STD 147 2002R PPR2 (Chair Approved R1)

BSR/ASHRAE Standard 147-2002R
Public Review
Draft
_____________________________________
ASHRAE Standard
Proposed Revision of
Standard 147-2002,
Reducing the Release of
Halogenated Refrigerants
from Air-Conditioning
Equipment and Systems
Second Public Review (May 2011)
(Complete Draft for Full Review)
This draft has been recommended for public review by
the responsible project committee. To submit a
comment on this proposed addendum, go to the
ASHRAE website at
http://www.ashrae.org/technology/page/331 and access
the online comment database. The draft is subject to
modification until it is approved for publication by the
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The appearance of any technical data or editorial
material in this public review document does not
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design, and ASHRAE expressly disclaims such.
May 13, 2011. This draft is covered under ASHRAE
copyright. Permission to reproduce or redistribute all or
any part of this document must be obtained from the
ASHRAE Manager of Standards, 1791 Tullie Circle, NE,
Atlanta, GA 30329. Phone: 404-636-8400, Ext. 1125. Fax:
404-321-5478. E-mail: standards.section@ashrae.org.
AMERICAN SOCIETY OF HEATING, REFRIGERATING
AND AIR-CONDITIONING ENGINEERS, INC.
1791 Tullie Circle, NE Atlanta GA 30329-2305
BSR/ASHRAE Standard 147-2002R, Reducing the Release of Halogenated Refrigerants from Refrigerating
and Air-Conditioning Equipment and Systems
(Second Public Review Draft)
BSR/ASHRAE Standard 147-2002R

Reducing the Release of Halogenated Refrigerants
from Refrigerating and Air-Conditioning Equipment and Systems
CONTENTS
SECTION PAGE
Foreword.........................................................................................................................................
1 Purpose....................................................................................................................................
2 Scope ..........................................................................................................................................
3 Definitions....................................................................................................................................
4 Design.........................................................................................................................................
5 Product Development.................................................................................................................
6 Manufacture.............................................................................................................................
7 Installation...................................................................................................................................
8 Service/Operation/Maintenance/Decommissioning..................................................................
9 Refrigerant Recovery, Reuse, and Disposal................................................................................
10 Handling and Storage of Refrigerants .......................................................................................
11 Normative References..............................................................................................................
Annex A: Recommended Procedures and Practices......................................................................
Annex B: Training of Personnel....................................................................................................
Annex C: Informative References ................................................................................................
Annex D: Bibliography..................................................................................................................
3
4
4
4
7
9
10
11
12
14
15
16
17
34
34
35
(This foreword is not part of this standard. It is merely informative and does not contain requirements
necessary for conformance to the standard. It has not been processed according to the ANSI
requirements for a standard and may contain material that has not been subject to public review or a
consensus process. Unresolved objectors on informative material are not offered the right to appeal at
ASHRAE or ANSI.)
FOREWORD
When the potential link between release of chlorofluorocarbons (CFCs) and depletion of stratospheric ozone
was first discovered, ASHRAE appointed a task group to study the issue and to develop appropriate policy
and program recommendations to the Board of Directors. In response, a comprehensive action program was
initiated. It included research, education, communication, and training directed toward the various aspects
of the CFC issue.
A part of this program was the development of a guideline for reducing CFC refrigerant release. This was
published as ASHRAE Guideline 3-1990, Reducing Emission of Fully Halogenated Chlorofluorocarbon
(CFC) Refrigerants in Refrigeration and Air Conditioning Equipment and Applications. Since that date, it
has been determined that all releases of chlorine containing refrigerants, hydrochlorofluorocarbons
(HCFCs) as well as CFCs, contribute to depletion of the stratospheric ozone layer. Not long after, it was
also determined that the release of CFCs, HCFCs, and hydrofluorocarbons (HFCs) contributes to global
warming, adding new urgency to controlling their release. At this time, in 1996, Guideline 3 was revised to
reflect this need for a more stringent policy, and in 2002 ASHRAE published Standard 147, Reducing the
Release of Halogenated Refrigerants from Refrigerating and Air-Conditioning Equipment and Systems.
Standard 147 took many of the recommended practices of Guideline 3 and made them mandatory
requirements, thus further increasing the stringency of the guideline, which was then withdrawn. However,
some of the material from Guideline 3 was preserved in the standard in informative annexes that provide
recommended practices that are not required by the standard.
This revision of Standard 147 updates the 2002 edition by expanding the number of equipment types and
systems covered, by providing significant requirements for field-erected systems, by adding more sections on
leak checking, by adding requirements for systems with larger charges, by addressing the shipping and
handling of containers for refrigerants, and by making many formerly recommended practices mandatory.
1. PURPOSE
This standard establishes practices and procedures that will reduce inadvertent release of halogenated refrigerants.
2. SCOPE
The practices and procedures in this standard cover release reduction of halogenated hydrocarbon and halogenated ether
refrigerants in the following circumstances:
(a) from stationary refrigerating, air-conditioning, and heat-pump equipment and systems;
(b) during manufacture, installation, testing, operation, maintenance, repair, and disposal of such equipment and
systems.
3. DEFINITIONS
Although the following terms may have broader interpretations elsewhere in the industry, their specific meanings as
used in this standard are as follows.
CFC (chlorofluorocarbon): a fully halogenated (no hydrogen remaining) halocarbon containing chlorine, fluorine, and
carbon atoms.
equipment type: a classification used to distinguish between the different kinds of refrigerant-containing systems and
equipment covered by this standard.
type 1 component: single refrigerant containing piece of a refrigeration system, (Examples: thermostatic
expansion valve [TXV] body, TXV power head, valves, receiver; controls, tube.)
type 2 - small assembly: the extension of the refrigerant volume by brazing/ welding/ mechanical connection
of components and can include other hardware. Internal volume is less than 61 in3 (1 liter).
type 3 large assembly: a further extension of the refrigerant volume by brazing/welding/mechanical
connection of multiple components. Internal volume is equal to or greater than 61 in3 (1 liter).
type 4 - appliance: A very small packaged piece of refrigeration equipment that is installed by the consumer
and has a design refrigerant operating charge of less than 5 lb (2.3kg) of refrigerant.
type 5 - small packaged equipment: A small piece of refrigeration equipment manufactured, assembled in its
entirety and which is typically installed by a contractor and with a refrigerant design operating charge of less
than 50 pounds (23kg) per circuit.
type 6 - small assembled equipment: small refrigeration equipment that is assembled and installed by a
professional and contains a refrigerant design operating charge of less than 50 lb (23kg) per circuit. These are
typically two assemblies, a condensing unit and an evaporator/air handler but may have as many as 3
AHU/evaporators.
type 7 - large packaged equipment: a large piece of refrigeration equipment manufactured and assembled in its
entirety in a manufacturing facility and which is installed by a professional, and contains a refrigerant design
operationg charge of 50 lb (23kg) or more per circuit.
type 8 - large assembled equipment: large refrigeration equipment that is assembled and installed by a
professional and contains a refrigerant design operating charge of 50 lb (23kg) or more per circuit. These are
typically two or three pieces being a compressor(s), evaporator(s), and condenser(s)
type 9 small field erected system: a system that is professionally and specifically designed, and erected for a
particular application. With a refrigerant design operating charge of less than 50 lb (23kg), a system of this
type may contain multiple compressors, evaporators, and condensers.
type 10 large field-erected system: a system that is professionally and specifically designed, and erected for
a particular application. With a refrigerant design operating charge of 50 lb (23kg) or more of refrigerant, a
system of this type often contains multiple compressors (rack), evaporators, and condensers as well as heat
recovery.
halocarbon: any of a class of compounds containing carbon, one or more halogens, such as fluorine, and sometimes
hydrogen.
HCFC(hydrochlorofluorocarbon): a halocarbon that contains fluorine, chlorine, carbon, and hydrogen.
hermetically sealed system: a factory-charged refrigerating system that is welded, brazed, soldered, or otherwise joined
together in such a manner as to create a completely sealed system.
HFC(hydrofluorocarbon): a halocarbon that contains only fluorine, carbon, and hydrogen.
holding charge: an inert gas used to temporarily create a positive pressure and thereby avoid the ingress of air or moisture
during shipment or storage.
joint, brazed: a gas-tight joint obtained by joining metal parts with alloys that melt at temperatures higher than 800F
(426C) but less than the melting temperatures of the joined parts.
joint, mechanical: a gas-tight joint obtained by joining metal parts through a positive-holding mechanical construction.
joint, soldered: a gas-tight joint obtained by joining metal parts with metallic mixtures or alloys that melt at
temperatures above 400F (204C) but not exceeding 800F (426C).
joint, welded: a gas-tight joint obtained by the joining of metal parts in the plastic or molten state or through the use of
filler metals that melt at temperatures 800F (426C) and above.
maintenance: the upkeep of property or equipment in order to keep it in an existing state (as of repair, efficiency, or
validity) and to preserve it from failure or decline.
maintenance, corrective: a type of maintenance program where failures are corrected or repaired as they occur.
Corrective action is always performed after failure occurs.
maintenance, planned: a type of maintenance program in which resources are invested in prudently selected functions
at specified intervals. In this type of program, all functions and resources are planned, budgeted, and scheduled.
maintenance, predictive: a type of maintenance program in which statistically supported objective judgment is used.
Non-destructive testing, chemical analysis, vibration and noise monitoring, as well as visual inspection and logging are
all used to predict when a particular part or system might fail so its useful life can be extended and maximized.
maintenance, preventive: a type of maintenance program in which inspections, checks, servicing, and replacements are
performed according to either a predetermined schedule or condition based monitoring indicators. Durability,
reliability, efficiency, and safety are the principle objectives. Preventive maintenance embodies two concepts: planned
and predictive maintenance.
maintenance, program: a systematic approach to maintenance in terms of time and resource allocation. It documents
the objectives and establishes the criteria for evaluation and commits the maintenance department to basic areas of
performance such as prompt response to mechanical failure, maintenance, and attention to planned functions that
protect the capital investment and minimize downtime or failure response.
pressure, design: the maximum allowable working pressure for which a specific part of a system is designed to operate
under normal or abnormal conditions, as defined in a relevant standard, such as UL 1995. 16
pressure, high: as this term applies to refrigerations systems, it refers to gage pressure at room temperature (74F
[23.3C]) that is typically more that 100 psig (689 kPa). Common high-pressure refrigerants include R-22, R-502, R404A, R-407A, R-407C, R-410A and R-507A.
pressure, low: a as this term applies to refrigerations systems, it refers to absolute pressure at room temperature (74F
[23.3C]) that is below ambient pressure absolute. Low-pressure refrigerants include R-11, R-113, and R-123.
pressure, maximum working: (see pressure, design).
pressure, medium: as this term applies to refrigerations systems, it refers to gage pressure at room temperature (74F
[23.3C]) that is greater than atmospheric pressure but typically less that 100 psig (689 kPa). Common mediumpressure refrigerants include R-12, R-500, R-134a, and R-245fa.
pressure, operating: the pressure occurring at a reference point in a refrigerating system when the system is in
operation.
pressure-relief device: a valve or rupture member designed to relieve excessive pressure automatically.
prevention-of-vacuum system: a refrigerant pressure control system that prevents refrigerant loss and infiltration into
idle low-pressure chillers and is also used to pressurize for leak testing without the use of non-condensables.
purging: removing non-condensable gases from the system.
purging device: an automatic, semiautomatic, or handoperated device that removes non-condensable gases introduced
into a system during charging, servicing, or normal operation.
receiver: a vessel in the refrigerating system designed to ensure the availability of adequate liquid refrigerant for proper
functioning of the system and to store the liquid refrigerant when the system is pumped down.
reclaim: to process used refrigerant so that it meets new product specifications.
recover: to remove refrigerant in any condition from a system and store it in an external container.
recycle: to reduce contaminants in used refrigerants by separating oil, removing non-condensables, and using devices
such as filter driers to reduce moisture, acidity, and particulate matter.
refrigerant charge: the mass of refrigerant in a closed system.
refrigerant, design operating charge: the mass of the refrigerant required for proper functioning of a closed system
refrigerant circuit: an assembly of refrigerant containing parts connected to allow the flow of refrigerant in the
refrigerating cycle. The refrigerant-containing parts are considered part of the circuit even if isolated by a valve. A system
or equipment may be considered to have multiple circuits only if there is no intended path for the refrigerant to cross over
from circuit to circuit.
refrigerant release: any movement of refrigerant out of its containment and into the atmosphere, including, but not limited
to, movement by a leak, by an action of filling or testing, or by failure.
rupture disc: a safety device that is designed to rupture at a predetermined pressure.
seasonal adjustment: the adding of refrigerant to a refrigeration or air conditioning system due to change in ambient
conditions caused by a change in season, followed by the subsequent removal of refrigerant in the corresponding change in
season where both the addition and removal occurs within one consecutive 12 month period.
topping off: adding refrigerant to a refrigeration or air conditioning system in order to bring the system to its normal
operating charge.
trace gas: a gas that is detectable by a leak detector and can be mixed with an inert gas. Typical trace gases are helium,
hydrogen, and most refrigerants.
vacuum, deep (high vacuum): a vacuum of 1000 m Hg (micron) (130 Pa) or less of absolute pressure.
valve, pressure-relief: a pressure-actuated valve held closed by a spring or other means and designed to automatically
relieve pressure in excess of its setting.
valve, purge: a device to allow non-condensable gases to flow out of the system.
4. DESIGN
This section covers the compliance requirements for designers of air-conditioning and refrigerating systems and
components. For all equipment and systems described in this section, the following requirements shall be met:
Informative Note: The understanding and application of established techniques in both the design and construction of
refrigerating systems provide a good foundation for the prevention of refrigerant release to the atmosphere. Examples of
recommended design practices and techniques to minimize refrigerant leakage are given in Annex A.
4.1 Safety. All equipment and systems shall be designed in accordance with a recognized national standard, such as
ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems1 or UL Standard 1995. 16
4.2 Documentation. Documentation to instruct field personnel how to install, operate, and service refrigerating
equipment to minimize refrigerant release shall be provided for factory-built equipment and for field-erected systems.
4.3 Compressors
Leaks associated with compressors may be related to the design of the compressor (e.g., oil pan, motor bell, oil pump)
or to the associated equipment fitted to it (e.g., gauge and cutout connections, relief valves, and connected piping).
Compressors shall meet the following requirements to minimize the possibility of leaks.
4.3.1 Shaft Seals. Seals shall be designed with materials compatible with the refrigerant and oil to be used in the
compressor.
Informative Note: Shaft seals used in open-style compressors can be a source of refrigerant leakage.
4.3.2 Vibration. To minimize leakage due to vibration, compressors, compressor mountings, and piping connections
shall be evaluated to see that vibration-induced stresses do not exceed material endurance limits. If the equipment is not
evaluated for material endurance testing, then all copper tubing that is of an outside diameter of 3/8 in.[9.5mm] or
smaller (excluding suction and discharge) and are connected to compressors or assemblies that are not isolated from
compressor vibrations shall be constructed with vibration loops to minimize fatigue at connections.
4.3.3 Semi-Hermetic Compressors. Materials used for gaskets and O-rings shall be compatible with the refrigerant
and lubricant used. All bolts shall be torqued to the required level as set by the compressor manufacturer.
4.4 Condensers and Evaporators. Connections shall be designed so that vibrational stresses from the suction,
discharge, and liquid line loads at the condenser and evaporator joint(s) do not exceed material endurance limits. All
electrical power and control wiring greater than 100V shall be routed and tethered in a way where an energized, severed
wire cannot come into contact with any refrigerant tubing. Thermal expansion valve (TXV) equalizer tubes shall be
routed and secured to support the weight of the tube.
4.4.1 Air-to-Refrigerant Condensers and Evaporators. These components shall be designed for the ability to
withstand stress, vibration, and corrosion under normal operation and during transport. Tubing supports shall be
designed to minimize vibration, to provide protection against abrasion due to movement, and to allow for thermal
expansion.
4.4.1.1 The user or the users designated agent shall select materials that will prevent corrosion failure in the installed
environment.
4.4.2 Liquid-to-Refrigerant Condensers and Evaporators
4.4.2.1 These components shall be designed to withstand stress, vibration, and corrosion under normal operation and
during transport. Tubing supports shall be designed to minimize vibration, to provide protection against abrasion due to
movement, and to allow for thermal expansion.
4.4.2.2 The characteristics of fluids used in liquid chillers and liquid-cooled condensers vary widely and can lead to
premature failure of tubes, resulting in release of the entire refrigerant charge. The user or the designated agent shall
select tube materials, tube configurations, tube-wall thicknesses, and filtration/ treatment techniques suitable for the
fluid characteristics.
4.4.2.3 The user or the users designated agent shall select tube and water-side materials that will prevent corrosion
failure when used with the intended fluids in the installed environment.
4.4.2.4 To prevent freeze-up of water-chilling machines during operation, safety controls shall be provided by the
manufacturer of the equipment. Examples include, but are not limited to, refrigerant pressure control and/or refrigerant
temperature control. See Section 7.6 for requirements when the system is not in operation.
4.4.2.5 When utilizing a brazed plate heat exchanger as an evaporator, insulation of the entire unit and attached tubing
is important. This insulation prevents the formation of frost in critical areas that may force the plates to separate and
eventually leak. Equipment and attached tubing shall be insulated to prevent frost from forcing plates to separate.
4.5 Piping, Tubing, and Connections

