Subpart B of Part 82 - SAE J2788 Standard for Recovery/Recycle and Recovery/Recycle/Recharging Equipment for HFC-134a Refrigerant
40:21.0.1.1.1.2.1.8.15 : Appendix C
Appendix C to Subpart B of Part 82 - SAE J2788 Standard for
Recovery/Recycle and Recovery/Recycle/Recharging Equipment for
HFC-134a Refrigerant Foreword
This Appendix establishes the specific minimum equipment
requirements for the recovery/recycling of HFC-134a that has been
directly removed from, and is intended for reuse in, mobile
air-conditioning systems and recovery/recycling and system
recharging of recycled, reclaimed or virgin HFC-134a. Establishing
such specifications will ensure that system operation with recycled
HFC-134a will provide the same level of performance and durability
as new refrigerant.
1. Scope
The purpose of this SAE Standard is to establish the specific
minimum equipment performance requirements for recovery and
recycling of HFC-134a that has been directly removed from, and is
intended for reuse in, mobile air-conditioning (A/C) systems. It
also is intended to establish requirements for equipment used to
recharge HFC-134a to an accuracy level that meets Section 9 of this
document and SAE J2099. The requirements apply to the following
types of service equipment and their specific applications.
a. Recovery/Recycling Equipment,
b. Recovery/Recycling - Refrigerant Charging,
c. Refrigerant Recharging Equipment Only.
1.1 Improved refrigerant recovery equipment is required to
ensure adequate refrigerant recovery to reduce emissions and
provide for accurate recharging of mobile air conditioning systems.
Therefore, 12 months following the publication date of this
standard, requirements in this standard supplements and supersedes,
SAE J2210.
2. References 2.1 Applicable Publications
The following publications form a part of this specification to
the extent specified herein. Unless otherwise indicated, the latest
issue of SAE publications shall apply.
2.1.1 SAE Publications
Available from SAE, 400 Commonwealth Drive, Warrendale, PA
15096-0001, Tel: 877-606-7323 (inside USA and Canada) or
724-776-4970 (outside USA), www.sae.org.
SAE J2099 Standard of Purity for Recycled HFC-134a (R-134a) for Use
in Mobile Air-Conditioning Systems SAE J2196 Service Hoses for
Automotive Air-Conditioning SAE J2197 Service Hose Fittings for
Automotive Air-Conditioning SAE J2296 Retest of Refrigerant
Container 2.1.2 CGA Publications
Available from CGA, 4221 Walney Road, 5th Floor, Chantilly VA
20151-2923, Tel: 703-788-2700, http://www.cganet.com.
CGA Pamphlet S-1.1 Pressure Relief Device Standard Part 1 -
Cylinders for Compressed Gases 2.1.3 DOT Publications
Available from the Superintendent of Documents, U.S. Government
Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320.
OT Standard, CFR Title 49, Section 173.304 Shippers - General
Requirements for Shipments and Packagings 2.1.4 UL Publications
Available from Underwriters Laboratories Inc., 333 Pfingsten
Road, Northbrook, IL 60062-2096, Tel: 847-272-8800,
http://www.ul.com.
UL 1769 Cylinder Valves UL 1963 Refrigerant Recovery/Recycling
Equipment 3. Specification and General Description
3.1 The equipment must be able to remove and process HFC-134a
(R-134a) from mobile A/C systems to the purity level specified in
SAE J2099.
3.2 The equipment shall be suitable for use in an automotive
service garage environment and be capable of continuous operation
in ambients from 10 °C to 49 °C (50 °F to 120 °F). If it is
designed to recharge a system, and it uses a scale for this
purpose, the scale must demonstrate the ability to maintain
accuracy per the test in 10.2.
3.3 The equipment must be certified that it meets this
specification by an EPA listed certifying laboratory.
3.4 The equipment shall have a label, which states, “Certified
by (Certifying Agent) to Meet SAE J2788 superseding SAE J2210” in
bold-type letters a minimum of 3 mm ( 1/8 in) in height.
4. Refrigerant Recycling Equipment Requirements 4.1 Moisture and
Acid
The equipment shall incorporate a desiccant package that must be
replaced before saturation with moisture, and whose mineral acid
capacity is at least 5% by weight of the dry desiccant.
4.1.1 The equipment shall be provided with a means of indicating
when the filter desiccant moisture capacity has reached the
allowable limit and desiccant replacement is required. This may
include a reliable means of detecting moisture level or an
algorithm based on the amount refrigerant recovered. The user must
be clearly alerted to replace the filter prior to the full
saturation. Warnings shall be displayed on screens and (printed on
printouts where applicable). The warnings must explain that the
machine is approaching the end of filter life. The manufacturer
must incorporate a lockout when the end of filter life is
reached.
