Danfoss Gas detection in refrigeration systems Application guide

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Application Guide

Gas detection in refrigeration systems

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Application Guide | Gas detection in refrigeration systems

Contents Page

Commonly used abbreviations......................................................................3

Introduction........................................................................................4

Sensor technology..................................................................................4

EC - Electrochemical sensor .....................................................................4

SC - Semiconductor sensor (solid state)..........................................................5

P- Pellistor sensor...............................................................................6

IR - Infrared.....................................................................................6

Which sensor is suitable to a given refrigerant? ..................................................6

Sensor response time ...............................................................................7

The need for gas detection..........................................................................8

Legislation and standards...........................................................................8

Requirements for gas detection according to EN 378:2016 and ISO 5149:2014 ....................9

F-Gas legislation.............................................................................. 10

Requirements for gas detection according to ASHRAE 15-2016 (USA)........................... 10

Requirements for gas detection according to ANSI/IIAR-2 (USA) ................................ 10

Installation guideline ............................................................................. 11

Location of gas detectors ......................................................................... 12

Number of gas detectors in a facility............................................................... 13

Calibration / test.................................................................................. 13

Calibration methods ..............................................................................14

Method I Calibration by means of replacing sensor heads...................................... 14

Method II Calibration of gas detectors by means of calibration gas .............................14

Bump test ....................................................................................15

Alarm / sensitivity range gas detectors ........................................................ 16

Danfoss recommendations for alarm levels.................................................... 16

Actions triggered by gas detection ...............................................................18

References .......................................................................................19

Annex I - Common refrigerant data................................................................ 20

Annex II - EN 378:2016 and ISO 5149:2014 ......................................................... 20

Annex III - ASHRAE 15-2016 ....................................................................... 21

Commonly used abbreviations

• LFL = Lower Flammability Level

• OEL = Occupational Exposure Limits

• ATEL = Acute-Toxicity Exposure Limit

• ODL = Oxygen Deprivation Limit

• OSH = Occupational Safety Limit

• ODP = Ozone Depletion Potential

• GWP = Global Warming Potential

• TRK = Technische Richtkonzentrationen

• MAK = Maximale Arbeitsplatzkonzentrationen

• TLV = Threshold Limit Value

• STEL = Short Term Exposure Limit

• PEL = Permissible Exposure Limits

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Application Guide | Gas detection in refrigeration systems

Sensitivity

Introduction Gas detection and leak detection are two distinct

activities that covers the same topic, but the methods are very diﬀerent.

Gas detection covers the analysis of air samples to determine whether they contain refrigerant gas. Leak detection is a systematic inspection of a refrigeration system to determine whether it is leaking. The terms gas detection and leak detection are not interchangeable, and must not be mixed.

Leak detection equipment is normally handheld equipment carried by people, and used for detection of leaks in refrigeration systems. There are several types of leak detectors available, ranging from simple techniques like soapy water to sophisticated electrical instruments.

Gas detection equipment is usually used in a ﬁxed installation with a number of sensors located in areas where refrigerant might be expected to accumulate in the event of a plant leak.

Sensor technology The choice of sensor technology for refrigerant

gas detection will depend on the speciﬁc target refrigerant gas and ppm range required. Danfoss oﬀers a range of diﬀerent sensor technologies

These locations depend upon the layout of the machinery room and adjacent spaces, on the conﬁguration of the plant and also on the refrigerant in question.

Before selecting the appropriate gas detection equipment, a number of questions have to be answered:

• Which gases have to be measured and in what

quantities?

– Which sensor principle is the most suitable? – How many sensors are needed? – Where and how should they be positioned

and calibrated?

• Which alarm limits are appropriate? – How many are required? – How is the alarm information processed?

This application guide will address these questions.

to match most commonly used refrigerants, appropriate ppm ranges, and safety requirements for refrigeration systems.

EC - Electrochemical sensor Electrochemical sensors are mainly used for toxic

gases and are suitable for ammonia.

They consist of two electrodes immersed in an electrolyte medium.

“High” gas concentration

“Low” gas concentration

Max. operating time

before calibration

Fig. 1: Sensitivity of electrochemical sensors

They are very accurate (+/- 2%) and tend to be used mainly for toxic gases, which cannot be detected otherwise, or where high levels of accuracy are needed (ﬁg. 1).

An oxidation / reduction reaction generates an electric current that is proportional to the gas concentration.

max.

Tolerance rang

min.

Time

Exposure to large ammonia leaks or constant background ammonia will shorten the sensor life (ﬁg. 2). EC sensors can be re-calibrated as long as the sensitivity of the sensor is above 30%.

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Danfoss oﬀers speciﬁc EC sensors for ammonia in ranges up to 0-5.000 ppm with an expected lifetime of 2 years, depending on exposure to target gas.

They are very selective and rarely subject to cross-interference. They may react to sudden large humidity changes but settle quickly.

Application Guide | Gas detection in refrigeration systems

Sensitivity

Gas speciﬁcation

Sensitivity

EC - Electrochemical sensor (continued)

“Substantial” gas leak

Important!

Sensor must be calibrated or new sensor must be installed.

max.

Tolerance rang

min.

