Retrofit A1 Refrigerants

WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 1

Preparation for Wholesaler Presentation Select 8

Retrofit A1 Refrigerants

2019 Wholesale Conference

Andreas Peselmann

Application Engineering


Agenda

• Refrigerants Overview

• Conclusions For Retrofitting

• Retrofitting Existing R404A Systems, Scroll + Semihermetic

• Retrofitting ZB56-11 TW*, ZS56-11 TW*, ZF24-48 TW*

• Retrofitting Existing R134a Systems, Scroll + Semihermetic


Refrigerant Options

R-410A

Like

Capacity

R404A &

R407/22

Like

R134a

Like

GWP Level

400-675

< 1500

~600HFO 1234yf

HFO 1234ze

R410A

R22

R407A

R407C

R407F, R452A

0 500 1000 1500 2000

Cooling Capacity

System Pressure

R32/HFC/HFO

Blends

R32/HFO

Blends

HFC/HFO

BlendsR134a

CO2

R404A

R507A

R290

NH3

A1 – Non Flammable

A2L – Lower Flammable

A3 – Higher Flammable

B2L – Toxic, Mildly Flam.Qualitative Chart –

Not To Scale

(3922)

R32/HFO

Blends R448A/R449A

R450A

R513A

<150 R455A (HDR110)

R454C (DR3)

R32 R452B (DR55)R454B


Refrigerant safety classification, according to ISO 817 .

Refrigerant Classification

Flammability

A3 B3 Higher Flammable

A2 B2 Flammable

A2L B2L Lower Flammable

A1 B1 Non Flammable

ToxicityLow

Toxicity

High

Toxicity



• refrigerant safety classification per ISO 817



• overview refrigerant safety

classification EN378-1, Annex E


Legislation and Safety

• system design safety devices and components depend on the refrigerant safety

class, like A1, A2L or A3

• A1 system design, safety and legislation is well known

• A2L and A3 system design have other requirements

- legislation (general, local) must be considered

- specific product norms, like for example EN60335-2-89 might work

- otherwise EN378 comes into place

- impact on system design, components selection, refrigerant filling, safety concept

- ped classification +1 for flammable refrigerants


Refrigerant And System Classification

Conclusions:

• A2L and A3 refrigerants for new systems only. The system and safety architecture

must be adapted to be appropriate for A2L and A3

• systems designed for A1 refrigerant, could only be operated with A1 refrigerants

• retrofit of an existing A1 system with A2L or A3 refrigerant is NOT possible


Retrofit Existing Systems With R404A


Retrofit Existing R404A Systems

Official Emerson released R404A

replacements:

R448A, R449A, R407A, R407F

-> see Select software for compressor

– refrigerant combination


Retrofit Existing R404A Systems, General Guidelines

Technical information for the refrigerant changeover from R404A

to R407A, R407F, R448A or R449A

• for Copeland compressors scroll + semi hermetic

• general advices

• changeover procedure

• pressure and temperature tables



Technical Information considerations:

• ester oil

• capacity and efficiency values

• discharge temperatures

• MT and LT operation envelopes

• material compatibility (gaskets)

• density and mass flow (piping)

• suction and discharge pressures (adjusting valves)



Technical information considerations:

• R407A, R407F, R448A and R449A are

blend refrigerants

-> temperature glide to be considered

Example: -10°C evaporating => 2,6 bar,g R448A

for the correct superheat measurement and calculation,

the dew point must be used.

-> eventually new expansion valve

-> expansion valve settings must be adapted

Warning: using the old R404A expansion valve without adapting, could damage the compressor!


Retrofit Existing R404A Systems, Scroll

MT + LT applications scroll.

compressor envelope

-> check for possible restrictions in terms of

suction gas return temperature or

superheat



MT + LT applications scroll

Capacity value comparison:

R404A vs replacement refr.

-> Select enables a direct comparison

of both refrigerants

-> replacement refrigerant might have

less cooling capacity



MT applications scroll.

Envelope comparison: R404A vs replacement

refrigerant

-> Select enables a direct comparison of the possible

operation envelope

-> for MT applications usually the envelope of the

R404A replacement refrigerant fits quite good!



LT applications scroll with liquid injection


refrigerant

-> due to liquid injection technology, mostly the

envelope fits quite good!



LT applications scroll with vapour injection


refrigerant

-> care must be taken for the pure EVI envelope

-> operating area with wet injection required


Retrofit Existing R404A Systems, Semih.

