Training Course

Hydrocarbon Refrigerants (HC)

Refrigeration & Air- Conditioning
Installation and commissioning
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Ozone Depletion

CFCs (e.g. R12) deplete

ozone and are being
phased out
HCFCs (e.g. R22)
Climate Change

HFCs (e.g. R134a) –

CFC & HCFC
replacements -
are potent
greenhouse gases
Hydrocarbon Refrigerant Issues
HC Pros and Cons
☺ Very good refrigerants, good capacity – efficiency
C ☺ Very low environmental impact
☺ Compatible with copper and mineral oils
H ☺ Cleanness procedures similar used with R12/R22
☺ Service procedures remain largely the same except safety
considerations
 Flammable / Explosive
 Availability in refrigeration quality min. 99,5...%
 Systems must be designed so that leak is no danger
 Appropriate equipment for servicing with HCs
 Service technicians must be trained for safe handling
ODP and GWP
GWP of HCFC R22
HCFC
R22
GWP 1

GWP 1800

4,5 Kg of R22 are equal to 8100 kg of CO2

Medium-class car exposes approx 0.200 Kg/Km CO2
You can drive 40500 Km (1 x round the Earth) for the same
CO2 Emission of 4,5 Kg HCFC-R22
e.g. HFC R-404A only 2 kg
Hydrocarbon Refrigerant Issues

Many hydrocarbon gases have successfully been used as

refrigerants in industrial, commercial and domestic
applications

Examples:
R1270, Propylene, C3H6
R290 , Propane C3H8
R600a, Isobutane, C4H10
Blends of the above Gases
Hydrocarbon Refrigerant Issues
Commonly used HC Refrigerants

and in contrast

HCFC R22 Chlorodifluoromethane -40,8 °C

HFC R404A R125/R143a/134a -46,4 °C
HC R290 Air-Conditioner EER

Generally 10 to 15 % higher Energy Efficiency Ratio (EER)

than R22
 Efficiency Test
Field trial, Sydney / Brisbane, 2000 / 2001
Energy consumption, kWh / 24 h

Temperature difference (ambient – cabinet) K

Refrigerants and lubricants
Why do we need lubricants:
• lubrication of the compressor
• Sealing and cooling for the oil-filled types
Table: Lubricants and indication of suitability for refrigerant
Refrigerant Mineral Alkyl- MO + Polyoleste Polyalpha Polyalkelene-
type Oil (MO) benzene AB r (POE) olelfin glycol (PAG)
(AB)
CFCs & HCFCs ✓ ✓ ✓ (✓) (✓) x
HCFC Blends (✓) ✓ ✓ (✓) x x
HFCs and HFC ✓ (✓) ✓ ✓ ✓ (✓)
Blends
Hydrocarbons ✓ (✓) (✓) ✓ ✓ (✓)
Ammonia ✓ (✓) (✓) x ✓ (✓)
(NH3)
CO2 (✓) (✓) x ✓ ✓ ✓

✓ – Good suitability (✓) – applicable with limitations x – not suitable

Lubricants for use with hydrocarbon refrigerants

➢ Most common refrigeration oils are compatible with HCs

• But: high solubility with certain mineral and POE oils.
• Various lubricant manufacturers provide refrigeration oils
specifically for HC refrigerants.
➢ Polyolester (POE) oils are specified as suitable for hydrocarbons
• But: higher viscosity class demand for hydrocarbon raw
materials in comparison with those used for HFCs.

Oil Type Compatibility Solubility

Mineral Oil (MO) Good High
Alkyl benzene (AB) Good Medium
Polyol Ester (POE) Good High
Polyol alpha olefin (PAO) Good High
Poly alkyl glycol (PAG) Good Medium
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Ease of application of natural refrigerants

Refrigeration

Storage and food

Domestic Retail
processing

Condensing Condensing
Fridge/
Integrals units Centralised Integrals units Centralised
freezers
(cabinets) (coldstores)

Direct Direct
Chillers Chillers
distributed distributed

Air conditioning

Residential Commercial

Self- Non-ducted Non-ducted

Ducted split Chillers Central split Multisplit Rooftop
contained single split single splits
Potential application of HC application

Viable if obstructive
Viable currently/in standards are remedied
short-term

system and

f n application
characteristics

NOTE: Viability
Not viable due to cost, proportions are
(Often, gap can be closed if
safety or performance approximate; they will
alternatives system concepts
limitations always be subject to
are used, e.g., chiller instead engineering
of piped refrigerant) interpretation
Viable application in small air conditioners

HCs

HCs HCs
Air conditioners – factory sealed

➢ De’Longhi
- Portable type air conditioners
➢ Safety aspects
- Designed to EN 60335-2-40
- Charge size up to 400 g of R290
➢ Cost of R290 systems same as HFC
products
➢ Energy consumption
- R290 gives 5-10% higher efficiency
than HFC options
Air conditioners – split type

➢ Several manufacturers in
Europe, China, India, Australia
primarily using R290
➢ Charge sizes up to 1 kg/7 kW
cooling capacity
― Very high efficiency
➢ Reversible systems available
➢ Major shift to R290 underway
in China
― Availability will improve over
time
Air conditioners – split type

GREE products
• Several models developed
• Split, window, portable
• Reversible and cooling only
• Products have safety system
integrated to reduce leak amount
• Lower cost than equivalent R22,
R410A models

Max noise
Capacity EER Charge Dimensions
ID/OD
(kW) (W/W) (g) (mm)
(dB)
Indoor
2.7 3.55 265 38/52
830×284×205
Outdoor
3.5 3.52 330 41/52
760×257×541
Air conditioners – split type

