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iCool Training: Service Technician Hydrocarbon (HC) Refrigerant Training
** Please note – this is for basic awareness only and is not updated. Please call QBD technical support
QBD Cooling Systems Inc. TORONTO / BRAMPTON 1 ONTARIO, CANADA THE NEXT GENERATION HYDROCARBON REFRIGERATION
With R-290 Hydrocarbon Refrigerant
HC Series
2
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Content
• CD 3.0 Introduction • R-290 Facts • Safety instructions and guidelines • CD 3.0 visual differences • Installation • Swap vs Repair
iCool Service Training 3
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R-290 Refrigerant All electrical parts are UL#471 approved - Compressor, motors, capacitor, Gasket is UL V0 Rated overload, relay, controller, electrical connectors
UL Required Labeling & Optimized condenser and RED identification sleeves evaporator coil design on service lines Technicians are responsible to ensure these RED SLEEVES are always present on access points as per UL#471 requirements.
Cooling Deck 3.0 4 …………
HC Series
• R-290 is a Natural Refrigerant
• Zero Ozone Depletion Potential (ODP)
• Very Low Global Warming Potential (GWP) • R134a = 1430 GWP • R-290 = 3 GWP
• 40 – 50% Less Refrigerant Charge
R-290 Facts 5 …………
HC Series
R-290 FACTS • R-290 is highly inflammable. • R-290 is heavier than air and the concentration will always be higher at floor level. • Cooling Decks containing R-290 refrigerant must NEVER be installed in the R134A Series cabinets. • HC Series coolers have been engineered to eliminate all possible ignition sources.
CAUTION: Exposure to R-290 can lead to frostbite
R-290 Facts 6 …………
HC Series
It is mandatory for technicians to carry MSDS of R- 290 and lubricant and be aware of hazards and precautions.
http://www.linde- gas.com/en/products_and_supply/refrigerants/nat ural_refrigerants/r290_propane/index.html
http://www.boconline.co.uk/internet.lg.lg.gbr/en/i mages/care40410_55784.pdf?v=1.0
Safety 7 ………… HC Series S No Points to consider before servicing an HC refrigerant cooler Compliance (Y/N) Check for the presence of Refrigerant
Do not plug or unplug before checking the area for flammable environment around the cooler 1 Monitor the area prior to and during work. Use a Combustible Gas Detector/ Monitor. Clear the area of any potential refrigerant leak. Make sure the leak detection equipment used is suitable for use with HCs. No ignition Sources No smoking, including displaying ‘No Smoking’ signs 2 Survey the area around the equipment prior to servcing to establish any flammable hazards or
PLEASE CHECK THE AREA FOR Cooler ignition risks. Remove all sources of ignition. Be aware that a cell phone or similar electronic devices could be source of ignition. Labels REFRIGERANT LEAK BEFORE Both cabinet and chassis labels must indicate for R290 refrigerant use. If the labels do not match assume the system has been retrofitted and is non-compliant. 3 STOP work on this system immediately Inform owner (operator*) of system violation Offer to replace system with approved systems PLUGGING/UNPLUGGING THE UNIT Refuse to service General Work Area Instruct anyone in the immediate area as to the nature of the work 4 Avoid confined spaces If possible, section off the workspace Be aware of any flammable material in the area Minimum Room Volume Consideration to ensure that equipment is not installed in a room where the release of the HC 5 could cause an explosion hazard. Always follow local laws and regulations for installation, operation and servicing an HC cooler. Personal Protective Equipment 6 Technicians should wear appropriate PPE, e.g.