ALPICAIR AM2O-120HRDC1 Split Air Conditioner Owner’s Manual

AM2O-120HRDC1 Split Air Conditioner
Owner’s Manual
AM2O-41HRDC1A AM2O-51HRDC1A
AM2O-61HRDC1A AM3O-71HRDC1A
AM4O-81HRDC1A AM4O-100HRDC1
AM5O-120HRDC1

In line with the company’s policy of continual product improvement, the aesthetic and dimensional characteristics, technical data, and accessories of this appliance may be changed without notice.

The products in this manual may be different from the rea one, according to different models, some models have a displayer and some models do without a displayer, the position and shape of the displayer please refer to the real one.
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction concerning the use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
If it needs to install, move or maintain the air conditioner, please contact the dealer or local service center to conduct it at first. The air conditioner must be installed, moved, or maintained by the appointed unit. Otherwise, it may cause serious damage or personal injury or death.
When refrigerant leaks or requires discharge during installation, maintenance, or disassembly, it should be handled by certified professionals or otherwise in compliance with local laws and regulations.

This marking indicates that this product should not be disposed of with other household wastes throughout the EU. To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle it responsibly to promote the sustainable reuse of material resources. To return your used device, please use the return and collection systems or contact the retailer where the product was purchased. They can take this product for environmentally safe recycling.
R32: 675

EXPLANATION OF SYMBOLS

DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury.
NOTICE
Indicates important but not hazard-related information, used to indicate risk of property damage.
Indicates a hazard that would be assigned a signal word WARNING or CAUTION.

EXCEPTION CLAUSES

Manufacturers will bear no responsibilities when personal injury or property loss is caused by the following reasons.

1. Damage the product due to improper use or misuse of the product;
2. Alter, change, maintain or use the product with other equipment without abiding by the instruction manual of the manufacturer;
3. After verification, the defect of the product is directly caused by corrosive gas;
4. After verification, the defects are due to improper operation during the transportation of the product;
5. Operate, repair, and maintain the unit without abiding by the instruction manual or related regulations;
6. After verification, the problem or dispute is caused by the quality specification or performance of parts and components that are produced by other manufacturers;
7. The damage is caused by natural calamities, bad using the environment, or force majeure.

CONFORMITY AND RANGE

Please read this owner’s manual carefully before operating the unit and keep it carefully for consultation.
Only use the air conditioner as instructed in this booklet. These instructions are not intended to cover every possible condition and situation. As with any electrical household appliance, common sense and caution are therefore always recommended for installation, operation and maintenance.

THE REFRIGERANT

Please read this operating manual carefully before operating the unit.
****Appliance filled with flammable gas R32.
Before using, the appliance, read the owner’s manual first.
Before installing the appliance, read the installation manual first.
Before repairing the appliance, read the service manual first.

The figures in this manual may be different from the material objects, please refer to the material objects for reference.

The Refrigerant

• To realize the function of the air conditioner unit, a special refrigerant circulates in the system. The used refrigerant is the fluoride R32, which is specially cleaned. The refrigerant is flammable and in odorous. Furthermore, it can lead to explosions under certain conditions. But the flammability of the refrigerant is very low. It can be ignited only by fire.
• Compared to common refrigerants, R32 is a nonpolluting refrigerant with no harm to the ozonosphere. The influence upon the greenhouse effect is also R32 has got very good thermodynamic features which lead to really high energy efficiency. The units, therefore, need less filling.

WARNING:

Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer. Should repair be necessary, contact your nearest authorized Service Centre.
Any repairs carried out by unqualified personnel may be dangerous.
The appliance shall be stored in a room without continuously operating ignition sources. (for example open flames, an operating gas appliance, or an operating electric heater.)
Do not pierce or burn.
The appliance shall be installed, operated, and stored in a room with a floor area larger than X m2. (Please refer to the table “a” in section of ” SAFETY OPERATION OF FLAMMABLE REFRIGERANT ” for Space X.)
Appliance filled with flammable gas R32. For repairs, strictly follow the manufacturer’s instructions only.
Be aware that refrigerants may not contain an odor.
Read the specialist’s manual.

