Hydrocarbon Refrigerants Training Refrigeration Service Presented by Refrigeration Service Engineers Society

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

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.

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

Why use Flammable Refrigerants? EPA Approves Use of HCs through the Significant New Alternatives Policy (SNAP) The Montreal Protocol Reduces CFC and HCFC Production Worldwide concerns about the ozone layer stemming from the Montreal Protocol and global warming concerns have led to the use of alternative flammable refrigerants.   CFCs and HCFC have high Ozone Depleting Potential (ODP) and/or high Global Warming Potentials. Natural Refrigerants like R-290 (Propane) have “0” ODP and a very low GWP of less than 3. Low Global Warming Potentials (GWP) Less than 3 Zero Ozone Depleting Potential (ODP)

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

HCs already used worldwide; The availability of the HC refrigerants in the United States of America (USA) is limited as is the access to vacuum pumps and recovery machines approved for the flammable refrigerants. Check with your local supplier. 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

Applications and Limits R-290-Propane R-600a-Isobutane R-441A-Flammable blend 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

Understanding HC Regulations Common Regulator Agencies EPA NFPA CSA EC ISO IEC ASHRAE UL Ultimately the technician is responsible for knowing the local regulations The Environmental Protection Agency (EPA), National Fire Protection Association (NFPA), Canadian Standards Association (CSA), European Community (EC), International Organization for Standardization (ISO), International Electrotechnical Commission (IEC), ASHRAE and Underwriters Laboratories (UL) establish regulations and set standards for the use and manufacturer of equipment using flammable refrigerants worldwide along with many individual jurisdictions. It is the responsibility of the technicians working on these flammable refrigerant systems to be aware of the local restrictions along with the global requirements.

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

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).

Unauthorized Refrigerants Before servicing equipment look for MATCHING refrigerants 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 If the owner does not want to replace the system or appliance, the owner may wish to contact the technician who changed the refrigerant to correct the problem. In any event, it is strongly recommended no further work be done on the system. Operating or servicing a system that contains an unauthorized flammable refrigerant can lead to risk of fire, excess system pressure, damage to the compressor, and/or an explosion.

EPA Further Information Statement Only technicians specifically trained in handling flammable refrigerants should service refrigerators and freezers containing these refrigerants. Technicians should gain an understanding of minimizing the risk of fire and the steps to use flammable refrigerants safely. 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.

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

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

Further Labeling Requirements Machine/Compressor Labeling Requirements "DANGER- Risk of Fire or Explosion. Flammable Refrigerant Used. To Be Repaired Only By Trained Service Personnel. Do Not Puncture Refrigerant Tubing." “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

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

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

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

Further Labeling Requirements Service Access &Tubing Painting 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

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

ASHRAE Refrigerant Ratings   SAFETY GROUP Increasing Flammability Higher Flammability A3 B3 Lower Flammability A2 B2 A2L* B2L* No Flame Propagation A1 B1 Lower Toxicity Higher Toxicity Increasing Toxicity A2L and B2L are lower flammability refrigerants See ASHRAE Standard 34 for full Details Refrigerant Safety Group Classification ASHRAE 34 has adopted a A2L classification for R-1234yf and R-1234ze and others to distinguish their lower flammability compared to R-152a which has an A2 classification.

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

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

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

Explosive (Flame) Limits 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% Lower Explosive Limit (LEL): The lowest concentration (percentage) of a gas or a vapor in air capable of producing a flash of fire in presence of an ignition source (arc, flame, heat). At a concentration in air below the LEL there is not enough fuel to ignite. Upper Explosive Limit (UEL): Highest concentration (percentage) of a gas or a vapor in air capable of producing a flash of fire in presence of an ignition source (arc, flame, heat). Concentration higher than UFL or UEL are "too rich" to burn. Currently there is no field equipment for determining the ignition concentration percentages, therefore ignition sources must be avoided at all times.

MSDS Material Safety Data Sheets Required to be availability to all employees Also required to be available to local Fire Departments Mention OSHA requiring the MSDS sheets CHECK WITH THE AUTHORITY HAVING JURISDICATION (AHJ) FOR LOCAL REGULATIONS

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.

Check the local Authority Having Jurisdiction 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

Check the local Authority Having Jurisdiction 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

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.

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

Confined Space In ventilating the area it needs to be understood that the work area should be clear around the entire piece of equipment. There should be approximately 10 foot of clear area so any refrigerant that may have leaked can disperse adequately to make sure the LEL and UEL are not reached. 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 alll sources of ignition

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

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

Always Use Approval Components When Replacing Refrigerant Cycle Components of system similar to regular systems. As all systems are new equipment the engineering of all of the components is complete. Follow the MFG requirements Generally Same Components Used Condenser Evaporator Metering Device Lubricants Gaskets, Seals, O-rings Always Use Approval Components When Replacing

Servicing Procedures When leak testing only use non-ignitable type detectors such as UV additive, Liquid detection solution, electronic leak detectors for flammable gasses or ultra sonic leak detectors. 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

Servicing Procedures When leak testing only use non-ignitable type detectors such as UV additive, Liquid detection solution, electronic leak detectors for flammable gasses or ultra sonic leak detectors. Use standard evacuation and pressure testing procedures Use standard recovery methods Use standard charging methods (weigh in)