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Change for life Owner's Manual Original Instructions Console Type Air Conditioner Thank you for choosing our product. Please read this Owner’s Manual carefully before operation and retain it for future reference. If you have lost the Owner's Manual, please contact the local agent or visit www.gree.com or send an email to global@cn.gree.com for the electronic version.
GEH09AA-K6DNA1F/O GEH12AA-K6DNA1A/O GEH18AA-K6DNA1F/O
Content Operation Notices Precautions............................................................................................................2 The Refrigerant......................................................................................................1 Parts name............................................................................................................7 Installation Notice Safety operation of flammable refrigerant.............................................................8 Installation dimension diagram ............................................................................10 Safety precautions for installing and relocating the unit.......................................11 Tools for installation .............................................................................................12 Selection of installation location ..........................................................................12 Requirements for electric connection ..................................................................13 Installation Installation of outdoor unit ...................................................................................14 Vacuum pumping .................................................................................................17 Leakage detection ...............................................................................................17 Check after installation ........................................................................................18 Test and operation Test operation ......................................................................................................18 Attachment Configuration of connection pipe Pipe expanding method .......................................................................................21 Specialist’s Manual ..............................................................................................22 This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. This marking indicates that this product should not be disposed with other household wastes throughout the EU. To prevent possible harm to the environment or human health from un- controlled waste disposal, recycle it responsibly to promote the sustainable reuse of mate- rial resources. To return your used device, please use the return and collection systems or contact the retailer where the product was purchased. They can take this product for envi- ronmental safe recycling. R32: 675 .........................................................................19
Explanation of Symbols DANGER WARNING CAUTION NOTICE Exception Clauses Manufacturer will bear no responsibilities when personal injury or property loss is caused by the following reasons. 1.Damage the product due to improper use or misuse of the product; 2.Alter, change, maintain or use the product with other equipment without abiding by the instruction manual of manufacturer; After verification, the defect of product is directly caused by corrosive gas; 3. After verification, defects are due to improper operation during transportation of product; 4. Operate, repair, maintain the unit without abiding by instruction manual or related regulations; 5. After verification, the problem or dispute is caused by the quality specification or performance of parts and components that produced by other manufacturers; 6. The damage is caused by natural calamities, bad using environment or force majeure. 7. If it needs to install, move or maintain the air conditioner, please contact dealer or local service center to conduct it at first. Air conditioner must be installed, moved or maintained by appointed unit. Otherwise, it may cause serious damage or personal injury or death. When refrigerant leaks or requires discharge during installation, maintenance, or disassembly, it should be handled by certified professionals or otherwise in compliance with local laws and regulations. Indicates a hazardous situation that, if not avoided, will result in death or serious injury. Indicates a hazardous situation that, if not avoided, could result in death or serious injury. Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury. Indicates important but not hazard-related information, used to indicate risk of property damage. Indicates a hazard that would be assigned a signal word WARNING or CAUTION.
Please read this operating manual carefully before operating the unit. to the material objects for reference. The Refrigerant ●To realize the function of the air conditioner unit, a special refrigerant circulates . lead to explosion ●Compared to common refrigerants, R32 is a nonpolluting refrigerant with no lower. R32 has got very good thermodynamic features which lead to a really high WARNING: Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacture.Should repair be necessary, contact your nearest authorized Service Centre. The appliance shall be stored in a room without continuously operating ignition electric heater.) Do not pierce or burn. Appliance shall be installed, operated and stored in a room with a floor area larger than “X”m .(Please refer to table "a" in section of " Safety operation of flammable refrigerant " for Space X.) 2 ’s instructions only. Be aware that refrigerants may not contain an odour. Read specialist’s manual. 1 . It can