MIDEA products
• Currently several sizes developed
• Most reversible
• Other products developed
• Safety systems under development

Indoor Outdoor Cooling Heating R290

Model EER COP
unit (mm) unit (mm) capacity capacity charge
KFR-
850 × 275 780 × 540
26GW/N7 2.6 kW 3.4 2.8 kW 3.6 290 g
× 160 × 250
Y-Y(C4)
KFR-
900 × 285 780 × 540
35GW/N7 3.5 kW 3.4 3.7 kW 3.6 350 g
× 160 × 250
Y-Y(C4)
Air conditioners – split type

GODREJ products
• Currently two sizes developed
• Each has four models, corresponding to
different Indian efficiency star rating categories
• Data for “five star” products

Model Name R290-12K R290-18K

Operating Mode Cooling Cooling
Cooling Capacity 3400 W 4900 W
Rated Power Input 914 W 1318 W
High efficiency
Rated Input Current 4A 6A
Very low specific refrigerant
EER 3.72 3.72
charge (<80 g/kW)
Refrigerant R 290 R 290
Also includes leak safety
Refrigerant Charge 0.290 kg 0.340 kg
mechanism to leak safe
Ducted with HCs

➢ AICOOL, Indonesia
― Rooftop ducted and ducted split
systems developed to use R290
➢ Safety aspects
― Designed to EN 378; up to 2.5 kg of
R290 per refrigerant circuit
― Cost slightly higher than R22 systems
Chillers

HCs

CO2

NH3
HC chillers
▪ Benson
―Air-cooled (scroll, screw)
―Water-cooled (scroll, screw)
▪ Safety aspects
―Designed to AS/NZS 1677
―Charge size up to 25 kg of R290 (per circuit)
▪ Cost of R290 systems not more than
HFC
▪ R290 gives higher efficiency than HFC
Viable application in domestic refrigerators
Domestic refrigerators

➢ More than 60% of new

domestic fridge/freezers on HCs
(R600a)
– Total production > 700 m
– All European manufacturers using
R600a in majority of production
– Large proportion from Korea,
Japan, China
– Introduction in South America and
now North America
➢ Charge size up to 150g
➢ Highest efficiency models
Domestic refrigeration refrigerant trends

Source: UNEP RTOC

Viable application in commercial refrigerat.
Plug-in chillers and freezers
➢ Many commercial cabinets
with R290, R1270, R600a
• End users report 5 – 15%
lower energy use
➢ Numerous manufacturers
within Europe, Japan,
Central America, Southern
Africa, China, SE Asia, etc
➢ Two general categories
• Movable type appliances
with charges up to 500 g
IEC 60335-2-89
• Fixed appliances charges up
to 1.5 kg
Plug-in catering

➢ Foster Refrigerator
• Commercial stand-alone cabinets
➢ Safety aspects
• Designed to EN 60335-2-89
• Charge size up to 500 g of R290
➢ Cost of R290 systems same as HFC products
➢ Energy consumption
• R290 gives 15% lower kWh/24h than R134a/R404A
option
Plug-in catering
➢ Gram refrigeration
―Commercial stand-alone cabinets; R290 is standard
➢ Safety aspects
―Designed to EN 60335-2-89
―Charge size up to 500 g of R290 and R600a
➢ Cost of R290 systems same as HFC products
➢ R290 has lower energy consumption than HFC options
Other appliances

➢ Professional food and

drinks preparation
equipment
• Shake sundae machine
• Post-mix beverage
machine
• Juice dispenser
➢ Ice makers
➢ Cold storage
• Meat freezers and chilled
produce rooms
Plug-in chillers and freezers – efficiency

Examples of data for chiller &

freezer cabinets R134a

Source:
Pedersen, R744: R600a:
2008 -11.7 % -27,7 %

Source: King et al, 2011 Source: van Gerwen et al, 2008

Viable application in condensing units

HCs
Viable application in larger coldstores

HCs
Centralised supermarket systems
➢ Options for different systems

Conventional Alternative
Direct
Indirect Indirect
expansion, Trans- Distribute
(liquid (phase-
Type multi- Cascade critical d water
sec)/ change sec)/
compressor booster cooled
cascade cascade
pack
Lower GWP HC-290, HC-290,
HC-290, HC-
Mediu R404A, R507A, HFC, (HC- HC-1270, HC-1270,
1270, R-717, R744
m temp R407F 290, HC- R-717, R-717,
CO2
1270) brine brine
Low R404A, R507A, HC-290,
R744 CO2 CO2 R744
temp R407F HC-1270
BASIC REFRIGERATION CYCLE
Indirect/cascade

R290,
R1270,
R717

Glycol/
brine
CO2

Source: Emerson
Examples of indirect systems using HCs
Distributed water cooled HCs

▪ Adopted by certain supermarkets

―All new installations to use HCs
▪ Safety aspects
―Designed to EN 378
―Charge size of cabinets up to 500g
―Charge size of chiller ~ 5 kg per circuit
▪ System based on chilled water-
circuit, removing heat from water-
cooled condensing units in display
cases
Common HCs
CFCs;
HCFCs, HFCs HCs

R600a (Iso-butane)

R134a
HC blend of R600a and R290
R12

R290 (Propane)
R404A R22
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
General – safety rules for natural refrigerants

Main topics within RAC safety standards:

➢ Classification of refrigerants, occupancy, systems
➢ Refrigerant charge size limits
➢ Safe design and testing of components and pipes
➢ Safe design and testing of assemblies (systems)
➢ Electrical safety, sources of ignition
➢ Installation areas, positioning, pipework, mechanical
ventilation, gas detection
➢ Instructions, manuals, data plates
➢ Refrigerant handling
Classification of refrigerants:
flammability and toxicity

Refrigerants are classified according to their flammability and

toxicity.

