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The air conditioning and refrigeration industry has developed the A2L classification of refrigerants to overcome the challenges of using lower-GWP refrigerants. While having slightly higher flammability characteristics as compared to traditional A1 refrigerants, A2Ls are much more difficult to ignite and less flammable than A3 hydrocarbon refrigerants, such as propane. A binational (U.S. and Canada) consensus group formed to update the product safety and application standards to allow for the safe use of these more environmentally friendly refrigerants within HVAC/R systems.
One of the risks associated with household electrical heat pumps, air conditioners and dehumidifiers is refrigerant leakage. A refrigerant leak detection system that senses a loss of refrigerant pressure, a critical component in mitigating this risk, is required for all systems in the occupied space exceeding a prescribed refrigerant charge limit. Refrigerant leak detection systems are required to have both sensors and control logic electronics that activate the evaporator fan and use circulated air to quickly disperse and dilute refrigerant in the event of a leak to prevent the formation of refrigerant concentrations.
UL 60335-2-40 also requires that refrigerant charge limits be based on the minimum occupied volume of the room where the equipment is expected to be used. This charge limit requirement also includes a safety factor of 4 to help ensure any leaked refrigerant is diluted to well below the lower flammability limit (LFL) based on room size. In addition, UL 60335-2-40 requires appliances to be free of potential internal ignition sources to mitigate the risk of fire due to a leak.
On Dec. 15, 2022, UL Standards & Engagement published the fourth edition of UL 60335-2-40. Among other updates, the fourth edition refined requirements for leak detection systems to accommodate various methods, increase robustness and reliability, and account for deviation and drift over the system life cycle.
Annex LL is a normative element in UL 60335-2-40, pertinent to refrigerant detection systems for flammable refrigerants. The fourth edition contains a rewritten Annex LL that no longer references IEC 60079-29-1 for the conformity of flammable gas detectors. It clearly establishes that when the refrigerant detection system senses a concentration of refrigerant gas that is 25% of the lower flammability limit (LFL) for that gas, the refrigerant detection system must initiate a system response to mitigate the potential hazard, as required by Clause 22 and Annex GG. When the refrigerant detection system incorporates a group controller, it must also comply with the requirements of Annex 101.DVN for informational technology equipment (ITE) cooling appliances.
The fourth edition Annex LL also contains rewritten test methods based on current North American carbon monoxide detector sensor requirements, as specified in UL 2075, the Standard for Gas and Vapor Detectors and Sensors.
An informative Annex 101.DVM, a supplement to Annex LL, was revised to include requirements for deviation and drift over the lifetime of the refrigerant sensor. Annex 101.DVM now describes examples of acceptable paths of compliance for providing data and evidence substantiating the claimed life of a refrigerant sensor, as required by Clauses LL.7.2.DV of Annex LL.DV.
Requirements specified in the fourth edition of UL 60335-2-40 needed to be published by the end of 2022 in order to be included in the 2024 building code. At that time, however, discussions about refrigerant detection system requirements were not yet complete.
The following table compares the requirements applicable to refrigerant leak sensors and detection systems in the third edition and the CRDs for the fourth edition. The right column lists the reasons the revisions were needed to help ensure refrigerant leak sensor reliability.
As far as is practicable, this standard deals with the common hazards presented by appliances that are encountered by all persons in and around the home. However, in general, it does not take into account
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The flammable refrigerant charge limits in IEC 60335-2-89 are per circuit. It is possible to have a greater charge in a system if there are multiple circuits. This is considered safe, as the main risk is from a leak rather than an ignition in the system itself.
This room size is calculated based on the refrigerant charge, and the lower flammability limit (LFL) of the refrigerant. The manufacturer needs to display the restriction prominently, on a standard label complying with IEC 60417-6415.
The manufacturer must ensure the calculations are correct and that the unit is labelled correctly, in a way that meets the standard. But it is the responsibility of the user to ensure the unit is installed in a way that complies with the regulations.
The standard sets a vibration limit of 0.3g RMS (measured with a low pass filter of 200 Hz) at 90% to 110% of the rated compressor frequency, or across the complete speed range of a variable speed compressor.
When new UL standards are enacted, electrical component makers and OEMs need to ensure compliance. OEMs in the HVAC market should ensure their suppliers for contactors can meet the new UL60335-2-40 standard by the January 1, 2024 deadline.
For HVAC equipment manufacturers, the most critical requirement of UL 60335-2-40 is that HFC (hydrofluorocarbon) refrigerants must be replaced with A2L-class refrigerants. These newer refrigerants have much lower global warming potential (GWP).
However, one drawback of the A2L-class refrigerants is that they are more flammable than the HFCs they replace. The new UL standard is in response to the increased fire hazard, and requires components to have passed testing verifying their reduced flame risk.
Panel builders therefore may need to redesign or update their products to comply. And even if their products meet the new standard without modification, the system will still need to be tested and certified. This must be done prior to January 1, 2024 when the new standard takes effect. OEMs that rely on these products will need time to ensure that the updated components can be integrated in their panels without any design changes.
Many component makers and OEMs lack the capability or manpower to have a dedicated testing and certification expert on staff, and must therefore rely on suppliers or wait in long third-party lab queues. This can delay both certification and the ability to sell your products in North America.
OEMs and panel builders that want to ensure their ability to fill customer orders for their HVAC-related products should be contacting their suppliers today regarding components like contactors. OEMs and panel builders should verify that their suppliers are well along in the process of updating or already have completed product certification.
This is especially important for larger contactors with a wider air gap, which have an increased risk of ignition in the system. Because these components are inherently more likely to generate a point of ignition, they require more stringent testing. There are only a few third-party labs globally that can accommodate testing large contactors with a 110mm frame and up.
The switch to A2L-class refrigerants is one of many small steps being taken to reduce global warming. But the efforts to reduce long-term damage to the environment is creating some short-term challenges. Failure to adhere to the new UL standard 60335-2-40 by the January 1, 2024 deadline will disrupt HVAC system manufacturers in serving the US market until they can achieve compliance.
This International Standard deals with the safety of electric battery chargers for household and similar use having an output at safety extra-low voltage, their rated voltage being not more than 250 V.-- Battery chargers not intended for normal household use, but which nevertheless may be a source of danger to the public, such as battery chargers intended for use in garages, shops, light industry and on farms, are within the scope of this standard. -- As far as is practicable, this standard deals with the common hazards presented by appliances that are encountered by all persons in and around the home. However, in general, it does not take into account - the use of appliances by young children or infirm persons without supervision; - playing with the appliance by young children.
This harmonized standard was prepared by CSA Group and Underwriters Laboratories Inc. (UL). The efforts and support of the Technical Harmonization Subcommittee on Air-Conditioning and Refrigeration (THSC 61D WG10) of the Council on the Harmonization of Electrotechnical Standards of the Nations of the Americas (CANENA) are gratefully acknowledged.
This part of IEC 60335 deals with the safety of electric HEAT PUMPS, including SANITARY HOT WATER HEAT PUMPS, AIR CONDITIONERS, and DEHUMIDIFIERS incorporating motor-compressors and HYDRONIC FAN COILS UNITS, their maximum RATED VOLTAGES being not more than 250 V for single phase appliances and 600 V for all other appliances. PARTIAL UNITS are within the scope of this International Standard.
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