Manual Sencor SDH 1020 (page 10 of 11) (English)

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- 10 - 12/2020

When it is absolutely necessary to have live power supply going into the appliance while

servicing the appliance, it is necessary to install apermanent device in the most critical

point to detect leakage so that adangerous situation is averted.

Special attention must be paid to ensuring that as aresult of the work performed on

electrical components the cover is not changed to the extent of affecting the level of

protection. This must also include damage to cables, excessive number of connections

and terminals not performed according to original specifications, damaged gaskets,

incorrect configuration of plugs, etc.

It is necessary to ensure that the appliance is mounted safely.

It is necessary to ensure that gaskets or sealing materials are not damaged in such

away that they no longer serve to prevent the entry of aflammable atmosphere. Spare

parts must conform to the manufacturer‘sspecifications.

NOTE The use of silicone gaskets and seals may suppress the efficiency of certain

type of leak detection devices. Intrinsically safe components do not need to be

disconnected prior to being worked on.

3. Repairs of intrinsically safe components

No permanently inductive or capacitative load may be placed on the circuit without it

being ensured that thereby the permitted voltage and current for the used appliance

is not exceeded.

Intrinsically safe components are the only type on which it is possible to work in

aflammable environment even while under live current. Testing equipment must have

correct specifications.

Parts are replaced using only parts specified by the manufacturer. Different parts could

result in ignition of refrigerant upon leakage into the environment.

4. Cabling

Check that cabling is not exposed to wear and tear, corrosion, excessive pressure,

vibrations, sharp edges or any other negative environmental effects. This check must

also take into consideration the effects of ageing and permanent vibrations from

sources such as compressors or fans.

5. Detection of ammable refrigerants

Under no circumstances may potential sources of ignition be used for locating or

detecting refrigerant leaks.

Ahalogen burner (or any other type of detector utilising an open flame) must not be

used.

6. Leak detection methods

The following leak detection methods are considered acceptable for systems

containing flammable refrigerants.

For the detection of flammable refrigerants, electronic leak detectors must be used,

however their sensitivity may not be appropriate or they may require recalibration.

(Detection equipment must be calibrated in an area without any refrigerant present).

It is important to ensure that the detector is not apotential ignition source and that

it is suitable for the used refrigerant. The leak detector must be set to apercentage of

LFL refrigerant and must be calibrated for the used refrigerant and the respective gas

percentage is confirmed (maximum 25 %).

Leak detection liquids are suitable for use on most refrigerants, however, detergents

containing chlorine must be excluded since chlorine may react with the refrigerant

and corrode copper pipes.

In the event of asuspected leak, all open flames must be removed/extinguished.

In the event that the refrigerant leak is found and requires hard soldering, then all

the refrigerant must be drained from the system or separated (by closing avalve) in

apart of the system distant from the leak. The system must then be cleaned out using

oxygen-free nitrogen (OFN) both before as well as after the hard soldering process.

7. Collection and pump discharge

In the event that the cooling circuit is breached due to repairs – or for any other reason

– conventional procedures must be followed. It is, however, important to adhere to the

best method due to flammability. It is necessary to adhere to the following procedure:

■ collect the refrigerant;

■ clean out the circuit using inert gas;

■ pump out;

■ again clean out using inert gas;

■ open the circuit by cutting or hard soldering.

The contents of the circuit must be collected into correct collection cylinders. The

system must be „flooded“ with OFN (oxygen-free nitrogen) for the unit to remain

safe. It may be necessary to repeat the procedure several times. For this task, neither

compressed air nor oxygen may be used.

Flooding may be achieved by disrupting the vacuum in the system with the use of

OFN, and by continued filling until the operating pressure is achieved, then venting

into the atmosphere and finally lowering to avacuum. This process must be repeated if

refrigerant still remains in the system. When the last OFN cartridge is used, the system

must be ventilated to atmospheric pressure to enable work to be performed. This

activity is absolutely necessary if hard soldering is to be performed on the pipes.

It is necessary to ensure that the vacuum pump outlets are not nearby to any ignition

source, and ventilation must be provided.

