TR35957 375-60325-00 R290 Service Manual
Contents
1. and follow lockout tagout procedures Do not pressurize system above 150 psig prior to evacuation or during leak procedure Special attention is required when recovering R 290 ONLY explosion proof HC recovery machines are suitable for recovery of R 290 The recovery cylinder must be suitable for the refr igerant used and designated for R 290 only Never mix R 290 with other refrigerants Ensure that all connections are secure and there are no potential ignition sources nearby Make sure that you are NOT in a confined space Make sure that you are in a well ventilated space It is recommended that a safety zone of at least 10 in diameter is maintained around the work area When possible extinguish all ignition sources After all connections are made you will need to check these connections with your combustible gas leak detector to assure that there is no R 290 pro pane leaking If there is not an explosion proof HC recovery available for use with R 290 follow the procedure outline in the REGOVERYING R 290 WITHOUT a FECOWERY MAGHINE section of this manual AWARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be wo2. vented Consult factory 6 Ensure you are not venting R290 into a low lying area A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to vacuation or during leak procedure Brazing and soldering It is of utmost importance to properly repair refrigerant leaks as soon as they are discovered If they cannot be repaired immediately the refrigerant charge should be removed from NEDRE OF LEAKS Cont the system until the point at which the leak can be repaired A number of considerations are relevant when attempting to repair a leak Repair the leak properly this means removing the refrigerant examining the leak source determining the reason for the leak and carrying out the proper course of action Before repairing the leak ensure that the refrig erant has been removed and the system flushed with nitrogen especially if brazing is to take place Always run low pressure nitrogen through the system when brazing this reduces the ri
3. 0 microns or less and then left to stand for 15 minutes to ensure that the entire refrigerant charge has been removed from the oil and any residual moisture has been evaporated from the system Ensure that the vacuum pump is of good quality and of appropriate capacity for the system and the oil level is correct A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to vacuation or during leak procedure Dial a charge cylinders with a sight glass should not be used to charge systems with flammable refrigerant The same charging procedures are used with R 290 refrig erants as with any other type of refrigerant except certain considerations are important 1 The Process Tube needs PT to be extended Remove the crimped tubing and piercing or saddle valve from the process tube Extend the process tube a minimum of 12 Crimp and braze the process tube extension Install piercing or saddle valve just after last crimp Evacuate the s
4. R 290 SERVICE MANUAL ITW Refrigeration ITW Refrigeration ITW Refrigeration Form Number TR35957 REV 08 03 15 Part Number 375 60325 00 KEY ERNA PEOUIRED TNS BEWARE OF IONITION SR GENERALE PE UNN TROUBLESHOOTING THE REFRIGERA HON SYSTEM E LEAR CHECKING SEN ACCESSING THE REFRIGERATION SYSTEM vrak REFN GERANT RECOVER EEE EEE EEE EEE RECOVERING R290 WITHOUT ARECOVERT MACHINE getest eege ukersdeder VENTING OF R290 PROPANE REFRIGERANT ssiseccecccacttccsteyeennecesictaseacanerientiensteeesmcesbsdeaasaveeaceedbianteemesnvaastsaameetece ee KO EA ET SENNA SEE Ch TE EE REMOVE ACCE A BRERA ere ee LE HE Lower Explosive Limit LEL The lowest concentration of a gas or vapor in the air capable of producing a flash fire in the presence of an ignition source arc flame heat A concentration lower than the LEL is not rich enough to burn The LEL of R 290 propane is 2 1 concentration of air Upper Explosive Limit UEL The highest concentration of a gas or vapor in the air capable of producing a flash of fire in the presence of an ignition source arc flame heat Concentration higher than the UEL is too rich to burn The UEL for R 290 propane is 9 5 concentration of air EPA SNAP Environmental Protection Agency Significant New Alternative Policy EPA SNAP has approved R 290 propane refrigerant for use in new equipment Global Warning Potential GWP Natural hydrocarbon refrigerants like R 290 propane ha
5. and plug values into formulas MEASUREMENT FORMULA TRAULSEN SPEC Condenser Split A B 2 Ambient Sub cooling A B 2 B 4F 12F SF 7F Superheat D C Compressor Inlet of Outlet of Condenser Evaporator Condenser Evaporator Outlet of TXV Inlet of Condenser amp Evaporator NOTE Unit must be running for at least 5 10 minutes before checking temperatures Insulate sensing bulb of thermometer for most accurate readings Interpreting Line Temperature Differences Superheat Subcooling Diagnosis Above 7F Below 4F Refrigerant Charge is Low Below 5F Above 12F System Overcharged Above ZE Above 12F Restriction in High Side or TXV You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to evacuation or during leak procedure Never use any dyes or other contaminants when working with the R 290 refrigeration system Refer to serial tag for maximum system pressures A number of means for leak detection ma
