CodeofPractice

DesignandManufactureofRefrigerated CabinetsRunningonHydrocarbon Refrigerants

FinalDraftV1forBRA,February2012

CodeofPracticefortheDesignandManufactureofRefrigerated CabinetsRunningonHydrocarbonRefrigerants
Inordertosupporttheincreasinguseofhydrocarbonrefrigerantsinintegralcommercial refrigeratedcabinetstheBritishRefrigerationAssociationCabinetandColdStoreSectionhas commissionedthisCodeofPractice.Itclarifiestheregulations,standardsandpractices whichapplytotheleaksimulationtestingandsubsequentdesignofsystemswhichuse hydrocarbonrefrigerants.Thiswillprovidethebasisforaconsistentapproachtobe adoptedbyallmanufacturers,endusersandspecifierswhenusingtheserefrigerants. IanGarvey ChairmanofBRACabinet&ColdstoreSectionHydrocarbonworkinggroup

Disclaimer
FederationofEnvironmentalTradeAssociationsLtd2012 Allrightsreserved.Apartfromanyfairdealingforthepurposesofprivatestudyorresearch allowedunderapplicablecopyrightlegislation,nopartofthepublicationmaybe reproduced,storedinaretrievalsystem,ortransmittedinanyformbyanymeans, electronic,mechanical,photocopying,recordingorotherwise,withoutthepriorpermission oftheFederationofEnvironmentalTradeAssociations,2WalthamCourt,MilleyLane,Hare Hatch,Reading,BerkshireRG109TH. FETAusesitsbesteffortstopromulgateStandardsandGuidelinesforthebenefitofthe publicinthelightofavailableinformationandacceptedindustrypracticesbutdonotintend suchStandardsandGuidelinestorepresenttheonlymethodsorproceduresappropriatefor thesituationdiscussed.FETAdoesnotguarantee,certifyorassurethesafetyor performanceofanyproducts,components,orsystemstested,installedoroperatedin accordancewithFETA'sStandardsorGuidelinesorthatanytestsconductedunderits StandardsorGuidelineswillbenonhazardousorfreefromrisk. FETA,andtheindividualcontributors,disclaimsallliabilitytoanypersonforanythingorfor theconsequencesofanythingdoneoromittedtobedonewhollyorpartlyinrelianceupon thewholeoranypartofthecontentsofthisbooklet.

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CodeofPracticefortheDesignandManufactureofRefrigerated CabinetsRunningonHydrocarbonRefrigerants
September2011
ThisCodeofPracticehasbeenpreparedbyCoolConcernsLtdattherequestoftheCouncil oftheBritishRefrigerationAssociation(BRA)becauseoftheincreaseindemandfor refrigeratedcabinetsrunningonhydrocarbon(HC)refrigerants.Cabinetsthataredesigned andmanufacturedinaccordancewiththisCodemeetbasicsafetyprincipleswithregardto theapplicationofaflammable(A3)refrigerant. ThisCodeshouldbereadinconjunctionwiththestandardssummarisedinAppendix2.

Scope
ThisCodedefinesstandardsinthedesignandmanufactureofintegral(pluginandhard wired)andclosecoupledremotetypecabinetsforfooddisplay,serviceandstorage(stand aloneandmultiplexed).Itisaimedatcabinetswithachargesizegreaterthan150g.Itis alsoapplicabletocabinetswithlessthan150g,butforthesecabinetsotherstandards, including60335224:2010and60335289:2010,alsoapply.Thesestandardsarealsooften usedforLowVoltageDirective(LVD)andElectromagneticCompatibility(EMC)directive compliance.

ATEX
ATEXisthenamecommonlygiventothelegalrequirementsforcontrollingexplosive atmospheresandthesuitabilityofequipmentandprotectivesystemsusedinthem.Itis unclearwhetherHCrefrigerationsystems,whicharedesignedtocontainarelativelysmall andfiniteamountofflammablegas,arecoveredbythisdirective,andifsotowhatdegree theyshouldcomply. DiscussionsarecurrentlyongoingbetweentheRACindustryandtheHealthandSafety ExecutivetoclarifythesituationregardingATEXandHCsystems.ThisCodeprovides guidancewhichfollowstheprinciplesofATEXwithregardtoareaclassificationand avoidanceofsourcesofignition.

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TableofContents
1.Introduction...........................................................................................................................4 2.Flammability..........................................................................................................................6 2.1HCsystemclassification..................................................................................................6 2.2Chargesizerestrictions....................................................................................................7 3.IntroductiontotheDesignProcess.......................................................................................8 3.1Reducingleakpotential...................................................................................................9 4.SimulatedLeakTesting........................................................................................................10 4.1Releaseratecalculation.................................................................................................11 4.2Thetestwork.................................................................................................................12 4.3Adjacentequipment......................................................................................................13 4.4Reporting.......................................................................................................................13 5.ElectricalDevicesTypesandEnclosures...........................................................................14 5.1Electricaldevicesforuseinpotentiallyflammableatmospheres.................................15 5.2Cabinetswithdoorsandwells ......................................................................................16 . 5.3Enclosures......................................................................................................................17 5.4Connection/disconnection..........................................................................................17 5.5Wiring............................................................................................................................17 6.Airflow................................................................................................................................18 7.LabellingandDocumentation.............................................................................................20 8.Manufacture........................................................................................................................21 9.EndUserPostInstallationChecks......................................................................................23 10.ServiceandRepair.............................................................................................................24 10.1Personalleakdetection...............................................................................................24 10.2Toolsandequipment...................................................................................................24 10.3Procedures...................................................................................................................25 11.Training..............................................................................................................................26 Appendix1,SourcesofFurtherInformation...........................................................................27 Appendix2,StandardsandRegulations..................................................................................28