Precautions Operation and Maintenance This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision. conditioner. Otherwise, it may cause electric shock. If the supply cord is damaged, it must be replaced by electric shock. shock or malfunction. 2
Precautions Maintenance must be performed by qualified professionals. Otherwise, it may cause personal injury or damage. Do not repair air conditioner by yourself. It may cause electric shock or damage. Please contact dealer when you need to repair air conditioner. Do not extend fingers or objects into air inlet or air outlet. It may cause personal injury or damage. Do not block air outlet or air inlet. It may cause malfunction. Do not spill water on the remote controller, otherwise the remote controller may be broken. When below phenomenon occurs, please turn off air conditioner and disconnect power immediately, and then contact the dealer or qualified professionals for service. ●Power cord is overheating or damaged. ●There’s abnormal sound during operation. ●Circuit break trips off frequently. ●Air conditioner gives off burning smell. ●Indoor unit is leaking. If the air conditioner operates under abnormal conditions, it may cause malfunction, electric shock or fire hazard. When turning on or turning off the unit by emergency operation switch, please press this switch with an insulating object other than metal. objects. It may cause damage or personal injury. Do not step on top panel of outdoor unit, or put heavy WARNING 3
Precautions Attachment Installation must be performed by qualified professionals. Otherwise, it may cause personal injury or damage. Must follow the electric safety regulations when installing the unit. According to the local safety regulations, use qualified power supply circuit and circuit break. Do install the circuit break. If not, it may cause malfunction. An all-pole disconnection switch having a contact separation of at least 3mm in all poles should be connected in fixed wiring. Including an circuit break with suitable capacity, please note the following table. Air switch should be included magnet buckle and heating buckle function, it can protect the circuit-short and overload. Air Conditioner should be properly grounded. Incorrect Don't use unqualified power cord. grounding may cause electric shock. Make sure the power supply matches with the requirement of air conditioner. Unstable power supply or incorrect wiring may result in electric shock, fire hazard or malfunction. Please install proper power supply cables before using the air conditioner. grounding wire of power socket. Properly connect the live wire, neutral wire and any work related to electricity and safety. Be sure to cut off the power supply before proceeding WARNING 4
Precautions Do not put through the power before finishing installation. the manufacturer, its service agent or similarly qualified If the supply cord is damaged, it must be replaced by persons in order to avoid a hazard. The temperature of refrigerant circuit will be high, please keep the interconnection cable away from the copper tube. The appliance shall be installed in accordance with national wiring regulations. Installation must be performed in accordance with the requirement of NEC and CEC by authorized personnel only. The air conditioner is the first class electric appliance. It must be properly grounding with specialized grounding device by a professional. Please make sure it is always grounded effectively, otherwise it may cause electric shock. The yellow-green wire in air conditioner is grounding wire, which can't be used for other purposes. The grounding resistance should comply with national electric safety regulations. The appliance must be positioned so that the plug is accessible. All wires of indoor unit and outdoor unit should be connected by a professional. If the length of power connection wire is insufficient, please contact the supplier for a new one. Avoid extending the wire by yourself. WARNING 5
Precautions reachable after finishing installation. For the air conditioner with plug, the plug should be If you need to relocate the air conditioner to another must be installed in the line. For the air conditioner without plug, an circuit break place, only the qualified person can perform the work. Otherwise, it may cause personal injury or damage. Select a location which is out of reach for children and far away from animals or plants. If it is unavoidable, please add the fence for safety purpose. The indoor unit should be installed close to the wall. Instructions for installation and use of this product are provided by the manufacturer. Working temperature range Indoor side DB/WB(℃) Outdoor side DB/WB(℃) Maximum cooling 32/23 43/26 Maximum heating 27/- 24/18 NOTICE: ● The operating temperature range (outdoor temperature) for cooling only unit is -15℃~ 43℃; for heat pump unit is -22℃~ 43℃. WARNING 6
Parts name Indoor Unit Outdoor Unit NOTICE: Actual product may be different from above graphics, please refer to actual products. air inlet Connection wire air outlet 7
