V2 R290 Repair and Service (Updated)

Service and Repair

Working with Equipment containing

Introduction

• This education is intended for personnel with expertise and knowledge in the handling of refrigerants and air conditioning products in accordance with the EN13313 standard. This also focuses on the safe handling, hazards and precautions of R290 refrigerant and R290 ATW products.

• This is intended for workers who are officially qualified in accordance with Regulation EU/2015/2067 (F-Gas Worker Certification). If non-qualified personnel attend this education, they will not be able to obtain certification for R290 ATW refrigerant handling operations.

• Note: Brazing and welding qualifications are not included in this education.

• Only those who are qualified in accordance with the laws of each country should conduct this education.

Before starting work on R290

Repair and Service (other than the refrigerant circuit =light service) Safety RequirementsBefore starting the work, perform the following safety checks and preparations. ①Check and secure the work area. ・Make sure that the work area has sufficient space and is well ventilated during work.・There must be no ignition sources, spaces where refrigerant can stay, or openings that can flow into the building in the protected area of the outdoor unit. ・Only authorised personnel shall be allowed in the work area during operation. (Notes or impulse bar, etc. to prevent occupants from entering) ②Check for and eliminate ignition sources. ・Do not bring in ignition sources. ・Be careful of static electricity on work clothes, gloves, shoes and tools. ・Confirm that the outdoor unit is shut down and cut off the power supply to the outdoor unit. ・Discharge the condenser or capacitors in a way that will not cause sparks. . Make sure that LED1 on the outdoor control board goes out and wait at least 1 minute . If there is a leak, never touch the electrical components while leak detection is being carried out because spark may occur even if LED1 goes out

Before starting work on R290

④Ensure that appropriate fire extinguishing equipment (e.g., fire extinguishers - type C ) is in place and ready for use.

-no refrigerant in the work area and around the outdoor unit.-no leakage from the outdoor unit.-no refrigerant leakage inside the water circuit. -no flammable material stored in the work area.

③Check the tools and equipment used.・Appropriate protective equipment must be worn. ・Verify that the R290 detector is working properly and carry it with you at all the times. The detector should be set to 25% of LFL and calibrated for R290 refrigerant. ・Make sure that there is

Before starting work on R290

⑤Confirmation of work procedures and methods.

• Repair and maintenance to electrical components shall include initial safety checks.

- Confirm the outdoor unit is shut down and cut off power supply - Make sure, in a way that will not cause sparks, that the condenser or capacitors is discharged. - Make sure that electrical components are grounded. - Remove all sources of ignition - only authorised personnel shall be allowed in the work area

• In case it has degraded the repairing of the sealed component that include ignition source, you must disconnect all electrical supplies from the unit. If it is absolutely necessary to have an electrical supply to equipment during servicing , be sure to locate a permanently operating form of leak detection at the most critical point. Alarm level should be set at 25% of the LFL

• Ensure that seals or sealing materials have not degraded to the point that they no longer serve the purpose of preventing the ingress of flammable atmospheres. In case it have degraded, replace them with new parts in accordance with the manufacturer's specifications.

• Replace components only with parts specified by the manufacturer since other parts may result in the ignition of refrigerant in the atmosphere from a leak.

Repair

Repair the refrigerant circuit components of R290ATW.Completely remove the refrigerant using the following the steps below.R290 dissolves into refrigerant oil better than R32/410A and is highly flammable, so be sure to follow the following procedure to remove the refrigerant in the refrigerant oil. For appliances containing R290 refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the system with oxygen-free nitrogen and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum. This process shall be repeated until no refrigerant is within the system. When the final oxygen-free nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. This operation is absolutely vital if brazing operations on the pipe-work are to take place.

Repair

1. Remove the refrigerant. Although R290 refrigerant is not F-gas, it should be properly recovered and disposed of according to the WEEE Directive. Please be sure to collect it in a dedicated recovery cylinder. Be sure to use a refrigerant recovery unit and other equipment and tools that are compatible with R290.

