DuPont HP62 User's Manual
Contents
1. Do not use flames or torches to search for leaks Do not use flames in high concentrations of refrigerant Open flames release large quantities of acidic compounds in the presence of all refrig erants and these compounds can be hazardous Do not use torches as leak detectors Old halide torches detect chlorine which may not be present with new refrigerants Use an electronic leak detector designed to find the refrigerants you are using If you detect a visible change in the size or color of a flame when using torches to repair equip ment stop work immediately and leave the area Ventilate the work area well and stop any refrigerant leaks before resuming work These flame effects may be an indication of very high refrigerant concentrations and continuing to work without adequate ventilation may result in injury or death Note Any refrigerant can be hazardous if used improperly Hazards include liquid or vapor under pressure and frostbite from the escaping liquid Overexposure to high concentrations of vapor can cause asphyxiation and cardiac arrest Please read all safety information before handling any re frigerant For more detailed information on the properties uses storage and handling of Suva refrigerants see DuPont Technical Bulletin P 134a or P HP or other literature specific to these products Refer to the appropriate Material Safety Data Sheet MSDS for more safety information about each refrigerant DuPont2. Using these procedures R 12 R 502 and R 22 equipment can be safely and efficiently retrofitted with HFC based Suva refrigerants allowing the equipment to continue in service for the remainder of its useful life These retrofit guidelines are in tended for equipment containing positive displace ment compressors R 12 Replacement Choices Suva 134a R 134a is the long term HFC re placement for R 12 in new equipment and for retro fitting some R 12 systems such as supermarket display cases commercial refrigeration and air conditioning equipment appliances and transport refrigeration equipment In stationary equipment Suva 134a is recommended for retrofit of equip ment with evaporator temperatures above 20 F 7 C to ensure best performance Suva 134a may be used in existing equipment at lower evaporator temperatures but it can exhibit reduced capacity compared with R 12 unless system modifications are made R 502 Replacement Choices Suva HP62 R 404A is widely recognized as the preferred HFC replacement for R 502 in new equipment and for retrofitting R 502 systems such as supermarket and food service industrial freezing and some transport refrigeration Suva HP62 offers the closest HFC match to R 502 performance and can be used over the full R 502 operating range Suva HP62 also provides lower compressor discharge temperatures than R 502 which can increase compressor reliability and life Suva 507 R 507
3. 300 325 350 375 400 425 450 475 500 550 600 650 700 750 800 850 900 950 13 12 R 502 507 Pressure Sat Temp Sat Temp kPa 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 19 21 16 17 19 21 22 24 25 27 28 30 31 32 34 35 36 37 38 41 43 45 47 49 51 53 54 56 58 59 Table 4 Pressure Temperature Chart Suvae HP62 R 22 Saturation Properties English Units SI Units R 22 HP62 R 22 HP62 R 22 HP62 R 22 HP62 Pressure Sat Temp Sat Temp Pressure Sat Temp Sat Temp Pressure Sat Temp Sat Temp Pressure Sat Temp Sat Temp psi F F psi F F kPa C C kPa c 25 100 107 58 32 22 25 67 71 1450 38 31 20 80 87 60 34 23 50 55 59 1500 39 32 15 66 75 62 35 25 75 47 52 1550 40 34 10 56 65 64 37 26 100 41 46 1600 42 35 5 48 57 66 38 28 125 36 41 1650 43 36 4 47 56 68 40 29 150 32 37 1700 44 37 3 45 54 70 41 30 175 28 34 1750 46 38 2 44 53 72 42 32 200 25 30 1800 47 40 1 43 52 74 44 33 225 22 28 1900 49 42 0 41 50 76 45 34 250 20 25 2000 51 44 2 36 45 78 46 35 275 17 22 2100 53 46 4 32 41 80 48 36 300 15 20 2200 56 48 6 28 37 82 49 37 325 12 18 2300 58 50 8 24 33 84 50 38 350 10 16 2400 59 52 10 20 30 86 51 40 375 8 14 2500 61 54 12 17 26 88 52 41 400 7 12 2600 63 56 14 14 2
4. Retrofit of R 22 Systems to Suva HP62 or Suva 507 6 Pressure Temperature Charts Introduction essen 8 How to Read the Pressure Temperature Charts pp 8 How to Determine Suction Pressure Superheat and Subcool 8 Retrofit Checklist for Suva 134a Suva HP62 or Suva 507 9 System Data Shoot eee cites N vaara aa rn aak a aa vaan mAn N KKKA Uva cda 10 Appendix Table 1 Pressure Temperature Chart Suva 134a R 12 pe 11 Table 2 Pressure Temperature Chart Suva HP62 R 502 suus 12 Table 3 Pressure Temperature Chart Suva 507 R 502 pp 13 Table 4 Pressure Temperature Chart Suva HP62 R 22 Ne 14 Table 5 Pressure Temperature Chart Suva 507 R 22 pe 15 Table 6 Suva 134a Physical Properties pp 16 Table 7 Suva HP62 and Suva 507 Physical Properties pp 16 Table 8 Compositions of Suva Refrigerants pp 16 DuPont Technical Assistance and Other Information back page Introduction With the phaseout of CFCs and HCFCS existing refrigeration and air conditioning equipment operat ing with CFCs and HCFCS will ultimately need to be either replaced with new equipment or retrofitted with alternative refrigerants Some service techni cians and equipment owners have elected to retrofit to hydrofluorocarbon HFC refrigerants such as Suva 134a Suva HP62 or Suva 507
