The “Changing State”

of Refrigerants

4/19/2013

4/19/2013

Refrigerant Chemistry •CFC = Chlorofluorocarbon

Rapid phase-out

Stopped U.S. production in 1996

R-11, R-12, R-113, R-114, R-500, R-502

• HCFC = Hydrochlorofluorocarbon

Slower, staged phase-out

U.S Product/Imports will stop in 2020, (2030 for R123)

R-22, R-123, R-124, R-142b

R-401a,b R-402a,b, R-408a, R-409a, R-414b, R-416a

• HFC = Hydrofluorocarbon

No U.S. phase-out planned – at this time ….

R-134a, R-143a, R-152, R-125, R-32,

R-404a, R-407a,c,f R-410a, R422a,b,c,d R-427a R-507……..

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0

65%

19

99

20

01

20

03

20

05

20

07

20

09

20

11

20

13

20

15

20

17

20

19

20

21

Year

US HCFC R-22 Phase-Out Plan

100%

2015 90% Reduction

13

SEER

2010 No New R-22

Equipment Allowed

2003 US restricts R-22 Imports & Exports.

HCFC R-141b phased out

2020 No HCFC Product.

2004 35% Reduction in R-22 production and import

35%

25%

10%

Effective 1-2011 Annual 10% step-down

Effective 10-07 2010 Reduction was

amended from 65 to 75%

Effective 1-2012 EPA Announced a

Immediate 45% cut

Effective 1-2013 EPA Announced a

Immediate 29% cut

Effective 3-28-2013 EPA Rescinded the

1-2013 Cut

4/19/2013

RSD Recovery Program

4/19/2013

RSD Recovery Program

4/19/2013

“Ozone Friendly“ HFC Refrigerant Blends

4/19/2013

Refrigerant Blend Basics

•Most all Refrigerant Blends are a mixture of some or all of the following components

•R-32 HFC

•R-125 HFC

•R-134a HFC

•R-143a HFC

•R-200 Series Hydro Carbon (Propane)

•R-600 Series Hydro Carbon (Butane)

•The mixture and percentage of each component varies depending on the blend and with (R290/R600) used solely to promote oil return in Mineral Oil systems

•Each manufacture has a vested position in one or more of the components and they Buy or Sell to each other as needed.

4/19/2013

Your HFC Choices

www.honeywell-refrigerants.com/resources/

4/19/2013

Low Temperature R22 Replacements

4/19/2013

Medium Temperature R22 Replacement

404A

407A, 407C

407F, 417A

421A,422A,

422B, 422C,

422D,424A,

427A,428A,

434A,438A,

507A

404A, 407A

407C,407F

422A, 422C,

427A, 428A

434A, 438A

507A

90-100% cap match

Commercial Options

407A, 407C

407F,427A

No TXV Change

422A, 422C

428A, 434A

438A

No Oil

Change

R22 Replacements in Med Temp Applications*

422A = 3100

422C = 3100

428A = 2100

434A = 3200

438A = 2260

407A = 2012

407C = 1677

407F =1825

427A = 2100

GWP Values

High Temp - AC R22 Replacement

Why all this talk about Oil ? • Proper Oil Return is a critical for any Refrigeration or AC System.

• Miscibility between the refrigerant and the oil ensures the lubricant stays where it belongs ( in the Crankcase).

• System design and operating temperature plays a key role

• If a system has oil return issues with R22, changing refrigerants will only make it more pronounced.

• Generally oils becomes trapped in the receiver, or is logged in the evaporator and low side piping. (Oil is harder to move at low temperature)

• Oil logging not only is bad for the compressor but can have a significant impact on the performance of the system.

• Oil acts as an insulator and inhibits heat transfer. An oil logged evaporator will act similar to an iced coil

More talk about Oil ? • In the early days Multiple Oil Changes were recommended.

“You must get +99% of the residual oil out”

• Most felt the change was necessary because the oils were not compatible. This was never the case.

• Some refrigerants claim to be no-oil-change solutions, but in most cases, system performance and compressor life are impacted.

• POE Oil is very Hydroscopic so Moisture Management is very important.

• A Vacuum Pump will not pull sufficient moisture from the system, so use a properly sized liquid line drier.

•POE Oil is a very good solvent and can cause issues in older, poorly maintained systems.

•Now it is widely agreed that only percentage of POE is required to ensure proper oil return.

Oil Return Testing

4/19/2013

Compressor Oil Level

4/19/2013

Seals and O-Rings • Rubber (Elastomers) Seals and O-Rings all absorb refrigerant.

• HCFC’s are absorbed more readily - Causing a greater Swell Rate. When the HCFC is removed, the seals contract to near there normal size.

