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Page 1 company presentation 2012 11/10/2012
3rd international GIZ Proklima Expert’s Day
Safety aspects for HC- R290 Air conditioners
Wednesday, 10th October 2012
Nuremberg, Germany
Rolf Huehren
Page 2
Introduction
• R290 is a flammable refrigerant
• Several manufactures recently are launching new R290
products on the international
• Given the large numbers of products anticipated to be
placed on the market, important to consider safety
• Two-fold approach
• Conformity to safety standards
• Quantitative risk analysis (in-use and servicing)
Page 3
Safety standards – general requirements
Two main safety standards for RAC
• EN 378: 2008 European standard for environmental and safety requirements
of refrigeration and air conditioning
• IEC 60335-2-40 Particular requirements for safety of household appliances,
electric air conditioners, heat pumps and dehumidifiers
Main requirements cover
• Sources of ignition
• Charge amount limit
• Markings and warnings
• Manuals/instructions
Page 4
• Specifically for room air conditioners / human comfort
• “Critical” charge size formulas
Charge size range Conditions
≤ 0.15 kg Can be located anywhere
0.15 kg to 0.3 kg
Minimum room area, Must be “non-fixed factory sealed single package units” with fan operating continuously, and have vibration and drop test
0.15 kg to 1 kg
Minimum room area, (depending upon indoor unit install height)
0.15 kg to 4.95 kg
If charge is more than Then must be installed in room or enclosure with no SOI and mechanical ventilation must be used, maybe with gas detector
A mmin = 48×
A m h 2min unit= 568×( ÷ )
A m h 2min unit= 568×( ÷ )
Safety standards – general requirements
Page 5
Safety standards – general requirements
Ref.
LFL Charge volume & Minimum floor area
(kg/m3) Charge
(kg) 0.15 0.2 0.24 0.29 0.34 0.41 0.53
R290 0.038
Min.
Area
m2
4 7 10 15 20 30 60
Example Mono Split AC System (cooling only)
IDU at 2.5 m height
Page 6
Safety standards – conformity
Avoid sources of ignition / Outdoor unit (ODU) ― Replace with non-sparking components
― Carry out leak simulation test
Page 7
Example: Safety standards – conformity
ODU-
Compressor
compartment
Page 8
8
Wiring- Terminal
Board (Plug )
Part I
Pre-assembled
Electrical
Interconnection
Load current
Control-
circuit
Example: Safety standards – conformity
Page 9
Exanple: Safety standards – conformity
ODU (example design features)
• Low pressure Switch
(1.5 barg / -19°C)
• Marking
Page 10
Safety standards – conformity
Avoid sources of ignition / Indoor unit (IDU) ― Replace with non-sparking components
― Carry out leak simulation test
Page 11
Printed Circuit
Board (PCB)
Part I
Fire protection
against Ignition
& protected
fuse
Relay Box components
Example: Safety standards – conformity
Page 12
12
IDU - Relay box (on PCB)
Part I
Example: Safety standards – conformity
Page 13
IDU – Connection cable with plug
Part I
Example: Safety standards – conformity
1. Durable sealed
2. Professional
installed
3. Multi-Plug
connectors –
potential safety risk
Page 14
ODU
Part I
IDU Special coating to prevent ignition from static electricity
Example: Safety standards – conformity
Page 15
Part I
Example: Safety standards – conformity
Indoor & Outdoor Unit
• With selection of any operational mode,
both fans start first simultaneous with
operation
• With cooling (heating) demand and a
time delay of a minimum of 20 seconds
the compressor is activated
• In case of leakage this will maintain
dilution of HC with air and to keep the
concentration below LFL
Page 16
Part I
Quick connecter( IDU) Quick connecter( ODU)
Example: Safety standards – conformity
Page 17
Safety standards – conformity
Marking and instructions
• On access points
• Information for technicians,
etc.
