Carrier 42QZA009DS series User manual

CONSOLE TYPE AIR CONDITIONER
INSTALLATION MANUAL
IMROPTANT NOTE:
Read this manual carefully before installing or operating your new air conditioning unit.
Make sure to save this manual for future reference.
Please check the applicable models, F-GAS and manufacturer information from the
“Owner's Manual - Product Fiche” in the packaging of the outdoor unit.
(European Union products only)
L
G B
ENG ISH
INSTALLATION MANUAL
S K
SLOVENČINA
S Q
H R
HRVATSKI
B G
C Z
M K
МАКЕ
Д
О
Н
С
КИ
SHQIP
ČEŠTINA
БЪЛГАРСКИ
S R SRPSKI
R O ROMÂNĂ
S L
B S
MAGYAR
SLOVENŠČINA
BOSANSKI
H U
E L
ΕΓΧΕΙΡΙΔΙΟ ΕΓΚΑΤΑΣΤΑΣΗΣ
ΕΛΛΗΝΙΚΑ
MANUALI I INSTALIMIT
NÁVOD NA INŠTALÁCIU
УПАТСТВО ЗА МОНТИРАЊЕ
PRIRUČNIK ZA UGRADNJU
PRIRUČNIK ZA INSTALACIJU
UPUTSTVO ZA UGRADNJU
NAVODILA ZA NAMESTITEV
MANUAL DE INSTALARE
SZERELÉSI ÚTMUTATÓ
NÁVOD K INSTALACI
РЪКОВОДСТВО ЗА МОНТАЖ

The manufacturer reserves the right to change any product specifications without notice.
This product has been determined to be in compliance with the Low Voltage Directive (2014/35/EC),
and the Electromagnetic Compatibility Directive (2014/30/EC) ofthe European Union.
GB-1
CorrectDisposal ofThis Product
(Waste Electrical &Electronic Equipment)
(Whenusingthisairconditioner inEuropeancountries,thefollowingguidancemustbefollowed)
- This marking shown on the product or its literature, indicates that waste electrical and eletrical equipment
(WEEE as in directive 2012/19/EU) should not be mixed with general household waste.
It is prohibited to dispose of this appliance in domestic household waste.
For disposal, there are several possibilities:
1. The municipality has established collection systems, where electronic waste can be disposed of at least
free of charge to the user.
2. When buying a new product, the retailer will take back the old product at least free of charge.
3. The manufacture will take back the old appliance for disposal at least free of charge to the user.
4. As old products contain valuable resources, they can be sold to scrap metal dealers.
Wild disposal of waste in forests and landscapes endangers your health when hazardous substances leak
into the ground-water and find their way into the food chain.
ThisproductcontainsfluorinatedgasescoveredbytheKyotoProtocol
Chemical Name ofGas
Global Warming Potential (GWP) of Gas
R410A/R32
2088/ 675
CAUTION
1. Paste the enclosed refrigerant label adjacent to the
charging and/or recovering location.
2. Clearly write the charged refrigerant quantity on the
refrigerant label using indelible ink.
3. Prevent emission of the contained fluorinated gas.
Ensure that the fluorinated gas is never vented to
the atmosphere during installation, service or
disposal. When any leakage of the contained
fluorinated gas is detected, the leak shall be
stopped and repaired as soon as possible.
4. Only qualified service personnel are allowed to
access and service this product.
5. Any handling of the fluorinated gas in this product,
such as when moving the product or recharging
the gas, shall comply under (EC) Regulation
No. 517/2014 on certain fluorinated greenhouse
gases and any relevant local legislation.
6. Contact dealers, installers, etc., for any questions.
Indoor Unit Dimension(IDU) Outdoor Unit Dimension(ODU) Rated Voltage & Hz
42QZA009DS* 700x600x210 38QUS009DS* 770x300x555
42QZA012DS*
42QZA012D8S*
42QZA018DS* 700x600x210 38QUS018DS* 800x333x554
220-240V~ 50Hz
700x600x210
38QUS012DS*
800x333x554