6. ere are no potential sources of ignition Electrical parts that should be checked include Terminal connections should be tightly affixed and not loose which could result in unintended arching Protective conductor connections should be checked each time a repair is mad Wiring and cabling should also be checked to make sure they are not damaged SERVICE MANUAL ITW Refrigeration ITW Refrigeration ITW Refrigeration HOURS OF OPERATION Monday thru Friday 7 30 am 4 30 pm CST Iasbsen 29 2015 Traulsen All Rights Reserved 4401 Blue Mound Road Fort Worth TX 76106 Phone 800 825 8220 Fax 817 740 6757 Traulsen com amp Kairak com
7. f 5PSGI for the liquid port of the recovery cylinder for 2 minutes outdoors 10 feet away from any structures or ignition sources Repeat steps 1 9 until the recovery cylinder and the system equalize into a vacuum NOTE Trace amounts of R290 will remain trapped in the POE oil of the compressor A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to evacuation or during leak procedure 1 Venting inside a building is not permissible under any circumstance 2 Venting must not be to a public area or where people are unaware of the procedure 3 The technician responsible for venting R290 must make all persons in the immediate area aware a flammable gas is being released to the atmosphere 4 Ensure there are no ignition sources within 10ft of the area you are venting R290 5 Ensure that all local legislation addressing safety of hazardous or flammable substances are satisfied Note The State of California does not allow R 290 to be
8. inch line off just before the temporary access port three times using a crimper tool Verify that there are no leaks Remove the piecing valve temporary access port Cut off the copper tubing between the location of the temporary access port removed in step 3 and the crimps made in step 1 Braze open end shut Leak check the system following the section in this document Disconnect the electrical power to the machine and follow lockout tagout procedures You must have a combustible gas leak detector on at all times Before you start work on electrical components Per ANSI UL 471 Ed 10th SB6 2 4 component parts Shall be replaced with like components WHEN IN DOUBT ALWAYS USE OEM COMPONENTS All electric al devices must not be potential ignition sources This is achieved through a number of ways Using components that do not produce arcs sparks etc Using components that are positioned in a location where leaked refrigerant cannot and will not reach in the event of a leak When working on such electrical components it is essential to ensure that Faulty components that are intended not to spark are not replaced by components that do spark Faulty components that are intended not to spark are not modified in a way such that they do spark It is important to check all components to ensure that no unauthorized modifications have been made to the equip ment there is no ageing wear mechanical stresses or th
9. ing and installation and cleaning as it may cause risk of refrigerant leak fire or explosion If damaged unit must be moved to well ventilated area away from any ignition sources You must have a combustible gas leak detector on at all times The following precautions should be taken when working with an R 290 refrigeration system e Notify all persons in the immediate area that you are working with a flammable refrigerant Do not work with R 290 in a confined space and insure the work area is well ventilated 4 a AF Fr F Sen Pas Fe Gm D AF s I Ag e i ul mp TN p GENERAL PRECAUTIONS CONU e Beware of flammable materials present in the work area e Extinguish ignition sources within 10 feet of the work area if possible e AClass B dry powder type fire extinguisher must be kept nearby e Technicians must only use spark resistant tools e Always use appropriate PPE Personal Protection Equipment TROUBLESHOOTING THE REFRIGERATION SYSTEM Troubleshooting of the refrigeration system should always be done using temperature sensors as outlined below Mani fold gauges should be used for refrigerant recovery and recharge only Trouble Shooting Refrigeration System by Temperature Use the below table and corresponding chart to aid in troubleshooting a Traulsen refrigeration system with the use of thermometers Place thermometer probes at corres ponding locations as indicated by letter markers
10. r tape hard hat with ARC flash rated face shield and ARC flash rated balaclava e Combustible gas leak detector e Spark resistant tools e PPE Personal Protection Equipment e Dedicated R 290 manifold gauges e Class B dry powder fire extinguisher e Empty recovery cylinder e Digital thermometer meter e Vacuum Pump A WARNING For models containing R290 Propane as a refrigerant all instructions labeled on the unit must be closely followed Service and repair must be performed by qualified refrigeration technicians familiar with applicable safety standards for flammable refrigerants Technician must use appropriate personal protective precautions to avoid risk of fire or explosion BEWARE OF IGNITION SOURCES Examples of potential ignition sources e Aspark from an electrical source such as o Contactors Relay Defrost heaters Condensate pan heaters Door Switches Light bulbs Electrical outlets Switches Electric Drill o Static electricity e Open flame ignition sources such as o Fryers o Cigarettes lighters o Gas appliances o Griddles O O O O O O 3 o Non spark resistant tools o Heat guns o Torches gt we ei ee J P FR Sr ee ae FD AE ARE ED DEDE GAFE re en oi Es dv ll dit ell FAU GA ih e D I MG DI MU ED AV GL E A WARNING Proper care must be taken to avoid any damage to refrigeration system including refrigerant tubing condenser evaporator coils during handling mov
