Download R-416a Installation Guide-1
Transcript
Airgas Refrigerants, Inc. 38-18 33rd Street Long Island City, NY 11101 (718) 392-8002 Tel (718) 392-8006 Fax (800) 473-3766 Toll Free Please fax completed form to Airgas Guide at (718) 392-8006 or mail to Airgas Refrigerants, Inc., 38-18 33 R-416A Installation rd Street, Long Island City, NY 11101. The information provided herein will be kept in strict confidence, and will be utilized only for the purpose of obtaining credit in accordance with our terms of sale. Installation Guide for Aspen R-416A Refrigerant in Stationary Air Conditioning The Lower Pressure Solution to Replace R-12 and Refrigeration Systems Credit Application Caution: Refrigerant conversions should only be performed by a trained and certified technician. Company ________________________Street Address:________________________________ Converting a working refrigeration system from R-12 to ASPEN R-416A refrigerant is simple. For City/State/Zip:_________________________________________________________________ optimum system performance and durability, you will only have to perform the following basic adaptation process: Tel.#:____________________________________ Fax#:___________________________________ Years in business:____________ Net Worth:______________ Credit Line Req:_________________ 1. Recover all R-12 from the system. 2. Evaluate system oil return conditions. See procedure step No. 3 for details. Type of business: 3. Evacuate the system to 29” of vacuum. Corporation Partnership Individual/Sole Proprietor Other 4. Charge it with liquid, not vaporR-416A. 5. Leak check and performance test the system. Fed. I.D.#:_______________ Resale or Exemption #:_________________ DUNS #______________ 6. Install an R-416A label on the system indicating the charge quantity and oil type. Primary products or services sold:___________________________________ Airgas Refrigerants, Inc. strongly recommends that you consult the appropriate system or compressor service manual for the oil viscosity, the proper settings for system controls and safeties, and review Names of Principals or Officers Home Address this R-416A refrigerant Adaptation Procedure before proceeding to retrofit your stationary equipment. ASPEN R-416A refrigerant is particularly well suited _____________________________________________ for medium temperature refrigeration and air _______________________________ conditioning applications with air cooled condensers. _______________________________ _____________________________________________ Note: that R-416A will enter into a vacuum at approximately -9°F, so air can leak through the compressor shaft seals of open drive compressors when evaporator temperatures fall below this Give us one bank three trade orreferences… (with similar credit lines) temperature. However, thisreference should not be and a concern in hermetic semi-hermetic (sealed) compressor systems. Bank Name:___________________________ Street Address:___________________________ Experimental data, bench tests, computer simulations and two years of field tests demonstrate that City/State/Zip: _________________________ Tel #:___________________________________ ASPEN R-416A refrigerant can be used successfully in stationary refrigeration and air conditioning applications. In many performance parameters, such as leak tolerance, compressor power, discharge Account # ____________________________ Fax #: __________________________________ pressure and temperature, oil circulation and environmental criteria, R-416A exhibits properties that are superior to other alternative R-12 replacement blends. Trade or Business References – Address & Tel.# Name:_____________________________ Preparation City/State/Zip: _______________________ Street address: ______________________________________ Tel #_____________________ Fax # ____________________ 1. Verify that the refrigeration system operating normally with the______________________________________ existing R-12 refrigerant. If the system Name:_____________________________ Street address: is not operating properly with R-12, replacing the R-12 with R-416A will not improve the system City/State/Zip: _______________________ Tel #_____________________ Fax # ____________________ performance. Name:_____________________________ Street address: ______________________________________ 2. A ttach manifold gauges and record the suction and discharge pressures, ambient City/State/Zip: _______________________ Tel #_____________________ Fax #temperature ____________________ and box or evaporator temperature(s) when the system is stable (after approximately 10-15 minutes I hereby authorize the above named bank and references to release financial information to Airgas Refrigerants, Inc., for the purposes of operation). These will be the “baseline” performance and operating parameters. establishing an account with them. ________________________________ _______________________ ___________________ 3. Leak check all service caps and joints. Make all necessary repairs. Signature Title Date 4. If any components such as the receiver/filter drier, condenser etc. are to be replaced, the mineral 1 of 4 Airgas Refrigerants, Inc. 38-18 33rd Street Long Island City, NY 11101 oil should be drained and replaced with the same amount of polyol ester (POE) synthetic oil. The POE (718) 392-8002 Tel synthetic oil should be of the same viscosity as that