icool Training: Service Technician Hydrocarbon (HC) Refrigerant Training QBD Cooling Systems Inc. TORONTO / BRAMPTON ONTARIO, CANADA

Size: px

Start display at page:

Download "icool Training: Service Technician Hydrocarbon (HC) Refrigerant Training QBD Cooling Systems Inc. TORONTO / BRAMPTON ONTARIO, CANADA"

Jeffry Malone
6 years ago
Views:

1 icool Training: Service Technician Hydrocarbon (HC) Refrigerant Training QBD Cooling Systems Inc. TORONTO / BRAMPTON ONTARIO, CANADA 1

2 THE NEXT GENERATION HYDROCARBON REFRIGERATION With R-290 Hydrocarbon Refrigerant HC Series 2

3 Content CD 3.0 Introduction R-290 Facts Safety instructions and guidelines CD 3.0 visual differences Installation Swap vs Repair icool Service Training 3

4 R-290 Refrigerant Gasket is UL V0 Rated Optimized condenser and evaporator coil design All electrical parts are UL#471 approved - Compressor, motors, capacitor, overload, relay, controller, electrical connectors UL Required Labeling & RED identification sleeves on service lines Technicians are responsible to ensure these RED SLEEVES are always present on access points as per UL#471 requirements. Cooling Deck 3.0 4

5 HC Series R-290 is a Natural Refrigerant Zero Ozone Depletion Potential (ODP) Very Low Global Warming Potential (GWP) R134a = 1430 GWP R-290 = 3 GWP 40 50% Less Refrigerant Charge R-290 Facts 5

6 R-290 FACTS R-290 is highly inflammable. R-290 is heavier than air and the concentration will always be higher at floor level. Cooling Decks containing R-290 refrigerant must NEVER be installed in the R134A Series cabinets. HC Series coolers have been engineered to eliminate all possible ignition sources. CAUTION: Exposure to R-290 can lead to frostbite HC Series R-290 Facts 6

7 HC Series It is mandatory for technicians to carry MSDS of R- 290 and lubricant and be aware of hazards and precautions. ural_refrigerants/r290_propane/index.html mages/care40410_55784.pdf?v=1.0 Safety 7

8 Recommended Checks before working on an HC Cooler PLEASE CHECK THE AREA FOR REFRIGERANT LEAK BEFORE PLUGGING/UNPLUGGING THE UNIT ENSURE R-290 APPROVED LEAK DETECTOR IS OPERATIONAL THROUGHOUT THE ENTIRE SERVICE CALL ALWAYS FOLLOW LOCAL LAWS AND REGULATIONS FOR SERVICING OF A HYDROCARBON REFRIGERANT COOLER. HC Series S No Points to consider before servicing an HC refrigerant cooler Compliance (Y/N) Check for the presence of Refrigerant Do not plug or unplug before checking the area for flammable environment around the cooler 1 Monitor the area prior to and during work. Use a Combustible Gas Detector/ Monitor. Clear the area of any potential refrigerant leak. Make sure the leak detection equipment used is suitable for use with HCs. No ignition Sources No smoking, including displaying No Smoking signs 2 Survey the area around the equipment prior to servcing to establish any flammable hazards or ignition risks. Remove all sources of ignition. Be aware that a cell phone or similar electronic devices could be source of ignition. Labels Both cabinet and chassis labels must indicate for R290 refrigerant use. If the labels do not match assume the system has been retrofitted and is non-compliant. 3 STOP work on this system immediately Inform owner (operator*) of system violation Offer to replace system with approved systems Refuse to service General Work Area Instruct anyone in the immediate area as to the nature of the work 4 Avoid confined spaces If possible, section off the workspace Be aware of any flammable material in the area Minimum Room Volume Consideration to ensure that equipment is not installed in a room where the release of the HC 5 could cause an explosion hazard. Always follow local laws and regulations for installation, operation and servicing an HC cooler. Personal Protective Equipment 6 Technicians should wear appropriate PPE, e.g.- including chemical goggles, protective gloves, grounding probe, anti-static band Free Air Movement Ensure that free air movement can be achieved around all refrigerant containing parts of the 7 systems. Depending on the size of the room, especially in a confined space, mechanical ventilation may need to be considered. The ventilation should displace any released refrigerant and preferably expel it externally. Floor Voids 8 HC refrigerants are heavier than air. Precautions should be made against refrigerant collecting in drains and low points of a flooring structure. Electrical Devices An initial safety check of components to see a fault exists that could compromise safety. 9 Capacitors should be discharged with a bleed resistors (minimum 2 Watt / 10,000 Ω ) or meter. Do not work on live electrical components. Maintain a good ground equipment and user Rated Equipment This includes, but not limited to - Gas Leak Detectors and Monitors 10 - Electrical Test meters (CAT III minimum) - Portable Lighting - non-sparking tools Work Space Guidelines -Good ventilation 11 - Purge refrigerant outdoors - Dry powder fire extinguishers Awareness Familiar with the information provided by other sources, such as the manufacturers of the system equipment, component manufacturers, refrigerant suppliers, and Material Safety Datasheets (MSDSs). 12 Occupants should be aware of manufacture operating instructions, procedures, guidelines and safety issues regarding the equipment. Be made aware to evacuate the space immediately following the accidental release of a flammable refrigerant. Pre-Service Checks 8

