HITACHI R32 Refrigerant Instruction Manual

HITACHI R32 Refrigerant

Instructions

Additional safety manual for R32 refrigerant air conditioner and heat pump according to IEC 60335-2-40:2018
Explanation of symbols displayed on the indoor unit or outdoor unit.

| WARNING| This symbol shows that this equipment uses a flammable refrigerant (A2L).
If the refrigerant is leaked, together with an external ignition source, there is a possibility of ignition.
---|---|---
| CAUTION| This symbol shows that the Operation Manual should be read carefully.
| CAUTION| This symbol shows that a service personnel should be handling this equipment with reference to the Installation Manual.
| CAUTION| This symbol shows that there is information included in the Operation Manual and/or Installation Manual.

WARNING

• Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer.
• 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.
• Be aware that the R32 refrigerant does not contain an odour.
• Do not disconnect the pipe connection after checking the leak otherwise it may cause refrigerant leakage.

CAUTION

Installation (Space)

• That the installation of pipe-work shall be kept to a minimum.

• That pipe-work shall be protected from physical damage and shall not be installed in an unventilated space.

• That compliance with national gas regulations shall be observed.

• That mechanical connections shall be accessible for maintenance purposes.

• In cases that require mechanical ventilation, ventilation openings shall be kept clear of obstruction.

• When disposing of the product is used, be based on national

• regulations, properly processed.
  An unventilated area where the appliance using flammable refrigerants is installed shall be so constructed that should any refrigerant leak, it will not stagnate so as to create a fire or explosion hazard

• The appliance shall be stored in a well-ventilated area where the room size corresponds to the room area as specified for operation;
  The appliance shall be stored in a room without continuously operating open flames (for example an operating gas appliance) and ignition sources (for example an operating electric heater).

• Other potential continuously operating sources known to cause ignition of the refrigerant used.

• The appliance shall be stored so as to prevent mechanical damage from occurring.

• The following chart, formulas and table shows the minimum floor area (Amin) required for the installation of an indoor unit from a refrigerant system containing a certain refrigerant charge (mc) of R32 (A2L refrigerant), and supposing a total room height
  not lower than 2.2 m. (According to IEC 60335-2-40:2018 and EN 378-1:2016).

• For mc<1.84 kg, IEC 60335-2-40:2018 and EN 378-1:2016 do not establish any minimum floor area restriction. In that case check local regulations to ensure that no hard restrictions may apply.

• In case of total refrigerant amount mc ≥ 1.84 kg, the unit should be installed, operated and stored in a room with a floor area larger than the minimum criteria.

• Floor mounted: Refrigerant parts not sealed installed <0.6m height
• Wall mounted: Refrigerant parts not sealed installed >1.0m height
• Ceiling mounted: Refrigerant parts not sealed installed >1.8m height
• Ceiling mounted: Refrigerant parts not sealed installed >2.2m height
• Ceiling mounted: Refrigerant parts not sealed installed >2.5m height

Minimum floor area for equipment installed inside

mc(kg)| A  (m2)

min

| A  (m2)

min

| A  (m2)

min

| A  (m2)

min

| A  (m2)

min

h0:0.6m| h0:1.0m| h0:1.8m| h0:2.2m| h0:2.5m
1.84| 28.88| 10.40| 4.44| 3.64| 3.20
1.9| 30.72| 11.06| 4.58| 3.75| 3.30
2.0| 34.04| 12.26| 4.83| 3.95| 3.47
2.1| 37.53| 13.51| 5.07| 4.15| 3.65
2.2| 41.19| 14.83| 5.31| 4.34| 3.82
2.3| 45.02| 16.21| 5.55| 4.54| 4.00
2.4| 49.02| 17.65| 5.79| 4.74| 4.17
2.5| 53.19| 19.15| 6.03| 4.94| 4.34
2.6| 57.53| 20.71| 6.39| 5.13| 4.52
2.7| 62.04| 22.34| 6.89| 5.33| 4.69
2.8| 66.72| 24.02| 7.41| 5.53| 4.86
2.9| 71.58| 25.77| 7.95| 5.73| 5.04
3.0| 76.60| 27.58| 8.51| 5.92| 5.21
3.1| 81.79| 29.44| 9.09| 6.12| 5.39
3.2| 87.15| 31.37| 9.68| 6.48| 5.56
3.3| 92.68| 33.37| 10.30| 6.89| 5.73
3.4| 98.39| 35.42| 10.93| 7.32| 5.91
3.5| 104.26| 37.53| 11.58| 7.75| 6.08
4.0| 136.17| 49.02| 15.13| 10.13| 7.84
4.5| 172.34| 62.04| 19.15| 12.82| 9.93
5.0| 212.77| 76.60| 23.64| 15.83| 12.26
6.0| 306.39| 110.30| 34.04| 22.79| 17.65
7.0| 417.03| 150.13| 46.34| 31.02| 24.02
8.0| 544.69| 196.09| 60.52| 40.51| 31.37
9.0| 689.38| 248.18| 76.60| 51.28| 39.71
10.0| 851.08| 306.39| 94.56| 63.30| 49.02

Servicing

Service personnel

• Any person who is involved with working on or breaking into a refrigerant circuit should hold a current valid certificate from an industry-accredited assessment authority, which authorizes their competence to handle refrigerants safely in accordance with an industry recognized assessment specification.
• Servicing shall only be performed as recommended by the equipment manufacturer. Maintenance and repair requiring the assistance of other skilled personnel shall be carried out under the supervision of the person competent in the use of flammable refrigerants.
• Servicing shall be performed only as recommended by the manufacturer.

