United States
Environmental Protection
lAgency
EPA430-R-11-012
The GreenChill Advanced Refrigeration Partnership
GREENCHILL
GreenChill Best Practices Guideline
Commercial Refrigeration Retrofits
U.S. Environmental Protection Agency
Stratospheric Protection Division
August 2011
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Disclaimer
The authors of this Guideline and the organizations to which they belong do not assume
responsibility for any omissions or errors, nor assume liability for any damages that result
from the use of the Guideline. Always check with your component manufacturers before
undertaking any action that may affect your equipment.
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History of Revisions
Version
1
2
3
4
Date Posted
Online
September 2008
April 2009
July 2009
August 20 11
Summary of Changes
Original version.
Updated recovery container table and performance data on Arkema
Forane R-427A. Added a case history on R-427A.
Added R-407A case histories.
Updated information on phaseout of HCFC-22. Added information on
ICOR R-422B and R-422C. Added Honeywell performance data, case
histories, and checklist for R-407F. Added Arkema performance data on
R-407A and DuPont information on R-438A. Added all new chemicals
to the recovery container table. Added a reference to the AHRI
Guideline Q-2010. Added Appendix 3 and additional data and guidance
from National Refrigerants.
Ill
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Table of Contents
I. Introduction 1
Mission 1
Purpose and Scope of this Guideline 1
II. The HCFC Situation - Why Retrofit? 2
Ozone Layer Protection and the Montreal Protocol 2
Montreal Protocol Implementation in the United States 3
HCFC-22 Supply and Demand 4
Reasons to Retrofit HCFC-22 Systems 5
III. HFC Refrigerant Retrofits 6
HFC Retrofit Options 6
HFC Refrigerant-only Retrofit 6
Retrofitting with New Mechanicals and HFC Refrigerant 7
Leak Tightness Improvements during Retrofits 8
Factors to Consider When Assessing Retrofit Options 9
Value/Cost Calculation 12
Lab Tests on Retrofit Refrigerants: Performance Data vs. HCFC-22 13
IV. Best Practices for Transitioning to HFC Substitute Chemicals 19
Conversion Guidelines for HFC Substitute Chemicals 19
Differences in Retrofit Procedures for Substitute Chemicals 21
V. Best Practices - End of Life 22
End-of-Life Options for Refrigerants and Equipment 22
Best Practices - Refrigerant Recovery 22
Best Practices - Recycling and Reclamation 25
Best Practices - Destruction 26
Best Practices - Insulation Foam 26
Safety Information 27
VI. Case Studies for Typical Low- and Medium-Temperature Conversions ..30
Case History Profiles 1-4: R-427A 30
Case History Profiles 5-10: R-422D 31
Case History Profiles 11-15: R-407A 32
Case History Profiles 16-21 :R-407A 33
Case History Profiles 22-25: R-407F 34
Case History Profiles 26-28: R-407F 35
VII. Appendices 36
Appendix 1: System Data Sheet 36
Appendix 2: Conversion Checklists for HFC Substitute Chemicals 37
Appendix 3: Valve Capacities for Alternatives in Retrofits 43
VII. Acknowledgments 46
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I. Introduction
Mission
GreenChill's mission in developing this document is to assist food retailers with an orderly, low-
cost transition option from HCFC-22 to a substitute refrigerant, and to provide food retailers with
a set of best practices related to the conversion process.
Purpose and Scope of this Guideline
The purpose of this Best Practices Guideline is to provide food retailers with fact-based, neutral
information on best practices for every aspect of the HCFC-22 conversion process, including:
• Reasons to consider retrofitting refrigeration equipment that uses HCFC-22;
• HFC retrofit options currently available to food retailers;
• Factors to consider when assessing substitute chemicals;
• Current best practices for transitioning to HFC refrigerants and improving leak tightness;
• Recovery techniques for HCFC-22;
• HCFC-22 disposal and reclamation options; and
• Case studies that provide real-life examples from retrofits in the field.
Different sections of this Guideline will be of value to various people within a food retail
organization. The document is designed to assist a wide range of stakeholders in the food retail
market including, but not limited to, strategic decision-makers, store managers, and technicians
participating in the HCFC-22 conversion process.
The scope of this document is limited to the conversion from HCFC-22 to non-ozone-depleting,
HFC-based substitutes in commercial refrigeration systems. Our goal is to include every non-
ozone-depleting HFC substitute that is readily available on the market for use by food retailers in
place of HCFC-22. Its only limitations are that the chemicals must be on the U.S. Environmental
Protection Agency (EPA) Significant New Alternatives Policy Program (SNAP)'s list of
acceptable substitutes, and they must be non-ozone-depleting. Under the SNAP program EPA
has reviewed these refrigerants for their health, safety, and environmental effects and has found
that their overall health and environmental risks are comparable to, or less than, those of other
available substitutes. The list of acceptable substitutes for use in retail food refrigeration is found
at http://epa.gov/ozone/snap/refrigerants/lists/foodref.html.
This Guideline is meant to be a living document. EPA's GreenChill team will make every effort
to include all relevant substitute refrigerants and to update this Guideline as future substitutes are
found acceptable by the SNAP Program.
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II. The HCFC Situation - Why Retrofit?
Ozone Layer Protection and the Montreal Protocol
HCFC-22 retrofitting is relevant to food retailers due to the phaseout of HCFC-22 under an
international treaty, the Montreal Protocol on Substances that Deplete the Ozone Layer, and
requirements under the Clean Air Act to protect the Earth's stratospheric ozone layer.
Stratospheric ozone depletion is caused by the release of chlorofluorocarbons (CFCs),
hydrochlorofluorocarbons (HCFCs), and other ozone-depleting substances, which were and are
used widely as refrigerants, as solvents, and in insulating foams. When these substances reach
the stratosphere, the UV radiation from the sun causes them to break apart and release chlorine
atoms which react with ozone, starting chemical cycles of ozone destruction that results in
significant thinning of the protective ozone layer. One chlorine atom can break apart more than
100,000 ozone molecules.
Ozone Hole
[Source: NASA 20071
Dark blue and purple
correspond to thinnest ozone;
light blue, green, and yellow
indicate progressively thicker
ozone.
As a result of ozone layer depletion, more UV radiation reaches the Earth's surface. In fact,
average UV radiation levels increased by up to a few percent per decade between 1979 and 1998.
This means more sunburns, skin cancer, cataracts, and other skin and eye damage. Some research
even shows that exposure to doses of UV radiation that are only 30-50% as high as what is
required to cause detectable sunburn can suppress human immune systems. A weakened immune
system means more colds, sick days, and other diseases. Increased UV can also reduce crop
yields and disrupt the marine food chain.
The Montreal Protocol is an agreement to protect the Earth's ozone layer and protect future
generations from the harmful effects of ultraviolet (UV) radiation. The U.S. signed the Montreal
Protocol in 1987. The Montreal Protocol and its amendments and adjustments have mandated the
complete phaseout of CFCs, and the eventual phaseout of HCFCs, according to a schedule
agreed upon by the signing parties, including the U.S. Today, the treaty has achieved universal
participation and represents a truly world-wide effort, involving both developed nations and
developing nations, to protect the ozone layer. Title VI of the Clean Air Act incorporates the
requirements of the Montreal Protocol. EPA regulations at Title 40, Part 82 of the Code of
Federal Regulations implement these requirements. EPA's Stratospheric Protection Division,
home of the GreenChill program, manages these regulations.
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While the Antarctic ozone hole (pictured above) still exists, it is slowly recovering as a result of
positive efforts to date. The World Meteorological Organization predicts that Antarctic ozone
will recover by the year 2060, assuming that the Montreal Protocol signatories continue to fulfill
their obligations under the treaty.
Ozone layer recovery means fewer cases of skin cancer and cataracts. EPA uses its Atmospheric
and Health Effects Framework (AHEF) model to estimate the U.S. health benefits of stronger
ozone layer protection policies. EPA estimates that the improved ozone layer protection afforded
by amendments and adjustments to the Montreal Protocol to date will avert millions of skin
cancer and cataract cases for Americans born between the years 1985 and 2100.
Montreal Protocol Implementation in the United States
The U.S. is reducing HCFC production and consumption in several stages to meet the Montreal
Protocol requirements. The chart shows the stepwise reductions required by the Protocol and
EPA's regulatory requirements to meet these expectations. Beginning on January 1, 2010, EPA
banned the production and import of HCFC-22 for use in new equipment (equipment
manufactured after December 31, 2009). HCFC-22 may still be used for servicing equipment
manufactured before this date (the so-called "servicing tail"), up until January 1, 2020, when all
production and import of virgin HCFC-22 will be banned.
HCFC Phaseout Plans: Montreal Protocol and U.S. EPA Regulations
Montreal Protocol
Implementation
Year
2004
2010
2015
2020
2030
% Reduction in
Consumption and
Production, Using
Cap as Baseline
35%
75% (reduced from
65% in 2007)
90%
99.5%
100%
U.S. (under EPA Regulations)
Implementation
Year
2003
2010
2015
2020
2030
Implementation of HCFC Phaseout Through
Clean Air Act Regulations
No production or import of HCFC-141b
No production or import of HCFC-22 or
HCFC-142b, except for use in equipment
manufactured before 1/1/2010 (no new
production or import for new equipment
using these refrigerants)
No production or import of any HCFCs
except for use as refrigerants in equipment
manufactured before 1/1/2020
No production or import of HCFC-22 or
HCFC-142b
No production or import of any HCFCs
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HCFC-22 Supply and Demand
As discussed above, the U.S. must meet an annual HCFC consumption cap under the Montreal
Protocol. As of 2010, the United States needed to reduce the amount of HCFCs it consumed and
produced by 75% from its baseline cap (the baseline cap is roughly the level of HCFC allowed in
1996-2003, and is calculated as the amount of HCFCs, plus 2.8% of the amount of CFCs,
consumed in 1989). By 2015, the supply of HCFCs will be reduced by 90%.
HCFC-22 users need to be aware of the upcoming HCFC-22 constraint due to the reduction in
total USA rights to consume ozone-depleting products. To address these concerns, there are
several options to move away from HCFC-22 use. Included in these options are opportunities to
repair leaky equipment, reclaim used HCFC-22, retrofit to new HFC products, and replace old
equipment. This Guideline specifically addresses retrofitting to new HFC products and the
reclamation of used HCFC-22.
EPA has estimated the continued demand for HCFC-22. The table below shows the projected
HCFC-22 demand (including that used in blends) in 2010, 2015, and 2020. These estimates were
developed based on EPA's Vintaging Model, which takes into account recent industry input
(EPA, December 2009). EPA estimates that in 2010, approximately 62,500 metric tons of
HCFC-22 were required to service AC and refrigeration equipment, of which the majority—
41,700 metric tons (67%)—were used to service AC systems. In 2015, servicing demand is
projected to reach approximately 38,700 metric tons of HCFC-22 for AC and refrigeration
equipment, and in 2020, the projected demand declines to 18,200 metric tons.
Projected HCFC-22 Servicing Demand (2010-2020) (Metric Tons)
Equipment Type
Total AC
Total Refrigeration
Overall Total
2010
41,700
20,800
62,500
2015
25,900
12,800
38,800
2020
11,300
7,000
18,200
HCFC consumption is capped as described below. Both the 2015 and 2020 projections of HCFC-
22 servicing demand exceed the U.S. consumption cap for all virgin HCFCs for these years.
However, a portion of the servicing needs are expected to be met by using recovered and
reclaimed refrigerant, thus decreasing the need for virgin HCFC-22. HCFC users should be
planning for this transition to avoid costly investments and uncertainty in the future availability
of the chemical.
HCFC Consumption Phaseout Targets Under the Montreal Protocol
Date
Jan 1, 1996
Jan 1, 2004
Jan 1, 2010
Jan 1, 2015
Consumption Cap
Consumption freeze capped at 2.8% of the 1989
OOP-weighted CFC consumption plus 100% of the
1989 OOP-weighted HCFC consumption
35% reduction of the cap
75% reduction of the cap
90% reduction of the cap
Quantity Expressed in
R-22 Metric Tons
277, OBI metric tons
180,109 metric tons
69,272 metric tons
27,709 metric tons
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Jan 1, 2020
Jan 1, 2030
99.5% reduction of the cap
100% reduction of the cap
1,385 metric tons*
0 metric tons
based on EPA regulation, no virgin HCFC-22 may be produced or imported starting January 1, 2020.