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1.Introduction
Thissectionprovidesbasicinformationabouthydrocarbonrefrigerants. Endusersareincreasinglyspecifyinghydrocarbon(HC)refrigerantsincabinets,mainlydue totheirlowglobalwarmingpotentialandgoodenergyefficiency.TherangeofHCs availableisshownbelow.Thehydrocarbonspredominantlyusedincommercial refrigerationsystemsareR290andR1270.R600aisusedinsomesmallcommercial systems,butismostlyusedindomesticsystems. Propane Propene(propylene) IsoButane Refrigerantnumber R290 R1270 R600a Tradename Care40 Care45 Care10

Thechart(right)showsan approximatecoolingcapacity comparisonbetweenHCsand HFCs.Theactualcomparison dependsonoperatingconditions andcompressortechnology. Generallytheenergyefficiencyis upto20%betterthanforHFCs. ThelatentheatofHCsisupto2.5 timeshigherandtheheattransfer upto1.5timeshigherthanfor HFCs.Thedensityis approximately45%thatofHFCs. Thegraphbelowshowstherelationshipbetweenpressureandsaturationtemperature. AccuratedatacanbeobtainedfromsoftwaresuchasCoolpack 1 .

Coolpackcanbeobtainedfromhttp://www.et.web.mek.dtu.dk/coolpack/uk/download.html

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29 24 pressure, bar g 19 14 9 4 -1 -40 -20 0 temp, C 20 40 60 R404A R1270 R290 R134a R600a

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2.Flammability
ThissectionprovidesinformationabouttheflammabilityofHCs,sourcesofignitionand chargesizelimits. Flammabilityinformationisshowninthetablebelow 2 . Lower Lower flammability Autoignition PEDfluid Practicallimit flammability limit(LFL,%, temperature, limit(LFL, group (kg/m3) 3 O C byvolumeof kg/m3) air) R600a R290 R1270 1 1 1 0.008 0.008 0.008 0.043 0.038 0.040 1.8 2.1 2.0 460 470 455

IftheconcentrationofHCinairisbetweentheLFLandtheUFL(upperflammabilitylevel, approximately10%)therefrigerantcanbeignited.Sourcesofignitionincludeunsealed (sparking)electricalswitchesandnakedflames.Moreinformationaboutelectricalsources ofignitionisinsection5.

2.1HCsystemclassification
UnderATEXareasareclassifiedaccordingtothehazardassociatedwiththeflammablegas. Accountistakenofthelikelihoodofanexplosiveatmosphereoccurringanditspersistenceif itdoes.Thefollowingclassificationstypicallyapplytorefrigeratedcabinets. Zone2areainwhichanexplosivegasatmosphereisnotlikelytooccurinnormal operationbut,ifitdoesoccur,willpersistforashorttimeonly 4 . Secondarygradeofreleasereleasewhichisnotexpectedtooccurinnormal operationand,isitdoesislikelytodosoonlyinfrequentlyandforshortperiods 5 . Equipmentcategory3Gequipmentsuitableforzone2. ElectricalequipmentofgroupIIisintendedforuseinplaceswithanexplosivegas atmosphereotherthanminessusceptibletofiredamp(flammablegasessuchas methane).GroupIIissubdivided;groupIIAincludesgasessuchaspropane 6 . UnderEN3781:2008,HCrefrigerantsareclassifiedinSafetyClassA3theyhavehigher flammabilityandlowertoxicity.

2 3

EN3781:2008,AnnexE EN3781:2008,AnnexE 4 EN60079101:2008,3.8 5 EN60079101:2008,3.10 6 EN600790,4.2 BRACodeofPractice,HCCabinetsFinalV1,January2012

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2.2Chargesizerestrictions
FlammabilityrestrictsHCchargesizesmaximumchargesizesandthepracticallimitare specifiedinEN3781:2008.ThepracticallimitisusediftheHCrefrigerantcouldleakintoan occupiedspace,forexampleasupermarketshopfloororpreparationarea,orintoacold room(seeexample,below).Inadditiontherearemaximumchargesizesdependentonthe occupancycategory.Whicheveristhelowestchargeapplies. Exampleofpracticallimit Inapreparationroom3mby5mby2.5mhigheachHCsystemcannothavemorethan 0.3kgcharge. Maxcharge=5mx3mx2.5mx0.008kg/m3=0.3kg ThefollowingisanextractfromEN3781:2008TableC.1whichprovidesmaximumcharge sizesforarangeofoccupanciesandequipmenttypes.Theinformationbelowwould encompassmostintegralrefrigeratedcabinetsfortheretailsector. Refrigerationsystemlocation Refrigerationsystemlocatedinahuman occupiedspace(occupancyclassAgeneral occupancy),whichisnotamachineryroom Maximumchargepersystem OnlysealedsystemswithMaxcharge= practicallimitxroomvolumeandnot exceeding1kgbelowgroundfloorleveland 1.5kgabovegroundfloorlevel OnlysealedsystemswithMaxcharge= practicallimitxroomvolumeandnot exceeding1kgbelowgroundfloorleveland 2.5kgabovegroundfloorlevel

Refrigerationsystemlocatedinahuman occupiedspace(occupancyclassB supervisedoccupancy),whichisnota machineryroom TheinformationinitalicshasbeenaddedbytheauthorsasitisnotincludedinEN378in errorandwillbecorrectedinrevisionsgoingforward OccupancyclassAiswherethenumberofpeoplepresentisnotcontrolledortowhichany personhasaccesswithoutbeingnecessarilyacquaintedwiththegeneralsafetyprecautions. Anexampleisasupermarketshopfloor. OccupancyclassBisrooms,partsofbuildingorbuildingswhereonlyalimitednumberof peoplemaybeassembled,someofthembeingnecessarilyacquaintedwiththegeneral safetyprecautions.MostdesignersassumeanoccupancyclassAbecausethedefinitionof occupancyclassBisdifficulttocontrolinreality. RefertoEN3781:2008TableC1forfullinformation,includinglimitsforindirectsystems, andforsystemsorpartsofsystemlocatedinmachineryroomsoroutsideetc.