• HFC’s are not absorbed at the same rate so the seals will not swell as much and can cause leaks.

• All Elastomer seals and O-Rings must be replaced. •EPR’s (SORIT) •Older Solenoid Valves (Wolverine seals are ok) •Heat Reclaim Valves •Shaft Seals on Open Drive Compressor •Schrader Cores and Seal Caps

•This is true with ALL HFC Refrigerants NO DROP-INS

4/19/2013

Compressor Shaft Seal

Schrader Cores and Seal Caps

4/19/2013

Evaporator Pressure Regulator

Heat Reclaim Valve

Solenoid Valve

Liquid Receivers and

Hydrocarbon Blends

• Hydrocarbons (Propane-Butane) are used to help with HFC- mineral oil/AB miscibility. •The hydrocarbon only assist oil return in the gas or vapor state using velocity to move the oil. • In the liquid form it is of no assistance and the oil can get stranded on top of the refrigerant. •To ensure proper oil return, you need to use a truly miscible combination HFC-POE

Most Popular Refrigeration Solutions Good Better Best

Characteristics R422D R407A R407F

System

Compatibility

Near Drop-In for

systems without a

liquid receiver

Close capacity match

with some system

change required

Closest capacity match

with some system

change required

Lubricant

Compatibility Works with Mineral

AB or POE Oil

Requires a %

of POE Oil

Requires a %

of POE Oil

Component

Compatibility

Expansion

Device

Compatibility

No TXV change.

Fixed orifices

should be

evaluated

No TXV or

Fixed orifice

change needed

Capacity

Relative to R22

89% at +20 f 103% at +20 f

95% at -20 f

107% at +20 f

101% at -20 f

No TXV or

Fixed orifice

change needed

All Elastomer/o-rings

should be replaced

All Elastomer/o-rings

should be replaced

All Elastomer/o-rings

should be replaced

Environmental &

Safety Factors

2700 GWP

A1/A1 Rated

Lowest 1825 GWP

A1/A1 Rated

2012 GWP

A1/A1 Rated

Popular Air Conditioning Solutions Good Better Best

Characteristics R422B R422D - R438A R407C System

Compatibility

Near Drop-In for

systems without a

liquid receiver

Closest capacity match

with some system

change required Lubricant

Compatibility Works with Mineral

AB or POE Oil

Requires 20 %

of POE Oil

Component

Compatibility

Expansion

Device

Compatibility

No TXV change.

Fixed orifices should

be evaluated

Capacity

Relative to R22

90% at +105 f cond.

No TXV or

Fixed orifice

change needed

All Elastomer/o-rings

should be replaced

All Elastomer/o-rings

should be replaced

All Elastomer/o-rings

should be replaced

Heat Pump

Considerations

Lower discharge

temperature may

impact heating

performance

99% at +105 f cond.

Similar discharge

temperature and

heating performance

94% at +105 f cond.

96% at +105 f cond.

Lower discharge

temperature may

impact heating

performance

Near Drop-In for

systems without a

liquid receiver

Works with Mineral

AB or POE Oil

No TXV change.

Fixed orifices should

be evaluated

R-407A LT MT AC

•Cap 95% 103% 110%

•Mass FL 105% 112% 112%

• Targeted at Low/Med

• Requires POE oil

• Currently Most Popular Refrigeration Substitute

• GWP 2107

•Copeland Approved for Retrofit

4/19/2013

R-407F LT MT AC

•Cap 101% 107% 114%

•Mass FL 102% 110% 110%

• Targeted at Low/Med

• Requires SOME POE oil

• Closest Capacity Match

• GWP 1825 (lowest)

•Copeland Approved for Retrofit

R-407C LT MT AC

•Cap 91% 99% 99%

•Mass FL 92% 99% 102%

• Targeted at Med /AC

• Requires POE oil

• Most Popular Full AC Retrofit

• GWP 1677

•OEM Approved New and Retrofit

4/19/2013

R-422B LT MT AC

•Cap 75% 85% 90%

•Mass FL 108% 116% 119%

• Targeted at Med/AC

• Intended to separate ICOR from R-417a, MO59

• Potential no-oil-change product

4/19/2013

R-422D LT MT AC

•Cap 79% 89% 94%

•Mass FL 123% 129% 131%

• Targeted at Med/AC

• Used Extensively by WM in 2008

• Potential no-oil Change Product

•AKA MO29

4/19/2013

R-438A LT MT AC

•Cap 81% 90% 96%

•Mass FL 100% 107% 112%

• Targeted at Low/Med /AC

• May Require POE oil

• GWP 2260

•Copeland Approved for Retrofit

AC Retrofit Considerations and Check list

• Always use proper tools and safety equipment.