Operation and Maintenance
This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if  they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved.

• Children shall not play with the appliance.
• Cleaning and user maintenance shall not be made by children without supervision.
• Do not connect the air conditioner to the multi-purpose socket. Otherwise, it may cause fire hazards.
• Do disconnect the power supply when cleaning the air conditioner. Otherwise, it may cause an electric shock.
• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent, or similarly qualified persons in order to avoid a hazard.
• Do not wash the air conditioner with water to avoid electric shock.
• Do not spray water on the indoor unit. It may cause electric shock or malfunction.
• After removing the filter, do not touch the fins to avoid injury.
• Do not use a fire or hair dryer to dry the filter to avoid deformation or fire hazard.
• Maintenance must be performed by qualified professionals. Otherwise, it may cause personal injury or damage.
• Do not repair the air conditioner by yourself. It may cause electric shock or damage.
• Please contact the dealer when you need to repair the air conditioner.
• Do not extend fingers or objects into the air inlet or air outlet. It may cause personal injury or damage.
• Do not block air outlets or air inlets. It may cause malfunction.
• Do not spill water on the remote controller, otherwise, the remote controller may be broken.
• When the below phenomenon occurs, please turn off the air conditioner and disconnect the power immediately and then contact the dealer or qualified professionals for service.
• The power cord is overheating or damaged.
• There’s abnormal sound during operation.
• Circuit break trips off frequently.
• The air conditioner gives off a burning smell.
• The indoor unit is leaking.
• If the air conditioner operates under abnormal conditions, it may cause malfunction，electric shock or fire hazard.
• When turning on or turning off the unit by emergency operation switch, please press this switch with an insulating object other than metal.
• Do not step on top panel of outdoor unit, or put heavy objects. It may cause damage or personal injury.

Attachment

• Installation must be performed by qualified professionals. Otherwise, it may cause personal injury or damage.

• Must follow the electric safety regulations when installing the unit.

• According to the local safety regulations, use a qualified power supply circuit and circuit break.

• Do install the circuit breaker. If not, it may cause malfunction.

• An all-pole disconnection switch having a contact separation of at least 3mm in all poles should be connected in the fixed wiring.

• Including a circuit breaker with suitable capacity, please note the following table.

• Air switch should be included a magnet buckle and a heating buckle function, it can protect the circuit short and overload.

• Air Conditioner should be properly grounded. The incorrect grounding may cause electric shock.

• Don’t use an unqualified power cord.

• Make sure the power supply matches the requirement of the air conditioner.

• An unstable power supply or incorrect wiring may result in electric shock, fire hazard, or malfunction. Please install proper power supply cables before using the air conditioner.

• Properly connect the live wire, neutral wire, and grounding wire of the power socket.

• Be sure to cut off the power supply before proceeding with any work related to electricity and safety.

• Do not put through the power before finishing the installation.

• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

• The temperature of the refrigerant circuit will be high, please keep the interconnection cable away from the copper tube.

• The appliance shall be installed in accordance with national wiring regulations.

• Installation must be performed in accordance with the requirement of NEC and CEC by authorized personnel only.

• The air conditioner is the first class electric appliance. It must be properly grounded with a specialized grounding device by a professional. Please make sure it is always grounded effectively, otherwise, it may cause electric shock.

• The yellow-green wire in the air conditioner is a grounding wire, which can’t be used for other purposes.

• The grounding resistance should comply with national electric safety regulations.

• The appliance must be positioned so that the plug is accessible.

• All wires of the indoor unit and outdoor unit should be connected by a professional.
  If the length of the power connection wire is insufficient， please contact the supplier for a new one. Avoid extending the wire by yourself.

• For the air conditioner with a plug, the plug should be reachable after finishing the installation.

• For the air conditioner without a plug, a circuit break must be installed in the line.

• If you need to relocate the air conditioner to another place, only a qualified person can perform the work. Otherwise, it may cause personal injury or damage.