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3.IntroductiontotheDesignProcess
ThissectionoutlinestheprocessnecessarytoensureHCsystemsaresafe.Moredetailed informationisprovidedinsubsequentsections. AleakofHCrefrigerantcanpotentiallyresultinaflammablezonearoundthesystem. Sourcesofignitionwithinthepotentiallyflammablezonewillpresentahazardintheevent ofaleak.Anessentialpartofthedesignprocessistoensuretherearenosourcesofignition insidepotentiallyflammablezones.Thiscanbeachievedbyensuringleaksdonotresultina flammablezoneorbyremovingsourcesofignitionfromtheflammablezone. TheprocessforensuringHCsystemsaresafeissummarisedbelowforanysystemwhich containssourcesofignition,regardlessofthechargesize. Carryoutflammablezonetesting(areaclassification)todeterminetheextentof Step1 thepotentiallyflammablezoneintheeventofaleak. Seesection4. Identifysourcesofignitionwithinthepotentiallyflammablezone. Step2 Seesection5. Movethesourceofignitionoutsidethepotentiallyflammable Option1 zone.EN6007914requiresthat,whereverpossible,electrical or equipmentshouldbelocatedinnonhazardousareas 7 . Replacethesourceofignitionwithasuitabledevice.Seesection5. Option2 Step3 or Increasetheairflowand/ormaintainapermanentairflowto Option3 reducethepotentiallyflammablezone.Seesection6. or Locatethesourceofignitioninasuitableenclosure(thisisusually Option4 costprohibitiveforsmallsystemsanddifficulttoachieve).See section5. Moredetailedinformationoneachoftheaboveisshowninsubsequentsectionsas indicated.

EN6007914:2008,4.1

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3.1Reducingleakpotential
Thepotentialforleakageshouldbereducedasmuchasispractical.Considerationshould begivento: Minimisingthenumberofjoints; Qualityofbrazingandbrazingprocedures; Competenceandqualificationofbrazers; Methodofaccesstothesystemforservice: o CappedSchradervalvesonboththehighandlowsidesofthesystemshould beused; Qualityofpipebending; Vibrationelimination; Minimisingthepotentialforchafing; Minimisingpotentialforexposuretodamage; Protectingpipeworkfromcorrosion,e.g.dischargepipeworkwhichevaporates defrostcondensate; Pressuretestingforstrengthandleaktightnessbeforecharginginaccordancewith EN378.

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4.SimulatedLeakTesting
Thissectioncoversthesimulatedleaktestingrequiredtodeterminetheextentofa potentiallyflammablezoneintheeventofaleak. Simulatedleaktestingiscarriedouttodeterminetheextentofapotentiallyflammablezone intheeventofaleak.ThetestworkshouldcomplywithEN66079101.Theprocedure belowsummarisestheprocess,andfurtherdetailisprovidedwithinthissection,but referenceshouldbemadetothestandardforfullinformation. Identifypotentialleaklocation(s)(seesectiononTestWorkforfurther Step1 information). CalculatethereleaseratefromEN60079101,AnnexAforeachlocation.The followingneedstobedetermined: Theholesizeoftheleak; Step2 Whetherthereleasewillbeliquidorgas; Themaximumpressureandtemperatureoftherefrigerantatthepoint ofleakage. Decidewhethertherewillbeairflow.Iffansrunpermanentlythentheycan runduringthetest.Iffansswitchoffwhentherefrigerationsystemisoff(on Step3 temperatureforexample)theyshouldnotberunduringthetest,i.e.testing shouldbecarriedoutatworstcasescenarioconditions. Carryouttheleaksimulationtest,measuringtheHCconcentrationwherethere Step4 aresourcesofignitionandaroundthesystemtofindtheextentofthe potentiallyflammablezone(areaclassification). Step5 Recordthetestworkinatechnicalfile.

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4.1Releaseratecalculation
ReleaseratecalculationsaregiveninEN60079101forleaksofbothliquidandgas.These modelsdonotaccountforvolatilefluids.Therequirementforamodelforvolatilefluidsis thesubjectofongoingdiscussionsbetweenindustryandtheHSE.Theliquidrelease calculationgivesanoverlyonerousreleaserateandisnotusuallyusedinrefrigeration systemsbecauseattheactualpointofleakage,forexampleinaliquidline,therefrigerant willeitherbetwophaseorgasveryshortlyaftertheleakstarts.Thecalculationisincluded inthisCodeforcompleteness. Catastrophicleaksdonotneedtobeconsidered 8 . Thegasreleaserateforgasisgiveninthestandardforbothchokedandnonchokedgas velocity.Thenonchokedgasvelocitycalculationisusedbecausethedischargeofleaking refrigerantisbelowthespeedofsoundfortheHC.Theequationisasfollows 9 :

dG/dt releaserateofgas(kg/s) p pressureinsidethesystem(Pa) pressureoutsidethesystem(Pa) p0 S crosssectionoftheopening(hole)throughwhichthegasisreleased(m2) M molecularmassofthegas(kg/kmol) =44.096forR290 =42.06forR1270 T absolutetemperatureinsidethesystem(K) polytropicindexofadiabaticexpansion =1.134forR290 =1.156forR1270 R theuniversalgasconstant =8314J/kmolK. Thereleaserateforliquidiscalculatedasfollows 10 :

dG/dt S p

releaserateofgas(kg/s) crosssectionoftheopening(hole)throughwhichthegasisreleased(m2) liquiddensity(kg/m3) =500forR290 =515forR1270 pressuredifferenceacrosstheopeningthatleaks(Pa)

8 9

EN60079101:20081notedandnote5 EN60079101,A3.2.2 10 EN60079101,A3.1 BRACodeofPractice,HCCabinetsFinalV1,January2012