The safety classifications are defined in ISO817:2014 and are also

used in EN378-1:2016

After years of standards revisions A2L safety classification are

included now in EN 378:2016, ISO 817:2014, ISO 5149:2014 and
ANSI/ASHRAE 34 standards (American Society of Heating,
Refrigeration and Air Conditioning Engineers).
SAFETY CLASSIFICATION

AB 123
HEAT GmbH – Habitat, Energy, Application & Technology 61
HEAT GmbH – Habitat, Energy, Application & Technology 62
SAFETY CLASSIFICATION
1 No flame propagation

2L Lower flammability

2 flammability

3 Higher flammability
SAFETY CLASSIFICATION

AB 123
HEAT GmbH – Habitat, Energy, Application & Technology 64
Classification of refrigerants

A “higher”
classification (i.e.
toxicity class B instead
of class A, and
flammability class 3
instead of class 1)
means:
➢ the refrigerating
system has more
demanding design
requirements,
➢ in order to handle
the higher risk
represented by
the refrigerant.

Note: In contrast to the previous version of EN378:2008/2012, A2L safety classification is included with the revisions
of EN378:2012, ANSI/ASHRAE 34, ISO817:2014 and ISO5149:2014.
Flammability Classification ASHRAE and for EN 378
and ISO 817: flammability rating
Classification of refrigerants: practical concentration limit

There is an additional measure for the application of refrigerants, the

Practical Limit (PL). This is, in principle, the lowest “dangerous”
concentration of a refrigerant, with a safety factor applied.

PL concentration is used for simplified calculation to determine the

maximum acceptable amount of refrigerant in an occupied space.

The estimation of PL is based on the lowest of the following parameters:

1. Acute-toxicity exposure limit (ATEL), based on mortality and/or

cardiac sensitisation, and/or anaesthetic or central nervous system
(CNS) effects
2. Oxygen Deprivation Limit (ODL)
3. Lower flammability limit (LFL)
Practical limit for HC concentration

For HC refrigerants, 20% of the LFL represents the lowest

concentration of the 3 parameters mentioned before.

➢ This characteristic is used to determine the practical limit (PL).

➢ PL is expressed in terms of mass per unit volume.

Practical Autoignition
Safety limit d ATEL/ODL g LFL h temperature
Refrigerant number Chemical name Chemical formula class (kg/m3) (kg/m3) (kg/m3) (°C)
R290 Propane CH3CH2CH3 A3 0,008 0,09 0,038 470
R600a 2-methyl propane (isobutane) CH(CH3)3 A3 0,011 0,059 0,043 460
R717 Ammonia NH3 B2L 0,00035 0,00022 0,116 630
R744 Carbon dioxide CO2 A1 0,1 0,072 NF ND
R32 Difluoromethane (methylene fluoride) CH2F2 A2L 0,061 0,3 0,307 648
R22 Chlorodifluoromethane CHCIF2 A1 0,3 0,21 NF 635
NF signifies non-flammable / / ND signifies not determined (EN 378-1 / Table E.1)
Practical HC Limit

Note!
For safety reasons a practical limit
of 8 g/m³ of hydrocarbon
refrigerant should not be exceeded
in a closed space or room
Related standards and personal competency requirements
for HC and other refrigerants
Standard Title Guidance
(among others)

EN378-1:2017 Refrigerating systems and heat pumps – Safety Practical limit

and environmental requirements, Basic Maximum charge sizes
requirements, definitions, classification and
selection criteria
EN378-2:2017 Refrigerating systems and heat pumps – Safety Pressure test
and environmental requirements, Design, Flared joints tightening
construction, testing, marking and torques
documentation
EN378-3:2017 Refrigerating systems and heat pumps – Safety Location of outdoor units
and environmental requirements, Installation HC detectors
site and personal protection
EN378-4:2017 Refrigerating systems and heat pumps – Safety Repairs to HC systems
and environmental requirements, Operation, Competency of personnel
maintenance, repair and recovery working on HC systems
Related standards and personal competency requirements

Standard Title Guidance

IEC 60335-2-40 Particular requirements for safety of household Electrical safety
appliances, electric air conditioners, heat Inappropriate
pumps and dehumidifiers operation
EN13313 Refrigerating systems and heat pumps - Job competencies and
Competency of personnel core activities
EN 50110 Operation of electrical installations Job competency
EN ISO/IEC 17024 Conformity assessment - General requirements Competency of
for bodies certification bodies
operating certification of persons
ISO 13585-2012 Brazing competencies certification Examination criteria,
inspection procedures
and the area of
application for a
brazing competencies
test certificate
Safety rules for alternative refrigerants

Standard Equipment type Coverage

EN 378:2017-3 Commercial and

industrial Components, safety devices, system design,
location, charge size limits, refrigerant
Commercial and classification, installation site, maintenance
ISO 5149:2014-4 industrial

EN 60335-2-24 Domestic fridges and Marking, pressure testing, electrical

freezers

EN 60335-2-40 Factory built a/c and Marking, pressure testing, maintenance,

heat pumps electrical, charge limits

EN 60335-2-89 Factory built commercial Marking, pressure testing, electrical

fridges
Safety standards and charge sizes

Up to 500 g

2018-10
ATEX: introduction

ATEX (Abbreviation: ATmosphère Explosive)

is the name commonly given to the legal requirements for
controlling explosive atmospheres and the suitability of
equipment and protective systems used in them.