Reasons to Retrofit HCFC-22 Systems
Owners and operators of HCFC-22 systems need to evaluate their future need for the chemical in
light of the limited supply as described above. Although EPA expects that an increasing amount
of refrigerant need will be met by utilizing reclaimed HCFC-22, the supply of reclaimed material
remains uncertain. What is known is that the availability of virgin HCFC-22 will continue to
decrease, and production and import to the U.S. will be eliminated by January 1, 2020.
Equipment owners can avoid the uncertainty regarding future HCFC-22 supplies and costs by
replacing their equipment with new equipment utilizing a different refrigerant. New equipment,
however, can be a costly investment. Instead, owners may choose from many SNAP-acceptable
refrigerants that can be used in their existing equipment, often with only minor modifications.
Performing a "refrigerant-only" retrofit allows an owner to transition away from HCFC-22 while
avoiding the capital outlays and development time required to install new equipment.
This Guideline provides neutral technical information to assist food retailers who choose to
retrofit their commercial refrigeration systems from HCFC-22 to ozone-friendly refrigerants.
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III. HFC Refrigerant Retrofits
HFC Retrofit Options
Range of Retrofit Options
Improve performance
Increase efficiency
Protect ozone layer
Fight climate change
There are two main approaches to retrofitting supermarkets from HCFC-22 to HFCs:
1. Replacing only the refrigerant, with minimal adjustment to the mechanical system.
2. Using new mechanical systems, which may include compressors, condensers, and
refrigerated cases, along with a change to an HFC refrigerant.
There are advantages and disadvantages to each approach, as explained in the following section.
Once a CFC, HCFC, or FIFC refrigerant is emitted, it is only a matter of time before it damages
the atmosphere. As discussed earlier, CFCs and HCFCs are not only ozone-depleting substances
but are also potent greenhouse gases. HFCs do not deplete the ozone layer but are still
greenhouse gases. Therefore food retailers should use the retrofit conversion process as an
opportunity to prevent refrigerant emissions and tighten up the leak rates of their systems.
Regardless of the approach chosen, a retrofit should always include leak tightness improvements
to the refrigeration system. This makes sense for the environment, but it also makes sense
economically. It costs money to replace refrigerant lost to leaks.
HFC Refrigerant-only Retrofit
A refrigerant-only retrofit allows conversion to a non-ozone-depleting fluid while minimizing
retrofit costs and store disruption. HFCs have a solid track record of performance and reliability.
Mechanics have been working with HFC-containing refrigerant blends for years, and the
handling of these fluids has become commonplace.
The type of installed system and the chosen HFC or HFC/hydrocarbon blend will determine the
amount of mechanical, lubricant, and control changes required to accomplish an HFC-only
retrofit. Selecting a refrigerant with mass flows within 30% of those of HCFC-22 may allow for
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the use of the existing thermal expansion valves (TXVs). Retrofit refrigerants with low-side
operating pressures close to those of HCFC-22 will assist in proper TXV operation.
Another advantage of retrofitting existing equipment to an HFC is the benefit of lower discharge
temperatures inherent to some of the R-400 series blends and R-507A as compared to HCFC-22.
If the discharge temperature is sufficiently low, issues associated with desuperheaters, liquid
injection, and oil coolers are eliminated, which may lead to reduced maintenance costs. A side
benefit of deactivating these devices may be a gain in system capacity and efficiency. If the
existing system uses heat recovery to heat air or water, then too low a discharge temperature may
necessitate changes to these systems.
One major disadvantage of retrofitting HCFC-22 equipment to some of the current commercial
HFC options is the potential efficiency decrease relative to HCFC-22. As noted above, reduced
discharge temperatures, particularly in low-temperature systems, with some of the available
substitutes can lead to efficiencies that match HCFC-22. The decrease in efficiency can be
aggravated or alleviated by system design, geographic location, and choice of refrigerant. Certain
blends benefit from sub-cooling more than others, and this technique can bring some HFCs very
close to performing like HCFC-22.
Caution is necessary when introducing a new refrigerant to an older system, and in addition to
the criteria listed here, an evaluation of the resultant operating pressures is in order.
If the choice is made to continue the use of mineral-based lubricants, an evaluation of the
system's oil separating technology should be made. The mineral oil-compatible
HFC/hydrocarbon blends may be ineffective if the oil carryover ratio to the low side of the
system is excessive. Systems without oil separators should not consider a non-miscible
refrigerant/oil approach.
Gasket materials used in an older installation should be evaluated, since shrinking may occur
after the HCFC-22 is removed. Valve and equipment suppliers are aware of this and can supply
suitable replacements to be installed during the retrofit. Elastomeric seals should be replaced
regardless of the retrofit path chosen.
The retrofit refrigerant should be selected after evaluating the current system's performance and
evaluating the selection criteria listed in this section.
Even for a refrigerant-only retrofit, the retrofit process is a good opportunity to examine your
refrigeration system and focus attention on performance to incur additional benefits by changing
seals, repairing leaks, and cleaning the system.
Retrofitting with New Mechanicals and HFC Refrigerant
Retrofitting with new mechanical systems as well as an HFC refrigerant is likely to be more
costly in the short term but could offer significant long-term savings. Such a retrofit enables a
retailer to convert a store to ozone-friendly refrigeration and adopt advances in mechanical
design concepts and control strategies. A food retailer can address existing mechanical
shortcomings due to age or store layout, change display cases, and remove leaky equipment or
piping.
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A mechanical and refrigerant retrofit allows a retailer to consider such factors as:
• Improved control strategies such as floating head pressure control, liquid amplification,
ambient and mechanical sub-cooling, and multiple suction groupings;
• Advances in compressor and motor design; and
• Improved microprocessor-based controllers, variable frequency drives, and flow controls,
which have also shown to contribute to energy savings.
Replacing equipment during a retrofit results in a system with known operating characteristics,
capacity, and performance values. For example, manufacturers and designers are familiar with
systems designed to use polyolester (POE) lubricants and HFC refrigerants, a
lubricant/refrigerant combination that reduces oil return problems and enhances compressor
longevity.
Equipment changes, of course, present the disadvantage of higher equipment purchase cost and
potential disruption of store operations. Retrofit costs are highly store-specific, reflecting the
type of installation, display case upgrades and change-outs, store piping layout, and refrigerant
selected. The location of the equipment room also affects the difficulty and cost of replacing
compressor systems. Other considerations include the following:
• On-grade outdoor mechanical rooms often can be retrofitted or completely changed with
minimal sales floor or rooftop disruption.
• Distributed systems may offer the opportunity to locate the new equipment closer to the
loads, for example on the rooftop; they also allow electrical hookup and pre-piping with
little sales floor interruption until final case tie-in.
• If the remodel calls for only back room mechanical changes with no case changes or
modifications, then selecting an HFC with mass flows similar to HCFC-22 will minimize
work on the sales floor.
• If the refrigerant chosen has less capacity than HCFC-22, more compressor displacement
can be added during the retrofit.
In summary, purchasing new equipment for a retrofit may be more expensive initially than a
refrigerant-only retrofit, but it provides the long-term advantage of matching the mechanical
system to the chosen HFC, which may maximize the performance of the mechanical system. On
the other side, some disruption to store operations is unavoidable.
Leak Tightness Improvements during Retrofits
EPA estimates that a typical supermarket refrigeration system holds a refrigerant charge of about
4000 pounds.1 Since the average leak rate for a typical supermarket is about 25% per year, on
average a supermarket emits approximately 1,000 pounds of refrigerant into the atmosphere
annually. If nothing is done during a retrofit to repair leaks in a refrigeration system, that system
will continue to emit 1000 pounds of a potent greenhouse gas into the atmosphere annually. The
Revised Draft Analysis of U.S. Commercial Supermarket Refrigeration Systems (EPA, 2005)
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retrofit conversion process presents an opportunity to tighten leak rates and prevent the emission
of a potentially dramatic amount of refrigerant.
Reducing leaks is economically sensible as well as environmentally sensible. Leaks cost money,
regardless of which refrigerant is used.
Factors to Consider When Assessing Retrofit Options
Before beginning the retrofit process, a retailer should evaluate which refrigerant is right for a
particular store by assessing factors such as the following:
• Cooling capacity
• Efficiency
• Mass flow of refrigerant
• Lubricant compatibility
• Compressor manufacturer's approval of substitute chemicals
• GWP of refrigerant candidates
• Estimated retrofit cost
• Store disruption
Cooling Capacity
A retrofit can only be deemed successful if the refrigeration system can maintain case and
product temperatures - that is, if the installed condensing unit capacity is compatible with the
case load. This necessitates survey of the refrigeration system's available capacity. Then the
retailer can survey commercially available HFCs, using thermodynamic data and variables such
as design suction, discharge temperatures, and available sub-cooling and superheat settings.
Some compressor manufacturers have evaluated retrofit HFCs, and they may have capacity data
available. It is important to understand how capacity is defined, since compressor manufacturers
normally include the "non-useful" heat picked up in the return line and the return gas
temperature is often quoted at 65° F, which overstates the capacity. The evaporator capacity will
determine whether the case temperature can be met. For systems that are running close to 100%
of the design capacity with R-22, such as a rack system that is running all compressors most of
the time, the installation of a lower-capacity fluid may lead to elevated case temperatures,
particularly on summer design days. Systems that are not currently running at 100% capacity
may be able to use a lower capacity refrigerant, which would translate into increased run times,
although other factors such as valve/case capacities must be evaluated. Anecdotal information
and even field trial data can be misleading indicators for a particular selection; thorough analysis
upfront helps to ensure a successful retrofit.
Efficiency
As in the analysis of capacity referenced above, the coefficient of performance (COP) of a
retrofit fluid can be determined using thermodynamic analysis or published compressor
manufacturers' data for selected fluids. Again, care should be taken in understanding whether the
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COP is truly based on evaporator load. In some cases the current commercial retrofit candidates
will be less efficient than HCFC-22. System efficiency may be enhanced by technology
upgrades.
Mass Flow of Refrigerant
The mass flow of refrigerant in a system depends on the installed compressor displacement and
the density of the suction vapor entering the compressor at the design conditions. In some cases
thermal expansion valves (TXVs) may need to be replaced, depending on the initial valve
selection, the low-side operating pressures of the selected refrigerant, and the mass flow relative
to HCFC-22. If the retailer determines that certain valves need to be replaced, he or she should
consult valve manufacturers before beginning the retrofit to determine the extent of
modifications required. Appendix 3 provides an analysis by one valve manufacturer for R-22
valve capacities used with various alternative refrigerants in a retrofit scenario. It should also be
noted that supermarket systems with electronic expansion valves can automatically compensate
valve capacities by a software correction.
Higher mass flows can also lead to greater pressure drop in refrigerant piping, decreasing system
efficiency. An analysis of the installed piping system with particular attention to suction line
piping will identify piping runs that may need to be replaced with larger diameters. While this
situation is rare with the use of current retrofit fluids, some instances have been reported.
Equipment Change
Equipment changes for a given DX system are determined at three points:
• Compressor: evaluate installed compressor capacity and efficiency
• Evaporator: evaluate flow rate required per ton of cooling, evaporator pressure and
suction line capacity
• Condenser: evaluate flow rate required for the heat rejected, condensing pressure and
liquid line capacity
No refrigerant is a "drop in" for HCFC-22. The more a replacement differs from HCFC-22 with
respect to compressor capacity, efficiency, mass flow per ton of cooling, evaporator and
condenser pressures, and suction and liquid line capacities, the more the system's operation
could be affected. Equipment owners should consult with manufacturers before retrofitting to
determine the extent of modifications required.
Lubricant Compatibility
HCFC refrigerants are partially miscible with mineral-based lubricants, while HFCs use more
polar synthetic lubricants. The addition of hydrocarbons to HFCs may enhance the ability of
some systems to use mineral-based lubricants. Oil separators and proper piping practices are
essential for satisfactory oil return when using a non-miscible combination.