CONTENTS
3
3
4
5
5
6
7
8
9
9
9
10
10
10
11
11
11
12
12
12
13
14
14
14
14
15
1. PREPARING FOR INSTALLATION ······································································
1.1 Safety Percautions ·························································································
1.2 Accessories ··································································································
2. INDOOR UNIT INSTALLATION ···········································································
2.1 Installation Site Choosing ················································································
2.2 Install The Indoor Unit ····················································································
2.3 How To Connect The Pipes And Wires ·······························································
2.4 Install The Drain Pipe ·····················································································
3. OUTDOOR UNIT INSTALLATION ······································································
3.1 Installation Site Choosing ················································································
3.2 Outdoor Unit Mounting Dimension ·····································································
3.3 Space Requirement For Outdoor Unit ·································································
3.4 Install The Outdoor Unit ················································································
3.5 Install The Drain Pipe For Outdoor Unit ······························································
4. REFRIGERANT PIPING WORK ··········································································
4.1 Flaring ·······································································································
4.2 Piping Work ·································································································
4.3 Refrigerant Pipe ··························································································
4.4 Air Evacuation ····························································································
4.5 Leakage Test ······························································································
5. WIRING ···········································································································
6. FINAL CHECK AND TRIAL OPERATION ····························································
6.1 Final Check List ····························································································
6.2 Manual Operation ·························································································
6.3 Trial Operation ·····························································································
7. INFORMATION SERVICING ·············································································
7
GB-2
Caution:Risk of fire
for R32/R290 refrigerant only
GB

GB-3
1. PREPARING FOR INSTALLATION
1.1 SAFETY PRECAUTIONS
WARNING
This symbol indicates the possibility of personnel injury or loss of life.
Refrigerant gas is heavier than air and replaces oxygen.Amassive leak could lead to oxygen depletion,
especially in basements, and an asphyxiation hazard could occur leading to serious injury or death.
When the air conditioner is installed in a small room, provide appropriate measures to ensure that
the concentration of refrigerant leakage occur in the room does not exceed the critical level.
If the refrigerant gas leaks during installation, ventilate the area immediately.
Refrigerant gas may produce a toxic gas if it comes in contact with fire such as from a fan heater, stove or
cooking device. Exposure to this gas could cause severe injury or death.
Disconnect from power source before attempting any electrical work. Connect the connective cable
correctly.
Wrongly connecting may result in electric parts damaged.
Use the specified cables for electrical connections and attach the wires firmly to the terminal block
connecting sections so that the external force is not exerted to the terminal.
Be sure to provide grounding.
Do not ground units to gas pipes, water pipes, lightning rods or telephone wires. Incomplete grounding could
cause a severe shock hazard resulting in injury or death.
Safely dispose of the packing materials.
Packing materials, such as nails and other matal or wooden parts, may cause stabs or other injuries. Tear apart
and throw away plastic pacaging bags so that children will not play with them. Children playing with plastic bags
face the danger of suffocation.
Do not install unit near concentrations of combustible gas or gas vapors.
Be sure to use the supplied or exact specified installation parts.
Use of other parts may cause the unit to come to lose, water leakage, electrical shock, fire or equipment
damage.
When installing or relocating the system, do not allow air or any substances other than the
specified refrigerant (R410A/R32) to enter the refrigeration cycle.
Never modify this unit by removing any of the safety guards or bypassing any of the safety
interlock switches.
Electrical work should be carried out in accordance with the installation manual and the national,
state and local electrical wiring codes.
Be sure to use a delicated power circuit. Never share the same power outlet with other appliance.
Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system ressures,
electrical components, and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should install, start-up, and serve this equipment.
When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached
to the equipment.
Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher
nearby when brazing. Use care in handing, rigging, and setting bulky equipment.
Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the
unit. Consult local building codes and National Electrical Code for special requirement.

