Mobile Air Conditioners (Automobiles)
The basic principles which underlie Sections 2 and 3 of this
report can also be applied to mobile air conditioning.
The operation, service, and repair of mobile air conditioning
systems is one of the major sources of ODS emissions.
With the new focus of pollution prevention and elimination of
refrigerant emissions into the atmosphere, the automobile
industry should address these concerns. Systems should be
designed in such a way that they do not leak. New improved
technologies such as hermetic compressors attached with
leak-proof tubing or hoses, leak-proof seals, and access fittings
should be assessed.
Automobile manufacturing, distribution, and service industries
should incorporate product stewardship into their corporate
policies, if not already present.
4.1 Design
Manufacturers should ensure that the design of mobile air
conditioners includes a series of proven features, such as the
following, that will eliminate refrigerant loss into the
atmosphere.
- anti-vibration mountings;
- heavy-duty clamps;
- near zero permeability, temperature resistance hoses;
- high pressure screwed or compression fittings; and
- access connection for recovery/service.
With the use of alternate refrigerants or interim
refrigerants, it is essential that zero permeability hoses be
used.
4.2 Manufacture
4.2.1 Cleanliness
The system should be absolutely clean to reduce the risk of
contamination of refrigerant or compressor damage, thus
eliminating the need for subsequent recharging. Supervisory
personnel should be conversant with refrigerant technology and
familiar with all aspects of the manufacturing process,
especially emission elimination procedures and refrigerant
recovery.
4.2.2 Discharge Evacuation
Discharge evacuation valves should be fitted to the suction
and discharge sides of the air conditioning system to assist in
the servicing and maintenance of the installation.
4.2.3 Leak Testing
Leak Testing for mobile use, using the refrigerant as the test
gas in accordance with SAE J1627 and J1628 (see Appendix A) is
acceptable provided that:
- visual inspection indicates no signs of oil deposits from
a large leak or any other obvious physical damage;
- non-operating system refrigerant pressure at or above
room temperature is a minimum gauge pressure of 340 kPa
(50 psi); and
- all refrigerant from the test must be recovered
immediately following the test, if there is a leak.
4.2.4 Fluorescent Dyes
Original Equipment Manufacturers (OEMs) should use fluorescent
dyes or other proven technology in new manufactured or imported
vehicles commencing on or before January 1, 1998.
4.3 Servicing
4.3.1 Venting
Venting refrigerants to the atmosphere during servicing
operations must be eliminated by the use of recovery equipment
and the subsequent reuse, recycling, and reclamation of the
refrigerant.
4.3.2 Container Size
Federal regulation requires that "No refrigerant will be
sold in containers of 10 kg (22 lb) or less". The disposable
containers should not be used. Only refillable approved
containers should be used.
4.3.3 Equipment Conversion
After January 1, 2000, automotive air conditioning systems
should not be recharged with CFC-12. Equipment conversion of
mobile air conditioning systems will become necessary after this
date.
Alternative Refrigerant . HFC-134a is the choice
supported by the OEMs at present for the alternatives to CFC-12.
Manufacturers should have conversion kits for most late models
cars or vehicles under warranty.
Use of HFC-134a . Avoid leaks and emissions by
following the manufacturers instructions EXACTLY. Do not omit any
steps. In addition:
- recover all the existing CFC-12 and store it in an
approved recovery container. Refer to the manufacturers'
instructions for your specific make and model;
- change all required parts using the correct kit; leak
test the system to ensure there are no leaks using an
electronic leak detector; repair any leaks as necessary;
- charge the correct amount of HFC-134a refrigerant and the
recommended oil;
- the system should be operated and leak checked again; and
- recycle or reclaim the used CFC-12 and retain for
servicing other older vehicles or for reclamation. Relabel
under the hood, stating the type of refrigerant and
quantity charged as well as type of oil and quantity
charged and the date. (see Appendix B).
Automotive Blends . There are several automotive blends
available. Use caution in selecting the one to be used. Blends
are not recommended or supported by the automotive manufacturer.
These blends should not contain a CFC ozone-depleting substance
and should have service fittings unique from R - 12 or R-134a, to
avoid contamination in the vehicle system or in the recovered
material. In the United States, some states have banned the use
of highly flammable blends.
- The use of all blends should be consistent with
requirements and standards of the SAE or EPA.
- Some blends may contain hydrocarbons which may attack
hoses or gaskets designed for fluorocarbons. This should
be confirmed, before retrofitting.
- The density of the blend may be different than CFC-12 so
the quantity may have to be adjusted to ensure proper
operation.
- The label, which should be applied under the hood, should
give the ASHRAE number of the blend and clearly identify
if it is flammable.
- Confirm if the oil needs to be changed or not.
- Information on performance of blends including safety and
compatibility should be verified by the manufacturer or
supplier and be available in a published format.
- Recovery/Recycle equipment should be suitable for the
specific refrigerant or blend being recovered. Recovery
equipment fittings should be different from those used
for R-12 or R-134a and consistent with of the vehicle.
- Relabel under the hood.
4.4 Handling
of Refrigerant in Automobiles Slated for Wrecking
It is essential that all refrigerant in the air conditioning
system be removed, and oil collected according to local
regulations before the car is wrecked or scrapped. The dealer or
wrecker must use a certified service person trained in the safe
handling of refrigerants, to remove the refrigerant. The
refrigerant should be recovered for recycling, reclaiming or
disposal of as a hazardous waste. Oil should be sent to the
reclaim facilities or disposed of in accordance with the local
regulation. Containers should be properly labelled, including
ASHRAE refrigerant number.
4.5 Training
of Personnel
Service personnel should be fully trained in leak test
procedures for mobile air conditioning refrigeration equipment
and possess an environmental awareness course certificate.
4.6 Records
Active service organizations must maintain up-to-date records
of receipts, shipments, inventory levels of new, used, and
recycled refrigerant (e.g., CFC, HCFC, HFC, other and ASHRAE
designated blends).
Some provinces require that accidental and intentional
releases of refrigerants be reported to the provincial authority.
All refrigerants must be removed before parts are shredded or
salvaged.
It is unlawful in some provinces to sell new or used
components from the closed loop side of the mobile air
conditioning system to people who are not certified in the safe
handling of refrigerants. To ensure that only trained certified
service/repair persons are purchasing new or used components for
or from the closed loop side of the system, the service/repair
person's certification number should be on the bill of sale.
Some provinces recognize businesses as corporate persons and
issue Secondary Distribution Certificates for larger companies
that assume the same responsibilities as service persons for the
care and safe keeping of refrigerant and components.
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