MT applications semihermetic.


refrigerant

-> Select enables a direct comparison of the possible

operation envelope

-> for MT applications usually the envelope of the

R404A replacement refrigerant fits quite good!


Retrofit Existing R404A Systems, Semiherm.

LT applications semihermetic


refrigerant

-> compare envelope with/without liquid injection

Demand Cooling DC


New Service BOM 951

ZB56-11KE/ME, ZS56-11KE/ME, ZF24-48K4E/KVE

Retrofit Options


New Service BOM951 ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*

Old „Specter“ compressor families still remain in

production, but now sold with service BOM 951


ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*

• Compressor series for service

purposes only

• Technical data still available under

„previous generation“

• Old data shown for R404A, R22,

R134a...

• No new refrigerant qualification, such

as R448A/R449A, R407A, R407F.

-> no technical data in Select



• Estimation of capacity values,

application envelopes possible with

comparison to newer model range,

see Select software:

- select old compressor and new

compressor family based on R404A

- select similar/comparable

displacement



• Estimation of capacity values,




- use new compressor family/model

as baseline for new refrigerant

calculation



• estimation of capacity values,




- use new compressor family/model

envelope for estimation of possible

operation range


ZF24-48 K4E TWD with liquid injection

ZF24-48 K4E TWD Specter family compressors with liquid injection

• Technical Information for the conversion of existing R404A systems

with capillary tube towards DTC valve liquid injection available


Retrofit Existing R404A Systems, Semihermetic

Old „previous generation“ compressor families, new technical data

• Compressor model families, which have been identified as phase-out

or obsoleted products have not been qualified for new refrigerants, such

as R448A, R449A ect.

Examples: DWM Models D2S*, D3S*, D4S*, D6S* D8S*, D4D*, D6D*, D6T*

• Consequently, there are no technical data in Select available.

• Theoretical calculated data for specified operation points could be provided on request

• Valuation of the possible operation envelope: comparison with released Stream models

Example:

MT Old: D4DH 250X (70,8 m³/h) 4MH 25X (71,4 m³/h)

LT Old: D4DL 150X (70,8 m³/h) 4ML 15X (71,4 m³/h)


Retrofit Existing Systems With R134a


Retrofit Existing R134a Systems

Official Emerson released R134a replacements:

R450A, R513A

• R450A (N13), A1 safety class, GWP 605

composition R134a (42%), R1234ze (58%)

• R513A (XP10), A1 safety class, GWP 631

composition R134a (44%), R1234yf (56%)



R450A, R513A qualification

• refrigerant migration of liquid R450A/R513A

into the compressor crankcase could cause

low oil viscosity and compressor damage.

When using R450A and R513A with the

standard compressor versions, it is critical to

meet some application requirements.

For new systems/applications with R513A/R450A:

Emerson offers a new compressor family

ZR24-92 KRE + ZRD36-92 KRE

launch planned for Q1 2019



R450A, R513A retrofit scrolls in the field

Dedicated application recommendations:

• maintain adequate superheat settings

with a minimum superheat of 8-10K

• no liquid refrigerant migration into the compressor at any time, especially during standstill, during

or after defrost, or after reverse mode for example in heat pumps

• pumpdown is recommended

• the use of a crankcase heater is mandatory;

• for R450A and R513A refrigerants Emerson recommends to use suction accumulators, unless it

has been qualified that an accumulator is not needed (procedure described in the Application

Guidelines).


Retrofit Existing R134a Systems, General Guidelines

Technical information for the refrigerant changeover from R134a

to R450A + R513A

• for Copeland compressors scroll + semi hermetic

• general advices

• changeover procedure

• pressure and temperature tables


Retrofit Existing R134a Systems, General Guidelines

Technical Information considerations:

• ester oil

• capacity and efficiency values

• discharge temperatures

• MT and LT operation envelopes

• material compatibility (gaskets)

• density and mass flow (piping)

• suction and discharge pressures (adjusting valves)


Retrofit Existing R134a Systems, Scroll

compressor envelopes R134a, R450A, R513A

-> compressor ebvelopes are quite comparable


Retrofit Existing R134a Systems, Scroll

Capacity value comparison:

-> Select enables a direct

comparison between all three

refrigerants


Retrofit Existing R134a Systems, Semih.

compressor envelopes R134a, R450A, R513A

-> compressor envelopes are quite comparable

Retrofit A1 Refrigerants

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