Opteon XP40. Opteon XP40 Retrofit Guidelines to Replace R-402A (HP80) and R-408A. Refrigerant (R-449A) Introduction. Important Safety Information

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1 Opteon XP40 (R-449A) Opteon XP40 Retrofit Guidelines to Replace R-402A (HP80) and R-408A Introduction Opteon XP40 (R-449A) is a low global warming potential (GWP) ydrofluoro-olefin (HFO)-based refrigerant developed as a direct replacement for HCFC-22 (R-22) and R-404A/R-507 in positive displacement, direct expansion, low- and mediumtemperature commercial and industrial applications. Opteon XP40 can also be used as a replacement for service blends, suc as Freon HP80 (R-402A) and Freon 408A. Because R-402A and R-408A contain a significant percentage of R-22, tese blends are subject to te same availability and cost constraints impacting pure R-22, wic is being pased out under te Montreal Protocol. R-402A and R-408A were designed and used as replacements for R-502 in low- and medium-temperature refrigeration systems in te early 1990s. Most systems operating on R-402A and R-408A today are likely to be quite old, and system replacement wit new equipment sould always be considered as a first step. Opteon XP40 is a HFC/HFO blend of HFC-32/HFC-125/ HFC-134a/HFO-1234yf (24.3/24.7/25.7/25.3 wt%) wit an ANSI/ASHRAE Standard 34 refrigerant designation of R-449A. It is commercially available around te world for bot retrofit of existing (R-22, R-402A, R-408A, R-404A, R-507) equipment, as well as a suitable option for new equipment. Opteon XP40 offers te best overall balance of performance, cost, safety, and sustainability as a class A1 refrigerant wit a GWP of 1282 and zero ozone depletion potential (ODP). Using tese retrofit guidelines, existing R-402A and R-408A direct expansion refrigeration systems can be converted to operate using Opteon XP40, allowing te equipment to continue to function safely and efficiently wit a greatly reduced environmental impact. Important Safety Information Like all Freon and Opteon refrigerants, Opteon XP40 is safe to use wen andled properly. However, any refrigerant can cause injury or even deat wen misandled. Please review te following guidelines and consult te product Safety Data Seet (SDS), including proper personal protective equipment recommendations, before using any refrigerant. At a minimum, appropriate and (gloves) and eye (safety glasses) protection sould be used. Do not work in ig concentrations of refrigerant vapors. Always maintain adequate ventilation in te work area. Do not breate vapors. Do not breate lubricant mists from leaking systems. Ventilate te area well after any leak before attempting to repair equipment. Do not use andeld leak detectors to ceck for breatable air in enclosed working spaces. Tese detectors are not designed to determine if te air is safe to breate. Use oxygen monitors to ensure adequate oxygen is available to sustain life. Do not use flames or alide torces to searc for leaks. Open flames (e.g., alide or brazing torces) in te presence of any fluorocarbon refrigerant can decompose te refrigerant, forming azardous acidic compounds. Halide torces are not effective as leak detectors for HFO or HFC refrigerants, as tey only detect te presence of clorine in te refrigerant. Clorine is not present in Opteon XP40, and, consequently, tese detectors will not detect te presence of tis refrigerant. Use an electronic leak detector specifically designed for te refrigerants you are using. If you detect a visible cange in te size or color of a flame wen using brazing torces to repair equipment, stop work immediately and leave te area. Ventilate te work area well, and stop any refrigerant leaks before resuming work. Tese flame effects may be an indication of very ig refrigerant concentrations, and continuing to work witout adequate ventilation may result in injury or deat.