5. Suva HP62 and Suva 507 are compared to R 502 Disch Suct Disch Refrig Suva Press Press Temp Cap y Refrig psi kPa psi kPa F C 96 134a 10 2 10 10 69 8 718 8 75 6 HP62 20 Same 10 Same 4137 9 75 6 507 30 Same 15 Same 4206 8 48 3 Suva HP62 is compared to R 22 evap temp O F 18 C Note Suva 507 provides perfor mance very similar to HP62 Disch Suct Compression Disch Refrig Suva Press Press Ratio Temp Cap Refrig psi kPa psi kPa 96 F C 99 HP62 45 10 5 64 6 310 69 8 36 How to read these tables Example R 12 to Suva 134a retrofit Discharge pressure with 134a will be in the range of 10 psig higher than R 12 using discharge pressure column above Retrofit Summary for HFC Refrigerants Selectthe Retrofit Checklist from the Appen dix for the refrigerant you are replacing 1 Establish baseline performance with CFC HCFC 2 Drain mineral oil or alkylbenzene MO AB from the system and measure the volume removed Leave the CFC HCFC refrigerant in the system 3 Add POE lubricant use the same volume as removed in Step 2 Start up system and operate for at least 24 hours or more if system has complex piping 4 Drain POE and repeat steps 2 and 3 at least two more times Continue flushing until MO AB is less than 5 by weight or as recommended by compressor manufacturer 5 Recover the CFC HCFC charge into a proper recovery cyli
6. is an HFC replacement option for R 502 in new equipment and for retrofitting R 502 systems Suva 507 can also be used over the full R 502 operating range and provides lower compressor discharge temperatures than R 502 which can increase compressor reliability and life Suva 407C R 407C is also an HFC retrofit option for R 502 in certain equipment Refer to ART 34 Retrofit Guidelines for Suva 407C for details R 22 Replacement Choices Suva HP62 R 404A and Suva 507 R 507 are HFC retrofit options for R 22 refrigeration eguip ment especially for medium and low temperature applications These products will provide similar cooling capacity at evaporator temperatures in the range of 30 F to 50 F 1 C to 10 C At evapora tor temperatures below 30 F 1 C the cooling capacity is greater than R 22 At 0 F 18 C the capacity is about 6 higher and at 40 F 40 C the capacity is about 30 higher At evaporator temperatures above 10 F 12 C there is an energy efficiency penalty of about 5 to 1096 At evaporator temperatures below 10 F 12 C Suva HP62 and 507 have similar energy efficiency increasing to about 20 at 40 F 40 C Suva HP62 and 507 will have higher discharge pressure than R 22 but lower compression ratios and also lower discharge temperature Suva 407C R 407C should also be considered as a retrofit option for R 22 in medium tempera ture equipment It will provide similar c
7. Sarugakucho Chiyoda Ku Tokyo 101 0064 Japan 81 3 5281 5805 Asia DuPont Taiwan P O Box 81 777 Taipei Taiwan 886 2 514 4400 DuPont China Limited P O Box TST 98851 1122 New World Office Bldg East Wing Tsim Sha Tsui Kowloon Hong Kong Phone 852 734 5398 Fax 852 236 83516 DuPont Thailand Ltd 9 11 Floor Yada Bldg 56 Silom Road Suriyawongse Bankrak Bangkok 10500 Phone 66 2 238 0026 Fax 66 2 238 4396 DuPont China Ltd Rm 1704 Union Bldg 100 Yenan Rd East Shanghai PR China 200 002 Phone 86 21 328 3738 Telex 33448 DCLSH CN Fax 86 21 320 2304 DuPont Far East Inc 6th Floor Bangunan Samudra No 1 JLN Kontraktor U1 14 SEK UI Hicom Glenmarie Industrial Park 40150 Shah Alam Selangor Malaysia Phone 60 3 517 2534 DuPont Korea Inc 4 5th Floor Asia Tower 726 Yeoksam dong Kangnam ku Seoul 135 082 Korea 82 2 721 5114 DuPont Singapore Pte Ltd 1 Maritime Square 07 01 World Trade Centre Singapore 0409 65 273 2244 DuPont Far East Philippines 8th Floor Solid Bank Bldg 777 Paseo de Roxas Makati Metro Manila Philippines Phone 63 2 818 9911 Fax 63 2 818 9659 DuPont Far East Inc 7A Murray s Gate Road Alwarpet Madras 600 018 India 91 44 454 029 DuPont Far East Inc Pakistan 9 Khayaban E Shaheen Defence Phase 5 Karachi Pakistan 92 21 533 350 DuPont Far East Inc P O Box 2553 Jkt Jakarta 10001 Indonesia 62 21 517 800 Theinformation containedherein
8. e Add the initial charge of Suva refrigerant to the high pressure side of the system compressor not running until the system and cylinder pressures equalize Then connect to the low pressure side of the system start the compressor and load the remainder of the refrigerant slowly to the suction side of the system Start up system adjust charge size Label system for the refrigerant and lubricant used Start the system and let conditions stabilize If the system is undercharged add Suva 134a in small amounts until the system conditions reach the desired level See the Pressure Temperature Charts in this bulletin to compare pressures and temperatures Suva refrigerants are more sensitive to charge size than CFCs System performance will change quickly if the system is overcharged or undercharged Sight glasses in the liquid line can be used in most cases as a guide but system charge should also be determined by measuring system operating conditions discharge and suction pressures suction line temperature compressor motor amps super heat etc Attempting to charge until the sight glass is clear may result in over charging the refrigerant Please read How to Determine Suction Pressure Superheat and Subcool on page 8 Retrofit of R 502 Systems to Suva HP62 or Suva 507 The following detailed discussion is the recom mended procedure for retrofitting R 502 systems to Suva HP62 or Suva 507 1 Establish
9. 0 1 3 24 8 10 100 51 48 600 2 0 26 6 7 105 54 51 650 4 2 28 3 5 110 57 53 700 7 5 30 1 3 115 60 56 750 9 7 32 1 1 120 62 58 800 11 9 34 3 2 125 64 60 850 13 11 36 5 3 130 67 63 900 15 13 38 7 5 135 69 65 950 17 15 40 9 7 140 71 67 1000 19 17 42 11 9 145 73 69 1050 21 19 44 13 11 150 75 71 1100 23 20 46 15 12 175 85 81 1150 25 22 48 16 14 200 95 89 1200 26 24 50 18 16 250 111 104 1250 28 25 52 20 17 300 125 118 1300 29 27 54 1 19 350 137 129 1350 31 28 56 23 20 400 148 140 1400 32 30 inHg vacuum 12 English Units Suva 507 R 502 Saturation Properties Table 3 Pressure Temperature Chart psi 25 20 15 10 R 502 108 507 Pressure Sat Temp Sat Temp i F F 110 R 502 507 Pressure Sat Temp Sat Temp i F F psi 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 105 110 115 120 125 130 135 140 145 150 175 200 250 300 350 400 24 26 27 29 30 32 33 34 36 37 38 40 41 42 43 45 46 47 48 49 50 51 54 57 60 62 64 67 69 71 73 75 85 95 111 125 137 148 19 21 22 24 25 26 28 29 30 32 33 34 35 37 38 39 40 41 42 43 44 46 48 51 53 55 58 60 62 64 66 69 78 87 102 115 127 137 inHg vacuum 13 SI Units R 502 507 Pressure Sat Temp Sat Temp kPa 25 50 75 100 125 150 175 200 225 250 275