• Select a location that is out of reach for children and far away from animals or plants.If it is unavoidable, please add the fence for safety purposes.

• The indoor unit should be installed close to the wall.

THE INSTRUCTIONS BEFORE USE

★When having a burning smell or smoke, please turn off the power supply and contact the service center.
If the abnormity still exists, the unit may be damaged and may cause electric shock or fire.| ★ The power supply must adopt a special circuit with air switch protection and assure it has enough capacity. The unit will be turned on or off according to your requirement automatically, please do not turn on or turn off the unit frequently, otherwise, a disadvantageous effect may be caused to the unit.| ★Never cut off or damage power cables and control wires. If the power cable and signal control wire was damaged, change them by professionals.

---|---|---
★ Power must adopt a special circuit to prevent fire.
Otherwise, it can cause electric
shock or fire.| ★Disconnect the power supply if long putting the air conditioner out of use.

Otherwise, the accumulated dust
may cause overheating or fire.| ★Never damage the electric wire or use the electric wire which is not appointed.
Otherwise,it will cause overheating or fire.
★ When cleaning, it is necessary to stop driving and turn off the power supply.

Cut off the power supply Otherwise, it may cause electric shock or damage.| ★Rated voltage of this air conditioner is 220- 240V, 50Hz, The compressor will vibrate sharply if the voltage is too low, disappointed. image to the refrigerating system. Electrical components are easy to damage if the voltage is too high.| ★Don’t attempt to repair the air conditioner by yourself.
The wrong repair will lead to an electric shock or fire, so you should contact the service center to repair it.
★Please note whether the installed stand is firm enough or not.
If it is damaged, it may lead to the fall of the unit and cause injury.| ★ Don’t step on the top of the outdoor unit or place something on it.
As falling off the outdoor unit can be dangerous.| ★ Earthing: The unit must be reliably earthed. The earthing cable shall be connected to the special earthing device in the construction.

NAME OF PARTS

AM2O-41HRDC1A AM2O-51HRDC1A AM2O-61HRDC1A AM3O-71HRDC1A AM4O-81HRDC1A AM4O- 100HRDC1 AM5O-120HRDC1

WARNING

• Be sure to cut off the power supply before cleaning the air conditioner; otherwise electric shock might happen.
• Wetting of air conditioners may cause the risk of electric shock. Make sure not to wash your air conditioner in any case.
• Volatile liquids such as thinner or gasoline will cause damage to the appearance of the air conditioner. (Only use a soft dry cloth moist cloth clean the air conditioner cabinet).
• This product must not be disposed of together with domestic waste.
• This product has to be disposed of at an authorized place for recycling of electrical and electronic appliances.
• The temperature of the refrigerant circuit will be high, please keep the interconnection cable away from the copper tube.

OUTDOOR UNIT

No.| Description
1| Air outlet grille
2| Valve

Note: The above figures are only intended to be a simple diagram of the appliance and may not correspond to the appearance of the units that have been purchased.

OUTDOOR UNIT WORKING TEMPERATURE RANGE

| Indoor side DBNVB(°C)| Outdoor side DBNVB(°C)
---|---|---
Maximum cooling| 32/23| 43/26
Maximum heating| 27/-| 24/18

• The operating temperature range (outdoor temperature) for the cooling-only unit is -15°C ~ 43°C; for the heat pump unit without an electric heating belt is -15°C ~ 43°C; for the heat pump unit with electric heating, the belt is -22°C ~ 43°C.

ELECTRICAL CONNECTIONS

AM2O-41HRDC1A, AM2O-51HRDC1A

1. Remove the handle at the right side plate of the outdoor unit (one screw).

2. Remove the cable clamp, connect the power connection cable with the terminal at the row of connection and fix the connection. The fitting line distribution must be consistent with the indoor unit. the terminal of the line bank. The wiring should meet that of the indoor unit.