7
GB-4
1. PREPARING FOR INSTALLATION
WARNING
In order to avoid a hazard due to inadvertent resetting of the thermal cut-out, this appliance must
not be supplied through an external switching device, such as a timer, or connected to a circuit
that is regularly switched on and off by the utility.
Use the prescribed cables for electrical connection with insulation protected by insulation
sleeving having an appropriate temperature rating.
Unconformable cables can cause electric leak, anomalous heat prodcution or fire.
NOTE: The following information are required for the units adopt R32/R290 Refrigerant.
The appliance shall be stored in a room without continuously operating ignition sources.
(for example: open flames, and operating gas appliance or an operating electric heater).
Do not pierce or burn.
Be aware that refrigerants may not contain an odour.
Compliance with national gas regulations shall be observed.
Appliance shall be stored in a well-ventilated area where the room size corresponds to the room
area as specified for operation.
Appliance shall be installed, operated and stored in a room with a floor area larger than X m²,
installation of pipe-work shall be kept to a minimum X m²(Please see the following form ).
Appliance shall not be installed in an unventilated space, if that space is smaller than X m²
(Please see the following form ).Spaces where refrigerant pipes shall be compliance with
national gas regulations.
Amount of refrigerant
to be charged (kg)
maximum installation
height (m)
Minimum room
area (m²)
≤2.048 1.8m 4
0.6m 35
2.048-3.0 1.8m 8
0.6m 80
>3.0 1.8m 9
Model(Btu/h)
≤30000
30000-48000
>48000
0.6m 80
CAUTION
This symbol indicates the possibility of property damage or serious consequences.
To avoid personal injury, be careful when handling parts with sharp edges.
Do not install the indoor or outdoor units in a location with special environmental conditions.
Do not install in a place that can amplify the noise level of the unit or where noise and discharged
air might disturb neighbors.
Note about Fluorinated Gases
This air-conditioning unit contains fluorinated gases. For specific information on the type of gas
and the amount, please refer to the relevant label on the unit itself.
Installation, service, maintenance and repair of this unit must be performed by a certified technician.
Product uninstallation and recycling must be performed by a certified technician.
If the system has a leak-detection system installed, it must be checked for leaks at least every 12
months.
When the unit is checked for leaks, proper record-keeping of all checks is strongly recommended.
GB

72GB-5
1. PREPARING FOR INSTALLATION
1.2 ACCESSORIES
1
Name of Accessories Q‘ty(pc)
1
Shape Use
To remote control the air conditioner
2
Battery
Tapped screw
Remote controller holder To hold the remote controller on the wall
For remote controller
The following accessories are supplied with the unit. The type and quantity may
differ depending on the specifications.
2
Remote Controller
To fix the remote controller holder
Note: The accessories related to remote controller will be unavailable for the models with wired
controller. For wired controller accessories, please refer to attached manual of wired controller.
3
1
Name of Accessories
Manual
Q‘ty(pc) Shape Use
1
<Installation manual>, <User manual>,
<Remote controller manual> (or
<Wired controller manual>)
Drain outlet
Connect drainage hose for outdoor unit.
Gasket
Seal the drainage outlet for outdoor unit.
The following accessories are related to remote controller.
1
Clamp filter
For conforming to EMC standards
(Used for indoor/outdoor connecting wires)
2
Hook
For installation
CAUTION
This symbol indicates the possibility of property damage or serious consequences.
Perform the drainage/piping work securely according to the installation manual.
Improper drain piping may result in water leakage and property damage.
Do not instal the air conditioner in the following places.
-The place where there is mineral oil or arsenic acid.
-The place where corrosive gas (such as sulfurous acid gas) or combustible gas (such as thinner)
can accumulate or collect, or where volatile combustible substances are handled.
-The place there is equipment that generates electromagnetic fields or high frequencey harmonics.
Mode
Timer
Turbo ION
LED
ON/OFF Fan
Follow
me
Self
clean

