Unit 2 — Introduction to Refrigerants & Handling Practices
Section 1 — Refrigerants, Gases and Oils
1.2 Types of Refrigerants: Characteristics and Applications
Blend behaviour, primary and natural refrigerant families, secondary fluids,
recovery methods, and the tools and equipment used in refrigerant service.
1.2.1 — Single Component, Azeotrope, Near-Azeotrope and Zeotrope
Refrigerants can be single chemical substances or blends of two or more components.
Understanding their behaviour is important for proper charging, leak detection, and
system service.
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Single Component
Consists of one pure chemical. Boiling and condensing temperatures are uniform
at a given pressure. Examples: R-22 (HCFC-22) and R-134a (HFC-134a).
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Azeotropic Blends
Mixtures that behave like a single substance at a specific composition. Boil and
condense at nearly constant temperature with little or no temperature glide. Leak
composition tends to remain relatively stable.
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Near-Azeotropic Blends
Very close to azeotropic behaviour, with a small but measurable temperature glide
between bubble point and dew point. Typically charged as liquid to maintain
composition.
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Zeotropic Blends
Mixtures with significant temperature glide — evaporation and condensation occur
over a temperature range at a given pressure. Component composition differs between
liquid and vapour phases. Must be charged as liquid to avoid fractionation.
1.2.2 — Types of Primary Refrigerants
Primary refrigerants directly absorb and reject heat in the refrigeration cycle.
They are grouped by chemical family, each with distinct environmental and safety
properties.
CFCs were widely used in older systems due to their stability and favourable
thermodynamic properties, but their high ODP led to a global phase-out.
- Typical examples: R-11 and R-12, once common in chillers and refrigeration systems.
- High ODP — contribute significantly to ozone layer depletion.
- Banned from new equipment and heavily controlled for servicing legacy systems.
HCFCs were introduced as transitional replacements for CFCs because they have
lower ODP. However, they still damage the ozone layer and are being phased out.
- R-22 (HCFC-22) was widely used in comfort cooling and refrigeration.
- Lower but non-zero ODP and moderate GWP.
- Production and import are being phased out under international agreements and Canadian regulations.
HFCs contain hydrogen, fluorine, and carbon but no chlorine, so they have zero
ODP. They became common replacements for many CFC and HCFC applications.
- Examples: R-134a, R-404A, and R-410A.
- Zero ODP, but many have high GWP — leading to current efforts to phase down high-GWP options.
- Widely used in commercial refrigeration, residential and commercial air conditioning, and automotive systems.
HFOs are unsaturated fluorinated refrigerants designed with very low GWP and
zero ODP, often used alone or in blends.
- Examples: R-1234yf and R-1234ze, as well as blends combining HFOs with HFCs.
- Many HFOs are classified as mildly flammable (A2L), requiring revised safety practices and updated codes.
- Increasingly used where regulatory pressure demands low-GWP alternatives.
Hydrocarbons such as propane and isobutane are natural refrigerants with very
low GWP and zero ODP.
- Common designations: R-290 (propane) and R-600a (isobutane).
- Highly flammable (Class 3) — subject to strict charge limits and installation requirements.
- Used in small commercial and household appliances and, in some jurisdictions, larger systems with proper safety measures.
1.2.3 — Natural Refrigerants
Natural refrigerants are substances that occur in nature and have minimal
environmental impact when used correctly.
Carbon dioxide is an environmentally friendly refrigerant with very low GWP
and zero ODP.
- R-744 systems often operate at much higher pressures than typical HFC systems.
- Common applications: supermarket refrigeration, heat pumps, industrial and transport systems.
- Technicians must be trained for high-pressure operation, appropriate piping, and specialized components.
Ammonia is a very efficient refrigerant widely used in industrial refrigeration.
- Zero ODP and essentially zero GWP.
- Classified as toxic and mildly flammable — systems are usually located in machinery rooms or industrial settings with strict safety controls.
- Commonly used in food processing plants, ice rinks, and large cold storage facilities.
