REFRIGERATOR

RETROFITTING

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 What is retrofit in the field of refrigeration?

• Retrofit is the process by which the equipment

currently using an ODS refrigerant is made to
run on a non-ODS refrigerant, without major
effects on the performance of the equipment,
and without significant modifications/changes for
the equipment, ensuring that existing equipment
operates until the end of its economic life.

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 WHY RETROFIT
• Imminent CFC-shortages would threaten the useful life of the
appliances of CFC-equipment.

• As CFC shortages increase, the cost of CFCs will rise, along

with operating costs of the equipment. Retrofit refrigerants
and technology are available for most applications.

• By retrofitting the equipment, you enable it to operate past the

CFC's phase-out dead lines, and the equipment lifetime
exceeds the phase-out dates.

• Existing plants which have reached the end of their economic

lifetime, should be replaced with new refrigeration equipment
based on non-ODS refrigerants and technologies.

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 The Need for New Refrigerants
• The phaseout of CFCs and HCFCs creates the urgent need
for nontoxic, nonflammable, environmentally safe refrigerants
with high energy efficiency and capacity.
• The ideal refrigerant should have the following properties:
1. High energy efficiency
2. High refrigeration capacity
3. Nonflammability
4. Low toxicity
5. Zero ODP
6. Very low (GWP) and total equivalent warming impact (TEWI),
7. Ability to use existing proven compressors and other
components
8. Low cost.

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 Desired Refrigerant Properties
• Environmentally acceptable
• Non-toxic
• Non-flammable
• High latent heat vaporization
• Material of construction compatible (hoses)
• Lubricant soluble
• Low moisture solubility
• Ease of transport handling
• Capable of recycling
• Detectable at low concentrations
• Reasonable cost
• Field system charging capability
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FACTORS INFLUENCING THE TIMING &
RATE OF CFC REPLACEMENT

• Key factors which influence the timing and

the rate of CFC replacement include:
– Lifetime of the Equipment and Servicing
Needs
– Retrofit Possibilities for Existing Equipment
– Product Energy Efficiency
– Toxicity, Flammability, and Environmental
Concerns

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 MONTREAL PROTOCOL
• In September 1987, the first worldwide step toward controlling ozone
depletion was established with the Montreal Protocol on Substances that
Deplete the Ozone Layer.

• Montreal Protocol – an international accord to reduce and eventually

eliminate the emissions of man-made ozone depleting substances.

• Its control provisions were strengthened through four adjustments to the

Protocol adopted in London (1990), Copenhagen (1992), Vienna (1995),
and Montreal (1997).

• To become a party – a nation must enact legislation and adopt regulations

to put into force legal instruments that will achieve the Protocol’s objectives
and meet its requirements for becoming a party.

• 175 countries have ratified the Protocol.

• The Montreal Amendment entered into force on January 1, 1999.

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 CHEMICALS LISTED IN THE MONTREAL PROTOCOL

• Class 1 Substances
• Group I: Fully-Halogenated Chlorofluorocarbons
– CFC-11 CFC-12 CFC-113
– CFC-114 CFC-115
• Group II: Halons (Fire suppression systems)
– Halon-1211 Halon-1301 Halon-2402
• Production of Group I & II refrigerants are frozen at 1986
levels as of 1989 and 1992.
• Phaseout of CFCs (Class I Substances)
• CFC Production Phased-out January 1, 1999
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 Table 2: Environmental Impact of Refrigerants
Refrigerant ODP GWP Comments
CFC-11 1 4000
CFC-12 1 8500
CFC 500 0.66 6300 CFC-12 + HFC-152a
CFC-502 0.28 5600 HCFC-22 + CFC-115
HCFC-22 0.055 1700
HCFC-123 0.02 93
HFC-134a 0 1300
R41OA 0 1890 HFC-32 + HFC-125
Propane 0 3 Very flammable
Ammonia 0 0 Toxic and flammable
ODP Ozone depletion potential relative to CFC-11 = 1
GWP = Global warming potential relative to CO 2 = 1 (100-yr time horizon basis)
Source BRE

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 EMMISSIONS & PROTOCOLS
Effect of the International Agreements on Ozone-Depleting
Stratospheric Chlorine/Bromine

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 RETROFIT STUDY INFORMATION
• Retrofit study involves the joint effort by equipment manufacturer,
equipment owner, service agency, refrigerant manufacturer and
research institute.
Study and experiments on retrofitting have to address the
following problems
• Technical
• i) Pressure and temperature level, performance and capacity
• ii) Compatibility of lubricants and refrigerants with construction,
sealing and insulation materials
• iii) Refrigerant and lubricant solubility (eg. capillary tube plugging)
• iv) Chemical and humidity residues and their impact on lubricants,
refrigerants, materials and operation performance

