GUIDE FOR THE USE OF HCs REFRIGERANTS
R600a AND R2901

R290 / R600a
SERVICE PROCESSSYSTEM
DESIGNSAFETY &PRACTICALCOMPRESSORREPLACEMENT

R600a and R290 are hydrocarbon refrigerants. They have consistentdifferences versus the HFCs or CHFCs that must be considered for designing,producing, testing, handling, storing, installing, repairing and disposing theapplications, as well as for the workplaces and storage, with particular careto the flammability aspects and their consequences. A complete risk
assessment of the use of HCs refrigerants must be carried out considering
all the above points. It is also important to carefully consult the in use
equipment manual. Only competent technicians trained on the safe use offlammable refrigerants are allowed to open refrigerant circuit or equipment
housing of hydrocarbon systems. Technicians using HCs must have available
and know the meaning of the applicable Material Safety Data Sheets (MSDSs)
and act accordingly.
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SYSTEM DESIGNINTERNATIONAL SAFETY STANDARDSSTANDARD

TITLE

VALIDITY FOR

IEC and EN60335-2-24

Applications for household
refrigerators, ice cream appliances
and ice makers

IEC and EN60335-2-89

Commercial applications withincorporated or remote condensing All Commercial applications
units

EN 00378

Refrigerating systems and heatpumps safety and environmental
requirements

Household appliances

ALLOWED MAX
REFRIGERANT CHARGE≤ 150g≤ 150gAll refrigerators / freezers, air conditioners, Variable, according to the application
heat pump; household, commercial,
and to the installation locationindustrial

NOTE: Limit of 150g is for each separate refrigeration circuit. No restrictions in room size and occupancy category.

SAFETY STANDARDS FOR ELECTRICAL APPLIANCESSTANDARD

TITLEapparatus for explosive gas atmospheres Part 15: construction, testing and marking electrical components
IEC 60079-15 Electricalfor use in explosive atmospheres

For more information on these equipment and parts requirements, look at these two standards online.
Always refer to local legislation as well.

4HCs R600A AND R290 GENERAL INFORMATIONAND CHARACTERISTICS
R600A

R290

Chemical Name

Isobutane (2-methylpropane)

PropaneMolecular Formula

C4H10

C3H8

Safety Class (1)A3A31

10.0089

0.008

ATEL/ODL [kg/m3]

0.00240.09

LFL [kg/m3]

0.0380.038

Vapour density 25°C, 101.3 kPa [kg/m3]

2.38

1.8

Molecular Mass [g/mol]

58.1

44.0

Normal Boiling Point [°C]0-42ODP00

GWP [100 years ITH]

43Autoignition temperature [°C]

365

470

Critical Temperature [°C]134.66

96.74

Critical Pressure [kPa abs]

3629

4251.2

PED fluid group
Practical Limit [kg/m3](2)

SYSTEM DESIGNACCORDING TO EN378(1) Highly flammable substances are defined by a flammability limit of less than or equal to 0.10 kg/m3 at 21°C and101 kPa or a heat of combustion greater than or equal to 19 kJ/kg; (according to ANSI/ASHRAE 34).
(2) Practical limit according to EN 378-: it is used if the HC refrigerant of the system can leak into an occupied ambient.
NOTE: HC refrigerants are classified in A3 Safety Class - lower toxicity, higher flammability, (according to ANSI/ASHRAE 34).

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R600A AND R290 IDENTIFICATION AND WARNING SYMBOLSSYSTEM DESIGNThe Embraco compressors for R600a and R290 have on the nameplate label - or as separate label- a warning symbol for flammable substances, even if they do not contain any refrigerants when
delivered from Embraco factories.

6The refrigerant to be used is printed on the compressor label, also the compressor model includes acode identifying the refrigerant to be used. The R600a and R290 Embraco compressors are certificatedby recognized testing agencies and adopt overload protectors and starting devices complying withthe EN 60079-15.

HCs System Components
SYSTEM

Must have refrigerant identification and “Risk of fire” label

CONDENSER

Same as R404A / R134a system or slightly smaller

EVAPORATOR

Same as R404A / R134a system
In case of roll bond evaporator, check supplier’sspecifications.