9 Do not work in confined space Strictly no smoking Area must be well ventilated Eliminate all ignition sources Create a safety work area of a minimum of two (2) meters (6 ft.) in perimeter standard industry practice HC Series AREA SAFETY Safety 9

10 HC Series Tube Cutter R-290 Gas Detector Vacuum Pump Scale Manifold Gauge Crimping Tool Piercing Valves Optional Safety Mandated Torch Recovery Tank Tools Recommended 10

60 lb or 0.27 kg of R-290 in total. This limits the number of HC coolers that can be placed in an area.

11 HC Series The limiting factors associated with the use of HCs are: -The occupancy category -The room volume -Unit type and capacity Maximum amount of R-290 in an area kg/m3 (0.60 lb/1000ft3) Maximum of 0.53% volume E.g.- a 10ft x 10ft x 10ft room can have a maximum of 0.60 lb or 0.27 kg of R-290 in total. This limits the number of HC coolers that can be placed in an area. Local Laws and Regulations 11 e.g. For Canada - CSA B52 Mechanical Refrigeration Code

12 Visual Differences Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

13 Visual Differences.. Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

14 Visual Differences Compressor platform (base) Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

15 Visual Differences CD Lift Rods Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

16 Visual Differences Gasket Seal Seal is upgraded to be UL-V0 rated. ¼ HP Gasket Seal PN ½ HP Gasket Seal PN Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

these RED SLEEVES are always present on access points as per

17 Visual Differences Access Lines R-290 Identified by red sleeves on access lines; Technicians are responsible to ensure these RED SLEEVES are always present on access points as per UL#471 requirements. Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

18 Visual Differences Compressor Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

19 Cooling Deck Reduced SKU s ¼ HP Single and Dual Evap Fan Motor ⅓ HP Single Evap Fan Motor ½ HP Dual Evap Fan Motor ¼ HP Single and Dual Evap Fan Motor ½ HP Single and Dual Evap Fan Motor Single Door = Single Evap. Fan / Double Door = Dual Evap. Fan Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

20 Fan Motors PSC Motors Very high efficiency ECM motors Wider operating range Brushless One 13W motor replaces 4W, 6W and 9W motors and reduces SKU s. Maintains high efficiency levels at part load Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

21 Securing Fan Blades Standard speed bolt for mounting blades on both Condenser and Evaporator motors Cooling Deck 2.0 (R134a) Single screw to mount blade to Condenser and Evaporator motors Cooling Deck 3.0 (R-290)

22 Mounting Bracket Standard mounting bracket for PSC motor Screws used to secure motor to mounting bracket Cooling Deck 2.0 (R134a) Mounting bracket redesigned for ECM motor Nut and Bolt is used to secure motor to mounting bracket Cooling Deck 3.0 (R-290)

23 Electrical Parts NEVER use a 3in1 Starting Kit on R-290 Refrigeration System Approved for Hydrocarbon applications Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

DC Spark proof design approved for R-290 application Lower energy

24 LED Lights LED+ Power Supply Class 2 Power Supply: 120V AC Standard LED - have ignition source (Not approved for R- 290 application) Power Supply: 12V DC Spark proof design approved for R-290 application Lower energy consumption 50% more product illumination Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

