Klimasan R600a User manual

Servicing Coolers Charged with
Hydrocarbon Refrigerants
R600a (Isobutane)
& R290 (Propane)
24 Jan 2014; Version 2

R600a General Specifications
Chemical Formula :C4H10
Effect to Ozone : None
Greenhouse Effect : 3(vs. R134a’s 1300)
Molecular weight : 58,1 kg/kmol (Heavier that air, falls down to ground)
Boiling Temperature : -11,7 °C (It is in the gas form under normal atmospheric conditions)
Critical Temperature : 135 ºC
Critical Pressure : 36.5 Bar
Colour : Colourless
Odour : Odourless
Specifications : Flammable and Explosive

Usage of R600a Gas
As R600a heat transfer coefficient is almost twice that of R134a, for the same cooling output the
R600a amount required will be almost 40 to 45% less than R134a.
The values in right table are given for
approximately comparison. Consider the
values on the product labels for gas charge.
In the systems using R600a gas the suction pressure is below 1 bar (g).
This situation should not be perceived as system blockage.
Different than R134a gas, mineral oil is used, while polyester oil is not used.
R600a gas dissolves in higher rates than R134a gas in mineral oil and its vacuum period is
Lengthier.
Volume R600a R134a R12
50 ml 28 g 62 g 67 g
100 ml 56 g 124 g 135 g
200 ml 113 g 249 g 269 g
500 ml 282 g 622 g 673 g
R600a + mineral oil combination, is less sensitive to paraffinic items than existing
R134a + polyester oil combination, in which we have problems of system blockage.
Therefore, in cooling systems with R600a, the problem of system blockage is less encountered

R600a - Points to Consider
In the cooling systems with R600a and R134a, different compressors are used!
On the compressors in products
where R600a gas is used
there is a flame warning sign
showing that a flammable
and explosive gas is used.
In addition to this flame sign, during the service to the products with R600a, a distinguishing
label/colour etc.is used for recognition of the fact that R600ais used in the product.
During servicing:
Look at the compressor! If you see YELLOW TRIANGLE flame sign, it means that in this
product R600a gas, which is a flammable and explosive gas, is used.
While gas exists in the system, do not approach to the product with any heat sources,
electrical arc sources or welding torch flames; make sure that the heat /flame / electrical arc
sources which are closely located are turned off.

R600a Effects of Overexposure
•Ingestion:
Aspiration Hazard!
•Inhalation:
Inhalation of vapor may produce anesthetic effects and feeling of
euphoria. Prolonged overexposure can cause rapid breathing,
headache, dizziness, narcosis, unconsciousness, and death from
asphyxiation, depending on concentration and time of exposure.
•Skin Contact:
Contact with evaporating liquid can cause frostbite.
•Eye Contact:
Liquid can cause severe irritation, redness, tearing, blurred vision, and
possible freeze burns.
Source: MSDS National Refrigerants / Dec 08

R600a First Aid Measures
Ingestion:
Do not induce vomiting. Contact a physician immediately.
Skin Contact :
For liquid contact, warm areas gradually and get medical attention if there is
evidence of tissue damage. Flush area with plenty of water.
Inhalation:
Remove to fresh air. If breathing has stopped, restore breathing at once.
Administer oxygen and get medical help.
Eye Contact:
For liquid contact, irrigate with running water for minimum of 15 minutes. Consult
physician immediately if frostbite occurs.
Source: MSDS National Refrigerants / Dec 08

R290 General Specification

R290 Handling & Storage
•Normal Handling:
Keep container closed.
Use only with adequate ventilation.
Keep away from heat, sparks and flame. To avoid fire, minimize ignition sources. Use
explosion-proof electrical (ventilating, lighting and material handling) equipment.
Do not puncture or incinerate container. High pressure gas. Use equipment rated for
cylinder pressure. Close valve after each use and when empty.
Protect cylinders from physical damage; do not drag, roll, slide, or drop. Use a suitable
hand truck for cylinder movement.
•Storage Recommendations:
Keep container tightly closed.
Keep container in a cool, well-ventilated area.
Cylinders should be stored upright, with valve protection cap in place, and firmly
secured to prevent falling or being knocked over.
Cylinder temperatures should not exceed 52°C (125°F).
Source: MSDS National Refrigerants / Dec 08