SC - Semiconductor sensor (solid state)

If the sensitivity of the sensor falls below 30%; install new sensor

Max. operating time

before calibration

Fig. 2: Large ammonia exposure shortens the lifetime of electrochemical sensors.

The semi-conductor sensor functions by measuring the resistance change (proportional to the concentration), as gas is absorbed on to the surface of a semi-conductor, which is normally

However, they are not selective, and are not suitable for detecting a single gas in a mixture, or for use where high concentrations of interfering gases are likely to be present (ﬁg. 3).

made from metal oxides.

Interference from short term sources (e.g. These can be used for a wide range of gases including combustible, toxic and refrigerant gases.

It is claimed that they perform better than the catalytic type in the detection of combustible gases at low concentrations, up to 1.000 ppm.

exhaust gas from a truck), creating false alarms,

can be overcome by enabling a delay of the

alarm.

Semi-conductors for halocarbons can be used

to detect more than one gas or a mixture

simultaneously. This is particularly useful in

monitoring a plant room with several diﬀerent These are low-cost, long life, sensitive and can be

refrigerants. used to detect a large range of gases including all the HCFC, HFC refrigerants, ammonia and hydrocarbons.

30% sensitivity

Time

“Broad” sensitivity spectrum – Semiconductor – Pellistor

“Narrow” sensitivity

Gas 1

Fig. 3: Sensitivity spectrum of various sensor technologies

Gas 2

Gas 3

Gas 4

Gas 5

Target Gas

spectrum – Electrochemical – Infrared

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Application Guide | Gas detection in refrigeration systems

P- Pellistor sensor Pellistors (sometimes called a bead or catalytic)

are mainly used for combustible gases including ammonia, and are the most popular sensors for this application at high detection levels.

The sensor functions by burning the gas at the surface of the bead and measuring the resultant resistance change in the bead (which is proportional to concentration).

These are relatively low-cost, well established and understood, and they have a good life span (expected life time 3 to 5 years). The response time is usually below 10 seconds.

They can be subject to poisoning in certain applications.

IR - Infrared Infrared technology utilises the fact that most

gases have a characteristic absorption band in the infrared region of the spectrum, and this can be used to detect them. Comparison with a reference beam allows the concentration to be determined.

Even though they are relatively expensive in comparison to other sensor, they have long life time of up to 15 years, high accuracy, and low cross sensitivity

Poisoning is the reduction of the reaction of the sensor to the target gas due to the presence (contamination) of another substance on the surface of the catalyst, that either reacts with it or forms a layer on top of it reducing its capacity to react to the target gas. Most common poisoning substances are silicon compounds.

Pellistors are used mainly with combustible gases and are therefore suited for ammonia and the hydrocarbon refrigerants at high concentrations.

They do sense all combustible gases, but they respond at diﬀerent rates to each, and so they can be calibrated for particular gases. There are ammonia speciﬁc versions.

Due to its measuring principle infrared sensors can be subject to issues in dusty environments, where the presence of too many particles in the air may disturb the reading.

They are recommended and commonly used for Carbon dioxide detection. Although technology exists for other gases also, it is not common to ﬁnd it in commercial solutions.

Which sensor is suitable to a given refrigerant?

Based on the target refrigerant gas and the actual ppm range the below table provides an overview of the suitability of the various sensor technologies oﬀered by Danfoss.

Suitability of diﬀerent sensor technologies:

Semi-conducter Electro-chemical

Ammonia “low” concentration (< 100 ppm)

Ammonia “medium” concentration (< 1000 ppm) 1)

Ammonia “high” concentration (<10000 ppm)

Ammonia “very high” concentration (> 10000 ppm)

Carbon Dioxide CO₂

HC Hydrocarbons

HCFC - HFC Halocarbons

Best solution

) Measuring range 0-1000 ppm. Can be adjusted in the whole range.

) Up to 5000 ppm. For speciﬁc applications.

–

(4) 4

4 (4)

– –

– – –

– –

Suitable - but less attractive Not suitable

Pellistor

(Catalytic)

– – –

– –

(4)

Infrared

–

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Application Guide | Gas detection in refrigeration systems

Time, s

Fraction of Concentration Change

250

Sensor response time

The response time is the elapsed time for a sensor to read a given percentage of the actual value for a step change in the target gas concentrations.

Response time for most sensors is given as t90, meaning the time that it takes the sensor to read 90% of the actual concentration. Fig. 4 shows an example of a sensor with a reponse time t90 of 90 seconds.

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

050 100 150 200

Fig. 4: Sensor with a response time t90 of 90 seconds

As shown in the graphic, the sensor reaction

above 90% becomes slower and takes longer to

read the 100%.

GAS Sensor technology Response time t90, seconds

Electrochemical 0-100/ 0-300 ppm <40s

Electrochemical 0-1000ppm <40s

Ammonia

Electrochemical 0-5000ppm <40s

Semiconductor >120s

Pellistor <20s

Infrared Infrared <90s

Halocarbons Semiconductor >120s

Hydrocarbons Pellistor <15s

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Application Guide | Gas detection in refrigeration systems

The need for gas detection

There are several reasons why gas detection is required. Two obvious reasons are to protect people, production and equipment from the impact of potential gas leakages and to comply with regulations. Other good reasons include:

• Reduced service cost (cost of replacement gas and the service call).

• Reduced energy consumption cost due to lack of refrigerant.

