Blaupunkt R290 Maintenance Manual [ml]

Arrifana 12C

BAC-PO-0012-C02D

For end-user to view ONLY

R290 Maintenance Manual

According to Annex DD of IEC/EN 60335-2-40

Dla użytkownika WYŁĄCZNIE w celu zapoznania się Zgodnie z dodatkiem DD IEC/EN 60335-2-40

Für Endverbraucher NUR zum Kenntnisnahme Gemäß Anhang DD von IEC/EN 60335-2-40

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CONTENTS

General instructions .................................................................................... 3

Repairs to sealed components .................................................................... 6

Repair to intrinsically safe components ........................................................ 8

Cabling ........................................................................................................ 8

Detection of flammable refrigerants ............................................................. 9

Leak detection methods .............................................................................. 9

Decommissioning ...................................................................................... 10

Labelling .................................................................................................... 12

Recovery ................................................................................................... 12

Specific information regarding appliances with R290/R32 refrigerant gas.. 14

Informacje dotyczące gazów R290 i R32 ................................................... 32

Sondern Informationen zu Geräten mit R290/R32 Refrigeration Gas ........ 52

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General instructions

1.1

Checks to the area

Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimised. For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system.

1.2

Work procedure Work shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapour being present while the work is being performed.

1.3 General work area All maintenance staff and others working in the local area shall

be instructed on the nature of work being carried out. Work in confined spaces shall be avoided.

The

area

around the workspace shall be sectioned off. Ensure that the conditions within the area have been made safe by control of flammable material.

1.4

Checking for presence of refrigerant

The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially flammable atmospheres. Ensure that

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the leak detection equipment being used is suitable for use with flammable refrigerants, i.e. nonspeaking, adequately sealed or intrinsically safe.

1.5 Presence of fire extinguisher If any hot work is to be conducted on the refrigeration equipment or any associate be available to hand. Have a dry powder or fire extinguisher adjacent to the charging area.

parts, appropriate fire extinguishing equipment shall

1.6 No ignition sources

No person carrying out work in relation to a refrigeration

system which involves exposing any pipe work that contains or has contained flammable refrigerant manner that it may

shall use

lead to

ignition sources, including cigarette smoking, should

any

sources of ignition in such a

the risk of fire

or explosion. All possible

be kept sufficiently far away from the site of installation,

repairing, removing and

refrigerant can

possibly be

disposal, during which flammable

released to the sur

rounding space.

Prior to work taking place, the area around the equipment is to

be surveyed to make sure that there are no flammable hazards or ignition risks.

,,No Smoking" signs shall be displayed.

1.7

Ventilated area

Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during

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the period that the work is carried out. The ventilation should safely disperse any

released refrigerant and preferably expel it extremely into the atmosphere.

1.8 Checks to the refrigeration equipment Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer's maintenance and service guidelines shall be followed. lf in doubt consult the manufacturer's technical department for assistance. The following checks shall be applied to installations using flammable refrigerants: - the charge size is in accordance with the room size within which the refrigerant containing parts are

installed;

the ventilation machinery and outlets are operating adequately and are not obstructed;

if an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant;

marking to the equipment continues to be visible and legible. Markings and signs that

refrigeration pipe or components are installed in a position

are illegible shall be corrected;

where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the

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components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded.

1. 9 Checks to electrical devices

Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. lf a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until

it is satisfactorily dealt with. lf the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used.

• that capacitors are discharged: this shall be done in a safe manner

to avoid possibility of sparking;

•

that there no live electrical components and wiring are

exposed while charging, recovering or purging the system;

• that there is continuity of earth bonding.

Repairs to sealed components

2.1 During repairs to sealed components, all electrical supplies

shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. lf it is absolutely necessary to have an electrical supply to equipment

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during servicing, then a permanently operating form of leak detection shall be located

the most critical point

to warm of a

potentially hazardous situation.

2.2 Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc.

Ensure that apparatus is mounted securely. Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing the ingress of flammable

atmospheres. Replacement parts shall be in accordance with the manufacturer's specifications. NOTE: The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment. intrinsically safe components do not have to be isolated prior to working on them.

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Repair to intrinsically safe components

Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use.

intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the

manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a

leak.

Cabling

Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.

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Detection of flammable refrigerants

vibration from sources such as

compressors or fans.

Leak detection methods

The following leak detection methods are deemed acceptable for

systems containing flammable refrigerants. Electronic leak detectors shall be used to detect flammable

refrigerants, but the sensitivity may not be adequate, or may need recalibration. (Detection equipment shall be calibrated in a refrigerant-free area). Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection

equipment shall be set at a percentage of the LFL of the refrigerant and shall be

calibrated to the refrigerant employed and the appropriate percentage of gas (25 % maximum

)

is confirmed.