4.1.2 The manufacturer shall use an identification system to
ensure that a new filter has been installed to reset the machine
for operation.
4.2 Filter
The equipment shall incorporate an in-line filter that will trap
particulates of 15 micron spherical diameter or greater.
4.3 Scale (if used)
The scale must maintain accuracy when moved, as per the test in
Section 10.
4.4 Purging Noncondensable Gases
4.4.1 The equipment shall automatically purge noncondensables
(NCGs), which are primarily air, if the acceptable level is
exceeded. NCG removal must be part of the normal operation of the
equipment and instructions must be provided to enable the task to
be accomplished within 30 min (to reach the refrigerant purity
level specified in SAE J2099).
4.4.2 Refrigerant loss from noncondensable gas purging during
the testing described in Section 8 shall be minimized by a method
that initiates a purge when the machine has not been in use for a
period long enough for air-refrigerant separation in the tank to
have occurred.
4.5 Recharging and Transfer of Recycled Refrigerant
Recycled refrigerant for recharging and transfer shall be taken
from the liquid phase only.
5. Safety Requirements
5.1 The equipment must comply with applicable federal, state,
and local requirements on equipment related to handling HFC-134a
material. Safety precautions or notices related to safe operation
of the equipment shall be prominently displayed on the equipment
and should also state “CAUTION - SHOULD BE OPERATED BY QUALIFIED
PERSONNEL.”
5.2 Under NO CIRCUMSTANCES should any equipment be pressure
tested or leak tested with air/HFC-134a mixtures.
Do not use compressed air (shop air) or leak detection in
systems containing HFC-134a.
6. Operating Instructions
6.1 The equipment manufacturer shall provide a warning in the
instruction manual regarding the possibility of refrigerant
contamination in the mobile A/C system being serviced.
6.1.1 If recovery/recycle equipment has refrigerant
identification equipment, the refrigerant identification equipment
shall meet the requirements of SAE J1771.
6.1.2 Recovery/recycling equipment not having refrigerant
identification capability shall have instructions in the equipment
manual covering possible contamination problems to the equipment
and the contamination of the existing recycled refrigerant in the
container in the equipment.
6.2 The equipment manufacturer must provide operating
instructions, including proper attainment of vehicle system vacuum
(i.e., when to stop the extraction process), filter/desiccant
replacement, and purging of noncondensable gases (air). Also to be
included are any other necessary maintenance procedures, source
information for replacement parts and, repair and safety
precautions.
6.2.1 The manual shall identify the proper maintaining of hose
and seals to prevent the addition of excess air, due to leaks,
during the recovery process, which would increase the NCG level in
the recovered refrigerant.
6.3 The equipment must prominently display the manufacturer's
name, address, the type of refrigerant it is designed to recycle, a
service telephone number, and the part number for the replacement
filter/drier.
7. Functional Description
The ability of the equipment to meet the refrigerant recovery
and recharge specifications of this section shall be determined by
the test procedures of Section 10.
7.1 The equipment must be capable of continuous operation in
ambient temperatures of 10 °C (50 °F) to 49 °C (120 °F). Continuous
is defined as completing recovery/recycle and recharge (if
applicable) operations with no more than a brief reset period
between vehicles, and shall not include time delays for allowing a
system to outgas (which shall be part of the recovery period
provided by this standard). Continuous may include time out for an
air purge if necessary, although it is understood that extended
equipment-off time is preferred to allow NCG and refrigerant
separation in the supply tank for optimum results.
7.1.1 The equipment shall be capable of removing a minimum of
95.0% of the refrigerant from the test system in 30 minutes or
less, without external heating, or use of any device (such as
shields, reflectors, special lights, etc.) which could heat
components of the system. The recovery procedures shall be based on
21 to 24 °C (70 to 75 °F) ambient temperature. The test system for
qualifying shall be a 1.4 kg (3.0 lbs) capacity orifice
tube/accumulator system in a 2005 Chevrolet Suburban with front and
rear A/C, or the test option described in 10.5, and shall be
determined by accurately weighing the recovery machine with the
resolution and accuracy of within 3 g (.006 lb) in the range of the
machine's weight. The laboratory shall maintain records of the
vehicle, including its VIN (vehicle identification number).