3. Fix the power connection wire by wire clamp.
   Ensure the wire has been fixed well.

4. Install the handle.

5. Including an air switch with suitable capacity, please note the following table. Air switch should be included a magnet buckle and a heating buckle function, it can protect the circuit short and overload. (Caution: please do not use the fuse only to protect the circuit)

AM2O-41HRDC1A
AM2O-51HRDC1A| 16A

An all-pole disconnection switch having a contact separation of at least 3mm in all poles should be connected in the fixed wiring.
Wrong wire connection may cause malfunction of some electric components. After fixing the cable, ensure that the leads between the connection to the fixed point have some space.
The connection pipes and the connection wirings of unit A, and unit B must correspond to each other respective.
The appliance shall be installed in accordance with national wiring regulations.
Note: The above figures are only intended to be a simple diagram of the appliance and may not correspond to the appearance of the units that have been purchased.

HANDLING

After having removed the packaging, check that the contents are intact and complete.
The outdoor unit must always be kept upright.
Handling must be done by suitably equipped qualified technical personnel using equipment that is for suitable the weight of the appliance.

AM4O-81HRDC1A,AM4O-100HRDC1

1. Remove the handle at the right side plate of the outdoor unit (one screw).
2. Remove the cable clamp, connect the power connection cable with the terminal at the row of connection and fix the connection. The fitting line distribution must be consistent with the indoor unit. the terminal of the line bank. The wiring should meet that of the indoor unit.
3. Fix power connection wire by wire clamp. Ensure the wire has been fixed well.
4. Install the handle.
5. Including an air switch with suitable capacity, please note the following table. Air switch should be included a magnet buckle and heating buckle function, it can protect the circuit short and overload. (Caution: please do not use the fuse only to protect the circuit)

An all-pole disconnection switch having a contact separation of at least 3mm in all poles should be connected in the fixed wiring.
Wrong wire connection may cause malfunction of some electric components. After fixing the cable, ensure that the leads between the connection to the fixed point have some space.
The connection pipes and the connection wirings of unit A, and unit B must correspond to each other respective.
The appliance shall be installed in accordance with national wiring regulations.
Note: The above figures are only intended to be a simple diagram of the appliance and may not correspond to the appearance of the units that have been purchased.

AM4O-81HRDC1A,AM4O-100HRDC1

1. Remove the handle at the right side plate of the outdoor unit (one screw).
2. Remove the cable clamp, connect the power connection cable with the terminal at the row of connection and fix the connection. The fitting line distribution must be consistent with the indoor unit. the terminal of the line bank. The wiring should meet that of the indoor unit.
3. Fix power connection wire by wire clamp.
4. Ensure the wire has been fixed well.
5. Install the handle.

Including an air switch with suitable capacity, please note the following table. Air switch should be included a magnet buckle and a heating buckle function, it can protect the circuit short and overload. (Caution: please do not use the fuse only to protect the circuit)

An all-pole disconnection switch having a contact separation of at least 3mm in all poles should be connected in the fixed wiring.
Wrong wire connection may cause malfunction of some electric components. After fixing the cable, ensure that the leads between the connection to the fixed point have some space.
The connection pipes and the connection wirings of unit A, and unit B must correspond to each other respective.
The appliance shall be installed in accordance with national wiring regulations.
Note: The above figures are only intended to be a simple diagram of the appliance and may not correspond to the appearance of the units that have been purchased. 

AM5O-120HRDC1

1. Remove the handle at the right side plate of the outdoor unit (one screw).
2. Remove the cable clamp, connect the power connection cable with the terminal at the row of connection and fix the connection. The fitting line distribution must be consistent with the indoor unit. the terminal of the line bank. The wiring should meet that of the indoor unit.
3. Fix power connection wire by wire clamp.
4. Ensure the wire has been fixed well.
5. Install the handle.

Including an air switch with suitable capacity, please note the following table. Air switch should be included a magnet buckle and a heating buckle function, it can protect the circuit short and overload. (Caution: please do not use the fuse only to protect the circuit)

An all-pole disconnection switch having a contact separation of at least 3mm in all poles should be connected in the fixed wiring.
Wrong wire connection may cause malfunction of some electric components. After fixing the cable, ensure that the leads between the connection to the fixed point have some space.
The connection pipes and the connection wirings of unit A, and unit B must correspond to each other respective.
The appliance shall be installed in accordance with national wiring regulations.
Note: The above figures are only intended to be a simple diagram of the appliance and may not correspond to the appearance of the units that have been purchased. 