evaporator 10%
suction line 1%
compressor 13%
discharge line 1%
liquid line 2%
condenser 73%
Reduce refrigerant charge size
• Component selection/
circuit design
Page 18
Risk analysis
Important to evaluate the risk of ignition associated with air
conditioner
• In operation mode
• During refrigerant handling (service/repair)
Output can be used to help determine whether system is
“safe” or “unsafe”
• Use findings to help optimise design of appliance
• Determine most favourable work procedures and use of
tools
Compare results against other risk indicators
Page 19
(same space and time)
Leak of refrigerant
Presence of ignition source
Refrigerant mixture with
air
Active ignition source
Ignition
Primary consequence (jet fire, flash fire, explosion
Secondary consequence
(thermal damage,
secondary fire, overpressure
damage, injury
Risk analysis – general approach
gas dispersion, distribution, local
conditions
leakage characteristics
ignition source characteristics
Quantify sequence of events that lead
to ignition event and consequences
flammable quantities, structural
characteristics
Page 20
Risk analysis – control volumes
Identify
applicable
regions where
leaked refrigerant
and SOIs may
occur
Page 21
Concluding remarks
Various European and international safety standards
• Provide guidelines for application of R290 in air conditioners
• Main topics are avoidance of ignition sources, charge size limits, marking
and instructions
Subsequent design of air conditioners can be further evaluated for safety using
risk analysis
• Additional risk for normal operation is extremely low; less than 0.01 ignition
events per million units in 10 years
• Additional risk for refrigerant handling low; less than 10 ignition events per
million visits with minor consequences
Additional risk can be considered “negligible”
• Results imply new R290 air conditioners offer very high level of safety
Page 22
NEW PRODUCTION OF R290 ACs GODREJ
• Currently two sizes developed
• Each has four models, corresponding to different Indian efficiency star rating categories
• Data for “five star” products
Model Name R290-12K R290-18K
Operating Mode Cooling Cooling
Cooling Capacity 3400 W 4900 W
Rated Power Input 914 W 1318 W
Rated Input Current 4 A 6 A
EER 3.72 3.72
Refrigerant R 290 R 290
Refrigerant Charge 0.290 kg 0.340 kg
High efficiency
Very low specific refrigerant
charge (<80 g/kW)
Also includes leak safety
mechanism to leak safe
Page 23
NEW PRODUCTION OF R290 ACs > MIDEA
Midea products
• Currently two sizes developed
• Both reversible
• Other products developed
• Safety systems under development
Model Indoor
unit (mm) Outdoor
unit (mm) Cooling capacity
EER Heating capacity
COP R290
charge
KFR-26GW/N7
Y-Y(C4)
850 × 275
× 160 780 × 540
× 250 2.6 kW 3.4 2.8 kW 3.6 290 g
KFR-35GW/N7
Y-Y(C4)
900 × 285
× 160 780 × 540
× 250 3.5 kW 3.4 3.7 kW 3.6 350 g
Page 24
NEW PRODUCTION OF R290 ACs > GREE
• Gree products • Several models developed • Split, window, portable • Reversible and cooling only • Products have safety system
integrated to reduce leak amount • Lower price than equivalent R22,
R410A models
Capacity (kW)
EER
(W/W)
Charge
(g)
Max noise
ID/OD
(dB)
Dimensions
(mm)
2.7 3.55 265 38/52 Indoor
830×284×205
Outdoor
760×257×541 3.5 3.52 330 41/52
Page 25
FINAL REMARKS
In major producing countries, use of HCs in single and split ACs is of
major interest
• At least 50% of R22 production lines in China will move to R290
• Production lines in other countries also shifting to HCs
• Other Article 5 countries are banning HFCs as part of R22 phase-
out
• Huge amount of R&D to analyse risk and introduce measures
Developments in EU regulations (Ecodesign for ACs and likely new F-
gas reg) encourage natural refts
Several major global AC producers introducing R290 technology
Page 26
Thank you for your
attention