10. 0 4 5 375 6 7 400 8 9 450 12 12 500 16 16 550 19 19 600 22 22 650 25 24 700 28 27 750 30 29 800 33 31 900 37 36 1000 42 39 1200 49 46 1400 56 52 1600 62 58 1800 68 63 2000 73 67 2200 78 72 2400 82 76 2600 86 79 2800 90 83 3000 94 86 3200 98 89 3400 101 93 3600 104 95 Table 2 Pressure Temperature Chart Suva HP62 R 502 Saturation Properties English Units SI Units R 502 HP62 R 502 HP62 R 502 HP62 R 502 HP62 Pressure Sat Temp Sat Temp Pressure Sat Temp Sat Temp Pressure Sat Temp Sat Temp Pressure Sat Temp Sat Temp psi oF oF psi oF oF kPa C CT kPa C 25 108 107 58 24 22 25 72 71 1450 34 31 20 88 87 60 26 23 50 60 59 1500 35 32 15 75 75 62 27 25 75 52 52 1550 37 34 10 65 65 64 29 26 100 46 46 1600 38 35 5t 56 57 66 30 28 125 41 41 1650 39 36 4 55 56 68 32 29 150 37 37 1700 4 37 3 54 54 70 33 30 175 33 34 1750 42 38 2 53 53 72 34 32 200 30 30 1800 43 40 1 52 52 74 36 33 225 27 28 1900 46 42 0 50 50 76 37 34 250 24 25 2000 48 44 2 45 45 78 38 35 275 22 22 2100 50 46 4 40 41 80 40 36 300 19 20 2200 52 48 6 36 37 82 41 37 325 17 18 2300 54 50 8 32 33 84 42 38 350 15 16 2400 56 52 10 29 30 86 43 40 375 13 14 2500 58 54 12 25 26 88 45 4 400 11 12 2600 60 56 14 22 23 90 46 43 425 9 10 2700 62 57 16 19 20 92 47 44 450 8 9 2800 64 59 18 16 18 94 48 45 475 6 7 2900 65 61 20 13 15 96 49 46 500 4 6 22 11 12 98 50 47 55
11. 2 or R 502 systems with other alter native refrigerants such as HCFC 22 may require more extensive modifications to the existing equip ment such as replacement of the compressor with multistage compressors or use of liquid injection For some systems this additional cost may be large Suva refrigerants provide the service contractor and equipment owner with a cost effective way to retrofit an existing system Note Suva refrigerants were not designed for use in conjunction with other refrigerants or additives that have not been clearly specified by DuPont or the equipment manufacturer Mixing Suva refriger ants with other refrigerants may have an adverse effect on system performance Topping off a different refrigerant with any Suva refrigerant is notrecommended Refrigerant Recovery Information Most recovery or recycle eguipment used for R 12 R 502 or R 22 can be used for Suva refrigerants Use standard procedures to avoid cross contamina tion when switching from one refrigerant to another Consult the equipment manufacturer for specific recommendations In the United States DuPont will take back for reclaim the Suva refrigerants discussed in this bulletin What to Expect Following a Retrofit These tables show approximate system performance changes following a retrofit These values are gen eral guidelines for system behavior and actual per formance will vary with each system Suva 134a is compared to R 12
12. 3 90 54 43 425 5 10 2700 65 57 16 11 20 92 55 44 450 3 9 2800 67 59 18 8 18 94 56 45 475 1 7 2900 68 61 20 5 15 96 57 46 500 0 6 22 2 12 98 58 47 550 3 3 24 0 10 100 59 48 600 6 0 26 2 7 105 62 51 650 8 2 28 5 5 110 64 53 700 11 5 30 7 3 120 69 58 750 13 7 32 9 1 125 72 60 800 15 9 34 11 2 130 74 63 850 18 11 36 13 3 135 76 65 900 20 13 38 15 5 140 78 67 950 22 15 40 17 7 145 81 69 1000 23 17 42 19 9 150 83 71 1050 25 19 44 21 11 175 93 81 1100 27 20 46 23 12 200 101 89 1150 29 22 48 24 14 250 117 104 1200 30 24 50 26 16 300 131 118 1250 32 25 52 28 17 350 143 129 1300 33 27 54 29 19 400 154 140 1350 35 28 56 31 20 1400 36 30 inHg vacuum English Units Suvae 507 R 22 Saturation Properties Table 5 Pressure Temperature Chart psi 25 20 15 10 R 22 100 31 507 Pressure Sat Temp Sat Temp i F F 110 R 22 507 Pressure Sat Temp Sat Temp i F F psi 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 105 110 120 125 130 135 140 145 150 175 200 250 300 350 400 32 34 35 37 38 40 41 42 44 45 46 48 49 50 51 52 54 55 56 57 58 59 62 64 69 72 74 76 78 81 83 93 101 117 131 143 154 19 21 22 24 25 26 28 29 30 32 33 34 35 37 38 39 40 41 42 43 44 46 48 51 55 58 60 62 64 66 69 78 87 102 115 127 137 inHg vacuu
13. 34a R 134a Suva HP62 Suva 507 Unit R 404A R 507 R 502 F 51 6 52 1 49 8 C 46 5 46 7 45 4 psia 182 187 168 kPa 1 255 1 287 1 162 lb ft3 65 45 65 5 75 9 kg m 1 048 1 049 1 217 Ip ft 4 0 4 3 4 2 kg m 64 1 68 9 67 3 R 12 1 0 0 0 23 CO 1 3260 3300 5494 Table 8 Compositions of Suva Refrigerants HFC 125 HFC 143a 44 52 50 50 16 R 12 21 6 29 8 94 51 651 6 81 84 1 311 2 32 37 2 8500 R 22 41 4 40 8 151 1 041 74 5 1193 2 8 44 9 1700 HFC 134a 4 100 For Further Information DuPont Fluorochemicals Wilmington DE 19880 0711 800 235 SUVA www suva dupont com Europe DuPont de Nemours International S A 2 Chemin du Pavillon P O Box 50 CH 1218 Le Grand Saconnex Geneva Switzerland 41 22 717 5111 Canada DuPont Canada Inc P O Box 2200 Streetsville Mississauga Ontario Canada L5M 2H3 905 821 3300 Mexico DuPont S A de C V Homero 206 Col Chapultepec Morales C P 11570 Mexico D F 52 5 722 1100 South America DuPont do Brasil S A Alameda Itapecuru 506 Alphaville 06454 080 Barueri S o Paulo Brazil 55 11 7266 8263 DuPont Argentina S A Casilla Correo 1888 Correo Central 1000 Buenos Aires Argentina 54 1 311 8167 Pacific DuPont Australia P O Box 930 North Sydney NSW 2060 Australia 61 2 99236111 Japan Mitsui DuPont Fluorochemicals Co Ltd Chiyoda Honsha Bldg 5 18 1 Chome