recommended for the mineral oil in the(718) service 392-8006 Fax manual. Once all repairs are made, the system is ready for adaptation to ASPEN R-416A refrigerant. (800) 473-3766 Toll Free 5. Assemble all the refrigerant, POE oil and equipment needed for the R-416A refrigerant installation. Please fax completed form to Airgas at (718) 392-8006 or mail to Airgas Refrigerants, Inc., 38-18 33rd Street, Long Island City, NY 11101. The information provided herein will be kept in strict confidence, and will be utilized only for the purpose of obtaining credit in accordance Procedure with our terms of sale. 1. Remove all R-12 from the system using an approved recovery/recycling system. The recovery/recycling Credit Application machine should be restarted several times to make sure all of the R-12 is removed. Note the amount of refrigerant recovered. If a system refrigerant charge amount is not found on the refrigeration unit or in the service manual, then use the recovered amount as the recommended charge level, assuming that the Company ________________________Street Address:________________________________ system is operating properly. City/State/Zip:_________________________________________________________________ 2. Note the type of Thermal Expansion Valve (TXV or TEV) inFax#:___________________________________ the system. If it must be removed for Tel.#:____________________________________ adjustment we suggest that this be done after the R-12 is recovered, and that the TXV superheat Years in business:____________ Net Worth:______________ Credit Req:_________________ adjustment be turned clockwise approximately 1 turn. In our experience, this Line usually results in the correct superheat setting (similar to R-12). See page 4 for more details. Type of business: Corporation Partnership Individual/Sole Proprietor 3. Under normal operating conditions no oil change is necessary when converting to R-416A. Fed. I.D.#:_______________ Other Resale or Exemption #:_________________ DUNS #______________ 4. Identify system operating conditions prior to conversion. If the system has a history of, or exhibits unfavorable oil return characteristics due to line lengths greater than 25 feet or evaporator temperatures Primary products or services sold:___________________________________ less than 15° F, we recommend changing from mineral oil to alkyl benzene (AB) or polyol ester (POE). Names of Principals or Officers Home Address 5. If the system has a semi-hermetic compressor, remove oil from compressor and add an equal amount of AB or POE. _______________________________ _____________________________________________ _______________________________ _____________________________________________ 6. If it is a hermetic compressor, simply add some AB or POE to the system. Add 1 oz. of AB or POE per 8 oz. system oil. Example: Up to 8 oz. system oil, add 1 oz. AB or POE; 9 oz. to 16 oz. system oil, add 2 oz. AB or POE; etc. Give us one bank reference and three trade references…(with similar credit lines) 7. A ny residual mineral oil in the system will not have any negative effects on performance; the system doesName:___________________________ not need to be flushed. The viscosity of the AB orStreet POE oil should be the same as the mineral oil Bank Address:___________________________ or the alkylbenzene oil recommended by the manufacturer in the service manual. See the table below City/State/Zip: _________________________ Telor#:___________________________________ for comparison of alkylbenzene oils, mineral oils and AB POE viscosity. If the oil removed from the system is dirty or contaminated, a second oil change is strongly advised. We recommend an oil change Account # ____________________________ Fax #: __________________________________ after one year of use for large non-hermetic systems, unless an oil analysis indicates otherwise. Trade or BusinessOils References – Address & Tel.# Recommended Name:_____________________________ Street address: ______________________________________ Alkylbenzene Mineral POE City/State/Zip: _______________________ Tel #_____________________ Fax # ____________________ Oil Type Oil Type Viscosity (ISO) Name:_____________________________ Street address: ______________________________________ 300 3GS 32 City/State/Zip: _______________________ Tel #_____________________ Fax # ____________________ 400 4GS 68 Name:_____________________________ 500 City/State/Zip: _______________________ Street address: ______________________________________ 5GS 100 Tel #_____________________ Fax # ____________________ I hereby authorize the above named bank and references to release financial information to Airgas Refrigerants, Inc., for the purposes of establishing an account with them. ________________________________ Signature _______________________ ___________________ Title Date 2 of 4 Airgas Refrigerants, Inc. 38-18 33rd Street Long Island City, NY 11101 8. Evacuate the system for at least one hour with a vacuum pump to a pressure below 500 microns (718) 392-8002 Tel (29.9 in. Hg). Close the manifold gauge set service valves, stop the vacuum pump and watch (718)the 392-8006 Fax gauges for a pressure rise. If the gauges hold steady for 10 minutes, you may proceed. However, if Toll Free (800) 473-3766 the pressure increases, there could be a leak (or some refrigerant trapped) in the system. Charge the system to 50 PSIG with ASPEN R-416A