11. rn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to evacuation or during leak procedure According to Environmental Protection Agency Significant New Alternative Policy R 290 can be vented to the atmosphere Use the following process to recovery and vented R 290 with the use of a recovery machine 1 10 Evacuate the empty recovery cylinder into a vacuum Using an accurate refrigerant scale zero out the refrigerant scale and weigh the empty recovery cyli nder prior to adding refrigerant gauges or hoses notate this weight Securely connect the evacuated cylinder to the refrigeration system using refrigerant gauges and hoses Open the refrigerant gauges to allow refrigerant to flow through the gauges to the recovery cylinder Once the pressures have equalized valve off the refrigerant gauges and the recovery cylinder securely Carefully remove the refrigerant hose from the recovery cylinder Zero out the refrigerant scale and weigh the recovery cylinder notate this weight Subtract the weight notated from line 2 from line 7 This is the amount of refrigerant recovered into the cylinder A recovery cylinder containing R290 can be vented outdoors See D for instructions on venting R 290 After venting the refrigerant purge the recovery cylinder with nitrogen at a flow rate o
12. sk of oxid ation and combustible gas ignition It is absolutely not acceptable to leave line tap valves or piercing valves attached to the system A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to evacuation or during leak procedure After the system has been sealed and leak checked it is necessary to evacuate it in order to remove air moisture and unwanted residual refrigerant It is necessary to purge the system with nitrogen This is necessary to prevent flammable mixtures from occurring When connecting the hoses between the system gauge manifolds and vacuum pump ensure that the connections are secure and there are no potential ignition sources nearby Ensure that the pump discharge is in an area free of potential ignition sources Ensure that a micron gauge is used since conve ntional manifold gauges may not provide a proper reading CUATION Conti The system should be evacuated to the desired pressure typically 25
13. ve a very low GWP of less than 3 Hydrocarbon Refrigerants HC Hydrocarbon refrigerants are natural non toxic non ozone depleting replacements for CFC refrigerants Ozone Depletion Potential ODP Natural hydrocarbon refrigerants like R 290 propane have an ODP of zero Flash Point Flash point is the minimum temperature at which a substance will burn with an ignition source The flash point of R 290 propane is 150F Auto Ignition Temperature The auto ignition temperature is the temperature at which a fuel will ignite without the need for a spark or flame In respect to auto ignition temperature of R 290 is 896 F Well Ventilated Any area or space where air flow can enter and exit freely Confined Space Per OSHA a confined space is defined as e Large enough for an employee to enter fully and perform assigned work e Not designed for continuous occupancy by the employee e Has a limited or restricted means of entry or exit Personal Protection Equipment PPE This is list is not meant to be all encompassing but should include safety glasses knee protection or kneeling aid first aid kit fire extinguisher insulated screwdriver set LOTO kit ear plugs slip resistant black leather safety toe shoes electrical glove kit rubber glove and goatskin protector cut resistant gloves cut resistant sleeves heat resistant sleeves GFCI cord set fall prevention kit nitrile gloves chemical googles ARC flash barrie
14. y be considered during on site work e Bubble test e Holding pressure test e Combustible gas detection A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to evacuation or during leak procedure Piercing valves can be used to access the refri geration system Access ports should be tempor arily placed on the proc ess tube suction and or liquid line as close to the end of the process tube as possible Never leave access ports of any kind on an R 290 refrigeration system A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine
15. ystem following the gt 0 ULGUR 01 section in this document Charge the System DO NOT OVERCHARGE A SYSTEM USING R 290 You must weigh in the exact charge Prior to charging ensure the system has been leak checked Hoses or lines should be a short as possible to minimize the amount of refrigerant contained in them Evacuate the hoses and manifold prior to charging to avoid contamination of the refrigerant Upon completion of charging a further leak check must be carried out prior to leaving the site After charging carefully disconnect the hoses atte mpting to minimize the release of refrigerant After charging all access ports must be removed following the 1H 1415 section in this document A WARNING You must have a combustible gas leak detector on at all times You must have a Class B dry powder fire extin guisher available at all times Notify all persons in the immediate area that you are working with a flammable refrigerant This procedure requires the use of refrigerants Be certain the work is well ventilated Safety goggles should be worn since refrigerants may cause burns to the skin Disconnect the electrical power to the machine and follow lockout tagout procedures Do not pressurize system above 150 psig prior to vacuation or during leak procedure Do NOT leave piercing valves on this system If you cannot finish the repair you will need to use Lock Out Tag Out proc edures 1 ag P
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