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Questions? +32 460 226 991 (English), +33 644 634 490 (French). EU-wide delivery!
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Refrigerant leaks from cooling systems are a serious issue concerning environmental and climate protection, personal health safety, general safety, and not least, the efficiency of resource utilization. Potentially hazardous substances can leak from air conditioners, heat pumps, and various refrigeration equipment.
Refrigerant leaks in HVAC systems (heating, ventilation, and air conditioning) cannot be reliably avoided because they often contain a large number of non-sealing joints that are assembled or welded. These leaks may not necessarily occur during manufacturing; most arise during operation due to adverse temperatures, environments, and vibrations that stress the material, leading to its bending or loosening. If these defects are not promptly addressed, refrigerant leaks occur, causing a decrease in the efficiency of the heating or cooling system and potential air intoxication.
Most refrigerant leaks from equipment are initially undetectable without detection methods. Some leaks amount to just 1oz over ten years and are not critical for system operation. Therefore, small leaks are often not addressed at all. In the case of greenhouse gases (F-gases) with the potential to contribute to global warming (GWP), the limits for leak checks, which depend on the amount of refrigerant in the equipment and the GWP potential of the refrigerant contained in the equipment, are crucial for assessing and addressing the leak.
Most leaks can be detected using simple methods like listening, or more advanced tools like electronic leak detectors. Gas detection not only ensures compliance with all regulations but also prevents the loss of expensive refrigerants and minimizes equipment repair costs. The detection method used depends on the type of refrigerant in the system. When working with refrigerants, appropriate safety measures such as wearing protective goggles and gloves must be followed. If the refrigerant is corrosive, like ammonia, careful handling with a suitable tool for leak testing and refrigerant handling is necessary.
Reliable allies for accurate detection of potential refrigerant leaks at low temperatures and high relative humidity are specialized devices – refrigerant leak detectors and gas concentration sensors, which are used to detect leaks of explosive or toxic gases, as well as evaluation units for these sensors. Thanks to specially developed heating technology, these devices can operate correctly in extreme conditions for the entire declared lifespan. Today, the market offers products for HFC detection (fluorinated hydrocarbons and their mixtures) as well as ammonia, propane, and carbon dioxide in industrial and commercial refrigeration equipment. The use of refrigerant detectors depends on the volume of refrigerant in the equipment and the size of the room into which the refrigerant can leak. The necessity of using a detection system is determined by calculation.
Every refrigeration system based on ammonia (NH3) poses a risk of leakage. Since ammonia is a flammable and toxic gas, all ammonia systems must be designed with safety in mind, which includes the preventive installation of gas detectors. However, adverse climatic conditions, such as temperature fluctuations or high humidity, can hinder the rapid and accurate detection of leaks in this equipment.
The use of carbon dioxide as a refrigerant gas also carries a risk of potential leakage that must be controlled in accordance with international regulations. Common issues in CO2 leak detection in refrigeration equipment include low temperatures, condensation, and the need for a wide detection range. Therefore, gas detectors in this case should have a built-in heating element and also the option to select different sensors, allowing them to operate at low temperatures down to -40 ℃ and be used in commercial and industrial refrigeration.
Propane (C3H8) is among the increasingly advocated natural refrigerants. As a refrigerant, C3H8 (or R290) is widely used in domestic, industrial, and commercial refrigeration equipment, specifically in refrigerated counters, ice machines, freezing units, and cold storage. Propane is a colorless, flammable gas without odor, which can be very dangerous for equipment and surrounding people when reaching the lower explosive limit (LEL). Therefore, all C3H8-based refrigeration systems must meet safety requirements (EN378), which means installing special measuring devices, such as gas detectors. Gas detection not only prevents C3H8 from reaching explosive concentrations due to accidental leaks but also prevents significant losses of expensive refrigerant and reduces its emissions into the air.
Hydrofluorocarbons (HFCs), or freons, are very widespread refrigerant gases on the market today. They are often used in commercial and industrial refrigeration equipment, such as refrigerated and frozen transport, ice makers, refrigerated counters, vending machines, cold storage, and warehouses. The main refrigerants used in these devices include R-23, R-134A, R-404A, R-407A, R-407C, R-410A, R-417B, R-449A, R-507, and R-508A. These HFCs are not toxic or flammable under normal environmental conditions (safety classification A1). However, they have a high potential as greenhouse gases contributing to global warming (GWP), so HFC/freon-based refrigeration systems must meet strict safety limits. With commonly available gas detectors, you can measure commonly used freons as well as more exotic mixtures.
According to internationally applicable safety standards, the operator of cooling equipment is obliged to take all technically and economically feasible measures to prevent and minimize unintentional refrigerant leaks. If a leak is detected, the equipment must be immediately taken out of operation and can only be put back into service after the leak has been repaired. Leaks must be repaired without delay. Within one month after the repair, the operator is obliged to ensure the inspection of this repair by a certified person. Another inspection follows within 6 months from the date of the originally recorded refrigerant leak.
The operator is obliged to establish a logbook and conduct regular inspections of the cooling equipment in accordance with § 29 paragraph 6 of Act 86/2002 Coll., on air protection as amended. The frequency of these inspections ranges from once every 3 months to once every 24 months depending on the volume of refrigerant used and the presence of a leak detection system. More information can be found in the relevant tables on the frequency of inspections of equipment containing F-gases, which should be part of the operating regulations and documentation for the operated equipment. The operator is obliged to keep the equipment logbook at the place of operation for 5 years.
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