EPA Section 608 Study Guide

INTERNATIONAL TRAINING INSTITUTE FOR THE SHEET METAL AND AIR CONDITIONING INDUSTRY

EPA Section 608 Study Guide

TABLE OF CONTENTS

  • INTRODUCTION
  • CORE SECTION
  • TYPE I
  • TYPE II
  • TYPE III
  • GLOSSARY
  • Temperature / Pressure Chart

INTRODUCTION TO THE SECTION 608 STUDY GUIDE

  • The Section 608 Study Guide is prepared by the International Training Institute to aid in preparing for the EPA Section 608 certification exam.
  • The guide is based on the most current information available at the time of publishing.
  • Important: Technicians must stay compliant with future EPA changes.
  • The guide highlights key concepts using BOLD text for easier recall.
  • At the end of each section—Core, Type I, Type II, and Type III—there are practice quizzes to test readiness for the certification exam.
  • Key requirements for the certification exam include:
    • Picture identification
    • Social security number (or a unique identification number in the format xxx‐xx‐xxxx)
    • Home address
  • Technicians must complete personal information at the beginning of the exam and must create a unique identifier, not their Social Security number.
  • During the exam, candidates should:
    • Read each test question thoroughly, focusing on clarifying words (e.g., always, never, not).
    • Review all answer options before selecting one.
    • Note that questions can be skipped and revisited later.

ABOUT THE SECTION 608 EXAM

  • The exam consists of four sections:
    • Core
    • Type I
    • Type II
    • Type III
  • Type I: Focuses on small appliances (e.g., domestic refrigerators, window air conditioners, PTACs, vending machines).
  • Type II: Covers high-pressure refrigerants (e.g., HCFC‐22) used in residential and light commercial ACs, heat pumps, rooftop units, supermarket refrigeration, and process refrigeration.
  • Type III: Pertains to low-pressure refrigerants (e.g., HCFC‐123, CFC‐11) primarily used in chillers.
  • Universal Certification: Earned by passing all three types of technician levels.
  • Each section has 25 multiple choice questions; a minimum score of 70% (18 out of 25) is required to pass.
  • The Core section pass is mandatory for certification in any other section.
  • Candidates can take combinations of sections and aren't required to take all four at once.
  • Exams are closed-book; only a temperature/pressure chart and calculator are permitted.
    • The temperature/pressure chart and calculator can also be accessed onscreen during the online version of the exam.

CORE CONTENT

  • The Core Section covers general knowledge, including:
    • Ozone depletion
    • The Clean Air Act and the Montreal Protocol
    • Section 608 regulations
    • Substitute refrigerants and oils
    • Refrigeration principles
    • The Three R's of refrigerants
    • Recovery techniques
    • Dehydration and evacuation processes
    • Safety protocols
    • Shipping regulations
  • The Core Section is seen as crucial since its concepts reappear in subsequent sections.

OZONE DEPLETION

  • Definition of Ozone: A gas molecule consisting of three oxygen atoms (O3), which is found both in the upper atmosphere (stratosphere) and at ground level.
    • Good Ozone: Protects Earth from harmful UV rays, located in the stratosphere (6-30 miles above Earth).
    • Bad Ozone: At ground level, considered a pollutant causing health risks and vegetation damage.
  • Consequences of Ozone Depletion:
    • Increased Earth temperatures
    • Higher incidences of skin cancer
    • Increased cataracts
    • Enhanced ground-level ozone
    • Decreased crop yields and vegetation loss
    • Deterioration of marine ecosystems
  • Ozone Destruction Process:
    • Chlorine and bromine atoms in the atmosphere can degrade ozone.
    • Reaction details: When chlorine interacts with ozone, it steals an oxygen atom, forming O2 and chlorine monoxide (ClO). ClO then can react with another ozone molecule, continuing the cycle. It is estimated that one chlorine atom can destroy 100,000 ozone molecules.
  • Controversy: Some argue natural sources (like volcanic eruptions) contribute to atmospheric chlorine, but studies show this natural contribution is minor compared to CFC emissions.
  • Chlorine from CFCs does not dissolve in water or degrade easily, leading to its accumulation in the stratosphere where it has a significant impact on ozone depletion.
  • Ozone Depletion Potential (ODP): Measures the effectiveness of various compounds (CFCs, HCFCs) in depleting ozone.
    • CFCs have the highest ODP, followed by HCFCs; HFCs have no ODP.
    • **Examples of Gases: **
    • CFC: R‐11, R‐12 (Elements: Cl, F, C; ODP: Higher)
    • HCFC: R‐22, R‐123 (Elements: H, Cl, F, C; ODP: Lower)
    • HFC: R‐134a (Elements: H, F, C; ODP: None)