7.1.2 However, the preceding shall not preclude a brief period
of engine operation at fast idle (up to 15 minutes, up to 2000 rpm)
to circulate refrigerant and oil, and provide some engine and
warm-up of A/C refrigeration components. The laboratory shall
monitor coolant temperature per the vehicle engine coolant
temperature sensor, and coolant temperature shall not be allowed to
exceed 105 °C (221 °F). The time required shall not be included in
the total time of 30 minutes set forth in 7.1.1.
7.1.3 The refrigerant that is recovered, following oil
separation, shall be measured and the quantity displayed, accurate
to within ±30 g (1.0 oz). The equipment must include a provision
for checking the accuracy, per the requirements of 9.1.
7.2 During recovery operation, the equipment shall provide
overfill protection to assure that the liquid fill of the storage
container (which may be integral or external) does not exceed 80%
of the tank's rated volume at 21 °C per Department of
Transportation (DOT) Standard, CFR Title 49, Section 173.304 and
the American Society of Mechanical Engineers.
7.3 Portable refillable tanks or containers used in conjunction
with this equipment must be labeled “HFC-134a (R-134a),” meet
applicable Department of Transportation (DOT) or Underwriters
Laboratories (UL) Standards, and shall incorporate fittings per SAE
J2197.
7.3.1 The cylinder valve shall comply with the standard for
cylinder valves, UL 1769.
7.3.2 The pressure relief device shall comply with the Pressure
Relief Device Standard Part 1 - Cylinders for Compressed Gases, CGA
Pamphlet S-1.1.
7.3.3 The tank assembly shall be marked to indicate the first
retest date, which shall be 5 years after the date of manufacture.
The marking shall indicate that retest must be performed every
subsequent 5 years. SAE J2296 provides an inspection procedure. The
marking shall be in letters at least 6 mm ( 1/4 in) high.
7.3.4 ASME tanks as defined in UL-1963 may be used and are
exempt from the retest requirements.
7.3.5 If the machine is designed for recharging, and the
marketer permits use of a non-refillable refrigerant tank, the
machine shall include a way to ensure refrigerant remaining in the
tank (called the “heel”) to no more than 2% of tank rated capacity
when the tank is indicated to be empty. This may be done by the
machine marketer as follows:
• Specify a non-venting procedure, to minimize the amount of
unused refrigerant remaining in the tank. The machine shall include
any devices required for the procedure, other than ordinary service
shop tools and supplies, and include in the operator's manual, any
instructions.
• Provide an automatic or (with instructions in the operator's
manual) semi-automatic non-venting procedure with the machine.
The laboratory shall test for the 2% capability. For testing
purposes it may use a refillable tank, minimum 15 lb capacity (6.8
kg) containing a minimum of 7.5 lbs (3.4 kg) refrigerant. The test
is as follows:
a. Weigh the tank at the start of the test, on a scale accurate
to plus/minus 3 grams, to ensure it contains sufficient
refrigerant.
b. Operate the machine to remove refrigerant from the tank,
charging into a holding container until the tank is indicated to be
empty. Continue with the marketer's recommended procedure for the
2% capability.
c. Weigh the tank, on a scale accurate to plus/minus 3
grams.
d. Using the recovery compressor and/or a vacuum pump, draw the
tank into a vacuum of 9 to 10 inches Mercury (225 to 250 mm
Mercury). The tank must hold that vacuum with a decay of less than
10% in 10 minutes. If vacuum decays 10% or more, the procedure
shall be repeated as necessary to ensure the tank is empty.
e. Weigh the tank on a scale accurate to plus/minus 3 grams. The
difference in weight from Steps 3 to 5 shall be within 2% of the
weight of the amount of refrigerant that is the tanks rated
capacity.
f. This test may be performed at the conclusion of testing in
10.4 or 10.5. If the machine passes or has passed all other testing
in this standard, the marketer may make modifications in procedure
and/or machine operation and retest once at a later date, within 90
days. If the machine fails the retest, the machine must be
completely retested per this standard, or may be certified per the
following alternative. The marketer of the machine may specify use
of a non-refillable refrigerant tank that provides for recycling
and/or disposal of the residual refrigerant, in either case in a
manner that does not vent. Or the marketer may exclude use of a
one-way container, in the machine's operating instructions.
7.4 All flexible hoses must comply with SAE J2196.
7.5 Service hoses must have shutoff devices located at the
connection point to the system being serviced. Any hoses or lines
connected to refrigerant containers on or in the machine also shall
have shutoff devices at the connection points, so that the
containers may be changed without loss of refrigerant. A tank that
is a permanent installation is exempt from this requirement.