14. Safety Bulletin AS 1 gives additional infor mation for safe handling of refrigerants Lubricant and Filter Drier Information Lubricants Lubricant selection is based on many factors in cluding compressor wear characteristics material compatibility and lubricant refrigerant miscibility that can affect oil return to the compressor Before starting a retrofit consult the compressor manufac turer to determine the correct lubricant for your compressor Other information sources are DuPont Refrigerant Distributors lubricant manufacturers and system manufacturers Polyol ester POE lubricants must be used with Suva 134a Suva HP62 or Suva 507 refriger ants These lubricants are available from DuPont Refrigerant Distributors To provide optimum oil return equipment using mineral oil or alkylbenzene must be flushed to remove at least 95 of these oils See the retrofit procedures below for more information Special care should be taken when handling POE lubricants because of their tendency to absorb wa ter Minimize contact with air and store the lubri cant in a sealed container Filter Drier Change the filter drier during the retrofit This is a routine practice following system maintenance There are two types of filter driers commonly used solid core and packed bead Replace the drier with the same type you currently use The drier label will show which refrigerants can be used with that drier Check with your DuPon
15. Technical Information ART 37 DuPont Suva refrigerants Retrofit Guidelines for Suva HFC Refrigerants Suva 134a for R 12 Retrofit Suva HP62 and Suva 507 for R 502 Retrofit Suva HP62 and Suva 507 for R 22 Retrofit The miracles of science The DuPont Oval Logo DuPont The miracles of science and Suva are trademarks or registered trademarks of Pont de Nemours and Company Retrofit Guidelines for Suva HFC Refrigerants Table of Contents Page lici Re S 1 R 12 Replacement Choices RN 1 R 502 Replacement Choices RN 1 R 22 Replacement Choices RN 1 Using HFCs versus Service Refrigerants Re 1 Important Safety Information sssssssssssseseeeeeeenn enne 2 Lubricant and Filter Drier Information seeeeeeeRI 2 LUbEICants oreet satuadenaceh eaa a a a sagitdand ses RAN ed pex Eau bern uS Ens eR NERA tease 2 ITER DIEN UMPPUE MEORUM INE MEI TEN DR EE 2 General Retrofit Information sess eene nnns 2 System ModifiGations i riot aan irren n nouae eS Kanaa Fan E RR Fe Ta Ra EE BR XAR ERR sana Na 2 Refrigerant Recovery Information pe 3 What to Expect Following a Retrofit ss 3 Retrofit Summary for HFC Refrigerants pp 4 Retrofit of R 12 Systems to Suva 134a 1 eee 4 Retrofit of R 502 Systems to Suva HP62 or Suva 507 5
16. baseline performance with CFC Collect system performance data while the R 502 is in the system Check for correct refrigerant charge and operating conditions The baseline data of temperatures and pressures at various points in the system evaporator condenser compressor suction and discharge superheat and subcool etc at normal operating conditions will be useful when optimizing operation of the system with the Suva refriger ant A System Data Sheet is included at the back of this document to record baseline data Drain mineral oil or alkylbenzene from the system and measure the volume removed Leave the CFC refrigerant in the system If mineral oil or alkylbenzene is the existing lubricant it will have to be drained This may reguire removing the compressor from the system particularly with small hermetic com pressors that have no oil drain port In this case the lubricant should be drained from the suction port on the compressor after the R 502 has been properly recovered For an effective flush it is important to remove at least 50 of the lubri cant in all cases Larger systems may reguire drainage from additional points in the system particularly low spots around the evaporator In systems with an oil separator any lubricant present in the separator should also be drained In all cases measure the volume of lubricant removed from the system Record this informa tion on the Retrofit Checklist see Appendix Compare
17. e T F C Discharge P psi kPa bar Box CaseT F C pO Evaporator Refrigerant Inlet T F C Refrigerant Outlet T F C Coil Air HO In T F C Coil Air H2O Out T F C Refrigerant T at Superheat Ctl Pt F C Condenser Refrigerant Inlet T F C Refrigerant Outlet T F C Coil Air H5O In T F C Coil Air H O Out T F C Motor Amps Exp Device Inlet T F C Run Cycle Time Ef 10 Appendix Table 1 Pressure Temperature Chart Suva 134a R 12 Saturation Properties English Units R 12 HFC 134a Saturation Saturation Pressure psi Temperature F Temperature F 15 49 40 10 38 30 5 29 22 0 22 15 5 9 3 10 2 7 15 10 15 20 18 22 25 26 29 30 32 35 35 38 40 40 43 45 45 48 50 50 53 54 55 58 58 60 62 62 65 66 66 70 70 69 75 74 73 80 77 76 85 81 79 90 84 82 95 87 85 100 90 88 110 96 93 120 102 98 130 107 103 140 112 107 150 117 112 165 123 118 180 130 123 195 136 129 210 141 134 225 147 139 240 152 143 255 157 148 270 162 152 285 166 156 300 170 160 inHg vacuum 11 SI Units R 12 HFC 134a Saturation Saturation Pressure kPa Temperature C Temperature C 25 59 53 50 45 40 75 37 32 100 30 26 125 24 21 150 20 17 175 16 13 200 12 10 225 9 7 250 6 4 275 4 2 300 1 325 2 3 35
18. ect to the low pressure side of the system start the compressor and load the remainder of the refrigerant slowly to the suction side of the system You should be removing liquid from the charging cylinder and therefore should charge slowly to allow the refrigerant to flash vaporize before entering the compressor suction and avoid compressor damage Start up system adjust charge size Label system for the refrigerant and lubricant used Start the system and let conditions stabilize If the system is undercharged add Suva HP62 or Suva 507 in small amounts still removing liquid from the charging cylinder until the system conditions reach the desired level See the Pressure Temperature Charts in this bulletin to compare pressures and temperatures for the Suva refrigerant you are using Suva refrigerants are more sensitive to charge size than CFCs System performance will change quickly if the system is overcharged or undercharged Sight glasses in the liquid line can be used in most cases as a guide but system charge should also be determined by measuring system operating conditions discharge and suction pressures suction line temperature compressor motor amps super heat etc Attempting to charge until the sight glass is clear may result in over charging the refrigerant Please read How to Determine Suction Pressure Superheat and Subcool on page 8 Retrofit of R 22 Systems to Suva HP62 or Suva 507 The fo