Guidance from EN 60079-10-1:2016:

Classification of hazardous areas
Generic types of RAC systems
ATEX zone classification
Description Gas, Vapour, Mist Dust Adaptable appliance group
Mixture of air and flammable Contained cloud of combustible dust,
Atmosphere gases, vapors or mists contained in the air
Gas / Dust

Area, in which a potentially

explosive atmosphere are
Zone 0 Zone 20 II 1 G / II 1 D
permanent,for longer periods
or often, available.

Area in which can

occasionally compose a II 1 G or II 2G
hazardous explosive Zone 1 Zone 21
atmosphere during normal
operation
/
II 1 D or II 2 D

Area where an explosive

II 1 G or II 2G or II 3 G
atmosphere does not normally
Zone 2 Zone 22
occur or only temporary
during normal operation

/
II 1 D or II 2 D or II 3 D
ATEX zone classification:

The more the ventilation, the lower the ATEX zone / requirements

EN 60079-10-1 2009 / Table B.1

ATEX zone classification: example

Zone 2

a a

According to EN 60079-1 Annex C, Example 1:

a = 3 m horizontally from source of release
b = 1 m from ground level and up to 1 m above the source of release.
ATEX zone classification: example

Pump

According to EN 60079-1 Annex C, Example 1:

a = 3 m horizontally from source of release
b = 1 m from ground level and up to 1 m above the source of release.
 ATEX zone classification: chiller example

Table C.2 − Hazardous area classification data sheet − Part II: List of sources of release EN 60079-10-01 / 2009
Plant: Chiller Example 1 Area: Roof top Reference
drawing:
1 2 3 4 5 6 7 8 9 10 11 12 13

Source of release Flammable material Ventilation Hazardous area

No. Description Location Grade of Referenc Operating State Type Degree Availabili Zone Zone extent Referenc Any other relevant
release e temperature (.c) (.d) (.e) ty type m e information and
(.a) (.b) and pressure (.e) 0-1-2 remarks

°C bar Vertica Horizo

l ntal
Seal of Chiller Semi hermetic
P 1
1 compressor Rack 59°C 19.72 G N High Good 2 3 1 1 compressor
Pipe joint Chiller
P 2
2 Evaporator Rack 38°C 12.11 G N High Good 2 3 1 1

(.a) C – Continuous; S – Secondary; P – Primary.

(.b) Quote the number of list in Part I.
(.c) G – Gas; L – Liquid; LG – Liquefied gas; S – Solid.
(.d) N – Natural; A – Artificial.
(.e) See IEC 60079-10-1 Annex B.

EN 60079-10-1 2009 / Annex C

Charge size restrictions for HCs

Regulation EN 378-1:2016 specifies maximum charge size

limitations and practical limits for both refrigeration and
comfort cooling/heating applications.
Most commonly applied limits:
• Systems with less than 150 g HC may be located
anywhere
• 1 kg charge for systems must be located below ground
• 1.5 kg for systems in public area (e.g. supermarket shop
floor)
• 2.5 kg for systems in a supervised area
• No limit for complete systems (e.g. chillers) outside and
/or in an authorised access area

Please refer to EN378:2016 for full details!

IEC EN 60335-2-89:2018 Charge size restrictions for HCs
Household and similar electrical appliances — Safety — Part 2-89: Particular requirements
for commercial refrigerating appliances with an incorporated or remote refrigerant
condensing unit or compressor

➢ The charge-limit increase to 500 g from 150 g will apply to

hydrocarbons like propane and isobutane in commercial
refrigeration equipment under the IEC global standard 60335–
2–89. The higher charge would likely widen the use of
hydrocarbons as natural refrigerants worldwide.

• Multi-storey refrigerated shelves

• Refrigerated shelves and cabinets with glass doors
• Bottle cooler
• Shock freezer
• Open refrigerated shelves
• Chest type refrigerators
• Ice cream sales counters
• …
Charge size restrictions for HCs

There are practical limits which apply if the HC refrigerant could leak
into an enclosed area.
• For non-comfort cooling / heating applications such as cold rooms
this is 8 grams / m³ (0.008 kg/m³) for R290.
• For comfort cooling and heating applications the maximum charge in
kg is:
mmax = 2,5 × LFL5/4 × h0 × A1/2
• The minimum room area in m2 is:
Amin = m2/(2,5 × LFL5/4 × h0)2
LFL = Lower Flammability Level
h0 = height of the unit, in m (0.6 m for floor mounted, 1.0 m for window, 1.8 m
for wall, 2,2 m for ceiling)
A= Floor area, in m²

Reference: EN378-1:2016
Maximum allowable charge sizes (R290)
Example: Allowable charge size

Minimum room size for a given refrigerant charge for ACs for human
comfort.

SAC : GSC 18 Godrej

IDU = min. 2,2m height 32,2 m² 15,8 m²

Charge: 375gr. R290 32,2m²

15,8 m²
A min = m²/(2,5 × LFL 5/4 × h0)²

A min = 0,375kg²/(2,5 × 0,038

5/4 × 3)² 24,8 m² 9,8 m²
9,8 m²
Amin= 16,5m²
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Principle design approach for explosion protection
Safety – risk analysis approach
Before addressing safety aspects directly, initial task to
minimise refrigerant charge
➢ Primarily target condenser; HX design
➢ With some effort, can approach <20% of HCFC/HFC charge
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Understand the basic concept of flammability
Three ingredients are needed for a fire:
1. Fuel at the right concentration!
2. Supply of oxygen (usually from air)
3. A source of ignition (SOI).