- including chemical goggles, protective gloves, ENSURE R-290 APPROVED LEAK DETECTOR grounding probe, anti-static band . Free Air Movement Ensure that free air movement can be achieved around all refrigerant containing parts of the 7 systems. Depending on the size of the room, especially in a confined space, mechanical IS OPERATIONAL THROUGHOUT THE ENTIRE ventilation may need to be considered. The ventilation should displace any released refrigerant and preferably expel it externally. Floor Voids 8 HC refrigerants are heavier than air. Precautions should be made against refrigerant collecting in drains and low points of a flooring structure. SERVICE CALL Electrical Devices An initial safety check of components to see a fault exists that could compromise safety. 9 Capacitors should be discharged with a bleed resistors (minimum 2 Watt / 10,000 Ω ) or meter. Do not work on ‘live’ electrical components. Maintain a good ground – equipment and user Rated Equipment This includes, but not limited to - Gas Leak Detectors and Monitors 10 - Electrical Test meters (CAT III minimum) - Portable Lighting - non-sparking tools Work Space Guidelines -Good ventilation ALWAYS FOLLOW LOCAL LAWS AND 11 - Purge refrigerant outdoors - Dry powder fire extinguishers Awareness REGULATIONS FOR SERVICING OF A Familiar with the information provided by other sources, such as the manufacturers of the system equipment, component manufacturers, refrigerant suppliers, and Material Safety Datasheets (MSDSs). 12 Occupants should be aware of manufacture operating instructions, procedures, guidelines and safety issues regarding the equipment. HYDROCARBON REFRIGERANT COOLER Be made aware to evacuate the space immediately following the accidental release of a flammable refrigerant. HC an on working before Checks Recommended
Pre-Service Checks 8 ………… HC Series
AREA SAFETY • Do not work in confined space
• Strictly no smoking
• Area must be well ventilated
• Eliminate all ignition sources
• Create a safety work area of a minimum of two (2) meters (6 ft.) in perimeter – standard industry practice
Safety 9 …………
HC Series
Tube Cutter R-290 Gas Detector Vacuum Pump Scale Manifold Gauge Crimping Tool Piercing Valves
Safety Optional Mandated
Torch Recovery Tank
Tools Recommended 10 …………
HC Series
The limiting factors associated with the • Maximum amount of R-290 in an area use of HCs are: – 0.0093 kg/m3 (0.60 lb/1000ft3) -The occupancy category – Maximum of 0.53% volume -The room volume -Unit type and capacity E.g.- a 10ft x 10ft x 10ft room can have a maximum of 0.60 lb or 0.27 kg of R-290 in total. This limits the number of HC coolers that can be placed in an area.
Local Laws and Regulations 11 e.g. For Canada - CSA B52 – Mechanical Refrigeration Code
Visual Differences
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)
290) -
Cooling Deck 3.0 (R …………………………………..
Visual Differences Visual Cooling Deck 2.0 (R134a) Visual Differences
Compressor platform (base)
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Visual Differences
CD Lift Rods
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Visual Differences
Gasket Seal
Seal is upgraded to be UL-V0 rated.
¼ HP Gasket Seal PN 47-0060-177 ½ HP Gasket Seal PN 47-0060-178
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Visual Differences
Access Lines R-290 Identified by red sleeves on access lines; Technicians are responsible to ensure these RED SLEEVES are always present on access points as per UL#471 requirements.
