R410A

Why Change Refrigerants?

1
 Why Change Refrigerants?

This presentation is based on the concept

that those attending have some background
in the HVAC industry

2
 Why Change Refrigerants?

The handling of any refrigerant is strictly

controlled by EPA guidelines.

All persons expecting to handle R-410A are

required to have EPA certification

3
 Why Change Refrigerants?

R-22 or HCFC-22 has been used as a

refrigerant in various refrigeration, industrial
cooling air conditioning and heat
applications for over fifty years.

4
 Why Change Refrigerants?

With it’s relative low ozone depletion potential

(0.055) and global warming potential (0.34),
compared to CFC-11 and CFC-12

along with its excellent refrigerant properties

have helped facilitate its use in a verity of
industries

5
 Why Change Refrigerants?

OZONE DEPLETION

Chlorine molecules that ultraviolet radiation

has broken away from the CFC and HCFC
refrigerants in the stratosphere react with
and destroy stratospheric ozone.

Stratospheric ozone protects the earth from

the sun’s harmful ultraviolet radiation
6
 Why Change Refrigerants?

GLOBAL WARMING

Tropospheric pollutants, like CFC’s, HCFC’s

carbon dioxide and carbon monoxide absorb
and reflect the earth’s infrared radiation.
This causes re-radiation back to the earth
which results in a gradual increase in the
earth average temperature
7
 Why Change Refrigerants?

In addition, R-22 is a HCFC. This means it

is a refrigerant that contains chlorine.

The Montreal Protocol originally signed by

most industrial nations in 1987 dictates that
as a “chlorinated” refrigerant, R-22
production must eventually be eliminated.

8
 Why Change Refrigerants?

Additional information about ozone depletion,

global warming or the Montreal Protocol can
be found on the Environmental Protection
Agency's web site:

www.epa.gov

9
What is the timetable for phasing out
R-22?

 January 1, 2010
Units can no longer be manufactured with
R-22

 January 1, 2020
Production of R-22 will cease

10
 What is being done to prepare?

In anticipation of the inevitable, air

conditioning equipment manufactures have
begun designing or producing equipment
using a new refrigerant: R-410A

11
 What is R-410A?

R-410A is a near-azeotrope. Its composition

is a blend of 50% HFC-32 and 50% HFC
125.

A near-azeotrope means that the mixture acts

as a compound when changing states.

12
 What is R-410A?

NEAR-AZEOTROPE
A blend which acts very similar to a azeotrope.

However, it has a small volumetric

composition change and temperature glide
as it evaporates and condenses

13
 What is R-410A?

The color of R-410A tanks is ROSE

R-410A is always removed from the tank as a

LIQUID.
Some tanks have dip tubes so, with the tank
upright and the valve opened, liquid is
removed from the tank

14
 What is R-410A?

Most new tanks do not have dip tubes. To

remove liquid, the tank must be turned over
so the valve is down

15
 Why was R-410A chosen as the
successor to R-22?

Superior Heat Transfer Characteristics: In

future design considerations, this should
allow for a reduction in coil surface area and
perhaps cabinet size

16
 Why was R-410A chosen as the
successor to R-22?

Greater Vapor Density: This permits higher

velocities and low pressure drop losses,
allowing smaller diameter tubing and
reduced sizes of components, including
compressors

17
 Why was R-410A chosen as the
successor to R-22?

Near-Azeotropic: its temperature glide is

virtually non-existent (<0.3°) and it does not
fractionate. This means a technician can
add refrigerant to a system that may have a
leak without first having to recover the
remaining charge from the unit.

18
 Why was R-410A chosen as the
successor to R-22?

Environmentally Safe: as an HFC, it

contains no chlorine, so its ODP (Ozone
depletion Potential) is zero and its GWP
(Global Warming Potential is only slightly
higher than R-22 (1870 vs. 1700)

19
 Why was R-410A chosen as the
successor to R-22?

FRACTIONATION: When one or more

refrigerants of the same blend leak at a
faster rate than other refrigerants in the
same blend.

20
 Why can’t HFC-32 be used as a
stand alone refrigerant?
While it’s true HFC-32 has excellent heat
transfer characteristics, it is also flammable.

However, when blended with 50% HFC-125 to

form R-410A. It will not sustain a flame.
This makes it eligible for use as a refrigerant
under today’s standards.

21
 What’s different about R-410A
compared to R-22?
Aside from the fact that R-410A is a HFC,
there are a number of other significant
differences.

