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6
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 be-
ing worked upon priot to any removal of sealed covers,
etc. If it is absolutely necessary to have an electrical
supply to equipment during servicing, then a perma-
nently operating form of leak detection shall be located
at the most critical point to warn of a potentially hazar-
dous 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 ca-
bles, excessive number of connections, terminals not
made to original specification, damage to seals, inco-
rrect fitting of glands, etc.
Ensure that apparatus is mounted securely.
Ensure that seals or sealing materials have not de-
graded such that they no longer serve the purpose of
preventing the ingress of flammable atmospheres. Re-
placement parts shall be in accordance with the manu-
facturer’s specifications.
NOTE: The use of silicon sealant may inhibit the effec-
tiveness of some types of leak detection equipment.
Intrinsically safe components do not have to be isola-
ted 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 com-
ponents onlu with parts specified by the manufacturer.
Other parts may result in the ignition of refrigerant in
the atmosphere form a leak.
9. Cabling
Check that cabling will not be subject to wear, co-
rrosion, excessive pressure, vibration, sharp edges or
any other adverse environmental effects. The check
shall also take into account the effects of aging or con-
tinual 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.
11. Lead detection methods
The following leak detection methods are deemed
acceptable for systems containing flammable refrige-
rants.
Electronic leak detectors shall be used to detect flam-
mable refrigerants, but the sensitivity may not be ade-
quate, or may need re-calibration. (Detection equip-
ment 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 appropiate percentage
of gas (25% maximum) is confirmed. Lead detection
fluids are suitable for use with most refrigerants but
the use of detergents containing chlorine shall be
avoided ad the chlorine may react with the refrigerant
and corrode the copper pipe-work. If a leak is suspec-
ted, all naked flames shall be removed/extinguished.
If a leakage of refrigerat is found which requires bra-
zing, 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 proce-
dures shall be used. However, it is important that best
practice is followed since flammability is a conside-
ration. 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 co-
rrect 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 achived, then venting to atmos-
phere, and finally pulling down to a vacuum. This pro-
cess 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 pres-
sure 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 outler for the vacuum pump is not
close to any ignition sources and there is ventilation
available.
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. Ho-
ses or lines shall be as short as possible to minimise
the amount of refrigerant contained in them.
Cylinders shall be kept upright.
Warnings (for using R-290 refrigerant only)
7


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