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 RETROFIT STUDY INFORMATION
• Typical retrofit may involve one or many of the following
changes/justifications:

 Lubricant

 Desiccant filter (dryer)

 Expansion valve

 Compressor (gearbox, speed, motor)

 Insulation and seal materials, elastomers

• For centrifugal chillers: purge systems, impeller/gearbox

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 RETROFIT STUDY INFORMATION
• RETROFITTING WITH NON-CFC SUBSTITUTES

• Storage/handling of lubricants and refrigerants, with regard to

moisture interaction

• Redesign of compressor and other components

• Field tests/reliability

• Others

• Time consumption for retrofitting

• Cost of retrofitting (equipment, lubricant, refrigerant)

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 GENERAL TERMS USED
• Drop-In Replacement - An alternative refrigerant that can be installed
directly into an existing system with minor equipment changes. Most
interim alternatives fall into this category.
• Interim Replacements (SHORT TERM) - Any of a number of refrigerants
intended to serve as an intermediate solution during the transition from
CFC to HFC refrigerants. Most interim replacements contain HCFC
refrigerants like R22.
• Long Term Replacements - Alternative refrigerants that are considered
to have no adverse affect on the stratospheric ozone layer. Most long
term replacements are HFC compounds.
• Medium Pressure Refrigerant (MP) - A term used for some alternative
refrigerants designed to operate in the medium temperature (0° F to 4° F)
range.
• High Pressure Refrigerants(HP) - A term used for some alternative
refrigerants designed to operate in the low temperature (-35° F to 0° F)
range.
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 The Eight Easy Steps to Retrofit
• Select the Retrofit Checklist from the Appendix for the
refrigerant you are replacing.
i. Establish baseline performance with CFC.
ii. Remove CFC from the system into a recovery cylinder. Weigh the
amount removed if possible.
iii. Drain mineral oil from the system and measure the volume removed.
(Skip steps 3 and 4 if AB lubricant is already in the system or you are
not changing the mineral oil).
iv. Add AB lubricant; use the same volume as removed in Step 3
v. Replace the filter/drier/ piping, controls, EV Compressor if required.
vi. Evacuate system and check for leaks.
vii. Charge with Suva® refrigerant. Remove liquid only from charging
cylinder. Typical charge is 75–90% of CFC charge.
viii. Start up system, adjust charge size. Label system for the refrigerant
and lubricant used.
Retrofit Complete 17
RETROFITTING
PROCEDURE

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 RETROFITTING PROCEDURE
• 100 Select facility to retrofit with alternative refrigerant.

 First activity in the retrofit process.

• 110 Evaluate existing refrigeration system.

 Evaluate the current refrigeration system

 Review as-built documents, facility visit and investigation.

 Consider the cooling demands of the facility, and capacity

of the existing system.

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 RETROFITTING PROCEDURE
• 120 Design equipment and piping for use with new
refrigerant.
 Objective is to maintain adequate refrigeration capacity &
minimizing retrofit cost
 Consider each piece of equipment & critical piping runs in the
system with the alternative refrigerant.
 For example, conversion of existing R-12 and R-502 systems to
R-22 involves the change of compressor bodies and associated
valves and controls, a change of expansion valves, and a
modification to suction and liquid lines, especially at risers.
 Determine what equipment and piping must be replaced.

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 RETROFITTING PROCEDURE
• 130 Consider and design other system changes.
 Consider other changes to the refrigeration system that may prove
beneficial to the operation.
 For example, excessive refrigerant losses in the existing system
 Replace old piping and valves, or install a leak-detection system.
• 140 Prepare equipment and material list for purchasing.
 Identify all items that must be purchased.

 150 Purchase materials and equipment.

 Pursue the most favorable pricing while satisfying the specifications.

 Execute purchase orders.

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 RETROFITTING PROCEDURE
• 160 Deliver materials and equipment.
 Deliver equipment and materials directly to the facility.
•  200 Notify retail operations of installation date.
 Notify the retrofit installation plan and schedule
 Ensure that the retrofit operation is well coordinated.
•  205 Start retrofit work at facility.
• 170 Cut and prepare for installation of new risers.
 Try to minimize the impact of retrofitting on the system operations.
 Perform the liquid and suction riser work can be during normal operating
hours.
 Preliminary riser work does not require shutting down the refrigeration
system.