➢ If these ingredients are controlled,

e.g. by eliminating at least one but
preferably two of these, fire can be
SOI HC
prevented.
➢ In order to achieve this, three general
guidelines should be followed:
❖ Sealed system provision;
❖ Avoidance of SOI;
❖ Use of ventilation.
Sources of ignition
Sources of ignition (SOI):
➢ electrical apparatus that could arc or spark,
➢ mechanically generated sparks,
➢ flames and hot gases that are not suitably enclosed,
➢ hot surfaces that exceed specified temperature limits,
➢ static electricity as well as stray electric currents,
➢ cathodic corrosion protection.
To determine whether a SOI is in a position where leaked refrigerant could flow or
stagnate, EN 60079-10-1: 2009 shall be used to estimate the size and extent of a
potentially flammable zone.
The leak simulation test according to EN 378-2 meets the requirements of EN60079-10-1.

EN 378-2 and EN 1127-1

Examples of SOI: electrical devices

 Light and socket switches

 Some relay / overload protectors (klixons)
 Contactors and most on / off switches
 Light starters (ballasts)
 Most pressure switches (HP, LP, oil)
 Timers, e.g. for defrosting
 Thermostats
 Some defrost heaters
Examples of SOI: tools / equipment

 Brazing equipment
 Some electronic leak testers
 Unsealed switches on equipment such as vacuum
pumps
 Generator
Safety – eliminating ignition sources

Identify items/components
that could be potential
sources of ignition (SOI)
➢ Using ‘zoning’ approach
➢ Potential varies by
substance

HEAT GmbH – Habitat, Energy, Application & Technology 97

Safety – eliminating ignition sources
Two basic approaches
➢ Move to a location where leaked refrigerant cannot collect
➢ Replace component with “protected type”

98
HEAT GmbH – Habitat, Energy, Application & Technology
Potentially hazardous situations

 If hydrocarbon refrigerant leaks out of the system,

combustion will occur if the correct mixture exists and
there is an ignition source.

Note:
It is very unlikely that combustion will occur
inside a system as there is insufficient air.
Example: flammability risk for R-290

Oxygen 0 % to 100 %
Flammable ONLY BETWEEN 2% AND 10%
2.1 % 9.5 %
HC R-290
refrigerant

If the concentration is below the lower flammability level (LFL) of

ca. 2% by volume in air, there is not enough HC for combustion.
If the concentration is above the upper flammability level (UFL) of
ca. 10%, there is insufficient oxygen for combustion.
➢The critical region to ignite R-290 is between
both conditions.
Dispersion of refrigerant leak

room
Flammability risk in a
room evaporator

Illustration of the
flammable region:

Following a refrigerant
leak from an evaporator
into a room
Auto-ignition temperatures of refrigerants and lubricant

Approximate auto-ignition temperatures

➢ R22 635 ºC
➢ R12 750 ºC
➢ R134a 743 ºC
➢ R290 470 ºC
➢ R600a 460 ºC
➢ HFC-1234yf 405°C
➢ Oil 222 °C
Products of burning refrigerants:

Chemical refrigerants strongly and negatively affect health and the

environment

➢ When HCs burn, they produce carbon and steam.

➢ When chemical refrigerants (such as HFCs and HCFCs) burn,
they ALL produce toxic fumes.
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Electrical Design - Overview

Due to their physical properties and high flammability, refrigerant

systems using hydrocarbon refrigerants require special safety
precaution measures.


➢ The electrical design plays a central role for safety and exceeds
the requirements for the use of non-flammable refrigerants.
➢ Careful consideration of the design and construction of HC
refrigeration systems and their installations is essential to achieve
maximum safety.
Electrical requirements: relevant standards

In general all system designs of the electrical equipment

should comply with:
• product standard of the EN 60335 series, or
• EN 60204-1 (Safety of machinery) and for electronically
controlled systems related with EN ISO 13849-1 and / or EN
62061 (Safety-related parts of control systems)

Additionally for flammable refrigerants:

EN 378-2:2016
6.2.14 Protection against fire and explosion hazards
6.2.15 Requirements for ventilated enclosures where applied for A2(L), B2(L), A3 and B3
refrigerants as defined in EN 378-1:2016 Annex C1, C2 (charge limits)
Electrical grounding is essential
All HC appliance components must be grounded!
Electrostatic discharge (ESD) is the sudden flow of electricity between two electrically
charged objects caused by contact, an electrical short, or dielectric breakdown. A build-up of
static electricity can be caused by tribocharging or by electrostatic induction. The ESD occurs
when differently-charged objects are brought close together or when the dielectric between
them breaks down, often creating a visible spark.
ESD can cause a range of harmful effects of importance in industry, including gas, fuel vapour
and coal dust explosions, as well as failure of solid state electronics components such as
integrated circuits.
Electrical safety

Examples of
suitable electrical
installations
Electrical safety – Arcing and sparks

These are
some no-goes!
Protection of equipment

Refrigerating systems using flammable refrigerants:

• must be constructed in a way that any leaked refrigerant
will not flow or stagnate → avoidance of fire or explosion
hazard.
• This applies to areas within the unit where components and
equipment could be sources of ignition (SOI) under normal
conditions or in the event of a leak.