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 Theholesizetypicallyusedis0.6mmdiameter(S=0.282mm2=0.000000282m2).Itis likelythatthiswillbeincludedforsealedsystemsintherevisionofEN378currentlybeing carriedout.Thisholesizecouldrepresentalargeleakandcanresultinoverclassifyingthe dimensionsofazone,soifajustificationcanbegiventouseasmallerholesizethisshould bedocumentedinthetechnicalfile. Thetablebelowshowsthemaximumpressuresandtemperaturesthatshouldbeused: R290 R1270 R600a Maxpressure(p),barg 11 Lowside 10.3 12.7 3.3 Highside 18.1 21.8 6.8 Maxtemperature(T),OC Lowside 32 32 32 Highside 55 55 55

4.2Thetestwork
Theleaksimulationtestingshouldbecarriedoutinanenvironmentsimilartothatwhere thesystemwillbelocated.Naturalairflowratesinthetestingenvironmentshouldbe limitedtobelow0.2m/sec 12 soasnottoadverselyinfluencethedispersionofHC refrigerant.Considerationshouldbegiventoroomsizeandadjacentequipmentwith regardstoignitionsourcesduringthetesting. Potentialleakpointstypicallyincludejoints,abendofmorethan90O,pipeandcomponents whichareexposedtodamageandanyotherweakpointinthesystem. TheHCreleaseistypicallyfromacylinderviaatubetotheleaklocationonthesystem.The leakcaneitherbe: ThroughaholeofsizeSwiththe refrigerantatthemaximumsystem pressure,connectedtothecylinders liquidorgasofftakeasrequired.The refrigerantpressureshouldbeas specifiedinthetableabove.Itis recommendedthattheleakrateis recorded.Thephotoshowsassemblies usedforsimulatedleaktestingwith holesizesof0.35mmand1.1mmdiameter; or Throughanadjustablemeteringvalveattherate calculatedbyoneoftheequationsabove.The photoshowsaneedlevalveusedforleaksimulation

11 12

Basedon32OCand55OCinaccordancewithEN3781:2008 InlinewithperformancetestingstandardISOEN239535.3.1.2

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 testing,capableofmeteringthereleaseattherequiredrate. Careshouldbetakentoensurethattheinstallationoftheleak,thepositioningofthe refrigerationsystemandtherefrigerantsamplingequipmentdonotnotablyinfluencethe testresults.Theequipmentformeasuringtherefrigerant concentrationshouldhavesufficientlyrapidresponseto changesinconcentration,typically2to3seconds.Ifthe measuringmethodisonethatremovesgassamples,thenit shalldosoataratelessthan4mlperminute 13 .The concentrationcanbemeasuredusingametersuchasthat showninthephoto(BWTechnologiesGasAlertMicro5). Anylocationwheretheconcentrationisabove50%ofthe LFLforanypartofthetestisdeemedtobepotentially flammable 14 .Thefactorof0.5isusedbecauseanHCrefrigerantleakisdefinedasa secondaryrelease. Section5showshowtodealwithsourcesofignitionwithinpotentiallyflammableareas.

4.3Adjacentequipment
Thesimulatedleaktestingalsoidentifiestheareaaroundasystemwhichmustbefreefrom sourcesofignition.IfapotentiallyflammablezonecanoccurbeyondthefootprintoftheHC equipmentitisimportantthatotherequipmentlocatedwithinthisareaissuitableforusein apotentiallyflammableenvironment. ForcabinetswithdoorswhereHCcouldleakinsidethecabinet,testingshouldbecarriedout todeterminetheextentofapotentiallyflammablezonewhenthedoor(s)areopenedafter aleakintothecabinet.

4.4Reporting
Recordingtheresultsofthesimulatedleaktestingprovidesevidenceofcompliancewiththe principlesofATEXanddemonstratestoendusersthatleaksimulationtestinghasbeen carriedouttotherelevantstandard.Thefollowinginformationshouldbeincluded: Refrigeration/airconditioningsystem(makeandmodel)tested; Leakrateandleakpositions; Standardsusedtodeterminethereleaserateandmaximumallowable concentration; Explanationoftestmethodology; Equipmentusedandrelevantcalibrationinformation; Refrigerantinformation; Assumptionsmadesuchasmaximumpressureandtemperaturewhererelevant; Airflowrateduringthetestassociatedwiththeequipmentandexternal;
13 14

InstituteofRefrigerationCodeforA2andA3refrigerants. EN60079101:2009B.5.2.1,2

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 Testresultsconcentrationmeasuredateachlocationthroughouttest.Itis recommendedthatthisispresentedasagraphofthe%LFLagainsttimeforeach leaklocation,withphotosshowingthelocationoftheleakandsensor.

5.ElectricalDevicesTypesandEnclosures
Thissectionsummarisestherequirementsforelectricaldevices,enclosuresandconnections usedinpotentiallyflammableatmospheres.Itisnotpossibletoincludefullanddetailed informationinthisCode.Therelevantstandardsareincludedandmustbereferredtofor specificinformation. Thesimulatedleaktestingwillidentifysourcesofignitionwhicharewithinthepotentially flammablezone.Electricaldeviceswithinthepotentiallyflammablezonemustnot: Produceanoperationalarcorspark(unlessthatarcorsparkispreventedfrom causingignitioninaccordancewithIECEN6007915,clauses16to20); Developamaximumsurfacetemperatureinexcessofthemaximumappropriateto thetemperatureclassoftheapparatus(unlessthetemperatureispreventedfrom causingignitioninaccordancewithIECEN6007915,clauses16to20). Sourcesofignitionassociatedwithrefrigeratedcabinetstypicallyinclude: On/offswitchesorcontactors; Relays(e.g.oncontrolsandsinglephasecompressors); Pressureswitches; Thermaloverloads; Fanmotors; Thermostats; Condensatepumps; Miniaturecircuitbreakers(MCBs); Defrostheatersifthesurfacetemperaturecanexceed360OC(maximumheater surfacetemperatureshouldbedemonstratedbytestingintheoperating environmentmaximumambient,assumingdefrostterminationhasfailed). Thisisnotanexhaustivelist,butincludesthemostcommonelectricaldeviceswhichneedto beconsidered. Thefollowingitemsaregenerallynotsourcesofignition: Cabinetlighting(theswitch,starterandterminationsmustbeconsideredevenfor lowvoltagelighting), Capacitors(itisrecommendedthatbleedresistorsarefittedtominimisethehazard causedbydischargeduringservice); Solenoidvalvecoils; Wiringconnections(accidentaldisconnection,forexampleduringservice,can produceaspark.Tominimisethisriskwithpushcrimpterminals,tagged terminationsthatcannotbeaccidentallydisconnectedarerecommended);

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 Fuses(deemednonsparkingdevicesiftheyarenonrewirable,nonindicating cartridgetypesorindicatingcartridgetypes,accordingtoIEC602693,operating withintheirrating 15 ).