19. ermine Suction Pressure Super heat and Subcool below Helpful Hints For Retrofit From R 22 To Suva HP62 or 507 Both Suva HP62 and 507 have minimal tempera ture glide and can be used in systems that have flooded evaporators and condensers as well as those that have direct expansion evaporators Since HP62 and 507 have higher cooling capacity than R 22 at lower evaporator temperatures the expansion device may need to be adjusted or re placed to maintain proper flow control and super heat settings Estimated capacity comparison Evaporator Temperature Capacity 30 to 50 F 1 to 10 C Same O F 18 C 6 40 F 40 C 30 Verify that compressor suction and discharge piping is the proper size to maintain proper refrigerant velocity and pressure drop Compressor discharge temperature will be lower than R 22 The compressor discharge pressure will be higher with HP62 and 507 Various pressure switches may need to be adjusted to maintain proper operating conditions for example Evaporator pressure regulators Cut in and cut out pressure switches Condenser fan cycling pressure switches Head pressure controls Crankcase pressure regulators Others Due to the higher oil miscibility with HFCs and POE verify proper compressor oil sump levels Check with the compressor manufacturer for proper amperage load ratings Pressure Temperature Charts Introduction How to Read the Pressure Tempe
20. he suction port on the compressor after the R 12 has been properly recovered For an effective flush it is important to remove at least 50 of the lubri cant in all cases Larger systems may require drainage from additional points in the system particularly low spots around the evaporator In systems with an oil separator any lubricant present in the separator should also be drained In all cases measure the volume of lubricant removed from the system Record this informa tion on the Retrofit Checklist see Appendix Compare this volume with the compressor system specifications to ensure that the majority of lubricant has been removed Consult the compressor manufacturer for recommendations on allowable residual MO AB in POE lubricant If poor system performance is noted on start up an additional lubricant change may be required Add POE lubricant use the same volume as removed in Step 2 Start up system and operate for at least 24 hours or more if system has complex piping Charge the com pressor with the same volume of new lubricant as the amount you removed from the system in step 2 Use a lubricant viscosity and grade recommended by the compressor manufacturer for the Suva refrigerant you are using or use a similar viscosity to the oil you removed if compressor information is not available A typical viscosity is 150 SUS or ISO 32 for many compressors Drain POE and repeat steps 2 and 3 at least two more times Cont
21. he volume of lubricant removed from the system Record this informa tion on the Retrofit Checklist see Appendix Compare this volume with the compressor system specifications to ensure that the majority of lubricant has been removed Consult the compressor manufacturer for recommendations on allowable residual MO AB in POE lubricant If poor system performance is noted on start up an additional lubricant change may be required Add POE lubricant use the same volume as removed in Step 2 Start up system and operate for at least 24 hours or more if system has complex piping Charge the com pressor with the same volume of new lubricant as the amount you removed from the system in step 2 Use a lubricant viscosity and grade recommended by the compressor manufacturer for the Suva refrigerant you are using or use a similar viscosity to the MO AB you removed if compressor information is not available A typical viscosity is 150 SUS or ISO 32 for many compressors Drain POE and repeat steps 2 and 3 at least two more times Continue flushing until MO AB is less than 5 by weight or as recommended by compressor manufacturer For an HFC refrigerant to operate properly in a retrofitted system the residual MO AB concen tration must be very low Repeatedly removing and replacing the POE will flush the old oil from the refrigeration system providing that enough time is allowed with each change to circulate oil through the entire sys
22. inue flushing until MO AB is less than 5 by weight or as recom mended by compressor manufacturer For an HFC refrigerant to operate properly in a retrofitted system the residual MO AB concen tration must be very low Repeatedly removing and replacing the POE will flush the old oil from the refrigeration system providing that enough time is allowed with each change to circulate oil through the entire system Recover the CFC charge into a proper recovery cylinder Use normal service prac tices If the correct charge size is not known weigh the amount of refrigerant recovered Replace the filter drier It is routine practice to replace the filter drier following system mainte nance Replacement driers are available that are compatible with Suva refrigerants See page 2 of this manual for additional information on driers Evacuate system and check for leaks To remove air or other noncondensables in the system evacuate the system to near full vacuum 29 9 inHg vacuum 500 microns or less than 10 kPa Charge with Suva refrigerant In general the refrigeration system will require less weight of the Suva 134a than of R 12 The optimum charge will vary depending on the system design and operating conditions For most systems the best charge size will be 75 90 by weight of the original R 12 charge For best results Itisrecommended that the system be initially charged with about 75 by weight of the original charge