INSTALLING THE OUTDOOR UNIT

Location
Use bolts to secure the unit to a flat, solid floor.
When mounting the unit on a wall or the roof, make sure the support is firmly secured so that it cannot move in the event of intense vibrations or strong wind.
Do not install the outdoor unit in pits or air vents

Installing the pipes
Use suitable connecting pipes and equipment for the refrigerant R32.

Models(m)| 14Kx2| 18Kx2| 21Kx3| 24Kx3| 28Kx4| 36kx4| 42Kx5
---|---|---|---|---|---|---|---
Max. connection pipe length| 40| 40| 60| 60| 70| 80| 100
Max. connection pipe length (Simple one indoor unit)| 20| 20| 20| 20| 20| 25| 25

The sum of the capacity codes of the indoor units should be 50%-150% of that of the outdoor unit.
The refrigerant pipes must not exceed the maximum heights of 15m(14~28K) or 25m(36~42K).
Wrap all the refrigerant pipes and joints.
Tighten the connections using two wrenches working in opposite directions.
Caution: Installation Must be Performed in Accordance with the NEC/CEC by Authorized Personnel Only.

Install the drain fitting and the drain hose (for a model with heat pump only)
Condensation is produced and flows from the outdoor unit when the appliance is operating in the heating mode. In order not to disturb neighbors and to respect the environment, install a drain fitting and a drain hose to channel the condensate water.
Install the drain fitting and rubber washer on the outdoor unit chassis and connect a drain hose to it as shown in the figure.
NOTE: As for the shape of the drainage joint, please refer to the current product. Do not install the drainage joint in the severe cold area. Otherwise, it will be frosted and then cause malfunction.

BLEEDING

Humid air left inside the refrigerant circuit can cause compressor malfunction.
After having connected the indoor and outdoor units, bleed the air and humidity from the refrigerant circuit using a vacuum pump.

1. Unscrew and remove the caps from the 2-way and 3- way valves.

2. Unscrew and remove the cap from the service valve.

3. Connect the vacuum pump hose to the service valve.

4. Operate the vacuum pump for 10-15 minutes until an absolute vacuum of 10 mm Hg has been reached.
   

5. With the vacuum pump still in operation, close the Stop the vacuum pump.

6. Open the 2-way valve by 1/4 turn and then close it after 10 seconds. Check all the joints for leaks using liquid soap or an electronic leak device.

7. Turn the body of the 2-way and 3-way valves. Di connect the vacuum pump hose.

8. Replace and tighten all the caps on the valves.

MAINTENANCE

Use suitable instruments for the refrigerant R32.
Do not use any other refrigerant than R32.
Do not use mineral oils to clean the unit.

INSTALLATION DIMENSION DIAGRAM

The installation must be done by trained and qualified service personnel with reliability according to this manual.
Contact the service center before installation to avoid malfunction due to unprofessional installation.
When picking up and moving the units, you must be guided by a trained and qualified person.
Ensure that the recommended space is left around the appliance.

Fix the support of the outdoor unit (select it according to the actual installation situation)

1. Select the installation location according to the house structure.
2. Fix the support of the outdoor unit on the selected location with expansion screws.

NOTICE:

Take sufficient protective measures when installing the outdoor unit.
Make sure the support can withstand at least four times the unit weight.
The outdoor unit should be installed at least 3cm above the floor in order to install a drain joint. (for the model with a heating tube, the installation height should be no less than 20cm.)
For the unit with a cooling capacity of 2300W ~ 5000W, 6 expansion screws are needed; for the unit with a cooling capacity of 6000W~ 8000W, 8 expansion screws are needed; for the unit with a cooling capacity of 10000W~16000W, 10 expansion screws are needed.
As for the shape of the drainage joint, please refer to the current product.
Do not install the drainage joint in the severe cold area. Otherwise, it will be frosted and then cause malfunction.