4.5.1 Minimized Connections. Systems shall be designed in such a manner as to minimize the number of fittings and
connections. Tapered pipe threads shall not be used for fittings in refrigerant circuits unless the threads are backwelded or sealed by equally effective means. Single-flare fittings shall not be used.
4.5.2 Flanged Joint Seals. Designers shall specify flanged joint seal materials that are compatible with both the
refrigerant and refrigerant oils to be used in the system.
4.5.3 Support. Pipe and tubing supports shall be designed to provide protection of tubing components against external
abrasion due to movement. Tubing inside refrigerated cases in Equipment Types 9 & 10 shall be supported by the case
at least every 36 in. (91 cm) of tube length and within 12 in. (30 cm) from any connection or elbow.
4.5.4 Corrosion Prevention. External protection shall be specified to prevent corrosion of metal components that
contain refrigerant or are in direct contact with refrigerant-containing components.
4.5.5 Over Pressurization. To prevent hydrostatic over pressurization due to thermal expansion, liquid-containing
system parts shall be protected as specified in Section 9.4.3 of ANSI/ASHRAE Standard 15, Safety Standard for
Refrigeration Systems.1
Exemptions. Equipment Types 4, 5 and 6 that is approved by a nationally recognized testing agency shall be exempt from
all provisions of Section 4.5 except the provisions in Section 4.5.1 regarding single flare fittings and tapered pipe threads.
4.6 Isolation Valves. Isolation valves shall comply with one of the following:
4.6.1 The valve stems are sealed by internal diaphragm.
4.6.2 The valve has a spindle, with a tethered cap .
4.6.3 The valve meets the requirements of Section 6.2.1
4.7 Access Valves for Charging, Evacuation, or Both. Access valves or couplings, except as noted below, shall have
a tethered metal-to-metal or metal-to-o-ring sealing surface to prevent leaking through the cap and shall be provided for
evacuation and liquid charging of refrigerating systems. Caps shall meet the leakage requirements of Section 6.2.1. For
Equipment Types 4, 5, and 6 using hermetically sealed compressors, an equally effective design feature (e.g., process
tube or stub) shall be considered to meet the requirements of this section
4.8 Relief Devices
System relief devices shall conform to the requirements of ANSI/ASHRAE Standard 15, Safety Standard for
Refrigeration Systems.1 Equipment types 7, 8, and 10 shall have an alarm that notifies personnel of high refrigerant
pressure that can result in refrigerant release through the relief device(s). Medium and high pressure refrigerant systems
shall not use a rupture disc as the sole relief device venting to the atmosphere.
Exemptions to 4.8: Equipment Types 4, 5, & 6 having sealed systems approved by a nationally recognized testing
agency shall be considered to comply with the provisions of Section 4.8.
4.9 Purging Devices
4.9.1 Sub-atmospheric Pressure. Purging devices shall be provided for Equipment Types 7, 8 & 10 that have any
portion of the system that operates at sub-atmospheric pressure. New equipment designs shall specify purging devices
that release less than one unit mass of refrigerant per unit mass of air as tested by ARI Standard 580, Performance of
Non-Condensable Gas Purge Equipment for Use with Low Pressure Centrifugal Chillers.2
4.9.2 Infiltration. Systems with purges as described in Section 4.9.1 shall be designed so that air infiltration under idle
storage conditions 74F (23.3C) saturated refrigerant temperature and 14.7 psia (101.235 kPa) atmospheric pressure
does not prevent systems from starting and operating. To conform, the system shall include one or more of the
following:
(a) A purge unit that operates while the system is under idle storage conditions.
(b) A prevention-of-vacuum system that prevents air infiltration while the system is under idle storage conditions. (See
Section A2.9.1 in Annex A for an explanation.)
(c) A system design means that allows a system to start and operate when air infiltration has occurred under idle storage
conditions. Any means to remove air from the chiller shall conform to the emissions requirement of Section 4.9.1.
4.9.3 Alarm. The purge unit shall automatically indicate purge activity and shall alarm if the amount of purging exceeds
the system manufacturer's preset limit.
4.10 Storage Capability
In large field-erected systems, such as supermarket refrigerating systems, one or more receivers shall be provided for
the system to store the charge as necessary to service various components. Systems shall be exempt from this
requirement if the condenser is large enough to contain the entire charge, is fully isolatable and is protected by a
pressure-relief valve in accordance with ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems.1
4.11 Shipping and Package Testing Procedures
The following testing procedures shall be used to ensure products arrive in acceptable condition:
Compression strength tests: ASTM D6423 and ASTM D45774
Vibration tests: ASTM D9995 and ASTM D47286
Mechanical handling tests: ASTM D 60557 and ASTM D61798
Shock and impact tests: ASTM D8809 and ASTM D527610
4.12 System Monitoring
All new Equipment Types 7, 8 & 10 with a refrigerant design operating charge greater than 500 lb (230kg) shall be
equipped with a feature to alert the owner that the system is releasing refrigerant or has released enough refrigerant to
affect system performance.
5. PRODUCT DEVELOPMENT
This section of the standard describes compliance requirements for products during their development phase.
5. 1 General. When components or systems are being tested for refrigerant leakage during development, the practices
and procedures specified in Sections 7.17.5 shall be followed. A refrigerant charge used for operational testing during
development shall not be released to the atmosphere following development tests or at the end of the development
period. The refrigerant shall be removed and stored in a suitable container.
5.2 Refrigerant Handling
The laboratory shall be equipped with a recovery/recycling system and storage capacity for holding charge recovered
from any individual test unit in the laboratory. When servicing of a recovery/recycling unit is required, refrigerant in the
unit shall be recovered and recycled or reclaimed in the same manner as that from test systems.
5.2.1 Recovery. Upon completion of tests, the refrigerant shall be recovered from an experimental system. It is
recognized that sometimes the recovered refrigerant must first be put into a container to determine or confirm charge
levels, but ultimately all refrigerant shall be recovered into appropriate storage devices as required under Section 10.
Refrigerant that is known to be contaminated, as with a motor burnout, for example, shall be recovered into proper
containers and recycled, reclaimed, or disposed of as described in Section 9.
5.2.2 Inventory Record. A refrigerant inventory record shall be maintained to account for virgin material received into
the laboratory and material shipped for reclaim or destruction. This inventory must include the types and quantities of
refrigerant received and shipped for reclamation or destruction and the dates of receipt and shipment.
5.2.3 Test Facility Air Conditioning Equipment. Test facilities have conditioning equipment that provides a
controlled environment for testing. This equipment shall be constructed and installed in accordance with this standard
and checked for leaks on a regular basis. When servicing is required, the refrigerant shall be recovered and recycled or
reclaimed in the same manner as that from test systems.
6. MANUFACTURE
This section applies to the manufacture of all equipment types.
Informative Note: Refer to Annex A for practices and procedures that are recommended but not required for
compliance with this standard.
6.1 General. All equipment, components, and complete systems shall be cleaned, dried, evacuated, leak-tested, and
sealed before shipment. Components or sub assemblies that will be tested in a larger assembly further in the
manufacturing process shall be exempt from this requirement.
6.2 Factory Leak Testing