Compressor Manufacturer Approval
Compressor manufacturers supply and often extend warranties on compressors, the most
expensive components of supermarket mechanical systems, and retailers should take advantage
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of manufacturers' experience and testing when selecting a retrofit fluid. Some installed
compressors on older mechanical packages may not be suitable for use with HFCs or may
require modification to use HFCs with synthetic lubricants. 2
Global Warming Potential
While not a factor in refrigeration capacity, efficiency, or other physical parameters, a selection
based on global warming potential is a prudent environmental choice.
Disruption to Store Operations
During the retrofit planning process the retailer should account for effects on store operations
such as time spent emptying and restocking cases, potential for lost sales, and interference with
customer shopping experiences. It is important, however, not to overestimate these effects, since
the losses associated with the time spent retrofitting cases can be offset by refrigerant and energy
savings.
2 For example, Copeland R22 to R407C guidelines, form no. 95-14 R2, state that compressors manufactured prior to
1973 should not be retrofitted with new refrigerants and oil.
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Value/Cost Calculation
Total cost of ownership should be considered when choosing a retrofit refrigerant. Total cost of
ownership consists of two elements: first cost and future operating costs.
First cost:
• Labor
o Engineering
o Installation & follow up for leak checks
• Materials
o Refrigerant
o Charge size (Ibs.)
o Seals, gaskets, and O-rings
o Filter driers
o Oil changes if necessary
o Expansion valves if necessary
o Line changes if necessary
o Ball valves if necessary
o Distributor nozzles if necessary
Future operating costs:3
• Energy consumption for medium-temperature refrigeration
• Energy consumption for low-temperature refrigeration
• Compressor life
• Service refrigerant
(= Refrigerant Charge Size (Ibs) x Leak Rate (%/yr) x Refrigerant Cost ($/lb))
• Service labor
3 3 Future operating costs should be discounted to present value. Some supermarkets use an 8% discount rate for an i
year period.
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Lab Tests on Retrofit Refrigerants: Performance Data vs. HCFC-22
The following laboratory data have been provided by GreenChill's current retrofit chemical
manufacturing partners: Honeywell, DuPont, Mexichem Fluor, and Arkema, and ICOR. Because
each company uses different equipment and methodologies to conduct its laboratory tests and
analyses, it was impossible to do a valid side-by-side comparison of the chemicals. GreenChill
does not endorse any of the following chemicals, and EPA has not verified the accuracy of the
following information. Please contact the appropriate chemical manufacturer with any questions
you may have about the lab data and analyses that are contained in this section of this Guideline.
Please note: all global warming potentials are taken from the IPCC 4* Assessment Report, 2007.
In some cases, the numbers are rounded to the nearest hundred.
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Lab Tests on Retrofit Refrigerants: Honeywell Performance Data vs.
HCFC-22
Honeywell has evaluated all of the commercially available and American Society of Heating,
Refrigerating, and Air-Conditioning Engineers (ASHRAE)-listed HFC and HFC/HC refrigerants
using thermodynamic, system, and calorimeter testing. Below is a partial list of these refrigerants
being considered as candidates for retrofitting HCFC-22 systems. The range of capacities and
efficiencies for each fluid is the result of using the three evaluation tools. The first table is meant
as a guide using the operating conditions listed in the table below it. Since many supermarkets
use mechanical sub-cooling, capacity and efficiency values for sub-cooled low-temperature
liquid are included to demonstrate the effect of this technique on the fluids. It should be noted
that the increased sub-cooling load is generally moved to the medium-temperature systems and
these systems should be evaluated when considering this technique. More information about
these test results is available from Honeywell Refrigerant Technical Services.
Low Temperature
Medium
Temperature
Refr.
R407A
R407C
R407F
R422D
R507A
R404A
R407A
R407C
R407F
R422D
R507A
R404A
Main Parameters
GWP
#
2107
1774
1824
2729
3985
3922
2107
1774
1824
2729
3985
3922
Evap
Glide
°F
7.2
7.6
7.6
4.8
0.0
0.8
7.7
8.4
8.0
4.9
0.0
0.7
Comp.
Ratio
%
112
116
111
108
94
95
107
108
106
104
97
97
Diff.
Disch.
T
°F
-56
-44
-35
-106
-106
-103
-29
-22
-17
-57
-57
-56
Mass
Flow
%
105
92
101
123
151
143
112
99
107
129
150
143
Standard
Performance
Capacity
%
90 to 96
86 to 92
98to104
76 to 82
93 to 99
91 to 97
100 to 106
96 to 102
107 to 113
87 to 93
100 to 106
98 to 104
Efficiency
%
89 to 95
91 to 97
92 to 97
83 to 89
81 to 87
82 to 88
93 to 99
94 to 100
94 to 100
90 to 96
87 to 93
88 to 94
Added
Subcooling
Performance
Capacity
%
96 to 102
91 to 97
102 to 108
86 to 92
106 to 112
103 to 109
NA
NA
NA
NA
NA
NA
Efficiency
%
94 to 100
94 to 100
94 to 100
93 to 99
92 to 98
92 to 98
NA
NA
NA
NA
NA
NA
Retrofit Issues
Preferred
Lubricant
(optional)
POE
POE
POE
POE (MO,AB)
POE
POE
POE
POE
POE
POE (MO,AB)
POE
POE
Equipment
Evaluation
TXV adjustment
TXV adjustment
No Change
No Change
Change TXV
Change TXV
TXV adjustment
TXV adjustment
No Change
No Change
Change TXV
Change TXV
Operating Conditions
Parameter
Condensing Temperature
Degree of Subcooling at TXV Inlet
Evaporation Temperature
Superheat at Evaporator Outlet
Superheat gain in the Suction Line
Compressor Isentropic Efficiency
Compressor Volumetric Efficiency
Medium
Temperature
105°F
10°F
20°F
10°F
15°F
60%
100%
Low
i Temperature
105°F
10°F
-25° F
10°F
40°F
60%
100%
Low
Temperatun
i Added
Subcooling
105°F
55°F
-25° F
10°F
40°F
60%
100%
14
-------
Lab Tests on Retrofit Refrigerants: ISCEON® Performance Data vs.
HCFC-22
DuPont has completed extensive compressor calorimeter tests on the leading R-22 replacement
refrigerants to help supermarket retailers make educated choices. The table below summarizes
the performance of several retrofit refrigerant options relative to R-22. More detail about the
actual test results for both Copeland® brand and Carlyle® brand compressors is available to
customers upon request.
Potential
Alternatives
Condenser Temp
Relative Med
Temp Capacity (20
°F)a
Relative Low-Temp
Capacity (-25 °F)b
Relative Med-
Temp EER (20 °F)C
Relative Low-Temp
EER (-25 °F)d
Copeland
Compressor
Retrofit Approval
Keep TXV
Keep Line Sets
UL Listed
GWP
Use Mineral Oil
Medium-Temp
Discharge Temp
Low-Temp
Discharge Temp
Unit
°F
BTUH
BTUH
BTUH/
W
BTUH/
W
AR4
°F
°F
HCFC-22
80
1
1
1
1
105
1
1
1
1
Yes
Yes
Yes
Yes
1810
Yes
186
230*
225
230*
R-404A
80
1.17
1.25
1
1.03
105
1.11
1.17
0.97
1.03
Yes
No
Evaluation
Yes
3920
No
149
201
111
225
R-407C
80
1.01
0.98
0.97
0.98
105
0.96
0.91
0.96
0.93
Yes
Yes
Yes
Yes
1760
No
170
225
204
230*
R-438A
80
1
0.96
1.01
1.03
105
0.94
0.92
1
1.02
Yes
Yes
Yes
Yes
2260
Yes
155
206
183
226
R-422A
80
1.13
1.24
0.92
1.06
105
1.08
1.19
0.94
1.07
Yes
No
Evaluation
Yes
3140
Yes
144
192
169
214
R-422D
80
1.01
1.06
0.99
1.04
105
0.96
0.97
1.00
1.04
Yes
Evaluation
Evaluation
Yes
2730
Yes
148
195
172
218
* Liquid Injection required to maintain 230 °F discharge temperature
a 65 °F return gas; Sub-cooled liquid 10 °F below average condenser temperature
65 °F return gas; Sub-cooled liquid 10 °F below average condenser temperature for 80 °F condenser conditions; Sub-cooled
liquid 15 °F below average condenser temperature for 105 °F condenser conditions
C65 °F return gas; Sub-cooled liquid 10 °F below average condenser temperature
d 65 °F return gas; Sub-cooled liquid 10 °F below average condenser temperature for 80 °F condenser conditions; Sub-cooled
liquid 15 °F below average condenser temperature for 105 °F condenser conditions
15
-------
Lab Tests on Retrofit Refrigerants: Klea® 407A Performance Data vs.
HCFC-22
The following table provides system performance data for Klea®407A. The data is derived from
laboratory tests and calorimeter data using compressors from a major manufacturer. More
information is available from Mexichem Fluor upon request.
Medium-Temperature Condition
Average condenser temperature
Average evaporator temperature
Liquid temperature at expansion valve
Evaporator superheat
Compressor suction gas temperature
Evaporator capacity
Evaporator EER
Discharge temp without demand cooling
Units
°F
°F
°F
°R
°F
BTU/hr
BTU/hr.W
°F
R-407A
80
20
70
10
45
100624
15.85
139.5
R-22
80
20
70
10
45
93186
15.85
162.7
R-407A
105
20
95
10
45
82023
9.99
176.2
R-22
105
20
95
10
45
78523
10.25
207.8
Low-Temperature Condition
Average condenser temperature
Average evaporator temperature
Liquid temperature at expansion valve
Evaporator superheat
Compressor suction gas temperature
Evaporator capacity
Evaporator EER
Discharge temp without demand cooling
Units
°F
°F
°F
°R
°F
BTU/hr
BTU/hr.W
°F
R-407A
80
-25
70
10
25
28867
6.50
213.2
R-22
80
-25
70
10
25
27604
6.67
264.5
R-407A
105
-25
95
10
25
21627
4.48
256.9
R-22
105
-25
95
10
25
17535
4.30
319.5
R-407A performance relative to R-22
Condition
Evap/cond
20°F/80°F
20°F/105°F
-25°F/80°F
-25°F/105°F
Evaporator
Capacity
108.0%
104.5%
104.6%
123.3%
Evaporator
EER
100.0%
97.5%
97.5%
104.2%
Change in
discharge temp
(°F)
-23
-32
-51
-63
Mass flowrate
at compressor
115.8%
115.8%
114.9%
123.7%
Change in evaporator
pressure (psia)
+4.3
+3.7
+0.5
+0.2
Points in red denote that liquid injection was used to limit R-22 discharge temperature to 270°F and the
EER/capacity adjusted accordingly
16
-------
Lab Tests on Retrofit Refrigerants: Arkema Forane" 427A / Forane" 407A
Performance Data vs. HCFC-22
Arkema completed testing of R-427A and R-407A as leading medium-to-low-temperature R-22
refrigeration retrofits. The tables below summarize their physical / performance properties. More
information is available from Arkema Technical Service upon request.
Physical Properties
PROPERTIES
Average Molecular Weight (g/mol)
Normal Boiling Point (NBP) (°F)
Latent Heat of Vaporization at NBP (BTU/lb)
Critical Temperature (°F)
Critical Pressure (psia)
Density of Saturated Vapor @ NBP (Ib/ft3)
Density of Saturated Liquid at 77 °F (Ib/ft3)
Specific Heat of Saturated Vapor at NBP (BTU/lb. °R)
Specific Heat of Saturated Liquid at 77 °F (BTU/lb. °R)
Ozone Depletion Potential (OOP) (CFC-11 = 1.0)
ASHRAE Safety Group Classification
Occupational Exposure Limits (8 hr time/wt. Avg.) (ppm)
Global Warning Potential (GWP)
HFC-427A
90.4
-44.8
102.0
185.6
637.1
0.30
71.9
0.18
0.38
0
Al
1,000
2,130
HFC-407A
90.1
-49.0
101.3
180.1
654.9
0.30
71.5
0.18
0.36
0
Al
1,000
2,100
HCFC-22
86.5
-41.3
100.5
204.8
722.3
0.29
74.5
0.14
0.30
0.055
Al
1,000
1,810
Performance Properties - Medium-Temperature Application
Test Conditions
105 °F Condensing Temperature
20 °F Evaporator Temperature
R-22 TXV, Optimized Charge
Capacity (%)
COP (%)
Mass Flow Rate (%)
Discharge Pressure (psig)
Discharge Temperature (°F)
HFC-427A
91.1
94.2
101.1
216
183
HFC-407A
97.3
94.2
110.6
242
191
HCFC-22
100.0
100.0
100.0
211
216
17
-------
Lab Tests on Retrofit Refrigerants: ICOR R-422B and R-422C Performance
Data vs. HCFC-22
The following table summarizes the laboratory tests of R-422B and R-422C on low-temperature
applications. More information is available from ICOR International upon request.
