User Manual
User Manual
MANUAL
1
2. Product appearance and installation dimension
Units: mm
Model KRCHRW10ZA-PBEN2
Size
A 420
B 700
C 1020
D 880
A D
Units: mm
Model
Size KRCHRW16ZA-PBEN2
A 420
B 700
C 1000
D 1480
2
II. Installation
1. Heat Pump Outdoor Unit installation position
Install the heat pump outdoor unit with good air flow both into and out from the unit. Ensure there is
sufficient space around the unit for maintenance and good operation, refer to the schematics and
points below:
Wrong Right
! Notice:
1. To get enough air for ventilation of the unit, the installation position should have good
air flow.
2. The position should not reflect noise from the air outlet or transfer vibration.
3. Protection from direct sunlight is advisable.
4. The water from rain and defrosting can be discharged from the installation position.
5. The unit should be protected by an awning from snow in Alpine areas.
6. The discharged air should not blow into prevailing wind.
7. Do not face the air outlet directly at a neighbour 's fence .
8. The position should not be affected by garbage, oil or flammable materials.
9. The installtion position should not be affected by sea salt spray or sulphides near
a thermal spring.
3
10. The unit can be installed on a balcony, roof or other convenient place if there is a
suitable load bearing structure to support its weight.
11. The control panel should not be installed in a bathroom due to high humidity and
moisture.
12. Leave enough space around the unit for good operation and servicing.
13. Consider installing rubber pads under the heat pump feet.
14. Use expansion bolts to fix the feet of the outdoor unit to the ground.
15. Ensure the condensate water from the heat pump is taken to a drain.
2. Installation requirement
A. Side fan type installation space requirements:
≥600mm
≥500mm
≥75mm
≥1500mm
≥500mm
≥600mm
≥600mm Unit
≥200mm
≥200mm
Air outlet
Unit
Air intlet
Bolt Bolt
Unit fix fix
≥200mm
≥600mm ≥400mm
≥700mm
≥700mm
≥400mm
≥400mm
Bolt
fix
≥1000mm
≥1000mm
3. Domestic Hot Water (DHW) Storage Tank and Buffer Tank Installation
3.1.The DHW and Buffer tanks may be installed inside or outside.
3.2. Both tanks must stand vertically on a concrete plinth or firm structure that will support its weight
when full of water and not lean or be prone to fall over during its service life.
3.3. The DHW tank should be installed in accordance with local or other relevant Government
regulations. It is best to install the DHW tank as close as
possible to the hot water outlet that has the greatest usage, such as the kitchen.
3.4. Some building codes require a seismic restraint. Consider using stainless steel bands to secure
the tank against the wall.
3.5. When filling the DHW tank, open the hot water taps in the laundry and kitchen to purge air from
the water lines.
3.6.When filling the Buffer Tank, use pure rain water with mould inhibitor, add Glycol if prone to
freezing conditions, and water pH should ideally be at 7.0.
3.7. An expansion tank amd bleeder valve must be included in the hydronic closed loop to allow the
heated water to expand and air to be easily purged from the system.
4
4. Water heating installation schematic
2 3
Air outlet
6
A
Unit
Cold water
5 inlet
1
4
1
Drain outlet
Note: The power lead must be properly earthed in accordance with electrical regulations and
1
Cold water
inlet
Air outlet
Unit A 6
8
1
Drain outlet
Cold water 5
inlet
Legend:
Globe valves Shower head 8 Mains pressure storage
Electric driven two-way valve 1 Heat Pump Outdoor Unit tank
Check valve 2 Cold Water inlet valve A Hot water tank temp.