Therearevariousoptionsfordealingwithsourcesofignitionwithinapotentiallyflammable zone.Inorderofsimplicityandeffectivenesstheyare: 1. Movethesourceofignitionoutsidethepotentiallyflammablezone. Or 2. Replacethesourceofignitionwithasuitabledevice. Or 3. Increasetheairflowand/ormaintainapermanentairflowtoreducethe potentiallyflammablezone. Or 4. Locatethesourceofignitioninasuitableenclosurewhichmeetstherequirements ofEN6007915:2010(thisisusuallycostprohibitiveforsmallsystems). Airflowiscoveredinthenextsection.Theremainderofthissectioncoverssafeelectrical devicesandenclosures.

5.1Electricaldevicesforuseinpotentiallyflammableatmospheres
IECEN6007915definestypenprotectionasthatwhich,innormaloperationandin certainspecifiedabnormalconditions,isnotcapableofignitingasurroundingexplosivegas atmosphere.Switchingelectricaldeviceswhicharelocatedinapotentiallyflammable atmosphereshouldthereforebetypeninaccordancewithIECEN6007915,which includesdifferenttypesofprotectionasfollows: nAnonsparking(deviceconstructedtominimisetheriskoroccurrenceofarcs orsparkscapableofcreatinganignitionhazardduringconditionsofnormal operation 16 ). nCenclosedbreak(deviceincorporatingelectricalcontactsthataremadeand brokenandthatwillwithstandaninternalexplosionoftheflammablegasorvapour whichmayenteritwithoutsufferingdamageandwithoutcommunicatingthe internalexplosiontotheexternalflammablegasorvapour 17 ). nChermeticallysealeddevice(devicewhichissoconstructedthattheexternal atmospherecannotgainaccesstotheinteriorandinwhichthesealismadeby fusion,forexamplebysoldering,brazing,weldingorthefusionofglasstometal 18 ).
15 16

EN6007915:2010,9.1 EN6007915:2010,3.7.1 17 EN6007915:2010,3.7.2.1 18 EN6007915:2010,3.7.2.2 BRACodeofPractice,HCCabinetsFinalV1,January2012

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 nCnonincendivecomponent(componentshavingcontactsformakingor breakingaspecifiedignitioncapablecircuitbutinwhichthecontactingmechanism isdesignedandconstructedsothatthecomponentsisnotcapableofcausing ignitionofthespecifiedexplosivegasatmosphere 19 ). nCsealeddevice(devicewhichissoconstructedthatitcannotbeopenedduring normalserviceandissealedeffectivelytoprevententryofanexternalatmosphere 20 ). nRrestrictedbreathing(enclosurethatisdesignedtorestricttheentryofgases, vapoursandmists 21 ).

SomeelectricaldevicesusedinrefrigerationsystemsmeettherequirementsofIECEN60079 typenprotection,buthavenotbeentestedtoconfirmthis.Deviceswhicharetypen mustbetestedbyanapprovednotifiedbodyandcorrectlydocumented.

5.2Cabinetswithdoorsandwells
Intheeventofaleakintoacabinetwithdoorstherefrigerantcannotdisperseifthedoors remainclosed,e.g.outoftradinghours.ThepersistencetimeabovetheLFListherefore greaterthanwithopencabinets.Thisaffectstheareaclassificationtheinsideofthe cabinetshouldbetreatedasazone2area.FanmotorsshouldcomplywithEN6007915or beExrated.Othersourcesofignitionshouldberemovedfromtheinsideofthecabinet suchasdoorswitchesandheaterklixonsorreplacedwithsuitableelectricstestedto EN6007915. Theabovemightalsoapplytowelltypecabinets.Testingshouldbecarriedouttocheckthe concentrationinthewellintheeventofaleak.Ifitisgreaterthan50%LFLtheabovewill apply. Considerationshouldbegiventotheareainfrontofcabinetwithdoorswhichcouldalsobe azone2areawhenthedoorsareopenedduring/afterarefrigerantleak.Measurements shouldbecarriedoutinfrontofthecabinettodeterminetheextentofthezone. Testingcarriedoutoncabinetswithdoorsorwellsshouldrecordthedurationthat50%LFL wasexceeded(i.e.thepersistencetime). Arefrigerantleakdetectorcouldbefittedintotheenclosedspacetoisolateallelectrical circuitsasanultimateprotection.Thedetectorshouldactivateatthepracticallimit (0.008kg/m3orapproximately4000ppm).Duetothenatureoftheoperatingenvironment andlongtermmaintenancethedetectorwouldbedeemedasfalliblesocannotactasa primaryprotectionmethod.

19 20

EN6007915:2010,3.7.2.3 EN6007915:2010,3.7.2.4 21 EN6007915:2010,3.7.3.ThespecifictestingcanbefoundinEN6007915,22.6. BRACodeofPractice,HCCabinetsFinalV1,January2012

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5.3Enclosures
Sparkingelectricaldevicescanbelocatedinasealedenclosurewithinthepotentially flammablezone.TheenclosuremustmeettherequirementsofIECEN6007915:2010.Any enclosurewillbedesignatedrestrictedbreathingduetoitsIPrating.Thetestingforthisis onerousanddifficulttoapplyphysicallyandisusuallycostprohibitive.