Safety operation of flammable refrigerant Qualification requirement for installation and maintenance man All the work men who are engaging in the refrigeration system should bear the valid certification awarded by the authoritative organization and the qualification for dealing with the refrigeration system recognized by this industry. If it needs other technician to maintain and repair the appliance, they should be supervised by the person who bears the qualification for using the flammable refrigerant. It can only be repaired by the method suggested by the equipment’s manufacturer. Installation notes The air conditioner is not allowed to use in a room that has running fire (such as fire source, working coal gas ware, operating heater). It is not allowed to drill hole or burn the connection pipe. The air conditioner must be installed in a room that is larger than the minimum room area. The minimum room area is shown on the nameplate or following table a. Leak test is a must after installation. table a- Minimum room area ( m ) 2 Charge amount (kg) ≤1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 floor location / 14.5 16.8 19.3 22 24.8 27.8 31 34.3 37.8 41.5 45.4 49.4 53.6 Minimum / room window mounted 5.2 6.1 7 7.9 8.9 10 11.2 12.4 13.6 15 16.3 17.8 19.3 2 area( m ) wall mounted / 1.6 1.9 2.1 2.4 2.8 3.1 3.4 3.8 4.2 4.6 5 5.5 6 ceiling mounted / 1.1 1.3 1.4 1.6 1.8 2.1 2.3 2.6 2.8 3.1 3.4 3.7 4 Maintenance notes Check whether the maintenance area or the room area meet the requirement of the nameplate. - It’s only allowed to be operated in the rooms that meet the requirement of the nameplate. Check whether the maintenance area is well-ventilated. - The continuous ventilation status should be kept during the operation process. Check whether there is fire source or potential fire source in the maintenance area. - The naked flame is prohibited in the maintenance area; and the “no smoking” warning board should be hanged. Check whether the appliance mark is in good condition. - Replace the vague or damaged warning mark. Welding If you should cut or weld the refrigerant system pipes in the process of maintaining, please follow the steps as below: 8
Safety operation of flammable refrigerant a. Shut down the unit and cut power supply b. Eliminate the refrigerant c. Vacuuming d. Clean it with N2 gas e. Cutting or welding f. Carry back to the service spot for welding The refrigerant should be recycled into the specialized storage tank. Make sure that there isn’t any naked flame near the outlet of the vacuum pump and it’s well-ventilated. Filling the refrigerant Use the refrigerant filling appliances specialized for R32. Make sure that different kinds of refrigerant won’t contaminate with each other. The refrigerant tank should be kept upright at the time of filling refrigerant. Stick the label on the system after filling is finished (or haven’t finished). Don’t overfilling. After filling is finished, please do the leakage detection before test running; another time of leak detection should be done when it’s removed. Safety instructions for transportation and storage Please use the flammable gas detector to check before unload and open the container. No fire source and smoking. According to the local rules and laws. 9
Installation dimension diagram Space to the obstruction Space to the At least 50cm obstruction At least 30cm At least 30cm Space to the wall Space to the obstruction At least 200cm At least 50cm Space to the obstruction Drainage pipe 10
Safety precautions for installing and relocating the unit To ensure safety, please be mindful of the following precautions. Warning When installing or relocating the unit, be sure to keep the refrigerant circuit free from air or substances other than the specified refrigerant. Any presence of air or other foreign substance in the refrigerant circuit will cause system pressure rise or compressor rupture, resulting in injury. When installing or moving this unit, do not charge the refrigerant which is not comply with that on the nameplate or unqualified refrigerant. Otherwise, it may cause abnormal operation, wrong action, mechanical malfunction or even series safety accident. When refrigerant needs to be recovered during relocating or repairing the unit, be sure that the unit is running in cooling mode.Then, fully close the valve at high pressure side (liquid valve).About 30-40 seconds later, fully close the valve at low pressure side (gas valve), immediately stop the unit and disconnect power. Please note that the time for refrigerant recovery should not exceed 1 minute. If refrigerant recovery takes too much time, air may be sucked in and cause pressure rise or compressor rupture, resulting in injury. During refrigerant recovery, make sure that liquid valve and gas valve are fully closed and power is disconnected before detaching the connection pipe. If compressor starts running when stop valve is open and connection pipe is not yet connected, air will be sucked in and cause pressure rise or compressor rupture, resulting in injury. When installing the unit, make sure that connection pipe is securely connected before the compressor starts running. If compressor starts running when stop valve is open and connection pipe is not yet connected, air will be sucked in and cause pressure rise or compressor rupture, resulting in injury. Prohibit installing the unit at the place where there may be leaked corrosive gas or flammable gas. If there leaked gas around the unit, it may cause explosion and other accidents. Do not use extension cords for electrical connections. If the electric wire is not long enough, please contact a local service center authorized and ask for a proper electric wire. Poor connections may lead to electric shock or fire. Use the specified types of wires for electrical connections between the indoor and outdoor units. Firmly clamp the wires so that their terminals receive no external stresses. Electric wires with insufficient capacity, wrong wire connections and insecure wire terminals may cause electric shock or fire. 11
Tools for installation
1 Level meter
2 Screw driver
3 Impact drill
4 Drill head
5 Pipe expander
6 Torque wrench
7 Open-end wrench
8 Pipe cutter
9 Leakage detector
10 Vacuum pump
11 Pressure meter
12 Universal meter
13 Inner hexagon spanner
14 Measuring tape
Note:
●Please contact the local agent for installation.
