- 12 - 09/2020
Copyright © 2020, F
SERVICING INSTRUCTIONS
1.1 Area check
Before starting work on asystem containing flammable refrigerants, saf
necessary to ensure that the risk of ignition is minimized.
system, the following measures must be adher
1.2. Work procedure
Work must be performed following a controlled procedure so that the risk of
flammable gases or fumes being present during this time is minimised.
1.3 General work area
The whole maintenance crew and other personnel at the sit
the nature of the works being performed. W
area around the work site must be divided into sections. It must be ensured that the
conditions inside the area are safe by means of inspections of flammable materials
1.4 Check for presence of arefriger
The area must be checked using an appropriate detector for the pr
before and during work to ensure that t
atmosphere. It must be ensured that the device used for the det
suitable for use on flammable refrigerants, i.e
intrinsically safe.
1.5 Presence of afire e
In the event that any work is performed on the cooling device or associated parts
under heat, then a
filling area, there must be apowder or C2 fire extinguisher.
1.6 No ignition sources
No person performing work related to the cooling system that encompasses the
uncovering of any pipes that con
use any ignition sources in a fire or explosion hazard.
All possible ignition sources, including the smoking of cigarettes should be kept at
a
which flammable refrigerant could potentially be released int
environment. Prior t
to ensure that there are no fir
sign must be installed.
1.7 Ven
It must be ensured that the area is ventilated or appropriat
penetrating the system or performing any work under heat.
must continue for the time that works are performed.
dissipate any released refrigeran
1.8 Cooling system checks
In places where electrical components are replaced, these components must be suitable
for this purpose and conform to correct specifications.
for maintenance and service must always be follo
necessary to request help from the manufacturer'stechnical department.
On installations containing flammable refrigerants, it is nec
following checks:
– the amount of refrigerant corresponds to the size of the room in which components
containing refrigerant are installed;
– ventilation systems and outlets are in full working order and are not clogged;
– if any indirect cooling circuit is used, the second circuit must be checked for the
presence of refrigerant;
– the markings on the appliance must remain constantly visible and legible, and
marking and signs that are illegible must be repaired;
– The cooling pipes and components are installed in locations wher
that they will be exposed to any substances that could c
refrigerant, unless these components are built using mat
resistant to corrosion or are appr
1.9 Electrical device check
The repair and maintenance of electrical components must include safety checks and
inspections of components.
In the event of a malfunction that could affect safety, no electrical power may be
connected to the circuit until the malfunction is satisfactorily resolved. In the event
that the malfunction cannot be immediately repaired but it is necessary to continue
running the appliance, an appropriate temporary solution must be used.
the appliance must be informed in such away that all parties know about it.
The initial safety check must ensure:
that capacitors are discharged: this must be performed in asafe way to preven
possibility of sparking;
that no electrical components or wiring is uncovered during the process of filling
draining or cleaning the system;
that the grounding is not interrupted.
2. Repair of sealed components
When repairing sealed components, all the electrical power supply must be
disconnected from the appliance on which work is being performed before sealed
lids, etc. are r
into the appliance while servicing the appliance, it is necessary to install apermanent
device in the most critical point to detect leakage so that a dangerous situation is
avert
Special attention must be paid to ensuring that as aresult of the work performed on
electrical components the cover is not changed to the extent of affecting the level of
protection. T
and terminals not performed according to original specifications, damaged gaskets,
incorrect configuration of plugs, etc.
It is necessary to ensure that the appliance is mounted safely
It is necessary to ensure that gaskets or sealing materials are not damaged in such
away tha
parts must conform to the manufacturer'sspecifications.
NOTE:
The use of silicone gaskets and seals may suppress the efficiency of
certain type of leak detection devices. Intrinsically safe components do
not need to be disconnected prior to being worked on.
3. Repairs of intrinsically safe components
No permanently inductive or capacitative load may be placed on the circuit without it
being ensured that thereby the permitted voltage and curr
is not exceeded.
Intrinsically safe components are the only type on which it is possible to work in
aflammable envir
correct specifications.
Parts are replaced using only parts specified by the manufacturer
result in ignition of refrigerant upon leakage into the environmen
4. Cabling
Check that cabling is not exposed to wear and tear
vibrations, sharp edges or any other negative en
also take into consideration the effects of ageing and permanent vibrations from
sources such as compressors or fans.
5. Detection of flammable refrigerants
Under no circumstances may potential sourc
detecting refrigerant leaks.
Ahalogen burner (or any other type of detector utilising an open flame) must not be
used.
6. Leak detection methods
The following leak detection methods are considered ac
containing flammable refrigerants.
For the detection of flammable refrigerants
however their sensitivity may not be appropriate or they ma
(Detection equipment must be calibrated in an area without any refrigerant pr
It is important to ensure that the detector is not a
it is suitable for the used refrigerant.
LFL refrigerant and must be calibrated for the used r
percentage is confirmed (maximum 25%).
Leak detection liquids are suitable for use on most refrigerants
containing chlorine must be excluded since chlorine may react with the refrigerant
and corrode copper pipes.
In the event of asuspected leak, all open flames must be removed/extinguished.
In the event that the refrigerant leak is found and requir
the refrigerant must be drained from the system or separ
apart of the system distant from the leak. The system must then be cleaned out using
oxygen-free nitrogen (OFN) both bef
7. Collection and pump discharge
In the event that the cooling circuit is breached due to r
– conventional proc
best method due to flammability. It is necessary to adhere to the following pr
collect the refrigerant;
clean out the circuit using inert gas;
pump out;
again clean out using inert gas;
open the circuit by cutting or hard soldering.
The contents of the circuit must be collected into c
system must be "flooded" with OFN (oxygen-free nitrogen) for the unit to remain
safe. It may be necessary to repeat the procedur
compressed air nor oxygen may be used.
Flooding may be achieved by disrupting the vacuum in the sy
OFN, and by continued filling until the operating pressur
into the atmosphere and finally lowering to a
refrigerant still remains in the system.
must be ventilated to atmospheric pressur
activity is absolutely necessary if hard soldering is to be per
It is necessary to ensure that the vacuum pump outlets are not nearby to any ignition
source, and ventilation must be pr
8. Filling procedure
Apart from conventional filling procedur
adhered to.
–
the filling device is used. Hoses or pipes must be as short as possible to minimise the
amount of refrigerant contained inside of them.
–
–
with refrigerant.
–
one already).
–
A
of a leak, the system must be tested after being refilled but also before being put
into operation. A
location.
9. T
Prior to performing this procedure it is essential that the technician fully acquain
him/herself with the device and all its particulars. Correct practice of safely collecting
all refrigerant is recommended. P
samples must be taken if an analysis is required prior to using the using the
regenerated refrigerant f
that electricity is available.