GB-6
2.1 INSTALLATION SITE CHOOSING
INDOOR UNIT
■Where it is out of direct sunlight.
■Where the airflow is not blocked.
■Where an optimum air distribution is ensured.
■Where the condensate can drain correctly and safely.
■Install the indoor unit on a wall/ceiling that prevents vibration and is strong enough to hold the product
weight.
■Maintain sufficient clearance around the indoor unit for maintenance and servicing.
■Where the air filter can be removed and cleaned easily.
■Where the piping between the indoor and outdoor units is within the allowable limits.
■Install the indoor unit 1m or more away from the TV or radio to prevent the screen from being distorted or
noise from being generated.
■Install the indoor unit as far away as possible from fluorescent and incandescent lights so that the remote
control can be operated well.
SPACE REQUIREMENT FOR INDOOR UNIT
The size of Outline dimension
Unit: mm
2. INDOOR UNIT INSTALLATION
≥100mm
≥100mm ≥100mm
≥1000mm
195
Hook
700 210
600
GB

2. INDOOR UNIT INSTALLATION
2.2.1 Fix the hook with tapping screw onto the wall.
2.2 INSTALL THE INDOOR UNIT
7GB-7
2.3 HOW TO CONNECT THE PIPES AND WIRES
2.3.1 Push the two switches simultaneously, then open the panel.
2.3.2 Remove the string and take off the panel.
The unit must be installed vertically.
CAUTION
195mm
Hook
Tapping
screw
Washer
＜6mm
2.2.1 Hang the indoor unit on the hook.
There should be no gap between unit and the
ground.
No gap between unit and the ground

Installation bearer
Piping connection port
Drain hose connection port
2. INDOOR UNIT INSTALLATION
2.3.3 Remove 4 screws, and then remove the frame from bottom side. Piping connection
port and drain hose connection port can be observed after take off the frame.
GB-8
2.3.4 Remove the installation bearer, and take off control box cover. Wiring terminator
can be observed.
Control box cover
2.4 INSTALL THE DRAIN PIPE
Bend S shape
The drain line must not have a trap anywhere in its length, must pitch downwards, and
must be insulated up to the outside wall.
GB

OUTDOOR UNIT
■Where it is out of rain or direct sunlight.
■Where it is well-ventilated and free from obstacles near the air inlet and air outlet.
■Where does not increase the operating noise or vibration of the outdoor unit.
■Where does not cause any drainage problem with discharged water.
■Install the outdoor unit properly at a place that is durable enough to the weight of the outdoor unit.
■Where provides appropriate clearances as outlined
■Where the piping between the indoor and outdoor units is within the allowable limits.
■In regions with snowfall and cold temperatures, avoid installing the outdoor unit in areas where it can
be covered by snow. If heavy snow is expected, a field supplied ice or stand and field supplied-installed
wind baffle should be installed to protect the unit from snow accumulation and blocked air intake.
■When installing the outdoor unit in a place that is
constantly exposed to a strong wind, it is recommended
that a wind baffle be used.
7
GB-9
3. OUTDOOR UNIT INSTALLATION
3.1 INSTALLATION SITE CHOOSING
X
O
Strong wind
3.2 OUTDOOR UNIT MOUNTING DIMENSION
Outline dimension
WHD A B
770 555 300 298 487
800 554 333 340 514
W
H
A
B
D
009
012/018
Model
(38QUS)