23. is based on technical data and tests which we believe tobereliable andisintended for use by persons having technical skill at their own discretion and risk Because conditions of use are outside of DuPont control we can assume no liability for results obtained or damages incurred through the application of the data presented 5 02 300229B Printed in U S A Replaces H 75326 2 Reorder No H 75326 3 The miracles of science
24. llowing detailed discussion is the recom mended procedure for retrofitting R 22 systems to Suva HP62 or Suva 507 1 Establish baseline performance with R 22 Collect system performance data while the R 22 is in the system Check for correct refrigerant charge and operating conditions The baseline data of temperatures and pressures at various points in the system evaporator condenser compressor suction and discharge superheat and subcool etc at normal operating condi tions will be useful when optimizing operation of the system with the Suva refrigerant A System Data Sheet is included at the back of this document to record baseline data Drain mineral oil or alkylbenzene from the system and measure the volume removed Leave the R 22 in the system If mineral oil or alkylbenzene is the existing lubricant it will have to be drained This may require removing the compressor from the system particularly with small hermetic compressors that have no oil drain port In this case the lubricant should be drained from the suction port on the com pressor after the R 22 has been properly recovered For an effective flush it is important to remove at least 50 of the lubricant in all cases Larger systems may require drainage from additional points in the system particu larly low spots around the evaporator In systems with an oil separator any lubricant present in the separator should also be drained In all cases measure t
25. m 15 SI Units R 22 507 Pressure Sat Temp Sat Temp kPa 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 550 600 650 700 750 800 850 900 950 15 12 R 22 507 Pressure Sat Temp Sat Temp kPa 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 16 17 19 21 22 24 25 27 28 30 31 32 34 35 36 37 38 41 43 45 47 49 51 53 54 56 58 59 Physical Property Boiling Point at 1 atm Vapor Pressure Sat d Liquid at 77 F 25 C Liquid Density at 77 F 25 C Density Sat d Vapor at 77 F 25 C Ozone Depletion Potential Compared with CFC 12 Global Warming Potential Compared with CO Table 6 Suva 134a R 134a Physical Properties Unit Suva 134a R 134a F 14 9 C 26 1 psia 96 61 kPa 666 1 Ip ft 75 28 kg m 1 206 Ib ft 2 02 kg m 32 4 CFC 12 1 0 CO 1 1300 Table 7 Suva HP62 R 404A and Suva 507 R 507 Physical Properties Physical Property Boiling Point at 1 atm Vapor Pressure Sat d Liquid at 77 F 25 C Liquid Density at 77 F 25 C Density Sat d Vapor at 77 F 25 C Ozone Depletion Potential Compared with R 12 Global Warming Potential Compared with CO Compositions wt Suva HP62 R 404A Suva 507 R 507 Suva 1
26. m the actual saturated vapor tempera ture the amount of liquid subcool is always calcu lated from the actual saturated liquid temperature Retrofit Checklist for Suva 134a Suva HP62 or Suva 507 1 Establish baseline performance with R 12 R 502 or R 22 See data sheet for recommended data 2 Consult the original equipment manufacturer of the system components for recommendations on the following Plastics compatibility Elastomers compatibility Lubricant viscosity manufacturer Retrofit procedure to sustain warranty 3 Drain lubricant charge from the refrigerant system unless polyol ester lubricant is already in the system Remove majority of lubricant from system Measure amount of lubricant removed and record 4 Charge polyol ester lubricant using amount equivalent to amount of mineral oil removed Run system with R 12 R 502 or R 22 for 24 hours minimum 5 Repeat lubricant drain and POE charging two more times or until mineral oil content is less than 596 6 Remove R 12 R 502 or R 22 charge from system Need 10 20 inHg vacuum 34 67 kPa 7 Replace filter drier with new drier approved for use with Suva 134a Suva HP62 or Suva 507 8 Reconnect system and evacuate with vacuum pump Evacuate to full vacuum 29 9 inHg vacuum 0 14 kPa 9 Leak check system Reevacuate system following leak check 10 Charge system with Suva Initially charge 75 by weight of
27. nder Replace the filter drier Evacuate system and check for leaks Charge with Suva refrigerant Remove liquid only from charging cylinder for Suva HP62 or Suva 507 Typical charge is 75 90 by weight of CFC HCFC charge 9 Start up system adjust charge size Label system for the refrigerant and lubricant used Retrofit Complete Retrofit of R 12 Systems to Suva 134a The following detailed discussion is the recom mended procedure for retrofitting R 12 systems to Suva 134a Establish baseline performance with CFC Collect system performance data while the R 12 is in the system Check for correct refrig erant charge and operating conditions The baseline data of temperatures and pressures at various points in the system evaporator condenser compressor suction and discharge superheat and subcool etc at normal operating conditions will be useful when optimizing operation of the system with the Suva refriger ant A System Data Sheet is included at the back of this document to record baseline data Drain mineral oil or alkylbenzene from the system and measure the volume removed Leave the CFC refrigerant in the system If mineral oil or alkylbenzene is the existing lubricant it will have to be drained This may require removing the compressor from the system particularly with small hermetic com pressors that have no oil drain port In this case the lubricant should be drained from t