6.2.1 Leak Rate Specification. All equipment types shall be leak-tested by either a leak rate measurement method or a
leak location method such as those described in Annex A4.3. The measured leak rate shall not exceed the values
established for the method selected in Table 1 (when tested at the conditions prescribed in ANSI/ASHRAE Standard
15, Safety Standard for Refrigeration Systems, Section 9.14.1).1 The components of Equipment Types 6, 9, and 10 shall
be tested as Type 1, 2 or 3 assemblies, as appropriate.
Table 1: Equipment Manufacture Leak Threshold Limits
Equip.
Type
Type 1
Type 2
Type 3
Type 4
Type 5
Type 7
Type 8
Description
Leak Rate Measurement Threshold
Component
Small Assembly
Large Assembly
Appliance
Small Packaged
Large Packaged
Large Assembled
0.1oz / year
0.5oz / year
1.0oz / year
1.0oz / year
3.0oz / year
Greater of 15oz / year or 0.25% of the charge
Greater of 15oz / year or 0.25% of the charge
Leak Location Method Threshold

0.1oz / year / joint
6.2.2 Leak-Test Gas. CFCs are prohibited by law from use as a leak test gas. HCFC or HFC refrigerants are prohibited
by this standard for use as leak-test gases unless they are recovered. A mixture of a trace quantity (no more than 10% by
mass) of non-CFC halocarbon refrigerant, such as HCFC-123, with nitrogen may be used as the leak-test gas. Leak-test
gas containing halocarbon refrigerants shall be recovered and reused.
6.3 Operating Test Gas Recovery
Refrigerant used during the manufacture and operational testing of systems and components shall be recovered from
systems and components prior to repair or re-work.
10
6.4 Evacuation
Systems shall be evacuated to 1000 microns of Hg and held long enough to remove moisture.
6.5 Holding Charge
A halogenated refrigerant shall not be used as a holding charge.
6.6 Purging
Purging with inert gas is required during brazing to prevent oxidation, which can cause plugged driers, filters, strainers,
dirty oil, and compressor failure.
7. INSTALLATION
This section specifies the installation requirements that must be met to comply with this standard. It applies only to
Equipment Types 6 through 10.
Informative Note: Practices and procedures that are recommended but not required for compliance with this standard
are described in Annex A.
7.1 Installation of Equipment Types 6, 8, 9, and 10
7.1.1 General. All piping, tubing, and connections shall be installed as required by Section 4.5.
7.1.2 Major Considerations
7.1.2.1 All cut piping shall be deburred and metal filings removed to prevent damage to the compressors and
refrigerating system parts, such as shaft seal, compressor bearing, motor, and capillary tube.
7.1.2.2 All tube and fittings shall be thoroughly cleaned prior to assembly. Both the outside of copper tube and the
inside of fittings must be bright and clean before brazing. Braze filler metal selection shall be consistent with the types
of materials being joined.
7.1.2.3 Except as provided for in Section 4.5.1, tapered pipe thread connections shall not be used to join pipe or tube to
fittings, valves, and other components.
7.1.2.4 The gasket material used on flanged connections shall be of a type and grade that is compatible for use with
refrigerants and refrigerant oils of the types being used.
7.1.2.5 Equipment shall be checked for tightness; moisture and non-condensables shall be removed before charging the
system with refrigerant.
7.1.2.6 Liquid line filter driers shall be provided on all installations of equipment types 6, 9, and 10 to ensure a dry and
clean system. Such filter driers shall be chosen to ensure that the size and desiccant material are appropriate for the
equipment.
7.1.2.7 Purging with inert gas is required during brazing to prevent oxidation, which can cause plugged driers, filters,
strainers, dirty oil, and compressor failure.
7.2 Field Leak Testing. Equipment Types 6, 8, 9, and 10 shall be leak tested per Section 6.2.1 as an equipment type 8
to ensure system integrity and minimize refrigerant leakage.
Informative Note: See Annex A for recommended procedures.
7.3 Field Evacuation. After it is determined that there are no refrigerant leaks, Equipment Types 6, 8, 9, and 10 shall
be evacuated to 500 microns or less and held until long enough to remove moisture.
7.4 Field Charging
11
7.4.1 Charging. After it is determined that the system does not leak, it shall be charged with refrigerant following the
procedure specified in the equipment manufacturers instructions. If the system uses a medium or high pressure
refrigerant and is not to be fully charged immediately after evacuation, it shall be placed under positive pressure with a
partial charge of the refrigerant to be used in the system.
7.4.2 Backflow Prevention. When connected for charging, refrigerant containers shall not be connected to a system at
a higher pressure or to hydraulic legs where the pressure is sufficient to cause a backflow of refrigerant into the
container.
7.5 Refrigerant Charging Log
For Equipment Types 6, 7, 8, 9, and 10, the owner shall keep a record of the following:
Identification of the installing contractor

Identification of the facility
The full charge
Refrigerant type and designation under ASHRAE Standard 3417
Lubricant type and amount added.
Lubricant additives type and amount added
This information shall be recorded in a clear, legible condition. This log shall be used to contain the records of future
maintenance actions described in Section 8.4.1.
7.6 Water-chilling Machines: During installation, the installer or operator shall provide and install controls to prevent
fluids from freezing in water-chilling machines when they are not in operation.
8. SERVICE/OPERATION/MAINTENANCE/DECOMMISSIONING
This section explains the requirements for operating, servicing and maintaining, and decommissioning air-conditioning
and refrigerating systems and equipment.
8.1 Servicing. Servicing of air-conditioning and refrigerating systems shall be undertaken only by properly trained
personnel. In the US and in some other countries, regulations require that personnel engaged in refrigerant handling be
certified. Reference shall be made to the manufacturer's operating and maintenance instructions for recommended
service procedures.
Informative Note: Generally recommended practices and procedures can be found in Annex A; however, they are not
required for compliance with this standard.
8.1.1 Incorrect Uses. Halogenated refrigerants shall not be used for the purpose of cleaning debris and dirt from aircooled condenser coils, cooling coils, or similar equipment.
8.1.2 When to Leak Check. Loss of capacity, loss of efficiency, unusual operating conditions or traces of oil may be
evidence of a refrigerant leak. If a refrigerant leak is suspected, refrigerant shall not be added without leak-checking the
system. Refer to the U.S. Code of Federal Regulations, 40 CFR, Part 82.15611 for the criteria for repairing leaks.
Special attention shall be given to all joints, gaskets, control bellows, and shaft seals. These items shall be thoroughly
leak-tested after servicing.
8.1.3 Pressurization. Equipment Types 5 10 that use a refrigerant and that have the potential to be in a vacuum at
normal room temperatures shall be put under positive pressure before leak testing. The low-side pressure increase could
typically be from the addition of heat to the system, or injecting another vapor into the system. Extreme care shall be
taken to prevent excessive pressure buildup and the subsequent refrigerant release into the atmosphere. Automatic
pressurization processes shall be provided with controls to prevent over-pressurization. Manual pressurization processes
shall be continuously monitored to prevent over pressurization. A pressure increase shall be accomplished by the
addition of dry nitrogen only if the system employs a refrigerant recovery type purge device. Air or oxygen shall not be
12
used for pressurization. Refrigerant and oil in the presence of pressurized air or oxygen can cause uncontrolled
combustion.
8.1.4 Leak Sources. Valve stem glands, blanks over gauge ports, and service valve seal caps shall be replaced and
tightened after removal for servicing and shall be thoroughly leak-tested after servicing.
8.1.5 Oil Removal. Before oil is removed from a compressor, the oil sump heater (if so equipped) shall be turned on
and the oil sump refrigerant pressure shall be repetitively reduced by safe and correct recovery, or by pump down to 0
psig or below until such time that the oil sump pressure does not noticeably rise within 10 minutes of terminating the
pressure reduction.
8.1.6 Repairs. For non-major repairs, refrigerant pressure shall be reduced to less than 0 psig by safe and correct
recovery or pumpdown to prevent refrigerant loss from a system or its components when opened to atmosphere during
maintenance of non-major repairs. Non-major repairs are those that do not involve removing the compressor,
condenser, evaporator, or auxiliary heat exchanger coil(s). See the U.S.E.P.A. regulations at 40 CFR 82.156(a) 11 for the
provisions governing major and non-major repairs to air-conditioning and refrigerating equipment. For major repairs,
the serviced part of the system shall be isolated to minimize the loss of refrigerant during recovery. If isolation is not
possible, the total refrigerant charge shall be pumped into the system receiver or recovered. Refer to 40 CFR, Part
82.15, 11 for evacuation requirements. Only then shall repair be undertaken. Under no circumstances shall the
refrigerant be discharged to the atmosphere.
8.1.7 Charging of Systems during Service. When connected for charging, refrigerant containers shall not be
connected to a system at a higher pressure or to hydraulic legs where the pressure is sufficient to cause a backflow of
refrigerant into the container.
8.2 Cleaning a Refrigerant System After a Mechanical Failure, Contamination, or Motor Burnout
If the refrigerant is to be removed from the system due to contamination, the refrigerant shall be recycled, reclaimed, or
disposed of in accordance with EPA regulations. In no case shall the refrigerant be vented to the atmosphere. After
reassembly, the system shall be evacuated, leak-tested, and charged in accordance with Section 7.
8.3 System Operation and Maintenance. HVAC systems shall have maintenance programs based on manufacturers
recommendations, ANSI/ACCA 4, Maintenance of Residential HVAC Systems,12 ANSI/ASHRAE/ACCA 180,
Standard Practice for Inspection and Maintenance of Commercial Building HVAC Systems,13 and industry recognized
practices followed to reduce and prevent refrigerant releases.
Informative Note: Recommended practices and procedures may be found in Annex A6; however, they are not required
for compliance with this standard.
8.3.1. Maintenance Program. Equipment types 7, 8, and 10 shall have a preventative maintenance program that shall
include inspections for evidence of refrigerant leaks. The maintenance plan shall be reviewed and updated annually.
(a) The maintenance program shall be planned and predictive.
(b) This inspection shall include both a visual inspection of the system, a review of any equipment operating logs, and
verification of the refrigerant charge containment.
(c) he program shall verify the function of the refrigerant leak monitoring and or charge monitoring system.
Informative Note: Recommended practices and procedures may be found in Annex A6; however, they are not required
for compliance with this standard.
8.4 Actions after Refrigerant Monitoring Alarm.
Owners of HVACR systems that are equipped with leak detection monitoring, or refrigerant charge monitoring, or both,
and that provide an alert when a potential refrigerant release has occurred shall not add refrigerant without leakchecking the system. The owner shall follow the criteria in U.S. Code of Federal Regulations, 40 CFR, Part 82.156,11
for repairing leaks. A refrigerant charging log as described in Section 7.5 shall be maintained.
Informative Note: Generally, recommended practices and procedures for system monitoring may be found in Annex A;
however, they are not required for compliance with this standard.
13
8.4.1 Refrigerant Charging Log: For Equipment Types 7, 8, and 10, the owner shall maintain the log initiated in
Section 7.5 and record of the following regarding any refrigerant leaks:
Identification of the servicing technician
The date a leak was discovered
The location of the leaks to the extent determined to date
Any leak repair work that has been completed thus far and the date the work was completed.
Any measure taken to assess whether the leak was effectively repaired, the date of such assessment, and the results or
conclusion
Retrofits of the system with alternative refrigerants, the type of alternative refrigerant used, and the date of any such
retrofit shall be recorded in the log.
8.5 Refrigerant/Lubricant Change-Out. Seals, gaskets, and valve packing shall be replaced in accordance with
manufacturers instructions when changing from one refrigerant or lubricant to another. Reusing these materials has a
high potential to result in leaks.
9. REFRIGERANT RECOVERY, REUSE, AND DISPOSAL
This section gives the requirements for recovery, reuse, and disposal of refrigerant from refrigerating and airconditioning equipment and systems.
9.1 General. Refrigerant used in any type of air-conditioning or refrigerating equipment shall be recovered and reused
in the owners equipment, or it shall be shipped in proper containers to a reclamation or destruction facility whenever it
is removed from equipment. It shall not be released to the atmosphere.
Informative Note: Recommendations on the disposition of recovered refrigerant may be found in Annex A; however,
they are not required for compliance with this standard.
9.2 Refrigerant Transfer, Transport, and Storage. Refrigerant withdrawn from a system or equipment shall be
transferred to an appropriate pressure vessel for storage on site or transport to another site. Disposable refrigerant
containers, including those identified as complying with the United States Department of Transportation DOT
Specification 39,14 shall not be reused under any circumstances.
9.2.1 Safety. Appropriate safety practices shall be followed when transferring refrigerant from equipment or a system to
a refrigerant container, when transporting refrigerant from one location to another, and when storing refrigerant (see
Section 10).
9.2.1.1 Color-Coded Containers. Refrigerant shall be transferred to a container that has been identified by the color
code for the refrigerant, as specified in AHRI Guideline K-2009, Containers for Recovered Fluorocarbon
Refrigerants,15 and shall comply with appropriate DOT regulations for refillable containers. 14
9.2.1.2 Overfilling Prohibited. Refrigerant containers shall not be overfilled (see Section 10.2.4). The design
maximum working pressure of the container shall not be exceeded, even temporarily, during any filling operation.
Informative Note: Refrigerant-oil mixtures have a lower density than refrigerant alone; the container capacity will
therefore be reduced for a refrigerant-oil mixture.
9.2.1.3 Mixing of Refrigerants Prohibited. Refrigerant shall not be placed in any container that contains a different or
an unknown refrigerant. In no case shall a refrigerant already in a container be vented to the atmosphere.
9.2.2 Transport. Refrigerant shall be transported from one location to another in a safe manner. All requirements of
relevant laws, including registration and obtaining permits, shall be observed. See, for example, DOT regulations in
Title 49 CFR Part 178. 14
9.2.3 Storage. Refrigerant shall be stored in a safe manner in accordance with local laws and regulations. The storage
site shall be dry and protected from weather to minimize corrosion of refrigerant containers. Containers (except those
14
designed for outside storage of refrigerant) shall not be stored in direct sunlight (see also Section 10.2) or in close
proximity to a heat source.
9.3 Disposal. If recovered refrigerant is not intended to be reused, recycled or reclaimed, it shall be destroyed in an
approved facility.
10. HANDLING AND STORAGE OF REFRIGERANTS
This section specifies how to comply with this standard in the handling and storage of halogenated refrigerants.
10.1 System Connections. Charging lines shall be made of materials that are compatible with the refrigerant.
10.2 Storage
10.2.1 Refrigerant Container Design. Refrigerant containers shall be constructed to meet DOT packaging
requirements as required by Title 49 CFR Part 178.14
10.2.2 Containers for Recovered Refrigerants. Pressure cylinders for recovered non-flammable fluorocarbon
refrigerants shall be of refillable design, which includes a properly set relief valve and a valve guard (49 CFR 178). 14
10.2.3 Non-Reusable Containers Prohibited for Recovered Refrigerants. Previously filled DOT Specification 3914
non-reusable (non-refillable) cylinders shall not be used for recovery and transportation of recovered refrigerants.
Informative Note: Title 49 CFR 178.6514 describes substantial fines and possible imprisonment for transportation of
refilled DOT 39 cylinders.
10.2.4 Maximum Mass for Medium and High-Pressure Refrigerants. In filling high-pressure and medium-pressure
refrigerant containers, the maximum allowable gross mass shall be equal to the sum of the cylinder tare mass plus 80%
of the water capacity mass multiplied by the specific gravity of the refrigerant recovered at 77 F [25 C].
Informative Note:Further recommendations on containers and proper storage of recovered refrigerants may be found in
AHRI Guideline K, Containers for Recovered Fluorocarbon Refrigerants.15
10.2.5 Dedicated Containers. For reasons of safety, and to avoid cross-contamination or misidentification of
refrigerants, containers shall only be filled with the refrigerant indicated on the container.
10.2.6 Vapor Space for Low-Pressure Refrigerants. Drums that originally contained low-pressure refrigerants such
as R-11, R-123, or refrigerant R-113 (excluding those originally used for cleaning agents), if used again for the same
recovered low pressure refrigerant, shall be filled to allow a vapor space that is at least equal to 10% of the drum height.
15
11. NORMATIVE REFERENCES