• Risk for damaging stock products due to a substantial leak.

• Possibility to reduce insurance costs.

• Taxes or quota on non-environmentally friendly refrigerants

The various refrigeration applications require gas detection for diﬀerent reasons.

Ammonia is classiﬁed as a toxic substance with a very unique smell, as such it is “self alarming”. However, gas detectors are required to guarantee early warnings, and to monitor areas where people are not always present, such as machinery rooms. It is important to be aware that ammonia is the only common refrigerant lighter than air. In many cases, this will lead to ammonia rising above the breathing zone making it impossible for people to early detect ammonia leakages. The use of gas detectors in the right zones ensures early warnings in case of ammonia leakages.

Hydrocarbons are classiﬁed as ﬂammable. Thus, it’s critical to verify that the concentration around the refrigeration system does not exceed the ﬂammability limit.

Fluorinated refrigerants all have a certain negative impact on the environment, for which reason it’s very important to avoid any leaks.

CO2 (Carbon Dioxide) is directly involved in the respiration process and should be treated accordingly. Approximately 0.04% CO2 is present in the air. With higher concentration, some adverse reactions are reported starting with increase in breath rate (~100% at 3% CO2 concentration) and leading to loss of consciousness and death at CO2 concentrations above 10%.

Legislation and standards The requirements for gas detection are diﬀerent

across countries worldwide. An overview of the most common rules and regulation can be found on the following pages.

Europe:

The present safety standard for refrigeration systems in Europe is EN 378:2016.

The speciﬁed alarm levels in EN 378:2016 are set at levels to allow evacuation of an area. The levels do not reﬂect the eﬀects of long term exposure to leaked refrigerants. In other words, in EN 378 a gas detector is to warn when a sudden large release occurs, while machine room ventilation and system quality measures are to ensure that small leaks are too small to cause adverse health eﬀects.

Note!

Requirements for gas detection equipment in Europe are covered by national legislation in the diﬀerent countries, and consequently may diﬀer from the requirements speciﬁed in EN

378.

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Application Guide | Gas detection in refrigeration systems

Requirements for gas detection according to EN 378:2016 and ISO 5149:2014

Start

Gas detector

used to start fan or

close valves

Gas detector

required

Below ground

in machinery room

or open air

Gas detector

required

Ammonia

Charge >

50 kg

Gas detection

required

high/low level

using alternative risk

Charge limits

for ventilated

enclosure

Charge limits

management

Charge >

100% practical

limit

Using EN 378

and charge >m

and A3 or B3

Fig. 5: Requirements for gas detection according to EN 378:2016 part 3 and ISO 5149:2014 part 3

With a few exceptions gas detection is required by EN 378:2016 and ISO 5149:2014 for all installations where the concentration in a room may exceed the practical limit for that space.

The practical limits for various refrigerants are given in Annex II, which are extracted from EN 378-2016 part 1. In these tables the practical limit of ammonia is based upon its toxicity. The

practical limits of the hydrocarbons are based In the case of ﬂammable and toxic refrigerants this means virtually all commercial and industrial systems In the case of A1 refrigerants it is possible to have small systems, which do not require gas

upon their ﬂammability and are set at 20% of

their lower ﬂammable limit. The practical limits

for all the A1 refrigerants are set at their Acute

Toxicity Exposure Limit (ATEL). detection. However, in most of the larger plants it is likely that the practical limit will be exceeded in the event of a major leak, and therefore gas detection is required.

If the total refrigerant charge in a room, divided

by the net room volume, is greater than the

“practical limit” (see Annex II), it is reasonable to

conclude that ﬁxed gas detection system should Guidance can be found in EN 378:2016 part

be installed. 3 or ISO 5149:2014 part 3. The requirements of the two standards are very similar, and are summarised in ﬁg. 5.

Both EN378:2016 and ISO 5149:2014 require that

an indicating device is provided to show whether

the relief valve has discharged on systems with If it can be shown by calculation that the concentration of refrigerant in a room can never

300 kg refrigerants or more. A possibility is to

place a gas detector in the discharge line. reach the practical limit; then there is no need for ﬁxed gas detection, except according to EN 378 if the system is below ground with a charge above m2 (approx. 1 kg of propane). ISO 5149 does not have this exception. m2 is a constant equal to 26m3 x LFL. For propane it is 26 m3 x 0,038 kg/m3 = 0,988 kg, or, if your LFL is measured in gram, it is 26 m3 x 38g/m3 =988 g. As such m2 does not have any units, since the units depend solely on which unit you chose for LFL. Most hydrocarbons have similar value of LFL, and m2 is therefore typically around 1kg.

No requirements

However, if the concentration can reach the practical limit, even for A1 refrigerants, then ﬁxed detection must be installed - again with a few minor exceptions.

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Application Guide | Gas detection in refrigeration systems

(Clause 7.2)

(Clause 8.11.2.1)

(Clause 7.2)

(Clause 7.2.2)

F-Gas legislation The F-Gas Regulation (EC) No 517/2014

One objective of the F-Gas Regulation is to contain, prevent and thereby reduce emissions of ﬂuorinated greenhouse gases covered by the Kyoto Protocol. The F-gas directive is mandatory in all EU member countries and in the three European Economic Area (EEA) EFTA countries including Iceland, Liechtenstein, and Norway.