7.6 The equipment shall separate oil from the refrigerant,
measure the amount accurate to 20 ml (0.7 oz.), so the technician
has an accurate basis for adding oil to the system.
7.6.1 This statement shall be predominately identified in the
equipment service manual.
Note:
Use only new lubricant to replace the amount removed during the
recycling process. Used lubricant should be discarded per
applicable federal, state and local requirements.
8. Testing
This test procedure and its requirements are to be used to
determine the ability of the recycling equipment to adequately
recycle contaminated refrigerant.
8.1 The equipment shall be able to clean the contaminated
refrigerant in § 8.3 to the purity level defined in SAE J2099.
8.2 The equipment shall be operated in accordance with the
manufacturer's operating instructions.
8.3 Contaminated HFC-134a (R-134a) Sample
8.3.1 The standard contaminated refrigerant shall consist of
liquid HFC-134a with 1300 ppm (by weight) moisture (equivalent to
saturation at 38 °C, 100 °F), 45000 ppm (by weight) HFC-134a
compatible lubricant, and 1000 ppm (by weight) of noncondensable
gases (air).
8.3.1.1 The HFC-134a compatible lubricant referred to in 8.3.1,
shall be polyalkylene glycol (PAG), ISO 100 such as UCLN or PAG ISO
46-55, such as Idemitsu or equivalent, which shall contain no more
than 1000 ppm by weight of moisture.
8.3.1.2 Although the test lubricant is a PAG, to conform to that
used in the test vehicle system, the equipment manufacturer also
shall ensure that it is compatible with polyol ester lubricant,
such as ND 11 as used in electrically driven compressors in some
hybrid vehicles.
8.4 Test Cycle
8.4.1 The equipment must be preconditioned by processing 13.6 kg
(30 lb) of the standard contaminated HFC-134a at an ambient of 21
to 24 °C (70 to 75 °F) before starting the test cycle. 1.13 kg
(2.56 lb) samples are to be processed at 5 min intervals. The test
fixture, depicted in Figure 1, shall be operated at 21 to 24 °C (70
to 75 °F).
8.4.2 Following the preconditioning procedure per 8.4.1, 18.2 kg
(40 lb) of standard contaminated HFC-134a are to be processed by
the equipment.
8.5 Sample Requirements
8.5.1 Samples of the standard contaminated refrigerant from
8.3.1 shall be processed as required in 8.6 and shall be analyzed
after said processing as defined in 8.7, 8.8, and 8.9. Note
exception for noncondensable gas determination in 8.9.4.
8.6 Equipment Operating Ambient
8.6.1 The HFC-134a is to be cleaned to the purity level, as
defined in SAE J2099, with the equipment operating in a stable
ambient of 10, 21, and 49 °C (50, 70 and 120 °F) while processing
the samples as defined in 8.4.
8.7 Quantitative Determination of Moisture
8.7.1 The recycled liquid phase sample of HFC-134a shall be
analyzed for moisture content via Karl Fischer coulometric
titration, or an equivalent method. The Karl Fischer apparatus is
an instrument for precise determination of small amounts of water
dissolved in liquid and/or gas samples.
8.7.2 In conducting this test, a weighed sample of 30 to 130 g
is vaporized directly into the Karl Fischer anolyte. A coulometric
titration is conducted and the results are reported as parts per
million moisture (weight).
8.8 Determination of Percent Lubricant 8.8.1 The amount of
lubricant in the recycled HFC-134a sample shall be determined via
gravimetric analysis. The methodology must account for the
hygroscopicity of the lubricant.
8.8.2 Following venting of noncondensable gases in accordance
with the manufacturer's operating instructions, the refrigerant
container shall be shaken for 5 min prior to extracting samples for
testing.
8.8.3 A weighed sample of 175 to 225 g of liquid HFC-134a is
allowed to evaporate at room temperature. The percent lubricant is
calculated from weights of the original sample and the residue
remaining after evaporation.
8.9 Noncondensable Gases - Testing for Amount
8.9.1 The amount of noncondensable gases shall be determined by
gas chromatography. A sample of vaporized refrigerant liquid shall
be separated and analyzed by gas chromatography. A Porapak Q column
at 130 °C (266 °F) and a hot wire detector may be used for the
analysis.
8.9.2 This test shall be conducted on liquid phase samples of
recycled refrigerant taken from a full container as defined in 7.2
within 30 min following the proper venting of noncondensable
gases.
8.9.3 The liquid phase samples in 8.9.2 shall be vaporized
completely prior to gas chromatographic analysis.