CHECK AFTER INSTALLATION

effect
Is the thermal insulation of the unit sufficient?| May cause condensation and water dropping
Is the drainage smooth?| May cause condensation and water dropping
Does the power supply voltage accord with the rated voltage specified on the nameplate?| The unit may break down or the components may be burned out
Are the lines and pipelines correctly installed?| The unit may break down or the components may be burned out
Has the unit been safely grounded?| Risk of electrical leakage
Are the models of lines in conformity with requirements?| The unit may break down or the components may be burned out
Are there any obstacles near the air inlet and outlet of the indoor and outdoor units?| The unit may break down or the components may be burned out
Has the length of refrigerating pipe and refrigerant charge amount been recorded?| It is not easy to decide the charge amount of refrigerant.

SAFETY OPERATION OF FLAMMABLE REFRIGERANT

Qualification requirement for installation and maintenance man
All the workmen who are engaging in the refrigeration system should bear the valid certification awarded by the authoritative organization and the qualification for dealing with the refrigeration system recognized by this industry.
If it needs another technician to maintain and repair the appliance, they should be supervised by the person who bears the qualification for using the flammable refrigerant.
It can only be repaired by the method suggested by the equipment manufacturer.

Installation notes
The air conditioner is not allowed to use in a room that has a running fire (such as a fire source, working coal gas ware, or operating heater).
It is not allowed to drill holes or burn the connection pipe.
The air conditioner must be installed in a room that is larger than the minimum room area. The minimum room area is shown on the nameplate or following table a.
A leak test is a must after installation.

table a Minimum room area ( m² )

Minimum
room²
area( m  )| Charge amount (kg)| ≤1.2| 1.3| 1.4| 1.5| 1.6| 1.7| 1.8| 1.9| 2| 2.1| 2.2| 2.3| 2.4| 2.5
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
floor location| /| 14.5| 16.8| 19.3| 22| 24.8| 27.8| 31| 34.3| 37.8| 41.5| 45.4| 49.4| 53.6
window mounted| /| 5.2| 6.1| 7| 7.9| 8.9| 10| 11.2| 12.4| 13.6| 15| 16.3| 17.8| 19.3
wall mounted| /| 1.6| 1.9| 2.1| 2.4| 2.8| 3.1| 3.4| 3.8| 4.2| 4.6| 5| 5.5| 6
ceiling mounted| /| 1.1| 1.3| 1.4| 1.6| 1.8| 2.1| 2.3| 2.6| 2.8| 3.1| 3.4| 3.7| 4

Maintenance notes

• Check whether the maintenance area or the room area meets the requirement of the nameplate.
  – It’s only allowed to be operated in the rooms that meet the requirement of the nameplate.

• Check whether the maintenance area is well-ventilated.
  – The continuous ventilation status should be kept during the operation process.

• Check whether there is a fire source or potential fire source in the maintenance area.
  – The naked flame is prohibited in the maintenance area; and the “no smoking” warning board should be hung.

• Check whether the appliance mark is in good condition.
  – Replace the vague or damaged warning mark.

Welding
If you should cut or weld the refrigerant system pipes in the process of maintaining, please follow the steps as below:
a. Shut down the unit and cut the power supply
b. Eliminate the refrigerant
c. Vacuuming
d. Clean it with N2 gas
e. Cutting or welding
f. Carry back to the service spot for welding
The refrigerant should be recycled into the specialized storage tank.
Make sure that there isn’t any naked flame near the outlet of the vacuum pump and that it’s well-ventilated.

Filling the refrigerant
Use the refrigerant filling appliances specialized for R32. Make sure that different kinds of refrigerant won’t contaminate with each other.

• The refrigerant tank should be kept upright at the time of filling the refrigerant.
• Stick the label on the system after filling is finished (or hasn’t finished).
• Don’t overfill.
• After the filling is finished, please do the leakage detection before the test runs; another time of leak detection should be done when it’s removed.