5.4Connection/disconnection
Electricalconnectionswithinapotentiallyflammablezonearehazardousifdisconnected whileenergised. Plugsandsockets,iftheyareallocatedandconnectedtoonlyonepartoftheequipment, shallbesecuredmechanicallytopreventunintentionalseparationorhaveaminimum separationforceof15Nm.Theequipmentshallbemarkedasfollows 22 : WARNINGdonotseparatewhenenergised. Fuseenclosuresshallbeinterlockedsothatthefusescanonlyberemovedorreplacedwith thesupplydisconnectedortheenclosureshallcarrythefollowingwarninglabel 23 : WARNINGdonotremoveorreplacefusewhenenergised. Thephotoshowsanexampleofalabelonadisplaycabinet.

5.5Wiring
Nonsheathedsinglecoresshallnotbeusedforliveconductors,unlesstheyareinstalled insideswitchboards,enclosuresorconduitsystems 24 .

22 23

EN6007915:2010,10.1and24.3.1 EN6007915:2010,9.4 24 EN6007914:2008,9.3.5 BRACodeofPractice,HCCabinetsFinalV1,January2012

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6.Airflow
Thissectioncoverstheuseofairflowtoreducetheextentofthepotentiallyflammable zoneintheeventofaleakandtheapplicationoftheoreticalVzcalculations. Zone2ofNE(NegligibleExtent) Ifitcanbedemonstratedthatatheoreticalflammablevolume(Vz)isbelow0.1m3theZone canbeclassedasaZone2ofNE(NegligibleExtent).ThecalculationforZone2NEcanbe foundinEN60079101,AnnexBwhichprovidesinformationandformulastoallowthe flammablezonetobecalculatedfromtherefrigerantleakrate,airflow,LFL,temperature andenclosurevolume.Iftheresultantpotentiallyflammablevolume(Vz)isequaltoorless than0.1m3itisconsideredtobeaZone2ofnegligibleextent. Theairflowassociatedwitharefrigerationsystemscondenserfan/sisusuallysufficientto reducethepotentiallyflammableareatoazoneofnegligibleextent 25 .Leaksimulation testingshouldbecarriedouttoprovetheresultsofanycalculationsasgeometryandactual airflowsachievedwillinfluencedispersionofHCrefrigerant.Anymeasurementexceeding 50%LFLindicatesthattheareacouldbepotentiallyflammableintheeventofaleakand thatairflowonitsownisnotsufficienttoprotectsourcesofignition.Seriousconsideration shouldalsobegiventofouledcondensersorfailedfanmotorswhichwouldreduce availableairflowsignificantly.

VentilationDegreeisHighwhenanevaluationoftheriskshowsthattheextentofpotential damageduetothesuddenincreaseintemperatureasaresultofignitionofanexplosivegas atmosphereofvolume=Vz,isnegligible.ThisisnormallywhenVzislessthan0.1m3.Air flowassociatedwithcondenserfansisgenerallyhigh. AvailabilityisGoodwhenventilationispresentvirtuallycontinuously. AvailabilityisFairifventilationisexpectedtobepresentduringnormaloperation. Discontinuitiesarepermittedprovidedtheyoccurinfrequentlyandforshortperiods.

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 Toavoidtheneedforchangestoelectricaldevicesorenclosureseither: Condenserfanscanberunconstantly(i.e.notswitchedoffwhenthesystemisdown totemperature).Thiswillincreasethepowerconsumptionofthesystem; or Asupplementaryfancanbeswitchedonwhenthecondenserfanisoff.Sufficient airflowisusuallyprovidedbyasmallerfanthanthatusedforcondensercooling,so thepowerrequirementassociatedwiththisoptionisusuallylessthanconstantly runningacondenserfan.Theairflowofthesupplementaryfanmustbetestedwith leaksimulationtoensuretheairflowissufficienttodispersetheHCrefrigerant. Note:Seriousconsiderationshouldbegiventofouledcondensersorfailedfanmotorsboth reducingavailableairflowsignificantly,especiallyiftheyaretheprimaryprotectionmethod forsourcesofignition.

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7.LabellingandDocumentation
ThissectioncoversthelabellingofsystemschargedwithHCrefrigerant. Systemsshouldbeclearlylabelled,withtheISOlabel(right),toshow therefrigeranttypeandthatitisflammable. Itisrecommendedthatanadditionallabelisfixedtothesystemtoprovidebasicsafety informationtoserviceengineers.AnexamplelabelforanR290systemisshownbelow. RefrigerantR290(Care40,Propane) ThisunitmustnotbelocatedinanroomorareawithavolumelessthanXXXm3. Note:Onlyengineerswhohavebeentrainedinthesafehandlinganduseofhydrocarbon (HC)refrigerantsshouldworkonthissystem. Workonthissysteminawellventilatedareaor outside. Usealocalleakdetectortoindicateifthereis hydrocarbonintheairaroundthesystembeforeand duringworkonthesystem(placeitatlowlevelHCs areheavierthanair). Ensuretherearenosourcesofignition(flamesor sparkingelectricalcomponents)within3m(10feet) ofyourworkarea. Ifreplacingcomponents,uselikeforlike replacements. TakegreatcarewhenbrazingtoensureallHChasbeenremovedfromthesystem. Userefrigerantgradepropane(R290orCARE40). Theminimumroomvolumeiscalculatedusingthepracticallimit(0.008kg/m3).