8.9.4 This test shall be conducted at 10 and 49 °C (50 and 120
°F) and may be performed in conjunction with the testing defined in
8.6. The equipment shall process at least 13.6 kg (30 lb) of
standard contaminated refrigerant for this test.
8.9.5 The equipment shall be capable of charging refrigerant
into systems with various lubrication types and shall deliver less
than 1% by weight residual oil during system charge if the machine
permits oil charging with refrigerant (due to residual oil in the
service hoses and recovery unit refrigerant circuit from prior
recovery, diagnostics and oil injection. This shall be determined
during SAE J2099 testing.)
9. Recharging the System
9.1 It is the responsibility of the equipment manufacturer to
ensure that the vacuum removal performance leaves the system 98%
free of NCGs before recharging, following recovery and recycle
under the provisions of this document.
The equipment must be capable of both indicating and recharging
the system to within 15 g (0.50 oz) of vehicle manufacturer's
specifications. The laboratory shall test for this capability by
choosing a charge amount that is within the range of the vehicle
manufacturer's specifications. The equipment must indicate and
charge the system with that chosen amount, within ±15 g (0.5
oz).
Example:If 500 g is chosen, the actual and indicated charge must be
485 to 515 g, with any difference between actual and indicated
charge within the laboratory scale accuracy requirements of this
standard. If a scale is used in the machine, the equipment
manufacturer shall provide a method or service for the technician
to check scale accuracy, and include any necessary
accuracy-checking device (such as a calibration weight(s)) with the
machine. If a mass flow system is used for charge determination, it
must maintain accuracy equal to the 15 g (0.50 oz) specification.
The equipment manufacturer shall provide a method for checking
accuracy and include any necessary accuracy testing device(s) with
the machine. If the accuracy testing device(s) for a scale or mass
flow machine includes a consumable, the manufacturer shall include
a quantity of replacement or refill devices for five years of
periodic testing as recommended.
9.2 If any other system is used for charge determination, such
as a positive displacement pump, the equipment manufacturer shall
provide a method and any needed device(s) to check accuracy that
is/are appropriate for its method of operation, including any
temperature-compensating trim if used.
10. Equipment Test Procedure by Laboratory for Recovery/Recycling
and Recovery/Recycling/Recharging Machines
10.1 Preliminary: Ambient (in shop) temperature shall be 21 to
24 °C (70 to 75 °F). Test vehicle shall be “overnight cold” (not
run for at least eight hours).
10.2 The machine must have a self-contained provision for
checking accuracy of the indicated amount of refrigerant recovered
in liquid or vapor or mixture form(s) from a vehicle system and (if
applicable) charged into a vehicle, and adjusting if necessary, to
meet requirements of 9.1, 9.2. Therefore: If the machine uses a
scale for that purpose, check the accuracy of that scale and make
any adjustment if necessary. If an alternative method of measuring
refrigerant is used, follow the equipment manufacturer's procedure
for ensuring accuracy. Next, move the machine, such as by rolling
it, along the floor, a minimum of 20 feet (6.1 meters) within 10
seconds. Follow with the test procedure in 10.3, then 10.4 or
10.5.
10.3 Test Procedure
If desired, this test procedure may be preceded by engine/system
operation for up to 15 minutes, up to 2000 rpm.
1. You must start with an empty system, using this method: (a)
Operate machine to recover refrigerant, per equipment
manufacturer's instructions. (b) Deep-vacuum system to a minimum of
710 mm (28 in) of mercury. (c) Monitor vacuum for decay, checking
every 20 minutes. If decay exceeds 75 mm (3 in), deep vacuum the
system again. When system holds 710 mm (28 in) 75 mm (3 in) of
mercury vacuum for three hours, it is considered empty.
2. Place machine on a platform scale with the capacity to weigh
the recovery/recycle/recharge machine, and with the resolution and
accuracy of within ±3 g (.006 lb) in the range of the machine's
weight. Weight should include the machine's service hoses draped
over the machine, and with the machine's oil reservoir removed. If
necessary to add oil to vehicle system as a result of a system
operation preparatory to the recovery process, inject the needed
quantity through the service valve at this time.
3. Record weight of machine in as weight A.
4. Reconnect service hoses to the test vehicle.
5. Follow the equipment manufacturer's specified procedure for
charging the vehicle manufacturer's recommended amount of
refrigerant into the system. Note: if this does not apply to the
machine under test, i.e. a recovery/recycling only machine,
the use of charging equipment that meets this standard and the
platform scale shall be used to verify the accuracy of the
charge.
6. Disconnect the service hoses from the test vehicle and drape
them on the machine. Check and record the weight of the machine.