To the technician, there are two primary

differences that must be recognized,
understood and respected in order to assure
not only the unit’s performance, but your
safety.

22
 What’s different about R-410A
compared to R-22?
#1 – The operating pressures of R-410A are
about 60% higher than those or R-22

The higher pressures should dictate to you

that extra care must be taken os ensure
your safety, as well as the safety of the
consumer.

23
 What’s different about R-410A
compared to R-22?
#2 – R-410A utilizes a different type of oil,
than R-22.

R-22 uses mineral oil, while R-410A uses a

Polyol Ester (POE) oil.

24
 What’s different about R-410A
compared to R-22?

Most residential or light commercial

applications using R-22 required mineral oil,
although some used alkylbezenes oil.

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 What’s different about R-410A
compared to R-22?

Why can’t mineral oil or alkybenezene oil be

used with R-410A?

These oils are carried through the system by

attaching to a chlorine molecule. Since R-
410A does not contain any chlorine, it is not
miscible.

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 What’s different about R-410A
compared to R-22?

MISCIBLE: Capable of being mixed in all

proportions

27
 What’s different about R-410A
compared to R-22?
Polyol Ester (POE) oils and mineral and
alkylbenzene oils are not compatible

Even small amounts of mineral oil (<5%) in

systems using R-410A can result in
problems

This is of particular concern in retrofit

applications
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 What’s different about R-410A
compared to R-22?

Since the mineral oil and alkylbenzene oil are

not miscible with R-410A.

It ends up being pushed through the system

as a liquid.

29
 Since mineral and alkylbezene oils are
not miscible with R-410A

If the metering device is an orifice, this liquid

blob has to be pushed through, creating a
pressure drop which can cause severe
fluctuations in the system performance

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 How else does POE oil differ from
mineral and alkylbezene oils?
POE oil is VERY hydroscopic. Meaning at
readily absorbs moisture, at a rate about 15
times faster than mineral oil.

This characteristic demands a higher level of

awareness from the technician to ensure the
oil is not exposed to the atmosphere
allowing moisture into the system.

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 How else does POE oil differ from
mineral and alkylbezene oils?

When transferring or adding POE oil to a

system, always use a pump to minimize
exposure.

If any oil remains in the opened container,

properly seal the container to preserve the
oil for future use.

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 How else does POE oil differ from
mineral and alkylbezene oils?

When the refrigeration system must be

opened for any reason, the maximum time
the system can remain open to the
atmosphere is 15 minutes.

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 How else does POE oil differ from
mineral and alkylbezene oils?
It must be also noted that POE oils can cause
skin to burn due to how quickly it absorbs
moisture.
Always wear protective clothing, eye wear and
gloves when handling POE oil to prevent
direct exposure to the skin
Thoroughly wash any areas that come into
contact with the oil

34
 POE oils will attack and damage
synthetic or rubberized roofing materials

Even small oil spills that are quickly cleaned

can have lasting negative effects on a roof.

Avoid roof damage, and the resulting liability,

by protecting the area where service ro
replacement work will take place

35
 Will the filter-driers we use change?

Filter-driers must be rated for use with

R-410A.
The desiccant pore size is smaller allowing it
to capture the smaller molecules of R-22.
Filter-driers may also contain more desiccant
than those used with R-22, although the
physical size may remain the same.

36
 Will the filter-driers we use change?

Remember, once a filter-drier absorbs its

capacity fo moisture, pressure drop occurs
and any additional moisture in the system
simply passes through.

Left unchecked, the moisture react with the

oil, refrigerant and heat in the compressor to
form acid and in extreme cases, sludge.

37
What tools will be needed to be different
to work on R-410A?
Gauge pressure on equipment operating at
high ambient conditions could exceed 600
psig (150 degrees)

This Is one example of why the tools and

equipment used with R-410A must be rated
for these high pressures

38
 What tools will be needed to be
different to work on R-410A?
First of all, the manifold used for R-410A must
be calibrated for at least 250 psig on the low
side gauge and 800 psig on the high side
gauge.

And remember don’t use your R-410A gauges

on R-22 systems or you risk mixing the
refrigerant and oils.

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 Recovery Equipment
 Must be rated for R-410A

 Kept separate to avoid mixing the refrigerant

and oils

 Follow the instructions and advice in the

manufacturers instructions to assure the
safety of the equipemnt as well as yourself
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 Recovery Cylinders

 You must have separate recovery cylinders

for each refrigerant you use

 Recovery cylinders must have a service

rating of 400 Psig. (DOT 4BA 400and
DOT4BW 499 are acceptable.