The regulation covers, among other topics, the import, export and use of the traditional HFCs and PFCs in all their applications. The regulation entered into force on January 1st, 2015.

Leakage checking requirements, to prevent leakage and to repair any detected leakage, depends on the CO2 equivalents of the refrigerant in each circuit with refrigerant. The CO2 equivalents is the charge in kg x the GWP of the refrigerant.

Requirements for gas detection according to ASHRAE 15-2016 (USA)

Requirements for gas detection according to ASHRAE 15-2016 state requirements for rooms with refrigerating equipment including machinery rooms. The “Low Level” alarm values are less or equal to TLV-TWA levels.

A periodical leakage check by certiﬁed personnel is required with the following frequency, depending on the quantity used:

• 5 tCO

or more: At least once every 12 months

2eq

– except for hermetically sealed systems containing less than 10 tCO

• 50 tCO

or more: At least once every 6 months

2eq

(12 months with an appropriate leakage detection system)

• 500 tCO

or more: At least once every 6

2eq

months. An appropriate leakage detection system is mandatory. The leakage detection system must be checked at least once every 12 months.

In practice, the Occupational Exposure Limit (OEL) values from ASHRAE 34 are used since they are based on TLV-TWA (see also “Occupational Exposure Limits”, page 18)

Start

Requirements for gas detection according to ANSI/IIAR-2 (USA)

No requirements

Gas detection

required

No requirements

Gas detection

required

Charge < 3 kg

Machinery

room

Charge >

RCL

Additional

requirements

Fig. 6: Gas detection requirements according to ASHRAE 15-2016.

* Note 1: The charge limit stated in ASHRAE 15-2016 can also be found in Annex II (RCL) - for selected refrigerants. Note 2: ASHRAE 15 does not include Ammonia. Refer to ANSI/IIAR-2.

ANSI/IIAR -2 requires machinery rooms to be provided with ammonia gas detectors. It requires 3 diﬀerent alarm levels (25, 150 and 40000 ppm) with diﬀerent response requirements according to each of the levels.

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Start

Gas detector required

Alarm at 25, 150,

and 40000 ppm (max)

Y N

Machine room

Fig. 7: Gas detection requirements according to the ANSI/IIAR-2

Gas detector required

Alarm at 25 ppm

Application Guide | Gas detection in refrigeration systems

Relative density

Installation guideline When it comes to installation of gas detection

there are two approaches:

• Perimeter detection

• Point detection

With perimeter detection, you place sensors all around the perimeter of the space in question, to make sure you monitor the whole space.

With point detection, you locate a sensor at a particular position, where you are concerned about a leak (e.g. at the compressor).

For gases heavier than air, sensors should be

located close to the ground/lowest point.

For gases lighter than air, sensors should be

mounted high up on the walls, ceiling or near

exhaust, but convenient for maintenance.

If the density is equal to air, the sensors should be

mounted at face level.

In some countries it may be mandatory to

have an UPS (Uninterruptible Power Supply)

connected to the gas detectors to ensure safe

operation during a power failure.

(refrigerant/air)

Fig. 8: Relative density refrigerant/air

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Application Guide | Gas detection in refrigeration systems

Location of gas detectors Gas detectors must be powered as speciﬁed in

the installation guide and located within the speciﬁed cable length from the central control unit/monitor.

In general:

• Do not mount to a structure that is subject to vibration and shock, such as piping and piping supports.

• Do not locate near excessive heat or in wet or damp locations.

The two methods of locating sensors:

• Point detection: Sensors are located as near as possible to the most likely sources of leakage.

• Perimeter detection: Sensors surround the hazardous area completely.

• Do not mount where it will be exposed to direct solar heating.

• Do not install in areas where condensation may form.

The most appropriate method is selected depending on the size and nature of the site.

• Detectors shall be located high/low according to the density of the actual refrigerant.

• If mechanical ventilation exists in a machinery room, air will move towards the fan. In problematic locations a smoke tube can indicate air movements in a space and assist in the location of sensors.

• In a cold store, sensors should, if possible, be placed on the wall in the return airﬂow.

• Consideration should also be given to the possibility of pockets of gas collecting in the event of a leak.

The arrangement of the equipment in the room can also have an impact on the most eﬀective place to monitor.

Locations requiring most protection in a machinery or plant room would be around gas boilers, compressors, pressurized storage tanks, gas cylinders, storage rooms, or pipelines.

Most vulnerable are valves, gauges, ﬂanges, T-joints, ﬁlling or draining connections etc.

Sensors should be positioned a little way back from any high-pressure parts to allow gas clouds to form. Otherwise any leakage of gas is likely to pass by in a high-speed jet and will not be detected by the sensor.

Important!

Do not place immediately in front of a coil due to temperature and humidity ﬂuctuations. These may occur especially during defrost or loading of a cold store.

Make sure that pits, stairwells and trenches are monitored since they may ﬁll with stagnant pockets of gas. Monitoring where leaked refrigerant can stagnate is generally required by standards.

As general guideline:

• If there is one compressor/chiller in the room; sample at the perimeter of the unit. For two chillers; sample between them, with three or more chillers; sample between and on each side. Ensure that the area being sampled is suﬃciently monitored. Do not skimp on sensors.