refrigerant through the high-side port. Check for leaks with an electronic leak detector, soap bubbles, or and repair as needed. R-12 or R-134a electronic leak Please fax completed form with to Airgas at (718) 392-8006 or mail to Airgas Refrigerants, Inc., 33rd Street, detectors will work ASPEN R-416A refrigerant. Recover/recycle the 38-18 R-416A, repairLong any Island leaksCity, NY 11101. The information provided herein will be kept in strict confidence, and will be utilized only for the purpose of obtaining credit in accordance found, and re-evacuate the system and repeat the ten minute vacuum hold test. If the system is tight, with our terms of sale. proceed with the installation. Credit Application 9. Charge the system with ASPEN R-416A refrigerant as follows. Note: R-416A must be charged as a liquid. Turn the cylinder up-side down for liquid charge. Company ________________________Street Address:________________________________ a. Make sure that the system is off. City/State/Zip:_________________________________________________________________ b. Place the cylinder on the charging scale in an up-side Fax#:___________________________________ down position. Tel.#:____________________________________ Years in business:____________ Net Worth:______________ Line Req:_________________ c. C alculate the appropriate ASPEN R-416A charge amount (see StepCredit 2 above). Set the amount of to be charged initially to eighty percent (80%) of the normal R-12 charge or recovered R-12 TypeR-416A of business: amount (see #2 above) [Example: 160 oz. X .80 = 128 oz. or 8 lbs.]. Corporation d. Zero the scale. Fed. I.D.#:_______________ Partnership Individual/Sole Proprietor Other Resale or Exemption #:_________________ DUNS #______________ e. Open the high-side valve on the manifold gauge set (the discharge side, red hose) releasing liquid Primary products or services sold:___________________________________ R-416A refrigerant into the system. When the scale shuts off indicating the correct amount of refrigerant has been transferred to the system, close the high-side valve on the manifold gauge Names of Principals or Officers Home Address set, start the equipment and turn the control to its desired temperature setting. Then slowly add R-416A to the low (blue hose) side (as a liquid),_____________________________________________ never exceeding 15-20 PSI above the normal _______________________________ suction pressure. This will prevent accidental slugging of the compressor with liquid refrigerant. _______________________________ Charge until the desired weight has entered the_____________________________________________ system. The suction pressure decreases as the evaporator temperature decreases. Discharge or head pressure will be similar to, or lower than, that with R-12. Give us one bank reference and three trade references…(with similar credit lines) Note: A liquid line sight glass should not be used exclusively to determine the correct ASPEN refrigerant charge level. Some systems thatStreet are optimally charged may have some bubbles BankR-416A Name:___________________________ Address:___________________________ in the sight glass. City/State/Zip: _________________________ Tel #:___________________________________ f. After#charging, performance check the system afterFax the #: pressures have stabilized (about 15 Account ____________________________ __________________________________ minutes operation). Operate the equipment and check against target or baseline temperature settings as recorded with R-12. Trade or Business References – Address & Tel.# The unit’s performance with ASPEN R-416A refrigerant installed ______________________________________ should be comparable to that when Name:_____________________________ Street address: R-12 was used. Generally, suction pressures will be about 2-10 PSIG below R-12 at the same ambient City/State/Zip: The _______________________ #_____________________ Faxat#the ____________________ temperatures. discharge pressure should beTel about the same (or lower) as R-12 same ambient temperature. Box or evaporator temperatures should be______________________________________ within a few degrees of that measured Name:_____________________________ Street address: for R-12. Performance readings should only be taken after operating for at least 15 minutes. This allows City/State/Zip: _______________________ Tel #_____________________ Fax # ____________________ a period for the box or space to cool down and the system to stabilize. Name:_____________________________ Street address: ______________________________________ City/State/Zip: _______________________ Tel #_____________________ Fax # ____________________ I hereby authorize the above named bank and references to release financial information to Airgas Refrigerants, Inc., for the purposes of establishing an account with them. ________________________________ Signature _______________________ ___________________ Title Date 3 of 4 Airgas Refrigerants, Inc. 38-18 33rd Street Long Island City, NY 11101 Troubleshooting (718) 392-8002 Tel (718) 392-8006 Fax 1. If the suction pressure is too high and discharge pressure too low compared to the original (800) 473-3766 Toll Free R-12 readings and the box or evaporator temperatures are too high, check the conditions at the compressor. If the compressor is running with a cold suction line, with heavy sweat or