Opteon XP40. Opteon XP40 Retrofit Guidelines to Replace R-404A/R-507. Refrigerant. Introduction. Important Safety Information

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1 Opteon XP40 Opteon XP40 Retrofit Guidelines to Replace R-404A/R-507 Introduction Opteon XP40 is a low global warming potential (GWP) ydrofluoro-olefin (HFO)-based refrigerant developed as a direct replacement for R-404A/R-507 and R-22 in positive displacement, direct expansion, low- and mediumtemperature, commercial and industrial applications. Opteon XP40 is te registered trade name for a 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 for bot retrofit of existing R-404A/R-507 or R-22 equipment, as well as a suitable replacement option for tese refrigerants in new equipment. Opteon XP40 offers improved energy efficiency and environmental properties versus R-404A/R-507, wit a GWP* of 1282 (vs for R-404A and 3985 for R-507), and as a zero ozone depletion potential (ODP). Using tese retrofit guidelines, existing R-404A/R-507 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 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 torces 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, R-404A, or R-507; and, consequently, tese detectors will not detect te presence of tese refrigerants. Use an electronic leak detector designed to find 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. *GWP = IPCC Fift Assessment Report (AR5)

2 Table 1: Comparison of Performance Data Evap (psig) R-404A Alts Low-Temperature Conditions Condenser = 104 F; Evaporator = -22 F; Subcool amount = 7 R: Return Gas T = 14 F; Comp Eff = 70% Cond (psig) Disc T ( F) Avg Glide ( R) Vol Cap (Btu/ft 3 ) Cap vs. R-404A EER (Btu/watt-r) EER vs. R-404A Mass Flow vs. R-404A R-404A % % 100% Opteon XP % % 75% R-404A Alts Medium-Temperature Conditions Condenser = 104 F; Evaporator = 14 F; Subcool amount = 7 R: Return Gas T = 50 F; Comp Eff = 70% R-404A % % 100% Opteon XP % % 75% Note: Any refrigerant can be azardous if used improperly. Hazards include liquid or vapor under pressure as well as frostbite from te escaping liquid. 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. Cemours Safety Bulletin AS-1 also gives 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 Information R-404A/R-507 to Opteon XP40 Expected Performance of Opteon XP40 vs. R-404A Table 1, based on termodynamic cycle analysis, provides a comparison of R-404A and Opteon XP40 across a number of key performance factors. Actual performance for a specific system depends on a number of factors, including equipment conditions and operating environment. System Modifications Lubricant For most systems operating on R-404A/R-507, te polyolester (POE) lubricant currently in te system sould be suitable for use wit Opteon XP40. If tere are questions about te lubricant, or tests indicate 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. Compressor Overall system performance (capacity and energy efficiency) will be similar wen operating on Opteon XP40 as to tat wen using R-404A/R-507. Compressor suction and discarge pressures for Opteon XP40 will differ from R-404A/R-507, 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 also as a modestly iger ( R) discarge temperature tan R-404A/R-507. Again, you sould consult wit your compressor manufacturer for details regarding operation of your specific compressor on Opteon XP40. 2

3 Expansion Device Opteon XP40 as a lower mass flow rate (~20-25%) tan R-404A/R-507, but sould be witin te usable range of a properly sized and installed R-404A/R-507 expansion device and sould not require replacement. Some adjustment to te expansion valve(s) may be needed in order to reset te supereat following conversion of te system. Use te pressure-temperature 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-404A/R-507. 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 in order 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-404A/R-507, it may be necessary to reset evaporator pressure regulators (EPR) and cutouts to properly operate te system. Te discarge pressure of Opteon XP40 is sligtly lower tan R-404A/R-507, and may require sligt 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. During conversions from R-404A/R-507 to Opteon XP40, altoug te controls will likely function adequately, for optimal performance tey sould be updated for operation using Opteon XP40 (R-449A) refrigerant properties. Consult wit te control system manufacturer for guidance on updating refrigerant data or operating instructions wen using Opteon XP40. Retrofit of R-404A/R-507 Systems to Opteon XP40 Te following detailed steps are te recommended procedure for retrofitting R-404A/R-507 systems to Opteon XP40: 1. Establis Baseline Performance wit R-404A/R-507 Collect system performance data wile R-404A or R-507 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 XP40. A System Data Seet is included at te back of tis bulletin to record baseline data. 2. Ceck Lubricant For most systems operating on R-404A/R-507, te POE lubricant currently in te system sould be suitable for use wit Opteon XP40. If tere are questions about te lubricant, or tests indicate 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 or brand of lubricant. 3. Remove te R-404A/R-507 Carge into Recovery Cylinders Remove te entire R-404A/R-507 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 It is routine practice to replace te filter drier during system maintenance. 5. Perform Oter System Modifications Perform any system modifications or upgrades as needed for te system. 3

4 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. 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 larger carge size of Opteon XP40 tan te original R-404A or R-507 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-404A or R-507. After startup and adjustment, te final carge amount will be approximately 105% of te R-404A or R 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 Table 2: Pysical Properties of Opteon XP40 Pysical Property Condition Opteon XP40 R-404A Boiling Point 1 atm (101.3 kpa) 50.7 F F Vapor Pressure 70 F psia psia Table 3: Composition of Opteon XP40 (wt%) HFC-32 HFC-125 HFO-1234yf HFC-134a Opteon XP Liquid Density 70 F 69.5 lb/ft lb/ft 3 Density Sat Vapor 70 F 2.73 lb/ft lb/ft 3 GWP AR5 CO 2 =

5 Appendix A. Table 4: Condenser Pressure Set Points R-404A psig Average Condenser Temp ( F) Opteon XP40 psig R-404A psig Average Condenser Temp ( F) Opteon XP40 psig After converting from R-404A to Opteon XP40, te condensing pressure can be determined by locating te desired average condenser temperature (or R-404A pressure setting) on tis cart and determining te new set point required for equivalent operation wit Opteon XP40. 5

6 Table 5: Evaporator Suction Pressure Set Points R-404A psig Average Evaporator Temp ( F) Opteon XP40 psig R-404A psig Average Evaporator Temp ( F) Opteon XP40 psig After converting from R-404A to Opteon XP40, te evaporator temperature can be set by locating te desired average evaporator temperature or (R-404A evaporator pressure) on tis cart and determining te new set point required for Opteon XP40 in order to acieve an equivalent average evaporator temperature. 6

7 Appendix B. Table 6: 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)

8 Table 7: Opteon XP40 Temperature-Pressure Data (Eng) Temp ( F) Sat Liq P (psig) Sat Vap P (psig) Temp ( F) Sat Liq P (psig) Sat Vap P (psig) Temp ( F) Sat Liq P (psig) Sat Vap P (psig)

9 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., ead pressure control): Date/Time Carge Size (lb) Ambient Temperature ( F) Compressor Suction Temperature ( F) Suction Pressure (psig) Discarge Temperature ( F) Discarge Pressure (psig) 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) 9

10 Cecklist for Opteon XP40 Retrofit Establis baseline performance wile operating on R-404A/R-507 (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 Ceck quality of existing POE oil, and cange if necessary Complete system modifications (TXV, line sizing, etc.) based on engineering analysis Replace filter drier wit new drier approved for use wit retrofit refrigerant 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-404A/R-507 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

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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. Replaces: K C (1/16)