GB-10
3. OUTDOOR UNIT INSTALLATION
3.3 SPACE REQUIREMENT FOR OUTDOOR UNIT
>30cm
>30cm
>200cm
>60cm
(Wall or obstacle)
Maintain channel
Air outlet
Air inlet
MP
Air inlet
N
>60cm
Fix with bolt
Single Unit Installation
Before installation, check strength and horizontality of the base so that abnormal sound does not
generate.
Fix the base firmly with anchor bolts (M10) to prevent it from collapsing.
Install the foundation and vibration-proof rubbers to directly support the bottom surface of the fixing
leg that is in contact with the bottom plate of the outdoor unit.
3.4 INSTALL THE OUTDOOR UNIT
≥100mm
100～300mm
Outdoor unit
Vibration-proof rubber
Anchor bolt (M10)
Drainage (Wide 100mm x Depth 150mm)Mortar Hole (Φ100mm x Depth 150mm)
>200 >50 >300 >300 >30
>60
>200
>30
Parallel connect the two units or above Parallel connect the front with rear sides.
Connect the drain outlet with an extension drain hose
Fit the gasket onto drain outlet.
Insert the drain outlet into the base pan hole of outdoor unit, and rotate 90 degree to securely assemble
them.
3.5 INSTALL THE DRAIN PIPE FOR OUTDOOR UNIT
unit:cm unit:cm
Base pan hole
of outdoor unit
Drain hose
(Field supply)
Gasket
Drain Outlet
GB

4. REFRIGERANT PIPING WORK
7GB-11
Check if the height difference between indoor unit & outdoor unit and the total length of refrigerant pipe
meet system requirement.
Refrigerant piping work follows the indoor unit and outdoor unit installation, connect the pipe at the indoor
side first, then the outdoor side.
Always keep ends of tubing sealed by placing a cap or covering with tape during installation and do NOT
remove them until you are ready to connect the piping.
Be sure to insulate any field piping all the way to the piping connection inside the unit. Any exposed piping
may cause condensation or burns if touched.
CAUTION
4.1 FLARING
90
Oblique Rough Burr
Outside diameter
A(mm)
Max
8.7Φ6.35mm
Φ9.52mm
Φ12.7mm
Φ15.88mm
Φ19.05mm
12.4
15.8
19.0
23.3
8.3
12.0
15.4
18.6
22.9
Min
R0.4~0.8
45°±2
90 °
±4
A
In case of needing brazing, work with Nitrogen gas blowing.
Improper torque will cause flare damage or gas leaks.
CAUTION
TorqueTubing size
18 ~ 20 N.m
25 ~ 26 N.m
35 ~ 36 N.m
45 ~ 47 N.m
65 ~ 67 N.m
Φ6.35mm
Φ9.52mm
Φ12.7mm
Φ15.88mm
Φ19.05mm
Use separate thermal insulation pipes for gas &
liquid pipes.
The thickness above is a standard of the indoor
temperatureof27°Candhumidityof80%.Ifinstalling
in an unfavorable conditions such as near bath-
rooms, kitchens, and other similar locations,
reinforce the insulation.
Insulation’sheat-resistancetemperatureshould be
more than 120°C.
Use the adhesives on the connection part of insula-
tion to prevent moisture from entering.
Repairandcoveranypossiblecracksintheinsulation
specially check the bent part or hanger of pipe.
4.1.1 Using a pipe cutter to cut the pipe to the requested
length. Ensure that the cut edge remains at 90° with
the side of the pipe.
4.1.2 Use a reamer to remove burrs with the cut surface
downward so that the chips do not enter the pipe.
4.1.3 Carry out flaring work using flaring tools as below.
4.1.4 Check if the flaring is properly made. See incorrectly
flared pipes sample below.
4.2 PIPING WORK
4.2.1 Align the center to tighten the flare nut and
finish connection using two wrenches.
Flare nut
Wrench Torque wrench
4.2.2 Select the appropriate insulation material for
refrigerant pipe. (Min. 10mm, thermal insulating
foam C)
Inclined Damaged
Surface Cracked Uneven Thickness
NOTE
Tools required for flaring are pipe cutter, reamer,
flaring tool and pipe holder.
For R32 refrigerant models, the pipe connection
points must be placed outside of room.