70°F Box Start Temperature
Time to achieve 0 °F (minutes)
Time to achieve -10 °F (minutes)
Time to achieve -15 °F (minutes)
Lowest Box Temperature (°F)
Time to achieve -10 °F after defrost (minutes)
Time to achieve -15 °F after defrost (minutes)
AMPs
Compressor Suction (psig)
Evaporator Suction Line Temp (°F)
Evaporator Temp Supply (Air) (°F)
Evaporator Temp Return (Air) (°F)
Evaporator Delta T (°F)
Evaporator TD(°F)
Liquid (psig)
Liquid Temperature (°F)
Liquid Subcooling (°F)
Discharge (psig)
Discharge Temperature (°F)
Compression Ratio
R-422B
74
101
128
-19
26
35
4.4
3
-24
-22
-16
6
18
164
82
6
173
110
10.4:1
R-422C
76
101
121
-31
22
25
4.6
7
-27
-26
-19
7
11
200
84
5
206
114
10.1:1
R-22
69
96
129
-18
16
43
4.8
7
-23
-21
-15
6
11
185
90
6
191
119
9.6:1
18
-------
IV. Best Practices for Transitioning to HFC Substitute
Chemicals
Conversion Guidelines for HFC Substitute Chemicals
This section lists conversion procedures that a typical retailer will likely undertake to retrofit
equipment that was designed to use HCFC-22. It also provides general guidance on a typical
conversion process. Appendix 2 contains retrofit checklists that are specific to each HFC
substitute refrigerant.
1. Determine alternative refrigerant to be used.
2. Determine oil type based on recommendations from refrigerant manufacturer, original
equipment manufacturer (OEM), and contractor.
3. Determine whether existing elastomer types are suitable for the proposed refrigerant.
4. Ensure all material is on hand before starting the retrofit.
5. Record performance of existing system using the System Datasheet in Appendix 1.
6. Analyze the condition of the lubricant and refrigerant to identify any pre-existing issues
that may prevent a successful retrofit like high moisture, acidity, non-condensibles, or
compressor wear issues.
7. Check for, and repair, any existing leak before proceeding with the retrofit. (See
GreenChill's leak repair guideline at
http://www.epa.gov/greenchill/downloads/leakpreventionrepairguidelines.pdf)
8. If a change of oil type from mineral oil to POE oil is required, complete this step. If no
change of oil is required, skip to step 9.
a. Isolate the refrigerant to avoid refrigerant losses during the oil flush. Pull a
vacuum on the system to minimize the amount of refrigerant dissolved in the oil.
b. Drain the oil from the system into suitable containers, paying particular attention
to the compressor sump, suction line accumulator, oil separator, long runs of
piping, and any low spots. Measure the amount of oil removed. Dispose of oil
properly.
c. Replace filter-drier with one that is compatible with the new refrigerant and POE
oil.
d. Add the recommended POE oil to the system.
e. Evacuate system to 500 microns to remove air and moisture. Hold vacuum to
check for leaks.
f Restart system and check oil level. Adjust oil level if needed. Run system for a
minimum of 24 hours to ensure time for the POE and residual oil to mix. Longer
running times will allow more complete mixing and oil return, particularly for
larger systems.
g. Check amount of mineral oil content in the system using a refractometer or other
commercially available device. If mineral oil content is above the recommended
level, repeat step 8.
19
-------
9. Remove HCFC-22 refrigerant from system.
a. Use an approved recovery machine and recovery cylinders.
b. Do not vent refrigerant to atmosphere.
c. Remove refrigerant to a target vacuum level of 15 inches Hg. The lower the
vacuum level achieved, the lower the refrigerant emission when the system is
opened and the higher the amount of potentially valuable refrigerant recovered.
d. Weigh amount of refrigerant recovered.
10. Break the vacuum.
11. Replace equipment as required for new refrigerant and as desired to reduce the potential
for leaks in subsequent operation.
a. Replace filter/drier, compatible with new refrigerant.
b. Replace thermal expansion valves (TXVs) if it has been determined necessary in
the initial system selection process.
c. Replace any seal on a joint that was opened. Replace all seals on the rack system.
This will reduce the likelihood of a leak even on joints that would not normally be
broken as part of a retrofit.
d. Replace old ball valves and repair/replace solenoid valves as necessary, as these
are sources of leaks.
e. If original oil type is to be used (step 8 was omitted), check condition of mineral
oil and replace if needed.
12. Reset the pressure controls and other equipment as required for the new refrigerant.
13. Pull a vacuum on the system.
a. Target is 500 microns.
b. Hold vacuum and check for leaks.
14. Charge system with new refrigerant.
a. Charge level will be based on refrigerant manufacturer's recommendation.
b. For blend refrigerants in the ASFIRAE 400 series, remove liquid from the
cylinder to ensure correct composition. Ensure liquid is vaporized before reaching
the compressor to avoid equipment damage.
15. Check system for any refrigerant leak.
a. Check low-pressure side of system with compressor off, as the higher vapor
pressure will enhance leak detection.
16. Adjust TXV setting as needed for new refrigerant.
a. For ASHRAE 400 series refrigerants, there will be temperature glide in the
condenser and evaporator, i.e. a difference in dew point and bubble point for a
given pressure. Consult refrigerant manufacturer for correct dew point / bubble
point information.
b. When calculating sub-cooling, use the bubble point as the reference temperature.
c. When calculating superheat, use dew point as the reference temperature.
17. Monitor oil level in compressor.
a. Check oil level in system and adjust as needed.
b. If oil return is not adequate or if oil level is unstable, refer to specific guidelines
from the refrigerant manufacturer for corrective action.
18. Properly label the system with refrigerant and lubricant type and charge.
20
-------
Material Compatibility
Generally, the same seal materials can be used in HCFC-22 and HFC service, but there are
exceptions, since the swelling characteristics for HCFCs differ from those for HFCs. For
example, Viton® does not perform well with R134a, a base component of certain HFC blends.
Different grades of the same material can behave differently. The type of lubricant can also
affect material choice. Consult refrigerant and equipment manufacturers to confirm material
suitability. Older systems manufactured before the development of HFCs in the early 1990s may
have compatibility issues.
Differences in Retrofit Procedures for Substitute Chemicals
The following chart shows some potential differences in the HCFC-22 conversion process for all
SNAP-approved, non-ozone-depleting, retrofit chemicals. This is a general guide, and the
procedures and requirements for your specific system may vary, so please check with equipment
manufacturers and refrigerant manufacturers. Appendix 2 provides a detailed, step-by-step
conversion checklist for each refrigerant.
Step
Change oil to POE
Flush with POE oil
again until residual
mineral oil is below
recommended level
Change TXVs
Change seals
Change powerhead
Significant
equipment changes
due to mass flow and
pressure drop
Pure HFC Blends
R-404A
Yes
Yes
Normally
yes
Yes
Yes
Yes
R-407A
Yes
Yes
No
Yes
No
No
R-407C
Yes
Yes
Normally
no
Yes
No
No
R-407F*
Yes
Yes**
No
Yes
No
No
R-427A
No*
No*
Normally
no
Yes
No
No
HFC/Hydrocarbon Blends
R-422D
No*
No*
Normally
no
Yes
No
No
R-422B
No
No
Normally
no
Yes
No
No
R-422C
No
No
Normally
No
Yes
Yes
No
R-438A
No
No
No
Yes
No
No
*A change to POE oil may not required for R-422D and R-427A if the system has an oil separator and the oil
circulation rate is acceptable; if the system does not have an oil separator, the oil must be changed to POE.
** Conversions from R-22 to R-407F have shown a high tolerance for residual mineral and alkyl benzene lubricants.
Check with the system or compressor manufacturer for residual maximums.
t Pending.
21
-------
V. Best Practices - End of Life
End-of-Life Options for Refrigerants and Equipment
When refrigeration equipment reaches its end of life, the HCFC-22 refrigerant must be recovered
and either recycled, reclaimed, or destroyed. EPA's GreenChill Partnership recommends
recycling or reclamation wherever possible, since HCFC-22 is a valuable resource that will likely
become more valuable as it continues to be phased out. Foam insulation from refrigeration
equipment, especially commercial refrigerators and freezers, can be recovered for additional
environmental benefits. This section describes end-of-life best practices for HCFC-22
refrigerant.
Other Factors
Before entering into any agreement with a reclamation service provider, the equipment owner
should make sure he or she understands all of the costs involved. There may be separate charges
for identifying the material, transporting it, and reclaiming or destroying it. If the equipment
owner is responsible for shipping the refrigerant, he or she should make sure the reclamation
service provider explains how to comply with any applicable U.S. Department of Transportation
(DOT), state, and local requirements for shipping.
The specific options and methods for recovery, recycling, and reclamation depend on the
application and refrigeration equipment size. Since reclamation requires specialized machinery
not available at a supermarket job site, an HVAC professional typically processes recovered
refrigerant for reuse on site or (in the case of retrofit) sends it to a reclaimer or back to the
refrigerant manufacturer. Regardless of which method is used, all personnel must be properly
trained to handle refrigerants.
Best Practices - Refrigerant Recovery
Recovery is the removal of refrigerant from a system and storage in properly rated recovery
cylinders without necessarily testing or processing it in any way. The following is a list of best
practice recovery techniques. Proper handling and recovery will prevent inadvertent mixing of
refrigerants and the accompanying handling and disposal fees.
• Do not mix refrigerants of different ASHRAE numbers either in the system or in a
recovery cylinder. Refrigerants that are mixed during recovery are much more costly to
reclaim, since they require a specialized separation process that few reclaimers provide.
Mixed material may need to be destroyed, which is costly and wasteful.
• Tag the recovery cylinder with the identity of the refrigerant.
• Do not overfill recovery cylinders. Weigh each cylinder once refrigerant is recovered
from a system and check this weight against maximum fill weights.
22
-------
A vacuum level of 10-15 inches Hg (50-67 kPa) is necessary to remove the charge (15
inches is recommended), relative to standard atmospheric pressure of 29.9 inches Hg.
Recover the existing refrigerant charge from the system into proper pressure-rated
recovery cylinders (see the table below). Return recovered refrigerant to your refrigerant
wholesaler or reclaim service provider.
Recovery Containers for Used Refrigerant Products
Container
4BA300 Cylinder
4BA350 Cylinder
4BA350 Cylinder
4BW400 Cylinder
4BA400 Cylinder
4BA400 Cylinder
3AA2400
3AA1800
3AA2265
4BW260 Half-ton
4BW400 Half-ton
Drum
Water
Capacity
123 Ib
26 Ib
48 Ib
123 Ib
26 Ib
48 Ib
96 Ib or smaller
1,000 Ib
1,000 Ib
55 gal, 20 gal,
10 gal
Used Refrigerant Types
R-12, R-114, R-123, R-124, R-134a, R-22, R-401A
(MP39), R-401B (MP66), R-404A, R-407C, R-408A,
R-409A, R-417A, R-422A, R-422B, R-422C, R-422D,
R-423A, R-500, R-502, R-507, R-427A, R-407A, R-
438A (M099) , R-407F (Performax LT)
R-402A (HP80), R-402B (HP81), R-410A
R-13, R-23, R-503, R-508B (Suva 95)
R-12, R-22, R-114, R-123, R-124, R-134a, R-401A
(MP39), R-401B (MP66), R-409A, R-417A, R-500, R-
502, R-427A
R-402A (HP80), R-402B (HP81), R-404A, R-407C, R-
408A, R-410A, R-422A, R-422B, R-422C, R-422D, R-
507, R-407A, R-407F (Performax LT)
R-ll, R-113, R-123, R-141b
Weight (Ib)
Avg. Tare
55
14
26
62
14
26
81
370
560
N/A
Max. Gross
150
34
64
150
34
64
135
1,150
1,360
N/A
One manufacturer has provided the weight chart on the next page, which provides similar
information in a different format. This chart recognizes that different recovery cylinders could
have different tare weights but the same water capacity, and lists the water capacity and the
maximum refrigerant weight allowed for each size cylinder (which is a calculation of the
refrigerant density and water capacity). The actual tare weight of the cylinder should be used to
determine the gross weight.