• Place the sensor in the location(s) most likely to develop a gas leak, including mechanical joints, seals, and where there are regular changes in the system’s temperature and pressure or excessive vibration, such as compressors and evaporator control valves.

Accessibility and space to allow calibration and service must be considered.

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Application Guide | Gas detection in refrigeration systems

Number of gas detectors in a facility

The requirements for the number of gas detectors in a facility are not speciﬁcally stated in standards.

As general guideline:

• A gas detector can normally cover an area of about 50-100 m2 depending on the actual condition of the space to be covered. In spaces with several obstructions and lack of ventilation the coverage is approx. 50 m2, provided it is mounted near ceiling level or near ﬂoor level depending on the refrigerant density. In non-obstructed spaces with good mechanical ventilation, the coverage can be increased up to approx. 100 m2.

• Machinery rooms: It is recommended that gasdetectors are placed above or at both sides of compressors or other non-static parts of the system or down wind of such equipment, in the direction of continuously operating ventilation extractors. Where there are deep beams and lighter than air refrigerants, it is recommended that the detectors are mounted between pairs of beams and on the underside of the beams.

Calibration / test Calibration/test of gas detectors is extremely

important to ensure and document the proper accuracy, responsiveness and operation of the unit.

If there is a continuous airﬂow in the room a sensor/sensing point should be located downstream from the last potential leak source.

From a technically and safety point of view, the sensors oﬀered by Danfoss should be calibrated/ tested according to the stated intervals in the table below.

Gas detectors are subject to changes in the measurement properties, dependent on the operation time and/or exposure time. Therefore, regular calibration is needed. The frequency depends on various factors, however the

IMPORTANT! If national legislation requires calibration/test with intervals shorter (stricter) than stated in the table below, these requirements must be followed.

following four are of particular importance:

• Requirements of national legislation

• Recommended calibration interval

Note: EN 378:2016 and ISO 5149 require gas detectors to be checked on an annual basis.

• Lifetime of the sensors

• The lifetime and calibration needs of

electrochemical sensors are highly aﬀected by exposure to the target gas, reducing the lifetime and the calibration interval. For that reason the concentrations of the target gas in the area should also be considered.

Estimated life time

[year]

SC Semi-conductor >5 1 1

EC Electrochemical >2* 1 1

P Pellistor 3-5 6 months 1

IR Infrared 15 5 1

* If the sensor is exposed to high or constant ammonia concentrations, the life time will be reduced. An EC sensor remain functional above 30% of sensitivity. ** If calibration is performed, test is not required. However, when calibration interval is longer than the test interval, then a “bump” test must be performed.

Min. recomended

calibration interval

[year]

Recomended test

interval**

[year]

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Application Guide | Gas detection in refrigeration systems

Certiﬁcate:

On-board test functionExchange of sensor head

Calibration methods

Method I Calibration by means of replacing sensor heads

Two diﬀerent methods are available for fulﬁlling the calibration requirements.

• Replacing the sensor (sensor cartridge) with a new factory pre-calibrated sensor.

• Performing a calibration to the sensor using calibration gas (gas mixture with known target gas concentration).

This method requires that the supplier oﬀers factory pre-calibrated sensor heads with calibration certiﬁcate and traceability codes. Additionally, an electrical simulation is required to verify the output signals and alarm settings .

This method can be compared with the method used for safety valves. The manufacturer produces, tests, and certiﬁes the product, which can then be mounted in the system.

Danfoss oﬀers the above-mentioned solution. The sensor head, which is the essential measuring element of the gas detector, is produced, tested, calibrated, and certiﬁed by Danfoss.

After the gas detection unit has been tested with the on-board test button function, which

In addition to these calibration methods, a “bump” test can be used, but only to test the responsiveness and operation of the sensor. It is important to highlight, that a bump test is not a calibration.

simulates alarm signals and relay activation, to ensure all electrical components are functional, the new calibrated sensor head can be installed.

Danfoss recommends that the calibration is done by means of pre-calibrated replacement sensors:

• As sensors have a limited lifetime, this method basically ensures that the customer has a gas detector as good as new after replacing the sensor head.

• The method is typically more eﬃcient and cost eﬀective compared to calibration carried out on site.

Method II Calibration of gas detectors by means of calibration gas

Gas/calibration levels etc. Traceability

Certiﬁcate

XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX

Fig. 9: Test and calibration of Danfoss gas detection unit (GDU) by the use of the on-board test function and replacement of the sensor head.

The calibration of gas detectors by means of calibration gas has traditionally been made by using multimeters and adjustment of potentiometers, which makes the process

Test function button

321

Sensor

In order to execute the calibration function, the gas detector unit needs to be equipped with a display or connection to either the service tool or the PC tool.

Gas detection unit



567

Sensor

tested and calibrated

relatively complicated, time consuming, and expensive. However, the Danfoss gas detection units have an integrated, digital calibration function that makes the calibration process

Some calibration gas cylinders are treated as dangerous substances, and therefore subject to

speciﬁc shipping requirements. easier, cheaper, and faster. Even though the calibration is a simple procedure, it still requires test equipment and basic competence in calibration.

Calibration equipment for Gas Detection Units (GDU) consists of:

• Valve/Flow regulator.