Water pressure switch 3 Domestic hot water supply valve
Water temp. sensor 4 Low pressure storage tank
5
Expansion Tank Ring maincycle pump
6 Bath room
5
4.3. Heating and cooling mode installation schematic
2
4
7 8 L
N
5
thermostat controller
7 8
6 three-way valve
9 10 Relay
L
N
11 11 12 thermostat controller
12
three-way valve
13 14 Relay
L
N
15 15 16 thermostat controller
16
three-way valve
17 18
Relay
L
19 N
thermostat controller
21 19 pump power
three-way valve switch
22 Relay
23
23 20
Legend:
Flexible connectors 6 Hydronic water return manifold 16 Room 6 electric three-way valve
Globe valves
7 Electric actuator 17 Room 5 fan coil
Electric three-way valve 8 Electric actuator 18 Room 6 fan coil
Check valve 9 Room 1 floor heating 19 Swimming pool three-way valve
Thermostat 10 Room 2 floor heating 20 Water to water excharge
Expansion Tank 11 Room 3 electric three way valve 21 Swimming pool
Water cycle pump 12 Room 4 electric three way valve 22 Sand cylinder filter
2
13 Room 3 Radiators 23 Swimming pool side water
Heat Pump Outdoor Unit
14 Room 4 Radiators cycle pump
4 Buffer tank
15 Room 5 electric three-way valve
5 Hydronic water flow manifold
6
4.4. Heating and cooling mode plus domestic hot water installation schematic
4 6
19
A 7
water inlet
water inlet
1 3
Note 4 1 5 5
8
Power on : port 1 and 5 are connected
Power off : port 1 and 8 are connected
L
N
15 16
thermostat controller
15 16
three-way valve
Relay 18
17
Legend:
Flexible connectors 3 Hot water cycle pump 12 Hydronic water return manifold
Globe valves 4 Hydronic system three way valve 13 Room 1 floor heating
5 Hot water storage tank
Electric three-way valve 14 Room 2 floor heating
6 Bath room
Check valve 15 Room 3 electric three way valve
Thermostat 7 Solar water cycle pump 16 Room 4 electric three way valve
8 Buffer tank 17 Room 3 Radiators
Expansion Tank
9 Room 1 electrothermal actuator 18 Room 4 Radiators
Water cycle pump
10 Room 2 electrothermal actuator 19 Optional solar heating input
1 Heat Pump Outdoor Unit
11 Hydronic water flow manifold A Hot water tank temp.
B Solar collector temp.
7
5. Installation of indoor heating and cooling equipment
5.1 Indoor heating and cooling equipment such as fan coils, radiator heating or floor
heating, should be installed in accordance with relevant regulatory requirements including
North American Standard,engineering design drawings, and the manufacturer's
installation instructions.
5.2 Use soft connectors to connect the outdoor unit and indoor heating and cooling
equipment.
5.3 Install condensate water drain pipes to the indoor fan coil units with smooth drainage
lines for the condensate water to flow easily.
6. Electrical wiring
6.1 The heat pump outdoor unit should be installed in accordance with electrical
regulations and North American Standard.
6.2 The power cable of the outdoor unit must support the maximum starting current
requirements.
6.3 The outdoor unit power supply circuit must have a grounding wire, which should
connect with a reliable and effective external ground wire.
6.4 Wiring must be installed by qualified technicians with reference to the circuit diagram.
6.5 The layout of power lines and signal lines should be neat, rational and strong with
weak lines separated so they cannot interfere with each other.
6.6 When power lines and control lines are parallel, the wires must be placed inside an
insulating tube, with appropriate distance between the lines.
6.7 For electrical connection of the outdoor unit, take the following wiring through the
wiring hole set into the electrical box, then connect to the appropriate terminals in the
electrical box according to wiring diagram:
· Power line
· Remote control three core lines
· Electric heater power line
· Solar circulating water pump control power line
· Water tank electrical boost element
· Temperature sensing line
· Solar collector temperature sensor line
· Terminal equipment
· Outdoor unit lines
The first step The second step The third step The fourth step
8
7.1 Firstly, daub heat conductive silicone onto the front of the temperature sensor, then
insert it
into the temperature detector.
7.2 Next, push the temperature sensor with the pin through to the end of the temperature
detector, then mark the level of the pin on the temperature detector.
7.3 Next, pull the pin out and check that the position of mark is at the same level as the
inletof the temperature detector and check whether the sensor is inserted into the pipe
terminal.
7.4 Finally, seal the inlet of the temperature detector with silicone, and keep the inlet of
the temperature detector upright for about an hour.