23
-------
Guidelines for Maximum Shipping Weights for Recovered Refrigerant Containers
Cylinder Size
Water Capacity
30 Ib.
26.2 Ibs.
One Shot
30 Ib.
29.7 Ibs.
40 Ib
38.1 Ibs.
50 Ib.*
47.7 Ibs.
125 Ib.
123 Ibs.
1/2 ton
1000 Ibs.
Iton
1600 Ibs.
* includes 50F and 50HP
Maximum Refrigerant Weight Allowed
Refrigerant Min
service
pressure
R-12 260 psig
R-22 260 psig
R-500 260 psig
R-502 260 psig
R-114 260 psig
R-134a 260 psig
R-401B 260 psig
R-402A 350 psig
R-402B 300 psig
R-403B 300 psig
R-404A 300 psig
R-407A 300 psig
R-407C 300 psig
R-407F 300 psig
R-408A 300 psig
R-409A 260 psig
R-410A 400 psig
R-416A 260 psig
R- 417A 260 psig
R- 422A 350 psig
R- 422B 350 psig
R- 422C 350 psig
R- 422D 350 psig
R-427A 260 psig
R- 507 350 psig
24
22
21
22
28
22
22
21
21
19
18
21
21
23
19
23
19
25
20
18
21
20
20
24
18
28
25
25
25
32
25
25
24
24
22
20
24
23
26
22
26
22
29
22
21
24
23
23
27
20
36
32
31
32
41
32
32
31
30
28
26
31
30
34
28
34
28
37
29
27
30
29
30
34
26
45
40
39
40
51
41
40
39
38
35
22
39
38
42
35
42
35
46
36
34
38
36
37
43
33
117
103
102
103
133
106
103
99
97
91
85
99
97
110
90
109
89
120
94
88
98
93
96
111
85
952
839
836
842
1088
864
857
809
792
736
688
808
790
896
735
888
726
979
770
723
793
758
111
904
688
1523
1342
1337
1347
1740
1382
1334
1294
1267
1177
1100
1292
1264
1433
1176
1420
1162
1566
1231
1157
1268
1213
1243
1446
1100
Low Pressure Containers
Refrigerant
R-ll, R-113, R-123
Drum size
100 Ibs
200 Ibs
650 Ibs
Max Allowable
Refrigerant Weight
90 Ibs
180 Ibs
585 Ibs
Avg Drum Tare
Weight
10 Ibs
20 Ibs
65 Ibs
Max Gross
Shipping Weight
100 Ibs
200 Ibs
650 Ibs
(Continued on next page.)
24
-------
Guidelines for Maximum Shipping Weights for Recovered Refrigerant Containers (cont.)
Very High Pressure Cylinders
Refrigerant
R-13
R-23
R-503
R-508B
R-13B1
RefWt/ShipWt
14 34
11 31
12 32
12 32
17 37
RefWt/ShipWt
19 49
15 45
16 46
17 47
12 52
RefWt/ShipWt
74 211
58 198
64 206
65 205
89 229
IMPORTANT: The tare weights listed in this guideline are only average weights. In order to determine actual gross shipping
weight of each individual cylinder must be used.
Always use a scale when filling any cylinder. DO NOT OVERFILL.
SOURCE: National Refrigerants, 2011.
Best Practices - Recycling and Reclamation
Recycling
Before refrigerant is reused it must be recycled or reclaimed. Recycling refers to the recovery of
refrigerant from a system and cleaning for reuse without necessarily meeting all of the
requirements for reclamation. In general, recycled refrigerant is refrigerant that is cleaned using
oil separation and single or multiple passes through devices, such as replaceable core filter-driers
that reduce moisture, acidity, and particulate matter.
Recycled refrigerant may be stored and used by the same equipment owner. It may not, however,
be sold for use or used in a different equipment owner's facility.
Reclamation
Reclamation is the processing of a recovered refrigerant, through such mechanisms as filtering,
drying, distillation and chemical treatment, to restore the substance to the original purity
specification indicated in AHRI Standard 700. Reclamation ensures that contaminated or mixed
refrigerants do not enter the marketplace, where they could cause equipment damage or leaks.
Reclamation by an EPA-certified reclaimer is required when recovered refrigerants will be
charged into a different owner's equipment.
To be properly reclaimed, used refrigerant must be reprocessed to at least the purity level
specified in Appendix A to 40 CFR Part 82, Subpart F.4 Reclaimed refrigerant must be verified
to meet AHRI-700 standards using analytical methodology prescribed in section 5 of Appendix
A.
4 See http://epa.gov/ozone/title6/608/reclamation/index.html
25
-------
Reclaimers' business practices vary. Some might charge the material owner a fee and return the
material to the owner. Others might buy used material from the owner, reclaim the material, and
retain ownership and resell. In some cases, where the owner of material does not intend to retain
ownership, the reclaimer may even charge for taking the material. Some reclaimers offer
refrigerant "banking," under which an equipment owner ships recovered refrigerant to the
reclaimer who then typically restores the refrigerant to AHRI Standard 700 condition. The
reclaimer then packages and holds the reclaimed refrigerant in storage for the equipment owner
until the equipment owner releases material from the "bank." The reclaimer would charge for
processing, packaging and storing the refrigerant.
See www.epa.gov/ozone/title6/608/reclamation/reclist.html for a list of EPA-certified refrigerant
reclaimers. You should check with a prospective reclaimer to verify its service area, its technical
capability to process recovered refrigerant to AHRI Standard 700, its capability to separate
mixed refrigerants or destroy contaminated refrigerant, and service options such as banking.
EPA requires that reclaimed refrigerant attain AHRI 700 standards prior to resale. Reclamation
facilities and processes should be designed to minimize emissions.
The following GreenChill partners offer refrigerant reclamation services through their wholesale
distributors. For more information, contact:
i. Arkema-(800) 245-5858
ii. DuPont - (800) 235-7882
iii. Honeywell-(800) 631-8138
iv. Mexichem Fluor -(800) 424-5532
v. ICOR International - (800) 497-6805
vi. National Refrigerants, Inc. - (800) 262-0012
Best Practices - Destruction
Refrigerant that cannot be reclaimed to AHRI 700's purity standard must be destroyed. In this
case, the reclamation service provider will most likely incinerate the refrigerant in an EPA-
approved facility. Be aware that not all reclaimers have the technology to handle all
contaminated or mixed refrigerants. Check with your reclamation service provider to verify that
it is equipped to dispose of refrigerant in an environmentally acceptable manner with required
permits (e.g., an incinerator equipped to decompose refrigerant into CC>2 and acid gases and
scrub the acid gases from the vent stream).
Best Practices - Insulation Foam
CFC, HCFC, and HFC blowing agents are used in insulating foam contained in commercial
refrigerators and freezers. ODS foam recovery presents a significant opportunity to reduce
emissions of ODS and GHGs. Although not required by law, as a best practice, ODS foam can
be recovered from commercial refrigerators and freezers at end of life and sent for reclamation or
destruction.
26
-------
To avoid the harmful release of ODS and GHGs, insulating foam should be removed from all
parts of refrigerators and freezers at time of equipment disposal. Foam can be recovered from
refrigerators and freezers either manually or through a fully automated process. Once foam is
recovered it should be sent for either (a) destruction (e.g., to a municipal solid waste incinerator
or waste-to-energy boiler) or (b) further processing to recover the blowing agent from the foam
matrix and ultimately reclaim or destroy the concentrated blowing agent. Several dedicated
appliance recycling facilities offer these types of foam removal and processing services across
the U.S. In addition, EPA's voluntary Responsible Appliance Disposal (RAD) Program,
designed to promote these types of best practices, serves as a technical clearinghouse on the
development and implementation of responsible disposal programs.
Safety Information
CFC, HCFC, and FIFC refrigerants are safe when handled properly. However, any refrigerant
can cause injury when mishandled. Please review the following guidelines before using any
refrigerant.
Do not work in areas with high concentrations of refrigerant vapors. Always maintain
adequate ventilation in the work area. Do not breathe vapors. Do not breathe lubricant mists from
leaking systems. Ventilate the area well after any leak, before attempting to repair equipment.
Do not use handheld leak detectors to check for breathable air. These detectors are not
designed to determine if the air is safe to breathe. Use oxygen monitors to ensure adequate
oxygen is available to sustain life.
Do not use flames or torches to search for leaks. Do not use flames in the presence of high
concentrations of refrigerant. Open flames release large quantities of acidic compounds in the
presence of all refrigerants and these compounds can be hazardous. Do not use torches as leak
detectors. Old halide torches detect chlorine, which may not be present with new refrigerants.
Use an electronic leak detector designed to find the refrigerants you are using.
If you detect a visible change in the size or color of a flame when using torches to repair
equipment, stop work immediately and leave the area. Ventilate the work area well, and stop
any refrigerant leaks before resuming work. These flame effects may be an indication of very
high refrigerant concentrations, and continuing to work without adequate ventilation may result
in injury or death.
Again: Any refrigerant can be hazardous if used improperly. Hazards include liquid or vapor
underpressure, and frostbite from the escaping liquid. Overexposure to high concentrations
of vapor can cause asphyxiation and cardiac arrest. Please read all safety information before
handling any refrigerant.
27
-------
Safe Handling Practices for Non-Reusable and Returnable Cylinders:
• Ensure valve is closed.
• Ensure cylinder remains in the original carton when transporting.
• Dispose of cylinders properly - check local requirements for disposal regulations.
Recover the refrigerant heel to a minimum 15" prior to recycling the metal cylinder.
• Return empty cylinders using DOT guidelines for proper transporting.
Refer to AHRI Guideline Q-2010 for Content Recovery & Proper Recycling of Refrigerant
Cylinders for more information on content recovery and recycling of cylinders.5
Filling Recovery Containers
When loading used refrigerant into recovery containers, particular care is necessary with respect
to the following:
• Container Pressure
Recover the refrigerant charge into proper pressure-rated recovery cylinders. Do NOT put
a higher-pressure refrigerant such as R-507 into a lower-pressure recovery cylinder.
• Container Integrity
Prior to filling, inspect the recovery container and valve for signs of damage such as
dents or corrosion. Do NOT fill a damaged recovery container.
• Test Date
Recovery cylinders and half-ton tanks should not be filled if the present date is more than
five years past the test date that is stamped on the unit. The test date, which will look
similar to the example below, is stamped on the shoulder of the cylinder or the collar of
the half-ton tank.
AO
12 09X
37
This designation indicates that the unit was retested in December 2009 by retester
number AO37.
If a recovery container is out of date, it must not be filled. Return it promptly for
retesting.
Containers filled prior to five years from test date may be shipped full to the
recovery/evacuation facility.
• Liquid Overfilling of Cylinders
1 Available online at www.ahrinet.org/ARI/util/showdoc.aspx?doc=1792>
28
-------
Liquefied refrigerant expands when exposed to high temperatures. If the container is
overfilled, the thermal expansion of the liquid could cause release of refrigerant through
the relief valve, or rupture or bulge the container.
The maximum gross weight (total weight of the container and its contents) MUST NOT
be exceeded.
• Vapor Overpressuring: Recovery Half-Tons and Cylinders
When a compressor is used to recover refrigerant, the pressure of the recovery half-ton or
cylinder must be monitored closely. Overpressurizing the cylinder could cause release of
refrigerant through the relief valve, or rupture or bulge the container.
Note: Only use designated recovery cylinders for used refrigerant.