References required for compliance with this standard are listed below. Informative references are listed in Annex C.
1. ANSI/ASHRAE Standard 15-2010, Safety Standard for Refrigeration Systems. 2007. American Society of Heating,
Refrigerating and Air-Conditioning Engineers, Inc., Atlanta, Ga.
2. AHRI 580-2009, Performance of Non-Condensable Gas Purge Equipment for Use with Low Pressure Centrifugal
Chillers.Air-Conditioning, Heating and Refrigeration Institute, Arlington, Va.
3. ASTM D642-2000 (RA2005), Standard Test Method for Determining Compressive Resistance of Shipping
Containers, Components, and Unit Loads. ASTM International, West Conshohcoken, Pa.
4. ASTM D4577-2005, Standard Test Method for Compression Resistance of a Container Under Constant Load. West
Conshohcoken, Pa.
5. ASTM D999-2008, Standard Test Methods for Vibration Testing of Shipping Containers. West Conshohcoken, Pa.
6.. ASTM D4728-2006, Standard Test Method for Random Vibration Testing of Shipping Containers. West
Conshohcoken, Pa.
7. ASTM D6055-1996 (RA 2007) Standard Test Methods for Mechanical Handling of Unitized Loads and Large
Shipping Cases and Crates. West Conshohcoken, Pa.
8. ASTM D6179-2007, Standard Test Methods for Rough Handling of Unitized Loads and Large Shipping Cases and
Crates. West Conshohcoken, Pa.
9. ASTM D880-1992 (RA 2008), Standard Test Method for Impact Testing for Shipping Containers and Systems. West
Conshohcoken, Pa.
10. ASTM D5276-1998 (RA 2009), Standard Test Method for Impact Testing for Shipping Containers and Systems.
West Conshohcoken, Pa.
11. U.S. Code of Federal Regulations, 40 CFR, Part 82, Subpart F.
12. ANSI/ACCA 4, Maintenance of Residential HVAC Systems.
13. ANSI/ASHRAE/ACCA Standard 180-2008, Standard Practice for Inspection and Maintenance of Commercial
Building HVAC Systems. American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., Atlanta, Ga
14. DOT 39, Department of Transportation, Code of Federal Regulations, 49 CFR, Part 178, Subpart C.
15. AHRI Guideline K-2009, Containers for Recovered Fluorocarbon Refrigerants. Air-Conditioning, Heating and
Refrigeration Institute, Arlington, Va.
16. UL 1995 (3rd Edition, 2/18/05), Heating and Cooling Equipment. Underwriters Laboratories.
17. ANSI/ASHRAE Standard 34-2010, Designation and Safety Classification of Refrigerants. American Society of
Heating, Refrigerating and Air-Conditioning Engineers, Inc., Atlanta, Ga.
16
(This annex is not part of this standard. It is merely informative and does not contain requirements
ASHRAE or ANSI.)
INFORMATIVE ANNEX A
RECOMMENDED PROCEDURES AND PRACTICES
A1 INTRODUCTION
This annex contains practices and procedures that are recommended but not required for compliance with this standard.
A2 RECOMMENDED DESIGN PRACTICES
A2.1 Compressors
A2.1.1 Shaft Seals. Shaft-seal designs that do not rely on the commonly used carbon faces are available. Double-faced
seals and single-carbon seals with improved features to keep the carbon in a wet state have been found to be effective
and may be used.
The design and installation of the shaft-seal assembly should minimize external oil loss and prevent direct refrigerant
loss. Lack of lubrication during shutdown periods can cause the mating faces of the seal to dry out and adhere together.
On large systems, a separate oil pump to lubricate the seal prior to starting the compressor is recommended.
Open compressors typically have carbon-face seals that require positive pressure in order to function properly. Since
these are not two-way seals, leakage may occur during evacuation. To prevent leakage, temporary sealing measures
such as shaft caps or clay-like weather stripping around the protrusion of the shaft should be used. The motorcompressor alignment is critical in limiting refrigerant leakage and is affected by the style of the coupling and the speed
and power of the motor. Refrigeration machinery requires stringent alignment to accommodate thermal growth over the
load and temperature ranges. It is recommended that a tool utilizing laser alignment technology be used. If the motor or
compressor is removed and replaced in the field, it is best practice to utilize this type of alignment tool.
At a minimum, it is recommended that a tool utilizing laser alignment technology be used. If the motor or compressor
is removed and replaced in the field, it is best practice to utilize this type of alignment tool.
Shutdown and start-up procedures should ensure that oil is present to wet the seal faces. It may be necessary to run the
oil pump and rotate the shaft periodically during long shutdown periods. If this is not possible, the seals should be
inspected and lubricated before starting the system.
A2.1.2 Vibration. Vibrations from gas pulses are best handled by a muffler placed as close to the compressor as
possible. For those compressors that are spring-mounted, vibration elimination should be provided in the suction and
discharge lines.
When piping vibration eliminators are used, they should be rated for the design pressure used and they should be
parallel with the shaft of the compressor and anchored firmly at the upstream end in the suction line and the
downstream end in the discharge line.
A2.2 Condensers and Evaporators
A2.2.1 Air-Cooled Condensers and Evaporators
A2.2.1.1 Excessive vibration from compressors or other equipment can cause tube failure. These effects should be
considered.
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A2.2.1.2 Construction materials and methods of design should be selected to preclude emissions of refrigerant as a
result of release during normal operation. For known corrosive environments (e.g; a service deli case where food items
are being refrigerated or a coastal environment where corrosion is eminent) the coil must have an adequate tubing
thickness or coating or other fin material to ensure adequate life of the heat exchanger.
A2.2.1.3 Condensers and evaporators should be designed to keep the refrigerant volume (charge) as small as possible.
A2.2.1.4 Air-cooled condensers and evaporators should be constructed with the fewest practicable number of joints and
return bends. Brazing is the preferred method of joining (see also Section 4.5.1).
A2.2.2 Liquid-Cooled Condensers and Evaporators
A2.2.2.1 Excessive vibration can cause failure of shell-and-tube heat exchangers. Vibration from any of several sources
can cause tube failure: (a) The boiling action in flooded evaporators can cause vibration at the natural frequency of the
tubes, creating excessive wear at tube supports and possible failure. This problem can be avoided with tube supports
that are properly spaced and sized. (b) Excessive fluid velocity in condensers and evaporators can set up vibrations that
will cause premature tube failure. Precautions similar to those described above can minimize the problem.
A2.2.2.2 Excessive fluid velocity in water-cooled condensers and evaporators can lead to premature failure by erosion.
As velocities increase, the potential for premature failure increases as the square of the velocity. Care must be taken that
design fluid velocities are within good practice for the material selected. Tube blockage, can result in increased
velocities above design for normal flow through the heat exchanger. The potential for damage will be reduced by
limiting velocities.
A2.2.2.3 In applications where condenser fluid flows inside the tubing, fouling can lead to premature tube failure.
Proper filtration can reduce erosion caused by foreign particles in the fluid. Proper chemical treatment can minimize the
effects of corrosive elements in the fluid.
A2.2.2.4 Seawater-cooled systems are especially susceptible to corrosion, as are some systems using waters containing
traces of ammonia or microbiological organisms. These contaminants will attack the tubes and may also attack tube
sheets and heat-exchanger heads leading to leakage. Facilities for routine flushing and inspection are advisable.
Special linings and special tube materials may be required to minimize attack on these surfaces.
A2.2.3 Evaporative Condensers

