COMPATIBILITY OF REFRIGERANTS AND LUBRICANTS WITH MOTOR MATERIALS UNDER RETROFIT CONDITIONS. Final Report
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1 DOE/CE/ COMPATIBILITY OF REFRIGERANTS AND LUBRICANTS WITH MOTOR MATERIALS UNDER RETROFIT CONDITIONS Final Report Volume IV PICTURES Robert G. Doerr and Todd D. Waite The Trane Company 3600 Pammel Creek Road La Crosse, Wisconsin October 1996 Prepared for The Air-Conditioning and Refrigeration Technology Institute Under ARTI MCLR Project Number This research project is supported, in whole or in part, by U.S. Department of Energy grant DE-FG02-91CE23810: Materials Compatibility and Lubricants Research (MCLR) on CFC-Refrigerant Substitutes. Federal funding supporting this project constitutes 93.57% of allowable costs. Funding from non-government sources supporting this project consists of direct cost sharing of 6.43% of allowable costs; and in-kind contributions from the air-conditioning and refrigeration industry.
2 DISCLAIMER The U.S. Department of Energy's and the air-conditioning industry's support for the Materials Compatibility and Lubricants Research (MCLR) program does not constitute an endorsement by the U.S Department of Energy, nor by the airconditioning and refrigeration industry, of the views expressed herein. NOTICE This report was prepared as an account of work sponsored by the United States Government. Neither the United States nor the Department of Energy, nor the Air-Conditioning and Refrigeration Technology Institute, nor any of their employees, nor any of their contractors, subcontractors, or their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product or process disclosed or represents that its use would not infringe privately-owned rights. COPYRIGHT NOTICE (for journal publication submissions) By acceptance of this article, the publisher and/or recipient acknowledges the rights of the U.S. Government and the Air-Conditioning and Refrigeration Technology Institute, Inc. (ARTI) rights to retain a non-exclusive, royalty-free license in and to any copyrights covering this paper.
3 FORMAT FOR THE FINAL REPORT Because of the large scope of this project and the large amount of data recorded, the final report is divided into four volumes. Volume I (148 pages) contains the abstract, introduction, significant results, conclusions, material identification, experimental procedures and summary data tables. This volume provides the results of the study and other information of interest to most readers. The other volumes are necessary only if the reader is interested in the individual data measurements rather than summaries or averages of the data sets. Volume II (250 pages) contains the measurements from tests on the three high pressure refrigerant-lubricant combinations and their alternatives. Original Refrigerant Alternative Refrigerant Exposure Temperature R-12/Mineral Oil R-134a/Polyol Ester 127 C (260 F) R-22/Mineral Oil R-407C/Polyol Ester 127 C (260 F) R-502/Mineral Oil R-404A/Polyol Ester 127 C (260 F) Volume III (155 pages) contains the measurements from tests on the three low pressure refrigerant-lubricant combinations and their alternatives. Original Refrigerant Alternative Refrigerant Exposure Temperature R-11/Mineral Oil R-123/Mineral Oil 100 C (212 F) R-11/Mineral Oil R-245ca/Polyol Ester 100 C (212 F) R-123/Mineral Oil R-245ca/Polyol Ester 100 C (212 F) Volume IV (44 pages) contains the photographs of the motor materials after exposure to the six refrigerant-lubricant combinations and their alternatives.
4 COMPATIBILITY OF REFRIGERANTS AND LUBRICANTS WITH MOTOR MATERIALS UNDER RETROFIT CONDITIONS Robert G. Doerr and Todd D. Waite The Trane Company ABSTRACT Compatibility tests were conducted on motor materials to determine if exposure to the original refrigerant/mineral oil would affect compatibility of the motor materials after retrofit to the alternative refrigerant/lubricant. The motor materials were exposed at elevated temperature to the original refrigerant and mineral oil for 500 hours, followed by exposure to the alternative refrigerant and lubricant for 500 hours. Measurements were also taken after 168 and 336 hours. As a control, some samples were exposed to the original refrigerant/mineral oil for a total of 1000 hours. The original refrigerants and the alternatives tested for retrofit were as follows: Original Refrigerant Alternative Refrigerant Exposure Temperature R-12/Mineral Oil R-134a/Polyol Ester 127 C (260 F) R-22/Mineral Oil R-407C/Polyol Ester 127 C (260 F) R-502/Mineral Oil R-404A/Polyol Ester 127 C (260 F) R-11/Mineral Oil R-123/Mineral Oil 100 C (212 F) R-11/Mineral Oil R-245ca/Polyol Ester 100 C (212 F) R-123/Mineral Oil R-245ca/Polyol Ester 100 C (212 F) Most motor materials exposed to the alternative refrigerant and lubricant (after an initial exposure to the original refrigerant and mineral oil) were compatible with the alternative refrigerant and lubricant. The only concern was delamination and blistering of the sheet insulation containing Nomex, especially after removal of absorbed refrigerant. This was attributed to solution of the adhesive and not to the Nomex itself. Embrittlement of the polyethylene terephthalate (PET) found in Mylar and Melinex sheet and sleeving insulations was initially observed, but subsequent tests under dry conditions showed that embrittlement of the PET materials was caused by moisture present during the exposure. Compatibility tests of elastomers with R-245ca, retrofitted from R-11 and R-123, showed that the nitrile was compatible with both R-11 and R-245ca, but not with R-123. The neoprene was unsatisfactory because of shrinkage in the R-245ca.