29
-------
VI. Case Studies for Typical Low- and Medium-
Temperature Conversions
Case History Profiles 1-4: R-427A
Supermarket
owner
Compressor
models
Compressor
capacity loading
Before retrofit,
After retrofit
Original
refrigerant
Retrofit
Refrigerant
Retrofit Lubricant
Change Date:
TXV's changed
Seals Changed
Energy Use
Comparison
Comments
Casel
Sherm's
Thunderbird,
Oregon
Copeland
4DB2200,
4DC2200,
4Ds2200,
6DT3000,
4TD2200
N/A
HCFC-22
HFC-427A
POE
6/2008
No
Not initially
7% reduction
Case 2
Geant Casino,
France
5 Copeland,
D6DJ3400AWM/D
N/A
HCFC-22
HFC-427A
Alkyl Benzene
4/2007
No
No
5% less power consumption
For comparable suction
temperature, the discharge
temp is over 10 °C below with
CaseS
Tutt OK
supermarket,
Italy
Med Temp - 3
Copeland
Low Temp -2
Copeland
N/A
HCFC-22
HFC-427A
POE
2004
No
No
Comparable to
HCFC-22
Oil return is good
despite a high
residual mineral oil
level (15%
medium-temp unit
and 5% low-temp
unit)
Case 4
Fiesta Food
Warehouse,
Fontana, CA
12 Copeland
N/A
HCFC-22
HFC-427A
Alkyl Benzene
2008
No
No
N/A
Discharge
temperatures are
lower and the
compressors are
running cooler
30
-------
Case History Profiles 5-10: R-422D
Supermarket
owner
Compressor
models
Compressor
capacity loading
Before retrofit,
after retrofit
Original
refrigerant
Retrofit
Refrigerant
Retrofit
Lubricant
Change Date:
TXV's changed
Seals Changed
Energy Use
Comparison
Comments
CaseS
Pathmark,
Massapequa,
NY
Copeland,
3DB3-0750,
3DB3A-075E,
3DS3-1000,
3DS3A-100E,
3DB3-1000,
3DS-1500,
3DB-1000,
3DB3R12MO
N/A
HCFC-22
R-422D
Mineral Oil
2/27/2007
No
Yes
N/A
Store was
remodeled,
confusion
about TXV
sizing in
cases due to
new
refrigerant
CaseS
National
Retailer -
Houston TX
Caryle
06CC228,
06CC337,
06CC550,
06CC665,
06CC675,
06DR228,
06DM337,
06EM450,
06EM475,
06DR724
N/A
HCFC-22
R-422D
Mineral Oil
8/14/2006
No
Yes
Comparable
to HCFC-22
Proceeding
with
additional
systems
Case 7
Northeast
Retailer,
Quincy MA
Copeland
4DH3-250L,
3DS3A-150L,
3DP3-100L
N/A
HCFC-22
R-422D
Mineral Oil
8/20/2006
No
Yes
Comparable
to HCFC-22 -
Medium
Temp
Proceeding
with
confidence
with
additional
systems
CaseS
Northeast
Retailer
Latrobe, PA
Copeland
4DL-150E,
4DT-220E,
4DT-2200
95%,
BTUH
387 000
BTUH
HCFC-22
R-422D
Mineral Oil
10/9/2007
No
Yes
12%
reduction in
energy
efficiency -
low temp
No reported
leaks after
startup.
Turned off
demand
cooling
modules
Case 9
National
Retailer,
Long
Beach, CA
Copeland
Carlyle
N/A
HCFC-22
R-422D
Alkyl
Benzene
No
Yes
N/A
Operating
properly
Case 10
Midwest Retailer
Copeland
06DM-316 06DR-
228 06DM-337
06DM-316,06DR-
228, 06DM-337,
06DR-820. 06 DM-
337, 06ER-175,
06ER-337 4DT3-
220E-TSK, 4DL3-
150E-TFD
0.92, 0.83, 0.92,
0.9, 0.9, 0.66, 0.83
HCFC-22
R-422D
Mineral Oil
10/23/08
No
Yes
Energy Impact
appeared similar
based on temps.,
pressures, (no
KWH monitoring
was used).
Operating
properly, more
stores scheduled
-------
Case History Profiles 11-15: R-407A
Supermarket
owner
Compressor
models
Relative
compressor
capacity loading
after retrofit
Original
refrigerant
Retrofit
Refrigerant
Retrofit
Lubricant
Change Date:
TXV's changed
Seals Changed
Energy Use
Comparison
ommen s
Case 11
K-VA-T Food Stores, Inc
MT: Copeland: 2DA-0750,
3DA-0750, 3DF-0900, 3DF-
1200, 4DL-1500
LT: Copeland: 2DC-0500,
2DA-0750, 3DB-1000, 3DS-
1500
MT: ~85% & 94%
LT: ~90%
R-22
R407A
ICI Emkarate RL68-H
(Original: Mineral Oil)
March 2008
No
Yes
NA
All packing glands
developed leaks during the
first week after the oil was
changed. This was easily
correctable by retightening
them. It does require
unloading display cases to
get to the TEVs. Technicians
are not trained to use
refrigerants with
appreciable glides. How to
set valves and staging has
to be explained and
reinforced several times
during and after the
conversion. When a new
technician is hired the
training process has to be
repeated. One-on-one
sessions are more effective
than bulletins or classroom
presentations.
Case 12
Food Lion #1453
4DE3-200L-TSK,
4DK3R22MO-TSK,
4DH3-250L-TSK,
4DJ3-300L-TSK,
4DR3R28ME-TSK,
4DJ3-300L-TSK,
4DJ3-300L-TSK
99.6%
R-22
R407A
POE
6/24/08
No
Yes
-24.63%
The relative
compressor
capacity loading
is based on
published
performance
data. The change
in energy use may
also be due to
other changes
made at the
store.
Case 13
Food Lion #1490
4DS3-220L-TSK,
4DS3-220E-TSK,
4DT3-220L-TSK,
4DT3F76KE-TSK,
4DT3-220L-TSK,
4DR3-300E-TSK
98.1%
R-22
R407A
POE
5/12/08
No
Yes
-10.63%
The relative
compressor
capacity loading
is based on
published
performance
data. The
change in energy
use may also be
due to other
changes made at
the store.
Case 14
Food Lion #1577
4DL3-150E-TSK,
4DP3-150L-TSK,
4DT3F76KE-TSK,
4DT3F76KE-TSK,
4DT3-220E-TSK,
4DT3F76KE-TSK,
4DT3-220E-TSK,
4DJ3-300L-TSK
98.0%
R-22
R407A
POE
2/26/08
No
Yes
6.67%
The relative
compressor
capacity loading
is based on
published
performance
data. The
change in energy
use may also be
due to other
changes made at
the store.
Case 15
Food Lion #1585
4DK3-2500-TSK,
4DK3-2500-TSK,
4DJ3-300L-TSK,
4DR3-3000-TSK,
4DJ3-300L-TSK
99.6%
R-22
R407A
POE
5/13/08
No
Yes
-18.24%
The relative
compressor
capacity loading
is based on
published
performance
data. The change
in energy use
may also be due
to other changes
made at the
store.
32
-------
Case History Profiles 16-21: R-407A
Supermarket
owner
Compressor
models
Relative
compressor
capacity
loading
after retrofit
Original
refrigerant
Retrofit
Refrigerant
Retrofit
Lubricant
Change Date:
TXV's
changed
Seals
Changed
Energy Use
Comparison
Comments
Case 16
Food Lion
#1608
4DA3-200L-
TSK, 4DH3-
250L-TSK,
4DR3A300E-
TSK, 4DR3-
300E-TSK,
4DR3R28ME-
TSK, 4DJ3-
300L-TSK
99.6%
R-22
R407A
POE
4/16/08
No
Yes
3.45%
The relative
compressor
capacity
loading is
based on
published
performance
data. The
change in
energy use
may also be
due to other
changes made
at the store.
Case 17
Food Lion
#2340
4DT3-22OL-
TSK-205,
3DB3-075L-
TFC-227,
2DA3-060L-
97.6%
R-22
R407A
POE
8/12/08
No
Yes
-11.29%
The relative
compressor
capacity
loading is
based on
published
performance
data. The
change in
energy use
may also be
due to other
changes made
at the store.
Case 18
Food Lion
#2376
4DH3-2500-
TSK-406,
4DK3-2500-
TSK, 3DB3-
1000-TFC,
3OS3-1000-
TFC
98.0%
R-22
R407A
POE
6/30/08
No
Yes
-5.64%
The relative
compressor
capacity
loading is
based on
published
performance
data. The
change in
energy use
may also be
due to other
changes
made at the
store.
Case 19
Food Lion
#2392
3DS3-150L-
TFC
96.6%
R-22
R407A
POE
9/16/08
No
Yes
-5.64%
The relative
compressor
capacity
loading is
based on
published
performance
data. The
change in
energy use
may also be
due to other
changes made
at the store.
Case 20
Food Lion
#2514
06EA565300,
06EA565300,
06EM475300,
06EM475300
93.0%
R-22
R407A
POE
4/2/08
No
Yes
-3.79%
The relative
compressor
capacity
loading is
based on
published
performance
data. The
change in
energy use
may also be
due to other
changes
made at the
store.
Case 21
Food Lion
#2759
4DL3A150L-
TSK,
4DL3A150L-
TSK,
4DL3A150L-
97.2%
R-22
R407A
POE
12/4/08
No
Yes
6.56%
The relative
compressor
capacity
loading is
based on
published
performance
data. The
change in
energy use
may also be
due to other
changes made
at the store.
33
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Case History Profiles 22-25: R-407F
Supermarket owner
Compressor models
Original refrigerant
Retrofit Refrigerant
Retrofit Lubricant
Resultant Lubricant
Composition
Change Date:
TXV's changed
TXV's Adjusted
Seals Changed
Energy Use
Comparison
Comments
Case 22
Sprouts Farmers
Market #4
Phoenix, AZ
Medium Temp
06DM-316
06DR-724
06DR-820
06DR-337
06DA-824
Low Temp
2DB3-0600
4DF3A-1500
R22
R407F
EMKARATE POE
80/20%
4/26/2010
0
1
All "O" ring seals @
rack
100%
One oil change, no
issues
Case 23
Albertsons #169
Boise, Idaho
Medium Temp
3DA3-0750-TAC
3DS3A-1500-TFC
3DS3A-1500-TFC
Low Temp
3DS3-1000-TFC
3DS3-1000-TFC
3DS3-1000-TFC
Singles
2DA3-0750-TFC
2DB3-060L-TFC
R22
R407F
POE
90/10%
6/23/2010,
7/26/2010
0
"o" rings @ rack
Solenoid gaskets
105%
Case 24
Weavers Markets
Adamstown, Pa
Medium Temp
3DA3-0750-TFC
3DS3-1500-TFC
4DA3-2000-TFC
2DL3750
Low Temp
3DB3-750-TFC
4DA3-100E-TSK
4DL3-150-TSK
4DL3-150-TSK
4DL3A1500E-TSK
R22
R407F
EMKARATE POE
100% LT, 80/20%
MT
3/23/2011,
3/29/2011
0
0
Solenoid valve
gaskets
89%
Dramatic power
reduction is partly
due to low
superheat during
R22 operation. No
adjustment to any
txv's during retrofit
corrected this
situation.
Case 25
Sprouts Farmers
Market #2
Phoenix, AZ
3DA3-0600
3DL3-1500
3DB3-1000
3DS3-1500
3DF3-1200
3DE3-0750
3DK3-1200
R22
Performax LT R407F
EMKARATE POE
85/15
2/17/2011
0
1
All "O" ring seals @
rack
100%
34
-------
Case History Profiles 26-28: R-407F
Supermarket owner
Compressor models
Original refrigerant
Retrofit Refrigerant
Retrofit Lubricant
Resultant Lubricant
Composition
Change Date:
TXV's changed
TXV's Adjusted
Seals Changed
Energy Use
Comparison
Comments
Case 26
Sobey's
3DS1500
3DS1500
3DS3 15 L
3DS1500
3DA3 750
3DS31500
2D3 750E
R22
Performax LT R407F
POE
100%
N/A
0
0
All "O" ring seals @ rack
100%
Chose to upgrade
compressors per copeland
Case 27
Rouses #28
Medium Temp
HSN 5352 25
SHL2 2500 TWK 200
HSN 646150
HSN?