Record this weight as weight B. The difference between weight A and
weight B should be equal to the recommended charge that was
installed per the machine's display, within 15 g (0.5 oz). If the
difference is greater than 15 g (±3 g), the machine fails the
charge accuracy test, and no other tests shall be performed at that
time. The manufacturer must document changes made to improve
accuracy and furnish them to the laboratory prior to a new test.
Exception: If the maximum deviation is no more than a total of 20
g, the calibration of the scale or other measuring system may be
rechecked and readjusted once, and the entire test repeated just
once.
10.4 Recovery Test Using a Vehicle
1. Following a successful system charge, the system and engine
shall be run for 15 minutes at 2000 rpm to circulate oil and
refrigerant, following which engine and system shall rest for eight
hours. Then the laboratory may begin the recovery test. If the
machine manufacturer specifies, operate the engine/system for up to
15 minutes, at up to 2000 rpm, then shut off engine/system.
2. If the machine has an automatic air purge, disable it. Check
the weight of the machine with the platform scale (service hoses
draped over machine, oil reservoir removed). Record the number as
Weight C. Reinstall oil reservoir if it had been removed in the
recovery procedure.
3. Start timer. Connect service hoses to system of test vehicle
and perform recovery per the equipment manufacturer's instructions.
The vehicle system service valves' cores must remain in the
fittings for this procedure.
4. When recovery is completed, including from service hoses if
that is part of the recommended procedure, disconnect hoses and
drape over machine. Stop timer. The elapsed time shall be 30.0
minutes or less. If it is in excess of this time, the machine fails
the test and no retest is allowed. The manufacturer must document
changes made to the machine to improve its performance before a new
test is allowed, and furnish them to the laboratory.
5. If the recovery is completed in no more than the 30.0
minutes, measure the oil level in the reservoir, remove the
reservoir and then determine the amount of refrigerant recovered,
as detailed in Nos. 6 and 7: As measured by the machine and also by
noting the weight of the platform scale, which shall be recorded as
Weight D.
6. The platform scale shall indicate that a minimum of 95% of
the amount charged into the system has been recovered. If the
platform scale indicates a lower percentage has been recovered, the
machine fails the recovery test.
7. The machine display shall indicate that a minimum of 95.0% of
the amount charged into the system has been recovered, within a
tolerance of ±30 g (1 oz) when compared with the platform scale
(Weight D minus Weight C). The 30 g (1 oz) tolerance may produce a
machine display reading that is below the 95.0% recovery. If a
greater difference between machine and platform scale occurs, the
machine fails the recovery test.
10.5 Recovery Test Fixture Test Option
If an equipment manufacturer chooses, as an alternative to the
actual vehicle, it may certify to SAE J2788 with a laboratory
fixture that is composed entirely of all the original equipment
parts of a single model year for the 3.0 lb capacity front/rear A/C
system in the 2005-07 Chevrolet Suburban. All parts must be those
OE-specified for one model year system and no parts may be
eliminated or bypassed from the chosen system, or reproduced by a
non-OE source. No parts may be added and/or relocated from the OE
position in the 2005-07 Suburban. No parts may be modified in any
way that could affect system performance for testing under this
standard, except adding refrigerant line bends and/or loops to make
the system more compact. Reducing the total length of the lines,
however, is not permitted. The fixture system shall be powered by
an electric motor, run at a speed not to exceed 2000 rpm, and for
this test option, no system warm-up or equivalent procedure may be
used. The certifying laboratory shall maintain records of all parts
purchased, including invoices and payments. The assembly of the
parts shall, as an outside-the-vehicle package, duplicate the OE
system and its routing, including bends, except for permitted
additions of bends and/or loops in refrigerant lines. Aside from
the absence of engine operation and the limitations posed by the
standard and the use of the electric motor, the test shall
otherwise be the same as the test on the Suburban, including test
temperature.
[72 FR 63495, Nov. 9, 2007]
Appendix C to Subpart F of Part 82 - Method for Testing Recovery Devices for Use With Small Appliances
40:21.0.1.1.1.6.1.15.25 : Appendix C
Appendix C to Subpart F of Part 82 - Method for Testing Recovery
Devices for Use With Small Appliances Recovery Efficiency Test
Procedure for Refrigerant Recovery Equipment Used on Small
Appliances
The following test procedure is utilized to evaluate the
efficiency of equipment designed to recover ozone depleting
refrigerants (or any substitute refrigerant subject to the
recycling rules promulgated pursuant to section 608 of the Clean
Air Act Amendments of 1990) from small appliances when service of
those appliances requires entry into the sealed refrigeration
system or when those appliances are destined for disposal. This
procedure is designed to calculate on a weight or mass basis the
percentage of a known charge of CFC-12 refrigerant removed and
captured from a test stand refrigeration system. Captured
refrigerant is that refrigerant delivered to a container suitable
for shipment to a refrigerant reclaimer plus any refrigerant
remaining in the recovery system in a manner that it will be
transferred to a shipping container after additional recovery
operations.