First Aid Measures for R290
No action shall be taken involving any personal risk or without suitable training. If fumes
are still suspected to be present, the rescuer should wear an appropriate mask or a self-
contained breathing apparatus. It may be dangerous to the person providing aid to give
mouth-to-mouth resuscitation.
Ingestion:
Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything
by mouth to an unconscious person. Get medical attention if symptoms appear.
Skin Contact :
In case of contact, immediately flush skin with plenty of water. Remove contaminated clothing
and shoes. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical
attention.
Eyes:
Immediately flush eyes with plenty of warm water for at least 15 min. Get medical attention.
Frostbite:
Try to warm up the frozen tissues and seek medical attention
Inhalation:
Immediately remove to fresh air. If breathing has stopped, give artificialrespiration. If
breathing is difficult, qualified personnel may give oxygen. Get medical attention at once
Source: MSDS National Refrigerants / Dec 08
.

Tips for Proper Use of R600a and/or R290 /1
1. R290 is a very flammable gas like R600a and needs special treatment and
precautions
2. R290 has higher pressure values in the same environment than R600a gas,
so needs to be handled more carefully
3. Because of the R290 is flammable gas like R600, it requires very careful
handling and special security. R290 is more pressurized gas than R600, so
technicians should be more careful
4. Flammable gas mixture, air and ignition source should not be together to
prevent accidents
5. When intervening to a product running with R290 refrigerant, the warning
instructions must be followed properly. They are very similar with the
warnings and instructions for R600a
6. Even though the gas amount seems to be low, flammability and high
pressure factor must be considered always.
7. R600a is used with mineral oil, while R290 is used with ester (polyester) oil.
8. The same driers are being used for R290 and R600a, should have XH-9
Molecular Sieve, check specs before using.

Tips for Proper Use of R600a and/or R290 /2
1. Open the doors of the product to secure a better ventilation
2. Brush the area near the compressor with a broom
3. Before intervening the system, open windows & doors of the room where the cooler is placed
4. Open a window before intervening to the system, pay attention that the door is open.
5. When you are sure that there is no internal gas leakages in the product, you can make gas
charge again.
6. Always carry R600a / R290 bottle / cylinder in a safe way and protect it from crushes
7. In cold weather, it may be required to warm up an R600a / R290 tube for realizing the gas
charge. In doing so, only warm water which is not hotter than 45°C should be used.
8. It is not permitted to replace R600a or R290 with R134a or any other refrigeration gas!
The coolers running with R134a cannot be modified and/or turned into R600a or
R290 system or in general to hydrocarbon system, due to electrical safety regulations
9. If the product to which service is given is in a cellar or in an environment which can not be
ventilated, it is recommended to intervene to this product by moving it to a workshop where
R600a or R290 can be evacuated safely
10. Before any intervention to a product, firstly identify which gas is used in the product. Look and
identify the label sign on the compressor. If you consider that the label sign on the compressor
is not readable or taken away, then please look at the product label and its operating manual
and confirm which cooling gas is used in the product

Tips for Proper Use of R600a and/or R290 /3
1. Electrical components documented for hydrocarbon use should be used.
2. During charge, always adequate ventilation should be provided.
3. It is not forgotten that both R600a and R290 gases are heavier than air: The gas leakage
detectors should be placed on ground.
4. In R600a and/or R290 leakage investigation, hydrocarbon gas leakage detectors must be used.
The detectors used for R134a can not be used for hydrocarbon R290 and/or R600.
On top as some R134a detectors heat up gas, their usages for HC gases are dangerous.
5. The leakage control in the system must definitely be tested with nitrogen (or hydrogen); AIR
MUST NOT BE USED.
6. After charging the system with R290 or R600a welding or flame must NOT BE USED!
7. Static electricity formation or discharging must be avoided. Non conductive shoes, clothing which
are produced by synthetic materials should be worn
8. Refrigerant bottles / cylinders should be carried in perpendicular position; it should be stored in a
well ventilated and safe enclosure and be kept away from direct sunlight and burning sources
9. R290 vacuum operation is the same as R600a’s vacuum operation. While making R290 gas
charge, all the details while making R600 gas charge should be followed
10. R290 gas charge apparatus is the same as R600a apparatus. With this apparatus, R134a gas
charge can be made