Unit
Power supply
1 2
PCB COM
Compressor
8.2.Size Table of Electrical Wire
The wiring specifications (mm )2
Starting current
(A) Mark②(Heat resistance
Mark①(Heat resistance temperature above 60℃) temperature above 120℃)
within 5m Within 10m Within 15m Within 20m Within 30m Within 50m Within 1m
Below 20 2.0 2.0 2.0 3.5 5.5 8.0 2.0
Below 30 ↑ ↑ 3.5 5.5 ↑ 14.0 ↑
Below 40 ↑ 3.5 5.5 ↑ 8.0 ↑ ↑
Below 50 ↑ ↑ ↑ 8.0 14.0 22.0 ↑
Below 60 ↑ 5.5 ↑ ↑ ↑ ↑ ↑
Below 70 3.5 ↑ 8.0 14.0 ↑ ↑ 3.5
Below 80 ↑ ↑ ↑ ↑ 22.0 30.0 ↑
Below 90 ↑ ↑ 14.0 ↑ ↑ ↑ ↑
Below 100 ↑ 8.0 ↑ ↑ ↑ 38.0 ↑
Below 110 ↑ ↑ ↑ ↑ ↑ ↑ ↑
Below 120 5.5 ↑ ↑ 22.0 30.0 ↑ ↑
Below 140 ↑ 14.0 ↑ ↑ ↑ 50.0 5.5
Below 160 ↑ ↑ 22.0 ↑ ↑ ↑ ↑
Below 180 ↑ ↑ ↑ ↑ 38.0 60.0 8.0
Below 200 8.0 ↑ ↑ 30.0 ↑ ↑ ↑
Below 220 ↑ ↑ ↑ ↑ 50.0 80.0 ↑
Below 240 ↑ ↑ ↑ ↑ ↑ ↑ 14.0
Power supply installation condition: The touching space of breaker should be more than 3mm,
use copper wire only.
9
8.3 Grounding caution
The internal motor protector does not protect the compressor against all possible
conditions. Please be sure that the system is properly earthed when installed in the field.
8.4 Warning:
To avoid fire, electric shock and other accidents, only use power supply voltage
indicated on the label.
8.5.To protect the power lines, they should be fixed appropriately so that they cannot
become damaged and people cannot trip over them. Pay particular attention to the
positioning and operation of electrical plugs, which should be easily plugged into the
socket.
8.6.Do not overload wall plugs or the power cable line. Overloading may cause fire or
electric shock.
8.7.Check to ensure your electrical socket is appropriate for the power load and is properly
grounded.
Note:
1.Used PVC insulated copper wire for the above wiring.
2.If your installation requires longer wiring than specified in the table above, contact your installer.
10
9. Trial operation by qualified installer
9.1 Pre-start-up checks:
· Check the whole pipe system. Ensure the water volume in the system is full and the air is
exhausted completely. Check whether the water valves are open throughout the system.
· Check the thermal insulation of the pipe work, make sure relevant pipes are appropriat-
ely lagged.
· Check the power supply and distribution system. Check whether the power supply volta-
ge is normal, the power distribution accessory screws are tight, supply power complies
with the wiring diagram and outdoor unit specifications and the wiring is properly grounded.
· Check the air cooled water chiller. Make sure all screws are tight. Check that the signal
indicator light (green) of the outdoor unit control panel is illuminated normally and the fault
indicating lamp (red) is illuminated.
· Connect pressure gauges to the suction Schrader valves in preparation for checking the
refrigerant pressure during operation. Disconnect them when testing is satisfactory.
9.2 Trial operation
· Press on/off on the remote controller, the water pump and fan should start immediately.
The compressor should start shortly after. Observe and determine if there is any abnormal
sound during operation. Stop to check the unit if there is abnormal sound. The outdoor unit
should continue to run only when there is no abnormal sound.
· Check whether the cooling system pressure is normal.
· Check whether the input power and current of the unit are within the parameters set out
in this manual. If not, stop the outdoor unit and check it.
· Observe whether the outlet water temperature is normal.
9.3 The parameters of the remote controller have been pre-set at the factory. We
recommend that you leave these parameters as set.
11
III. WIFI remote control
2. 2 If you download the app, users who have no account can click the “Register” function on
the login page to apply, and then click “Agree”.And then you can register by phone number
or email address. After registration is complete, you need "Create family", set "Family
Name", "Family Location", and then click "Done".