The test stand refrigeration system required for this procedure
is constructed with standard equipment utilized in currently
produced household refrigerator and freezer products. The procedure
also accounts for compressor oils that might be added to or removed
from the test stand compressor or any compressor used in the
recovery system.
I. Test Stand
Test stands are constructed in accordance with the following
standards.
1. Evaporator - 5/16 in. outside dia. with 30 cu. in.
volume.
2. Condenser - 1/4 in. outside dia. with 20 cu. in volume.
3. Suction line capillary heat exchanger - appropriate for
compressor used.
4. An 800-950 Btu/hr high side case (rotary) compressor; or
(depending on the test senario);
5. An 800-9500 Btu/hr low side case (reciprocating)
compressor.
A person seeking to have its recovery system certified shall
specify the compressors by manufacturer and model that are to be
used in test stands constructed for evaluation of its equipment,
and the type and quantity of compressor to be used in those
compressors. Only a compressor oil approved for use by the
compressor's manufacturer may be specified, and the quantity of
compressor oil specified shall be an appropriate quantity for the
type of oil and compressor to be used. In order to reduce the cost
of testing, the person seeking certification of its recovery system
may supply an EPA approved third party testing laboratory with test
stands meeting these standards for use in evaluating its recovery
system.
II. Test Conditions
Tests are to be conducted at 75 degrees F, plus or minus 2
degrees F (23.9 C ±1.1 C). Separate tests are conducted on both
high side case compressor stands and low side case compressor
stands. Separate tests are also conducted with the test stand
compressor running during the recovery operation, and without the
test stand compressor running during the recovery operation, to
calculate the system's recovery efficiency under either
condition.
These tests are to be performed using a representative model of
all equipment used in the recovery system to deliver recovered
refrigerant to a container suitable for shipment to a refrigerant
reclaimer. The test stands are to be equipped with access valves
permanently installed as specific by the recovery system's vendor
to represent the valves used with that system in actual field
operations.
A series of five (5) recovery operations are to be performed for
each compressor scenario and a recovery efficiency is calculated
based on the total quantity of refrigerant captured during all five
(5) recoveries. Alternatively, at the request of the recovery
system's vendor, a recovery efficiency is to be calculated for each
recovery event. In this case, a statistically significant number of
recovery operations are to be performed. Determination of what is a
statistically significant number of recoveries is to be calculated
as set out below. These individual recovery efficiencies are then
averaged.
There are four (4) compressor scenarios to be tested. These are
a high side case compressor in working condition; a high side case
compressor in nonworking condition; a low side case compressor in
working condition; and a low side case compressor in nonworking
condition. Recovery efficiencies calculated for the two working
compressor scenarios are to be averaged to report a working
compressor performance. The two nonworking compressor efficiencies
are also to be averaged to report a nonworking compressor
performance.
If large scale equipment is required in the system to deliver
recovered refrigerant to a refrigerant reclaimer (eg. carbon
desorption equipment) and it is not possible to have that equipment
evaluated under the procedure, the system's vendor shall obtain
engineering data on the performance of that large scale equipment
that will reasonably demonstrate the percentage refrigerant lost
when processed by that equipment. That data will be supplied to any
person required to evaluate the performance of those systems. The
following procedure will also be modified as needed to determine
the weight of refrigerant recovered from a test stand and delivered
to a container for shipment to the large process equipment for
further processing. The percentage loss documented to occur during
processing is then to be applied to the recovery efficiencies
calculated in this modified procedure to determine the overall
capture efficiency for the entire system.
The following are definitions of symbols used in the test
procedure.
Test Stand: “TSO” means an original test stand weight. “TSC” means
a charged test stand weight. Shipping Containers: “SCO” means the
original or empty weight of shipping container(s). “SCF” means the
final or full weight of shipping container(s). Recover/Transfer
System: “RSO” means the original weight of a recovery/transfer
system. “RSF” means the final weight of a recovery/transfer system.