41
 Recovery Cylinders

 Overfilling cylinders creates hydrostatic

pressure which leads to explosions. Follow
the filling instructions of the manufacturer.

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 Recovery Hoses

 Hoses must be rated for 700 Psig

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 Leak Detection
 Leak detectors must be rated for use with
 R-410A

 Your current leak detector maybe OK to use.

Check the instructions

 Halide leak detectors do not work with

HCF’s due to the lack of chlorine

44
 What safety precautions mist be
taken when using R-410A
 Federal law mandates that refrigerants may
not be vented to the atmosphere

 When removing refrigerants always follow

the recovery equipment manufacturers
recommendations.

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 What safety precautions mist be
taken when using R-410A

Refrigerant is heavier than air. When working

indoors, provide adequate ventilation to
avoid asphyxiation

46
 What safety precautions mist be
taken when using R-410A

Toxicity levels of R-410A are similar to, but

lower than those of R-22

For a complete breakdown on the effects of

exposure levels and safety considerations,
consult the MSDS sheet for R-410A

47
 What safety precautions mist be
taken when using R-410A

As mentioned earlier, R410A is nonflammable

at atmospheric pressure. However, if
pressurized with air in specific mixtures, it
will become combustible

NEVER pressurize R-410A with anything

other nitrogen

48
 What safety precautions mist be
taken when using R-410A

The thermal stability of R-410A is such that its

chemical composition will breakdown when
exposed to high temperatures (such as
during brazing). This is similar to what takes
place with R-22

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 What safety precautions mist be
taken when using R-410A
This means its vapor will decompose,
resulting in toxic and irritating compounds

While lack of chlorine in HCF’s prevent

phosgene gas from forming, the gases that
do form are none the less very toxic. Avoid
inhalation and use only well ventilated
areas.

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 What installation practices need to
be changed with using R-410A

 Applications
 Retrofit
 Refrigeration Piping
 Evacuation
 Refrigerant Charging

51
 Application

 Always perform a heat loss/Heat gain load

calculation to insure the correct sized
components are used for residential and
light commercial.

52
 Application

ACCA Manual J provides reliable, accurate

results. Computer software for load
calculation based on Manual J is available.
Refer to the tech guides for help is selecting
the correct equipment match ups.

53
 Application

 For duct sizing, following the principals

outlined in ACCA Manual D assures
adequate air delivery for each room.
Computer software for duct sizing, based on
Manual D is available.

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 Retrofit Applications – Existing
Evaporator Coils may be used, but:
 Capillary tubes are not acceptable

 TXV’s can be used, but must be rated for

use with R-410A

 Purge existing refrigerant lines of any oil.

– Traps may need to be replaced

55
 Retrofit Applications – Existing
Evaporator Coils may be used, but:

 Fixed orifices may be use, but must be sized

for use with R-410A

 Always follow the recommendations for the

unit being installed as some
recommendation may change

56
 Refrigerant Piping
 Use clean, dry ACR grade copper tubing

 Always seal copper tubing ends to avoid

moisture getting into the lines

 Always crimp and braze lines that will be left

unconnected

57
 Evacuation

 Vacuum pump oil must be changed after

each use.

 Vacuum pump oil changes color (turns

white) as it absorbs moisture

58
 Evacuation
 An evacuation to 500 microns is usually
sufficient to remove moisture from a system
using R-22 and mineral oil lubricant.

 A 500 micron evacuation, however, will not

separate moisture from Polyolester oil
(POE) in R-410A systems.

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 Evacuation

In addition to a 500 micron evacuation, a

liquid line filter-drier must be installed.

The liquid line filter-drier must be R-410A

compatible and should be installed any time
the system is opened.

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 Charging Procedures

 On new or retrofit applications, always

weigh in the correct charge as per the
manufacturers instructions

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 Charging Procedures
 SUBCOOLING – used when calculation
charge on systems with TXV’s

 SUPERHEAT – used when calculating

charge on systems with fixed orifices

 On R-410A, use slide rule

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 Charging Procedures
 Always remove refrigerant from the tank as
a LIQUID.

 Some tanks has dip tubes, so with the stem

up and the valve open, liquid is removed
from the tank

63
 Charging Procedures

 Most new tanks DO NO have a dip tube.