• Gas cylinder with the correct calibration gas for

each refrigerant and concentration (ppm).

• Calibration adapter.

• If the gas detector unit does not have a display,

the service tool or the PC tool is required.

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Application Guide | Gas detection in refrigeration systems

Method II Calibration of gas detectors by means of calibration gas (Continued)

Valve/Flow regulator

Generic

calibration

gas

Calibration equipment

Fig. 10

Bump test A bump test cannot supersede any tests

involving calibration. It is only a function test (signal or no signal).

Bump test of gas sensors (this test is a function test - it is not a calibration)

Method Refrigerant

Ampoules Ammonia

Ampoules (or lighter gas) HCFC, HCF

Lighter gas HC - Hydro Carbon

Ampoules (or breath on sensor) CO

Calibration

adapter

GDU without displayService tool

Integrated digital calibration function

GDU with display

SC EC P IR

Semi-

conductor

4 4

Electro-

chemical

Gas detection unit tested and calibrated

Pellistor Infrared

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Application Guide | Gas detection in refrigeration systems

Alarm / sensitivity range of gas detectors

Danfoss recommendations for alarm levels

All commonly used gas detectors have a proportional output signal (4-20 mA, 0-10 V, or 0-5 V), and some pre-set alarm settings.

When selecting the actual measuring range and sensor type, several factors should be considered:

In general, alarm levels should be as low as practically possible, depending on the actual refrigerant and the purpose of the alarm. There are often requests for more alarm levels, but experience shows that two alarm limits are suﬃcient for gas detection.

The pre-alarm provokes a reaction, either automatically and/or in the form of alarm instructions; if not, the main alarm may be triggered. This entails a whole series of consequences, including switching oﬀ machines.

A main alarm should rarely (and preferably never) be necessary!

DANFOSS recommendations for alarm levels: EN 378:2016

Machinery rooms EC 500 P 30000

Alarms can be chosen to warn against gas

concentrations less than levels acceptable for

personal safety on short term or long term. Alarm

levels can also be chosen to speciﬁc levels due to

ﬂammability/explosion risk.

The following recommendations are based on

the present experience with suitable limits,

taking into account the above mentioned

conditions, but also requirements in EN 378:2016,

ISO 5149:2014, IIAR 2-2017 and ASHRAE 15:2016.

The Danfoss gas detection units oﬀer two pre-

set alarms and a proportional output signal,

both analog 4-20 mA and digital Modbus.

With this conﬁguration, is it possible to fulﬁl all

requirements for alarm levels needed within the

speciﬁc operation range of the sensor.

National

requirements

LEVEL

Personal safety

(occupational)

(TWA-values)

Sensor type

[ppm] [ppm] [ppm]

Comply with: EN 378

LEVEL

(pre-alarm)

Sensor type

LEVEL

III

(main-alarm)

Sensor type

Ammonia R717

Carbon Dioxide R744 (CO2) IR 5000 IR 9000

Halocarbon HFC

Hydrocarbon HCR290, R600, R600a,

) 50% of TWA-value

Note: All proposed levels are ≤ the max. values in EN 378:2016

DANFOSS recommendations for alarm levels: ASHRAE 15:2016

Carbon Dioxide R744 (CO2) IR 5000 IR 9000

Halocarbon HFC

Hydrocarbon HCR290, R600, R600a,

) 50% of TWA-value

Note: All proposed levels are ≤ the max. values in ASHRAE 15:2016

R134a, R404A, R407C, R410A, R507

R1270

R134a, R404A, R407C,R410A, R507

R1270

Machinery rooms EC 25 EC 150

Safety valves vent line

Concentration ≤ 20% of LFL

Concentration ≤ 25% of LFL

SC 5001) SC 900

CT 800 CT 2500

SC 5001) SC 900

CT 500 CT 2500

– SC 9000

Comply with: ASHRAE 15:2016

LEVEL

Personal safety

(occupational)

(TWA-values)

Sensor type

[ppm] [ppm]

Sensor type

LEVEL

(pre-alarm)

16 | DKRCI.PA.S00.A2.02 | 520H12772

Application Guide | Gas detection in refrigeration systems

Danfoss recommendations for alarm levels (Continued)

DANFOSS recommendations for alarm levels: ANSI/IIAR 2-2014

Ammonia R717

Machinery rooms EC 25 EC 150 P 30000

Safety valves vent line

Comply with: ANSI/IIAR 2-2014

LEVEL

Personal safety

(occupational)

(TWA-values)

Sensor type

[ppm] [ppm] [ppm]

– SC 9000

LEVEL

(main-alarm)

Sensor type

(deenergize

components)

Sensor type

LEVEL

III

main

DKRCI.PA.S00.A2.02 | 520H12772 | 17

Application Guide | Gas detection in refrigeration systems

Actions triggered by gas detection

Actions for Ammonia – R717

Up to 50 kg refrigerant At max. 157 ppm:

More than 50 kg refrigerant

More than 3000 kg refrigerant

More than 4500 kg refrigerant

The actions to be triggered when leaked refrigerant is detected depends on the standard applied. National regulations, especially the “Occupational Exposure Limits”, varies from country to country.