28. nown weigh the amount of refrigerant recovered Replace the filter drier It is routine practice to replace the filter drier following system mainte nance Replacement driers are available that are compatible with Suva refrigerants See page 2 of this manual for additional information on driers Evacuate system and check for leaks To remove air or other noncondensables in the system evacuate the system to near full vacuum 29 9 inHg vacuum 500 microns or less than 10 kPa Charge with Suva refrigerant Remove liquid only from charging cylinder The proper cylinder position for liquid removal is indicated by arrows on the cylinder and cylinder box Once liquid is removed from the cylinder the refrigerant can be charged to the system as liquid or vapor as desired Use the manifold gauges or a throttling valve to flash the liquid to vapor if required In general the refrigeration system will require less weight of the Suva refrigerant than of R 502 The optimum charge will vary depend ing on the system design and operating condi tions but for most systems the best charge size will be 75 90 by weight of the original charge For best results e Itisrecommended that the system be initially charged with about 75 by weight of the original charge e Add the initial charge of Suva refrigerant to the high pressure side of the system com pressor not running until the system and cylinder pressures equalize Then conn
29. o the high pressure side of the system com pressor not running until the system and cylinder pressures equalize Then connect to the low pressure side of the system start the compressor and load the remainder of the refrigerant slowly to the suction side of the system You should be removing liquid from the charging cylinder and therefore should charge slowly to allow the refrigerant to flash vaporize before entering the compressor suction and avoid compressor damage 9 Startup system adjust charge size Label system for the refrigerant and lubricant used Start the system and let conditions stabilize If the system is undercharged add Suva HP62 or Suva 507 in small amounts still removing liquid from the charging cylinder until the system conditions reach the desired level See the Pressure Temperature Charts in this bulletin to compare pressures and temperatures for the Suva refrigerant you are using Suva refrigerants are more sensitive to charge size than R 22 System performance will change quickly if the system is overcharged or under charged Sight glasses in the liquid line can be used in most cases as a guide but system charge should also be determined by measuring system operating conditions discharge and suction pressures suction line temperature compressor motor amps superheat etc Attempting to charge until the sight glass is clear may result in overcharging the refrigerant Please read How to Det
30. ooling capacity and energy efficiency at evaporator temperatures above 25 F 4 C Refer to ART 34 Retrofit Guidelines for Suva 407C for details Using HFCs versus Service Refrigerants Refrigerants such as Suva MP39 Suva 409A Suva HP80 and Suva 408A are often selected for retrofit instead of HFCs because these service refrigerants typically involve an easier and more cost effective retrofit procedure while providing improved performance over the CFCs they replace The compressor oil change procedures are typically less complicated with the service refrigerants which results in lower retrofit costs Refer to DuPont bul letin ART 36 Retrofit Guidelines for Suva Ser vice Refrigerants for full details Important Safety Information Like CFCs Suva refrigerants are safe when handled properly However any refrigerant can cause injury or even death when mishandled Please review the following guidelines before using any refrigerant Do not work in high concentrations of refriger ant vapors Always maintain adequate ventilation in the work area Do not breathe vapors Do not breathe lubricant mists from leaking systems Ventilate the area well after any leak before attempting to repair equipment Do not use handheld leak detectors to check for breathable air These detectors are not designed to determine if the air is safe to breathe Use oxygen monitors to ensure adequate oxygen is available to sustain life
31. original eguipment manufacturer R 12 R 502 or R 22 charge Amount of refrigerant charged 11 Start equipment and adjust charge until desired operating conditions are achieved If low in charge add in increments of 2 396 of original R 12 R 502 or R 22 charge Amount of refrigerant charged e Total refrigerant charged 12 Label components and system for type of refrigerant Suva 134a Suva HP62 or Suva 507 and lubricant polyol ester Retrofit is complete Type of System Location System Data Sheet Equipment Mfg Compressor Mfg Model No Model No Serial No Serial No Original Charge Size Original Lubricant Drier Mfg Type Mfg LubricantCharge Size New Lubricant Type Mfg 1stCharge Size 2nd Charge Size Additional Charge Size Drier Type check one Model No Loose Fill Solid Core Condenser Cooling Medium air water Expansion Device check one If Expansion Valve Manufacturer Capillary Tube Expansion Valve Model No Control Set Point Location of Sensor Other System Controls ex head press control Describe circle units used where applicable Date Time Refrigerant Ambient Temp F C Relative Humidity Compressor Charge Size Ib oz g Suction T F C Suction P psi kPa bar Discharg
