SERVICE ENGINEERS’ SECTION GOOD PRACTICE GUIDE 29

Safe Use of Service Manifolds

Introduction

Earlier this year we carried out a survey of members of the Section on the use of service manifolds.
Most engineers are carrying more than one service manifold and many carry up to four, which are used
with different refrigerants. Some of the good practice issues you highlighted in your responses were:

Use of specialist manifolds for carrying out leak tightness testing with OFN

Specific Nitrogen Pressure test kits are available which use braded steel hoses. These are
recommended for use during pressure testing for leaks using oxygen free nitrogen (OFN) for safety
reasons. It is essential to use a suitable regulator with the nitrogen cylinder. The regulator has an
output limiting device to prevent over pressurising of systems. The rating of this must be higher than
the test pressure to be used but not excessively so. A risk assessment must be carried out before
commencing this procedure.

Maximum likely pressures

Refrigerant Maximum Suitable regulator
Pressure
R134a 13.7bar maximum output of 26bar
R407C 23.6bar maximum output of 33bar
R404A 24.8bar maximum output of 33bar
R410A 33bar maximum output of 40bar

See Good Practice Guide 24 Leak Tightness Testing published December 2007 for recommended
procedures.

Risks of associated with sight glasses

Manifolds with sight glasses are not recommended for use with R410A, R744 (CO2) or pressure testing
systems for strength or tightness with nitrogen. These sight glasses have been known to fail and risk
causing serious injury to the engineer - the risk is greater with higher pressure fluids such as R410A,
R744 and nitrogen .Further advice about suitability of manifolds should be sought from your wholesaler.

Concerns over safety of R410A adaptors

Most R410A systems are fitted with 5/16” service connections to ensure that only the correct service
equipment is used. This is to highlight the higher pressures of R410A (see table above). However, an
adaptor is available which converts this back to ¼”. The adaptor makes it possible to connect to a
standard service manifold which does not have gauges rated for the pressures of R410A. This could
lead to a gauge being over pressurised, potentially resulting in the gauge breaking, shattering the cover
and resulting in personal injury. Service manifolds with gauges suitable for use with R410A with 5/16”
connections are readily available. It is therefore recommended that Service engineers should only use a
gauge manifold suitable for the higher pressures of R410A when working on R410A systems. See Good
Practice Guide 28 Connecting to R410A safely for further guidance.

The information contained in this Guide should be seen as a guide to interpretation of relevant industry standards, legislation and statutory information
which should be consulted by the relevant competent person responsible for servicing refrigeration equipment. The Service Engineers’ Section and the
www.ior.org.uk
Institute of Refrigeration accept no liability for any errors or omissions. page 1 of 1 Sept 2008
Service Engineers’ Section of the Institute of Refrigeration, Kelvin House, 76 Mill Lane, Carshalton SM5 2JR