service section technical training december 2003
DESCRIPTION
Service Section Technical Training December 2003. Alternative Refrigerant R410A. Index. Introduction Cause for Change Refrigerants Service Procedures Caution Safety Conclusions. Introduction. Introduction. Introduction. WHAT IS A REFRIGERANT?. - PowerPoint PPT PresentationTRANSCRIPT
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Service SectionService Section
Technical Training Technical Training
December 2003December 2003
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Alternative RefrigerantAlternative RefrigerantR410AR410A
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• Introduction • Cause for Change• Refrigerants• Service Procedures• Caution• Safety• Conclusions
IndexIndex
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Alternative Refrigerant R410AAlternative Refrigerant R410A
IntroductionIntroduction
IntroductionIntroduction
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• Substance that is used to absorb and transport heat
• Example: CO2 , NH3 , CFC, HCFC, etc.
• Modern refrigerants (Fluorinated Hydrocarbon) are noncorrosive, nonflammable, nontoxic, nonexplosive, clear water-white and have a slightly sweet odor
WHAT IS A REFRIGERANT?WHAT IS A REFRIGERANT?
IntroductionIntroduction
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Alternative Refrigerant R410AAlternative Refrigerant R410A
R 1 2 3 4
R – ASHRAE numbering system
1 – Number of unsaturated C – C
2 – Number of Carbon atom - 1
3 – Number of Hydrogen atom + 1
4 – Number of Fluorine
REFRIGERANT STRUCTUREREFRIGERANT STRUCTURE
IntroductionIntroduction
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Alternative Refrigerant R410AAlternative Refrigerant R410A
EXAMPLEEXAMPLE
For R22For R22
Number of Fluorine = 2
Number of Hydrogen = 2 - 1 = 1
Number of Carbon = 0 + 1 = 1Cl F
C
F
H
HCFC (R22)
IntroductionIntroduction
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Alternative Refrigerant R410AAlternative Refrigerant R410A
IntroductionIntroduction
H FC
F
H
23% R32
F FC
F
H
52% R134a
C
F
H+ + F F
C
F
H
25% R125
C
F
F
HFC (R407C)
Cl
C F
F
Cl
CFC (R12)
Cl FC
F
H
HCFC (R22)
F FC
F
H
HFC (R134a)
C
F
H
H FC
F
H
50% R32
+ F F
C
F
H
50% R125
C
F
F
HFC (R410A)
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Cause for ChangeCause for Change
Cause for ChangeCause for Change
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Alternative Refrigerant R410AAlternative Refrigerant R410A
1.01.0
0.0550.055
00
00
ODP Ozone Depletion Potential
R12
R22
R407C
R410A
90% Ozone
Cause for ChangeCause for Change
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Alternative Refrigerant R410AAlternative Refrigerant R410A
HGWP Halocarbon Global Warming Potential
R12
R22
R407C
R410A
0.330.33
0.360.36
0.440.44
3.03.0
Cause for ChangeCause for Change
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Alternative Refrigerant R410AAlternative Refrigerant R410A
PHASE OUT SCHEDULE OF PHASE OUT SCHEDULE OF REFRIGERANTREFRIGERANT
100
50
65
25
35
010
0
0
20
40
60
80
100
% 1
99
6 C
AP
2002 2004 2010 2015 2020 Year
HCFC Phase Out
Montreal Protocol EC Directive
Cause for ChangeCause for Change
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Alternative Refrigerant R410AAlternative Refrigerant R410A
RefrigerantsRefrigerants
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R22For R22
• Standard refrigerant used worldwide
• Used in a broad spectrum of different applications
• Replacement for CFC 12
• With excellent physical and thermodynamic properties
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R407CFor R407C
• Designed to substitute R22
• Physical and thermodynamic properties comparable to R22
• Zeotropic refrigerant blend containing R32, R125 & R134a (23/25/52% by weight)
• Temperature glide approximately 7K (zeotropic behavior)
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R407CFor R407C
• Shifting blend composition resulting from leaks and charging operations
• Different concentration of the individual components at different points in the cycle
• Refrigerant must be charged in liquid form
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R407CFor R407C
• Miscible with polyoester oils (POE)
• Environmentally acceptable (ODP = 0)
• Able to retrofit existing R22 units
• Non-flammable and safe to use
• Commercially available
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R410AFor R410A
• Favoured worldwide as long-term alternative to R22
• Excellent thermodynamic properties
• Higher working pressure (~1.6 times > R22 systems)
• Higher refrigerating capacity achievable (~50% > R22)
• Relatively low critical temperature (~73°C)
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R410AFor R410A
• Near azeotropic refrigerant containing R32 and R125 (50/50% by weight)
• Negligible temperature glide < 0.17 K
• Refrigerant must be charged in liquid form
• Able to top up if losses are low (<25% from initial charge)
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
For R410AFor R410A
• Compressors must be charged with polyolester oils
• Environmentally acceptable (ODP = 0)
• Unable to retrofit existing R22 units
• Non-flammable and safe to use
• Commercially available
• More expensive compared to R22
RefrigerantsRefrigerants
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Alternative Refrigerant R410AAlternative Refrigerant R410A
RefrigerantsRefrigerants
0
50
100
150
200
250
300
350
400
Pre
ss
ure
(p
sig
)
1950's 1960's to 1990's 1996 and Beyond
Year
Pressure Evolution
Evap. Pressure Cond. Pressure
Evaporation Pressure at 45ºF and Condensing Pressure at 115ºF
HCFC: R22
CFC: R12
HFC: R410A
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Alternative Refrigerant R410AAlternative Refrigerant R410A
RefrigerantsRefrigerants
Comparison of Vapour Pressure
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Service ProceduresService Procedures
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Tools UsedTools Used
• Tools used when servicing R410A units can be separated in 2 categories:
a) Specifically for R410A
b) Commonly used for R22, R407C, R410A.