8. Filling procedure

Apart from conventional filling procedures, also the following requirements must be

adhered to.

– It is necessary to ensure that no contamination by various refrigerants occurs when

the filling device is used. Hoses or pipes must be as short as possible to minimise the

amount of refrigerant contained inside of them.

– Cylinders must be held vertically.

– It is important to ensure that the cooling system is grounded prior to being filled

with refrigerant.

– When filling is complete, the system must be marked with alabel (if it does not have

one already).

– It is necessary to pay extreme care to ensure that the cooling system is not overfilled.

Apressure test using OFN must be performed before refilling the system. In the case

of a leak, the system must be tested after being refilled but also before being put

into operation. Averification test must be performed before leaving the installation

location.

9. Taking out of operation

Prior to performing this procedure it is essential that the technician fully acquaints

him/herself with the device and all its particulars. Correct practice of safely collecting

all refrigerant is recommended. Prior to performing this activity, oil and refrigerant

samples must be taken if an analysis is required prior to using the using the

regenerated refrigerant for the first time. It is essential that prior to starting this activity

that electricity is available.

a) Acquainting one‘sself with the device and its activity.

b) Electrical disconnection of the system.

c) Prior to starting the procedure, ensure that:

■ if required, mechanical device for handling the cylinder with refrigerant is available;

■ all personal protective devices are available and used correctly;

■ the collection process is constantly under the supervision of acompetent person;

■ the collection device and cylinders comply with respective norms.

d) Pump out the cooling system if possible.

e) If achieving vacuum is not possible, collection pipes are created to enable the

collection of refrigerant from various parts of the system.

f) Ensure that the cylinder is placed on the scale before the collection of refrigerant is

started.

g) The collection device is turned on and runs according to the

manufacturer‘sinstructions.

h) Cylinders are not overfilled. (No more than 80 % of liquid content capacity).

i) The maximum operating pressure of the cylinder is not exceeded, even temporarily.

j) When the cylinders are properly filled up and the procedure is complete, ensure that

the cylinders and devices are immediately removed from the installation location

and that all the separation valves on the device are closed.

k) The collected refrigerant must not be filled into adifferent cooling system until it is

cleaned and checked.

10. Marking with alabel

The appliance must be marked with a label indicating that it has been put out of

operation and is without refrigerant. The label must be dated and signed. It is ensured

that there are labels on the appliance indicating that it contains flammable refrigerant.

11. Collection

When the refrigerant is collected from the system, either due to servicing or when it is

put out of operation, it is recommended to adhere to proper practice and safely collect

all the refrigerant.

When the refrigerant is transferred into the cylinders, it is necessary to ensure that

appropriate cylinders for collecting refrigerant are used.

It is necessary to ensure that there is a sufficient number of cylinders available to

contain the complete contents of the system. All the cylinders that are to be used must

be intended for collecting refrigerant and be marked with alabel for this refrigerant

(i.e. special cylinders for collecting refrigerant). The cylinders must be complete with

asafety valve and associated closing valves in good working condition. The empty

collection cylinders are pumped empty and if possible cooled prior to collecting

refrigerant.

The collection device must be in good operating condition with a set of manuals

relating to the device, which are on hand and it must be suitable for collecting

flammable refrigerants. Apart from this, aset of calibrated scales in good operating

condition must also be available. Hoses must be complete with couplers without

seepage and in good condition. Prior to using the collection device, check that it is in

satisfactory operating condition, has been properly maintained and all the associated

electrical components are sealed to prevent ignition in the event of refrigerant being

released. If in any doubt, consult the manufacturer.

The collected refrigerant must be returned to the refrigerant supplier in the correct

collection cylinder and with arespectively arranged waste transport letter. Refrigerants

are not to be mixed in the collection units and especially not in the cylinders.

In the event that compressors or compressor oils are to be collected, ensure that they

are pumped out to an acceptable level in order to ensure that flammable refrigerant

does not remain in the lubricant. The pump discharge process must be performed

before the compressor is returned to the supplier. To speed up this process, only

electrically heated compressor elements may be used. When the oil is drained from

the system, it must be disposed of safely.

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Sencor SDH 1020 Manual

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