service section technical training december 2003

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Alternative Refrigerant R410AAlternative Refrigerant R410A

Service SectionService Section

Technical Training Technical Training

December 2003December 2003

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Alternative RefrigerantAlternative RefrigerantR410AR410A

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• Introduction • Cause for Change• Refrigerants• Service Procedures• Caution• Safety• Conclusions

IndexIndex

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IntroductionIntroduction


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• 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?


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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


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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)


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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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Cause for ChangeCause for Change


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1.01.0

0.0550.055

00

00

ODP Ozone Depletion Potential

R12

R22

R407C

R410A

90% Ozone


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HGWP Halocarbon Global Warming Potential

R12

R22

R407C

R410A

0.330.33

0.360.36

0.440.44

3.03.0


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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


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RefrigerantsRefrigerants


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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


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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)


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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


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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


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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)


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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)


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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


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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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Comparison of Vapour Pressure

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Service ProceduresService Procedures


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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.


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Tools Used Specifically for R410ATools Used Specifically for R410A

• Gauge manifold

• Charging hose

• Refrigerant cylinder

• Charging cylinder Coated in

Pink


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• 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


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• Gas leak detector

• Vacuum pump

a) New pump that comes built-in anti-reverse flow

b) Conventional pump with additional anti-reverse flow adaptor


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• Electronic scale for charging refrigerant

• Flare tool

a) Clutch-type flare tool (recommended)

b) Conventional flare tool


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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


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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)


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• Refrigerant recovery method

a) Pre-fill procedure

b) Filling procedure

c) Post-fill procedure


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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


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• 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


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• 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


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• System evacuation

a) Vacuum pump

b) Measuring instrument


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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


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System evacuationSystem evacuation

• Select measuring instruments

Use an absolute vacuum measuring meter (vacuum or torr meter)


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• Refrigerant charging

Invert cylinders to charge in liquid (no dip-pipe anymore)


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CautionCaution

CautionCaution

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• 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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• 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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SafetySafety

SafetySafety

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• 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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• 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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• 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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ConclusionsConclusions


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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


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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


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Thank you…Thank you…

service section technical training december 2003

Documents

r32 f f c f h

r32 f f c f h

r134a c f h f f c f

introduction h f c f

r125 c f f hfc r410a

c refrigerants

change slide

number of unsaturated