1、 Collection of SANS standards in electronic format (PDF) 1. Copyright This standard is available to staff members of companies that have subscribed to the complete collection of SANS standards in accordance with a formal copyright agreement. This document may reside on a CENTRAL FILE SERVER or INTRA
2、NET SYSTEM only. Unless specific permission has been granted, this document MAY NOT be sent or given to staff members from other companies or organizations. Doing so would constitute a VIOLATION of SABS copyright rules. 2. Indemnity The South African Bureau of Standards accepts no liability for any
3、damage whatsoever than may result from the use of this material or the information contain therein, irrespective of the cause and quantum thereof. ISBN 978-0-626-23664-9 SANS 10250:2010Edition 2SOUTH AFRICAN NATIONAL STANDARD Fitment and repair centres for automotive air-conditioning systems Publish
4、ed by SABS Standards Division 1 Dr Lategan Road Groenkloof Private Bag X191 Pretoria 0001Tel: +27 12 428 7911 Fax: +27 12 344 1568 www.sabs.co.za SABS SANS 10250:2010 Edition 2 Table of changes Change No. Date Scope Foreword This South African standard was approved by National Committee SABS SC 22J,
5、 Steering committee for construction of motor vehicles Automotive after market centres, in accordance with procedures of the SABS Standards Division, in compliance with annex 3 of the WTO/TBT agreement. This document was published in April 2010. This document supersedes SANS 10250:2006 (edition 1).
6、Reference is made in 6.2.1, 6.2.2 and 6.2.3 to an “accredited body“. In South Africa this accredited body refers to MERSETA, one of 23 Sector Education and Training Authorities (SETAs) established in South Africa in terms of the Skills Development Act, 1998 (Act No. 97 of 1998). The MERSETA is the S
7、ETA for Manufacturing, Engineering and Related Services, covering the metal and engineering, auto manufacturing, motor retail and components, new tyre and plastics industries. Reference is made in 12.11 and 13.6 to the “relevant national legislation“. In South Africa this means the Occupational Heal
8、th and Safety Act, 1993 (Act No. 85 of 1993) (as amended from time to time). Refrigerant CFC R-12 has been banned in the Republic of South Africa since March 2004. The only refrigerant used for automotive air-conditioning systems is pure (no blends) R-134a. SANS 10250:2010 Edition 2 1 Contents Page
9、Foreword 1 Scope . 3 2 Normative references. 3 3 Definitions and abbreviations. 4 4 Quality management systems 4 5 Facilities . 5 6 Management and personnel 5 7 Documentation . 6 8 Equipment 8 9 Communication and logistics . 9 10 Product safety and liability . 9 11 Customer care 9 12 Storage and han
10、dling . 11 13 Safety, health and environmental subjects 12 14 Minimization of environmental pollution during the servicing and repair of automotive air-conditioning equipment 12 Bibliography. 22 SANS 10250:2010 Edition 2 2 This page is intentionally left blank SANS 10250:2010 Edition 2 3 Fitment and
11、 repair centres for automotive air-conditioning systems 1 Scope 1.1 This standard specifies the site conditions and operating methods that should be uniformly applied in all franchised and independent fitment and repair centres to ensure that a high level of customer satisfaction is maintained. 1.2
12、This standard also addresses protection of the environment (air, ground and water) particularly where the use, care, handling, monitoring and disposition of fluorocarbons (refrigerant gas) are concerned. 1.3 This standard is applicable to fixed fitment and repair centres where the use of mobile serv
13、ice facilities could be applicable. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments)
14、 applies. Information on currently valid national and international standards can be obtained from the SABS Standards Division. ISO 4126-1, Safety devices for protection against excessive pressure Part 1: Safety valves. SAE J 2099, Standard of purity for recycled HFC-134a (R-134a) for use in mobile
15、air-conditioning systems. SAE J 2788, HFC-134a (R-134a) Recovery/recycling equipment and recovery/recycling/recharging for mobile air-conditioning systems. SANS 1518, Transportation of dangerous goods Design, construction, testing, approval and maintenance of road vehicles and portable tanks. SANS 1
16、0228, The identification and classification of dangerous goods for transport. SANS 10263-0, The warehousing of dangerous goods Part 0: General requirements. SANS 10378, General requirements for the competence of verification laboratories in terms of the Trade Metrology Act. SANS 16949/ISO/TS 16949:2
17、002, Quality management systems Particular requirements for the application of ISO 9001:2000 for automotive production and relevant service part organizations. SANS 17025/ISO/IEC 17025, General requirements for the competence of testing and calibration laboratories. SANS 10250:2010 Edition 2 4 3 Def