32. rature Charts Tables 1 through 5 contain pressure temperature charts for the refrigerants discussed in this bulletin R 12 R 22 and Suva 134a are all single compo nent refrigerants with no temperature glide in the evaporator or condenser Suva HP62 and 507 have very small glide less than 1F 0 6C For field service purposes this glide can be neglected in calculating superheat and subcool The evaporator temperature can be considered equal to the saturated vapor temperature at the compressor suction pres sure the condenser temperature can be considered equal to the saturated vapor temperature or the satu rated liquid temperature at the compressor discharge pressure For Suva HP62 and 507 the saturated vapor temperatures are listed in the tables How to Determine Suction Pressure Superheat and Subcool Suction Pressure Determine the expected evaporator temperature using the R 12 R 502 or R 22 column from the baseline data you collected prior to the retrofit Find the same expected evaporator temperature in the column for Suva 134a HP62 or 507 Note the corresponding pressure for this temperature This is the suction pressure at which the system should operate Superheat and Subcool Using the temperature column for Suva 134a HP62 and 507 the amount of superheat and subcool is calculated in the same manner as for the CFC or HCFC refrigerant Note The amount of vapor superheat is always calculated fro
33. t Refrigerant Distributor for the correct drier to use in your system General Retrofit Information System Modifications The compositions of these Suva refrigerants have been selected to provide performance comparable with the refrigerants they are replacing in terms of both capacity and energy efficiency As a result minimal system modifications are anticipated with retrofitting Suva HP62 and Suva 507 are near azeotropes at most temperatures therefore the vapor composition in the refrigerant cylinder is slightly different from the liquid composition This small difference will not affect performance in direct expansion systems but it could affect per formance in systems with flooded evaporators You should consult the original equipment manufac turer for recommendations concerning the compat ibility of elastomers and plastics used in their system and the new refrigerant Although many system components used with CFCs are also compatible with Suva refrigerants there are exceptions that if not replaced can cause refrigerant leakage or sys tem failure Field experience has shown that some systems retrofitted directly from R 502 to Suva HP62 or Suva 507 can have increased leakage due to shrinkage of elastomers o rings gaskets follow ing removal of the R 502 This same situation might exist in an R 22 retrofit Replacement of these elastomers may add additional cost and time to the retrofit Retrofits of R 1
34. tem Recover the R 22 charge into a proper recovery cylinder Use normal service prac tices If the correct charge size is not known weigh the amount of refrigerant recovered Replace the filter drier It is routine practice to replace the filter drier following system mainte nance Replacement driers are available that are compatible with Suva refrigerants See page 2 of this manual for additional information on driers Evacuate system and check for leaks To remove air or other noncondensables in the system evacuate the system to near full vacuum 29 9 inHg vacuum 500 microns or less than 10 kPa Charge with Suva refrigerant Remove liquid only from charging cylinder The proper cylinder position for liquid removal is indicated by arrows on the cylinder and cylinder box Once liquid is removed from the cylinder the refrigerant can be charged to the system as liquid or vapor as desired Use the manifold gauges or a throttling valve to flash the liquid to vapor if required In general the refrigeration system will require less weight of the Suva refrigerant than of R 22 The optimum charge will vary depending on the system design and operating conditions but for most systems the best charge size will be 75 90 by weight of the original charge For best results Itisrecommended that the system be initially charged with about 75 by weight of the original charge Add the initial charge of Suva refrigerant t
35. this volume with the compressor system specifications to ensure that the majority of lubricant has been removed Consult the compressor manufacturer for recommendations on allowable residual MO AB in POE lubricant If poor system performance is noted on start up an additional lubricant change may be reguired Add POE lubricant use the same volume as removed in Step 2 Start up system and operate for at least 24 hours or more if system has complex piping Charge the com pressor with the same volume of new lubricant as the amount you removed from the system in step 2 Use a lubricant viscosity and grade recommended by the compressor manufacturer for the Suva refrigerant you are using or use a similar viscosity to the MO AB you removed if compressor information is not available A typical viscosity is 150 SUS or ISO 32 for many compressors Drain POE and repeat steps 2 and 3 at least two more times Continue flushing until MO AB is less than 5 by weight or as recommended by compressor manufacturer For an HFC refrigerant to operate properly in a retrofitted system the residual MO AB concen tration must be very low Repeatedly removing and replacing the POE will flush the old oil from the refrigeration system providing that enough time is allowed with each change to circulate oil through the entire system Recover the CFC charge into a proper recovery cylinder Use normal service prac tices If the correct charge size is not k
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