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8.Manufacture
Thissectionprovidesoutlineinformationabouttheaspectsofmanufacturerelatedtothe useofHCrefrigerants. Systemsshouldbeprocessedtoensurejointsaresafeandleaktightinaccordancewith EN378: Strengthtestedto1.1xPS; Leaktightnesstestedto1xPS,measuredusingasystemwithasensitivityof 3g/year; wherePSisthesystempressureasdefinedinEN3781:2008. Thesystemshouldthenbeevacuatedto375microns(0.375Torr,0.5mbar)beforecharging. Thepressuretestingforstrengthandleaktightness,thevacuumachievedandperformance checksshouldberecorded. ConsiderationshouldbegiventothefollowingpointswhendesigningtheHCcharging facility: Accuracyofchargeforcriticallychargedsystems.Becauseofthelowerchargeweight comparedtoHFCs,thetolerancecanbeaslowas5gincommercialcabinets. Location.TheHCchargingareamustnotbebelowgroundlevel.Theremustbenobelow groundareasadjacenttothechargingareaswhereleakingHCcouldcollect. Ventilation.Usuallytwolevelsofventilationareusedlowlevelfornormaloperation switchingtoahighlevelforemergencyoperation(e.g.intheeventofanHCleak).The ventilationshouldextractairatlowlevelfromthechargingareaanddischargeittoanarea outsidewhereHCwillbesafelydispersed.Fansandmotorsshouldberatedforuseina potentiallyflammableatmosphere. Sourcesofignition.Anareaaroundthechargingequipmentshouldbefreefromsourcesof ignition.Typicallythiswillbeanarea3mfromtheequipment,buttheactualzonewill dependonventilation,factorylayout,leakdetectionetc. HCgasdetection.ThetypeusedshouldaccuratelysensetheHC(s)beingused,andnotbe affectedbyotherairbornesubstances.Aninfraredsystemwillbethemostreliable.The systemshouldbeproperlycommissionedandregularlychecked.Sufficientsensorsshould beusedtoensurealeakofHCrefrigerantisdetected.Inthiseventthecontrolsystem shouldswitchonthehighlevelventilationandactivateanalarm.Thedetectionsystem shouldbesettoactivateat20%LFL. StorageofHCrefrigerant.TheminimumquantityofHCshouldbeinsidethechargingarea. AllotherHCcylindersshouldbestoredoutsideinasafearea. Operatortraining.OperatorschargingHCrefrigerantandtheirsupervisorsshouldbe trainedinthesafehandlingofHCs(seesection10formoreinformation).
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 Access.AccesstotheHCchargingareashouldberestrictedtopersonnelwhohave receivedsafehandlingtraining.Theareashouldbeclearlymarkedwithwarningsigns.The chargingareashouldbeeasilyaccessibleintheeventofanemergency. HCsupply.AnypipeworkassociatedwithHCchargingshouldbeprotectedfromaccidental damage.TheHCcylinderorvesselshouldbefittedwithanexcessflowvalve. Fireextinguishers.Fireextinguishersshouldbelocatedinthechargingarea(drypowderor CO2types). Afterchargingthefinaljoint(s)mustbeleaktested.

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9.EndUserPostInstallationChecks
EndusersusuallydrivethemovetoHCrefrigerants,butwherethisisnotthecasethey shouldbemadeawarethatsystemsarechargedwithHCs.Whereapplicableinformation abouttheminimumroomsizetheequipmentcanbelocatedinandtheflammablezone aroundthecabinetshouldbeprovided. ItisrecommendedthattheapplicationandinstallationofHCcabinetsarechecked,for examplebyanindependentexpert.Thisshouldincludeconfirmationthat: Thecabinethasbeenproducedtospecification; ItslocationisinaccordancewithEN3781:2008; SourcesofignitionarenotlocatedinapotentiallyflammablezonearoundHC cabinets; Appropriatelytrainedandqualifiedengineersworkonthecabinets.

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10.ServiceandRepair
ThissectionprovidesanoutlineoftheserviceandmaintenanceofHCsystems,where proceduresandequipmentdifferfromserviceofHFCsystems.

10.1Personalleakdetection
AnHCgasdetectorshouldbeusedtomonitortheairinthe Thedetectorshouldnothaveazerobackgroundfacility alarmatamaximumof20%LFL.Theengineerwouldneed todeterminethemostappropriateplacetolocatethe sensordependentontheworkingenvironment.Thephotos showsuitabledetectors. workarea. andshould

10.2Toolsandequipment
Standard(HFC)equipmentcanbeusedforservicingHCsystemswiththefollowing exceptions: Electronicleakdetectors.MostHFCleakdetectorsarenotsafeforusewithHCs andarenotsensitivetoHCs.ElectronicHC(combustiblegas)leakdetectorsare availablefromanumberofsuppliers. Recoverymachines.HFCrecoverymachinesarenotsafeforusewithHCssoone speciallydesignedforusewithHCsmustbeused. Scales.MoreaccuratescalesarenecessarywhenchargingHCsystemswithasmall, criticalcharge.Anaccuracyof5gisoftennecessarymostscalesusedforservice arenotthisaccurate. Additionalsafetyequipmentisalsorequired: AdrypowderorCO2fireextinguisher. Asuitableventilationfanshouldbeusedwhen workinginsideifthereisinsufficientnatural ventilation.Anexampleisshowninthephoto whichhasanExratedfanmotoranda5m extensionleadsothefancanbeswitched outsidethe3mworkarea.

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10.3Procedures
Ingeneral,goodrefrigerationpracticeshouldbefollowedwhenservicingHCequipment. Differencesareoutlinedbelow. Theworkareamustbewellventilatedwithnosourceofignitionwithin3m (typically)oftheHCsystemandequipmentsuchasavacuumpumpandrecovery machine. Thevacuumpumpshouldbecontrolledbyaswitchoutsidethe3mzone(the vacuumpumpsswitchshouldnotbeusedasitisasourceofignition).Careshould betakentoensurethatthevacuumpumphasnomotorstarterssuchasrelaysor centrifugalswitches.ThevacuumpumpcoulddischargeresidualHCssoshouldbe locatedinawellventilatedarea. IftheHCchargeislessthan150gitcanbeventedratherthanrecovered,providing itcanbeventedtooutsideabuildingandsafelydispersed. PriortounbrazingjointstheHCmustberemovedfromthesystem,andthesystem filledwithnitrogen.Forsystemwithmorethan150gchargetheprocedureis: 1. RecovertheHCfromthesystem. 2. Runtherecoverymachineforaslongaspossiblesothesystemisundervacuum andasmuchoftheHCchargeisremovedfromthesystemaspossible.Note themachinecommonlyusedforHCrecovery(theCaresaver)canonlyberunfor 5minuteswiththelowpressureswitchbypassed,butthisshouldbesufficient. 3. Fillthesystemwithdrynitrogentoaslightpositivepressure. 4. Releasethepressureandleavethesystemconnectedtotheventlineandopen. 5. Unbrazeconnectionsasquicklyaspossiblewearglovesandgoggles. NotewhenrecoveringHCfromlargesystemstheprocesscanbespeededupby recoveringintoevacuated,chilledrecoverycylinders. Faultyelectricaldevicesandcompressorsmustbereplacedwithlikeforlike components.