A2.2.3.1 Proper water treatment can minimize the effects of corrosive elements in the evaporative fluid.
A2.3 Piping, Tubing, and Connections
Strainers, filters, and driers should be utilized to control moisture and capture solid contaminants, which will minimize
damage to moving parts and avoid plugging of refrigerant circuits caused by contaminants in the system. These
components should be isolated with valves (or pump-out capability provided) to permit quick recovery of refrigerant
before component servicing and to reduce the potential for excessive refrigerant loss. Supports and bimetal transition
joints should be designed to guard against electrolytic corrosion.
A2.4 Access and Isolation Valves
Access valves should be located where pressure readings will be taken. Adequate isolation of system components such
as gauges, operating controls, and major components (compressors, heat exchangers, expansion devices, receivers, and
accumulators) should be provided to minimize refrigerant loss during servicing or replacement in accordance with
ANSI/ASHRAE Standard 15-2010, Safety Standard forRefrigeration Systems. Valves not having an internal stem
diaphragm should be provided with seal caps to fit over the stem (if so equipped) in order to minimize leak sources.
Seal caps should be tightened metal-to-metal seal type or should have equally effective long term sealing capability and
should be attached to the valve body by a strap or chain to avoid losing them in service.
A2.5 Relief Devices
18
A2.5.1 separate relief devices may be provided for the high and low sides; however, high-side, pressure-relief devices
may be piped so as to discharge into the low side of the system provided that
(a) they are of a type not appreciably affected by back pressure and that
(b) the low side is equipped with a pressure-relief device of sufficient capacity as specified in ANSI/ASHRAE Standard
15-2007, Safety Standard for Refrigeration Systems, to protect all connected vessels, compressors, and pumps subjected
to excess pressure simultaneously. In centrifugal systems where the condenser cannot be isolated from the evaporator,
a single pressure-relief device will suffice to protect the system in accordance with ANSI/ASHRAE Standard 15-2007,
Safety Standard for Refrigeration Systems.
A2.5.2 Where a relief valve is used, a rupture disc should be installed upstream of the valve to protect the valve from
corrosion or inadvertent release. An indicator should be installed between the rupture disc and the relief valve to
indicate that the disc has ruptured. The rupture disc should be a non-fragmenting type. Once the rupture disc has burst,
it should be replaced as soon as possible. It may be necessary to remove the remaining refrigerant charge before
replacing the disc. Where a rupture disk is used as the sole relief device, a relief valve is not required downstream, and
the use of a non-fragmenting rupture disk is not required.
Note: When pressure-relief devices are installed in series, provisions of Section VIII of the ASME Unfired Pressure
Vessel Code should be observed.
A2.6 Marking and Instruction
The manufacturer should document for the user the refrigerant name, charging quantity, and needed instructions of
equipment installation, testing, operation, maintenance, repair, and disposal.
A2.7 Type 4 -Specific Topics: For factory-sealed systems, soldering, epoxy joining, and any other method
demonstrated to maintain the hermetic nature of the system is acceptable as an alternative to brazing.
A2.8 Type 5, 6, 7 -Systems-Specific Topics
A2.8.1 Compressors. Suction and discharge fittings, whether mechanical or brazed joints, should be easily accessible
for the service person. This will help to ensure a leak-free installation if the compressor fails and must be replaced.
A2.8.2 Air-Cooled Condensers and Evaporators.
Some commercially available silicone marine sealants have proven effective for protecting copper-aluminum joints
from electrolytic corrosion.
A2.8.3 Piping and Connections
A2.8.3.1 Brazing is the preferred method of joining pipe to fittings, valves, and other components.
A2.8.3.2 It is recommended that driers have a hermetic shell and braze fittings; however, the shell and fittings, whether
brazed or mechanical, should be easily accessible for the service person if the drier needs to be replaced.
A2.8.3.3 Pre-charged line sets are the preferred method of connecting HFC-based split systems. EPA regulations
prohibit the sale of line sets pre-charged with HCFC-22. Field-installed lines requiring brazing, evacuation, and
charging introduce more risk of release. If pre-charged line sets are provided for connecting the indoor and outdoor
units of split systems, an adequate array of choices is recommended in order to allow proper line selection. This will
facilitate better control of cleanliness, minimize use of fittings, and help ensure proper line sizing for oil return and
charge control.
A2.8.4 Valves
A2.8.4.1 Due to temperature excursions while in heating-cycle duty and cooling-cycle duty, nonmetallic O-ring or
gasket seals beneath a thumb-tightened cap tend to vulcanize or set with time and temperature, allowing refrigerant
that seeps past the self-closing stems to escape the system. Metal-to-metal-type seal caps will help minimize this
leakage. Adequate instructions for proper tightening of the access valve caps should be provided.
19
A2.8.4.2 Expansion valves, if used in a unitary system, should be of the type that has superheat preset at the factory,
thus eliminating mechanical joint s that accommodate a superheat stem. The body and element should be hermetic with
brazed fittings.
A2.8.4.3 Where possible, check valves, reversing valves, and solenoid valves should be brazed into the system at the
factory.
A2.9 Type 7 and 8 Equipment-Specific Topics
A2.9.2 Prevention-of-Vacuum Systems and Leak-Test Pressurization Systems. Low-pressure systems can develop
a vacuum during idle periods, causing non-condensable infiltration into the system. A prevention-of-vacuum system
controls refrigerant pressure by applying heat to the evaporator. This results in maintenance of a pressure equilibrium
between the chiller and atmosphere when idle. As a result, neither air can infiltrate nor refrigerant escape through
possible leak paths. Prevention-of-vacuum systems may also be used to pressurize low-pressure chillers for the purpose
of leak testing.
A3 PRODUCT DEVELOPMENT
A3.1 Refrigerant Handling
Refrigerant recovery/recycling systems are recommended in laboratories employing refrigerant. Laboratory
recovery/recycling systems should be examined for leaks on a frequent (at least monthly) basis.
A3.2 Vibration Tests
Vibration testing should be done to identify packaging or tubing weaknesses that could cause leaks during shipment.
A3.3 Storage
Temporary and prototype systems should not be stored for more than six months while containing refrigerant.
Temporary and prototype systems stored for more than six months should contain positive-pressure inert gas.
A4 MANUFACTURE
A4.1 Evacuation
To remove moisture during the manufacture of new air-conditioning or refrigerating equipment, the unit should be
purged with heated dry air (40F [40C] dew point). After purging, a deep vacuum evacuation, which involves a
single extended evacuation of the unit, should be performed. Air and other noncondensable gases may be removed by
deep evacuation.
A4.2 Internal Cleanliness: Every effort should be made to ensure internal cleanliness of components and equipment.
A4.3 Factory Leak Test
A4.3.1 Leak Test Methods
All factory leak test methods fall into one of two catagories: the leak rate measurement method (reveals the presence of
a leak) or the leak location method (reveals the location of a known leak). Some common examples of these two
methods being used in the HVAC industry are as follows:
A4.3.1.1 Leak Rate Measurement Methods

A4.3.1.1.1 Pressure Decay
A4.3.1.1.2 Vacuum Decay
A4.3.1.1.3 Helium Inside-Out Vacuum Chamber Test (ASTM E493)
A4.3.1.1.4 Helium Accumulation Test (Method B of ASTM E499)
A4.3.1.1.5 Helium Hood Test (ASTM 1603)
A4.3.1.2 Leak Location Methods
A4.3.1.2.1 Bubble Test Immersion
20
A4.3.1.2.2 Bubble Test Application of Liquid Film
A4.3.1.2.3 Detector Probe Test (Method A of ASTM E499)
A4.3.1.2.4 Tracer Probe Test (Method A of ASTM E498)
Leak rate measurement methods do not provide information on the number and location of individual leaks. Leak
location methods alone can not give reliable assurance that no leaks exist or that tests have revealed all leaks that exist.
Without prior assurance that leaks do exist, leak location test methods become arbitrary in application. Multiple sources
for this often overlooked conclusion and resulting misapplication of leak location methods can be cited in the literature
including:
ASTM E432, Paragraph 6.1.
ASME Boiler & Pressure Vessel Code, Section V - Nondestructive Examination, Article 10 Leak
Testing, Paragraphs III-1010, IV-1010, and V-1010(a).
ASNT Nondestructive Testing Handbook, Volume 1 Leak Testing, 3rd Edition, pages 20, 320, 345, 346,
348.
In practice, preliminary leak testing is usually done first by a less sensitive means to permit the identification, location,
and repair of gross leaks. Next the system or component is subjected to an overall leak rate measurement test to
determine if it meets the leakage acceptance criterion. When the system or component fails to meet the leakage
acceptance criterion, individual leak sites are identified through the use of a sensitive leak location test method and
repaired. For final assurance that the system or component meets the leakage acceptance criterion, it is necessary to
repeat the leak rate measurement test at the conclusion of the location and repair process.
A4.3.2 Selection and Sensitivity of Leak Testing Methods

(Note that statements below are based largely on ASTM E432 Standard Guide for Selection of a Leak Testing
Method)
The correct choice of a leak test methods optimizes sensitivity, cost, and reliability of the test. It is important to
recognize that leak location should be attempted after the presence of a leak has been verified by a leakage
measurement test. One approach to choosing a leak measurement method is to rank the various methods according to
test system sensitivity. The various testing methods must be individually examined to determine their suitability for the
particular system being tested. Only then can the appropriate method be chosen. It is important to distinguish between
the sensitivity associated with the instrument employed to measure leakage and the sensitivity of the test methodology
followed using the instrument.
Test methods that are based on pressure change (pressure decay and vacuum decay) do not typically have sufficient
sensitivity to meet the needs of components and systems used in HVAC applications (see Section 8.3.1 of Zero Leaks
Limiting Emissions of Refrigerants published by ASHRAE).. The pressure change test methods are useful to verify
that a component or system is free from gross leaks.
In general, leakage measurement procedures suited to HVAC components and systems involve covering the whole of
the suspected region with tracer gas, while establishing a pressure differential across the system by either pressurizing
with a tracer gas or by evacuating the opposite side. The presence and concentration of tracer gas on the lower pressure
side of the system are determined and then measured. A dynamic test method (like the vacuum chamber test) can be
performed in a relatively short time. Static techniques (involving accumulation) can be employed to increase the test
sensitivity while also increasing the time required for testing.
Leakage measurement methods that evacuate the internals of the component or system (like the hood test) are not
suitable for HVAC applications where the component or system is subjected to a positive pressure in operation. Leaks
may temporarily plug due to moisture, lubricants, flux, etc. and go undetected when tested at the low differential
pressure conditions typical of testing evacuated components or systems.
Optimum leakage measurement methods suited to HVAC components and systems are vacuum chamber testing (as
described in ASTM E493) and accumulation testing (as described in Method B of ASTM E499). These two methods
are used in practice with a number of different tracer gases including Helium (pure or mixed with Nitrogen), refrigerant
21
(pure or mixed with Nitrogen) and 5% Hydrogen / 95% Nitrogen. The resulting sensitivity of the leakage measurement
test will depend on a number of design factors and operating parameters. For small components and systems
(nominally 1m3 external volume) these two methods are capable of readily and realistically detecting tracer gas leakage
equivalent to R-410A leakage of less than 1 oz/yr from 250 psig into atmosphere. For larger components and systems,
the sensitivity that is readily and realistically attainable will be somewhat higher.
A4.3.3 Leak Rate Measurement Methods

A4.3.3.1 Pressure Decay
Typically this test consists of charging the system or component with a gas, closing a valve to isolate the gas
supply, and monitoring the pressure inside the system or component. A decrease in pressure over time is
indicative of a leak. If the internal free volume of the pressurized unit under test is known, the leak rate can be
calculated by using the following formula:
Q =
P V
t
where: Q = Leak Rate (atm-cc/sec)

P = Pressure Change Inside the Part Under Test (atm)
V = Internal Free Volume (cc)
t = Time over which the P occurred (sec)
The ultimate sensitivity of a pressure decay test is limited by the effects of temperature because changes in
temperature result in corresponding changes in pressure. Calculations in the literature show that in regards to
HVAC systems and components, pressure decay testing is suitable to insure that gross leaks do not exist.
Pressure decay testing sensitivity is typically insufficient for HVAC systems and components (see Section
8.3.1 of Zero Leaks Limiting Emissions of Refrigerants published by ASHRAE).
Advantages of the pressure decay test are
tests the system or component under positive pressure (most HVAC systems and components operate
under positive pressure conditions)
requires relatively inexpensive hardware
can be done at high pressure to simultaneously satisfy any proof pressure test requirements on the
assembly line
easily automated
simple to understand, requires minimal training of personnel
also can serves as a simultaneous leak location test
Disadvantages of the pressure decay test are
internal free volume is often unknown and must be measured to get a quantifiable result
tests at high pressure can pose a safety hazard to personnel
suitable only for gross leak testing in most HVAC applications
unacceptable leaks may take excessive amounts of time.
this test procedure should not be used as a final test to ensure a leak free joint or assembly.
4.3.3.2 Vacuum Decay
Typically this test consists of evacuating the system or component with a vacuum pump, closing a valve to
isolate the pump, and monitoring the pressure inside the system or component. An increase in pressure over
time is indicative of a leak. If the internal free volume of the evacuated unit under test is know, the leak rate
can be calculated by using the following formula:
Q =
P V
t
where: Q = Leak Rate (atm-cc/sec)