2 Table 1: Comparison of Performance Data for R-402A Alternatives R-402A Alternatives Low-Temperature Conditions -20 F Evaporator, 110 F Condenser, 100 F Liquid Line, 30 F Suction Temp., 70% Isentropic Efficiency Relative Capacity Relative COP Relative Mass Flow Suction Pressure (psia) Discarge Pressure (psia) Discarge Temperature ( F) R R-402A (HP80) R-449A (XP40) R-402A Alternatives Medium-Temperature Conditions 20 F Evaporator, 110 F Condenser, 100 F Liquid Line, 50 F Suction Temp., 70% Isentropic Efficiency R R-402A (HP80) R-449A (XP40) Table 2: Comparison of Performance Data for R-408A Alternatives R-408A Alternatives Low-Temperature Conditions -20 F Evaporator, 110 F Condenser, 100 F Liquid Line, 30 F Suction Temp., 70% Isentropic Efficiency Relative Capacity Relative COP Relative Mass Flow Suction Pressure (psia) Discarge Pressure (psia) Discarge Temperature ( F) R R-408A R-449A (XP40) R-408A Alternatives Medium-Temperature Conditions 20 F Evaporator, 110 F Condenser, 100 F Liquid Line, 50 F Suction Temp., 70% Isentropic Efficiency R R-408A R-449A (XP40) Overexposure to ig concentrations of refrigerant vapor can cause aspyxiation or cardiac arrest. Please read all safety information before andling any refrigerant Refer to te Opteon XP40 SDS for more specific safety information. Te Safety of Freon s bulletin also provides additional information for safe andling of refrigerants. Flammability Opteon XP40 is nonflammable. It as been assigned an A1 safety classification under te ANSI/ASHRAE Standard 34. However, as wit all HFC-containing blends, Opteon XP40 sould not be mixed wit air to ceck for system leaks. General Retrofit Considerations: R-402A and R-408A to Opteon XP40 Expected Performance of Opteon XP40 vs. R-402A and R-408A Tables 1 and 2, based on termodynamic cycle analysis, provide a comparison of R-402A and R-408A vs. Opteon XP40 across several key performance factors. Actual performance for a specific system depends on several factors, including equipment conditions and operating environment. As mentioned before, R-402A and R-408A were designed as replacements for R-502 in low- and medium-temperature refrigeration systems. Refrigeration systems containing R-402A and R-408A were likely at one time retrofitted from R-502. Tese older systems migt ave obsolete seals tat are not compatible wit syntetic lubricants. Special consideration sould be taken wen deciding to retrofit tese systems to Opteon XP40. System Modifications Lubricant Most R-402A and R-408A systems use mineral oil (MO) or alkylbenzene (AB) lubricants; owever, tere may be some systems operating wit polyolester (POE) lubricants. POE lubricants are recommended for use in most HFO and HFC systems. If te R-402A or R-408A system currently uses POE lubricant, te POE lubricant currently in te system sould be suitable for use wit Opteon XP40. If tere are questions about te POE lubricant or tests indicate tat it is contaminated or as a ig acid number, ten te lubricant sould be canged. Consult wit te compressor manufacturer for specific recommendations on viscosity and brand of lubricant. 2