EN 378:2016 ISO 5149:2014 ASHRAE 34-2016 IIAR 2-2014

- Actuate an alarm

- Notify an authorised person

- Audible buzzer 15 dBA above background noise level

- Flashing lamp

- Alarm to be inside the room

- For machinery rooms: Also outside the room, which can be at a supervised location

- For machinery rooms: Start emergency ventilation

Same actions as above, but starting at max. 500

ppm

At max. 30000 ppm also:

- Stop the system

- Stop the power supply to everything which is not Ex approved

Same as above, but also

- central alarm station

- specialized personnel on site within 60 min of alarm

Same actions as above, but starting at max. 200

ppm

At max. 30000 ppm also:

- Stop the system

- Stop the power supply to everything which is not Ex approved

Same as above, but also:

- central alarm station

- specialized personnel on site within 60 min of alarm

At max. 1000 ppm:

- Audible and visual alarm

- Inside the machinery room and outside each entrance

- Start mechanical ventilation

- Shut down combustion processes drawing air from the room (except if the combustion is driving the compressor)

Machinery rooms at max. 25 ppm:

- Audible and visual alarm

- Inside the machinery room and outside each entrance

- Alarm to monitored location

- Stop non-emergency ventilation (unless it is designed to work with R717)

Machinery rooms at max. 150 ppm also:

- Start emergency ventilation

Machinery rooms at max. 40000 ppm also:

- De-energize compressors, refrigerant pumps, and normally closed valves

Not in machinery rooms at max. 25 ppm:

- Alarm to monitored location

- Other actions depends on system type and location

Actions for refrigerants other than ammonia

For all systems except ventilated enclosures and systems using alternative risk management

For ventilated enclosures

For systems using alternative risk management

18 | DKRCI.PA.S00.A2.02 | 520H12772

At 50% ATEL/ODL/RCL or 25% LFL (see Annex II):

- For ﬂammable refrigerants: Stop the system

- Actuate an alarm

- Notify an authorised person

- Audible buzzer 15 dBA above background noise level

- Flashing lamp

- Alarm to be inside the room

- For occupancy A: Also outside the room, which shall be at a supervised location

- For occupancy B and C: Only inside is needed

- For machinery rooms: Also outside the room, which can be at a supervised location

- For machinery rooms: Start emergency ventilation

If a detector is used for staring ventilation: Start ventilation at 25% LFL (see Annex II)

If a detector is used for staring ventilation: Start ventilation at 50% ATEL/ODL/RCL or 25% LFL (see Annex II)

EN 378:2016 ISO 5149:2014 ASHRAE 34-2016

At OEL (see Annex III):

- Audible and visual alarm

- Inside the machinery room and outside each entrance

- Start mechanical ventilation

- Shut down combustion processes drawing air from the room (except if refrigerant is R744)

Not applicable

Application Guide | Gas detection in refrigeration systems

References • EN 378:2016 Refrigerating systems and

heat pumps – Safety and environmental requirements

• ASHRAE 15:2016 Safety Standard for Refrigeration Systems

• ASHRAE 34:2016 Designation and Safety Classiﬁcation of Refrigerants

• ANSI/IIAR 2-2014 American National Standard for Safe Design of Closed-Circuit Ammonia Refrigeration Systems

• ISO 5149:2014 Refrigerating systems and heat pumps – Safety and environmental requirements

• EU F-Gas Regulation (EC) No 517/2014

• Danfoss gas detector documentation (www.danfoss.com/ir)

DKRCI.PA.S00.A2.02 | 520H12772 | 19

Application Guide | Gas detection in refrigeration systems

Annex I

Common refrigerant data

Refrigerant type

– R717 Ammonia NH

– R744 Carbon Dioxide CO

HCFC R22 Chlorodiﬂuoromethane CHCIF

HFC R134a 1,1,1,2-tetraﬂouroroethane CH2FCF

HFC R404A R125/143a/134a (44/52/4) – A1 3.99 3.3 0 3260

HFC R407C R32/125/134a (23/25/52) – A1 3.53 2.9 0 1520

HFC R410A R32/125 (50/50) – A1 2.97 2.5 0 1900

HFC R507 R125/143a (50/50) – A1 4.04 3.4 0 3800

HC R290 Propane CH3CH2CH

HC R600 Butane CH3CH2CH2CH

HC R600a Iso-butane CH(CH3) A3 2.38 2.0 0 3

HC R1270 Propylene CH3CH=CH

HFC R32 Diﬂuoromethane CH2F

HFO/HFC R1234ze(E) Trans-1,3,3,3-tetraﬂuoro-1-propene CF3CH=CHF A2L 4.66 3.9 0 7

Refrigerant Name Formula Safety

group

B2L 0.700 0.6 0 0

A1 1.80 1.5 0 1

A1 3.54 3.0 0.055 1810

A1 4.17 3.5 0 1430

A3 1.8 1.5 0 3

A3 2.38 2.0 0 4

A3 1.72 1.4 0 2

A2L 2.13 1.8 0 675

Vapour density

@ 25°C /

1 bar

[kg/m3] [–] [–] [–]

Relativ density ODP

Ozone Pepletion

Portential

GWP

Global Warming

Potential

(100 yr ITH/F

gas regulation)