Tube remove liquid, the technician must turn
the tank upside down

 To avoid compressor damage, use a

metering tool to flash the liquid to a vapor

64
 BACKGROUND
 Based on the 1974 Molina-Roland theory
that Chlorine and Bromine were responsible
for depleting the earth’s ozone layer.

 Numerous global actions were taken to

reverse this environmental problem

65
 BACKGROUND
 1978 – U.S. ban all non-essential aersols
containing chlorine
 1987 – 23 countries sign the Montreal
Protocol establishing timelines for
phase-out of CFCs and HCFCs
 1990 – The Clean air Act is signed in the
U.S. calling for reduction in
production and emissions of CFCs
and HCFCs

66
 BACKGROUND
 1992 – Unlawful to vent CFC and HCFC
to atmosphere
 1994 – Technicians required to become
certified for purchasing and
handling CFCs and HCFCs
 1995 – Unlawful to vent alternate
refrigerants to atmosphere

67
 BACKGROUND
 1996 – Unlawful to manufacturer or import
CFCs into U.S.

 1997 – Kyoto Protocol established in

response to global warming.

 2004 – a 35% reduction cap in HCFC

consumption goes in effect.
68
 BACKGROUND
 2010 – OEM new equipment production
using R-22 ends, and a 65%
reduction cap in HCFC consumption
goes into effect
 2020 – no production or importing of
HCFC-142b and HCFC-22

69
 BACKGROUND
 In 2006, the U.S. Department of Energy is
scheduled to require that air conditioning
efficiencies be raised from 10 SEER to 12
SEER or higher.

 ASHRAE -90-1standard is calling for

increased efficiencies in commercial
equipment to be increased by 20%

70
 BACKGROUND
 The Federal Clean Air Act calls for the
phase out of HCFC based R-22 with no
production or importing beginning in 2020.

 Manufacturers of air conditioning equipment

must discontinue the use of HCFC based
R-22 in new equipment by January 1, 2010

71
 BACKGROUND
 The newly designed R-410A systems
employ thicker walled tubing, new
developed compressors, components and
high grade oils that require different
installation and service procedures

 HFCs such as R-410A, and R-134a are the

refrigerants of choice for this generation

72
 BACKGROUND
 These refrigerants solve the initial problem
of stratospheric ozone depletion.

 As the transition to R410A continues,

technological changes and pressures may
bring newer refrigerant .

 Change is inevitable
73
 BACKGROUND
 These newly manufactured R-410A air
conditioning systems will require contractors
and technicians to shift to different tools,
equipment and safety standards when
installing or changing out (retrofitting) older
split system air conditioning equipment.

74
 BACKGROUND

 The evaporator or indoor coil should be

removed and replaced when changing out
existing R-22 equipment and replacing with
a R-410A model.

75
 BACKGROUND
 Some R-22 indoor coils may meet the
UL approved design and service
pressure rating of 235 Psig (Heat pump
applications).

 Always confirm with the equipment

manufacturer before using a R-22
indoor coil with R-410A
76
 BACKGROUND
 Manufacturers have redesigned their
compressors with increased wall thickness
doue to the higher pressures associatd with
R-410A

 A compressor designed for R-22 should

never be used with R-410A

77
 BACKGROUND
 Compressor internal relief settings are
different for R-22 and R-410A systems.

 The IPR will open at pressures of 375 to 450

Psig for R-22 systems.

 And pressures of 550 to 625 for R-410A

systems
78
 BACKGROUND

 Although suction and discharge pressures

are 50 to 70% grater with R-410A than R-22,
the discharge temperature is R-410A is
lower due to its higher vapor heat capacity

79
 BACKGROUND

 Systems that use R-410A will require

changes in the high and low pressure switch
settings due to the increased pressure of the
refrigerant.

80
 BACKGROUND
 The high pressure switch will now open at
620 Psig plus or minus 10 Psig

 And will close at 500 Psig plus or minus 15

Psig.

 The low pressure control will open at 50

Psig.
81
 BACKGROUND
 Metering device capacity increases as the
pressure difference across the metering
device increases.
 If the same metering device were used in a
R-410A system and a R-22 system,
 The metering device would be oversized for
the R-410A system

82
 BACKGROUND
 The higher pressures of the R-410A system
causes a greater refrigerant flow through the
metering device.
 R-410A metering devices are designed to be
about 15% smaller than in R-22 systems to
achieve the same capacity

83