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11.Training
Thissectionoutlinesthetopicstobeincludedintrainingofserviceengineersand manufacturingpersonnel. EN378specifiesthatanyoneworkingonHCsystemsshouldbetrainedtoincludethe following 26 : Knowledgeoflegislation,regulationandstandardsrelatingtoflammable refrigerants; Detailedknowledgeofandskillinhandlingflammablerefrigerants,personal protectiveequipment,refrigerantleakageprevention,handlingofcylinders, charging,leakdetection,recoveryanddisposal. BOCspecifiesthatanyonepurchasingCARE(HC)refrigerantfromthemorHRPattendtheir awarenesstrainingsession.TheyregistertrainedengineersandissuephotoIDcards.The BOCsessioncoversthetopicslistedabove. CityandGuildsiscurrentlydevelopingahydrocarbonrefrigerantCPDmodulewhichalso coversthetopicslistedabove.ItwillbeanoptionalpartofC&G2079andshouldbe availableearly2012.

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Appendix1,SourcesofFurtherInformation
Thistablebelowprovidesdetailsoforganisationsandpublicationsformoreinformation aboutvariousaspectsofHCrefrigerants. Item Companieswhoprovideproductsand servicesrelatedtoHCrefrigerants InstituteofRefrigerationSafetyCodeof PracticeforsystemsutilisingA2andA3 refrigerants StandardsreferencedinthisCode CityandGuilds Website www.hydrocarbons21.com www.ior.org.uk http://shop.bsigroup.com/ www.cityandguilds.com

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Appendix2,StandardsandRegulations
ATEXisthenamecommonlygiventothelegalrequirementsforcontrollingexplosive atmospheresandthesuitabilityofequipmentandprotectivesystemsusedinthem.Itis unclearwhetherHCrefrigerationsystemswhicharedesignedtocontainsmallamountsof flammablegasarecoveredbythisdirective,andifsotowhatdegreetheyshouldcomply. ATEX95(94/9/EC)coversthedesignofequipmentandprotectivesystemsintendedforuse inpotentiallyexplosiveatmospheres. ATEX137(99/92/EC)coverstheminimumrequirementsforimprovingthesafetyandhealth protectionofworkerspotentiallyatriskfromexplosiveatmospheres.Itapplies,for example,toserviceengineersworkingonHCsystems.DSEAR(DangerousSubstancesand ExplosiveAtmosphereRegulations)istheUKimplementationofATEX137.Italsocovers, forexample,oxyacetylenebrazingintheworkplace. EN378isnotharmonisedwiththeATEXdirectiveanditdoesnotspecifythatATEXapplies, butitdoesreferenceotherATEXharmonisedstandardssuchasEN60079. DiscussionsarecurrentlyongoingbetweentheRACindustryandtheHealthandSafety ExecutivetoclarifythesituationregardingATEXandHCsystems.ThisCodeprovides guidancewhichfollowstheprinciplesofATEXwithregardtoflammablezonetestingand avoidanceofsourcesofignition.Manufacturersshouldfollowtheseprinciplesand documentallsimulatedleaktesting,assumptionsonleakrates,methodsofreducingleakage potentialanddecisionsregardingsourcesofignition. ThefollowingstandardsincludeguidanceonHCsystems. Guidance(relevanttorefrigerated Standard Title cabinetsusingHCrefrigerants) Refrigeratingsystemsandheat pumpsSafetyandenvironmental Practicallimit EN3781:2008 requirements,Basicrequirements, Maximumchargesizes definitions,classificationand selectioncriteria Refrigeratingsystemsandheat pumpsSafetyandenvironmental Highpressureprotection EN3782:2008 requirements,Design, Ventilatedenclosures construction,testing,markingand documentation Refrigeratingsystemsandheat pumpsSafetyandenvironmental Machineryrooms EN3783:2008 requirements,Installationsiteand HCdetectors personalprotection Refrigeratingsystemsandheat RepairstoHCsystems pumpsSafetyandenvironmental EN3784:2008 Competenceofpersonnelworkingon requirements,Operation, HCsystems maintenance,repairandrecovery

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 Categorisationofflammablegases Classificationofequipment Zones Zonesandclassificationofequipment Leaksimulationtesting Vz(volumeofflammablezone) Airflowrequirements Locationofsourcesofignition Wiring Electricalequipmentandenclosures foruseinpotentiallyflammable areas Labellingofelectricalequipment Systemswithlessthan150gHC charge.

EN60079 0:2009 EN6007910 1:2009 EN60079 14:2008 EN60079 15:2010

Explosiveatmospheres Equipmentgeneralrequirements Explosiveatmospheres Classificationofareasexplosive gasatmospheres ExplosiveatmospheresElectrical installationsdesign,selectionand erection Explosiveatmospheres Equipmentprotectionbytypeof protectionn Household&similarelectrical appliancesSafety Part224:Particularrequirements forrefrigeratingappliances,ice creamappliances&icemakers Household&similarelectrical appliancesSafety Part289:Particularrequirements forcommercial refrigeratingapplianceswithan incorporatedor remoterefrigerantcondensingunit orcompressor SafetyCodeofPracticefor RefrigeratingSystemsutilisingA2 andA3refrigerants

EN603352 24:2010

EN603352 89:2010

Systemswithlessthan150gHC charge,leaksimulationtestingfor areaclassification.

Instituteof Refrigeration

Generalguidance

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