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 RETROFITTING PROCEDURE
• 180 Install new risers.
 After the cutting and preparation for the installation of the new risers is
completed, the risers can be installed.
 The risers are installed alongside the existing risers.
 Make piping connections after shutting down the system and evacuating
refrigerant.
• 210 Retail operations empty product from cases.
 Remove all food products from the refrigerated cases that are connected
to the compressor rack to be retrofitted.
 The food is temporarily stored in another refrigerated area.
• 220 Shut down compressor rack.
 After the food products have been relocated, the compressor rack can be
shut down.
 Disconnect the power at the electrical panel

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 RETROFITTING PROCEDURE
• 230 Evacuate and recover CFC refrigerant.
 Recover CFC refrigerant from the system through both high and low-side
ports.
 Store recovered refrigerant is in an external tank.
 Do not vent any CFC refrigerant into the atmosphere (penalties may be
imposed).
 Recover refrigerant without any losses.
 Remove Lubricant
• 240 Haul recovered CFCs to reclamation center.
 After the modified system has been started up and balanced.
• 250 Reclaim CFC refrigerant.
 Reprocess the hauled refrigerant to new product specifications.
 Chemical analysis  to determine that appropriate product specifications
are met

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RETROFITTING PROCEDURE
• 260 Store reclaimed CFC refrigerant for service use.
 Store in a secured warehouse for future use in service
applications.
 Until an organization has completely retrofitted all of its CFC
applications, it needs additional CFC refrigerant for service
applications.
• 270 Remove existing compressors from system.
 After the CFC refrigerant has been evacuated and recovered,
disconnect and remove the existing compressors from the
equipment pad.
• 280 Install new compressors.
 For use with Alternative refrigerant (R-22) can be installed on
the pad.
 Replace Seals/O-rings, hose material, compressor, desiccant,
condenser, refrigerants controls, lubricant if required
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 RETROFITTING PROCEDURE
• 300 Install new pressure relief valve on receiver.
 Differences in operating liquid refrigerant pressures between R-22 and
R-12 or R-502, it is necessary to install a new pressure relief valve on
the liquid refrigerant receiver when performing the retrofit.
• 310 Remove existing expansion valves.
 In every retrofit, all expansion valves must be replaced.
• 320 Install new expansion valves.
 Install the new expansion valves
• 330 Make piping connections.
 After the compressors have been installed, make all piping connections.
 These connections include those at the compressor, at the new risers,
and anywhere else in the system where piping is being replaced.

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 RETROFITTING PROCEDURE
• 340 Leak check system.
 Evacuate the system & leak test.
 This involves pulling a vacuum through the system at the service
valves.
 Leak checking can be done using a standing pressure test.
 Nitrogen is commonly used as the pressure source.
• 350 Insulate piping and patch at new risers.
 After the system has passed leak testing, required insulation can
be installed on new piping sections.
 Also, the cut area where the new risers have replaced the old
ones should be patched as necessary.

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 RETROFITTING PROCEDURE
• 360 Introduce new Refrigerant Charge into the system.
 After the leak test, introduce the new refrigerant charge into the
system.
• 370 Reprogram electronic controls for new refrigerant .
 Because the retrofit system will operate at different pressures and
corresponding temperatures at various points in the cycle, it is
necessary to reprogram the electronic controls accordingly.
•  380 Startup and balance system.
 Reprogram the electronic controls, startup and balancing of the
system.
 Startup requires greater attention to operating temperatures.
 Operation at high temperatures during startup can shorten
compressor life. be Coordinate and test settings of relief valves,
HP/LP safety switches, and computer-controlled high-pressure
shutdown.
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 RETROFITTING PROCEDURE
• 390 Monitor revised system operation.
 Monitor the retrofit system during the first several hours of
operation.
 Check operating temp./press., cooling capacity, COP, Leakages,
EER

•  400 Restock refrigerated cases.

 After balancing and testing  Restock the retrofitted cases.

•  410 Refrigerant retrofit complete.

 Finally, after all retrofit tasks have been performed, the
refrigerant retrofit is complete.

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 ALTERNATIVE REFRIGERANTS

Product Application Comments

To Replace R-12 and R-500

Service Refrigerants (HCFC)

Retrofit R-12 Preferred retrofit option for R-12.

Suva® MP39
Medium/low temp., best above No oil change for small close-coupled
(R-401A) -15°F evap. systems.
R-500 quick, cost-effective retrofit; one oil
Retrofit R-500, R-12 change.
Suva® MP66 Higher capacity for low-temp. R-12 retrofit where higher capacity is
(R-401B) R-12, best below -15°F evap. needed at low temp.
No oil change for small close-coupled
systems.

Long Term (HFC)

Good option for new equipment. Also
New Equipment and Retrofit
Suva® 134a R-12
retrofit option; best above 20°F (-7°C)
(R-134a) evap.; MP39 less costly option for
Medium temp.
retrofit.