25 Cold Controller Carel Control Approved for Hydrocarbon applications / Electronic / Built in Defrost Timer Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

26 Visual Differences Condenser Motor PSC Motor ECM Motor Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

27 Visual Differences Evaporator Motor PSC Motor ECM Motor Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

28 Refrigerant Charge R134a R-290 ¼ HP chassis = 210 gms ¼ HP chassis = 110 gms ⅓ HP chassis = 245 gms ½ HP chassis = 310 gms ½ HP chassis = 148 gms R-290 charge can not exceed 150 gms as per UL471 Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

29 Operating Pressures Technical Data R134a Suction Pressure: PSI Discharge Pressure: PSI R-290 Suction Pressure: PSI Discharge Pressure: PSI Cooling Deck 2.0 (R134a) Cooling Deck 3.0 (R-290)

30 Labeling for R-290 Cooling Deck 3.0 (R-290) 30

31 Labeling for R-290 Cooling Deck 3.0 (R-290) 31

32 Labeling for R-290 Cooling Deck 3.0 (R-290) 32

33 Labeling for R-290 Cooling Deck 3.0 (R-290) 33

34 Installation Cooling Deck 3.0 (R-290) 34

35 HC Series PLEASE NOTE It is extremely important that QBD installation instructions are followed to ensure trouble-free and safe operation of the cooler. Installation 35

Use the Metal Support For Hinged Door MUST Remove The Door Support

36 HC Series ALWAYS Use The Door Support Brackets During Transport (Wood/Sliding, Metal/Swing) Use the Wooden Support For Sliding Door Use the Metal Support For Hinged Door MUST Remove The Door Support Bracket (Wood/Sliding, Metal/Swing) After Installation Installation 36

Nut insert (to fit casters) is flush with the bottom surface of base channel.

37 HC Series CASTERS INSTALLATION The cooler has a new design for caster installation. It does not require a transfer plate anymore. Nut insert (to fit casters) is flush with the bottom surface of base channel. This design will allow caster top in firm contact with cooler base channel. Hence, transfer plate can be avoided. No Transfer plate required as caster top is directly in contact with the vase channel plate. Shim plate may be required for leveling of cooler. Installation 37

38 HC Series PROPER LEVELING Cooler must be leveled (front to back / side to side) to ensure proper drainage & door operation Use LEG ADJUST For Proper Leveling Use SHIMS If Installing Caster Wheels For Proper Leveling WARNING Improper leveling may cause door(s) to close incorrectly. May result in performance issues e.g. freeze-up of evaporator coil Installation 38

39 HC Series CLEARANCES Minimum clearances required for proper operation IMPROPER CLEARANCE MAY CAUSE PREMATURE COMPRESSOR FAILURE AND CAN COMPROMISE THE COOLER SAFETY. Installation 39

40 HC Series INTERNAL CLEARANCES Minimum clearances requirement for proper air circulation inside the cooler Installation 40

41 HC Series INTERNAL CLEARANCES PLACE Bottom Shelf On Top Of Base Step (Return Air Duct) NEVER Allow Solid Packaging To Be Placed On Bottom Shelf, As This Will Block The Air Flow Installation 41

42 HC Series ELECTRICAL REQUIREMENT Dedicated, 3 prong, grounded 115~120 VAC / 60HZ receptacle is required. Extension cords, power bars and/or wiring devise adapters should NEVER be used. Installation 42

43 HC Series REMOVING THE COOLING DECK Loosen Front Grill Screws Remove Locking Screws Slide Up Lift Bar Holder Unplug the Power Cord Rotate Lift Bars Inward to Release CD from Lock Position Slide CD Out By Pulling Lift Bars Towards You Removing the CD 43

44 CONDENSER FAN MOTOR Remove 2 screws that secure the shroud. Lint tolerant Condenser is less prone to Condenser blockage. Remove 4 screws that secure the Condenser Motor bracket. Condenser Fan Motor 44

45 EVAPORATOR FAN MOTOR Remove the 5 screws that secure the shroud. Disconnect Evaporator motor wire from controller Remove top screw from both sides of the fan shroud. Remove the screws that secure the wires with the P-Clip. Evaporator Fan Motor 45

Slide the evap. Fan shroud up and out of the evap box.