• Identify and correct any system deficiencies.

• Record baseline system data. •Suction and Discharge Pressure • Liquid Sub Cooling and Suction Superheat Temps • Compressor Amps

• Disconnect electrical power .

• Evacuate the system and weigh the R22 Charge.

• Replace Elastomers – Rubber o-rings and seals. •Schrader Cores and Seal Caps •Shaft Seals on Open Drive Compressor •Older Solenoid Valves (Wolverine seals are ok) not typical on AC System.

AC Retrofit Considerations - Continued

• Change to or add POE lubricant if required.

• Replace liquid line filter driers and suction filters.

• Perform a system leak check.

• Charge the system with replacement refrigerant blend. • Start at about 95% of the recovered R22 charge. • Charge blended refrigerants in a liquid state using a throttling valve. • On Expansion Valve systems us the sub cooling method and refrigerant bubble point. • On Fixed Orifice systems use the superheat method and the refrigerant dew point.

• Allow the system to stabilize and adjust the charge as needed.

• Label the system showing the new refrigerant and oil.

4/19/2013

Pending Regulations • Now that the wheels in motion to phase out Ozone Depleting Substances, the focus has been turned to Global Warming and the products believed to be the root cause. • GWP is a relative scale which compares the gas in question with carbon dioxide with a GWP of 1. • Refrigerant Gases (CFC’s, HCFC’s and HFC’s) are known to have high Global Warm Potential (GWP) and are under review.

• There are a variety of domestic and international policies under consideration that will directly impact this issue and could have a dramatic impact on our industry. •California Refrigerant Management Program IS NOW THE LAW

• Auto Makers are scheduled to phase out R-134a in auto AC Europe is underway, GM in 2013. • Proposing a carbon tax on GWP gases – Dead for Now

4/19/2013

New Regulations California Refrigerant Management Program

• Defined a HGWP (High Global Warming Potential) substance as any that has as GWP value greater than 150

• Defined System sizes

Small = 50 to 200 lb charge

Medium = 201 to 1999 lb charge

Large = 2000 lb and greater

• Established Registration and Leak Monitoring requirement based on system size

4/19/2013

GWP of Current Generation Refrigerants

Refrigerant AKA IPCC Ver 4 GWP

R-134a 1430

R-22 1700

R-407C KLEA 66 SUVA 9000 1677

R-407F Proformax LT 1825

R-407A KLEA60 2107

R-410A AZ20 SUVA9100 2100

R-427A FX100 2100

R-438A MO99 2260

R-417A MO59 NU22 2300

R-424A RS-44 2400

R-422B NU-22b XAC1 2500

R-421A 2600

R-422D MO29 2700

R-422A MO79, One Shot 3100

R-422C One Shot B XLT1 3100

R-434A RS-45 3200

R-428A RS-52 3600

R-404A FX70/HP62 3900

R-507A AZ 50 3985

4/19/2013

Continuous Leak Monitoring Change – CA Only

• The minimum Alarm threshold is now 100 ppm • Most existing systems are set at 250 ppm • Instantaneous infrared systems can be reprogrammed (Honeywell Analytics) • Most sample draw systems cannot meet this requirement (CPC) • 100 ppm Calibration gas will be available soon

4/19/2013

South Coast AQMD Rule 1415-1415.1

•AQMD Governs : LA-OC –SBD-Riverside Counties only •In Dec-2010 Rule 1415 Modified to cover AC System only. • In Dec-2010 Rule 1415.1 Adopted to match the CARB Refrigerant Management Program. • AQMD also requires semi-annual inspection of recovery equipment. • All Documentation on the RSD/Refrigerant Suite

4/19/2013

What’s on the Horizon HFO Refrigerants (Hydro-Fluoro-Olefins)

R-1234yf

• The Replacement R-134a in New automotive Model starting in 2011 **Co2 is the other options with several limitations • A Jointly developed by Honeywell and DuPont • GWP rating = 4 • Very similar performance to R-134a - No Glide •Commercial production now underway

4/19/2013

4/19/2013

What’s on the Horizon HFO Refrigerant Blends – Cont

• Honeywell’s (Solstice®) refrigerants are now underdevelopment • Honeywell has already commercialized R-1234ze which is a good LGWP 134a replacement in 1 component foams and aerosol applications. • TEWI* ( Total Equivalent Warming Impact) is the new measure.

*A factor of GWP and energy efficiency • L & N low GWP blends could be available as early as 2013

4/19/2013

What’s on the Horizon HFO Refrigerant Blends

4/19/2013 For more info go to www/rsd.net/refrigerantsuite or Call 800-245-8007 ex 00405

4/19/2013

Gary Parker gparker@rsd.net

Thank you !