3 Special care sould be taken wen andling POE lubricants due to teir tendency to absorb water. Contact wit air sould be minimized, and te lubricant sould be stored in a sealed metal container. Canging to POE lubricant is recommended wen converting to Opteon XP40 from a system wit MO or AB lubricant. To acieve equivalent miscibility after retrofitting te system, te residual MO/AB lubricant sould be ~5 wt% or less. Allowable residual MO/AB lubricant is igly dependent on system configuration and operating conditions. If te system sows signs of poor eat transfer in te evaporator or poor oil return to te compressor, it may be necessary to furter reduce te residual MO/AB. A series of successive lubricant canges using POE can normally reduce te MO/AB concentration to adequate levels. Lubricant manufacturers ave developed field test metods for determining te weigt percent of MO in POE lubricant. Contact te lubricant manufacturer for te recommended test metod. Filter Drier Cange te filter drier during te retrofit. Tis is a routine system maintenance practice. Tere are two types of filter driers commonly used, solid core and loose filled. Replace te drier wit te same type currently in use in te system. Te drier label will sow wic refrigerants can be used wit tat drier. Select a drier specified to work wit HFO refrigerants. (Many driers sold today are universal tey will work wit most fluorocarbon refrigerants.) Ceck wit your Cemours s Distributor for te correct drier to use in your system. Elastomeric Seals R-22 and, to a lesser extent, R-22-containing refrigerant blends, suc as R-402A and R-408A, interact relatively strongly wit many elastomers, causing significant swelling and often, over time, a measurable increase in ardness. Opteon XP40, like oter HFO or HFC refrigerants, does not ave as strong of an effect on elastomers commonly used as seals in refrigeration systems. Tus, wen performing an R-402A/R-408A retrofit to an HFO/HFC alternative, it is possible for leaks to occur at elastomeric seals tat ave been previously exposed to R-402A/R-408A refrigerant. Tis is not a problem attributable specifically to te use of Opteon XP40. Suc seal leaks ave been reported wen replacing R-22-containing blends wit oter HFC refrigerants, suc as R-407A/C or R-404A. Components commonly affected are Scrader core seals, liquid level receiver gaskets, solenoid valves, ball valves, flange seals, and some saft seals on open drive compressors. Leaks do not occur in every system retrofitted, and, in practice, it is difficult to predict weter suc leaks will occur. (As a rule of tumb: te older te system, te iger te probability tat leaks will be observed after a retrofit.) Consequently, it is recommended to cange elastomeric seals and gaskets as a matter of course during a retrofit, particularly any system-critical seals (tose tat would require removal of te refrigerant carge to allow seal replacement, e.g., liquid receiver, refrigerant ig pressure side, etc.). It is also recommended to ave spare seals for oter components available during restart of te system. Te same type of seal can be used; it sould just be a new one tat as not previously been used wit an R-22- containing refrigerant. A rigorous leak ceck regime pre- and post-retrofit will minimize any refrigerant losses. Obviously, any seals found to be leaking before te retrofit takes place sould be replaced during te retrofit. Compressor Overall system performance (capacity and energy efficiency) will be similar wen operating on Opteon XP40 as to tat wen using R-402A or R-408A. Compressor suction and discarge pressures for Opteon XP40 will differ from R-402A or R-408A, and it may be necessary to adjust set points and cutouts to avoid exceeding te operating limits of te compressor. Consult wit te specific system manufacturer for guidance. Opteon XP40 as a modestly iger ( R) discarge temperature tan R-402A. Consult te compressor manufacturer for details regarding operation of your specific compressor on Opteon XP40. Opteon XP40 as a comparable (+2-3 R) discarge temperature relative to R-408A. Again, you sould consult wit your compressor manufacturer for details regarding operation of your specific compressor on Opteon XP40. Compatibility Retrofitting systems wit Copeland compressors manufactured prior to 1973 is not recommended. Tis is due to te different materials used in motor insulation tat ave not been evaluated for compatibility wit te new refrigerants and lubricants. Failure to eed tis advice will violate te U.L. Standard for Field Conversion/Retrofit of Alternate s in Refrigeration and Air Conditioning Equipment (UL 2170). 3