Checks to the area
Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized. For repair to the refrigerating system, the precautions in 2-2 to 2-10 shall be complied with prior to conducting work on the system.

Work procedure
Work shall be undertaken under a controlled procedure so as to minimize the risk of a flammable gas or vapour being present while the work is being performed.

General work area
All maintenance staff and others working in the local area shall be instructed on the nature of work being carried out. Work in confined spaces shall be avoided. The area around the workspace shall be sectioned off. Ensure that the conditions within the area have been made safe by control of flammable material.

Checking for 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 flammable atmospheres.
• Ensure that the leak detection equipment being used is suitable for use with flammable refrigerants, i.e. non sparking, adequately sealed or intrinsically safe.

Presence of 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.

No ignition sources

• No person carrying out work in relation to a refrigeration system which involves exposing any pipe work that contains or has contained flammable refrigerant shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion.
• All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation, repairing, removing and disposal, during which flammable refrigerant can possibly be released to the surrounding space.

No ignition sources
Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. “No Smoking” signs shall be displayed.

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.

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 manufacturer’s technical department for assistance.

• 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.

Checks to electrical devices

• Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures.
• If a fault exists that could compromise 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 capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking.
  That there no live electrical components and wiring are exposed while charging, recovering or purging the system.
  That there is continuity of earth bonding.

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, excessive number of connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc.
• Ensure that apparatus is mounted securely.
• Ensure that seals or sealing materials have not degraded such 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 may 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 searching for or detection of refrigerant leaks.
• A halide torch (or any other detector using a naked flame) shall not be used.

Leak detection methods

• Electronic leak detectors shall be used to detect flammable refrigerants, but the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.)
• Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used.
• Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas (25 %maximum) is confirmed.
• 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.
• If a leak is suspected, all naked flames shall be removed/extinguished.
• If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak.
• Oxygen free nitrogen (OFN) shall then be purged through the system both before and during the brazing process.

Removal and evacuation

• When breaking into the refrigerant circuit to make repairs –or for any other purpose –conventional procedures shall be used. However, it is important that best practice is followed since flammability is a consideration.
• The following procedure shall be adhered to:
  • remove refrigerant
  • purge the circuit with inert gas
  • evacuate
  • purge again with inert gas
  • open the circuit by cutting or brazing
• The refrigerant charge shall be recovered into the correct recovery cylinders.
• The system shall be “flushed” with OFN to render the unit safe.
• This process may need to be repeated several times.
• Compressed air or oxygen shall not be used for this task.
• Flushing shall be achieved by breaking the vacuum in the system with OFN 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 OFN 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.
• Ensure that the outlet for the vacuum pump is not close to any ignition sources and there is ventilation available.

Charging procedures

• In addition to conventional charging procedures, the following requirements shall be followed.
  • Ensure that contamination of different refrigerants does not occur when using charging equipment.
  • Hoses or lines shall be as short as possible to minimize the amount of refrigerant contained in them.
  • Cylinders shall be kept upright.
  • Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
  • Label the system when charging is complete (if not already).
  • Extreme care shall be taken not to overfill the refrigeration system.
• Prior to recharging the system it shall be pressure tested with OFN.
• 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.

Decommissioning

• Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its details.
• 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.
• Become familiar with the equipment and its operation.
• Isolate system electrically.
• 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.
  • Pump down refrigerant system, if possible.
  • If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
  • Make sure that cylinder is situated on the scales before recovery takes place.
  • Start the recovery machine and operate in accordance with manufacturer’s instructions.
  • Do not overfill cylinders. (No more than 80 % volume liquid charge).
  • Do not exceed the maximum working pressure of the cylinder, even temporarily.
  • 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.
  • Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.

Labeling

• Equipment shall be labeled stating that it has been de-commissioned and emptied of refrigerant.
• The label shall be dated and signed.
• 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 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 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 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 returning 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.

Johnson Controls-Hitachi Air Conditioning Spain, S.A.U.
Ronda Shimizu, 1 – Políg. Ind. Can Torrella
08233 Vacarisses (Barcelona) Spain
© Copyright 2021 Johnson Controls-Hitachi Air Conditioning Spain, S.A.U. – All rights reserved.

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