Selection of installation location
Basic requirement
Installing the unit in the following places may cause malfunction. If it is un-
avoidable, please consult the local dealer:
1.The place with strong heat sources, vapors, flammable or explosive gas, or
volatile objects spread in the air.
2.The place with high-frequency devices (such as welding machine, medical
equipment).
3. The place near coast area.
4. The place with oil or fumes in the air.
5. The place with sulfureted gas.
6. Other places with special circumstances.
7. The appliance shall not be installed in the laundry.
8. It’s not allowed to be installed on the unstable or motive base structure
(such as truck) or in the corrosive environment (such as chemical factory).
Outdoor unit
will not affect neighborhood.
2. The location should be well ventilated and dry, in which the outdoor unit
won't be exposed directly to sunlight or strong wind.
3. The location should be able to withstand the weight of outdoor unit.
4. Make sure that the installation follows the requirement of installation
dimension diagram.
5. Select a location which is out of reach for children and far away from animals
or plants.If it is unavoidable, please add the fence for safety purpose.
12Requirements for electric connection
Safety precaution
1.
Must follow the electric safety regulations when installing the unit.
3.
Make sure the power supply matches with the requirement of air conditioner.
Unstable power supply or incorrect wiring or malfunction. Please install proper
power supply cables before using the air conditioner.
Properly connect the live wire, neutral wire and grounding wire of power socket.
Be sure to cut off the power supply before proceeding any work related to
electricity and safety. For models with a power plug, make sure the plug is
within reach after installation.
4.
5.
7.
If the supply cord is damaged, it must be replaced by the manufacturer, its
The temperature of refrigerant circuit will be high, please keep the interconnec-
tion cable away from the copper tube.
9.
10.
The appliance shall be installed in accordance with national wiring regulations.
8.
Appliance shall be installed, operated and stored in a room with a floor area
larger than “X”m (see table a).
2
Please notice that the unit is filled with flammable gas R32. Inappropriate
treatment of the unit involves the risk of severe damages of people and
material. Details to this refrigerant are found in chapter “refrigerant”.
Grounding requirement
grounding with specialized grounding device by a professional. Please make
sure it is always grounded effectively, otherwise it may cause electric shock.
2.
The yellow-green wire in air conditioner is grounding wire, which can't be used
for other purposes.
3.
4.
5.
The grounding resistance should comply with national electric safety regulations.
The appliance must be positioned so that the plug is accessible.
An all-pole disconnection switch having a contact separation of at least 3mm in
6.
Including an air switch with suitable capacity, please note the following table. Air
switch should be included magnet buckle and heating buckle function, it can
protect the circuit-short and overload. (Caution: please do not use the fuse only
for protect the circuit)
Air-conditioner
Circuit break capacity
09K
12K
16A
10A
18K
16A
13
air switch.Installation of outdoor unit (select it according to the actual installation situation) 1. Select installation location according to the house structure. 2. Fix the support of outdoor unit on the selected location with expansion screws. Note: installing the outdoor unit. Make sure the support can withstand at least four times of the unit weight. ● ● The outdoor unit should be installed at least joint. (for the model with heating tube, the installation height should be no less than 20cm.) ●For the unit with cooling capacity of 2300W ~5000W, 6 expansion screws are needed; for the unit with cooling capacity of 6000W ~8000W, 8 expansion screws are needed; for the unit with cooling capacity of 10000W ~16000W, 10 expansion screws are needed. Step two: install drain joint (Only for some models) 1. Connect the outdoor drain joint into the hole on the chassis, as shown in the picture below. 2. Connect the drain hose into the drain vent. foot holes NOTE: As for the shape of drainage joint, please refer to the current product. Do not install the drainage joint in the severe cold area. Otherwise,it will be frosted and then cause malfunction. drain vent chassis Drain hose outdoor drain joint at least 3cm above the floor 1. Place the outdoor unit on the support. Fix the foot holes of outdoor unit with bolts. 2. foot holes 14
Installation of outdoor unit
Step four: connect indoor and outdoor pipes
3. Pretighten the union nut with hand.
1. Remove the screw on the right han-
dle of outdoor unit and then remove
the handle.
pipe joint
screw
union nut
handle
2. Remove the screw cap of valve and
aim the pipe joint at the bellmouth of
pipe.