Low Temperature
HSK 5353 35 2ND
SHM2 3500 TWK 200
HSK 5363 40
SHM2 3500
R22
Performax LT R407F
Solest 170
90/10%
N/A
0
0
All "O" ring seals @ rack
100%
Bitzer Screws, Running
synthetic lube, water
cooled oil
Case 28
Bi-Lo #93
06DR3370DA3250
06DR3370DA3200
06DR3370DA3200
06DR3370DA3200
06DR3370DA3200
R22
Performax LT R407F
POE
85/15%
5/24/2011
0
0
All "O" ring seals @ rack
100%
Customer chose to ignore
Carlyle recommendations
pertaining to valve plate and
oil pump modifications to
accommodate synthetic lube.
35
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VII. Appendices
Appendix 1: System Data Sheet
System Data Sheet
Type of System/Location:.
Equipment Mfg.:
Model No.:
Serial No.:
Original Charge Size:
Drier Mfg.:_
Model No.:
Compressor Mfg.:
Model No.:.
Serial No.:.
Lubricant Type:.
Lubricant Charge Size:
Drier Type (check one):
Loose Fill:.
Solid Core:
Condenser Cooling Medium (air/water):
Expansion Device (check one):
If Expansion valve:
Manufacturer:
Model No.:
Capillary Tube:
Expansion Valve:
Control/Set Point: _
Location of Sensor:
Other System Controls (ex.: head press control). Describe:,
(circle units used where applicable)
Date/Time
Refrigerant
Charge Size (Ib, oz/g)
Ambient Temp. i°F/°Ci
Relative Hurni'ility
'/orn|M~N:::<:>[.
Suction T(°F/°C!
Suction P (psi/kPa.'bar)
Discharge T(°F/=Q
Discharge P 'psi/kPa/bar1
Box'FixtureT (°F/°C1
Evaporator
Refrigerant Inlet T i°F/°C)
Refrigerant Outlet T (°F/°Ci
Coil Air/HjO In T (°F/°C)
Coil Air/H20 Out T (°F/°O
Refrigerant Tat Superheat Ctl. Pt. (°F.KC)
Condenser:
Refrigerant Inlet T W°C)
Refrigerant Outlet T i°F/°C)
Coil Air/H,OlnT(°F/°C)
Coil Air/H,0 Out T (°F/=C)
Exp. Device Inlet T(°F/°Ci
Motor Amps
Run/Cycle Time
Comments:
36
-------
Appendix 2: Conversion Checklists for HFC Substitute Chemicals
Retrofit Checklist for DuPont™ ISCEON® Refrigerants MO99 (R438A) or
MO29 (R422D)
1. Establish baseline performance with existing refrigerant.
• Use the System Data sheet given in Appendix 1
• Note oil type used and system operating data (if system is operating properly).
• Check for existing leaks and repair.
2. Remove existing refrigerant charge from system. (Need 10-15 in. Hg [50-67 kPa] vacuum to
remove charge.)
• Use recovery cylinder (DO NOT vent to atmosphere).
• Weigh amount removed if possible):
• Break the vacuum with dry nitrogen.
3. Replace the filter dryer and seals.
• Change elastomeric seals (O-rings. sight glasses, etc.).
• Check that oil is in good condition; replace if necessary.
4. Evacuate system and check for leaks.
• Does the system hold a vacuum?
• Break vacuum with dry nitrogen, pressurize to below system design pressure.
• Does the system hold pressure?
• Check for any leaks.
5. Charge system with ISCEON® refrigerant.
• Remove liquid only from cylinder.
• The initial charge amount should be approximately 85% of the standard charge for R-22
and the final charge amount will be approximately 95%.
6. Adjust TXV and/or refrigerant charge to achieve the same superheat as the original system. If
adjustment is not adequate, replace TXV.
7. Monitor oil levels in compressor. If necessary add original oil to attain normal operating level
(mid-sight glass).
• If a sudden surge in oil level occurs (e.g., during/just-after defrost) remove a small
(approximately 10%) quantity of the mineral oil and replace with POE oil. Repeat if
necessary.
• If oil level falls below the minimum, top-up to minimum level.
• If the oil level continuously falls or large oscillations occur during operation, add a
sufficient amount of an equivalent POE until oil return becomes normal.
8. Label system clearly. Ensure System Data sheet is completed and filed
securely. Retrofit is complete!
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Retrofit Checklist for Mexichem Fluor Klea®407A
1. Before converting R22 systems to Klea®407A, check OEM recommendations to ensure compatibility
with equipment and seal materials. Klea®407A is a HFC refrigerant and POE oil will be required.
The older the system the greater the possibility of incompatibility with HFCs or POE oil. Follow all
regulatory and safety requirements for handling refrigerants.
2. Record system performance to obtain a baseline prior to the retrofit, eg. suction and discharge
pressures, discharge temperature, temperatures in and out of condenser and evaporator, energy
usage.
3. Check and repair any existing leaks in the system.
4. Remove mineral oil from system. Most of the mineral oil can be removed by draining the compressor
sump, suction line accumulators, oil float, oil separators, etc. Record the amount of oil removed.
5. Replace oil drier and oil screens.
6. Add the compressor OEM recommended POE oil.
7. Evacuate system and check for any leaks.
8. Restart system and check for any leaks. Check oil level.
9. Run system for at least 24 hours to allow for mixing of POE and remaining mineral oil. Larger systems
may require more time. Check mineral oil concentration in POE using a refractometer.
Historically, a target of less than 5% mineral oil in POE has been used for HFCs and the normal
practice was three flushes to achieve this. However, systems have run satisfactorily after a single
flush of POE. Contact Mexichem Fluor for more information.
10. Remove refrigerant from system. Record weight removed.
11. Replace equipment as required. Install a HFC compatible filter drier. Replace all seals on joints that
have been opened and on the receiver. Replace receiver float seal. Replace or repair old solenoid
valves and ball vales to minimize future leaks.
12. Reset pressure controls for Klea®407A. Temperature/pressure data is available at
www.mexichemfluor.com or call 1 -800 ASK KLEA.
13. Remove air in system by pulling a vacuum to 500 microns. Hold vacuum and check and repair any
leaks.
14. Charge system with Klea®407A with a target level of 95% of the R22 charge amount. The
concentration of the blend components will be different than the liquid. Remove liquid from the
cylinder to ensure the correct composition. To avoid equipment damage, vaporize the liquid before
entering a running system.
15. Start system and check for any leaks.
16. Set TXV settings. For calculating sub-cooling, use the bubble point as the reference temperature. For
calculating superheat, use the dew point as the reference temperature.
17. Monitor refrigerant and oil levels and adjust as needed.
18. Record performance data.
19. Label the system to indicate refrigerant and oil type and amount.
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Retrofit Checklist for Honeywell Genetron 407C
Genetron 407C is an HFC blend and a close match to R22 but will require an oil change to a
synthetic lubricant. Consult the original equipment manufacturer for recommended lubricants.
The mass flow of Genetron 407C is very close to that of R22 and in most cases the existing
thermal expansion valves can remain although adjustment may be necessary. Genetron 407C is a
refrigerant blend having glide which requires the technician to use dew point values for checking
superheat and bubble values for checking sub-cooling. A pressure temperature chart is available
at Genetron.com or by contacting Honeywell Refrigerants Technical Service.
Retrofit Checklist
1. Record baseline data on original system performance.
2. Recover HCFC-22 refrigerant charge using appropriate recovery equipment.
3. Record the amount of HCFC recovered.
4. Choose compressor lubricant.
5. Drain the existing lubricant from the compressors, separators and oil reservoirs.
6. Measure amount of lubricant removed.
7. Change lubricant filters if present.
8. Recharge the system with polyol ester lubricant, use the same amount that was removed.
_9. Traditionally at this point the R22 would be returned to the system and the system run for at least 24
hours to return as much of the residual mineral oil in the system to the compressors and oil
management system. Typically an acceptable residual mineral oil content of 5% was the target. Recent
field data suggests the possibility of a successful retrofit with only one oil change performed before the
addition of Genetron 407C. Consult Honeywell Refrigerants for guidance.
_10. Evaluate the expansion devices; consult the valve manufacturers for recommendations. No change is
necessary in most cases.
_11. Evaluate and replace all elastomer seals including receiver float, alarm and level control gaskets.
_12. Replace filter driers and suction filters.
_13. Leak check the system.
_14. Evacuate the system.
_15. Charge the system with Genetron 407C. Remove only liquid from the charging cylinder. Initial charge
should be approximately 85% of the R22 charge by weight. Record the amount of refrigerant charged.
_16. Check system operation and adjust TXV's and operating controls. The discharge pressure of R407C is
slightly higher and condenser fan and ambient controls may require adjustment.
_17. Adjust refrigerant charge if necessary, final charge should not exceed 95% of the original R22 charge.
_18. Label components and the system with the type of refrigerant and lubricant.
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Retrofit Checklist for Honeywell Genetron® Performax™ LT (407F/
Genetron Performax LT is an HFC blend and a close match to R22, but will require an oil change to a
synthetic lubricant. Consult the original equipment manufacturer for recommended lubricants. The mass
flow of Genetron Performax LT is very close to that of R22 and, in almost all cases, the existing thermal
expansion valves can be utilized without adjustment. Genetron Performax LT is a refrigerant blend
having glide, which requires the technician to use dew point values for checking superheat and bubble
values for checking sub-cooling. A pressure temperature chart is available at www.genetron.com, or by
contacting Honeywell Refrigerants Technical Service.
Retrofit Checklist
1. Record baseline data on original system performance (Amp draw, suction pressure, discharge pressure,
superheat, sub cooling).
2. Run each circuit through a defrost cycle to return as much lubricant as possible to the condensing unit.
3. Recover HCFC-22 refrigerant charge using appropriate recovery equipment.
4. Record the amount of HCFC recovered.
_5. Choose compressor lubricant. Consult compressor manufacturer for lubricant recommendations. Note that
lubricants from various manufacturers must not be mixed.
_6. Drain the existing lubricant from the compressors, separators and oil reservoirs.
_7. Measure amount of lubricant removed.
_8. Change lubricant filters if present.
_9. Recharge the system with synthetic lubricant, using the same amount that was removed.
_10. Traditionally at this point the R22 would be returned to the system and the system run for at least 24
hours to return as much of the residual mineral oil in the system to the compressors and oil management
system. Typically an acceptable residual mineral oil content of 5% was the target. Recent field data
suggests the possibility of a successful retrofit with only one oil change performed before the addition of
Genetron Performax LT. Consult Honeywell Refrigerants for guidance.
_11. Evaluate the expansion devices; consult the valve manufacturers for recommendations. No change or
adjustment is necessary in most cases.
_12. Evaluate and replace all elastomer seals including receiver float, alarm and level control gaskets.
_13. Replace filter driers and suction filters.
_14. Check the system for leaks and make repairs as required.
_15. Evacuate the system.
_16. Charge the system with Genetron Performax LT. Remove only liquid from the charging cylinder. Initial
charge should be approximately 85% of the R22 charge by weight. Record the amount of refrigerant
charged.
_17. Check system operation and operating controls. The discharge pressure of Genetron Performax LT is
slightly higher. Condenser fan and ambient controls may require adjustment.
_18. Adjust refrigerant charge if necessary. Final charge should not exceed 95% of the original R22 charge.
_19. Label components and the system with the type of refrigerant and lubricant.
_.20. Monitor the system and pay particular attention to the condition of the lubricant. Change lubricant filters
or suction filters if necessary. Synthetic lubricants are good solvents and may clean up and return
material to the condensing unit.
6 Pending
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Retrofit Checklist for Arkema Forane® 427A
1. Establish baseline performance with existing refrigerant.
• Use the System Data sheet in Appendix 1.
• Note the oil type in use and system operating data (if system is operating properly).
• Check for existing leaks and repair.
2. Remove existing refrigerant charge from system. (Need 10-15 in. Hg
[50-67 kPa] vacuum to remove charge.)