4. REFRIGERANT PIPING WORK
GB-12
After the piping work is finished, make sure to check the connection part of each refrigerant pipe and confirm
that there is no gas leak by applying soapy water to them or by using a leak detector specific for HFC refrigerants.
Refer below picture for illustration.
A: Low pressure stop valve B: High pressure stop valve
C& D: Indoor unit flare nuts
Check-point of indoor unit
Check-point of outdoor unit
A
BC
D
4.3 REFRIGERANT PIPE
Gas SideLiquid Side Allowable
pipe length (m)
Max. Height
difference (m)
Charge less
length (m)
Additional charge
per meter (R410A/R32)
NOTE: 1) Please use tools for R410A/R32 system respectively;
2) When the pipe length is over 5m, the additional refrigerant should be added according to the
piping length.
4.4 AIR EVACUATION
Connect the charge hose from the manifold gauge to the service port of the gas side packed valve.
Connect the charge hose to the port of the vacuum pump.
Fully open the handle Lo of manifold gauge.
Operate the vacuum pump to evacuate air from the system until 76cmHg.
Close the handle Lo of manifold gauge.
Fully open the valve stem of the packed valves.
Remove the charging hose from the service port.
Securely tighten caps of packed valve.
-76 cmHg
Handle Lo Handle Hi
Charge hose Charge hose
Vacuum pump
Packed valve
Manifold valve
Compound gauge Pressure meter
4.5 LEAKAGE TEST
Φ6.35mm Φ9.52mm 525 10 15/12 g/m
Φ6.35mm Φ12.7mm 530 20 15/12 g/m
009/012
018
Model
(38QUS)
GB

5. WIRING
7
GB-13
Power supply and connecting wires specification
Wiring figure
All the electrical connections must be carried out by qualified installers and all the wirings must be
connected according to the wiring diagram.
Make ground connection prior to any other electrical connections.
All power sources must be turned off before wiring work and do not turn on the power until you have
made sure all the wirings have been safety checked.
A main switch and circuit breaker or fuse must be installed, the capacity should be above 1.5 times of
maximum current in circuit.
An individual branch circuit and single socket used only for this appliance must be available.
Wire cross section is depending on the rated current and national, state and local electrical wiring
code. Consult local building codes and National electrical code for special requirement.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly
qualified persons in order to avoid a hazard.
The unit must be connected to the main power supply by means of a circuit breaker or a switch with a
contact separation of at least 3mm in all poles. Installation of a residual current device (RCD) having
a rated residual operating current not exceeding 30mA is advisable.
CAUTION
Ground wiring
Gr ou nd w iri ng
Power supply
Switch/Fuse
Power Cord
High voltage wiring (Power supply)
Signal line
Indoor
Unit
Outdoor
Unit
5.1 POWER FROM OUTDOOR SIDE
Model(Btu/h)
H07RN-F; 3×2.5mm2
Power Cord(Field Supply)
Indoor/outdoor connecting wiring
(Field Supply)
Power
Supply
Phase 1-Phase
220-240V~ 50Hz
Frequency and volt
10A
Rated Current
Fuse Rating(Field Supply) 20A
H07RN-F; 4×1.5mm2
H07RN-F; 3×2.5mm2
1-Phase
220-240V~ 50Hz
10A
20A
H07RN-F; 4×1.5mm2
H07RN-F; 3×2.5mm2
1-Phase
220-240V~ 50Hz
11A
20A
H07RN-F; 4×2.5mm2
9k 12k 18k
NOTE OF FUSE SPECIFICATIONS:
(applicalbe to units adpot R32 refrigerant only, and the fuse is made of ceramic.)
1. The specification of outdoor unit fuse is T20A/250VAC(for <24000Btu/h unit), T30A/250VAC(for
>24000Btu/h unit )
2. The specification of indoor unit fuse is T5A/250VAC, T10A/250VAC.