100

Annex II

EN 378:2016 and ISO 5149:2014

Refrigerant type

- R717 Ammonia B2L 0.00035 0.00022 0.116 157 33143

- R744 Carbon Dioxide A1 0.1 0.072 - 20000 - 20000

HCFC R22 Chlorodiﬂuoromethane A1 0.3 0.21 - 29661 - 29600

HFC R134a 1,1,1,2-tetraﬂouroroethane A1 0.25 0.21 - 25180 - 25100

HFC R404A R125/143a/134a (44/52/4) A1 0.52 0.52 - 65163 - 65100

HFC R407C R32/125/134a (23/25/52) A1 0.31 0.29 - 41076 - 41000

HFC R410A R32/125 (50/50) A1 0.44 0.42 - 70707 - 70700

HFC R507A R125/143a (50/50) A1 0.53 0,53 - 65594 - 65500

HC R290 Propane A3 0.008 0.09 0.038 25000 4222 4200

HC R600 Butane A3 0.0089 0.0024 0.038 504 3193 500

HC R600a Iso-butane A3 0.011 0.059 0.043 12395 3613 3600

HC R1270 Propylene A3 0.008 0.0017 0.046 494 5349 490

HFC R32 Diﬂuoromethane A2L 0.061 0.30 0.307 70423 28826 28800

HFO/HFC R1234ze(E) Trans-1,3,3,3-tetraﬂuoro-1-propene A2L 0.061 0.28 0.303 30043 13004 13000

Refrigerant Name Safety

group

Practical

Limit

[kg/m3] [kg/m3] [kg/m3] [ppm] [ppm] [ppm] [ppm]

Toxicity

ATEL /ODL

Flammability

LFL

50% of

ATEL/

ODL

25% of

LFL

Alarm settings

Pre-alarm level MAX

refrigeration

concentration

EN 378: 500

ISO 5149: 200

Main-alarm

MAX

refrigeration

concentra-

tion

30000

20 | DKRCI.PA.S00.A2.02 | 520H12772

Application Guide | Gas detection in refrigeration systems

Annex III

ASHRAE 15-2016

Refrigerant type

- R717 Ammonia B2L 0.22 0.014 320 25

- R744 Carbon Dioxide A1 54 3.4 30000 5000

HCFC R22 Chlorodiﬂuoromethane A1 210 13 59000 1000

HFC R134a 1,1,1,2-tetraﬂouroroethane A1 210 13 50000 1000

HFC R404A R125/143a/134a (44/52/4) A1 500 31 130000 1000

HFC R407C R32/125/134a (23/25/52) A1 290 19 81000 1000

HFC R410A R32/125 (50/50) A1 420 26 140000 1000

HFC R507 R125/143a (50/50) A1 520 32 130000 1000

HC R290 Propane A3 9.5 0.56 5300 1000

HC R600 Butane A3 2.4 0.15 1000 1000

HC R600a Iso-butane A3 9.6 0.59 4000 1000

HC R1270 Propylene A3 1.7 0.11 1000 500

HFC R32 Diﬂuoromethane A2L 77 4.8 36000 1000

HFO/HFC R1234ze(E) Trans-1,3,3,3-tetraﬂuoro-1-propene A2L 75 4.7 16000 800

Refrigerant Name Safety

group

RCL RCL RCL OEL/TWA

[g/m3] [lb/Mcf] [ppm] [ppm]

(40 hours work week

without eﬀect)

DKRCI.PA.S00.A2.02 | 520H12772 | 21

Danfoss Industrial Refrigeration

Danf

his also applies to products already on order pro All trademarks in this material are property of the respec

A world of expertise at the click of a button

Turn to Danfoss if you want to combine quality components with expert knowhow and support. Try out these free tools, designed to make your work much easier.

DIRbuilder

DIRbuilder is designed to make selection processes for industrial refrigeration projects easier and less time-consuming. Specify the valves you need from an extensive pool of configuration options. The DIRbuilder library comprises all Danfoss Industrial Refrigeration valves. Free of charge – no software needed.

Coolselector® 2 – New calculation software for Industrial Refrigeration

Coolselector® 2 is a calculation and support tool for contractors and system designers, offering complete pressure drop calculations, analysis of pipe and valve design and the ability to generate performance reports. It replaces the well-known DIRcalc™ software and offers several new functionalities.

Danfoss IR app

The free IR App gives you a spare parts tool, which makes it easy for you to find the spare part number for a given Danfoss industrial refrigeration valve.

Download 3D CAD symbols

From our online product catalogue on our website, you can download 3D CAD symbols and illustrations to help you when designing refrigeration plants.

IR application tool

With this interactive PowerPoint slideshow, you can explore all the details of a two-stage ammonia plant. You will find detailed cut-away drawings and information on the valves in the installation along with links to videos, literature and product animations.

Application handbook

The Application Handbook is designed to help you every step of the way when working with industrial refrigeration systems. Among many other things, it contains examples of how to select control methods for different refrigeration systems, their design and which components to choose.

Visit www.danfoss.com/IR-tools and find all the tools you need.

oss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. T

24 | DKRCI.PA.S00.A2.02 | 520H12772

vided that such alterations can be made without subsequential changes being necessary in specications already agreed.

DKRCI.PA.S00.A1.02 | 520H12772

Danfoss Gas detection in refrigeration systems Application guide

Specifications and Main Features

Frequently Asked Questions

User Manual