A leak simulation test

should be according EN378-2
Annex I

EN 378-2:2016, clause 6.2.14

Electrical safety: electrical panel design and cabling
Design principles:
• The electrical panel should be positioned
externally, i.e. outdoors.
• The electrical panel should be mounted
at an elevated position.
• Make sure that refrigerant cannot enter
the electrical panel in the event of a leak.
• Make sure that the cable entries are
sealed with appropriate
grommets/glands.
• The electrical panel doors must seal
when closed (use of appropriate gaskets).
It is necessary to carry out a leak simulation
test to ensure that refrigerant cannot enter
the electrical panel in the event of a leak
(EN 378-2).
Sources of ignition: exemption rules

Components and apparatuses are not considered to be a SOI if

they comply with at least one of the following:
• Positioned such that it is out of the potentially flammable zone where any
leaked refrigerant could flow or stagnate
• Ventilated with a sufficiently high airflow that is either permanent or initiated
prior to energising the components and apparatus. Sufficiently high airflow is
such that the concentration of refrigerant at the potential source of ignition does
not exceed 50 % of the LFL
• Requirements for protected equipment suitable for zone 2, zone 1 or zone 0
areas as defined in EN 60079-10-1, or
• For electrical equipment, the maximum possible energy of a spark or arc within
its circuit will not ignite the most flammable concentration of the refrigerant
used.

EN 378-2:2016-3 clause 6.2.14

Electrical safety: suitable panel design and cabling

Design of electrical panel assembly:

• Must comply with requirements by EN
60079-10.
• Use cable glands to feed electrical
cables into the panel.
• Make sure that gland and cable sizes
match.
• Tighten the inner gasket after inserting
the cable.

Example: compressor housing

Electrical safety: suitable ventilation

Design principle for ventilation:

➢ Supply of sufficiently high
airflow at the time needed with
adequate control mechanisms.

Ventilation design cases:

• Emergency ventilation
• Natural ventilation
• General constant ventilation
Ventilated enclosures: requirements for operation

Requirements for the operation of ventilation systems (either option

1 or 2):
• Option 1:
• The ventilation system runs at all times, with continuous monitoring of the airflow.
• Switch into a safe mode within 10 seconds after the airflow falls below Qmin. The
safe mode should be maintained until the airflow is restored.
• Option 2:
• The ventilation system is switched on by a refrigerant gas sensor before 25 % of LFL
(Lower Flammability Limit) is reached, as per EN 378-1:2017-03, Annex E.

EN 378-2, clause 6.2.15

Refrigerant gas sensor: turns on before 25 % of LFL
Gas sensor:
• Should switch on ventilation before 25 % of
LFL is reached (378-1:2015, Annex E).
• Should be suitably located considering the
refrigerant’s density. -> max. 30cm above
bottom
• The sensor and ventilation function should
be checked at regular intervals according
to the manufacturer’s instructions.
→ see also chapter maintenance
• A failure should be indicated and the
system should be switched to a safe mode
with the fan switched on until the failure
has been resolved.

EN 378-2, clause 6.2.15 & 378-4 Annex E

Example: HC chiller model range Sabroe SAB light

Machinery
room zone
classification
according to
EN60079-10

Sabroe SAB light by Johnson Controls

Product regulatory compliance
Correct application of flammability standards

Machinery room
zone classification
according to EN
60079-10

Distance between el.

components and
leakage points
according to EN
60079-10

Sensor for
flammable gas Total of 50 pipe joints inside a machinery room.
Emergency ventilation
detection Non-permanent joints are potential leakage points
according to EN 378-3 and
according to EN according to EN 60079-10. Leakage rate depending on
EN 60079-10
378-3 method of detection according to EN 1779

EN 378-3, EN 1779, EN 60079-10

Checklist for electrical installation

Checklist for el. installation (switchgear) at factory and installation site

This checklist may consist of the following:
1. Mechanical functional check (operating controls, interlocking, …)
2. Devices installation according to regulations
3. Cable rooting is performed correctly (e.g. no fixation on pipes or devices)
4. Protection classification of the box, cable glands, build-in components at door
5. Air-, creep distances and separation distances of build-in devices
6. Connection of structural parts and connectors among each other and with devices
7. Compliance of wiring, labelling, identification marks, etc. with construction documents
and design layouts
8. Electrical functional check
9. Insulation test or confirmation of insulation strength / Insulation resistance
10. Protective measures
11. Continuous protective earth conductor
12. Integrity check of the system controls (on-off switches, emergency stop, circuit breakers,
overload protection …)
Key take-away’s

✓ Control the “fire triangle”: eliminate at least one, better two ingredients
for a fire
✓ Know the corresponding safety measures and related design principles.
✓ Adhere to the relevant rules & regulations and to the instructions given
by the manufacturer/supplier.
✓ Any leaked refrigerant is not permitted to flow or stagnate in HC
refrigerating systems.
✓ Know the potential sources of ignition (SOI) and know how to avoid them.
✓ Know the requirements for ventilated enclosures, regarding both their
design and operation.
✓ Know the requirements for the operation and use of refrigerant gas
sensors.
✓ Know to evaluate the existing electrical design in with respect to safety
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Basic personal protective equipment (PPE)

Wear the adequate PPE for

each activity!
Gloves and goggles for
protection against freeze
burns (as with all
refrigerants)
Overall / long sleeves and legs
Safety shoes
Check: All necessary personal
protective equipment is
available and being used
correctly.
Portable gas sensor: how to use it
While technicians are working on the system, it can
be advisable to use a portable gas detector.
➢ Detector can be clipped to clothing or placed on
the floor within the working area.
➢ It should be switched on for the duration of the
work and set to alarm at 15% of the LFL, to alert
staff members of imminent flammable
concentration.
➢ For safety reasons, the gas detector should not
have a “Zero Background” function.
➢ Technicians can be alerted whenever an
inadvertent release of flammable refrigerant
occurs.
➢ Technicians are capable of immediately acting on
the relevant emergency procedures.
Need for background ventilation and instructions

