SERVICE MANUAL QBD HYDROCARBON COOLERS
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QBD HYDROCARBON COOLERS
SERVICE MANUAL
Logo should read as Natural Refrigerant
Content
Description Page
• Why R-290 3
• Overview of R-290 4
• Introducing Cooling Deck 3.0 5
• Labeling for R-290 6
• HC Coolers- Electrical Parts 7
• Recommended Tools 10
• Replace vs Repair 12
• Recommended Service Procedures 14
• Do’s and Don’ts 18
• FAQs 19
QBD Cooling Systems Inc. 2
Why R-290
Hydrocarbon (HC) refrigerants are non-synthetic substances, have
ZERO Ozone Depletion Potential and are environmental friendly
substances.
#1: Regulatory Forces
In line with the Montreal Protocol’s calls for
reduction/elimination of CFC & HCFC production, the
EPA has mandated a ban on HFC Refrigerants R-
134a and R-404A by 2020.
In North America, the Significant New Alternatives
Program (SNAP), accepted hydrocarbon R-290 as an
alternative for small charge refrigeration applications.
Department of Energy (DOE) has mandated approx.
40-70% reduction in energy consumption by 2017
#2: Improved Efficiency
R-290’s specific cooling capacity is approximately 90%
greater than that of R134a resulting into lesser amount
(45-60% reduction) of refrigerant charge while
maintaining the same cooling performance. This means
approximate 30% reduction in size of the compressor,
resulting into better energy efficiency of the system.
Hydrocarbon Coolers are approximately 30% more
energy efficient compared to previous generation HFC
coolers.
#3: Sustainability
R-290 is a natural, non-toxic refrigerant with zero ozone
depletion potential and very low global warming
potential (GWP). Compared to R134a, which has GWP
of 1430, R-290’s GWP index is just 3. It is one of the
most climate-friendly and energy efficient refrigerants
available.
(https://www.epa.gov/snap/unacceptable-substitute-refrigerants)
(https://www.epa.gov/snap)
(https://www.epa.gov/ozone-layer-protection/recent-international-developments-under-montreal-protocol) 3
(https://www.epa.gov/snap/acceptable-substitutes-industrial-process-refrigeration ).
Overview of R-290
• R-290 is Propane with 99.5% purity with minimum levels of
critical impurities.
• R-290 is Odorless / Inflammable / Non-Toxic
• The use of R-290 has been increased due to its low
environmental impacts and greater economic gains
• Has excellent thermodynamic performance, leading to higher
energy efficiency and operating cost reduction
• R-290 is classified as extremely inflammable. Therefore the
handling and use of R-290 requires adequate safety
measures.
• Only a maximum 150 grams (5.3 oz.) of R-290 charge is
required in each refrigeration system. (Ref: UL#471).
• EPA has approved the venting of Hydrocarbon refrigerant into
the atmosphere
It is recommended to ensure all employees have access to MSDS
of R-290 to fully understand the hazard and pre-cautions
Use of NON OEM parts is strictly prohibited. Use of non OEM parts will not only void the warranty, but may
also lead to a major fire or explosion causing property damage, severe personal injury or even death.
QBD Cooling Systems Inc. 4
Introducing Cooling Deck 3.0
UL Required Labeling &
Gasket is UL V0 RED identification sleeves
Rated on Service Lines*
Green Base R290 specific
labels
Green Lift Rods
* Technicians are responsible to ensure these RED SLEEVES are
always present on access points as per UL#471 requirements.
QBD Cooling Systems Inc. 5
Labeling for R-290
6
HC Cooler- Electrical Parts
CONTROLLER
Approved for Hydrocarbon
applications / Electronic /
Built in Defrost Timer
ECM MOTORS
UL Approved / Very High
Efficiency / Brushless /
Wider operating range
ELECTRICAL
CONNECTORS
Approved for Hydrocarbon
applications
QBD Cooling Systems Inc. 7
HC Cooler- Electrical Parts
NEVER use a 3in1 Starting Kit on R-290 Refrigeration System
COMPRESSOR
RELAY
Approved for
Hydrocarbon
applications
COMPRESSOR
CAPACITOR
Approved for
Hydrocarbon
applications
COMPRESSOR
OVERLOAD
Approved for
Hydrocarbon
applications
QBD Cooling Systems Inc. 8
HC Cooler- Electrical Parts
LED POWER
SUPPLY
Approved for
Hydrocarbon / Class 2
Type Power supply: 12V
DC / High Energy
Efficiency
LED+ Lighting
Approved for
Hydrocarbon cooler
application/
up-to 50% more product
illumination & efficiency
QBD Cooling Systems Inc. 9
Recommended Tools
Tube Cutter R-290 Gas Detector Vacuum Pump
Scale Crimping Tool Manifold Gauge
Optional
Piercing Valves Torch Recovery Tank
Safety Mandated
10Ignition Sources R290 is highly inflammable. Please be aware of all ignition sources before servicing any HC cooler. Below is a list of some common ignition sources to watch out for: • Temperature greater than 460*C (860*F) • Flame from a match, pilot, burner etc. • Torch including Halide Leak detectors • Hot wire refrigerant leak detector • Open spark • Static electricity • Light and socket switches • Unsealed relays and overloads • On Off switches • Contactors • Pressure switches • Defrost timers • Thermostats • Vacuum pump switches • Electronic leak detectors • Open motors • Cellular Phones and other electronic devices
Replace 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.