frosting, and the discharge line is warm (not hot to the touch), this may be due to some liquidrdrefrigerant carry over Please faxcompressor. completed form This to Airgas (718) or mail Airgas Refrigerants, Inc., on 38-18 Street, Long Island City, NY 11101. to the callsat for an392-8006 adjustment totothe superheat setting the33thermal expansion The information provided herein will be kept in strict confidence, and will be utilized only for the purpose of obtaining credit in accordance valve(s). The most accurate approach is to measure the superheat. Ideally, the superheat should be with our terms of sale. the same or slightly higher with ASPEN R-416A refrigerant than that specified for R-12. Credit Application 2. If the system has a thermal expansion valve (TXV or TEV), superheat can be adjusted by turning an adjustment screw. The methods and adjustments of superheat settings varies by valve manufacturer. Many TXV’s can be adjusted externally with a wrench or screw driver. Before adjusting the TXV, mark Company ________________________Street Address:________________________________ and record the starting point. To increase superheat, turn the TXV adjustment screw clockwise to City/State/Zip:_________________________________________________________________ increase spring tension. The suction pressure should drop and box or evaporator temperature to the thermostat setting. Superheat screw adjustments may vary from one to several turns depending on Tel.#:____________________________________ Fax#:___________________________________ many factors; therefore, super heat calculations should be made. ASPEN R-416A may operate at or Years in higher business:____________ Credit Req:_________________ slightly superheat (2-3 degrees)Net thanWorth:______________ R-12. TXV adjustment should onlyLine be attempted after the system is properly charged: between 80-90% of the original R-12 charge levels. See the charging Type of business: table, pressure temperature table and superheat adjustment procedure for further details. Corporation Partnership Individual/Sole Proprietor Other 3. Since R-416A operates at lower pressures than R-12, some system control set points [i.e., pressure Fed. I.D.#:_______________ Resale or Exemption #:_________________ DUNS #______________ unloaders, low pressure cut-outs, switches, back pressure regulators, Evaporation Pressure Regulator (EPR) or controlsold:___________________________________ set to operate on suction or low-side pressure] may require Primary products orany services adjustment. Always check the systems or compressor service manual when setting these safeties or controls. ASPEN R-416A refrigerant will also work well in reverse or heat pump cycle for heating or Names of Principals or Officers Home Address defrosting but will work at lower pressures than with R-12 in the system. _______________________________ _____________________________________________ 4. If the system is equipped with a distributor, superheat can be increased by either adjusting the TXV _______________________________ in series with it, or by replacing the orifice with one_____________________________________________ having a smaller diameter. Alternatively, removal of some of the refrigerant from the system will also increase the superheat. Give one bank reference and references… (with from similar 5. If the us system is equipped with a capillary tube three some oftrade the refrigerant can be removed thecredit lines) system to optimize performance. Bank Name:___________________________ Street Address:___________________________ Account # ____________________________ Fax #: __________________________________ 6. L eak check the system, after removing the refrigeration manifold gauge set. Replace seal caps on City/State/Zip: _________________________ Tel #:___________________________________ the service ports. 7. Install a label, showing the system adaptation date, quantity of R-416A refrigerant installed, and quantity of lubricant added. Trade or Business References – Address & Tel.# NOTE: EPA recovery/recycle rules apply to all refrigerants; therefore, if any service work needs to be Name:_____________________________ Street address: ______________________________________ performed on a system that contains R-416A refrigerant, it must be recovered or recycled. It can not be City/State/Zip: Tel #_____________________ Fax # ____________________ vented into the _______________________ atmosphere. Name:_____________________________ Street address: ______________________________________ CAUTION: Exposure to any refrigerant can cause personal injury. Refer to Airgas Material Safety Data City/State/Zip: _______________________ Tel #_____________________ Fax # ____________________ Sheet (MSDS) for ASPEN R-416A additional safety information. Name:_____________________________ Street address: ______________________________________ Note: Airgas Refrigerants, Inc. believes the information provided in this web site to be#accurate to the City/State/Zip: _______________________ Tel #_____________________ Fax ____________________ best of our knowledge at the current time. I hereby authorize the above named bank and references to release financial information to Airgas Refrigerants, Inc., for the purposes of establishing an account with them. ________________________________ Signature _______________________ ___________________ Title Date 4 of 4