➢ The work area is to be properly

ventilated before working on the
refrigerant circuit or before brazing or
handling electrics.
➢ Ventilation should safely disperse any
released refrigerant and preferably
expel it externally to the outside
➢ All maintenance staff must be
instructed.
➢ Erect appropriate warning signs,
including “no smoking” and “do not
enter the area” signs
Fire extinguisher

Suitable fire extinguishing equipment

must be available within the
immediate work area: when servicing,
storing or transporting HCs
• Dry powder type (usually identified
with a blue flash) or CO2
• 2 kg charge size
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Access tools for HC technology
Suitability for different applications:

Venting Evacuation Charging Sealing

Piercing
pliers ☺  
Line tap
valve ☺   
Lockring
☺ ☺ ☺
Schrader
 ☺ 
Manifold set (4-Way)

Standard 4 valve
manifold gauge set
• R600a
• R290
• R22
Vacuum pump

Exhaust hose for HC

Standard vacuum pump venting to the safe
environment
improvements
(electrical connections
and sealing)
E.g. remove on/off switch
E.g. switch on/off remote
outside 3 m area
Do not use “home-made”
vacuum pumps
Vacuum pump

Vacuum pump for flammable HC gases Exhaust hose for HC

two stage, 46 L/min; ultimate vacuum venting to the safe
1x10-2 mbar; Power consumption environment
120W; Protection classification IP54;
Oil charge 300 cc; CE confirmation and
according II3GD nA tD 4T IP55 (zone 2-
22 ATEX); 3/8” and ¼” SAE/UNF
connection;
Gas ballast valve;
Exhaust port with hose adapter
(venting hose)
Oil filter
Recovery unit

For use on refrigeration

systems utilizing class
A3 (non-toxic,
flammable)
Ignition proof ON-OFF
switch
Sealed start relay
Hardwired
Oxygen free dry nitrogen (OFDN)
Must have for the applications:

• Pressure / strength test

• Equipment flushing

• Inert gas brazing

Cylinder Filling Gas Content Cylinder gross

Content (Litre) Pressure (bar) (m³) weight (ca. kg)
5 200 1 9,8

10 200 1.911 15,7

20 200 3.822 37,0

50 200 9,556 77,7

Purity 4.0 OFDN gas is of 99,99 % and a water content of maximum of 30 ppm.
Charging equipment – option 1

For refrigerant charge >

500 g
Measuring range ≤ 100 kg
Accuracy of about +/- 0.5%
needed
Resolution 2 g
Charging equipment – option 2
For refrigerant charge ≤ 500 g

!
➢ Measuring range ≤ 5 kg
➢ Resolution 1 g
Sealing tools – option 1

Lockring seals without

brazing
Sealing tools – option 2

➢ A crimping tool seals before

brazing
Brazing equipment
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Refrigerant recovery
Requirements
Commercial systems:

• Refrigerant must be recovered

➢ Recovery unit certified for A3
refrigerants (EN 378)
➢ Potential equalisation needed
between storage cylinder, recovery
(HC refrigerant transferring
equipment) unit and technician

Removal of liquid
refrigerant is possible!
- Receiver
- Expansion valve
- Solenoid valve
Refrigerant venting instead of recovery:
What must be considered (1)
Normally, venting to a safe place is carried out with systems containing a small
quantity of HC refrigerant only and operating with capillary tubes.
➢ Use a vent-line and place the end within the outside ambient (end of hose about
1 m height)
➢ Ensure low refrigerant flow by metering with manifold, for effective dilution of HC
with air!
➢ Charge amount max. 500 g!

Venting only
in the vapour
and gas
phase!
Refrigerant venting instead of recovery:
What must be considered (2)

Charge system
limit for venting in capillary systems ≤ 500 g !

While removing the

refrigerant from the Outdoor
side
system, oil should
be separated.

IDU
Cylinder to
collect oil Diffuser

Hose
Indoor side
1m

3m
ODU
Refrigerant venting:
Minimise deflagration risk!

Risk of deflagration!

Make sure that refrigerant does not accumulate.

It always moves to the coldest and deepest point

and therefore often accumulates at the following
locations:
- in floor ducts
- siphons
- gutters
- air vent at the brine loop
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Inerting with OFDN (oxygen free dry nitrogen)
Why it is needed

After recovering and before

opening the RAC system, the
system has to be rendered
inert.

Only use OFDN!

The following procedure should be followed before working on the
refrigerant circuit:
• purge circuit with inert gas OFDN
• evacuate to an absolute pressure of 0.4 bar (= 0.04 MPa)
• purge again with inert gas OFDN
• open the circuit.
Inerting with OFDN
(oxygen free dry nitrogen)

➢ Use oxygen free

A B HD
and dry nitrogen C D

only! ND
3

4
2
Inerting with OFDN: considerations for brazing
(oxygen free dry nitrogen)

Always apply OFDN

to inert the refrigerant
circuit (components,
tubing) before and
during any brazing
activity:

➢ Due to the risk of

hidden propane in
pipes und
accessories
(siphons etc.)

