7. Service Maintenance is an essential operation to ensure safety, correct heat pump operation and long-lasting life of the system. It must be carried out in accordance with applicable regulations. i i i The manufacturer’s maintenance and assistance guidelines must be observed at all times. In case of doubts, contact the Technical Assistance Centre. Work 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. All maintenance 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. It is necessary to verify the refrigerant gas pressure during annual maintenance operations. Before beginning maintenance work: – Disconnect the power supply to the system. – If they are present, close the water taps of the space heating and domestic hot water circuits. Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised. Initial safety checks: – check that the capacitors are empty; this must be done safely to prevent possible sparks; wait at least 10 minutes for the capacitor to discharge before performing further interventions; – check that no live component and electrical wiring are exposed during charging, recovery or purging of the system; – check that the earthing connection is uninterrupted. a a Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. If any work must be carried out on hot cooling equipment or on any other associated part, adequate fire-safety equipment must be on hand. Keep a dry powder or CO2 fire extinguisher close to the charging area. a a a a a a a a a Service The ventilation should safely disperse the refrigerant released and preferably expel it towards the outside. A degree of ventilation shall continue during the period that the work is carried out. The repair and maintenance of electrical components should include initial safety checks and component inspection procedures. Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. If there is a fault that could jeopardise safety, do not connect the power supply to the circuit until the problem has been adequately resolved. If the fault cannot be resolved immediately but the device must nonetheless continue operating, adopt an adequate temporary solution. This must be signalled to the owner of the equipment so that all relevant parties can be notified. 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. The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially toxic or flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants, i.e. non-sparking, adequately sealed or intrinsically safe. 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 seals or sealing materials have not degraded to the point that they no longer serve the purpose of preventing the ingress of flammable atmospheres. 70 / EN
a a a a a a a a a a Replacement parts shall be in accordance with the manufacturer’s specifications. The check must also take into account the effects of ageing or the continuous vibrations generated by sources such as compressors or fans. It is possible to use electronic leak detectors to find refrigerant leakages, but if flammable refrigerants are used their sensitivity may be inadequate or may have to be recalibrated. Fluids for detecting leaks are also suitable for use with most refrigerants, however detergents containing chlorine must be avoided, as chlorine may react with the refrigerant and corrode the copper pipes. If a leak is suspected, all ignition sources must be removed/extinguished. Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak. Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. However, for flammable refrigerants it is important that best practice is followed since flammability is a consideration. The following procedure must be observed: – Remove the refrigerant. – Purge the circuit with inert gas. – Flush the system. – Purge with inert gas. – Open the circuit through cutting or brazing. a a a a a a a a a Service If repairs (or any other intervention) must be carried out in the refrigerant circuit, conventional procedures must be used. When the final oxygen-free nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and that ventilation is available. Cylinders shall be kept in an appropriate position according to the instructions. Ensure that the refrigerating system is earthed prior to charging the system with refrigerant. Extreme care shall be taken not to overfill the refrigerating system. Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the site. 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 recovered refrigerant. It is essential that electrical power is available before the task is commenced. EN / 71
7. Service Maintenance is an essential operation to ensure safety, correct heat pump operation and long-lasting life of the system. It must be carried out in accordance with applicable regulations. i i i The manufacturer’s maintenance and assistance guidelines must be observed at all times. In case of doubts, contact the Technical Assistance Centre. Work 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. All maintenance 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. It is necessary to verify the refrigerant gas pressure during annual maintenance operations. Before beginning maintenance work: – Disconnect the power supply to the system. – If they are present, close the water taps of the space heating and domestic hot water circuits. Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised. Initial safety checks: – check that the capacitors are empty; this must be done safely to prevent possible sparks; wait at least 10 minutes for the capacitor to discharge before performing further interventions; – check that no live component and electrical wiring are exposed during charging, recovery or purging of the system; – check that the earthing connection is uninterrupted. a a Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. If any work must be carried out on hot cooling equipment or on any other associated part, adequate fire-safety equipment must be on hand. Keep a dry powder or CO2 fire extinguisher close to the charging area. a a a a a a a a a Service The ventilation should safely disperse the refrigerant released and preferably expel it towards the outside. A degree of ventilation shall continue during the period that the work is carried out. The repair and maintenance of electrical components should include initial safety checks and component inspection procedures. Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. If there is a fault that could jeopardise safety, do not connect the power supply to the circuit until the problem has been adequately resolved. If the fault cannot be resolved immediately but the device must nonetheless continue operating, adopt an adequate temporary solution. This must be signalled to the owner of the equipment so that all relevant parties can be notified. 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. The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially toxic or flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants, i.e. non-sparking, adequately sealed or intrinsically safe. 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 seals or sealing materials have not degraded to the point that they no longer serve the purpose of preventing the ingress of flammable atmospheres. 70 / EN
a a a a a a a a a a Replacement parts shall be in accordance with the manufacturer’s specifications. The check must also take into account the effects of ageing or the continuous vibrations generated by sources such as compressors or fans. It is possible to use electronic leak detectors to find refrigerant leakages, but if flammable refrigerants are used their sensitivity may be inadequate or may have to be recalibrated. Fluids for detecting leaks are also suitable for use with most refrigerants, however detergents containing chlorine must be avoided, as chlorine may react with the refrigerant and corrode the copper pipes. If a leak is suspected, all ignition sources must be removed/extinguished. Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak. Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. However, for flammable refrigerants it is important that best practice is followed since flammability is a consideration. The following procedure must be observed: – Remove the refrigerant. – Purge the circuit with inert gas. – Flush the system. – Purge with inert gas. – Open the circuit through cutting or brazing. a a a a a a a a a Service If repairs (or any other intervention) must be carried out in the refrigerant circuit, conventional procedures must be used. When the final oxygen-free nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and that ventilation is available. Cylinders shall be kept in an appropriate position according to the instructions. Ensure that the refrigerating system is earthed prior to charging the system with refrigerant. Extreme care shall be taken not to overfill the refrigerating system. Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the site. 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 recovered refrigerant. It is essential that electrical power is available before the task is commenced. EN / 71
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