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Visual Differences
Compressor
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Cooling Deck Reduced SKU’s
¼ HP Single and Dual Evap Fan Motor ¼ HP Single and Dual Evap Fan Motor
⅓ HP Single Evap Fan Motor ½ HP Single and Dual Evap Fan Motor ½ HP Dual Evap Fan Motor
Single Door = Single Evap. Fan / Double Door = Dual Evap. Fan
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Fan Motors
• Very high efficiency ECM motors • Wider operating range • Brushless PSC Motors • One 13W motor replaces 4W, 6W and 9W motors and reduces SKU’s. • Maintains high efficiency levels at part load
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Securing Fan Blades
• Standard speed bolt for mounting • Single screw to mount blade to blades on both Condenser and Condenser and Evaporator motors Evaporator motors
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Mounting Bracket
• Standard mounting bracket for • Mounting bracket redesigned for “PSC” motor “ECM” motor • Screws used to secure motor to • Nut and Bolt is used to secure mounting bracket motor to mounting bracket
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Electrical Parts
NEVER use a 3in1 Starting Approved for Kit on R-290 Refrigeration Hydrocarbon applications System
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) LED Lights
LED+ Power Supply Class 2
• Power Supply: 120V AC • Power Supply: 12V DC
• Standard LED - have ignition • Spark proof design approved source (Not approved for R- for R-290 application 290 application) • Lower energy consumption
• 50% more product illumination
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)
Cold Controller
CarelControl
Approved for Hydrocarbon applications / Electronic / Built in Defrost Timer
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Visual Differences
Condenser Motor
PSC Motor
ECM Motor
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Visual Differences
Evaporator Motor
PSC Motor
ECM Motor
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Refrigerant Charge
R134a R-290 • ¼ HP chassis = 210 gms • ¼ HP chassis = 110 gms
• ⅓ HP chassis = 245 gms
• ½ HP chassis = 310 gms • ½ HP chassis = 148 gms R-290 charge can not exceed 150 gms as per UL471
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Technical Data
Operating Pressures
R134a R-290
Suction Pressure: 15 – 20 PSI Suction Pressure: 35 – 40 PSI
Discharge Pressure: 125 – 150 PSI Discharge Pressure: 200 – 250 PSI
Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) Labeling for R-290
Cooling Deck 3.0 (R-290) 30 Labeling for R-290
Cooling Deck 3.0 (R-290) 31 Labeling for R-290
Cooling Deck 3.0 (R-290) 32 Labeling for R-290
Cooling Deck 3.0 (R-290) 33 Installation
Cooling Deck 3.0 (R-290) 34 …………
HC Series
PLEASE NOTE It is extremely important that QBD installation instructions are followed to ensure trouble-free and safe operation of the cooler.
Installation 35 …………
HC Series
ALWAYS Use The Door Support Brackets During Transport (Wood/Sliding, Metal/Swing)
MUST Remove The Door Support Bracket (Wood/Sliding, Use the Wooden Support For Use the Metal Support For Metal/Swing) After Installation Sliding Door Hinged Door
Installation 36 ………… HC Series
CASTERS INSTALLATION
The cooler has a new design for caster installation. It does not require a transfer plate anymore.
Nut insert (to fit casters) is flush with the bottom surface of base channel. This design will allow caster top in firm contact with cooler base channel. Hence, transfer plate can be avoided.
No Transfer plate required as caster top is directly in contact with the vase channel plate. Shim plate may be required for leveling of cooler.
Installation 37 ………… HC Series
PROPER LEVELING
Cooler must be leveled (front to back / side to side) to ensure proper drainage WARNING & door operation Improper leveling may cause Use LEG ADJUST For door(s) to close incorrectly. May Proper Leveling result in performance issues e.g. freeze-up of evaporator coil Use SHIMS If Installing Caster Wheels For Proper Leveling
Installation 38 ………… HC Series
CLEARANCES
Minimum clearances required for proper operation
IMPROPER CLEARANCE MAY CAUSE PREMATURE COMPRESSOR FAILURE AND CAN COMPROMISE THE COOLER SAFETY.
Installation 39 ………… HC Series INTERNAL CLEARANCES
Minimum clearances requirement for proper air circulation inside the cooler
Installation 40 ………… HC Series
INTERNAL CLEARANCES
PLACE Bottom Shelf On Top Of Air Duct Return EXCEPTION Is the CD10 Cooler That Now Has a Base Step, Product Can Be Loaded Directly on the Base Step
NEVER Allow “Solid” Packaging To Be Placed On Bottom Shelf, As This
Base Step on CD10-HC. Air Duct on CD12-HC. Will Block The Air Flow
Installation 41 ………… HC Series
ELECTRICAL REQUIREMENT
• Dedicated, 3 prong, grounded 115~120 VAC / 60HZ receptacle is required.
• Extension cords, power bars and/or wiring devise adapters should NEVER be used.
Installation 42 ………… HC Series
REMOVING THE COOLING DECK
1 2 3
Loosen Front Grill Screws Remove Locking Screws Slide Up Lift Bar Holder
4 5 6
Unplug the Power Cord Rotate Lift Bars Inward to Slide CD Out By Pulling Lift Release CD from Lock Position Bars Towards You
Removing the CD 43
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CONDENSER FAN MOTOR
Remove 2 screws that secure the Lint tolerant Condenser is less Remove 4 screws that secure the shroud. prone to Condenser blockage. Condenser Motor bracket.