P = Pressure Change Inside the Part Under Test (atm)
22
V = Internal Free Volume (cc)
t = Time over which the P occurred (sec)
The ultimate sensitivity of a vacuum decay test is limited by the effects of outgassing. Outgassing in the
system or component causes the pressure to rise for reasons other than leakage and this inherent P can lead to
false failures. (There are a number of sources of outgassing in HVAC systems and residual water is almost
always present to some degree.) Calculations in the literature show that in regards to HVAC systems and
components, vacuum decay testing is suitable to insure that gross leaks do not exist. Vacuum decay testing
sensitivity is typically insufficient for HVAC systems and components (see Section 8.3.2 of Zero Leaks
Limiting Emissions of Refrigerants published by ASHRAE).
Advantages of the vacuum decay test are
vacuum assists in sealing to the unit under test
easily automated
Disadvantages of the vacuum decay test are
internal free volume is often unknown and must be measured to get a quantifiable result
tests the system or component under vacuum (most HVAC systems and components operate under
positive pressure conditions)
leaks may temporarily plug due to moisture, lubricants, flux, etc. and go undetected when tested at
low differential pressure conditions
suitable only for gross leak testing in most HVAC applications
leak location on the system or component while it is under vacuum can be problematic and often a
separate positive pressure test is required to locate the site of a gross leak
4.3.3.3 Helium Inside-Out Vacuum Chamber Test (ASTM E493)

This test is referred to as an Inside-Out test because the tracer gas (Helium) is inside the system or
component under test and it is detected on the outside of the unit under test when a leak is present. The test
is performed with the unit under test inside a vacuum chamber which is coupled to a mass spectrometer leak
detector. The unit under test can be filled with tracer gas prior to loading it into the chamber (referred to as a
pre-charged test) or the unit can be filled with tracer gas while it is inside the chamber via a line that is
connected to it through the chamber wall (referred to as a charge-in-chamber test). The output of the leak
detector during the inside-out test of the unit is compared to the output registered by a calibrated leak at the
same test conditions to determine if the unit satisfies the leakage acceptance criterion. Analogous inside-out
vacuum chamber test methods can be employed with tracer gases other than Helium.
Advantages of the inside-out vacuum chamber test are
sufficient sensitivity to meet the leak testing needs of most all HVAC systems and components
chamber can serve as a safety guard for personnel when the charge-in-chamber technique is utilized
easily automated
Disadvantages of the inside-out vacuum chamber test are
hardware is expensive relative to other leak rate measurement methods
requires trained personnel for maintenance and troubleshooting
presence of tracer gas in the ambient air (background) can be problematic
4.3.3.4 Helium Accumulation Test (Method B of ASTM E499)

In this test the system or component is pressurized with tracer gas (Helium) and it is held in a sealed enclosure.
The air in the enclosure is well mixed with a fan over a period of time allowing any leakage to accumulate.
23
When the necessary dwell time has elapsed, the air inside the enclosure is sampled with a mass spectrometer
leak detector. By introducing a calibrated leak into the same volume for the same elapsed time, the leak
detector output with the unit under test can be compared to the output registered by the calibrated leak to
determine if the unit satisfies the leakage acceptance criterion. Analogous accumulation test methods can be
employed with tracer gases other than Helium.
Advantages of the Helium accumulation test are
sufficient sensitivity to meet the leak testing needs of most all HVAC systems and components can be
attained
hardware cost is lower than chamber test
easily automated
Disadvantages of the Helium accumulation test are
dwell time necessary to accumulate sufficient tracer gas for reliable go-no-go test may be
unacceptable in a production line setting
4.3.3.5 Helium Hood Test (ASTM 1603)

The test is performed with the unit under test inside a hood which is filled with Helium. The unit under test
is evacuated and coupled to a mass spectrometer leak detector. This test is sometimes referred to as an
Outside-In test because the tracer gas (Helium) is outside the system or component under test and it is
detected on the inside of the unit under test when a leak is present. The output of the leak detector during
the test of the unit is compared to the output registered by a calibrated leak at the same test conditions to
determine if the unit satisfies the leakage acceptance criterion. Analogous hood test methods can be
employed with tracer gases other than Helium.
Advantages of the hood test are
sufficient sensitivity to meet the leak testing needs of most all HVAC systems and components
easily automated
Disadvantages of the hood test are
A4.3.4 Leak Location Methods

A4.3.4.1 Bubble Test Immersion
In this simple test, the system or component is pressurized with tracer gas (typically air) and then immersed in a
liquid bath (typically water) and an operator looks for bubbles. Bubbles may emerge from the unit under test at
such a rapid rate that there is no question of the existence and location of a leak. When small leaks are to be
located the unit under test must remain submerged long enough for any bubbles coming from crevices to have a
chance to collect and rise. Although longer waiting periods theoretically should result in higher sensitivity, the
sensitivity is limited when the rate of bubble evolution approaches the rate at which the gas is dissolving in the
liquid. In addition to dwell time, test sensitivity is influenced by clarity of the liquid, lighting, proximity of the leak
site to the operator, and a number of human factors.
24
Advantages of the bubble immersion test are
tests the system or component under pressure (most HVAC systems and components operate under
with proper safety guarding, testing can be done at high pressure to simultaneously satisfy any proof
pressure test requirements on the assembly line
the entire pressurized component can often be examined simultaneously
leaks at test fittings and can be effectively ignored by the operator and will not influence test
sensitivity
Disadvantages of the bubble immersion test are
introduces water into the manufacturing process which can be problematic for subsequent dehydration
operations in the HVAC industry
there are often housekeeping and safety issues associated with the immersion tank and dripping wet
parts
human factors have a strong influence on test results, especially in the location of small leaks
4.3.4.2 Bubble Test Application of Liquid Film

The liquid film application test technique can be used to locate leaks on any system or component on which a
positive pressure differential exists across the wall. The test liquid is applied to the exterior surface (application by
spray or brush is common) and the joint is examined for bubbles in the solution film. The area to be inspected
should be positioned to allow the liquid to lie on the surface without dripping off.
Advantages of the liquid film application bubble test are

sensitivity
Disadvantages of the liquid film application bubble test are
introduces water and soap into the manufacturing process which can be problematic for subsequent
dehydration operations in the HVAC industry
4.3.4.3 Detector Probe Test (Method A of ASTM E499)

In this test the system or component is pressurized with tracer gas and the detector is used to probe the external
surfaces of the unit under test to locate leak sites. This test technique is commonly referred to as Helium sniffing
or refrigerant sniffing where reference is made to the specific tracer gas in use. Factors that influence the
sensitivity of the detector probe test include the speed at which the probe is moved, the distance between the
surface of the part and the probe, and the orientation of the probe relative to the direction of the gas exiting the
defect. When Helium is used as the tracer gas test sensitivity can be limited by the natural presence of about five
parts per million (ppm) Helium in the air. Successful detector probe leak testing with Helium is contingent on the
ability of the detector to discriminate between natural atmospheric Helium, which is very constant, and an increase
in Helium concentration due to a leak. If the normally stable atmospheric Helium level is increased by the release
of Helium in the test area, the reference level becomes unstable, and sensitive leak testing is more difficult. When
using tracer gases other than Helium, similar precautions must be taken to limit inadvertent releases and to control
the ambient background.
25
Advantages of the detector probe test are
sensitivity
Disadvantages of the detector probe test are
susceptible to changes in ambient background
4.3.4.4 Tracer Probe Test (Method A of ASTM E498)

In this test the system or component is evacuated and the internal volume of the unit under test is sampled by the
leak detector. The external surfaces of the unit under test are then probed with tracer gas and the response of the
leak detector is used to locate leak sites. This test technique is commonly referred to as the Helium spray test
where reference is made to the specific tracer gas in use. In use it is common to first flood the surface with a flow
of tracer gas to determine if a leak exists, and when a leak is detected the flow is throttled to a minimum in order to
pinpoint the location.
Advantages of the tracer probe test are