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Family Name Enter the name
Add Room
2. 3 If you have account can log in directly, as shown in the figure below:
Pasword
Log In
13
2. 4 If you forget the password can choose login authentication code
Password
Get Verification Code
Log In
2. 5 Add equipment
Create family after completion, or log in into the main interface, click the "Add Device",
then click "Large Home Ap... ", and then click on the "Air Conditioner"
Electrical
Lighting
Sensors
2
Small
Home Ap...
Kitchen 3
Appliances
1 Exercuse&
Health
Camera&
Lock
Gateway
Control
Outdoor
Travel
Energy
14
2. 6 Under the main interface, briefly press the WIFI icon “ ” in the upper left corner to
enter the WIFI settings interface. At this time, briefly press the “ SMART ” button and continue
operating on the APP.
14 ℃
Inlet
14 ℃
27
℃
SET
Outlet
-1 ℃
-2 ℃
Ambient SMART AP
15
1 device(s) added successfully
Added successfully
16
IV. USE
1. Icon instruction
symbol icon instructions
A 16:37 Time A B C DE F GH I J
TUE
B 06-06-2023 Date
C Current
ROOM operating mode
D Water cycle pump
E Fan
F Compressor
G flectrical heating 14 ℃
K
Inlet
H
I
defrost
Anti-freezing 14 27
℃
SET
Outlet
-1 ℃ L
J Oil return -2 ℃ M
Ambient
K Inlet
Inlet water temp. N
L Outlet
Outlet water temp.
M Ambient
Ambient temp.
ON MODE MENU TIMER
N 27
℃
SET Setting temp.
O TIMER
Timer setting
P MENU
Setting
ROOM
Q Mode selection S R Q P O
MODE
R ON
Unit on/off
S 14 actual temp.
Heating+DHW
49
52 27 52
-12
50 55
17
ECO Silent Power
:Cooling mode
:Heating mode
:DHW mode
:Automatic mode
+ :heating+DHW
:cooling+DHW
Notice: In automatic mode, the icon displayed next to the actual temperature is the current operating mode.
All possible modes are listed above for reference only.
Some modes are only available for specific models
L9~L10 21 ~ 06 35
ON 00:00
Time 1
OFF 00:00 L10~L11 04 ~ 09 35
L11~L12 07 ~ 17 54
ON 00:00
Time 2 L12~L9 13 ~ 23 49
OFF 00:00
18
2.6 Check the operating status of the unit
In the main interface, press to enter the settings interface, press to enter the unit operation
status interface, press to flip the page to check the operating status of the unit.
function settings interface. In this interface, you can adjust the time, date, language, screen time, and
remote control mute as required.
DATE Language
09 / 06 / 2023 06 : 26 English
SLIENT
General Factory
Status User param. Error 23-06-09 06 E21 Display and PCB communication error
23-06-09 06 PC High/low ambient temp protection
23-06-09 19 E21 Display and PCB communication error
General Factory
19
2.10 Start eheat
In the main interface, press to enter the settings interface, long press ,and press to start
eheat. At this point, icon will appear on the main interface.
Confirm Cancel
General Factory
Confirm Cancel
General Factory
20
V .Maintenance and repair
1.Note
1.1 Check whether the exhaust equipment is normal.
1.2 Keep the unit environment dry, clean and well ventilation. Clean the side air exchanger regularly(once
per1-2 months) in order to maintain high exchange efficiency and save energy.
1.3 Often check the performance of all the parts in the unit. Check whether the working pressure of the
refrigerant system is normal. Repair and change the parts timely if there's any abnormity.
1.4 Often check whether the wiring of the power and electric system is tightened and or electric parts
perform abnormally or smells. Repair and change the parts timely if there's any abnormity.
1.5 To check the operation of every process in the unit, the operation pressure of the refrigerant system.
You should maintain or change it in time.
1.6 To check the power supply and cable connection often, there is abnormal action or bad smell about
the electrical component. If there is, please maintain or change it in time.
1.7 This appliance is intended to be used by expert or trained users in shops, in light industry and on farms,
or for commercial use by lay persons. The instructions includes a warning to disconnect the appliance
from its power source during service and when replacing.