Condenser Fan Motor 44
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EVAPORATOR FAN MOTOR
Remove the 5 screws that secure Disconnect Evaporator motor wire Remove top screw from both sides Remove the screws that secure the shroud. from controller of the fan shroud. the wires with the P-Clip.
Evaporator Fan Motor 45
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EVAPORATOR FAN MOTOR
Please Note:
Single door coolers have 1 evap. motor and double door coolers have 2 evap. motors.
Slide the evap. Fan shroud up and Replace the fan blades or fan out of the evap box. motors as required.
Evaporator Fan Motor 46 ………… HC Series
ADJUSTING SLIDING DOORS
1 2 3
Remove wheel / spring cover & Align wheels over opening in door track. Remove wheel, relocate to track filler Lift & remove door adjacent slot and adjust position
4 5
Reinstall door & check Reinstall track fillers and wheel / spacing between door and spring cover. cabinet. Repeat until aligned.
Glass Doors 47 …………
HC Series
ADJUSTING SLIDING DOORS
ADDITIONAL STEPS
• Adjust spring tension to achieve 3-5 second closing. • Add washers if doors are rubbing in the center • Clean Door Track • Lubricate wheel rollers with light machine oil (don’t use WD40 as a lubricant)
Glass Doors 48 ………… HC Series
REVERSING DOOR SWING
REQUIRED PARTS
• Top LH Hinge 47-0090-014
• Bottom LH Hinge 47-0090-015
• Bronze Bushing 47-0080-006/47-0080-011 (2 are required)
Glass Doors 49 ………… HC Series
REVERSING DOOR SWING
Open the door slightly and lift up firmly. Remove top RH hinge while supporting Set the bracket aside while supporting The spring will be released on the the door. the door. bottom.
Glass Doors 50 ………… HC Series
REVERSING DOOR SWING
Place the door on a flat non-scratching surface and interchange the doors top and bottom pivot pins
Glass Doors 51 ………… HC Series
REVERSING DOOR SWING
Remove the bottom RH hinge (no longer required). Remove the black plugs on the LH side, exposing the threaded inserts
Position the flat side of the spring on the Attach the new bottom LH hinge complete with spring on the bottom left corner of the cooler pin of the new bottom hinge bracket
Glass Doors 52 ………… HC Series
REVERSING DOOR SWING
Install the door by inserting the bottom pivot pin into the bronze bushing in the Install the top LH hinge on the LH side while supporting the door. bottom LH hinge.
Glass Doors 53 ………… HC Series
REVERSING DOOR SWING
To help with adjusting spring tension, a Spring Key is available. PN. 47-0034-128
Re-install the door spring and align the spring blade into the slot on the Front grill should be removed to give easier access. To create tension of the bottom pivot pin. spring, turn the spring key counter-clockwise 1 to 1.5 turns. Re-attach the front grill.
Glass Doors 54 Cold Control and LED
Cooling Deck 3.0 (R-290) 55
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Temperature Control 56
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DISPLAY INDICATORS
This indicates the Evaporators Motors are running but the Compressor is not. On initial power up, there is an intelligent delay for protection of the Compressor. After 1 minute delay, power to the Compressor will initiate.
Evap Motor Indicator
Temperature Control 57
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This is the typical look of the Carel control while in use. "USE" indicates the unit is in working order. The symbols to the left of "USE" indicate that the Compressor and Evaporator Motor(s) are both running. If the Compressor Indicator is blinking, the compressor is under "Time Evap Motor Indicator Compressor Indicator Protection“ mode.