• Use recovery cylinder (DO NOT vent to atmosphere).
• Weigh amount removed if possible:
• Break the vacuum with dry nitrogen.
3. Replace the filter-drier and seals.
• Change elastomeric seals (O-rings, sight glasses, etc.).
• Check that oil is in good condition; replace if necessary.
4. Determine oil change requirements.
• If an oil separator is currently used, replacement of original mineral oil or alkylbenzene
is often not needed (skip to step 6).
• If no oil separator is present, drain existing mineral oil or alkylbenzene from the
compressor sump, suction line accumulators, etc. Record the amount of oil removed.
5. Add an equivalent amount of OEM recommended POE oil.
• In most cases, no flushing is required. Only one oil change is required with up to 15%
residual AB or mineral oil accommodated.
6. Evacuate system and check for leaks.
• Does the system hold a vacuum?
• Does the system hold pressure?
• Check for any leaks.
7. Charge system with Forane® 427A refrigerant.
• Remove liquid only from cylinder.
• The initial charge amount should be approximately 95% of the standard charge for
HCFC-22, topping up to 100% if necessary
8. Adjust TXV setpoint and/or refrigerant charge to achieve the same superheat as the original
system.
9. Monitor oil levels in the compressor. If necessary, add/remove oil to attain normal operating
level (mid sight glass).
• If original mineral oil or alkylbenzene used, and oil level surges (e.g. after defrost), falls
below minimum, or large oscillations in oil level are observed, replace small amounts («
10 %) of original oil with equivalent POE until satisfactory oil return is achieved.
10. Label system clearly. Ensure System Data sheet is completed and filed securely.
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Retrofit Checklist for ICOR International R422B "NU-22B" and R422C
"ONE SHOT"
Change from CFC and HCFC to HFC refrigerants may cause a retraction in o-rings and
elastomers. Be sure to repair or replace after recovery of the original refrigerant. Failure to
address this at this time may cause unnecessary loss of refrigerant. ICOR International also
recommends verification of the metering device sizing with the distributor or manufacture of the
device.
1. Record System Pre-Conversion Data: Prior to converting, the system should be monitored
and all system and component operating conditions recorded for future reference.
2. Recover the R-22: 100% of the refrigerant must be recovered from system in accordance
with EPA guidelines.
3. Perform Oil Analysis: Check system oil for acidity, water and solids (metal shavings). If
detected perform a complete system oil change using the OEM specified type and amount of oil.
4. Install New Filter Drier and Oil Filter: The oil analysis will tell you what type of filter
drier you need to use. Systems with coalescent oil separators and/or compressor oil filters need
to be changed, too. If converting the system to 422C the expansion valve power element will
need to be changed.
5. Leak Check System: Pressure test system with dry nitrogen. DO NOT exceed the
equipment's design pressure. 422B/422C can be detected with any standard leak detection
designed to detect HFC refrigerants
6. Evacuate System: To remove non-condensables and moisture in the system, a minimum 500
micron vacuum must be achieved.
7. Charge System: Remove LIQUID ONLY from 422B/422C cylinder. When initially charging
the system, 422B/422C can be added directly into the receiver or high side of the system with
compressor(s) off. The initial charge of 422B/422C should be 95% of the original R-22 charge.
8. Run System: Check pressures, subcooling and superheat. Use ONLY 422B/422C P/T chart.
If additional 422B/422C needs to be added, do so in 5% increments and DO NOT exceed 115%
of the original charge of R-22. If system performance is inadequate, call ICOR International at
866-433-8324 ore-mail: tech2tech(@,icorinternational.com
9. Properly Label System: Avoid mixing refrigerants by properly labeling your system.
10. Post conversion Leak Check: After operation of system begins, do a thorough system leak
check.
11. Record System Post-Conversion Data: Monitor and evaluate system performance and
record data. This information can be compared to your pre-conversion data for a full conversion
evaluation and can be used if technical support is required.
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Appendix 3: Valve Capacities for Alternatives in Retrofits
This Appendix provides an analysis by one valve manufacturer for R-22 valve capacities used
with various alternative refrigerants in a retrofit scenario. It should also be noted that
supermarket systems with electronic expansion valves can automatically compensate valve
capacities by a software correction.
TXV Rating Example
The nominal capacity of a Thermostatic Expansion Valve (TXV) is simply the capacity at the
conditions it is rated. For high pressure refrigerants, such as R-22 or its alternatives, the AHRI
industry standard rating point is: 40°F evaporator temperature, 100°F liquid temperature, and a
100 psi pressure drop across the TXV port. If any of these conditions change, the valve's
capacity will also change.
Table 1 shows the capacities of a nominal 2 ton R-22 TXV when used with R-22, R-407A, and
R-407C. Capacities are shown at varying evaporator temperatures, but in each instance the
standard rating conditions of 100°F liquid temperature and a 100 psi pressure drop across the
TXV port are used in conjunction with the various evaporator temperatures. Note the highlighted
nominal capacities for the three refrigerants listed and how they differ. This is the result of
differing thermodynamic properties between the three refrigerants.
Table 1. Nominal TXV Capacities
Valve
Type
G
Nominal
Capacity
2
Refrigerant
R-22
R-407A
R-407C
R-407F
Recommended Thermostatic Charges
VC, VCP100, VGA
40°
2.00
20°
2.18
0°
VZ, VZP
-10° -20°
1.91
1.96 1.75
-10°
VC, VCP100
-10°
1.31
1.87
-10°
2.00
VGA
0°
VZ, VZP40
-10°
1.71
1.74
-20°
1.54
-40°
NC, NCP100,
NGA
40° 20° 0°
VZ,VZP40
-10° -20°
1.12
1.84 1.97 1.70
1.63 1.20
-40°
1.11
If a specific application is utilizing a liquid temperature or pressure drop across the TXV port
which is different than the AHRI rating condition, the correction factors in Table 2 and/or Table
3 would be applied to the capacity listed in Table 1 to determine the actual TXV capacity.
Table 2. Liquid Correction Factors
Valve
Type
R-22
R-407A
R-407C
R-407F
Liquid Temperature Entering TXV °F
0°
10°
20°
30°
40°
50°
60°
70°
80°
90°
100°
110°
Correction Factor, CF Liquid Temperature
1.56
1.75
1.69
1.72
1.51
1.68
1.62
1.65
1.45
1.61
1.55
1.58
1.40
1.53
1.49
1.51
1.34
1.46
1.42
1.44
1.29
1.39
1.35
1.37
1.23
1.31
1.28
1.30
1.17
1.24
1.21
1.22
1.12
1.16
1.14
1.15
1.06
1.08
1.07
1.08
1.00
1.00
1.00
1.00
0.94
0.92
0.93
0.92
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Table 3. Pressure Drop Correction Factors
Evaporator
Temperature
(°F)
40°
20° & 0°
-10° & -20°
-40°
Pressure Drop Across TXV (PSI)
30
50
75
100
125
150
175
200
225
250
275
Correction Factor, CF Pressure Drop
0.55
0.49
0.45
0.41
0.71
0.63
0.58
0.53
0.87
0.77
0.71
0.65
1.00
0.89
0.82
0.76
1.12
1.00
0.91
0.85
1.22
1.10
1.00
0.93
1.32
1.18
1.08
1.00
1.41
1.26
1.15
1.07
1.50
1.34
1.22
1.13
1.58
1.41
1.29
1.20
1.66
1.48
1.35
1.25
For example: An R-22 application, operating at +20T is being retrofitted to R-407C. The
evaporator capacity is 24,000 Btu/hr and the evaporator has a nominal 2 ton R-22 TXV installed.
The application is designed to operate at 100°F condensing, with a 90°F liquid temperature.
The nominal capacity of the TXV for R-407C can be calculated as follows:
• Nominal capacity at +20°F (from Tablel): 1.97 tons.
• Corrected for liquid temperature at 90°F (from Table 2): 1.97 x 1.07 = 2.10 tons.
To determine the correct pressure drop across the TXV port, the difference between the
corresponding pressures at the condensing temperature and evaporator pressure must be used:
• 223 psi (100°F condenser saturation) - 37 psi (20°F evaporator saturation ) = 186 psi.
The pressure drop through the refrigerant distributor and feeder tubes, the evaporator, and the
frictional line loss in the piping between the condenser (where the pressure value is determined
based on the condenser saturation temperature) and the TXV inlet must also be considered when
determining the actual pressure drop across the TXV port.
For this example, we will assume the above mentioned pressure drop to be 36 psi.
• The actual pressure drop across the TXV port will be: 186 psi - 36 psi = 150 psi.
• Actual TXV capacity at the design condition for this application: 2.10 tons (corrected
for liquid temperature) x 1.10 (from Table 3) = 2.31 tons.
• This would represent the TXV capacity at the design condition in the summer time.
To ensure that the TXV has sufficient capacity, a similar sizing exercise must be undertaken at
the low ambient condensing temperature expected in the winter months. If the system utilizes fan
cycling or head pressure control valves and fixes the minimum condensing temperature at 70 °F
(137.5 psi), the TXV capacity will also need to be considered at this condition.
For most applications the correction factors listed in Table 4 can be used to determine if the
existing R22- TXV will have sufficient capacity when used with the retrofit refrigerant of choice.
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Table 4. Capacity Multipliers for R-22 Alternative Refrigerants
Evaporator
Temp (°F)
40
20
0
-20
Condensing
Temp(°F)
105
105
70
105
70
105
70
Liquid
Temp (°F)
95
95
60
95
60
95
60
R-22
1.00
1.00
1.00
1.00
1.00
1.00
1.00
Capacity Multiplier *
R-417A
0.75
0.72
0.82
0.69
0.77
0.67
0.74
R-422B
0.74
0.71
0.83
0.68
0.77
0.66
0.74
R-422D
0.72
0.69
0.83
0.66
0.77
0.64
0.74
R-424A
0.72
0.69
0.83
0.66
0.77
0.64
0.74
R-438A
0.88
0.85
1.00
0.81
0.92
0.79
0.88
R-407A
1.04
1.01
1.20
0.98
1.11
0.96
1.06
R-407C
1.07
1.04
1.22
1.00
1.13
0.97
1.07
R-407F
0.96
0.95
0.99
0.95
0.99
0.94
0.98
* Apply Capacity Multiplier to the TXV's R-22 rating to determine approximate TXV rating with the service retrofit
replacement refrigerant. A total 40 psi pressure loss across the TXV from the refrigerant distributor and liquid line is
assumed in the capacity multiplier calculation.
Thermodynamic data provided by NIST Refprop v8.0.
Capacity and correction factors courtesy of Sporlan Division - Parker Hannifin.
Source: Adapted from National Refrigerants, Inc., Retrofit Handbook: R-22 Retrofit Guidelines
and Procedures. 2009.
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VII. Acknowledgments
GreenChill is an EPA partnership with food retailers and other stakeholders to reduce refrigerant
emissions and decrease the retail food industry's impact on the ozone layer and climate change.
Working with EPA, GreenChill Partners:
• Transition to environmentally friendlier refrigerants;
• Lower refrigerant charges and eliminate leaks; and
• Adopt green refrigeration technologies, strategies, and
practices.
Original authors:
Keilly Witman, U.S. EPA
Craig Thomas, Arkema
Kevin O'Shea and Nick Strickland, DuPont
Ron Vogl, Honeywell
Sean Cunningham, Mexichem Fluor
Other contributors:
Dave Godwin, U.S. EPA
Patti Conlan, Arkema
David Callender, ICOR International
Jim Lavelle and Maureen Beatty, National Refrigerants
Stephen Spletzer, Arkema
Expert reviewers:
Jon Perry, Farm Fresh / SUPERVALU
George Ronn, SUPERVALU
Michal Shepard, Harris Teeter
Ed Estberg, Raley's
Steve Sloan, Publix Super Markets
Steve Millard, Food Lion
Scott Martin, Hill PHOENIX
Steve Hagler, Hussmann
Buzz Schaeffer, Hussmann
Travis Lumpkin, Kysor Warren
Bruce Hierlmeier, Zero Zone
Pat Murphy, NATE
Jerry Weis, HVAC Excellence
Warren Beeton, Emerson
Charles Allgood, DuPont.
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