21
r01 IPM modular temperature too high Please contact with the dealer
r02 Compressor start fault Please contact with the dealer
r06 Compressor phase current protection Please contact with the dealer
r10 AC voltage too high or too low protection Please contact with the dealer
r11 DC bus voltage too high or too low protection Please contact with the dealer
r13 IPM modular fault Please contact with the dealer
r20 Compressor protection Please contact with the dealer
Check water system,water pump,water flow switch is normal
P01 Water flow swtich protection
or not
1.Check inlet water temperature is too high or not and if it is
block
2.Check whether fan blade is dirty,it will influence the heat
P02 High pressure protection
exchang efficiency of heat exchanger
3.Check if refrigerant is too much
4.Check whetehr water temperature is too high
1.Check whether the unit is leak of refrigerant
P06 Low pressure protection 2.After confirm unit is leak of refrigerant,repair and
vacuum,then fill the refrigerant accoring to nameplate
22
Wiring diagram
L12
L N
1.KRCHRW10ZA-PBEN2
VI. Wiring diagram
23
Water cycle pump Electric heating 3-way valve signal(S)
(220V/1PH/50Hz) power output signal output and power output(LN)
( 220V/1PH/50Hz ) ( 220V/1PH/50Hz ) (220V/1PH/50Hz)
Wiring diagram
L11
L12
S1
W V U
PFC1 PFC2
PFC_COM
2.KRCHRW16ZA-PBEN2
N GND L
L10 L9 L8 L7 L6 L5 L4 L3 L2 L1
L11
CN4
Cn9 Cn7
Cn12
L12
CN3
Cn13
Cn11 Cn8
Cn4
Cn18
24
On/off switch
EARTH
AC-N AC-L 1 2
A.C on/off switch Cn35 Cn36
CN5 Water flow switch
CN10A CN10 EE burner
CN6
F1 F2 CN7 CN9 CN8 Low pressure switch Cn33 Cn34
T T T T
Cn5 High pressure switch
Mode switch Cn31 Cn32
Cn21 Cn23 Cn25 Cn27 Cn29 Cn30
Cn16 Cn17 Cn10 Cn6 Cn20 Cn22 Cn24 Cn26 Cn28
T T T T
S1 L12 L11
1
Red
Blue
Red
Red
Red
Red
Blue
Blue
Blue
L N
1 2 3 4 5 6 7
Unit power input 123 45 67
(220V/1PH/50Hz) 3-way valve signal (1) Water cycle pump Electric heating
and power output(23) power output signal output
(220V/1PH/50Hz) (220V/1PH/50Hz) (220V/1PH/50Hz)
VII.Precautions for flammable refrigerants
1. Transport of equipment containing flammable refrigerants
Compliance with the transportregulations
2. Marking of equipment using signs
Compliance with local regulations
3. Disposal of equipment using flammable refrigerants
Compliance with national regulations
4. Storage of equipment/appliances
The storage of equipment should be in accordance with the manufacturer’s instructions.
5. Storage of packed (unsold) equipment
Storage package protection should be constructed such that mechanical damage to the
equipment inside the package will not cause a leak of the refrigerant charge.
The maximum number of pieces of equipment permitted to be stored together will be
determined by local regulations.
6. Information on servicing
1) 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 minimised. For repair to the refrigerating
system, the following precautions shall be complied with prior to conducting work on the
system.
2) Work procedure
Work shall be undertaken under a controlled procedure so as to minimise the risk of a
flammable gas or vapour being present while the work is being performed.
3) 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.
4) 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.
5) 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.
25
6) 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. 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.
7) 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.
8) 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
9) 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. .
26
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.
7. Repairs to sealed components
1) 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 isabsolutely
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.
2) 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.
8. 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.
9. 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.
10. 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.
27
11. Leak detection methods
The following leak detection methods are deemed acceptable for systems containing
flammable refrigerants.
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.
12. 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. .
28
13. 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 minimise 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.
14. 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 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 cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with 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. ;
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15. Labelling
Equipment shall be labelled 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.
16. 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 is available. All cylinders to be used are designated for the
recovered refrigerant and labelled 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..
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