1.2.4 — Secondary Refrigerants
Secondary refrigerants transport heat between the conditioned space and a central
plant that contains the primary refrigerant. They do not change phase in the
distribution piping.
Brine solutions are typically salt-water mixtures designed to remain liquid at
low temperatures.
- Common salts: calcium chloride or sodium chloride.
- Used in low-temperature secondary loops such as ice rinks and some industrial processes.
- Can be corrosive — requiring compatible piping materials and corrosion inhibitors.
Glycol solutions are widely used as secondary coolants in hydronic and
refrigeration systems.
- Types: ethylene glycol and propylene glycol mixed with water in various concentrations.
- Provide freeze protection — used in chilled water, process cooling, and commercial refrigeration loops.
- Care must be taken to prevent environmental contamination from leaks and to maintain proper inhibitor levels.
Water and other engineered secondary solutions are also used as intermediate
heat-transfer media.
- Water (R-718) is a natural refrigerant/secondary fluid used in many chilled-water systems for comfort cooling.
- Other engineered secondary fluids combine low freezing point, low viscosity, and corrosion inhibitors for specialized applications.
- System design must ensure adequate flow, expansion volume, and corrosion control.
1.2.5 — Methods of Recovery and Associated Procedures
Recovery is the first step in any major service task involving opening the
refrigerant circuit. The objective is to remove refrigerant — and in some cases oil —
from the system without releasing it into the atmosphere. Recovery procedures must
comply with Canada's environmental regulations, manufacturer instructions, and site
safety rules.
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Before Every Recovery
Identify the refrigerant type and check the system label. Mixing refrigerants
in a single recovery cylinder is not acceptable — it complicates recycling or
reclamation. Weigh, document, and tag all recovered refrigerant with identification
and condition information.
Absorption recovery uses the principle that some liquids or media can absorb
refrigerant vapour.
- An absorbent medium captures refrigerant vapour drawn from the system.
- The absorbed refrigerant is later processed or recovered in a controlled facility.
- Must follow approved environmental and safety guidelines; less common than mechanical units in typical field work.
Liquid recovery removes refrigerant while it is still in liquid state — typically
the fastest way to remove large quantities when conditions permit.
- Recovery cylinder placed on a scale and connected to the liquid line or receiver outlet.
- Liquid flows or is pumped into the cylinder by gravity, pressure difference, or a recovery unit designed for liquid.
- Cylinders must not exceed ~80% liquid fill at the specified temperature — monitor mass on the scale at all times.
- Hoses must be rated for liquid refrigerant; flow must be controlled to avoid hydraulic shock.
Migration uses the natural tendency of refrigerant to move toward colder areas
in the system. By cooling one part and warming another, refrigerant is induced to
collect in a specific component for easier removal.
- A cold condition (ice bath, cooling jacket, or cold ambient) is applied to a receiver, condenser, or high point in the system.
- Warmer conditions elsewhere cause refrigerant to preferentially condense in the cooled component.
- Once most refrigerant has migrated, a recovery unit connects to that component for efficient removal.
- Helpful when isolating refrigerant away from components being serviced, such as evaporators or compressors.
The push-pull method is designed for rapid recovery of large liquid charges from
systems equipped with receivers or large condensers.
- The recovery unit is connected so that vapour "pushes" liquid from the system into the cylinder.
- Vapour drawn from the recovery cylinder is discharged into the top of the system's receiver or condenser, increasing pressure on the liquid.
- The increased pressure forces liquid from the bottom of the receiver into the recovery cylinder through a liquid line.
- Continues until most liquid is transferred; final vapour recovery is then completed using standard vapour techniques.
- Most effective on systems with a large liquid volume and a clear liquid reservoir such as a receiver tank.
Vapour recovery removes refrigerant in its vapour state. Often used once the bulk
of liquid has been removed, or on small systems where liquid lines are not easily
accessed.
- The recovery unit draws vapour from the top of the system or receiver through the service manifold.
- As vapour is removed, system pressure drops, causing remaining liquid to boil off and be recovered as vapour.