18、initions and abbreviations For the purposes of this document, the following definitions and abbreviations apply. 3.1 CFC chlorofluorocarbon refrigerant that has been phased out by the Montreal Protocol and that has been banned from use in new automotive applications since 1 January 1996 owing to its
19、 high ozone depleting potential and also its global warming potential 3.2 CO2carbon dioxide refrigerant that is used in automotive air-conditioning (AC) applications in new platform vehicles as of 1 January 2011 3.3 customer owner of a vehicle 3.4 HCFC hydrochlorofluorocarbon refrigerant that is use
20、d in automotive AC as a replacement and that is an alternative to the existing CFC automotive AC systems 3.5 HFC hydrofluorocarbon approved refrigerant that is used in new automotive AC from 1 January 1996 until 31 December 2010 3.6 HFO hydrofluoro olefin refrigerant that is used in automotive AC in
21、 new platform vehicles as of 1 January 2011 3.7 R-12 refrigerant that is used in automotive applications and that is the number allocated to CFC refrigerant dichlorodifluoromethane, chemical composition CCI2F2as given in ANSI/ASHRAE 34 3.8 R-134a refrigerant that is used in automotive applications a
22、nd that is the number allocated to HFC refrigerant 1,1,1,2-tetrafluoroethane, chemical composition CH2FCF3as given in ANSI/ASHRAE 34 4 Quality management systems All fitment and repair centres for automotive air-conditioning (AC) systems shall establish and maintain effective quality management syst
23、ems based on the requirements of this standard. SANS 10250:2010 Edition 2 5 5 Facilities 5.1 The fitment or repair centre shall be a registered company and shall be in possession of valid permits to operate a business in the location stated on the permits. These permits shall include labour, safety,
24、 health and environmental aspects. 5.2 The company shall have a fixed business address and a postal address. 5.3 The fitment or repair facility building shall be a permanent enclosed structure with a roof, built on a foundation and shall have entrances and exits for vehicle manoeuvrability. 5.4 The
25、fitment or repair facility building shall be secured to protect stock and assets. A lockable room or closet shall be available for the safe custody of kits, parts and other valuable items. 5.5 The workshop area shall be clean and tidy. The floor shall be free from dirt, water and oil. 5.6 The worksh
26、op area shall have a hard dry floor and shall be suitable to accommodate the work to be performed and movement of vehicles. 5.7 The street access to the building shall carry a sign indicating the street number and the name of the company. 5.8 If vehicles and customers are received at the facility, a
27、 suitable reception area and waiting room with adequate comforts shall be available. 5.9 Access to and exit from the building shall be paved or capped. 6 Management and personnel 6.1 Management 6.1.1 The fitment or repair centre shall have an adequate level of management and teamwork practices in op
28、erating the business. 6.1.2 Good practice shall include efficient administration and direction of the following key functions: a) communications; b) logistics; c) work processing; d) customer care; e) financial stability; f) safety; g) health; and h) environmental issues. 6.1.3 The company shall est
29、ablish and maintain a basic management system to implement the provisions of this standard. SANS 10250:2010 Edition 2 6 6.1.4 The management system shall include quality, safety and health aspects and environmental control. 6.1.5 The manager of the fitment or repair centre shall a) be responsible fo
30、r the overall operation of the fitment or repair centre, b) be responsible for the competence and supervision of personnel, c) be familiar with the requirements of this standard, and d) ensure compliance with all the requirements of this standard. 6.2 Personnel 6.2.1 Technicians who install, trouble
31、shoot or repair automotive air conditioners and associated systems shall have a certificate of competency in theoretical and practical safe handling of refrigerants as well as motor vehicle air-conditioning (MVAC) maintenance, service and repair. Certificates shall be issued and provided by a traini
32、ng institution that is an approved accredited body (see foreword) in that field of the industry, and that complies with all the required standards applicable to the MVAC industry. 6.2.2 Technicians who install, troubleshoot or repair automotive electronic systems or components shall have a certifica
33、te of competency in theoretical and practical automotive auto electrical or electronic training issued by an accredited body (see foreword). 6.2.3 If a trained electronic technician is not available, work required on electronic systems or components may be subcontracted to a subcontractor that perfo
34、rms electrical or electronic work on automotives and that has been approved by an accredited body (see foreword). 6.2.4 If trained MVAC personnel are not available on site, the work may be subcontracted to a fitment and repair centre that is fully compliant with 6.2.1. 6.2.5 Certificates of training