5 TABLE OF CONTENTS PICTURES, VOLUME IV PICTURES OF PROCEDURES AND UNEXPOSED MATERIALS 1 R-12/MINERAL OIL TO R-134a/POLYOLESTER PICTURES 2 R-22/MINERAL OIL TO R-407C/POLYOLESTER PICTURES 3 Section PICTURES OF SHEET INSULATION EXPOSED TO R-12/R-134a AND R-22/R-407C UNDER DRY CONDITIONS 4 R-502/MINERAL OIL TO R-404A/POLYOLESTER PICTURES 5 R-11/MINERAL OIL TO R-123/MINERAL OIL PICTURES 6 R-11/MINERAL OIL TO R-245ca/POLYOLESTER PICTURES 7 R-123/MINERAL OIL TO R-245ca/POLYOLESTER PICTURES 8 NUMBERING ORDER FOR ALL PICTURES Upper Left: 1, 5, 9, 13 Lower Left: 2, 6, 10, 14 Upper Right: 3, 7, 11, 15 Lower Right: 4, 8, 12, 16 1, 5, 3, 7, 2, 6, 4, 8,
6 PICTURES SECTION 1 PROCEDURES AND UNEXPOSED MATERIALS
7 PROCEDURES AND UNEXPOSED MATERIALS PICTURE PROCEDURES 1. Dipping Helical Coils 2. Reclaiming Refrigerant 3. Removing Lubricant From Parr Bombs After Exposures UNEXPOSED MATERIALS 4. Bomb 1: Unexposed Motorettes, Tapes, Tie Cords and Lead Wires 5. Bomb 2: Unexposed Helical Coils and Three Sheet Insulations 6. Bomb 3: Unexposed Helical Coils and Three Sheet Insulations 7. Bomb 4: Unexposed Twisted Pairs 8. Bomb 5: Unexposed Motorettes, Varnish Disks, and Sleeving
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10 PICTURES SECTION 2 R-12/Mineral Oil to R-134a/Polyolester
11 R-12/MINERAL OIL TO R-134a/POLYOLESTER PICTURES PICTURE R12/Mineral Oil 500 Hour Exposure. 1. Bomb 1: Motorettes, Tapes, Tie Cords and Lead Wires 2. Bomb 2: Helical Coils and Three Sheet Insulations 3. Bomb 3: Helical Coils and Three Sheet Insulations 4. Bomb 4: Twisted Pairs 5. Bomb 5: Motorettes, Varnish Disks, and Sleeving 6. Sleeving Showing Brittleness. R12/Mineral Oil 500 Hour plus R-134a/Polyolester 168 hour Exposure 7. All Materials Except Motorettes 8. Nomex-Mylar-Nomex (NMN), Blistered. R12/Mineral Oil 500 Hour plus R-134a/Polyolester 336 hour Exposure 9. All Materials Except Motorettes.
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15 PICTURES SECTION 3 R-22/Mineral Oil to R-407C/Polyolester
16 R-22/MINERAL OIL TO R-407C/POLYOLESTER PICTURES PICTURE R22/Mineral Oil 500 Hour Exposure. 1. Bomb 1: Motorettes, Tapes, Tie Cords and Lead Wires 2. Bomb 2: Helical Coils and Three Sheet Insulations 3. Bomb 3: Helical Coils and Three Sheet Insulations 4. Bomb 5: Motorettes, Varnish Disks, and Sleeving 5. Sheet Insulation and Varnish 6. Sheet Insulation and Varnish 7. Parr Bomb Cover Showing Polyethylene Terephthalate (PET) Precipitate 8. Parr Bomb Cover Showing Polyethylene Terephthalate (PET) Precipitate R22/Mineral Oil 1000 Hour Exposure. 9. All Materials Except Motorettes 10. Magnet Wire with PET Residue 11. Nomex-Mylar-Nomex (NMN) showing blistering 12. Delamination of NMN Sheet Insulation 13. Blisters in NMN Sheet Insulation R22/Mineral Oil 500 Hour plus R-407C/Polyolester 168 hour Exposure 14. All Materials Except Motorettes R22/Mineral Oil 500 Hour plus R-407C/Polyolester 336 hour Exposure 15. All Materials Except Motorettes. R22/Mineral Oil 500 Hour plus R-407C/Polyolester 500 hour Exposure 16. All Materials Except Motorettes.