not as sensitive to human factors as other leak location test methods
Disadvantages of the tracer probe test are
A5 INSTALLATION
A5.1 Installation of Assembled and Field-Erected Equipment and Systems (Types 6, 8, 9, and 10)
Cleaning of tubing and fittings prior to assembly may be done with a wire fitting brush or sand cloth. Avoid abrasive
materials that may leave deep marks on the copper surfaces. Preparation may include cleaning to remove oil. Purging
with inert gas is required during heating to prevent oxidation, which can cause plugged driers, filters, strainers, dirty oil,
and compressor failure. Isolation valves may be installed to allow service of all filter driers without removal of
refrigerant charge.
A5.2 Leak Testing by Pressure
A5.2.1 Uncharged, Assembled and Field-Erected Systems.
Remove all transducer and pressure-sensitive equipment that may be affected by excess pressure or vacuum during
installation. These ports should now be sealed. Pressurize the entire system with dry nitrogen to near operating
pressure and observe pressure decay over a
period of time for any loss in pressure.
A5.2.2 Field-Charged, Factory-Built Systems.
On systems that have been factory-built and that have been pressure-tested in accordance with ANSI/
ASHRAE Standard 15-2007, Safety Standard forRefrigeration Systems, and require no field refrigerant piping, no
additional pressure testing is suggested unless required by the manufacturer.
A5.2.3 Pre-charged, Field-Erected Systems.
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Some field-erected systems use factory pre-charged line sets and condensing units. Pressure testing of pre-charged
components is not required prior to field assembly.
A5.2.4 Factory-Charged, Factory-Built Systems.
On systems that have been factory built and that have been manufactured in accordance with ANSI/
ASHRAE Standard 15-2007, Safety Standard forRefrigeration Systems, and require no field refrigerant piping, no
additional pressure testing is suggested unless required by the manufacturer.
A5.3 Leak Testing
A5.3.1 Initial Leak Testing of Uncharged of Type 6, 8, 9 and 10.
Leak detection may be performed in three steps:
(a) With the system under nitrogen pressure, apply soap solution to all likely leak spots and observe; bubble formation
indicates a likely large leak. This test should not be the only leak detection performed; methods (b) and/or (c) below
should be performed.
(b) With a trace halocarbon gas mixed with nitrogen at pressure, check probable leak spots with a halogen leak detector,
preferably an electronic type, or an ultrasonic leak detector.
(c) After removing pressurization gas, perform a triple evacuation with nitrogen purges in between. Draw first vacuum
to 1500 microns, hold for one hour, then purge with nitrogen. Draw second vacuum to 1000 microns, hold for one
hour, then purge with nitrogen. Draw third vacuum to 500. Valve off the system from the vacuum pump. Monitor the
system to determine if it holds the vacuum, thus indicating acceptable leak tightness and dehydration. Step (a) or (b)
may be skipped, but step (c) should be used as a final check of leak tightness. If step (c) fails, return to step (a) or (b) to
locate the leak(s). Then repeat step (c). Completing step (c) fulfills the minimum requirement of Section 7.4.
A5.3.2 Leak Testing of Field-Charged, Factory-Built Systems. On systems that are factory-built and that have been
factory leak-tested according to Section 6.3, no further leak testing is necessary unless required by the manufacturer.
After charging refrigerant, the field charging port or process tube should be leak-tested.
A5.3.3 Leak Testing of Pre-Charged, Field-Erected Systems. Some field-erected systems use factory pre-charged
line sets and condensing units. Before assembly, leak testing of pre-charged components is not required. After
assembly, the field connection joints should be inspected using point test methods described in Section A4.2.4. No
additional leak testing is suggested unless required by the manufacturer.
A5.3.4 Leak Testing of Factory-Charged, Factory-Built Systems. On systems that have been factory-built and that
have been manufactured according to Section 6 and require no field refrigerant piping, no additional leak testing is
suggested unless required by the manufacturer.
A6 SERVICE/OPERATION/MAINTENANCE/DECOMMISSIONING
A6.1 Servicing
Care should be taken in the selection and use of cleaners for clearing dirt and debris from condenser coils or other
similar equipment. They should be compatible with the composition of the coils and environmental conditions. Cleaners
should be used in accordance with manufacturers' instructions and based upon need. Systems that normally operate
under a vacuum may be put under positive pressure by applying heat to the evaporator. If the system has an electric
defrost cycle, the system may be pumped down and the defrost cycle initiated after the compressor is shut off. Belts on
open belt-driven condensing units and couplings on open direct-drive compressors should be thoroughly checked at
least annually for wear, damage, and misalignment. Misalignment, damaged belts, or over tensioning belts can cause
compressor shaft seal or front-end bearing failure, resulting in refrigerant leaks. Charging lines not equipped with selfclosing connections should be lightly purged prior to use on the system.
A6.2 Cleaning a Compressor System after a Mechanical Failure, Contamination, or Motor Burnout
A6.2.1 Removal of Compressor and other components. When removing the compressor, isolate the compressor
from the system as much as possible. Follow Federal Guidelines for removal of the refrigerant. Remove and replace
the compressor as required.
27
A6.2.1.1 Other components that should be replaced include but are not limited to:
Suction Filters (depending on the type of compressor failure) or suction filter dryer cores should be used.
The Oil Filter and Liquid Line Filter Drier should be replaced.
The Oil Level Float (or other oil level control device) should be cleaned and serviced.
A6.3 System Operation and Maintenance
A6.3.1 Advice to Service Technicians and Users. Less refrigerant leakage will be experienced when equipment
designed to minimize leakage is used. All equipment should be properly operated and maintained to ensure minimum
refrigerant leakage during its operating life. The following are offered as guidelines to minimize refrigerant leakage
from equipment during operation and maintenance.
A6.3.2 General Inspections. Proper and frequent inspection of equipment can preclude catastrophic failures and can
minimize refrigerant loss. A simple walk-around inspection can point out things such as oil leaks and, in some cases,
excessive refrigerant leaks. A portable refrigerant leak detector can enhance this search for refrigerant leaks. In general,
a system that is routinely inspected is less likely to leak excessive amounts of refrigerant.
A6.3.3 Compressor Inspections. The most significant routine compressor inspection would be for oil leaks. This could
indicate a severe seal leak that would probably leak either refrigerant out of a high-pressure system or air into a lowpressure system. Seals on open compressors that are shut down for any length of time will dry out. The seal faces
should be oiled periodically. This can be accomplished by running the compressor to ensure that the seal has a
continuous oil film for sealing. Periodic oil analysis should be performed to determine the condition of the compressor.
The appearance of bearing metals, tube metals, and contaminants can be used to catch a failure before it occurs.
Catastrophic damage and the associated loss of refrigerant can therefore be avoided.
A6.3.4 Water Side of Shell-and-Tube Condenser and Evaporator Inspections. The water side of condensers should
be opened annually and evaporators drained as often as needed to permit visual inspection of the tubes, the tube sheets,
and the heads. This inspection should detect excessive corrosion, plugging of tubes, and excessive fouling. An eddy
current test may be performed to check relative tube-wall thickness. Eddy current tests can also detect a hole or signs of
wear or corrosion in a tube. These inspections can minimize catastrophic failure of the tubes and will facilitate timely
replacement of damaged tubes.
A6.3.5 DX Coil and Air-Cooled Condenser Inspections.
These heat exchangers can generally be inspected externally when the air handlers are shut down. Visual inspection
should include checking the condition of fins, for excessive fouling with foreign matter, for corrosion of fins and tubes,
the appearance of oil leaks, for dye leaks on equipment charged with a dye-leak detector, and for cracks in tubes or
manifolds.
A6.4 System Monitoring
A6.4.1 General. Significant loss of refrigerant can be attributed to improper operation, just as improper operation can
be a sign that refrigerant has leaked. To track proper operation, the following should be logged whenever the system is
serviced:
(a) Chilled water or other secondary coolant inlet and outlet temperatures
(b) Chilled water or other secondary coolant flow (if available)
(c) Chilled water or other secondary coolant inlet and outlet pressures (or differential pressure)
(d) Evaporator refrigerant pressure and temperature
(e) Condenser refrigerant pressure and liquid temperature
(f) Condenser water inlet and outlet temperatures
(g) Condenser water inlet and outlet pressures (or differential pressure)
(h) Condenser water flow (if available)
(i) Refrigerant levels
(j) Oil pressures and temperatures
(k) Oil levels
(l) Compressor refrigerant discharge temperature
(m) Compressor refrigerant suction temperature
28
(n) Addition of refrigerant (in refrigerant log, see Section 7.5)
(o) Addition of oil
(p) Vibration levels (if monitored) or observation that vibration is not excessive
(q) Motor amperes per phase
(r) Motor volts per phase
(s) PPM refrigerant monitor level (if provided)
(t) Purge exhaust time or discharge count (if provided)
(u) Ambient temperatures (dry-bulb and wet-bulb)
(v) Date and time data logged
(w) Signature or initials of person reviewing log
A6.4.2 Condensers. A periodic review of logged condenser performance data can show the presence of air in-leakage
or fouled heat-exchanger surfaces. By checking system temperatures and pressures, the presence of air and
noncondensables can easily be confirmed and corrective action taken without excessive refrigerant loss. In water-cooled
condensers, periodic checks of water flow, pressure drops, and temperatures will reveal when the condenser is fouled or
when the tubes are subjected to excessive velocities, which can cause erosion.
A6.4.3 Water Chiller Evaporators. Checks of performance logs of the evaporator and review of service logs can show
evidence of excessive fouling or plugging, low or high refrigerant levels, or damaged heat exchangers. Fouling or
plugging can cause tube leaks directly due to erosion or indirectly if low evaporator temperatures are experienced in the
evaporator. Low evaporator temperatures can cause freezing in the tubes and rupture the tubes. Low refrigerant levels
can decrease performance, reduce capacity, and cause excessively low evaporator pressures and temperatures.
A6.4.4 System Overpressurization. Fluid pumps should be monitored to prevent extended operation without chiller or
system fans. Such operation can cause overheated fluid temperature. This results in high refrigerant pressure that can
burst the system rupture disk and/or open the relief valve, discharging refrigerant into the atmosphere.
A6.4.5 Freeze Damage. Any water-to-refrigerant heat exchanger can experience freeze damage, resulting in rupture of
the refrigerant circuit, total loss of charge, refrigerant contamination, and water damage to the compressor. Included in
the types of heat exchangers subject to freeze damage are: water-cooled condensers, flooded evaporators, DX
evaporators, and plate-type condensers and evaporators. When there is refrigerant liquid in a heat exchanger and the
refrigerant pressure is allowed to fall below the saturation pressure corresponding to the freezing temperature of the
fluid, and particularly if there is non-flowing fluid in the heat exchanger, the fluid can freeze. This will almost always
rupture the heat exchanger, with the catastrophic results mentioned above. Proper setting of safety controls for
operation of the system and care in servicing will avoid freeze damage. The following precautions should be taken with
water-chilling systems:
(a) Low suction pressure controls should be set to no lower than the freezing temperature of the fluid or the
manufacturer's recommendation.
(b) The chilled-water flow switch should be checked for reliable operation.
(c) A low-temperature cutout in the leaving chilled water stream, set at 34F to 38F (1C to 3C), is a good precaution.
(d) Compressor should not be operable unless the low pressure switch, chilled-water flow switch, and low-temperature
cutout (if provided) are all closed.
(e) When transferring refrigerant from an evaporator or water-cooled condenser during servicing, it is always advisable
to have water flowing through the heat exchanger.
(f) When recovering the refrigerant charge from a heat exchanger, it is safer to remove liquid, maintaining high pressure
in the heat exchanger, than to remove vapor and cause the pressure to drop below 32F (0C) saturation.
(g) If water chillers are mounted outdoors, where the system may be idle during periods with ambient temperatures
below 32F (0C), thorough freeze protection should be practicedinsulation of heat transfer vessels and piping,
including refrigerant piping and heat tracing is advised. Alternatively, water should be thoroughly drained from heat
exchangers during the cold season.
A6.4.6 Refrigerant Monitor. The refrigerant PPM level logged in Section A6.4.1 should be periodically reviewed. If a
significant increase in PPM level is detected, a unit leak test and repair are indicated.
A6.4.7 Inspection for Leaks. Visual inspections should check for possible leak paths, such as loose fittings, joints,
worn shaft seals, and oil leaks. A containment check could include logging of the system refrigerant level, measurement
29
of the system refrigerant charge quantity, and use of leak detection methods. Verification of containment can also be
made through logging of the quantity of non-condensables purged when the system is in a vacuum. If evidence of
leakage is found, or if containment of the system charge cannot be verified, a leak test is recommended to determine the
location of leak(s).
A6.4.8 Leak Detection Methods. Commercially acceptable leak-testing methods should be used for the detection of
refrigerant leaks.
A6.5 Appliance-Specific Topics
Factory-charged, hermetically sealed systems with less than 5 lb (2.3 kg) of refrigerant should follow a servicing
procedure similar to the following:
(a) RecoverySecure entry through the access point and recover the refrigerant.
(b) Leak TestingThe system should be pressurized to at least 75 psig (500 kPa gage). Soap bubbles, a halide torch, an
electronic leak detector, or other equally effective method may be used to locate any leaks.
(c) System PreparationProcedures using a vacuum pump, the system compressor, or other proven methods to ensure
a clean system free from non-condensables are acceptable.
(d) ChargingA charging cylinder that is accurate to within 0.25 oz (7 g), regardless of the ambient temperature,
should be used for charging the system. Wait at least five minutes after the charge has entered before energizing the
system.
A6.6 Large Equipment Specific Topics
A6.6.1 Purge Inspections. Proper operation and maintenance of purge units will avoid excessive refrigerant losses.
Purge system pressures should be compared to design values. Oil and water levels should be checked on units equipped
with such indicators. Excessive water collection in the purge unit can indicate air in-leakage or a tube leak. The
pressure-relief set-point should be checked and adjusted at least monthly. At least annually, a mechanical purge unit
should be opened and inspected for oil fouling and corrosion. At this time, the mechanical components, such as the
purge float valve, should be inspected and renewed. The purge unit should be fitted with an exhaust indicator that notes
either exhaust time or number of discharges. This is an indication of the condition of the purge unit and leakage in the
refrigeration system.
A6.6.2 Monitoring
A6.6.2.1 Large Equipment Monitoring. The purge exhaust quantity logged in Section A6.4.1 should be periodically
reviewed. If a significant increase in purge activity is detected, a unit leak test and repair are indicated. On systems
without purges, the system refrigerant temperatures should be periodically reviewed. If a significant increase of
superheat is detected, a unit leak test and repair are indicated.
A6.6.2.2 High-Pressure Refrigerant Alarm. On large refrigerating systems, additional protection can be provided by
an alarm that notifies personnel of high system refrigerant pressure. Increase in refrigerant pressure, if uncorrected, can
result in refrigerant release through the systems pressure relief device(s).
A6.6.2.3 Compressor Monitoring. Typically, critical variables for a compressor are pressure, temperature, and
vibration. Oil temperatures should be maintained within design tolerance to maintain bearing life and performance. Oil
pressure should be held within design tolerance in order to supply adequate lubrication to prevent bearing overheating
and to maintain sealing surfaces. On open drive machines, excessive vibration could damage the seal and will
eventually damage the compressor; suction and discharge should also be logged. These will give performance
indications that can be tied to carryover caused by faulty evaporator eliminators and high liquid level in the evaporator.
A6.6.3 Maintenance
A6.6.3.1 Compressor Maintenance. Predictive, scheduled, and preventive maintenance should be practiced with semihermetic and open-type compressors. Several key parameters to the successful continued operation of a compressor can
be checked externally on the compressor without a tear-down; however, the compressor should be opened periodically
for inspection and maintenance. (Opening any compressor introduces the possibility of refrigerant loss and seal
problems when the system is restarted.) The equipment manufacturer's operating guides should be consulted concerning
30
the recommended frequency. Some typical frequencies for various equipment types are shown in Table A-1. The
frequency of inspection and maintenance should be based upon the equipment manufacturers recommendation but can
be adjusted on the basis of experience. The use of trained technicians to perform or direct overhauls is recommended.
A6.6.3.2 Additional System Maintenance. Routine inspections are described in Section A6.6. Several items to be
noted during major internal inspections include metering or expansion devices, eliminators in the evaporator, suction
dampers and butterfly dampers (air seals), slide-valve operators, cylinder unloader mechanisms, discharge-line oil
separators and coolers, and filter driers. The presence of excessive rust and loose material should be noted and
corrective action taken.
A6.6.3.3 Storage of Large Equipment. When high pressure systems are idle, their refrigerant pressure causes
continued leakage from the system. Such leaks can result in the loss of the entire refrigerant charge. To minimize this
loss, many systems have pump-down capability that isolates the system charge for storage in a heat exchanger or other
suitable vessel. Use of system pump-down during idle periods is recommended. If a high-pressure system does not
have pump down capability, the removal and storage of the charge during long idle periods is recommended. When
low-pressure systems are idle, their refrigerants are usually under a vacuum. Because of the vacuum, air can infiltrate
the system, requiring purging and possible loss of refrigerant. For this reason, low-pressure systems may be stored for
long periods without removing their refrigerant charge, and no pump-down system or external storage is required.
However, maintaining the system at an atmospheric equilibrium as described in Section A2.9.2 can eliminate air
infiltration. To prevent open shaft seals from drying during storage, periodic operation of the compressor is
recommended to keep the shaft seal oiled and functional.
A7 REFRIGERANT RECOVERY, REUSE, AND DISPOSAL
A7.1 General
Refrigerant disposition can usually be decided before it is removed from the equipment or system. That decision will be
based upon considerations that may include the reason for system shutdown and refrigerant removal, the condition of
the equipment and system, and whether or not it is to be returned to service.
A7.1.1 Recovery of Refrigerant. Refrigerant withdrawn from equipment so that routine service or major overhaul can
be performed can usually be returned to the equipment without reprocessing. If there is any question about the quality
of the refrigerant, it should be analyzed for acids, moisture, high boiling-point residues, and other contaminants before
it is reused. The evacuation and charging procedures described in Section 7 should be followed when returning the
refrigerant to the system. It is advisable to install fresh filter dryer elements before returning the refrigerant to the
system.
A7.1.2 Recycling for Reuse. When a system has been taken out of service because of mechanical failure, refrigerant
contamination, or motor burnout, the refrigerant should be analyzed for contaminants and reprocessed before reuse. The
reprocessing may involve only filtering and drying the refrigerant or it may involve distillation to remove physical and
chemical contaminants.
A7.1.2.1 Once it has been decided that the refrigerant is to be reused in the system from which it has been removed, it
may be recycled for reuse following the procedures described in the 2010 ASHRAE HandbookRefrigeration, Chapter
9, Refrigerant Containment, Recovery, Recycling and Reclamation
A7.1.2.2 When refrigerant is not to be reprocessed for use in the system from which it was removed, it should be
reclaimed to comply with the provisions of AHRI Standard 700-2006, Specifications for Fluorocarbon Refrigerants.
A7.1.2.3 Mixtures of refrigerant and inert gas should not be used for leak testing. If they are, they will generally not
have to be reprocessed before reuse. These mixtures should be withdrawn from equipment prior to charging with
refrigerant and should be stored for future use as a leak-test gas. If the leak-test gas becomes contaminated, particularly
by moisture, it should be filtered and passed through a drier before being injected into a system.
A7.2 Refrigerant Transfer, Transport, and Storage Safety
Refrigerant containers should be examined externally and, if possible, internally for corrosion or other damage that may
weaken the walls, heads, or joints. The examination should be undertaken before filling with refrigerant.
A7.3 Disposal
Destruction of refrigerant usually requires incineration in a facility that is equipped to absorb and neutralize acids and
other toxic or destructive processing products. U.S. EPA regulations for safe disposal of refrigeration and air
conditioning equipment may be found in 40 CFR 82.156.
31
TABLE A-1 Suggested Schedules of Preventative Maintenance

