Hydrocarbon Refrigerants Training Presented by Refrigeration Service Engineers Society

1. Hydrocarbon Refrigerants Training Presented by Refrigeration Service Engineers Society

2. Topics to Cover • Uses of Hydrocarbons as Refrigerants • HC Regulations and Standards • Refrigerant Properties and Safety • The Refrigerant Cycle • System Components • Servicing Procedures

3. History of Hydrocarbons as Refrigerants • 1900’s - HCs used in infancy of the refrigeration industry; • 1930’s - CFCs developed (non-flammable), HC use reduces; • 1970’s - Ozone depletions by CFCs discovered; • 1980 - HFC and HC start to replace CFCs; • 2000 - Launch of HC ice cream cabinets; • 2005 - Over 50,000 HC cabinets in use in Europe.

4. Must follow recommended safety practices when working with these approved flammable refrigerants R-600a-Isobutane R-441A-Flammable blend R-290-Propane

5. Why use Flammable Refrigerants? EPA Approves Use of HCs through the Significant New Alternatives Policy (SNAP) The Montreal Protocol Reduces CFC and HCFC Production Zero Ozone Depleting Potential (ODP) Low Global Warming Potentials (GWP) Less than 3

6. Technician servicing procedures need to change with the introduction of flammable refrigerants

7. HCs already used worldwide; • Over 80 million domestic refrigerators in use worldwide; • HCs also used in commercial appliances-bottle coolers, chest freezers, commercial refrigerators; • Also used in split system and portable AC systems in use, however not yet approved in USA

8. Applications and Limits • R-600a and R-441A – New Household Refrigerators and Refrigerator/Freezers-57 grams (2.0 ounces) Equipment Constructed following UL250-Current Edition • R-290 – New Retail Food Refrigerators Freezers-150 grams (5.3 ounces) Equipment Constructed following UL471-Current Edition R-600a-Isobutane R-441A-Flammable blend R-290-Propane

9. Understanding HC Regulations Common Regulator Agencies EPA NFPA CSA EC ISO IEC ASHRAE UL Ultimately the technician is responsible for knowing the local regulations

10. Keeping Up with Regulations http://www.epa.gov/ozone/snap/regulations.html

11. Unauthorized Applications • HCs allowed for use in only new systems under the SNAP approved program; • NO RETROFITTING allowed in the USA (retrofitting is allowed in other countries).

12. Unauthorized Refrigerants • Before servicing equipment look for MATCHINGrefrigerants equipment labels (the unit and compressor) • If the compressor and refrigerant match then it should be acceptable to service the system • If the labels do not match assume the system has been retrofitted and • STOP work on this system immediately • Contact the owner • Inform owner of system violations • Refuse to service • Offer to replace system with approved systems

13. EPA Further Information Statement • Be an qualified refrigeration technician; • Be familiar with the safety precautions for flammable refrigerants; • Be familiar with the information provided by other sources, such as the manufacturers of the system equipment, component manufacturers, and refrigerant suppliers.

14. Identification Labeling • Compressors and systems will have labels identifying the type of flammable refrigerant. • UL 250 and 471 require labeling as part of the SNAP approval

15. Further Labeling Requirements "DANGER- Risk of Fire or Explosion. Flammable Refrigerant Used. Do Not Use Mechanical Devices To Defrost Refrigerator. Do Not Puncture Refrigerant Tubing." Evaporator Labeling Requirements Labeling attach on or near any evaporators

16. Further Labeling Requirements "DANGER- Risk of Fire or Explosion. Flammable Refrigerant Used. To Be Repaired Only By Trained Service Personnel. Do Not Puncture Refrigerant Tubing." Machine/Compressor Labeling Requirements “CAUTION- Risk of Fire or Explosion. Flammable Refrigerant Used. Consult Repair Manual/Owner’s Guide Before Attempting To Service This Product. All Safety Precautions Must be Followed." Attach near the machine/compressor compartment

17. Further Labeling Requirements “CAUTION- Risk of Fire or Explosion. Dispose of Properly In Accordance With Federal Or Local Regulations. Flammable Refrigerant Used." Exterior Labeling Requirements Attach on the exterior of the refrigerator

18. Further Labeling Requirements “CAUTION- Risk of Fire or Explosion Due To Puncture Of Refrigerant Tubing; Follow Handling Instructions Carefully. Flammable Refrigerant Used." Near Refrigerant Tubing Labeling Requirements Attach near any and all exposed refrigerant tubing

19. Further Labeling Requirements All of these markings shall be in letters NO LESS than 6.4 mm (1/4”) high. Letter Sizing “CAUTION- Risk of Fire or Explosion Due To Puncture Of Refrigerant Tubing; Follow Handling Instructions Carefully. Flammable Refrigerant Used."