4. Tighten the union nut with torque
wrench by referring to the sheet
below.
Hex nut diameter Tightening torque
liquid pipe
(N.m)
Φ 6
Φ 9.52
15~20
liquid
valve
gas pipe
30~40
45~55
60~65
70~75
Φ 12
Φ 16
Φ 19
gas valve
1. Remove the wire clip; connect the power connection wire and signal control
wire (only for cooling and heating unit) to the wiring terminal according to the
09、12K：
18K：
N(1)
2
3
N(1)
2
3 L N
N
L
(black)
black
yellow-
green
blue
blue
brown brown
yellow-
green
blue
blue
black
yellow-
green
yellow-
green
brown
brown
(black)
L
N
N
L
Indoor unit connection
POWER
Indoor unit connection
POWER
Note: the wiring board is for reference only, please refer to the actual one
15Installation of outdoor unit 2. Fix the power connection wire and signal control wire with wire clip (only for cooling and heating unit). Note: ●Never cut the power connection wire to prolong or shorten the distance. Step six: neaten the pipes 1. The pipes should be placed along the wall, bent reasonably and hidden possibly. Min. semidiameter of bending the pipe is 10cm. 2. If the outdoor unit is higher than the wall hole, you must set a U-shaped curve in the pipe before pipe goes into the room, in order to prevent rain from getting into the room. wall U-shaped curve drain hose 16
Vacuum pumping
Use vacuum pump
1. Remove the valve caps on
the liquid valve and gas
valve and the nut of refri-
gerant charging vent.
2. Connect the charging hose
of piezometer to the refri-
gerant charging vent of gas
valve and then connect the
other charging hose to the
vacuum pump.
3. Open the piezometer com-
pletely and operate for
10-15min to check if the
pressure of piezometer re-
mains in -0.1MPa.
4. Close the vacuum pump
and maintain this status for
1-2min to check if the pres-
sure of piezometer remains
in -0.1MPa. If the pressure decreases, there may be leakage.
5. Remove the piezometer, open the valve core of liquid valve and gas valve
completely with inner hexagon spanner.
6. Tighten the screw caps of valves and refrigerant charging vent.
7. Reinstall the handle.
Leakage detection
1. With leakage detector:
Check if there is leakage with leakage detector.
2. With soap water:
If leakage detector is not available, please use soap water for leakage detection.
Apply soap water at the suspected position and keep the soap water for more
than 3min. If there are air bubbles coming out of this position, there's a leakage.
liquid valve
piezometer
Lo
Hi
gas valve
refrigerant
charging vent
valve cap
nut of refrigerant
charging vent
vacuum pump
inner hexagon
spanner
close
open
17Check after installation Items to be checked Possible malfunction Have you done the refrigerant leakage test? (heating) capacity. Is water drained well? It may cause condensation and water dripping. Is the voltage of power supply accord- ing to the voltage marked on the nameplate? Is electric wiring and pipeline installed correctly? Is the unit grounded securely? It may cause electric leakage. Does the power cord follow the speci- It may cause malfunction or damaging the parts. Is there any obstruction in the air inlet and outlet? (heating) capacity. The dust and sundries caused during installation are removed? The gas valve and liquid valve of connection pipe are open completely? Is the inlet and outlet of piping hole been covered? Test operation 1. Preparation of test operation ●The client approves the air conditioner. ●Specify the important notes for air conditioner to the client. 2. Method of test operation ●Put through the power, press ON/OFF button on the remote controller to start operation. ●Press MODE button to select AUTO, COOL, DRY, FAN and HEAT to check whether the operation is normal or not. ●If the ambient temperature is lower than 16℃, the air conditioner can’t start cooling. The unit may drop, shake or emit noise. It may cause condensation and water dripping. It may cause malfunction or damaging the parts. It may cause malfunction or damaging the parts. It may cause malfunction or damaging the parts. (heating) capacity. It may cause insufficient cooling (heating) capacity or waster eletricity. 18
Configuration of connection pipe
1. Standard length of connection pipe
●5m、7.5m、8m
2. Min. length of connection pipe
For the unit with standard connection pipe of 5m, there is no limitation for the
min. length of connection pipe. For the unit with standard connection pipe of
7.5m and 8m, the min. length of connection pipe is 3m.