4 Emerson Climate Tecnologies does not recommend retrofitting Discus compressors prior to te release of te Delta Reed design of te suction valve. For te 3D models, te design cange took place in 1999, and for te 4D and 6D model compressors, in Te combination of HFC refrigerants and POE oil may cause increased wear in te older Floating Reed design. Please consult Emerson s Cangeover Guidelines for specific information, ttps://opi. emersonclimate.com/cpid/graphics/types/aeb/95-14.pdf It is recommended tat Carlyle reciprocating compressors manufactured before 1994 be retrofitted wit a iger flow oil pump. Tis pump is designed for eavier POE lubricants. See section 2.4 of te Carlyle 06D/E Application Guide, ttp://www. utcccs-cdn.com/vac/docs/2002/public/09/ pdf Expansion Device Opteon XP40 as a lower mass flow rate (~23-30%) tan R-402A, but sould be witin te usable range of a properly sized and installed R-402A expansion device and sould not require replacement. Some adjustment to te expansion valve(s) may be needed to reset te supereat following conversion of te system. For a conservative approac, it is recommended tat te termostatic element be replaced wit a R-449A/R-407A type element. Use te pressuretemperature cart (dew point [saturated vapor] values) at te end of tis guide for correct measurement and setting of evaporator supereat. If you ave furter questions, consult wit te expansion device manufacturer for correct valve sizing and supereat adjustments. Opteon XP40 as a sligtly iger mass flow rate (~5%) tan R-408A, but sould be witin te usable range of a properly sized and installed R-408A expansion device; tus, not requiring replacement. Some adjustment to te expansion valve(s) may be needed to reset te supereat following conversion of te system. Use te pressuretemperature cart (dew point [saturated vapor] values) at te end of tis guide for correct measurement and setting of evaporator supereat. If you ave furter questions, consult wit te expansion device manufacturer for correct valve sizing and supereat adjustments. Line Sizing Opteon XP40 as lower mass flow rates and density tan R-402A. It is recommended tat te existing refrigerant line sizing be cecked to verify tat te system pressure drops and line velocities are acceptable wit te new refrigerant. Correct pipe sizing is important to ensure adequate refrigeration capacity and sufficient oil return to te compressor Opteon XP40 as sligtly lower mass flow rates and density tan R-408A. It is recommended tat te existing refrigerant line sizing be cecked to verify tat te system pressure drops and line velocities are acceptable wit te new refrigerant. Correct pipe sizing is important to ensure adequate refrigeration capacity and sufficient oil return to te compressor. Condenser and Evaporator Due to te differences in suction pressure between Opteon XP40 and R-402A or R-408A, it may be necessary to reset evaporator pressure regulators (EPRs) and cutouts to properly operate te system. Te discarge pressure of Opteon XP40 is modestly iger tan R-402A and sligtly lower tan R-408A and may require adjustments to condenser fans and ead pressure controls. Opteon XP40 is a blend refrigerant; terefore, wen setting supereat, te dew point (saturated vapor) in te pressuretemperature cart sould be used. Similarly, te bubble point (saturated liquid) sould be used for measuring subcooling. System Controls Many supermarkets use refrigeration control systems and metodologies tat rely on te pressure-temperature relationsip of a specific refrigerant for proper operation. For optimal performance, during conversions from R-402A or R-408A to Opteon XP40 (altoug te controls will likely function adequately), tey sould be updated for operation using Opteon XP40 refrigerant properties. Consult wit te control system manufacturer for guidance on updating refrigerant data or operating instructions wen using Opteon XP40. Retrofit R-402A (HP80)/R-408A Systems to Opteon XP40 Te following detailed steps are te recommended procedure for retrofitting R-402A/R-408A systems to Opteon XP40: 1. Establis Baseline Performance wit R-402A/R-408A Collect system performance data wile R-402A/R-408A refrigerant is in te system. Ceck for correct refrigerant carge and operating conditions. Te baseline data of temperatures and pressures at various points in te system (evaporator, condenser, compressor suction and discarge, evaporator vapor supereat, and condenser liquid subcool) at normal operating conditions will be useful in noting any deficiencies in system operation and wen optimizing operation of te system wit Opteon 4