GB-14
6. FINAL CHECK AND TRIAL OPERATION
To complete the installation, perform the following checks before the trial operation.
Strength of the installation site for both indoor and outdoor sides, confirm no obstruction of the unit air outlet
or return.
Tightness of Refrigerant piping connection and confirm no leakage
Electric wiring connections are correctly completed and unit has been grounding connected
Check the total length of the piping and record the volume of the additional charged refrigerant
The power supply should complying with the rated voltage of the air conditioner
Insulation of the pipe
Drainage
6.1 FINAL CHECK LIST
Set the air conditioning under the COOLING mode with the remote controller (or manual button) and check the
running status of both indoor unit and outdoor unit. In case of any malfunction, resolve it according to chapter
“Trouble shooting” in the “Service Manual”.
Indoor unit
Whether the buttons (such as ON/OFF, MODE, TEMPERATURE, FAN SPEED etc.) on the remote controller
work well.
Whether the louver moves normally.
Whether the room temperature is adjusted well.
Whether the indicator lights on the display panel are normal.
Whether the “manual” button works well.
Whether the drainage is normal.
Whether there is a vibration or abnormal noise during the operation.
Whether the indoor unit works well in COOLING or HEATING mode.
Outdoor unit
Whether there is a vibration or abnormal noise during the operation.
Whether the wind, noise or condensed generated by the air conditioner have disturb your neighborhood.
Whether there is any refrigerant leakage.
6.3 TRIAL OPERATION
When restart the unit, there will be approximately 3 minutes delay to run for protection.
CAUTION
6.2 MANUAL OPERATION
Manual operation can be accessed by pressing manual button on display panel.
Press the manual button repeatedly to change modes as follows:
Once = AUTO mode [heat, cool or fan, 24 °C and auto fan speed .
Twice = COOLING mode [switch to AUTO mode after 30 minutes (mainly used for trial operation)]
Three times = OFF
GB

7.1 CHECKS TO THE AREA
Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure
that the risk of ignition is minimised. For repair to the refrigerating system, the following precautions shall be
complied with prior to conducting work on the system.
7.2 WORK PROCEDURE
Works shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapour
being present while the work is being performed.
7.3 GENERAL WORK AREA
All mintenance staff and others working in the local area shall be instructed on the nature of work being carried
out. work in confined spaces shall be avoided. The area around the work space shall be sectioned off. Ensure
that the conditions within the area have been made safe by control of flammable material.
7.4 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 flammable atmospheres. Ensure that the leak detection equipment being used
is suitable for use with flammable refrigerants, i.e. no sparking, adequately sealed or intrinsically safe.
7.5 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 power or CO2 fire extinguisher adjacent to the
charging area.
7.6 NO IGNITION SOURCES
No person carrying out work in relation to a refrigeration system which involves exposing any pipe work that
contains or has contained flammable refrigerant shall use any sources of ignition in such a manner that it may
lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept
sufficiently far away from the site of installation, repairing, removing and disposal, during which flammable
refrigerant can possibly be released to the surroungding space. Prior to work taking place, the area around the
equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. “NO SMOKING”
signs shall be displayed.
7.7 VENTILATED AREA
Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conduct-
ing any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventila-
tion should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.
7.8 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. The following checks shall be applied to
installations using flammable refrigerants:
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CAUTION
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 circuits shall be checked for the presence of
refrigerant; marking to the equipment continues to be visible and legible.
marking 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 components, unless the components are constructed of
materials which are inherently resistant to being corroded or are suitably protected against being so corroded.
7.9 CHECKS TO ELECTRICAL DEVICES
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, and 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 possibility of sparking
that there no live electrical components and wiring are exposed while charging, recovering or purging the system;
that there is continuity of earth bonding.
7.10 REPAIRS TO SEALED COMPONENTS
10.1 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 servicing, then a permanently operating form of leak detection shall be located
at the most critical point to warn of a potentially hazardous situation.
10.2 Particular attention shall be paid to the following to ensure that by working on electrical 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 apparatus is mounted securely.
Ensure that seals or sealing materials have not degraded such 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 may inhibit the effectiveness of some types of leak detection equipment.
Instrinsically safe components do not have to be isolated prior to working on them.
7.11 REPAI 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. Intrinscially 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.
GB