46 EVAPORATOR FAN MOTOR Please Note: Single door coolers have 1 evap. motor and double door coolers have 2 evap. motors. Slide the evap. Fan shroud up and out of the evap box. Replace the fan blades or fan motors as required. Evaporator Fan Motor 46

47 HC Series ADJUSTING SLIDING DOORS Remove wheel / spring cover & track filler Align wheels over opening in door track. Lift & remove door Remove wheel, relocate to adjacent slot and adjust position 4 5 Reinstall door & check spacing between door and cabinet. Repeat until aligned. Reinstall track fillers and wheel / spring cover. Glass Doors 47

48 HC Series ADJUSTING SLIDING DOORS ADDITIONAL STEPS Adjust spring tension to achieve 3-5 second closing. Add washers if doors are rubbing in the center Clean Door Track Lubricate wheel rollers with light machine oil (don t use WD40 as a lubricant) Glass Doors 48

49 HC Series REVERSING DOOR SWING REQUIRED PARTS Top LH Hinge Bottom LH Hinge Bronze Bushing / (2 are required) Glass Doors 49

50 HC Series REVERSING DOOR SWING Remove top RH hinge while supporting the door. Set the bracket aside while supporting the door. Open the door slightly and lift up firmly. The spring will be released on the bottom. Glass Doors 50

51 HC Series REVERSING DOOR SWING Place the door on a flat non-scratching surface and interchange the doors top and bottom pivot pins Glass Doors 51

HC Series REVERSING DOOR SWING Remove the bottom RH

on the pin of the new bottom hinge bracket Attach the

52 HC Series REVERSING DOOR SWING Remove the bottom RH hinge (no longer required). Remove the black plugs on the LH side, exposing the threaded inserts Position the flat side of the spring on the pin of the new bottom hinge bracket Attach the new bottom LH hinge complete with spring on the bottom left corner of the cooler Glass Doors 52

53 HC Series REVERSING DOOR SWING Install the door by inserting the bottom pivot pin into the bronze bushing in the bottom LH hinge. Install the top LH hinge on the LH side while supporting the door. Glass Doors 53

HC Series REVERSING DOOR SWING To help with

the spring blade into the slot on the bottom

Front grill should be removed to give easier

54 HC Series REVERSING DOOR SWING To help with adjusting spring tension, a Spring Key is available. PN Re-install the door spring and align the spring blade into the slot on the bottom pivot pin. Front grill should be removed to give easier access. To create tension of the spring, turn the spring key counter-clockwise 1 to 1.5 turns. Re-attach the front grill. Glass Doors 54

55 Cold Control and LED Cooling Deck 3.0 (R-290) 55

56 Temperature Control 56

57 DISPLAY INDICATORS This indicates the Evaporators Motors are running but the Compressor is not. On initial power up, there is an intelligent delay for protection of the Compressor. After 1 minute delay, power to the Compressor will initiate. Evap Motor Indicator Temperature Control 57

58 Evap Motor Indicator Compressor Indicator This is the typical look of the Carel control while in use. "USE" indicates the unit is in working order. The symbols to the left of "USE" indicate that the Compressor and Evaporator Motor(s) are both running. If the Compressor Indicator is blinking, the compressor is under "Time Protection mode. Temperature Control 58

59 DEFROST CYCLE Defrost Indicator Indication that unit is in DEFROST and Evaporator Motors are running. There is an automatic defrost cycle of 20 minutes every 6 hours. Evaporator Fan Motors cycle ON and OFF during defrosting. Temperature Control 59

60 Defrost Indicator Evaporator Motor Indicator To manually initiate the defrost, push and hold the "WARMER" button for 3 seconds. The controller will automatically come out of DEFROST after 20 minutes. To manually take out of defrost, push the "WARMER" button for 3 seconds. Temperature Control 60

Indication that the cold control is "OFF" and power to the Compressor and condenser fan motor has been disabled. Power to Evaporator fan Motors is still live.