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21 PICTURES SECTION 4 SHEET INSULATION UNDER DRY CONDITIONS
22 SHEET INSULATION EXPOSED UNDER DRY CONDITIONS R-22/MINERAL OIL TO R-407C/POLYOLESTER PICTURES PICTURE R22/Mineral Oil 500 Hour Exposure. 1. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered R22/Mineral Oil 500 Hour plus R-407C/Polyolester 168 hour Exposure 2. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered 3. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered 4. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered R22/Mineral Oil 500 Hour plus R-407C/Polyolester 336 hour Exposure 5. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered 6. Nomex Sheet Insulation, Blistered R22/Mineral Oil 500 Hour plus R-407C/Polyolester 500 hour Exposure 7. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered 8. Nomex-Mylar-Nomex (NMN) Sheet Insulation, Blistered, Compared to 1000 Hour Exposure to R-22/Mineral Oil. R-12/MINERAL OIL, 500 HOURS TO R-134A/POLYOLESTER 1. Nomex-Mylar-Nomex (NMN), R-134a 336 Hours, Blistered 2. Nomex, R-134a 336 Hours, Blistered 3. Nomex-Mylar-Nomex (NMN), R-134a 500 Hours, Blistered
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26 PICTURES SECTION 5 R-502/Mineral Oil to R-404A/Polyolester
27 R-502/MINERAL OIL TO R-404A/POLYOLESTER PICTURES PICTURE R502/Mineral Oil 500 Hour Exposure. 1. Bomb 1: Motorettes, Tapes, Tie Cords and Lead Wires 2. Bomb 2: Helical Coils and Three Sheet Insulations 3. Bomb 3: Helical Coils and Three Sheet Insulations 4. Bomb 4: Twisted Pairs 5. Bomb 5: Motorettes, Varnish Disks, and Sleeving 6. Nomex Sheet Insulation, Blistered 7. Nomex Sheet Insulation, Blistered, Close-up 8. Nomex-Mylar-Nomex (NMN), Blistered 9. Nomex-Mica, Blistered 10. All Materials Except Motorettes R502/Mineral Oil 1000 Hour Exposure. R502/Mineral Oil 500 Hour plus R-404A/Polyolester 336 hour Exposure 11. All Materials Except Motorettes. 12. Nomex, Blistered 13. Nomex, Blistered, Side View 14. Nomex-Mylar-Nomex, Delaminated 15. Nomex-Mylar-Nomex, Delaminated, Close View R502/Mineral Oil 500 Hour plus R-404A/Polyolester 500 hour Exposure 16. All Materials Except Motorettes.
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32 PICTURES SECTION 6 R-11/Mineral Oil to R-123/Mineral Oil
33 R-11/MINERAL OIL TO R-123/MINERAL OIL PICTURES PICTURE R11/Mineral Oil 500 Hour plus R-123/Mineral Oil, 168 hour Exposure 1. All Materials Except Motorettes 2. Permacel Tape 3. Motorettes, Showing Blistering of the Varnish on Steel. Note: Varnish blistering was not observed with additional exposures to R-123. R11/Mineral Oil 500 Hour plus R-123/Mineral Oil, 500 hour Exposure 4. All Materials Except Motorettes.
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35 PICTURES SECTION 7 R-11/Mineral Oil to R-245ca/Polyolester
36 R-11/MINERAL OIL TO R-245ca/POLYOLESTER PICTURES PICTURE R11/Mineral Oil 500 Hour Exposure. 1. All Materials 2. Nomex-Mylar-Nomex (NMN). Blistered 3. Magnet Wire 4. Oil Sample 5. Motorettes. R11/Mineral Oil 1000 Hour Exposure. 6. All Materials Except Motorettes 7. Nomex-Mylar-Nomex (NMN), Blistered R11/Mineral Oil 500 Hour plus R-245ca/Polyolester 168 hour Exposure 8. All Materials Except Motorettes 9. Nomex-Mylar-Nomex (NMN), Blistered R11/Mineral Oil 500 Hour plus R-245ca/Polyolester 336 hour Exposure 10. All Materials Except Motorettes. 11. Nomex-Mylar-Nomex (NMN), Blistered R11/Mineral Oil 500 Hour plus R-245ca/Polyolester 500 hour Exposure 12. All Materials Except Motorettes. 13. Nomex-Mylar-Nomex (NMN), Blistered 14. Motorettes
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41 PICTURES SECTION 8 R-123/Mineral Oil to R-245ca/Polyolester
42 R-123/MINERAL OIL TO R-245ca/POLYOLESTER PICTURES PICTURE R123/Mineral Oil 500 Hour Exposure. 1. Sheet Insulation, Sleeving, Tapes, Tie Cords and Lead Wires 2. Magnet Wire 3. Motorettes. R123/Mineral Oil 1000 Hour Exposure. 4. All Materials Except Motorettes 5. Nomex-Mylar-Nomex (NMN), Blistered R123/Mineral Oil 500 Hour plus R-245ca/Polyolester 168 hour Exposure 6. All Materials Except Motorettes 7. Nomex-Mylar-Nomex (NMN), Blistered R123/Mineral Oil 500 Hour plus R-245ca/Polyolester 336 hour Exposure 8. All Materials Except Motorettes. 9. Nomex-Mylar-Nomex (NMN), Blistered R123/Mineral Oil 500 Hour plus R-245ca/Polyolester 500 hour Exposure 10. All Materials Except Motorettes. 11. Nomex-Mylar-Nomex (NMN), Blistered 12. Distillation Apparatus to Recover low Pressure Refrigerants.
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