CLEAN AIR ACT

  • Regulated by the U.S. Environmental Protection Agency (EPA) under Section 608 of the Clean Air Act.
  • Non-compliance penalties can reach $27,500 per day per violation, alongside potential rewards of $10,000 for whistleblowers.
  • Violating Clean Air Act provisions can lead to fines, loss of certification, and requirements for Federal court appearances.
  • Technicians must demonstrate capabilities in refrigerant recovery/recycling.
  • Violations include:
    • Falsifying or failing to maintain required records.
    • Failing to achieve required evacuation rates before handling refrigerants.
    • Knowingly venting CFCs, HCFCs, or HFCs, except for minimal releases (de minimis).
    • Uncertified servicing, maintenance, or disposal of appliances containing refrigerants.
    • Venting CFCs or HCFCs after July 1, 1992; venting HFCs since November 15, 1995.
    • Improper disposal of refrigerant containers or appliances without pre-removal of refrigerant.
    • A breach of state and local laws regarding refrigerant management.

MONTREAL PROTOCOL

  • An international treaty starting in 1989 aimed at regulating the production and usage of Ozone-Depleting Substances (ODS) including CFCs, HCFCs, halons, methyl chloroform, and carbon tetrachloride.

  • Required an initial freeze on production/consumption and advocated for phased reductions for ODS in developed countries.

  • CFC production ceased on December 31, 1995.

  • HCFCs are also slated for future phase-out, with recovery and recycling as the method for future supply management.

  • Since November 15, 1995, venting any refrigerant is against the law, except for minimal releases during standard service procedures.

    • Nitrogen used for leak detection can be released; however, it must not be added to a fully charged system and then vented.

    • All refrigerants must be recovered before servicing systems or disposal.

CYLINDER & APPLIANCE DISPOSAL

  • Refrigerants in appliances must be recovered prior to disposal. Responsibility lies with the final handler in the disposal chain.
  • Disposable cylinders can only be used for virgin refrigerant—never for recovery.
  • Recovery cylinders:
    • Specifically designed for refilling, must have liquid and vapor ports.
    • Overfilling or heating can be dangerous; must not be filled above 80% capacity.
    • Must be hydrostatically tested every 5 years.
    • DOT-approved recovery cylinders known by their yellow tops and gray bodies.
    • Rusty or damaged cylinders should be reduced to 0 psig and disposed of.

REFRIGERANT OILS

  • As refrigerant technologies evolved, technicians encounter a mixture of new, old refrigerants, and blends requiring compatible oils.
  • Types of oils include:
    • Mineral Oil: Used primarily in CFC systems.
    • Alkylbenzene: Compatible with R-22 and other systems.
    • Polyolesterol (POE): Used in HFC systems.
    • Polyalkylene glycol (PAG): Typically found in R-134a automotive systems.
    • Polyalphaolefin (PAO): Used for ammonia refrigeration systems.
  • Common oil properties:
    • Hygroscopic: All oils attract moisture.
    • Viscosity: Refers to oil thickness.
    • Stability: Ability to lubricate without chemical change.
    • Solubility: Ability to mix with refrigerants.
    • Miscibility: The ability to remain mixed at low temperatures.
    • Foaming: Affects lubrication capacity during pressure changes.
    • Dielectric Strength: The maximum electrical conductivity before breakdown.
    • Oxidation Value: Resistance to sludge formation.
    • Boundary Film-Forming Ability: Separates high-pressure from low-pressure areas in the system.

SUBSTITUTE REFRIGERANTS

  • No direct drop-in replacements for R‐12 systems exist; all alternatives necessitate additional retrofitting.
  • R-134A (HFC-134a) is prominently used for retrofitting R-12 systems:
    • Oils in R-134A systems are ester-based; these oils are non-miscible with other oils.
    • Leak detection involves using pressurized nitrogen.
  • Temperature Glide: Definition: Difference in temperature during the evaporation/condensation of the refrigerant at constant pressure, leading to inconsistencies in evaporator/condenser temperatures.
    • Temperature glide is determined by the difference between dew point (saturation temperature during evaporation) and bubble point (saturation temperature during condensation).
  • Refrigerant Mixture Types:
    • Ternary Blends: Comprise three refrigerants, often HCFCs.
    • Zeotropic Blends (Non-Azeotropic): Components boil/evaporate at different temperatures while at consistent pressure and must be charged as liquids.
    • Azeotropic Refrigerants: Components that boil at the same temperatures, behaving effectively as single substances, can be charged as vapor or liquid.
    • Near-Azeotropic Mixtures (NARM): behave similarly to azeotropes but exhibit slight temperature glide during phase changes; should be charged as liquids.