20. Further Labeling Requirements • The refrigerator or freezer must have red, Pantone® Matching System (PMS) #185 marked pipes, and other devices through which the refrigerant is serviced, such as any service port; • This color must be present at all service ports and where service puncturing or otherwise creating an opening from the refrigerant circuit to the atmosphere might be expected (e.g., process tubes). • The color mark must extend at least 2.5 centimeters (1”) from the compressor and must be replaced if removed, repaint if necessary Service Access &Tubing Painting

21. Liability • Working with any refrigerant carries a certain liability • Check with your insurance carrier before with HC refrigerants

22. ASHRAE Refrigerant Ratings

23. Flammability and Ignition Sudden release of refrigerant can result in proper concentrations for: Flash Fire • Sustained Fire • Explosion

24. Ignition Sources • Temperatures greater than 460°C or 860°F; • Flame from a match; • Torch including halide leak detectors.

25. Ignition Sources Electric sparks from: • Light and Socket Switches • Unsealed Relays and Overloads • On Off switches • Contactors • Pressure Switches • Defrost Timers • Thermostats • Vacuum Pump Switches • Electronic Leak Detectors

26. Upper and Lower Explosive (Flame) Limits LEL -Lower Explosive Limits R290-2.1% R600a-1.8% UEL-Upper Explosive Limit R-290-9.5% R600a-8.5%

27. MSDS Material Safety Data Sheets • Required to be availability to all employees • Also required to be available to local Fire Departments CHECK WITH THE AUTHORITY HAVING JURISDICATION (AHJ) FOR LOCAL REGULATIONS

28. Cylinder Safety • Never store or expose to temperatures above 125°F (52°C); • Never apply open flame; • Never heat with water or heat blanket above 110°F (43°C); • Never refill single trip cylinders; • Never exceed refillable limits; • Never remove labels; • Never smoke near flammable refrigerant cylinders.

29. Cylinder Transport • Department of Transportation Division 2.1 Classification-Flammable Gas • Transport in upright position • Label vehicle as carrying flammable gas • Inventory vehicle contents • Some jurisdictions require • Storage in explosive proof cabinets • Venting of cabinet to exterior Check the local Authority Having Jurisdiction

30. Cylinder Storage • Store in a locked cage; • Store at ground level; • Store away from air intakes; • Keep ignition sources away from area; • Limit access; • Install combustible gas monitors. Check the local Authority Having Jurisdiction

31. Brazing Requirements • Recover refrigerant; • Ventilate the area; • Wear personal protection equipment (PPE); • Check brazing equipment for leaks and proper pressure settings; • Purge with inert gas while brazing (Nitrogen); • Only trained and qualified personal should be brazing.

32. Rated Equipment • Flammable gas leak detectors and monitors; • Personal safety monitors.

33. Confined Space All refrigerants in confined space have inherent dangers. Remember to: • Use a combustible gas detector and /or monitor • Ventilate area and clear the area of any potential LEL or UE; • Eliminate alllsources of ignition

34. Refrigerant Cycle Basic cycle is the same as it is for CFCs, HCFCs, & HFCs

35. Refrigerant Cycle What is different • Additional safety requirements • Monitor area and prevent possible ignition sources • Ventilate area when required • Using tubing cutting to remove refrigeration components – do not use a torch

36. Refrigerant Cycle Generally Same Components Used Condenser Evaporator Metering Device Lubricants Gaskets, Seals, O-rings Always Use Approval Components When Replacing

37. Servicing Procedures • Use only spark proof equipment-like a brass screwdriver, • Use non-ignitable type detectors such as UV additive, liquid detection solution, electronic leak detectors for flammable gasses or ultra sonic leak detectors

38. Servicing Procedures • Use standard evacuation and pressure testing procedures • Use standard recovery methods • Use standard charging methods (weigh in)