Apparatus For Servicing R290 and R600a Cooling Systems
VACUUM
MANOMETER
LOW PRESSURE
MANOMETER
HIGH
PRESSURE
MANOMETER
OIL FILLING
COVER
VACUUM
PUMP
VALVES
VACUUM OIL
GAS BOTTLE
IMPORTANT
“ Reclaim / Release / Disposal of
Refrigerant must comply with local,
state, country disposal laws”
In case the HC gas
should be recovered:
use the appropriate
recovery system
VACUUM PUMP 2-STAGES
With 3 manometers for HC:
SPARK FREE PUMP

ACURATE
SCALE (±1g) GAS RELEASE HOSE
LOW PRESSURE HOSE HIGH PRESSURE HOSE
With same apparatus,
R134a gas charge can
be realized too
(apparatus is SPARK
FREE for HC)
Before starting gas
charge, detailed
information on all
components should be
obtained.
YELLOW
BLUE RED
Apparatus For Servicing R290 and R600a Cooling Systems

Vacuum
gauge
Low
pressure
gauge
High
pressure
gauge
Vacuum
valve
Vacuum valve
should be opened
durign vacuuming!
Low
pressure
control
valve
Vacuum
control
valve
High
pressure
valve
Gas
control
valve
Apparatus For Servicing R290 and R600a Cooling Systems
VACUUM PUMP 2-STAGES
With 3 manometers for HC:
SPARK FREE PUMP

OIL FILLING OPERATION
Fill the pump oil tank with oil up to half level
of glass indicator. Be careful, as in case the
vacuum pump runs without oil will be
inevitably broken down
Apparatus For Servicing R290 and R600a Cooling Systems
VACUUM PUMP 2-STAGES
With 3 manometers for HC:
SPARK FREE PUMP

After vacuuming has been achieved the yellow and blue valves should be turned on; the vacuum
pump to remain still in operation, until vacuuming is completed in about 20 minutes. During
vacuuming, the gauge should be fixed between 0 and 100 psi by turning on the valve under the
vacuum manometer.
Black
butterfly
valve
Blue
butterfly
valve
Vacuuming is very important for correct
operation of the system.
The air left in the system and other parts
can cause the blockage of the system.
Therefore, it is required that the vacuum
operation should be realized with care.
Apparatus For Servicing R290 and R600a Cooling Systems
After fixing the gas tube, firstly the black valve on the manifold and then slowly the blue valve is
opened and the gas starts to enter into the system.
We detect how much gas has been released through the scale, and when it comes to the amount
we want then firstly the blue valve and then the black valve and turned off and pump is stopped.
VACUUM PUMP 2-STAGES
With 3 manometers for HC:
SPARK FREE PUMP

Unplug the cooler before
attempting any maintenance work!
Servicing a Cooling System Charged with R290 or R600a
All Service Providers should comply to local legislation!
Do NOT forget!
SAFETY FIRTS
in your priority list!

Never smoke in the working area during the repair!
A CO2portable fire extinguisher should always be available
Before / during an intervention the repairing area must be well ventilated
Use a Hydrocarbon leak detector for Hydrocarbons (Not a halogen
leak detector or halide torch for leak detection as with R134a!)
All electrical tools & vacuum pump must be explosion safe (SPARK FREE)
Do not use open fire while the cooling circuit is charged with R290 and/or
R600, but only when the system is completely free from refrigerant
Do not remove or worn out the warning labels placed on the cooler’s
compressors by their suppliers
Always use the proper refrigerant!
It is not permitted to replace R600a or R290 with R134a or other refrigerant!
The coolers running with R134a cannot be modified and/or turned into a
hydrocarbon system, due to electrical safety regulations!
Use always the recommended and specified amount of Hydrocarbon gas
when charging the system. Do not overcharge or undercharge!
Always be reminded that:
Service Providers MUST comply
to local regulations & legislation!

The gas should be removed from the system
and ‘thief’ piercing pliers should be used.
The gas releasing hose is attached to the thief
pliers. The pliers is used on the low pressure
part at service tube ‘Picture 1’
Picture 1
In order to remove gas inside the system, the pipe
which is used (gas released hose) should be put out
of the window and/or door (open air). The gas
shouldn’t be released in a closed room. ’Picture 2’
Picture 2
Discharging of Gas from the System
Service Providers MUST comply
to local regulations & legislation!