- Monitor system pressure to achieve the required final recovery level as mandated by regulations.
- Avoid liquid slugging of the recovery unit — slow flow or reconfigure lines if liquid is suspected.
1.2.6 — Recovery and Recycling Tools and Equipment
Effective recovery and recycling depend on using specialized tools correctly and
maintaining them in safe working condition.
Core removal tools allow technicians to remove Schrader valve cores under
pressure, creating a larger flow path and reducing restriction during recovery
or evacuation.
- Attached to the service port and seals it while the internal mechanism removes the core.
- With the core removed, full-size hose connections can be used for higher flow rates.
- After work is complete, the core is reinstalled using the tool without venting refrigerant.
Refrigerant cylinders are specifically designed and rated containers for storing
and transporting refrigerant. Using the correct type and following capacity limits
are legal and safety requirements.
- Recovery cylinders are usually grey or another standardized colour with a yellow band — clearly labeled with the refrigerant type.
- Disposable cylinders (factory-charged) must never be refilled and must be disposed of according to regulations when empty.
- Refillable cylinders must be hydrostatically tested and inspected at regulated intervals and must not be used beyond their test date or if damaged.
Filter driers in recovery and recycling setups remove moisture, acids, and
particulates from recovered refrigerant or from the system itself.
- Installed in the refrigerant flow path to protect the recovery unit and improve refrigerant quality.
- Must be replaced regularly — especially after compressor burnouts or on contaminated systems.
Gauge manifolds provide controlled access to system pressures and connection
points for recovery, evacuation, and charging.
- Include high- and low-side gauges, hand valves, and hose connections.
- Used to monitor suction and discharge pressures and to connect to recovery units, vacuum pumps, and charging cylinders.
- Must be rated for the refrigerant and maximum working pressure of the system — especially for high-pressure refrigerants like R-410A and R-744.
Service hoses connect manifolds, recovery units, cylinders, and system service
ports.
- Must be pressure-rated for the refrigerant in use and in good condition with intact gaskets and seals.
- Low-loss fittings or self-sealing couplers are commonly used to minimize refrigerant loss.
- Keep hoses clean and capped when not in use to prevent moisture and debris entry.
Recovery units are mechanical devices that compress and transfer refrigerant
from a system into a recovery cylinder.
- Handle vapour, liquid, or both — depending on design; some have specific procedures for different recovery modes.
- Must be compatible with the refrigerant being recovered and maintained according to manufacturer schedules.
- Monitor operating conditions carefully — overheating, liquid slugging, or contaminated refrigerant can damage recovery units.
Service valves and access fittings provide connection points for manifolds,
recovery equipment, and vacuum pumps.
- May be factory-installed (on condensing units or compressors) or field-installed as part of the system piping.
- Must be checked for leaks and capped to reduce the risk of accidental refrigerant loss and contamination.
Electronic refrigerant scales measure the mass of refrigerant transferred to
or from a cylinder or system.
- During recovery: prevent overfilling a cylinder and record the amount recovered for documentation.
- During charging: ensure the correct refrigerant mass is added to meet manufacturer specifications — especially for critically charged systems.
1.2.7 — Types of Refrigerant Cylinders
Several types of cylinders are used in refrigeration and air conditioning work.
Each type has specific requirements for use, handling, and disposal.
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Disposable Cylinders
Factory-charged with virgin refrigerant and used once. Must not be refilled and
must be disposed of responsibly when empty — in accordance with applicable
regulations.
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Refillable Service Cylinders
Used to transport and store virgin or reclaimed refrigerant. Must meet transport
regulations and be hydrostatically tested as required by the applicable standard.
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Recovery Cylinders
Specifically designed for recovered refrigerant. Equipped with pressure relief
devices and often have both liquid and vapour valves for flexible operation during
recovery procedures.
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Cylinder Safety
Never mix refrigerant types in a single recovery cylinder. Always label cylinders
clearly, monitor fill mass on a scale, and verify test dates before use. Cylinders
must be stored upright, protected from heat, and never left unsecured in a vehicle
or confined space.