➢ To avoid the
creation of tinder
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Vacuum: why it is needed

Before charging with refrigerant, the refrigerant circuit must

be evacuated in order to remove

• non-condensable gases (air, N2 or residual refrigerants),

• humidity.
Commissioning setup

A B H
C D

L
3

4
2
Evacuation: pressure/temperature diagram for water
Pressure
Required pressure range for evacuation

 

☺
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints
Gas detection technologies

TCD
Electronic Gas Detector (sniffer)

▪ Recommended
▪ Check if design is for one or multiple types of refrigerant,
e.g. HFC, HCFC, HCs
▪ Check sensitivity range of sniffer
▪ probing tip that creates an electric emission in the
presence of a refrigerant
▪ Audible and/or visual signal
▪ Close proximity to leak can be identified. Afterwards,
increase sensitivity or use bubble test to identify exact
location
▪ The device should be checked at least once a year to
ensure reliability and accuracy. For most cases it is
possible to use a “reference leak source” for calibration.
Electronic Gas Detector (sniffer)

Warning:
▪ Many electronic gas detectors are not recommended to be used in
atmospheres that contain flammable or explosive vapours or
refrigerants. Sensor may operate at an extremely high temperature. If
this sensor comes in contact with a combustible gas, ignition will
occur.
▪ Check manufacturer’s instruction manual for use with
hydrocarbon/flammable refrigerants
▪ Carbon monoxide and alcohol can affect the sensitivity of some
electronic gas detectors. Be sure neither is present when leak
detecting.
See SAR standard 1627 for Criteria for Electronic Refrigerant Leak Detectors
See European standard EN 14624: 2012 on “Performance of portable leak
detectors and of room monitors for halogenated refrigerants”.
Electronic TCD gas detector (sniffer): requirements
➢ Device must be compatible with the refrigerant that is
contained in the system undergoing the leak testing.
➢ Technicians must know their leak detector’s capabilities
and also what they are not capable of detecting.
➢ Carbon monoxide and alcohol can affect the sensitivity of
some electronic gas detectors. Be sure neither is present
when trying to detect a leak.
➢ The device should be checked at least once a year to
ensure reliability and accuracy.
➢ If possible, use a “reference leak source” for calibration.
➢ Having a „reference leak source“ it can be used before any
job for gas detection (leak finding)
Warning: Most electronic gas detectors are not recommended to be used in atmospheres that contain flammable or
explosive vapours or refrigerants. Sensors may operate at an extremely high temperature. If the sensor comes in contact
with a combustible gas, ignition will occur.
Leak finding: what is needed

➢ Understand what is being done

➢ Gas detection is not leak detection!
• Leak detection = gas detection + person
• Gas detectors assist with leak detection, they do not do all
work!
➢ Very important for the repairing of leaks:
• Safety
• Performance (5% leakage means 10% higher energy
consumption)
➢ Modern reliable “gas detectors” (Sniffer) devices are
sensitive to leakage ranges as low as 3 g/year.
➢ Testing with a reference leak (about 5 g/year) is the only
way to prove the performance of a gas detector.
What is leak detection?

+ =
Gas detector + detective work = find leak
Leak finding: general requirements

Use of gas TCD

Example F-Gas Regulation - EC 517/2014:

➢ Service technicians must give their gas detector a formal

calibration test at least every 12 month

➢ Regularly check (at least before every use) that the

equipment is sensitive enough to detect a refrigerant leak
of 5 g/year on a system.
Moving the sniffer (TCD) sensor

Move at 0.2 cm per second along the

tubes and around spots suspected for a
leak!
Bubble solution and pressure drop test:

No field approved suitable alternatives to the gas detector (sniffer)!

Example: car tyre

• car tyre filled to 2.7 bar (40 PSI) air
• with a leak of 5 g per year
• it takes over 4 years to drop by 0.1 bar
(1.5 PSI) of pressure
With a 5 g gas leak available,
➢ a bubble solution takes over 20 hours to form a 1
ml bubble,
➢ a pressure drop test would show a change of only
ca. 0.7 mbar (0.01 PSI) after 48 hours.
In practice, the bubble test is only accurate for 50 – 200 g/year
Comparison of leak detection methods
5 g 5/gyear
/ Year (HFC-134a)
(HFC R-134a)

Ultrasonic Test

Bubble Test Method

Pressure Decay Test

Sniffer: Thermal Conductivity

Sniffer: Electron Capture (SF6)

Sniffer: 5% H2, 95% N2 Gas

Overpressure Mode

Sniffer: Helium Quarz Membrane

Sniffer: Mass Spectrometer

Vacuum Mode

Vacuum Mode: Helium Mass Spectrometer

103 … 100 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12

Minimum Detectable Flow Rate in millibar · Litres / Second (mbl/s)

Key take-away’s

✓ Valid rules and regulations must be followed.

→ HC systems can be operated safely and energy-
efficiently.
✓ A risk assessment is obligatory before starting the
job.
✓ Do not work if it is not completely safe.
✓ Always use the right tools and PPE.
✓ Always keep the fire triangle in mind.
Work with Ammonia

Targets
no Accident
no Environment Pollution
no Health Hazard
Thank You for Your attention!
Overview: Modules and Sections

Hydrocarbon Refrigerant Issues

Potentials application of Hydrocarbon refrigerants
European standards and regulations
Design approaches and considerations on safety
How to practically deal with HC refrigerant flammability
Electrical circuit and components requirements
Risk assessment
Basic personal protection
Tools and servicing equipment
HC refrigerant recovery and venting
The importance of Oxygen Free and Dry Nitrogen (OFDN)
Deep vacuum procedures for refrigeration system commissioning
Methods of gas detection (leak finding) in the field
Other useful hints