• Please contact QBD Technical Assistance at 1-(800) 663-3005 or (905)
459-0709
QBD Cooling Systems Inc. 12Replacing the Cooling
Deck
1 2
Loosen Front Grill Screws Remove Locking Screws
3 4
Unplug the Power Cord
Slide Up Lift Bar Holder
5 6
Rotate Lift Bars Inward to Slide CD Out By Pulling Lift
Release CD from Lock Position Bars Towards You
Watch Youtube video of QBD cooling deck replacement
https://www.youtube.com/watch?v=yLMDcNMOEos
Check more troubleshooting guidelines at
http://www.qbd.com/sales_service.php
QBD Cooling Systems Inc. 13Recommended Service
Procedures for HC cooler
All inflammable refrigerants when mixed with air form highly inflammable
mixtures. The effects of ignition on this mixture can be severe. It is
extremely important that all appropriate safety requirements are observed at
all times when working with inflammable substances.
HC refrigerant systems must always be serviced and repaired by a qualified
refrigeration technician and must follow the applicable safety precautions.
Before entering any service area, a HC refrigerant monitor or detector must
be switched ‘on’ and it should remain in operation until the service is
completed.
All service procedures for HC coolers must be done in a well ventilated area
and away from any ignition source.
Electrical Safety
• Check the area using a certified gas detector prior to carrying out
servicing of a HC cooler.
• Disconnect power supply to the cooler.
• Ensure all the electrical components are de-energised
• Authorised service personnel should use certified spark-proof tools only
If diagnosis indicate failure of any sealed system component (e.g.-
compressor, evaporator or condenser leak, partial blockage, full/partial loss
of refrigerant, etc.), follow recommended repair procedures.
QBD Cooling Systems Inc. 14Servicing HC Coolers
Venting or Recovery
R-290 refrigerant recovery is not required under SNAP but may still be
called for under other authorities, controls or practices. Always follow local
laws and regulations for recovery or venting of hydrocarbon refrigerant. If
the HC refrigerant is to be vented to the atmosphere, either the unit should
be moved to a well ventilated area before the venting procedure begins or
use hoses long enough to discharge it safely to outside environment.
• Attach gauges to both the high and low sides of the system using an
approved method.
• To avoid accidental release of refrigerant and lubricant, ensure that they
are recovered/ vented safely from the system before removing the failed
component of the sealed system.
• Always recover the refrigerant from both high and low sides of the
system to assure that no refrigerant is trapped in the system.
• Purge the system with Oxygen Free Dry Nitrogen (OFDN) several times
to ensure complete removal of refrigerant from refrigeration system.
• Achieve a 500 micron vacuum in the refrigeration system using a
certified vacuum pump before replacing failed sealed system
component(s).
• Use a tube cutter rather than a torch to remove the failed component as
shown below. Using a torch may cause a fire hazard, especially if the
refrigerant has not been completely discharged/recovered. If you must
use a torch to remove the failed component of sealed system, do so
while running dry nitrogen continuously through the system.
• Always use OEM parts only. Use of non-OEM parts will not only void
the warranty but may also lead to a major fire or explosion.
15Servicing HC Coolers
Pressure testing and Evacuation
• Pressurise the serviced refrigeration system with oxygen free dry
nitrogen (OFDN) up to 150 psig.
• Hold the pressure and check for possible leak.
• Purge OFDN before starting the evacuation process.
• Never use a compressor to evacuate a system. Instead, use a certified
vacuum pump specifically designed for this purpose.
• Connect a certified vacuum pump to the repaired system using manifold
gauges as before starting evacuation.
• The discharge of the vacuum pump must be vented to an open-air area.
• Ensure the refrigeration system holds a vacuum pressure of at least
100 micron before charging.