5 XP40. A System Data Seet is included at te back of tis bulletin to record baseline data. 2. Drain/Carge System Lubricant Were MO or AB oil is te existing lubricant in te system, it must be drained. Tis may require removing te compressor from te system, particularly wit small ermetic compressors tat ave no oil drain. In tis case, te lubricant can be drained from te suction line of te compressor. In most small systems, 90-95% of te lubricant can be removed from te compressor in tis manner. Larger systems may require drainage from additional points in te system, particularly low spots around te evaporator, to remove most of te lubricant. In systems wit an oil separator, any lubricant present in te separator sould also be drained. In all cases, measure te volume of lubricant removed from te system. Compare to te compressor/system specifications to ensure tat most of te lubricant as been removed. Polyol ester lubricant is recommended for use wit Opteon XP40. To acieve equivalent miscibility to R-402A/R-408A/MO, te residual mineral oil sould be about 5 wt% or less of te total lubricant used in te system. In larger systems, tis amount of residual mineral oil can be acieved by using a flusing tecnique. Tree or more lubricant fluses may be required. Lubricant fluses involve: Draining existing lubricant from te system, as described above. Selecting a polyol ester lubricant wit similar viscosity to te existing lubricant. Carging an amount of polyol ester equal to te amount of lubricant removed. Running te system wit R-402A/R-408A for toroug mixing of polyol ester/existing lubricant (48 to 72 ours of operation may be required). Repeat tese steps two more times. On te last flus, R-402A/R-408A will be replaced wit te retrofit refrigerant. 3. Remove te R-402A/R-408A Carge into Recovery Cylinders Remove te entire R-402A/R-408A refrigerant from te system into a recovery cylinder(s). Use a recovery device capable of pulling in Hg vacuum (50-67 kpa absolute). Weig te amount removed to use as a guide for te quantity of Opteon XP40 to be carged to te system. 4. Replace Filter Drier and Critical Elastomeric Seals/ Gaskets It is routine practice to replace te filter drier during system maintenance. Replacement filter driers are available tat are compatible wit Opteon XP40. Wile te system is empty, ceck and replace any elastomeric seals tat may be near te end of teir serviceable life. Even if tey were not previously leaking, te cange of swell caracteristics wen canging to any new refrigerant and te general disturbance to te system may cause worn seals to leak after retrofit. Components commonly affected are Scrader core seals, liquid level receiver gaskets, solenoid valves, ball valves, flange seals, and some saft seals on open drive compressors; but, all external seals in contact wit te refrigerant sould be viewed as a potential leak source post-retrofit. Field experience as sown tat te older te system, te greater te likeliood of seal and gasket leaks. It is recommended to cange any system critical seals (e.g., tose tat require removal of te refrigerant carge to allow seal replacement, e.g., liquid receiver, condenser system) as a matter of course and to ave spare seals for oter components available during te retrofit sould any seal failure occur. A rigorous leak ceck regime pre- and post-retrofit will minimize any refrigerant losses. 5. Perform Oter System Modifications Perform any system modifications or upgrades as needed for te system. 6. Evacuate System and Ceck for Leaks To remove air or oter non-condensable gases and any residual moisture from te system, evacuate te system to full vacuum (<1000 microns [<29.88 in Hg vacuum] [<1.33 mbar]). If te system is not able to old vacuum, it may be an indication of a leak. After vacuum test, pressurize te system wit dry nitrogen, taking care not to exceed te system design maximum pressure, and ceck for leaks. Do not use mixtures of refrigerant and air to ceck for leaks, as tese mixtures can become combustible. After leak cecking, remove residual nitrogen wit a vacuum pump. 7. Carge System wit Opteon XP40 Opteon XP40 is a blend; so, it is important to remove liquid only from te carging cylinder. (If te cylinder does not ave a valve wit a dip tube, invert te cylinder so tat te valve is underneat te cylinder.) Te proper cylinder position is often indicated by arrows on te cylinder and te cylinder box. Once liquid is removed from te cylinder, te refrigerant can be allowed to enter te refrigeration system as liquid or vapor as desired. 5

6 WARNING: Do not carge liquid refrigerant into te suction line. Tis can cause irreversible damage to te compressor. Use te manifold gauges or a trottling valve to flas te liquid refrigerant to a vapor prior to entering te suction line. In general, refrigeration systems will require a sligtly smaller carge size of Opteon XP40 tan te original R-402A/R-408A carge. Te optimum carge will vary depending on te system design and operating conditions. Te initial carge sould be approximately 85% of te standard carge size for R-402A/R-408A. After startup and adjustment, te final carge amount will be approximately 95% of te R-402A/R-408A carge. 8. Start Up System and Ceck Operation Monitor and adjust TXV and/or carge size to acieve optimum supereat/subcooling. Monitor oil levels in compressor. Add oil as required to maintain proper levels. 9. Label System wit New and Lubricant Appendix A. Table 3: Condenser Set Points R-402A (HP80) R-408A Average Condenser Temp. ( F) Opteon XP40 R-402A (HP80) R-408A Average Condenser Temp. ( F) Opteon XP After converting from R-22 to Opteon XP40, te condensing pressure can be determined by locating te desired average condenser temperature (or R-402A or R-408A pressure setting) on tis cart and determining te new set point required for equivalent operation wit Opteon XP40. 6

7 Table 4: Evaporator Set Points R-402A (HP80) R-408A Average Condenser Temp. ( F) Opteon XP40 R-402A (HP80) R-408A Average Condenser Temp. ( F) Opteon XP After converting from R-22 to Opteon XP40, te evaporator temperature can be set by locating te desired average evaporator temperature (or R-402A or R-408A evaporator pressure) on tis cart and determining te new set point required for Opteon XP40 to acieve an equivalent average evaporator temperature. 7