GAUGE MANIFOLD SET

  • An essential HVACR tool consisting of:
    • Compound Gauge (Blue): Measures low pressure (in psig) and vacuum (in inches Hg).
    • High-Pressure Gauge (Red): Measures high-side (discharge) pressure.
    • The manifold connects to hoses that access system measurement ports.
    • An additional center port (yellow hose) connects to recovery devices, evacuation pumps, or charging devices.
    • Hoses must have low-loss fittings, minimizing refrigerant loss during disconnections.

THE REFRIGERATION CYCLE

  • The Vapor/Compression Refrigeration Cycle processes occur as follows:
    1. High-pressure liquid refrigerant enters a metering device, leading to pressure and saturation temperature reduction.
    2. The refrigerant travels to the evaporator, absorbing heat, and transitions from liquid to vapor.
    3. The now low-temperature, low-pressure vapor moves to the compressor inlet.
    4. The vapor is compressed, reaching high temperature, high pressure, and expelled into the condenser.
    5. Rejecting heat in the condenser, the refrigerant condenses back into a high-pressure liquid.
    6. The high-pressure liquid returns to the metering device, completing the cycle.
  • Some systems utilize receivers or accumulators depending on the type of metering devices employed.
  • Maintaining a refrigeration system includes:
    • Use of approved EPA equipment
    • Leak detection and repair
    • Ensuring all fittings are secure during service or recovery.
  • Leak detection can involve a halide torch or evacuating the system to establish a vacuum.
  • If a compressor burns out, follow a specific recovery process including triple evacuation and installing a permanent filter-drier.

THE THREE R'S

  • The Three R's of refrigerants include:
    1. Recover: Remove refrigerant from a system and store it externally.
    2. Recycle: Clean for immediate reuse by separating oil and removing moisture/acidity.
    3. Reclaim: Process to meet new product specifications based on a chemical analysis.
  • Recovery devices need to fulfill EPA certifications post-November 15, 1993, to be compliant with regulations.
    • There are two types of recovery devices:
    1. System-Dependent: Utilize appliance components to aid recovery.
    2. Self-Contained: Independently extract refrigerants.

RECOVERY TECHNIQUES

  • Key recovery standards include:
    • EPA mandates that recovery appliances contain a service aperture or process stub to ease recovery using Schrader valves, which need consistent checks to ensure functionality and avoid leaks.
    • Inform clients that refrigerant recovery is law, vital for health and environmental protection, and all responsible professionals must comply with the law.
    • Proper recovery focuses on isolating refrigerants into uniquely designated tanks, preventing mixing, and paying attention to several factors including:
    • Size of the refrigeration system
    • Size and length of suction hoses
    • Ambient temperature affecting the speed of recovery

RECOVERY CYLINDERS

  • Recovery cylinders differ from disposable cylinders—meant for virgin refrigerant only.
  • Recovery cylinders:
    • Must not be filled above 80% capacity; overfilling can lead to explosions.
    • Composed of two ports for liquid and vapor recovery, must meet DOT standards, and marked appropriately.
    • Require inspections for rust or damage; those failing checks must be disposed of safely.

DEHYDRATION / EVACUATION

  • The objective of dehydration in refrigeration systems is to eliminate moisture.
  • Evacuation method is predominantly preferred.
  • Factors affecting evacuation speed include:
    • Equipment size
    • Ambient temperature (warmer accelerates evacuation)
    • Moisture amount within the system
    • The capacity and length of the vacuum pump and suction line.
  • Vacuum gauges should be placed as far from the pump as possible for accurate readings.
  • Successful dehydration is confirmed when the vacuum gauge holds the required vacuum level; over-evacuating is not a concern.

SAFETY

  • Maintaining environmental safety involves strict adherence to regulations when handling refrigerants.
  • Recommended safety practices include:
    • Use of protective gear (safety glasses, gloves)
    • Regulatory compliance (monitoring for leaks, ensuring component integrity)
    • Employing nitrogen for pressurizing systems with caution to avoid over-pressurization or rupturing.
  • Special guidelines include:
    • Never use oxygen or compressed air with refrigerants to avoid explosions.
    • Always consult material safety data sheets (MSDS) for proper chemical handling techniques.