PIPINGSame as R404A / R134a system

5mm tubes or
MCHE could
help to minimize
refrigerant charge

Same as R404A / R134a system (XH-9)

CAPILLARY

Same as R404A / R134a or slightly longer (10-15%)

EXPANSION VALVES

Specifically to R290. Heat Exchangers with smaller
channels can help to minimize refrigerant charge under
150 grams

FAN MOTOR

Has to be spark free (shaded pole or ECM)

FAN BLADES

Must be made in plastic or aluminium material

OTHER ELECTRICALCOMPONENTS

Have to be approved according to IEC 60079-15 (2005)

Refrigerant Charge

MAX CHARGE 150g

R290 vs R134a/R404A
48%
reduction

R404A ➔ R290

R600a vs R134a

41%
reduction

R134a ➔ R290

46%
reduction

SYSTEM DESIGNFILTER DRYER

R134a ➔ R600

NOTE: Values are just indicative; the proper refrigerant charge depends on the system design.

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Common sense and staying alert will go a long way towards working safely with flammable
refrigerants.

SAFETY AND PRACTICAL

Always conduct a risk assessment to determine whether it is appropriate to use a flammable gas
refrigerant in the particular workplace.

8

Hydrocarbon refrigerants do not have an odorant, so leaks can’t be identified by smell.
A quality combustible gas leak detector is mandatory for HC service work.
The work area must be free from sources of ignition such as naked flames and sparking electricaldevices.
Assure the presence of fire extinguisher equipment.
This safe zone also applies around a vacuum pump because it could discharge some residual
HC gas during evacuation.

General precautions for service
Always wear appropriate safety glasses
and gloves when working with HCs and while
brazing/unbrazing tubing.
The work area must be monitoredwith a hydrocarbon detector, located at lowlevel, because HCs are heavier than air.
Good ventilation is essential to reduce thepotential of a flammable mix.

The sensor should provide an audible and visual
alarm of HC in the air, well before there is enoughto form a flammable mix(approximately 2% of HC in air by volume).

SPECIFICATION OF TOOLS AND EQUIPMENT
Use only tools and equipment certified for use inhazardous areas.
(i.e. vacuum pump, electrical components and parts,
original replacement parts).

Normal vacuum pumps can be used if outside the flammable zone
but the on/off switch must not be used, as this is usually the only
ignition source in most pumps. It is anyway recommended to have a
HC specific pump.
Use leak detectors rated for combustible gas, if the leak cannot belocated with a electronic detector, remove the charge, purge and fillwith nitrogen and use a micro leak detector spray.

Wear an antistatic-electricity tag.

SAFETY AND PRACTICAL

For internal areas forced ventilation is required by a fan ratedfor explosives atmospheres

9SAFETY AND PRACTICAL

Use recovery machines specifically designedfor HCs (they can also be used with HFCs).

STANDARD RECOVERY MACHINES FOR HFCS MUST NOT
BE USED WITH HC REFRIGERANTS BECAUSE OF SOURCES
OF IGNITION SUCH AS SWITCHES, HIGH
AND LOW PRESSURE CONTROLS AND RELAYS.

Recovery cylinders: be specific for HC(pressure rating and the compatibility of valve seals, etc).
Always check local requirements for handling,storage and transportation.

REPLACEMENT OF ELECTRICAL PARTS
In case of replacement of electrical parts inside the cabinet(i.e. neon lamp, thermostat, etc.):

Sweep the worksite with the HC gas detector
Disconnect the main electrical supply

10Open the refrigerator doors and keep them open for a few minutes

Replace failed components
using original equipment parts

NOTE: HCs are heavier than air, so if there is an internal leakage, there could be a highconcentration of refrigerant in the bottom of the cabinet, creating a flammable mix.

LEAKAGEInternal of cabinet
HC leaks from evaporator to the internal compartment can form a flammable mixture.
Any source of ignition (thermostat, on/off switches, etc.) may produce a flame orexplosion.
All electrical devices must be encapsulated or fire and explosion proof.

External of cabinet
The possibility of HC leakage external of the cabinet forming a flammable mix
with air is remote, considering the small charge.
“Built-in” systems inside another structure are more susceptible to thispossibility.

SAFETY AND PRACTICAL

Close the doors and connect the refrigeration equipment
to power source

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121

Disconnect cabinet from electrical supply.

2

Remove the protective coverto access the compressor.