See ACCA/ASHRAE 180 - 2008 and ACCA 4 - 2007 Maintenance Standards
Positive Displacement Units (reciprocating and screw)
Normal temperature5 years or 15,000 hours
Low temperature2 years
Centrifugal Units
Normal temperature5 years
Open unitsannually for external bearings and seals
A8 HANDLING AND STORAGE OF REFRIGERANTS

A8.1 System Connections
Service hoses should not be left connected to refrigerant circuits long term. They may leak or burst, resulting in
refrigerant release.
A8.2 Storage
A8.2.1 Refrigerant containers should be stored in a cool place, away from fire risk, out of direct sunlight, and away
from sources of direct heating.
A8.2.2 Containers should not be dropped.
A8.2.3 When not in use, container valves should be closed and the valve cover nut fitted. Gaskets should be replaced as
required.
A8.2.4 Refrigerant containers with liquid and vapor ports located in the top of the container should not be manifolded
together. This will result in refrigerant transfer and the danger of overfilling the coldest container. Containers with the
vapor port at the top and the liquid port at the bottom may be manifolded as long as the liquid and vapor ports are
connected in parallel.
A8.2.5 Refer to AHRI Guideline K-2009, Containers for Recovered Non-Flammable Fluorocarbon Refrigerants for
additional details and recommended practices regarding containers for recovered fluorocarbon refrigerants.
A8.3 Charging
A8.3.1 Backflow of refrigerant can result in a charging error or in containers being overfilled, with subsequent danger
of liquid-full containers, which may result in the development of hydraulic pressure sufficient to burst the container or
open the relief valve.
A8.3.2 Refrigerant transferred to a sealed system should be metered by either mass or volume using weigh scales or a
volumetric charging device.
A8.3.3 When topping a chargeadding a refrigerant to a system after repair while watching high and low side
pressures care should be exercised to add refrigerant in small amounts to avoid overcharging.
A8.3.4 Safe and approved methods should be used to transfer refrigerant from one container to another. A pressure
differential will have to be established between the containers. The receiving container may be cooled in a refrigerator
or cold store. Under no circumstances should refrigerant be vented to atmosphere from the receiving container in order
to lower the pressure.
The only approved method of heating the discharging cylinder is to use heated water or a blanket heater. The heated
water temperature should be limited to 130F (54C) or less or to a temperature that does not cause pressure to exceed
85% of the container relief valve setting. The blanket heater should be equipped with a thermostat set at 130F (54C)
or less and a thermal fuse or an additional thermostat set at a temperature at which the refrigerant saturation pressure
does not exceed 85% of the container relief-valve settings. Only charging cylinders with graduated volumetric scales
constructed in accordance with ASME Standard Unfired Pressure Vessel Code, ASME Boiler and Pressure Vessel
Code, Section VIII 2007 and equipped with a pressure-relief valve should be used. These cylinders should be filled in
32
accordance with this subsection. Immersion heaters for this type of cylinder are permissible without a thermostat if the
wattage is limited such that continuous operation of the heater results in a cylinder pressure for the subject refrigerant
less than 85% of the relief-valve setting regardless of the liquid level inside the cylinder.
A8.4 Recovery Equipment
This equipment is normally a mechanical system consisting of evaporator, oil separator, compressor, and condenser,
that draws refrigerant out of the refrigeration system and stores it in a storage container. The equipment may use
replaceable core filter driers to remove moisture, acid, particulates, and other contaminants.
A8.4.1 Recovery equipment also requires maintenance.
When changing replaceable core filter driers contained within the recovery equipment, the section containing the filter
should be isolated and the refrigerant captured into a suitable storage container before opening the filter shell.
A8.4.2 Recovery equipment and filters should be maintained to the recovery equipment manufacturer's specifications.
33
ASHRAE or ANSI.)
INFORMATIVE ANNEX B
TRAINING OF PERSONNEL
As with most technical problems, reducing refrigerant release will involve many details. For design engineers
(especially those engaged in developing documentation for installation and servicing of equipment and systems) and
service technicians, the changes in required practices are of such significance that persons in these segments of the
industry should have a thorough understanding of means and methods for minimization of refrigerant release. U.S.
EPA regulations require that personnel engaged in refrigerant handling be certified. The North American Technician
Excellence, Inc. (NATE) organization is a recognized authority for providing rigorous education and testing leading to
certification of HVAC&R technicians in the US and Canada. For Europe the recommendations contained in Code of
Good Practice issued by the Commission of the European Communities, Report EUR 9509 EN should be consulted for
appropriate engineer and technician training.
ASHRAE or ANSI.)
INFORMATIVE ANNEX C
ANNEX A and B REFERENCES
Informative references, which are not required for compliance with this standard, are listed below. The numbering is
consistent with citations in the text of the standard. Normative references are listed in Section 11
C1. ANSI/UL 250-1993, Household Refrigerators and Freezers. 1993. Underwriters Laboratories, Northbrook, Ill.
C2. ANSI/UL 474-2004, Dehumidifiers. 2004. Underwriters Laboratories. Northbrook, Ill.
C3. ANSI/UL 484-2007, Room Air Conditioners. 2007. Underwriters Laboratories, Northbrook, Ill.
C4. ANSI/UL 471-2006, Commercial Refrigerators and Freezers. 2006. Underwriters Laboratories, Northbrook, Ill.
C5. ANSI/UL 1995- 2005 Heating and Cooling Equipment 2005. Underwriters Laboratories, Northbrook, Ill.\
C6ARI Guideline K-2005, Containers for Recovered Fluorocarbon Refrigerants2005. Air-Conditioning, Heating and
Refrigeration Institute, Arlington, Va.
C7. ASHRAE Terminology of Heating Ventilation, Air Conditioning & Refrigeration 1991 American Society of
Heating, Refrigerating and Air-Conditioning Engineers, Inc. Atlanta, GA
C8 ASME Unfired Pressure Vessel Code, ASME Boiler and Pressure Vessel Code, Section VIII 2007. American
Society of Mechanical Engineers, New York.
C9 Handbook of Fundamentals Refrigeration Handbook 2010 Chapter 8 Refrigerant Containment American
Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. Atlanta, GA
C10 EUR 9509 EN Code of Good Practice, Commission of the European Communities
C11. U.S. Code of Federal Regulations, 40 CFR, Part 82, Subpart F.
C12 Zero Leaks Denis Clodic
34
ASHRAE or ANSI.)
INFORMATIVE ANNEX D
BIBLIOGRAPHY
1.
2.
3.
4.
SAE J639-91, Safety and Containment of Refrigerant of Mechanical Vapor Compression Systems Used for Mobile
Air-Conditioning Systems. 1991.
IIAR 2-92, American National Standard for Equipment Design and Installation of Ammonia Mechanical
Refrigerating Systems. 1992.
IRG-2, Handling and Reuse of Refrigerants in the United States, December 1994. Air-Conditioning and Refrigeration
Institute, Arlington, VA.
ARI 740-95, Refrigerant Recovery/Recycling Equipment. 1995. Air-Conditioning and Refrigeration Institute,
Arlington, VA.
35

STD 147 2002R PPR2 (Chair Approved R1)

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BSR/ASHRAE Standard 147-2002R

BSR/ASHRAE Standard 147-2002R

4.5 Piping, Tubing, and Connections

6.2 Factory Leak Testing

Leak Rate Measurement Threshold

Leak Location Method Threshold

Identification of the installing contractor

11. NORMATIVE REFERENCES

A2.2.3 Evaporative Condensers

A4.3.1.1 Leak Rate Measurement Methods

A4.3.2 Selection and Sensitivity of Leak Testing Methods

A4.3.3 Leak Rate Measurement Methods

where: Q = Leak Rate (atm-cc/sec)

where: Q = Leak Rate (atm-cc/sec)

4.3.3.3 Helium Inside-Out Vacuum Chamber Test (ASTM E493)

4.3.3.4 Helium Accumulation Test (Method B of ASTM E499)

4.3.3.5 Helium Hood Test (ASTM 1603)

A4.3.4 Leak Location Methods

4.3.4.2 Bubble Test Application of Liquid Film

Advantages of the liquid film application bubble test are

4.3.4.3 Detector Probe Test (Method A of ASTM E499)

4.3.4.4 Tracer Probe Test (Method A of ASTM E498)

Advantages of the tracer probe test are

TABLE A-1 Suggested Schedules of Preventative Maintenance

A8 HANDLING AND STORAGE OF REFRIGERANTS

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