SHIPPING

  • Ensure that used refrigerant cylinders meet DOT standards before shipping,
  • Proper paperwork must be filled, indicating the refrigerant type and quantity,
  • Cylinders should be transported upright, clearly labeled as "2.2 non-flammable gas."

TYPE I: RECOVERY REQUIREMENTS

  • Definition: A small appliance houses five pounds or less of refrigerant, such as hermetically sealed units.
  • Technicians handling refrigerants must be Type I or Universal certified.
  • Sales of CFCs and HCFCs restricted to certified personnel.
  • Recovery Standards:
    • Recovery equipment requirements:
    • Before Nov. 15, 1993:
      • Operating Compressor: 80% or 4" Vacuum
      • Non-Operating Compressor: 80% or 4" Vacuum
    • After Nov. 15, 1993:
      • Operating Compressor: 90% or 4" Vacuum
      • Non-Operating Compressor: 80% or 4" Vacuum
  • All appliances must have a service aperture valve for refrigerant recovery, typically a piercing access valve.
  • Mixing refrigerants in recovery cylinders is prohibited, as it could lead to complications in processing.
  • For small appliances, recovery can involve either self-contained or system dependent methods.

TYPE II TECHNICIANS

  • Technicians servicing high-pressure systems or Very High-Pressure appliances require Type II or Universal certification.
  • Leak Detection:
    • Must use nitrogen for leak checking, followed by soap bubbles for pinpointing leaks.
  • Leak Repair Requirements:
    • Appliances with over 50 lbs. refrigerant must repair when annual leak rates exceed thresholds:
    • Comfort cooling: 15%
    • Commercial and Industrial Process: 35%

RECOVERY TECHNIQUES FOR TYPE II

  • Efficient recovery and compliance require certified recovery equipment approved by EPA standards.
  • Involves regular maintenance of oil and filter on recycling/rescue machines.
  • For different refrigerants, all prior refrigerant must be purged before transitioning to a different type.
  • Notably slower recovery can be supported by cooling recovery cylinders or heating appliances during recovery.

TYPE III TECHNICIANS

  • Low-pressure appliances necessitate certification as Type III or Universal Technician.
  • Leak Detection:
    • Controlled hot water or nitrogen is the preferred method for establishing system pressure for leak checks.
  • Leak Repair Requirements:
    • Repair standards to match Type II specifications on leak repair rates.

RECOVERY TECHNIQUES FOR TYPE III

  • Recovery of low-pressure is characterized by liquid removal first, followed by vapor recovery.
  • Water circulation is necessary to prevent freezing during evacuation.
  • Maintenance of high-pressure refrigerant connection during recovery, especially in case of leaks or possible filtration.

GLOSSARY

  • ASHRAE: American Society of Heating, Refrigerating, and Air Conditioning Engineers. Develops standards for refrigerant safety classification.

  • Blended refrigerant (NARM): Refrigerants with temperature glide, requiring liquid phase charging techniques.

  • Azeotrope: Mixture whose vapor and liquid compositions are invariant.

  • Filter-Drier: Equipment accessory that ensures refrigerant cleanliness.

  • Low-Pressure Appliance: Utilizes refrigerant with pressures below 45 psia at 104°F.

    • Must adhere to evacuation requirements.

  • Recovery Efficiency: Measure of refrigerant retrieved from systems by recovery equipment.

  • Substitutes: Any chemical replacing class I or II refrigerants in applications.

REFRIGERANT TEMPERATURE / PRESSURE CHART

  • Essential to bring to the exam for referencing:
Temperature (°F)    Pressure PSI

-100     29.8    27.0    25.0    29.9    27.8    26.4    25.3
-90     29.7    25.7    23.0    29.8    26.9    24.9    20.6
-80     29.6    24.1    20.2    29.7    25.6    22.9    17.2
-70     29.4    21.8    16.6    29.6    23.8    20.3    12.8
-60     29.2    19.0    12.0    29.5    21.5    17.0    7.2
-50     28.9    15.4    6.2     29.2    18.5    12.8    0.2
-40     28.4    11.0    0.5     28.9    14.7    7.6     4.1
...
  • [The full temperatures/pressures must be included for comprehensive study]