3

Remove all the compressor electrical components.

4Fit a needle valve on the service tube.

5

Connect a schrader valve in order to start
the venting procedure.

6

Remove the refrigerant by venting itin the atmosphere in an outside ambient
away from heat and ignition sources.

WARNING:
During the refrigerant recovery (and generally when filling a vessel)take care to the amount (weight) of Refrigerant put in the vessel andto the weight of the vessel itself. Due to the different density of HCs Vs
HCFCs/HFCs refrigerants, it’s possible to fill the same cylinder(same volume) with only 40% of HCs vs HCFCs/HFCs.

R290

R290

10 kg

4 kg

4 kg

At 25°C

At 25°C

At 45°C

R22

Мax
80%FILLCOMPRESSOR REPLACEMENT

Refrigerant Removal

7Remove the needle valve and insert a schrader valve(to get a larger port).

8

Make a 1st vacuum for at least 5 minutes.
Fill the system with Nitrogen (OFDN)
at 6 bar pressure (1st washing).

9

Release the nitrogen and make a 2nd vacuum for 5 min.
Fill the system with nitrogen at 6 bar (2nd washing).
Release the nitrogen and make vacuum for 5 minutes.

Fill the system with nitrogen at 6 bar (3 washing). Release the nitrogen. Unsolder the line
10 tubesat the compressor suction/discharge: this operation must be done immediately after.
rdInstallation of new compressor
1

Remove old compressor and place the new one.

2

Braze, on the compressor service tube, a tube, approx 15 cm long, with a schrader valve
on its end. Schrader valve plug must be removed while brazing.

3

Braze the suction/discharge line tubes to the corresponding compressor tubes.

4Fill the system with nitrogen at 6 bar.

5Check system leakages.

COMPRESSOR REPLACEMENTSystem evacuation

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COMPRESSOR REPLACEMENT

Refrigerant charge
6

Release the nitrogen and make a proper vacuum.

7Always use refrigerant that is labeled “R290” and never just Propane.
R290 labeling insures purity and no odorant or moisture, a 1% degradation in purity can lead to a 3-6% degradationin system performance.
Charge the refrigerant and measure carefully the amount of refrigerant filled in the system, in order to be sure tocharge the same quantity originally charged by the cabinet producer, as specified on the cabinet label.
NOTE: due to the small amount of the HCs refrigerant charge (max 150 g), an accurate weighting of the HC charged
in the system is mandatory to assure proper performance of the repaired cabinet.

8Install and connect new electrical components using only factory original parts.

9

Check electrical connections using the spec sheet and verify that the compressor and the unit areproperly grounded.

10 Reinstall the terminal cover.
11 Check leaks by using a specific leak detector for hydrocarbons.

14Start up and check the repaired cabinet

13 Connect the cabinet to the electrical supply line.
a final inspection of the cabinet and be sure all guards and14 Perform
access panels are reinstalled. Check the cabinet working conditions.

Troubleshooting and service chart
The operational failures effecting the compressors that may happen to the refrigeration
system, can be, in most cases, identified and eliminated by consulting Table 12.1 of ourCompressors Handbook. This Troubleshooting Chart is not comprehensive and does notintend to replace the instruction provided by the producer of the refrigeration system.
The listed failures in Table 12.1 are among the most common to be found in established applications. For other possible
defects which do not appear in the list or for running problems in the design phase of the applications, contact Embraco
Technical support team. It is recommended (before verifying the cabinet working conditions, analyze the deviation fromnormal conditions and define the problem root causes), to start from a check list like:• Visual check of the electric boards, wiring, fuses etc.
• Check that the compressor electrical components are the ones specified by EMBRACO.
• Check their assembly compared with the electrical corresponding diagram as indicated in Chapter 6.1of the Compressors Handbook.
• Check settings and proper operation of all safety and protection devices.
• Check pressure and other switches, if installed.
• Check that all valves (eventually installed) are in the correct position for the running conditions.
• Check the system for leaks, starting from the most critical points.

COMPRESSOR REPLACEMENT

12Close the Schrader valve with its nut (put sealing glue on the threads).
Optionally: grip the service tube by a grip pliers, eliminate the schrader
valve and close the tube with a Lockring connection.

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Subject to alteration without previous notice - EN - Date: October 2019 - Version 01

www.embraco.com
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