61 Indication that the cold control is "OFF" and power to the Compressor and condenser fan motor has been disabled. Power to Evaporator fan Motors is still live. To manually place the controller "OFF", push and hold the "COLDER" (upper) key for 3 seconds. To turn back "ON", push and hold the "COLDER" (upper) button for 3 seconds Temperature Control 61

62 ERROR CODE Indication that an ERROR has occurred with the probe. Either the probe is faulty or is has been disconnected from the controller. Temperature Control 62

CHANGE THE TEMPERATURE SETTING Push WRENCH button for 3 seconds Check controller temperature setting. Proper setting should be #5 on CAREL Controllers.

63 CHANGE THE TEMPERATURE SETTING Push WRENCH button for 3 seconds Check controller temperature setting. Proper setting should be #5 on CAREL Controllers. Push the "WRENCH" button for 3 seconds to get to the settings mode. Use the "COLDER" or "WARMER" buttons to adjust to the desired setting. To save the new setting, you MUST push and hold the "WRENCH" button for 3 seconds or until the controller returns to "USE". Temperature Control 63

64 TEMPERATURE PROBE POSITION TEMPERATURE PROBE MUST BE IN RETURN AIR AS SHOWN INCORRECT PROBE POSITION WILL RESULT IN COOLING RELATED ISSUES COMPRESSOR CUT IN AND CUT OUT IS DETERMINED BY THE TEMPERATURE MEASURED BY PROBE Temperature Control 64

65 Only change to the existing CD cabinet is the LED lighting and removal of the light switch. CD2.0 vs CD3.0 65

66 HC Series ACCESS TO LED Supply wires are hidden in a channel. Channel cover is pressed in place. Simply pry the cover off Channel cover runs across the top and sides of the cooler. LED Lights 66

67 HC Series ACCESS TO LED Removing the channel cover give full access to the LED terminal connection. Pull up on the wire connection. Once wire leads are removed, access to the LED mounting screws are visible. LED Lights 67

68 HC Series LED DRIVER LED Driver is located in the cooler control box. LED Driver is 12V DC Output LED Lights 68

69 HC Series SWAP vs REPAIR Replace (swap) the cooling deck under the following circumstances: Compressor failure Refrigerant leak Damaged/broken base (platform) Repair the cooling deck under the following conditions: Controller failure Motor (condenser/evaporator) malfunction Damaged fan blade(s) NOTE: Use only OEM parts for replacement. Swap vs Repair 69

70 HC Series SWAP vs REPAIR Do not replace sealed or solid state devices with components that can spark. Do not reposition electrical components For any Technical assistance please contact QBD 1-(800) or (905) Swap vs Repair 70

71 QBD Cooling Systems Inc. 31 Bramsteele Rd. Brampton, Ontario Canada L6W 3K6 Toll Free: Phone: FAX: info@qbd.com WEB: QBD Contact Information 71

HC Series General Manager Safder Jaffer 1-800-663-3005 x-201 Direct Office : 905-459-6944 Cell: 416-456-6069 Safder@qbd.

com Product Engineer, Technical Support and Service School Trainer Keith Woods 1-800-663-3005 x-228 Cell: 416-884-0117 Keith@qbd.

72 HC Series General Manager Safder Jaffer x-201 Direct Office : Cell: Safder@qbd.com Key Account Manager Jim Anderson x-240 Jim@qbd.com Product Engineer, Technical Support and Service School Trainer Keith Woods x-228 Cell: Keith@qbd.com Technical Support Bart Mudgal x-248 bart@qbd.com Order Desk Equipment and Parts Support Angela Gnanabakthan x-239 Angela@qbd.com Business Development Manager (USA) Raul Alvarado Cell: (352) Raul@qbd.com QBD Cooling Systems Inc. 31 Bramsteele Rd. Brampton, Ontario, Canada L6W 3K6 Toll Free: Main Phone: (905) Fax: (905) info@qbd.com 72

73 HC Series 73

R C O O L E R S ( C D H C S E R I E S )

R C O O L E R S ( C D H C S E R I E S ) 31 Bramsteele Rd, Brampton, Ontario, Canada L6W 3K6 1-800-663-3005 TEL : (905) 459-0709 FAX: (905) 459-1478 info@qbd.com R - 2 9 0 C O O L E R S ( C D H C S E R I E S ) INSTALLATION, OPERATION AND MAINTENANCE