7.12 CABLING
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, 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.
7.13 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.
7.14 LEAK DETECTION METHODS
The following leak detection methods are deemed acceptable for systems containing flammable refrigerants.
Electronic leak detectors shall be used to detect flammable refrigerants, but the sensitivity may not be adequate,
or may need re-calibration.(Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the
detector is not a potential source of ignition and is suitable for the refrigerant. Leak detection equipment shall be
set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the
appropriate percentage of gas (25% maximum) is confirmed. Leak detection fluids are suitable for use with most
refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the
refrigerant and corrode the copper pipe-work. If a leak is suspected ,all naked flames shall be removed or
extinguished. If a leakage of refrigernat is found which requires brazing, all of the refrigerant shall be recovered
from the system, or isolated(by means of shut off valves) in a part of the system remote from the leak . Oxygen
free nitrogen(OFN) shall then be purged through the system both before and during the brazing process.
7.15 REMOVAL AND EVACUATION
When breaking into the refrigerant circuit to make repairs of for any other purpose conventional procedures shall
be used, However, it is important that best practice is followed since flammability is a consideration. The following
procedure shall be adhered to:
remove refrigerant;
purge the circuit with inert gas;
evacuate;
purge again with inert gas;
open the circuit by cutting or brazing.
The refrigerant charge shall be recovered into the correct recovery cylinders. The system shall be flushed with
OFN to render the unit safe. This process may need to be repeated several times.
Compressed air or oxygen shall not be used for this task.
Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fill until the
working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum. This process
shall be repeated until no refrigerant is within the system.
When the final OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to
take place. This operation is absolutely vital if brazing operations on the pipe-work are to take place. Ensure that
the outlet for the vacuum pump is not closed to any ignition sources and there is ventilation available.
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7.16 CHARGING PROCEDURES
In addition to conventional charging procedures, the following requirements shall be followed:
Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or
lines shall be as short as possible to minimize the amount of refrigerant contained in them.
Cylinders shall be kept upright.
Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
Label the system when charging is complete(if not already).
Extreme care shall be taken not to overfill the refrigeration system.
Prior to recharging the system it shall be pressure tested with OFN. The system shall be leak tested on
completion of charging but prior to commissioning. A follow up leak test
7.17 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 protetive 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 instructions.
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.
7.18 LABELLING
Equipment shall be labelled stating that it has been de-commissioned and emptied of refrigerant. The label shall
be dated and signed. Ensure that there are labels on the equipment stating the equipment contains flammable
refrigerant.
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7.19 RECOVERY
CAUTION
When removing refrigerant from a system, either for service or decommissioning, it is recommended good
practice that all refrigerants are removed safely.
When tranferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are
employed. Ensure that the correct numbers of cylinders for holding the total system charge are available. All
cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant(i.e special
cylinders for the recovery of refrigerant). Cylinders shall be complete with pressure relief 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 flammable refrigerants. In addition, 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 order, has been properly maintained and that any associated
electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult manufacturer 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 refrigerants 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 retruning 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.
7.20 TRANSPORTATION, MARKING AND STORAGE FOR UNITS
1. Transport of equipment containing flammable refrigerants
Compliance with the transport regulations
2. Marking of equipment using signs
Compliance with local regulations
3. Disposal of equipment using flammable refrigerants
Compliance with national regulations
4. Storage of equipment/appliances
The storage of equipment should be in accordance with the manufacturer’s instructions.
5. Storage of packed (unsold) equipment
Storage package protection should be constructed such that mechanical damage to the equipment inside the
package will not cause a leak of the refrigerant charge.
The maximum number of pieces of equipment permitted to be stored together will be determined by local
regulations.