“OL” means the net amount of oil added/removed from the recovery
device and/or transfer device between the beginning and end of the
test for one compressor scenario. Weighing steps are conducted with
precision and accuracy of plus or minus 1.0 gram. III. Test
Procedure
1. Evacuate the test stand to 20 microns vacuum (pressure
measured at a vacuum pump) for 12 hours.
2. Weigh the test stand (TSO).
3. If this is the first recovery operation being performed for a
compressor scenario (or if a recovery efficiency is to be
calculated for each recovery event), then weigh all devices used in
the recovery system to deliver recovered refrigerant to a container
suitable for shipment or delivery to a refrigerant reclaimer. Weigh
only devices that can retain refrigerant in a manner that it will
ultimately be transferred to a shipping container without
significant release to the atmosphere (RSO).
4. Weigh final shipping containers (SCO).
5. Charge the test stand with an appropriate CFC-12 charge
(either 6 oz. or 9 oz.).
6. Run the test stand for four (4) hours with 100% run time.
7. Turn off the test stand for twelve (12) hours. During this
period evaporate all condensation that has collected on the test
stand during step 6.
8. Weigh the test stand (TSC).
9. Recover CFC-12 from the test stand and perform all operations
needed to transfer the recovered refrigerant to one of the shipping
containers weighed in step 4. All recovery and transfer operations
are to be performed in accordance with the operating instructions
provided by the system's vendor. The compressor in the test stand
is to remain “off” or be turned “on” during the recovery operation
depending on whether the test is for a nonworking or working
compressor performance evaluation. If a recovery efficiency is to
be calculated for each recovery event, transfer the captured
refrigerant to a shipping container and then skip to step 13.
Otherwise continue. If the system allows for multiple recovery
operations to be performed before transferring recovered
refrigerant to a shipping container, the transfer operation can be
delayed until either the maximum number of recovery operations
allowed before a transfer is required have been performed, or the
last of the five (5) recovery operations has been performed.
10. Perform any oil removal or oil addition operations needed to
properly maintain the test stand and the devices used for recovery
or transfer operations. Determine the net weight of the oil added
or removed from the recovery device and/or transfer device. (OP1
for oil added, OP2 for oil removed).
11. Evacuate the test stand to 20 microns vacuum for 4
hours.
12. Return to step 2 unless five (5) recovery operations have
been performed.
13. Weigh all final shipping containers that received recovered
refrigerant (SCF).
14. Weigh the equipment weighed in step three (3) above (RSF).
If a recovery efficiency is to be calculated for each recovery
event, perform calculations and return to step one (1) for
additional recoveries.
IV. Calculations A.
For Five (5) Consecutive Recoveries
Refrigerant Recoverable equals the summation of charged
test stand weights minus original test stand weights.
Oil Loss equals the net weight of oil added to and
removed from the recovery device and/or transfer device.
Refrigerant Recovered equals the final weight of shipping
containers minus the initial weight of final shipping containers,
plus final recovery system weight, minus original recovery system
weight, plus the net value of all additions and removals of oil
from the recovery and transfer devices.
n = number of shipping containers used.
Recovery Efficiency equals Refrigerant Recovered divided
by Refrigerant Recoverable times 100%.
B.
For Individual Recoveries
Refrigerant Recoverable equals the charged test stand
weight minus the original test stand weight.
Refrigerant Recovered equals the final weight of the
shipping container minus the initial weight of the shipping
container plus the final weight of the recovery system minus the
original recovery system weight.
Recovery Efficiency equals Refrigerant Recovered divided
by Refrigerant Recoverable times 100 percent.
C.
Calculation of a Statistically
Significant Number of Recoveries Where:
Nadd = the number of additional samples required to achieve 90%
confidence. sd = Standard deviation, or (X/(N−1) 5) X = Sample
average N = Number of samples tested
Number of samples |
t for 90% confidence |
2 |
6.814 |
3 |
2.920 |
4 |
2.353 |
5 |
2.132 |
6 |
2.015 |
7 |
1.943 |
8 |
1.895 |
9 |
1.860 |
10 |
1.833 |
Procedure:
1. Compute Nadd after completing two recoveries.
2. If Nadd>0, then run an additional test.
3. Re-compute Nadd. Continue to test additional samples until
Nadd<0.
V. Test Procedure Approval and Certification
Each vendor of capture equipment for small appliances desiring
certification will provide a representative model of its capture
system and its recommended recovery procedures to an EPA approved
third party laboratory for testing in accordance with this
procedure. The third party laboratory will certify recovery systems
that when tested in accordance with this procedure demonstrate a
sufficient recovery efficiency to meet EPA regulatory
requirements.