3397 version 3 Page 1 of 5

Convert an automotive air conditioning system from R-12 to R-134a

Level Credits Purpose 3 2 This unit standard is for people in the automotive repair industry. People credited with this unit standard are able to: evaluate condition of existing air conditioning system on a vehicle; prepare air conditioning system for retrofitting; convert an air conditioning system for R-134a operation; and test R-134a air conditioning system operation. Motor Industry Automotive Heating, Ventilation, and Air Conditioning Registered 25 January 2008 25 January 2008 31 December 2012 Recommended: Unit 981, Install an automotive air conditioning system, or demonstrate equivalent knowledge and skills. Evaluation of documentation and visit by NZQA and industry. NZ Motor Industry Training Organisation (Incorporated) 0014

Subfield Domain Status Status date Date version published Planned review date Entry information

Accreditation

Standard setting body (SSB)

Accreditation and Moderation Action Plan (AMAP) reference

This AMAP can be accessed at http://www.nzqa.govt.nz/framework/search/index.do. Special notes 1 Legislation and publications relevant to this unit standard include but are not limited to Health and Safety in Employment Act 1992; Ozone Layer Protection Act 1996; Society of Automotive Engineers (SAE) recommended practices as described in J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compressions Systems, 2005; J1660 Fittings and Labels for Retrofit of Cfc-12 (R-12) Mobile Air-Conditioning Systems to HFC-134a (R-134a), 1998; and J1661 Procedure Retrofitting CFC-12 (R12) Mobile Air-Conditioning Systems to HFC-134a (R-134a), 1998; Motor Trade Association (MTA) Automotive Air Conditioning Code of Practice; vehicle manufacturer published retrofit procedures.

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3397 version 3 Page 2 of 5 2 Society of Automotive Engineers Standards are available online at http://www.sae.org/technical/standards/. MTA Automotive Air Conditioning Code of Practice is available from the Motor Trade Association, PO Box 9244, Wellington, phone 04 385 8859, website http://www.mta.org.nz/. Definitions: R-12 refers to Refrigerant 12 known as CFC 12, a chlorofluorocarbon which is a controlled substance within the meaning of the Ozone Layer Protection Act 1996. It is used as a refrigerant in automotive air conditioning systems. R-134a refers to Refrigerant 134a known as HFC134a, a hydrofluorocarbon used as a substitute refrigerant for automotive R-12 air conditioning systems and for dedicated systems. Suitable tools and equipment means industry approved tools and equipment that are recognised within the industry as being the most suited to complete the task in a professional and competent manner with due regard to safe working practices.

Elements and performance criteria

Element 1 Evaluate condition of existing air conditioning system on a vehicle. Performance criteria 1.1 Safe working practices are observed throughout the task in accordance with legislative requirements. Range personal safety, safety of others, vehicle safety, workshop safety, environmental safety, tools and equipment safety.

1.2

A visual inspection of all air conditioning components is performed as specified by the manufacturer. Any problems are reported to the supervisor. Range may include but is not limited to damage, lubricant leaks, corrosion, suitability to be converted, condenser change.

1.3

The vehicle's air conditioning system is operated to check that the system performs on R-12 as intended by the manufacturer. Any malfunction is reported to the supervisor. A leak test is performed immediately after the air conditioning system has been operating for 10 to 15 minutes using a compatible leak detector. Any leaks found are repaired in accordance with manufacturer specifications. Range leaks around compressor, hose fittings, evaporator and condenser.

1.4

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3397 version 3 Page 3 of 5 Element 2 Prepare air conditioning system for retrofitting. Performance criteria 2.1 Safe working practices are observed throughout the task in accordance with legislative requirements. Range personal safety, safety of others, vehicle safety, workshop safety, environmental safety, tools and equipment safety.

2.2

Suitable tools and equipment are selected and used that enable the system to be prepared for retrofitting. Faults identified from a visual inspection and from an operational check are rectified, so that the air conditioning system operates in accordance with manufacturer specifications. The amount of oil in the compressor is optimised by running the R-12 air conditioning system with the blower on high speed. All R-12 refrigerant is recovered from the vehicle's air conditioning system using compatible refrigerant recovery and recycling equipment in accordance with legislative requirements and Code of Practice. The air conditioning system is evacuated to remove as much R-12 as possible from the residue mineral oil. Range minimum of 30 minutes, steady vacuum of 450 microns (29 in.) Hg (mercury) unless otherwise specified by the compressor and vehicle manufacturer.

2.3

2.4

2.5

2.6

2.7

The mineral oil is removed from the system following compressor and vehicle manufacturer recommendations. Range may include but is not limited to removing and draining components, flushing using the recommended flushing fluid or system.

Element 3 Convert an air conditioning system for R-134a operation. Performance criteria 3.1 Safe working practices are observed throughout the task in accordance with legislative requirements. Range personal safety, safety of others, vehicle safety, workshop safety, environmental safety, tools and equipment safety.

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3397 version 3 Page 4 of 5 3.2 Suitable tools and equipment are selected and used that enable R-134a compatible components to be installed to compressor and vehicle manufacturer specifications. Non-compatible components are replaced following compressor and vehicle manufacturer recommendations. Range may include but is not limited to seals, O-rings (where disturbed), desiccant, receiver-drier (accumulator-drier), compressor oil.

3.3

3.4

R-134a quick connect service ports are installed over the existing R-12 service ports in a manner that prevents the service ports from being easily removed. The air conditioning system is evacuated, so that no air and moisture is present in the system, using R-134a compatible servicing equipment following the procedure outlined in the recovery equipment instructions. The specified amount of R-134a compatible oil (Polyalkylene Glycol [PAG oil] or ester oil) is installed following compressor and vehicle manufacturer recommendations and instructions. The air conditioning system is charged with R-134a using compatible servicing equipment, following the compressor and vehicle manufacturer guidelines in accordance with legislative requirements and Code of Practice. Retrofit labels are installed close to the service ports, clearly noticeable and displaying information relating to the retrofit. Range name and address of company (or individual) performing retrofit service, date service performed, type and amount of refrigerant, type and amount of lubricant, warning to use only R-134a refrigerant and the specified oil.

3.5

3.6

3.7

3.8

3.9

The vehicle is checked to ensure that no existing labels containing R-12 refrigerant information remain on the vehicle.

Element 4 Test R-134a air conditioning system operation. Performance criteria 4.1 Safe working practices are observed throughout the task in accordance with legislative requirements. Range personal safety, safety of others, vehicle safety, workshop safety, environmental safety, tools and equipment safety.

4.2

Suitable tools and R-134a compatible equipment are selected and used that enable the system to be tested to compressor and vehicle manufacturer specifications.

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3397 version 3 Page 5 of 5 4.3 The air conditioning system is checked for leaks by the use of an R-134a leak tester. Any leaks located as a result of leak detection tests are sealed in accordance with compressor and vehicle manufacturer instructions. The air conditioning system functions within compressor and vehicle manufacturer acceptable limits of temperatures and pressures.

4.4

4.5

Please note Providers must be accredited by NZQA, or an inter-institutional body with delegated authority for quality assurance, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment. Industry Training Organisations must be accredited by NZQA before they can register credits from assessment against unit standards. Accredited providers and Industry Training Organisations assessing against unit standards must engage with the moderation system that applies to those standards. Accreditation requirements and an outline of the moderation system that applies to this standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The AMAP also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements. Comments on this unit standard Please contact the NZ Motor Industry Training Organisation (Incorporated) info@mito.org.nz if you wish to suggest changes to the content of this unit standard.

New Zealand Qualifications Authority 2008