• Never attempt to start the compressor while the system is under
vacuum.
• Always break a vacuum with refrigerant charge before starting the
compressor.
Charging refrigerant
• Do not overcharge a refrigeration system (maximum 150 grams or
5.3 oz.). Overcharging can result in an explosion.
• Use only recommended type and amount of refrigerant as indicated on
the serial label
• Always use proper charging techniques e.g.- using only certified and
calibrated weighing scales
QBD Cooling Systems Inc. 16Servicing HC Coolers
Leak test
Leaks inside or outside of a cooler may result in a inflammable mixture.
Leak detection must be done using electronic or ultrasonic leak detectors
calibrated for hydrocarbon refrigerants.
Sealing the process tubes
Seal the process tube using an approved method or by pinching the tubing
with the recommended equipment and then sealing it with brazing material
or silver solder. Improper sealing of the process tube may lead to leaks or a
sudden release of inflammable refrigerant.
Note: Always use OEM parts. Use of non-OEM
parts will not only void the warranty but may also
lead to a major fire or explosion.
QBD Cooling Systems Inc. 17Do’s and Don’ts
Do's
• Area must be well ventilated & free from any source of
ignition
• Use only OEM parts
• Purge the system with Oxygen Free Dry Nitrogen
(OFDN) several times
• R-290 Cooling Decks must be installed in Hydrocarbon
certified cabinets only
• Leak Detector – must be designed specifically for HC
refrigerants. Ensure HC approved leak detector is
operational at all times.
• Only “Refrigerant Grade Propane” should be used. Do
not use any other grade of propane.
Don'ts
• Do not use non-OEM parts.
• Do not use spark producing tools to repair the unit
• Do not retrofit cooling system
• Do not reposition electrical components or temperature
probe
• Do not use extension cords, power bars and/or wiring
devise adapters.
• Do not ‘modify’ the system
QBD Cooling Systems Inc. 18FAQs
How do I know if a cooler is working on R-290?
A number of visual differences have been made in coolers running on R-290.You can
check for R-290 indication on Cooling Deck and the serial plate of the cooler.
Do you need any specialized training to service R-290?
Although it is not mandatory, we recommend you to attend specialised training for this.
You can check more details at Refrigeration Service Engineers Society www.rses.org.
Can I retrofit any cabinet to HC/R-290 refrigerant?
NO, the EPA has ruled that the retrofitting of any existing equipment is prohibited. All
potential spark producing parts in the system, including those in cabinet have to be UL
certified. Any negligence may lead to a major fire or explosion.
Can I use/add light switches in R-290 cabinet?
NO. All electrical fittings must comply with UL # 471 and must be explosion proof. It is
therefore recommended not to add any electrical switch in the cabinet. LEDs provided
with the cooler are compliant to UL#471 and must be replaced with OEM parts only.
Can the same tools be used to service a hydrocarbon cooler that are used on a R-
134a/R-404A cooler?
Since refrigerant R-290 is highly inflammable, no spark producing tool can be used with
HC cooling system. More details of recommended tools in provided in this manual.
Please check with QBD technical support team if you have any question.
Can the same parts be used in a hydrocarbon cooler that are used on a R-134a/R-
404A cooler?
NO
Is there a maximum charge amount for R-290 refrigeration systems?
YES. You can only have a maximum charge amount of 150 grams (5.3 ounces) in HC
refrigeration system.
Do I need to recover the R-290 refrigerant?
NO, it is not mandatory. Always follow local laws and regulations for recovery or venting
of hydrocarbon refrigerant.
Where can I get R-290 refrigerant?
You can source this refrigerant from an HVAC supply house or a company that sells
gases and welding supplies. Always make sure you are purchasing “refrigerant grade
propane R-290”.
19MSDS of R290
It is mandatory for users to go through MSDS of R290 and be aware of hazards and precautions.
• http://www.linde-
gas.com/en/products_and_supply/refrigerants/natural_refrigerants/r290_propane/index.html
• http://www.boconline.co.uk/internet.lg.lg.gbr/en/images/care40410_55784.pdf?v=1.0
Service Checklist for HC Coolers
It is recommended to use attached check-sheet before servicing any HC cooler.
QBD Cooling Systems Inc. 20Service Checklist for HC Coolers
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.
Capacitors should be discharged with a bleed resistors (minimum 2 Watt / 10,000 Ω ) or
9
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.Contact Us
31 Bramsteele Rd., Brampton, Ontario, Canada L6W 3K6
Telephone: (905) 459-0709
Toll Free: (800) 663-3005
Fax: (905) 459-1478
info@qbd.com
www.qbd.com
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