Leak detection fluids are suitable for use with most refrigerants

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but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. lf a leak is suspected, all naked flames

leak test shall be

shall be removed but prior to commissioning. A

carried out prior to leaving the site.

follow up

Decommissioning

Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. lt is recommended good practice that all refrigerants are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of reclaimed refrigerant. lt is essential that electrical power is available before the task is commenced.

• Become familiar with the

equipment and its operation.

• lsolate system electrically.

•

Before attempting the procedure ensure that: mechanical handling equipment is handling refrigerant

cylinders;

available, if

required, for

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all

personal

correctly; the

protective equipment is

available

and being

re covery process is supervised at all limes by a

used

competent person;

recovery equipment and cylinders conform to the appropriate

standards.

•

Pump down refrigerant system, if possible.

a vacuum is not

• lf

refrigerant

can

possible, make a

be removed

manifold so that

from various parts of the system.

• Make sure that cylinder is situated on the scales before

recovery takes place.

•

Start the recovery machine and operate in accordance with manufacturer's instructions.

Do not overfill cylinders.

•

charge).

•

Do not cylinder,

•

When the cylinders have been filled correctly and the

exceed the

even

temporarily

maximum working pressure of

process completed, make sure equipment

are removed

isolation valves on the equipment are closed

•

Recovered refrigerant shall not be charged into another

(No more

that the cylinders and the

from

sile

than 80 % volume liquid

promptly and all

off.

refrigeration system un- less it has been cleaned and checked.

the

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Labelling

Equipment shall be labelled stating that it has been decommissioned and emptied

of refrigerant. The label shall be dated and signed. Ensure that there are labels on the equipment stating the equipment contains flammable refrigerant.

Recovery

When removing refrigerant from a system, either for servicing or

decommissioning, it is recommended good practice that all

refrigerants are removed safely. When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery

cylinders are employed. Ensure that the correct number of

cylinders

for holding the total system charge are available. All cylinders to be

used are designated for the recovered refrigerant and labelled for

that refrigerant (i.e. special cylinders for the recovery of refrigerant).

Cylinders shall be complete with pressure relief valve and associated

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shut-off valves in good working order. Empty recovery cylinders are

evacuated and, if possible, cooled before recovery occurs.

The recovery equipment shall be in good working order with a set of instructions

concerning the equipment that is at hand and shall be suitable for the recovery of flammable refrigerants. In addition, a set of calibrated

weighing scales shall be available and in good working order.

Hoses shall be complete with leak free

disconnect couplings

and in good condition. Before using the recovery machine,

check that is in satisfactory working order, has been properly

maintained and that any associated electrical components

are sealed to prevent ignition in the event of a refrigerant

release. Consult manufacturer if in doubt.

The recovered refrigerant shall be returned to the refrigerant

supplier in the correct recovery cylinder, and the relevant Waste

Transfer Note arranged. Do not mix refrigerants in recovery units

and especially not in cylinders.

lf compressors or compressor oils are to be removed, ensure that

they have been evacuated to an acceptable level to make certain

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that flammable refrigerant does not remain within the lubricant.

The evacuation process shall be carried out prior to

returning the compressor to the suppliers. Only electric heating to the compressor body shall be employed to accelerate process. When oil is drained from a system, it shall be carried out safely.

this

Specific information regarding appliances with R290/R32 refrigerant gas

● Thoroughly read all of the warnings.

● When defrosting and cleaning the appliance, do not use any tools

other than those recommended by the manufacturing company.

● The appliance must be placed in an area without any continuous sources of ignition (for example: open flames, gas or electrical appliances in operation).

● Do not puncture and do not burn.

● Refrigerant gases can be odourless.

● The appliance must be installed, used and stored in an area that is

greater than 13 m

● R290/R32 is a refrigerant gas that complies with the European directives on the environment. Do not puncture any part of the refrigerant circuit.

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● If the appliance is installed, operated or stored in a non-ventilated area, the room must be designed to prevent the accumulation of refrigerant leaks resulting in a risk of fire or explosion due to ignition of the refrigerant caused by electric heaters, stoves, or other sources of ignition.

● The appliance must be stored in such a way as to prevent mechanical failure.

● Individuals who operate or work on the refrigerant circuit must have the appropriate certification issued by an accredited organisation that ensures competence in handling refrigerants according to a specific evaluation recognized by associations in the industry.

● Repairs must be performed based on the recommendations from the manufacturing company.