35、 and competency shall be displayed in the fitment or repair centre. 6.2.6 Competency of personnel shall be maintained through continuous training and re-certification after a period of 36 months. 7 Documentation 7.1 Work instructions 7.1.1 Specific work (fitting) instructions shall be available for
36、each model (kit or system installation) and shall be continually updated to accommodate current modifications and technical bulletins. 7.1.2 Generic work instructions for AC system gas recovery, cleaning, evacuation, purging, charging and initial leak testing shall be available. 7.1.3 Torque control
37、 shall be practised where specified in work (fitting) instructions. 7.1.4 Methods and instructions for investigative leak detection procedures shall be clearly defined and documented. SANS 10250:2010 Edition 2 7 7.2 Checklist 7.2.1 Each kit work (fitting) instruction shall be accompanied by a checkl
38、ist that is regarded as a job sign-off. This checklist shall contain the following verification checks: a) torque values, where applicable; b) routeing of liquid and suction lines; c) routeing of electrical cables (harnesses); d) correct insulation and cleating of electrical cables (harnesses); and
39、e) quality checks for abrasion (chafing) of pipes (hoses) and electrical cables on the bodywork and engine compartment components. 7.2.2 Generic troubleshooting guidelines, charts or visual aids shall be available. 7.2.3 Accessory drive belt tension checks shall be done during the fitment of belts a
40、nd after the engines have been run for new installations. NOTE Post-fitment checklists should normally be made available by the air-conditioner kit manufacturer. 7.3 Calibration 7.3.1 A system for the calibration of process control instruments and gauges shall be available and documented. 7.3.2 The
41、calibration of process control instruments and gauges shall be done in accordance with the periods specified in table 1. Table 1 Certified calibration periods 1 2 Equipment Period Pressure (vacuum) gauges 12 months Electrical multimeters 12 months Torque wrenches 6 months Belt tension gauge 6 months
42、 Electronic leak detectors 6 months 7.4 Work records, traceability and document control 7.4.1 An electronic or hard copy filing system for work records shall be available and retrievable. 7.4.2 For traceability and field performance analysis purposes, work records shall be kept for a minimum period
43、of five years. 7.4.3 Warranty cards (tickets) in AC kits shall be filled in by a technician from the fitment or repair centre and mailed to the address shown on the card. 7.4.4 Controlled documents such as bills of materials, replacement parts lists, installation instructions, wiring diagrams and ca
44、libration records shall be kept current throughout the process of ordering and receiving. 7.4.5 Unless a previous revision of a document is required to be kept for special purposes, all superseded documents shall be discarded. SANS 10250:2010 Edition 2 8 8 Equipment 8.1 The fitment or repair centre
45、shall have the equipment and accessories specified in table 2. 8.2 Numerous designs and models of refrigerant recovery, recycling and recharging devices are available. The AC centre management shall ensure that manufacturers model-specific instructions are followed to maintain safety, health and env
46、ironmental standards when processing and disposing of refrigerant gas. Table 2 Equipment and accessories for automotive air-conditioning workshops 1 2 3 4 Reference Description Mandatory Recommended1 Recovery, recycling, recharging devices rig X 2 Vacuum micron gauge X 3 Flushing equipment X 4 Oxyge
47、n free nitrogen and a pressure regulator gauge assembly X 5 Digital thermometer X 6 Electronic leak detector X 7 Fluorescent dye leak test kit X 8 Multimeters, digital or moving coil X 9 Portable hose crimping tool kit X 10 Manifold gauge set for road testing X 11 Master manifold gauge set for calib
48、ration X 12 Hoists or hydraulic jacks and trestles X 13 Wire strippers and crimping kit X 14 Electric or pneumatic hand drilling machines X 15 Bench press drilling machines X 16 Bench grinder with safety guards, rests and goggles X 17 Set of spanners and necessary hand tools per technician X 18 Radi
49、ator test kit for standard and integrated cooling modules X 19 Belt tension tester X 20 Fender covers and seat covers X 21 Spare set of charging hoses X 22 Spare set of quick couplers (service taps) X 23 Polyaklylene glycol (PAG) oil and dye injector X 24 Torque wrench kit X 25 Two-stage vacuum pump with suitable gauges X 26 PAG oil for R-134a systems at correct OEM viscosity X 27 Certified pure SAE J 2099 R-134a X 28 Flushing solvent (non-volatile organic compounds), or R-134a coupled to a flushing device operating at the correct flushing pressure and filtration levels inc
