………… 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 ………… 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 ………… 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) Visual Differences………………………………….. Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290) 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 Carel Control Carel 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.