Opteon XP10. Opteon XP10 Retrofit Guidelines to Replace R-134a. Refrigerant. Introduction. Important Safety Information

Transcription

1 Opteon XP10 Opteon XP10 Retrofit Guidelines to Replace R-134a Introduction Opteon XP10 is a low global warming potential (GWP) ydrofluoro-olefin (HFO)-based refrigerant developed to replace R-134a in medium-temperature refrigeration systems. Opteon XP10 is te registered trade name for a blend of HFC-134a/HFO-1234yf (44/56 wt%) wit an ANSI/ASHRAE Standard 34 refrigerant designation of R-513A. It is a nonflammable azeotropic mixture wit negligible temperature glide. It is commercially available for bot retrofit of existing R-134a equipment as well as a suitable replacement option in new equipment. Opteon XP10 offers improved environmental properties versus R-134a, wit a GWP* of 573 (compared to 1300 for R-134a). Opteon XP10 refrigerant as a zero ozone depletion potential (ODP). Using tese retrofit guidelines, many R-134a systems can be converted to operate using Opteon XP10, allowing existing equipment to continue to operate safely and efficiently wit a greatly reduced environmental impact. Important Safety Information Like all Freon refrigerants, Opteon XP10 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/HFC refrigerants, as tey only detect te presence of clorine in te refrigerant. Clorine is not present in Opteon XP10; 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 Medium Temperature Conditions T Condenser = 104 F, T Evaporator = 14 F, Liquid Subcool = 7 R, Return Gas = 50 F, Compressor Isentropic Efficiency = 70% Evap P (psig) Cond P (psig) Disc T ( F) Avg Glide ( R) Vol Cap (Btu/ft 3 ) Cap Rel to R-134a EER (Btu/watt-our) EER Rel to R-134a Mass Flow Rel to R-134a R-134a % % 100% Opteon XP % % 119% 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 XP10 SDS for more specific safety information. Safety Bulletin AS-1 also gives additional information for safe andling of refrigerants. Flammability Opteon XP10 is nonflammable in air under normal conditions. Wen mixed wit ig concentrations of air or oxygen under elevated pressure, owever, tis product can become combustible in te presence of an ignition source. Tis product sould not be mixed wit air to ceck for system leaks. General Retrofit Information: R-134a to Opteon XP10 Expected Performance of Opteon XP10 vs. R-134a Table 1, based on termodynamic cycle analysis, provides a comparison of R-134a and Opteon XP10 performance data for a number of key system variables. 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-134a, te polyolester (POE) lubricant currently in te system sould be suitable for use wit Opteon XP10. 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 XP10 versus R-134a. Compressor suction and discarge pressures for Opteon XP10 will differ sligtly from R-134a, and it may be necessary to adjust system pressure set points and cutouts to avoid exceeding te operating limits of te compressor. Consult wit te specific system manufacturer for guidance. Opteon XP10 also as lower compressor discarge temperature tan R-134a. Again, you sould consult wit your compressor manufacturer for details regarding operation of your specific compressor on Opteon XP10. 2

3 Expansion Device Opteon XP10 as sligtly iger mass flow rate tan R-134a, but sould be witin te usable range of a properly sized and installed R-134a expansion device. Some adjustment to te expansion valve(s) may be needed in order to reset te supereat following conversion of te system. Use te PT 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 XP10 as sligtly iger mass flow rates and sligtly lower liquid density compared to R-134a. It is always 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 XP10 and R-134a, it may be necessary to reset evaporator pressure regulators (EPR) and pressure cutouts to properly operate te system. Te discarge pressure of Opteon XP10 is sligtly iger tan R-134a, and may require sligt adjustments to condenser fans and ead pressure controls. Opteon XP10 is an azeotropic refrigerant; so, tere are negligible differences between te dew point and bubble point. However, it is good industry practice to use te dew point (saturated vapor) in te PT cart wen setting supereat. 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-134a to Opteon XP10, altoug te controls will likely function adequately, for optimal performance tey sould be updated for operation using Opteon XP10 refrigerant properties. Consult wit te control system manufacturer for guidance on updating refrigerant data or operating instructions wen using Opteon XP10 (R-513A). Retrofit of R-134a Systems to Opteon XP10 Te following detailed steps are te recommended procedure for retrofitting R-134a systems to Opteon XP10: 1. Establis Baseline Performance wit R-134a Collect system performance data wile R-134a 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 XP10. 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-134a, te POE lubricant currently in te system sould be suitable for use wit Opteon XP10. 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-134a Carge into Recovery Cylinders Remove te entire R-134a refrigerant from te system into a recovery cylinder(s). Weig te amount removed to use as a guide for te quantity of Opteon XP10 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. 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. 3

4 7. Carge System wit Opteon XP10 Opteon XP10 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. 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 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 similar to sligtly smaller carge size of Opteon XP10 tan te original R-134a 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-134a. After startup and adjustment, te final carge amount will be approximately 97% of te R-134a carge. 4

5 Appendix I. Opteon XP10 Pressure-Temperature Data (Eng) P Sat Liq T Sat Vap T P Sat Liq T Sat Vap T P Sat Liq T Sat Vap T psig ºF ºF psig ºF ºF psig ºF ºF

6 Opteon XP10 Temperature-Pressure Data (Eng) Temp Sat Liq P Sat Vap P Temp Sat Liq P Sat Vap P Temp Sat Liq P Sat Vap P F psig psig F psig psig F psig psig

7 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) 7

8 Cecklist for Opteon XP10 Retrofit Establis baseline performance wile operating on R-134a (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 XP10 (R-513A) refrigerant Initially carge ~85% by weigt of original equipment manufacturer specified R-134a 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! For more information on te Opteon family of refrigerants, or oter Cemours refrigerants products, visit opteon.com, call (800) , or follow us on Twitter@RefrigCemours. 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 (11/15)