Safety instructions for transportation and storage

• Please use the flammable gas detector to check before unloading and opening the container.
• No fire source and smoking.
• According to the local rules and laws.

SPECIALIST’S MANUAL

• The following checks shall be applied to installations using flammable refrigerants:
  – the charge size is in accordance with the room size within which the refrigerant-containing parts are installed;
  the ventilation machinery and outlets are operating adequately and are not obstructed;
  if an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refriger­ant;
  marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected;
  refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant- containing components unless the components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded.

• Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise the safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised.

• Initial safety checks shall include:
  – that capacitor are discharged: this shall be done in a safe manner to avoid the possibility of sparking;
  – that no live electrical components and wiring are exposed while charging, recovering or purging the system;
  – that there is continuity of earth bonding.

• Checking for the presence of refrigerant
  The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the techni­cian is aware of potentially toxic or flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants, i.e. non-sparking, adequately sealed or intrinsically safe.

• Presence of a fire extinguisher
  If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire extin­guishing equipment shall be available to hand. Have a dry powder or CO2 fire extinguisher adjacent to the charging area.

• Ventilated area
  Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.

• Leak detection methods
  Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work.

• Checks to the refrigeration equipment
  Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt, consult the manu­facturers technical department for assistance.

• Checks to electrical devices
  – that capacitor are discharged: this shall be done in a safe manner to avoid the possibility of sparking;
  – that no live electrical components and wiring are exposed while charging, recovering or purging the system.

• Repairs to sealed components
  During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation.
  Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, an excessive number of connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc.

• Ensure that the apparatus is mounted securely.

• 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. Replacement parts shall be in accordance with the manufactur­er’s specifications.
  NOTE: The use of silicon sealant can inhibit the effectiveness of some types of leak detection equipment. Intrinsi­cally safe components do not have to be isolated prior to working on them.

• Repair to intrinsically safe components
  Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use.
  Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating.
  Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrig­erant in the atmosphere from a leak.

• Cabling
  Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.

• Detection of flammable refrigerants
  Under no circumstances shall potential sources of ignition be used in the search for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used.

• Decommissioning
  Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all  refrigerants are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of reclaimed refrigerant. It is essential that electrical power is available before the task is commenced.
  a) Become familiar with the equipment and its operation.
  b) Isolate system electrically.
  c) Before attempting the procedure, ensure that:
  – mechanical handling equipment is available, if required, for handling refrigerant cylinders;
  – all personal protective equipment is available and being used correctly;
  – the recovery process is supervised at all times by a competent person;
  – recovery equipment and cylinders conform to the appropriate standards.
  d) Pump down the refrigerant system, if possible.
  e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
  f) Make sure that the cylinder is situated on the scales before recovery takes place.
  g) Start the recovery machine and operate in accordance with the manufacturer’s instructions.
  h) Do not overfill cylinders. (No more than 80% volume liquid charge).
  i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
  j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.
  k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.
  Labelling Equipment shall be labeled stating that it has been decommissioned and emptied of refrigerant. The label shall be dated and signed. For appliances containing flammable refrigerants, ensure that there are labels on the equipment stating the equipment contains flammable refrigerant.

• Recovery
  When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
  When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge are available. All cylinders to be used are designated for the recovered refrigerant and labeled for that refrigerant (i.e. special cylinders for the recovery of refrigerant). Cylinders shall be complete with a pressure-relief valve and associated shut- off valves in good working order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
  The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of all appropriate refrigerants including, when applicable, flammable refrigerants.
  In addition, a set of calibrated weighing scales shall be available and in good working order.
  Hoses shall be complete with leak-free disconnect couplings and in good condition. Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained, and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult the manufacturer if in doubt.  The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant waste transfer note arranged. Do not mix refrigerants in recovery units and especially not in cylinders.
  If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The evacuation process shall be carried out prior to re-turning the compressor to the suppliers.
  Only electric heating to the compressor body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried out safely.

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>