8 Appendix B. Table 5: Opteon XP40 Pressure-Temperature Data (Eng) P (psig ) Sat Liq T ( F) Sat Vap T ( F) P (psig ) Sat Liq T ( F) Sat Vap T ( F) P (psig ) Sat Liq T ( F) Sat Vap T ( F)

9 Table 6: Opteon XP40 Temperature-Pressure Data (Eng) Temp ( F) Sat Liq P Sat Vap P Temp ( F) Sat Liq P Sat Vap P Temp ( F) Sat Liq P Sat Vap P

10 Cecklist for Opteon XP40 Retrofit Establis baseline performance wile operating on 402A or R-408A (see data seet for recommended data). Consult te original equipment manufacturer of te system components for teir recommendation on te following: Plastics compatibility Elastomeric compatibility Lubricant (viscosity, manufacturer, additives) Termal expansion device sizing Retrofit procedures to sustain warranty, if applicable If POE lubricant in system: Ceck quality of existing POE oil and cange necessary. If MO or AB lubricant in system: Remove 90 95% MO or AB lubricant from te system. Measure amount of lubricant removed and record. Carge POE lubricant. Run system for at least 8 ours. Recarge wit amount equivalent to amount of MO removed. Repeat lubricant drain and POE carging until MO content is less tan 5%. Replace filter drier and elastomeric seals/gaskets. Ceck and replace elastomeric seals and gaskets tat cannot be replaced witout removing refrigerant. Components commonly affected are Scrader core seals, liquid level receiver gaskets, solenoid valves, ball valves, flange seals, or saft seals on open drive compressors; but, all external seals in contact wit te refrigerant sould be viewed as a potential post-retrofit leak source. Complete system modifications (e.g., TXV, line sizing, etc.) based on engineering analysis. Reconnect system, and evacuate wit vacuum pump to full vacuum (<1000 microns [<29.88 in Hg vacuum] [<1.33 mbar]). Leak ceck system (re-evacuate system following leak ceck). Carge system wit Opteon XP40 (R-449A) refrigerant. Initially carge ~85% by weigt of original equipment manufacturer specified R-402A or R-408A carge. Amount of refrigerant carged: Start up equipment, and adjust carge until desired operating conditions are acieved. If low in carge, add in increments of 2 3% by weigt Amount of refrigerant carged: Total refrigerant carged: Label components and system for type of refrigerant and lubricant. Conversion is complete! 10

11 System Data Seet Type of System/Location: Equipment Mfg.: Compressor Mfg.: Model No.: Model No.: Serial No.: Serial No.: Date of Manufacture: Date of Manufacture: Original Carge Size: Lubricant Type: Lubricant Carge Size: Drier Mfg.: Drier Type: Condenser Cooling Medium: Expansion Device (ceck one): Capillary Tube: Expansion Valve: If Expansion Valve: Manufacturer: Model No.: Control/Set Point: Location of Sensor: Oter System Controls (e.g., Head Pressure Control): Date/Time Carge Size (lb) Ambient Temperature ( F) Compressor Suction Temperature ( F) Suction Pressure Discarge Temperature ( F) Discarge Pressure Evaporator Coil Air/H 2 O In T ( F) Coil Air/H 2 O Out T ( F) Operating Service Temperature ( F) Condenser Coil Air/H 2 O In T ( F) Coil Air/H 2 O Out T ( F) Supereat and Subcool (derived values) T at Supereat Ctl. Pt. ( F) Calculated Supereat ( R) Expansion Device Inlet T ( F) Calculated Subcool ( R) Motor Amps If Rack: Total 11

12 For more information on te Opteon portfolio of refrigerants, or oter Cemours refrigerants products, visit opteon.com, call (800) , or follow us on Te information set fort erein is furnised free of carge and based on tecnical data tat Cemours believes to be reliable. It is intended for use by persons aving tecnical skill, at teir own risk. Because conditions of use are outside our control, Cemours makes no warranties, expressed or implied, and assumes no liability in connection wit any use of tis information. Noting erein is to be taken as a license to operate under, or a recommendation to infringe, any patents or patent applications Te Cemours Company FC, LLC. Opteon and any associated logos are trademarks or copyrigts of Te Cemours Company FC, LLC. Cemours and te Cemours Logo are trademarks of Te Cemours Company. C (12/17)