Temperature Control 58
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DEFROST CYCLE
Indication that unit is in DEFROST and Evaporator Motors are running. There is an automatic defrost cycle of 20 minutes every 6 hours. Evaporator Fan Motors cycle ON and OFF during defrosting. Defrost Indicator
Temperature Control 59
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To manually initiate the defrost, push and hold the "WARMER" button for 3 seconds. The controller will automatically come out of DEFROST after 20 minutes. To manually take out of defrost, push the "WARMER" button for 3 seconds. Defrost Indicator Evaporator Motor Indicator
Temperature Control 60
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Indication that the cold control is "OFF" and power to the Compressor and condenser fan motor has been disabled. Power to Evaporator fan Motors is still live. To manually place the controller "OFF", push and hold the "COLDER" (upper) key for 3 seconds. To turn back "ON", push and hold the "COLDER" (upper) button for 3 seconds
Temperature Control 61
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ERROR CODE
Indication that an ERROR has occurred with the probe. Either the probe is faulty or is has been disconnected from the controller.
Temperature Control 62
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CHANGE THE TEMPERATURE SETTING
Check controller temperature setting. Proper setting should be #5 on CAREL Controllers. Push the "WRENCH" button for 3 seconds to get to the settings mode. Use the "COLDER" or "WARMER" buttons to adjust to the desired setting. To save the new setting, you MUST Push WRENCH button for 3 seconds push and hold the "WRENCH" button for 3 seconds or until the controller returns to "USE".
Temperature Control 63
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TEMPERATURE PROBE POSITION
TEMPERATURE PROBE MUST BE IN RETURN AIR AS SHOWN
INCORRECT PROBE POSITION WILL RESULT IN COOLING RELATED ISSUES
COMPRESSOR CUT IN AND CUT OUT IS DETERMINED BY THE TEMPERATURE MEASURED BY PROBE
Temperature Control 64
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Only change to the existing CD cabinet is the LED lighting and removal of the light switch.
CD2.0 vs CD3.0 65 ………… HC Series
ACCESS TO LED
Channel cover is pressed in place. Channel cover runs across the top and Supply wires are hidden in a channel. Simply pry the cover off sides of the cooler.
LED Lights 66 ………… HC Series
ACCESS TO LED
Removing the channel cover give full Once wire leads are removed, access to Pull up on the wire connection. access to the LED terminal connection. the LED mounting screws are visible.
LED Lights 67 ………… HC Series
LED DRIVER
• LED Driver is located in the cooler control box.
• LED Driver is 12V DC Output
LED Lights 68 ………… HC Series
SWAP vs REPAIR
Replace (swap) the cooling deck under the following circumstances: Compressor failure Refrigerant leak Damaged/broken base (platform)
Repair the cooling deck under the following conditions: Controller failure Motor (condenser/evaporator) malfunction Damaged fan blade(s) NOTE: Use only OEM parts for replacement.
Swap vs Repair 69 ………… HC Series
SWAP vs REPAIR
• Do not replace sealed or solid state devices with components that can spark.
• Do not reposition electrical components
• For any Technical assistance please contact QBD 1-(800) 663-3005 or (905) 459-0709
Swap vs Repair 70
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QBD Cooling Systems Inc. 31 Bramsteele Rd. Brampton, Ontario Canada L6W 3K6
Toll Free: 1 800 663 3005 Phone: 905 459 0709
FAX: 905 459 1478 EMAIL: [email protected] WEB: www.qbd.com
QBD Contact Information 71 …………
HC Series
General Manager Product Engineer, Technical Order Desk – Equipment and Parts Support Safder Jaffer Support and Service School Angela Gnanabakthan Trainer 1-800-663-3005 x-201 1-800-663-3005 x-239 Keith Woods [email protected] Direct Office : 905-459-6944 1-800-663-3005 x-228 Cell: 416-456-6069 Cell: 416-884-0117 [email protected] [email protected]
Key Account Manager Technical Support Business Development Manager (USA) Jim Anderson Bart Mudgal Raul Alvarado 1-800-663-3005 x-240 1-800-663-3005 x-248 Cell: (352) 242-8189 [email protected] [email protected] [email protected]
QBD Cooling Systems Inc.
31 Bramsteele Rd. Brampton, Ontario, Canada L6W 3K6 Toll Free: 1-800-663-3005 Main Phone: (905) 459-0709 Fax: (905) 459-1478 [email protected] www.qbd.com 72
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HC Series
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