• Tools used in (a) should be designed to withstand the higher pressures and temperatures of R410A.
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Tools Used Specifically for R410ATools Used Specifically for R410A
• Gauge manifold
• Charging hose
• Refrigerant cylinder
• Charging cylinder Coated in
Pink
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Tools Used Specifically for R410ATools Used Specifically for R410A
• Refrigerant recovery unit
a) Recovery machine
- maximum shut off pressure of 550 psi
- capable to operate at high ambient temperatures
b) Recovery cylinder
- minimum working pressure of 400 psi and relief pressure of 600 psi
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Tools Used Specifically for R410ATools Used Specifically for R410A
• Gas leak detector
• Vacuum pump
a) New pump that comes built-in anti-reverse flow
b) Conventional pump with additional anti-reverse flow adaptor
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Tools Used Specifically for R410ATools Used Specifically for R410A
• Electronic scale for charging refrigerant
• Flare tool
a) Clutch-type flare tool (recommended)
b) Conventional flare tool
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Tools Used Commonly for R22, R407C, Tools Used Commonly for R22, R407C, R410AR410A
• Copper pipe bender
• Torque wrench
• Copper cutter and reamer
• Welding / brazing equipment
• Nitrogen gas cylinder
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Installation & Service checklistInstallation & Service checklist
• Size of flare
• Flare nut used
• Tubing useda) Narrow tube (ø6.35 x t0.8 mm)b) Wide tube (ø19.05 x t1.0 mm)
• Compressor oil used
• Refrigerant used (only R410A)
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Installation & Service checklistInstallation & Service checklist
• Refrigerant recovery method
a) Pre-fill procedure
b) Filling procedure
c) Post-fill procedure
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Refrigerant recovery methodRefrigerant recovery method
• Pre-fill procedure
Identify refrigerant to be recovered
Ensure cylinder is marked and labeled for
this refrigerant
Read all labels
Ensure cylinder retest date has not
expired
Inspect cylinder for damage
Inspect valve for damage and ease
of operation
Determine maximum
allowable gross (filled) weight
Carry out filling
procedure
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Refrigerant recovery methodRefrigerant recovery method
• Filling procedure
Ensure proper equipment is
available
Ensure cylinder is free standing on scale
Ensure maximum service pressure is
not exceeded
Ensure overfilling does not occur
Close cylinder valve securely
Check cylinder weight
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Refrigerant recovery methodRefrigerant recovery method
• Post-fill procedure
Check cylinder for leakages
Apply outlet cap on cylinder
Apply steel valve protector cover on
cylinder
Ensure cylinder bears all appropriate labels
and markings
Inspect valve for damage and ease
of operation
Confirm maximum
allowable gross (filled) weight
Send for retest
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Installation & Service checklistInstallation & Service checklist
• System evacuation
a) Vacuum pump
b) Measuring instrument
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Air conditioning sizePumping capacity
Small air conditioners up to 2.5 kW cooling capacity
Sv = 1 m3/h
Small and middle air conditioners from 2.5 up to 11 kW cooling
capacitySv = 4-8 m3/h
Big air conditioners above 11 kW cooling capacity
Sv = 8 - 15 m3/h
General guide to recommended vacuum pump capacity based on air conditioning size
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
System evacuationSystem evacuation
• Select measuring instruments
Use an absolute vacuum measuring meter (vacuum or torr meter)
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
Installation & Service checklistInstallation & Service checklist
• Refrigerant charging
Invert cylinders to charge in liquid (no dip-pipe anymore)
Service ProceduresService Procedures
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Alternative Refrigerant R410AAlternative Refrigerant R410A
CautionCaution
CautionCaution
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• Extra attention to moisture prevention is necessary
• Recommended to use liquid-line filter drier
• Remove filter drier with copper cutter
• Always charge the refrigerant in liquid phase
!
CautionCaution
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• Ensure system is properly evacuated
• Always work with absolute cleanliness
• Ensure safety gas is always used during brazing works
• Do not retrofit R22 systems to use R410A
!
CautionCaution
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Alternative Refrigerant R410AAlternative Refrigerant R410A
SafetySafety
SafetySafety
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• Ensure only certified technicians (by your own local body) are allowed to handle refrigerants
• Ensure the use of proper personal protective equipment:
a) Side shield glasses
b) Gloves
c) Safety shoes
d) Hard hat
SafetySafety
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• R410A is environmentally friendly but deadly in confined spaces
• Avoid skin contact with liquid refrigerant
• Do not heat cylinder or apply open flame above 52ºC (125ºF)
• Do not artificially cool cylinder
SafetySafety
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Alternative Refrigerant R410AAlternative Refrigerant R410A
• Air and refrigerants mixed together under pressure can become combustible
• Do not reuse cylinders intended for virgin refrigerant
• Check, read, and understand all labels before use
SafetySafety
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Alternative Refrigerant R410AAlternative Refrigerant R410A
ConclusionsConclusions
ConclusionsConclusions
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Alternative Refrigerant R410AAlternative Refrigerant R410A
R410AR410A
• High energy efficiency
• More advantages in comparison to zeotropic mixture
• Long term reduction in machinery sizes and costs.
• Substitute refrigerant for R22 in future and development is taking part worldwide
ConclusionsConclusions
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Alternative Refrigerant R410AAlternative Refrigerant R410A
R410AR410A
• Proven safety and reliability if procedures are followed and proper equipments are used
• Clean and dry as you go
• Don’t assume you know everything about R410A
ConclusionsConclusions