3. Max. length of connection pipe
Sheet 1 Max. length of connection pipe
Unit: m
Max. length of
connection pipe
capacity
capacity
5000Btu/h
(1465W)
24000Btu/h
(7032W)
15
25
7000Btu/h
(2051W)
28000Btu/h
(8204W)
15
30
9000Btu/h
(2637W)
36000Btu/h
(10548W)
15
30
12000Btu/h
(3516W)
42000Btu/h
(12306W)
20
30
18000Btu/h
(5274W)
48000Btu/h
(14064W)
25
30
4. The calculation method of additional refrigerant oil and refrigerant charging amount
after prolonging connection pipe
After the length of connection pipe is prolonged for 10m at the basis of standard
length, you should add 5ml of refrigerant oil for each additional 5m of connection
pipe.
The calculation method of additional refrigerant charging amount (on the basis
of liquid pipe):
(1) Additional refrigerant charging amount= prolonged length of liquid pipe × additional
refrigerant charging amount per meter
Basing on the length of standard pipe, add refrigerant according to the
requirement as shown in the table. The additional refrigerant charging amount
per meter is different according to the diameter of liquid pipe. See Sheet 2.
(2)
19
Max. length of
connection pipeConfiguration of connection pipe Sheet 2. Additional refrigerant charging amount for R32 Diameter of connection pipe mm Indoor unit throttle Outdoor unit throttle Cooling only, cooling and heating cooling and Cooling only Liquid pipe Gas pipe heating (g / m) (g / m) (g / m) Ф6 Ф9.5 or Ф12 16 12 16 Ф6 or Ф9.5 Ф16 or Ф19 40 12 40 Ф12 Ф19 or Ф22.2 80 24 96 Ф16 Ф25.4 or Ф31.8 136 48 96 _ Ф19 200 200 200 _ Ф22.2 280 280 280 Note: The additional refrigerant charging amount in Sheet 2 is recommended value, not compulsory. 20
Pipe expanding method
Note:
Improper pipe expanding is the main cause of refrigerant leakage. Please expand
the pipe according to the following steps:
A: Cut the pipe
E: Expand the port
●Expand the port with expander.
the distance of indoor unit and
outdoor unit.
●Cut the required pipe with pipe cutter.
pipe
hard
mold
expander
pipe
pipe cutter
Note:
●"A" is different according to the
diameter, please refer to the sheet
below:
leaning
uneven
burr
A(mm)
Outer diameter
B: Remove the burrs
●Remove the burrs with shaper and
prevent the burrs from getting into
the pipe.
(mm)
Max
Min
Φ6 - 6.35(1/4")
1.3
0.7
Φ9.52(3/8")
1.6
1.0
pipe
Φ12-12.7(1/2")
1.8
1.0
shaper
Φ15.8-16(5/8")
2.4
2.2
downwards
F: Inspection
●Check the quality of expanding port.
If there is any blemish, expand the
port again according to the steps
above.
C: Put on suitable insulating pipe
D: Put on the union nut
●Remove the union nut on the indoor
connection pipe and outdoor valve;
install the union nut on the pipe.