● Maintenance and repairs that require the assistance of other qualified personnel must be performed under the supervision of an individual specified in the use of flammable refrigerants.

● Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer.

● The appliance shall be stored in a room without continuously operating ignition sources (for example: open flames, an operating gas appliance or anoperating electric heater).

● Do not pierce or burn.

● Be aware that the refrigerants may not contain an odour.

● Compliance with national gas regulations shall be observed.

● Keep ventilation openings clear of obstruction.

● The appliance shall be stored so as to prevent mechanical damage

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from occurring.

● A warning that the appliance shall be stored in a well-ventilated area where the room size corresponds to the room area as specified for operation.

● Any person who is involved with working on or breaking into a refrigerant circuit should hold a current valid certificate from an industry-accredited assessment authority, which authorises their competence to handle refrigerants safely in accordance with an industry recognised assessment specification.

● Servicing shall only be performed as recommended by the equipment manufacturer.

● Maintenance and repair requiring the assistance of other skilled personnel shall be carried out under the supervision of the personcompetent in the use of flammable refrigerants.

● Appliance should be installed, operated and stored in a room with

a floor area larger than 13 m

WARNING: System contains refrigerant under very high pressure. The system must be serviced by qualified persons only.

1. Transport of equipment containing flammable refrigerants （Annex CC.1） Compliance with the transport regulations.

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2. Marking of equipment using signs（Annex CC.2） Compliance with local regulations.

3. Disposal of equipment using flammable refrigerants（Annex CC.3） Compliance with national regulations.

4. Storage of equipment/appliances （Annex CC.4） The storage of equipment should be in accordance with the

manufacturer’s instructions.

5. Storage of packed (unsold) equipment（Annex CC.5） Storage package protection should be constructed such that

mechanical damage to the equipment inside the package will not cause a leak of the refrigerant charge. The maximum number of pieces of equipment permitted to be stored together will be determined by local regulations.

6. Information on servicing（Annex DD.3）

1) Checks to the area Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimised. For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system.

2) Work procedure Work shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapour being present while

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the work is being performed.

3) General work area All maintenance staff and others working in the local area shall be instructed on the nature of work being carried out. Work in confined spaces shall be avoided. The area around the workspace shall be sectioned off. Ensure that the conditions within the area have been made safe by control of flammable material.

4) Checking for presence of refrigerant The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with flammable refrigerants, i.e. non-sparking, adequately sealed or intrinsically safe.

5) Presence of fire extinguisher If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry powder or CO2 fire extinguisher adjacent to the charging area.

6) No ignition sources No person carrying out work in relation to a refrigeration system which involves exposing any pipe work that contains or has contained flammable refrigerant shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation, repairing, removing and disposal, during which lammable refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are

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no flammable hazards or ignition risks. “No Smoking” signs shall be displayed.

7) Ventilated area Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.

8) Checks to the refrigeration equipment Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt consult the manufacturer’s technical department for assistance. The following checks shall be applied to installations using flammable refrigerants: – The charge size is in accordance with the room size within which the refrigerant containing parts are installed; – The ventilation machinery and outlets are operating adequately and are not obstructed; – If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant; – Marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected; – Refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded.

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9) Checks to electrical devices Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised. Initial safety checks shall include:

• That capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking;

• That there no live electrical components and wiring are exposed while charging, recovering or purging the system;

• That there is continuity of earth bonding.

7. Repairs to sealed components（Annex DD.4）

1) During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. If it isabsolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation.

2) Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc.

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Ensure that apparatus is mounted securely. Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing the ingress of flammable atmospheres. Replacement parts shall be in accordance with the manufacturer’s specifications.

NOTE: The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment. Intrinsically safe components do not have to be isolated prior to working on them.

8. Repair to intrinsically safe components （Annex DD.5） Do not apply any permanent inductive or capacitance loads to the

circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak.

9. Cabling（Annex DD.6） Check that cabling will not be subject to wear, corrosion, excessive

pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.

10. Detection of flammable refrigerants（Annex DD.7） Under no circumstances shall potential sources of ignition be used

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in the searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used.

11. Leak detection methods（Annex DD.8） The following leak detection methods are deemed acceptable for

systems containing flammable refrigerants. Electronic leak detectors shall be used to detect flammable refrigerants, but the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas (25 % maximum) is confirmed. Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. If a leak is suspected, all naked flames shall be removed/ extinguished. If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak. Oxygen free nitrogen (OFN) shall then be purged through the system both before and during the brazing process.

12. Removal and evacuation（Annex DD.9） When breaking into the refrigerant circuit to make repairs – or for

any other purpose – conventional procedures shall be used.

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