Download R-416a Installation Guide-1

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 vapor†R-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
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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
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