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1 - INTRODUCTION
2. Ensure that the refrigerant is never released to the
atmosphere during installation, maintenance or equipment
disposal.
3. The deliberate gas release into the atmosphere is not
allowed.
4. If a refrigerant leak is detected, ensure that it is stopped
and repaired as quickly as possible.
5. Only a qualified and certified personnel can perform
installation operations, maintenance, refrigerant circuit
leak test as well as the equipment disposal and the
refrigerant recovering.
6. The gas recovery for recycling, regeneration or destruction
is at customer charge.
7. Periodic leak tests have to be carried out by the customer
or by third parties. The EU regulation set the periodicity
here after:
System WITHOUT
No Check 12 Months 6 Months
leakage detection
System WITH leakage
No Check 24 Months 12 Months
detection
Refrigerant charge/
< 5 Tons
circuit (CO
equivalent)
2
Charge
R134A
(GWP 1430)
< 3.5 kg
Charge
R407C
< 2.8 kg
(GWP 1774)
R410A
Charge <
2.4 kg
(GWP 2088)
HFO's: R1234ze
(1) From 01/01/2017, units must be equipped with a leakage detection system.
8. A logbook must be established for equipments subject to
periodic leak tests. It should contain the quantity and the
type of fluid present within the installation (added and
recovered), the quantity of recycled fluid, regenerated
or destroyed, the date and output of the leak test, the
designation of the operator and its belonging company,
etc.
9. Contact your local dealer or installer if you have any
questions.
During the life-time of the system, inspection and tests must
be carried out in accordance with national regulations.
Protection device checks:
Periodic inspections of the safety devices and external
overpressure devices (external relief valves) must be carried
out in accordance with national regulations.
The safety device shall be tested at least once a year to verify
good operation and cut out value.
The company or organisation that conducts a pressure switch test
shall establish and implement a detailed procedure to fix:
- Safety measures
- Measuring equipment calibration
- Validating operation of protective devices
- Test protocols
- Recommissioning of the equipment.
An example of test procedure without removing the pressure
switch is given from Section 11.10 of this manual.
Consult Carrier Service for this type of test.
CAUTION: If the test leads to replacing the pressure switch,
it is necessary to recover the refrigerant charge, these
pressure switches are not installed on automatic valves
(Schraeder type).
3 Months
6 Months
5 ≤
50 ≤
Charge
Charge
Charge
> 500
< 50 Tons
< 500 Tons
Tons
(1)
3.5 ≤
34.9 ≤
Charge
Charge
Charge
> 349.7 kg
< 34.9 kg
< 349.7 kg
2.8 ≤
28.2 ≤
Charge
Charge
Charge
> 281.9 kg
< 28.2 kg
< 281.9 kg
2.4 ≤
23.9 ≤
Charge
Charge
Charge
> 239.5 kg
< 23.9 kg
< 239.5 kg
No requirement
At least once a year thoroughly inspect the protection devices
(valves, pressure switches). If the machine operates in a
corrosive environment, inspect the protection devices more
frequently.
Regularly carry out leak tests and immediately repair any
leaks.
Ensure regularly that the vibration levels remain accep-table
and close to those at the initial unit start-up.
Before opening a refrigerant circuit, purge and consult the
pressure gauges.
Change the refrigerant when there are equipment failures,
following a procedure as the one described in NF E29-795 or
carry out a refrigerant analysis in a specialist laboratory.
If the refrigerant circuit remains open for longer than a day after
an intervention (such as a component replacement), the
openings must be plugged and the circuit must be charged
with nitrogen (inertia principle). The objective is to prevent
penetration of atmospheric humidity and the resulting
corrosion on the internal walls and on non-protected steel
surfaces.
1.4 - Repair safety considerations
Equip the engineers that work on the unit with the protections
described in section 1.3 above.
It is compulsory to wear personal protection equipment.
The insulation must be removed and warming up must be
limited by using a wet cloth.
Before opening the unit always ensure that the circuit has
been purged.
If work on the evaporator is required, ensure that the piping
from the compressor is no longer pressurised (as the valve
is not leaktight in the compressor direction.)
All installation parts must be maintained by the personnel in charge,
in order to avoid material deterioration and injuries to people. Faults
and leaks must be repaired immediately. The authorized technician
must have the responsibility to repair the fault immediately. Each
time repairs have been carried out to the unit, the operation of the
protection devices must be re-checked.
Comply with the regulations and recommendations in unit and
HVAC installation safety standards, such as: EN 378, ISO 5149,
etc.
If a leak occurs or if the refrigerant becomes contaminated (e.g.
by a short circuit in a motor) remove the complete charge using
a recovery unit and store the refrigerant in mobile containers.
Repair the leak detected and recharge the circuit with the total
R-134a charge, as indicated on the unit name plate. Certain parts
of the circuit can be isolated. Only charge liquid refrigerant R-134a
at the liquid line.
Ensure that you are using the correct refrigerant type before
recharging the unit.
Charging any refrigerant other than the original charge type
(R-134a) will impair machine operation and can even lead to a
destruction of the compressors. The compressors operating
with this refrigerant type are lubricated with a synthetic
polyolester oil.
RISK OF EXPLOSION
Never use air or a gas containing oxygen during leak tests to
purge lines or to pressurise a machine. Pressurised air
mixtures or gases containing oxygen can be the cause of an
explosion. Oxygen reacts violently with oil and grease.
Never exceed the specified maximum operating pressures.
Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and
the pressures given on the unit name plate.
7
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