2. If it is permissible to release the refrigerant into the open air, it must be done safely following the restrictions ie openings and waste water systems. The R290 should be directed to a safe area that is well ventilated. Between the machine and the discharge point , an oil seperator should be mounted to take care of any oil droplets3. Purge the refrigerant circuit with oxygen-free nitrogen for 5 mins. Compressed air or oxygen shall not be used for purging refrigerant systems.

Repair

4. Purge the refrigerant circuit with oxygen free nitrogen for 5 min. Compressed air or oxygen shall NOT be used for purging refrigerant systems.

• Evacuate down to a pressure of 2 torr or lower.
• Note : Be sure to use a vacuum pump that is compatible with R290 refrigerant
• Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and that ventilation is available.

3. Evacuate the refrigerant circuit.

Repair

Repair the refrigerant circuit components of R290ATW.According to the following procedure.Remove parts to be replaced by cutting, not by flame.・Never attempt to remove parts by brazing.・If the parts are brazed with refrigerant in them, an explosion or fire may occur causing serious damage to people and buildings. In the worst case, there is a risk of loss of life. . Never use tools such as a hacksaw or mechanical cutting tools, they can cause sparking. Non-electrical type is preferred . Removed components like compressors must be in a well ventilated area for at least 5 hours Brazing the new parts.・Purge the braze point with nitrogen during the brazing procedure.・Do not braze the pipe and unit which contain refrigerant.・Before and during operation, be sure to check the area for refrigerant leaks with a suitable refrigerant detector compatable with R290 . The method and procedure are the same as R32 refrigerant

Repair

Carry out an air tightness test before charging with refrigerant. The method and procedure are the same as the R32 refrigerant modelCharging the refrigerant.In addition to conventional charging procedures, the following requirements shall be followed: . Do not turn unit on when charging ( must not add refrigerant while running) . Use a siphon cylinder to charge the refrigerant・Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or lines shall be as short as possible to minimise the amount of refrigerant contained in them.・Cylinders shall be kept in an appropriate position according to the instructions. ・Ensure that the refrigerating system is earthed prior to charging the system with refrigerant. . Use a fan compliant with R290, so if a leak is found on the cylinder connection the R290 will be blown away from the work area and forms of ignition and dilute to atmosphere

Repair

・Label the system when charging is complete (if not already).・Extreme care shall be taken not to overfill the refrigerating system. Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the site. . Carry out vacuum drying before charging Use the vacuum pump that is R290 compatible It is necessary to remove a sufficient level of moisture below 0.5Torr or less

Repair

The following actions are prohibited with R290 refrigerant and must not be performed. 【Precautions】 ・Make sure to provide sufficient space and ventilation. ・Make sure that there is no leakage of R290 refrigerant. ・Use a detector which is suitable for R290 (specifications that can detect properly and not become an ignition source). ・Do not place anything that could ignite in the protected area. (Sparks from tool friction and static electricity can also be ignition sources.) ・R290 dissolves well in refrigeration oil and is highly flammable, so be sure to follow the instructions for proper refrigerant recovery.・Use appropriate tools and equipment approved for R290 refrigerant.

Repair

The following actions are prohibited with R290 refrigerant and must not be performed. 【Prohibitions】 ・When repairing the refrigerant parts, remove parts to be replaced by cutting, NOT by flame. ・Do not brazing the pipe and unit which contain refrigerant. Before brazing, refrigerant should be removed.・Do not smoke. ・Do not use the tools not approved with R290.

Repair

If the proper work procedures and prohibitions are not followed, there is a possibility that the R290 may explode or cause a fire accident. In the worst case, there is a risk of loss of life.Danger of brazing with R290 refrigerant in the system.・If brazing is performed with R290 refrigerant within the system, R290 may burn rapidly over a wide area and the worker may be severely burned or, in the worst case be killed.・Depending on the surrounding conditions, fire or damage to the building may occur.