smooth surface
improper expanding
union pipe
leaning
damaged
crack
uneven
thickness
surface
pipe
the length is equal
21Specialist’s Manual The following checks shall be applied to installations using flammable refrig- erants: – the charge size is in accordance with the room size within which the refrigerant containing parts are installed; – the ventilation machinery and outlets are operating adequately and are not obstructed; – if an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant; – marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected; – refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing compo- nents, unless the components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded. Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised. Initial safety checks shall include: – that capacitors are discharged: this shall be done in a safe manner to avoid possi- bility of sparking; – that no live electrical components and wiring are exposed while charging, recover- ing or purging the system; – that there is continuity of earth bonding. Checking for presence of refrigerant The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially toxic or flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants, i.e. non-sparking, adequately sealed or intrinsi- cally safe. Presence of fire extinguisher If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry powder or CO2 fire extinguisher adjacent to the charging area. Ventilated area Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere. Leak detection methods Leak detection fluids are suitable for use with most refrigerants but the use of deter- gents containing chlorine shall be avoided as the chlorine may react with the refrig- erant and corrode the copper pipe-work. 22
Specialist’s Manual Checks to the refrigeration equipment Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer's maintenance and service guidelines shall be followed. If in doubt, consult the manufacturer's technical department for assistance. Checks to electrical devices – that capacitors are discharged: this shall be done in a safe manner to avoid possi- bility of sparking; – that no live electrical components and wiring are exposed while charging, recover- ing or purging the system. Repairs to sealed components During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely necessary to have an electrical supply to equipment during servic- ing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation. Particular attention shall be paid to the following to ensure that by working on electri- cal components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc. – Ensure that the apparatus is mounted securely. – Ensure that seals or sealing materials have not degraded to the point that they no longer serve the purpose of preventing the ingress of flammable atmospheres. Replacement parts shall be in accordance with the manufacturer’s specifications. NOTE:The use of silicon sealant can inhibit the effectiveness of some types of leak detection equipment. Intrinsically safe components do not have to be isolated prior to working on them. Repair to intrinsically safe components Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak. Cabling Check that cabling will not be subject to wear, corrosion, excessive pressure, vibra- tion, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans. Detection of flammable refrigerants Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used. 23
Specialist’s Manual
Decommissioning
Before carrying out this procedure, it is essential that the technician is completely
familiar with the equipment and all its detail. It is recommended good practice that
all refrigerants are recovered safely. Prior to the task being carried out, an oil and
refrigerant sample shall be taken in case analysis is required prior to re-use of
reclaimed refrigerant. It is essential that electrical power is available before the task
is commenced.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically.
c) Before attempting the procedure, ensure that:
– mechanical handling equipment is available, if required, for handling refrigerant
cylinders;
– all personal protective equipment is available and being used correctly;
– the recovery process is supervised at all times by a competent person;
– recovery equipment and cylinders conform to the appropriate standards.
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed
from various parts of the system.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with manufacturer's instruc-
tions.
h) Do not overfill cylinders. (No more than 80% volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make
sure that the cylinders and the equipment are removed from site promptly and all
isolation valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another refrigeration system
unless it has been cleaned and checked.
Labelling
Equipment shall be labelled stating that it has been de-commissioned and emptied
of refrigerant. The label shall be dated and signed. For appliances containing flam-
mable refrigerants, ensure that there are labels on the equipment stating the equip-
ment contains flammable refrigerant.
Recovery
When removing refrigerant from a system, either for servicing or decommissioning,
it is recommended good practice that all refrigerants are removed safely.
When transferring refrigerant into cylinders, ensure that only appropriate refrigerant
recovery cylinders are employed. Ensure that the correct number of cylinders for
holding the total system charge are available. All cylinders to be used are designat-
ed for the recovered refrigerant and labelled for that refrigerant (i.e. special cylin-
ders for the recovery of refrigerant). Cylinders shall be complete with pressure-re-
lief valve and associated shut-off valves in good working order. Empty recovery
cylinders are evacuated and, if possible, cooled before recovery occurs.
The recovery equipment shall be in good working order with a set of instructions
concerning the equipment that is at hand and shall be suitable for the recovery of all
appropriate refrigerants including, when applicable, flammable refrigerants. In addi-
tion, a set of calibrated weighing scales shall be available and in good working
order. Hoses shall be complete with leak-free disconnect couplings and in good
condition. Before using the recovery machine, check that it is in satisfactory working
24Specialist’s Manual order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult manufac- turer if in doubt. The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant waste transfer note arranged. Do not mix refrig- erants in recovery units and especially not in cylinders. If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The evacuation process shall be carried out prior to re- turning the compressor to the suppliers. Only electric heating to the compressor body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried out safely. 25
GREE ELECTRIC APPLIANCES, INC. OF ZHUHAI Add: West Jinji Rd, Qianshan, Zhuhai, Guangdong, China, 519070 Tel: (+86-756) 8522218 Fax: (+86-756) 8669426 E-mail: global@cn.gree.com Web: www.gree.com 600005061344