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 Conversion Capacity & Efficiency Losses

The following has occurred:

 
Conversions Capacity Loss Efficiency Loss
CFC-11 to HCFC-123 2%-15% 7%-20%
CFC-12 to HFC-134a Negligible Negligible
 

Conversion capacity losses and efficiency loss are

dependent on the specific piece of equipment converted and
the details of what is actually replaced during the
conversions, such as impellers, gears, etc.

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 CFC-11 Replacement HCFC-123
• Blend refrigerant
• Short term alternative
• Contains chlorine
• Ozone Depletion Potential (ODP) of 0.03
• (R-11 is 1.0)
• Can tolerate up to 20% mineral oil
• Use alkylbenzene synthetic oil

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 CFC-12 Replacement HFC-134a

• Contains no chlorine

• Zero Ozone Depletion Potential (ODP)

• Medium and high temperature applications

• Used in automotive applications

• Cannot use mineral oils or be retrofitted

• Low Global Warming Potential (GWP) of 0.26

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 ALTERNATIVE REFRIGERANTS

Product Application Comments

To Replace R-22
Long Term (HFC)

Suva® 407C New Equipment and Retrofit - A/C and Heat Pumps
Available today for retrofit
(R-407C) and new equipment.

High pressure/high
efficiency refrigerant of the
Suva® 410A Only for Equipment Designed for 410A - A/C and
future; only for equipment
(R-410A) Heat Pumps
designed for R-410A.
Often referred to as AZ-20.

To Replace R-11
Suva® 123 Low-press. chillers, engg. modifications may be  
(R-123) required.

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 REFRIGERANT DESCRIPTION
CFCs
Color Gas type Chemical Name Container sizes Application Oil type

. 100lb Mineral
11 Tricholorofluoromethane Centrifugals
200lb Alkylbenzene
12oz
30lb Med & Hi temp Refrig. Mineral
white 12 Dichlorodifluoromethane
50lb & Auto Alkylbenzene
145lb
9lb Ultra low
. Mineral
13 Chlorotrifluoromethane 23lb temp
Alkylbenzene
80lb refrigeration
. 100lb Comm. Indust Mineral
113 Thrichlorotrifluoroethane
200lb A.C. Alkylbenzene

. Ind. Process Mineral

114 Dichlorotetrafluoroethane 150lb
Centrifugals Alkylbenzene

. 30lb Mineral
500 12/152a blend Comm. A.C.
125lb Alkylbenzene
30lb
. Med & low Mineral
502 22/115 blend 50lb
Temp Ref Alkylbenzene
125lb
8lb
. Ultra low Mineral
503 13/23 blend 20lb
temp refrig. Alkylbenzene
80lb
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 REFRIGERANT DESCRIPTION
HCFCs
Container
Color Gas type Chemical Name Application Oil type
sizes
30lb-
A.C. & Low Mineral
singles
. 22 Chlorodifluoromethane &Med Alkylbenzene
30lb-pallets
temp Ref. Polyol Ester
50lb,125lb
100 lb, Low Pressure Mineral
. 123 Dichlorotrifluoroethane
200lb Centrifugals Alkylbenzene
Med Temp Alkylbenzene
. 401A (MP39) 22/124/152a blend 30lb, 125lb
refrigeration Polyol Ester
Low Temp Alkylbenzene
. 401B(MP66) 22/124/152a blend 30lb, 125lb
refrigeration Polyol Ester
Low & Med
Alkylbenzene
. 402A(HP80) 22/125/290 blend 27lb, 110lb Temp
Polyol Ester
refrigeration
Mobile,
9.6oz Mineral
A.C. & Med.
. 416A/FR-12 134a/124/600blend 25lb Alkylbenzene
Temp. Ref
125lb Polyol Ester
& Chillers
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 REFRIGERANT DESCRIPTION
HFCs
Chemical Container
Color Gas type Application Oil type
Name sizes
9lb Ultra Low Polyol
. 23 Trifluoromethane
20lb Temp. Ref. Ester
30lb
A.C. & Med. Polyol
. 134a Tetrafluoroethane 125lb
Temp. Ref Ester
1000lb
404A 125/134a/143a Low & Med. Polyol
. 24lb, 100lb
(FX70/HP62) blend Temp. Ref. Ester
507 25lb Low & Med. Polyol
. 125/143a blend
(AZ50) 100lb Temp. Ref. Ester

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 OILS USED
• Ester Oil - A general term that applies to a family of synthetic refrigeration
oils based on the chemistry of polyol esters. Ester oils are generally
regarded as the oil to use with most of the alternative refrigerants. Ester oils
are generally compatible with existing mineral oils, and system components.
Ester oils are slightly hygroscopic and should be in non-porous containers.

• P.A.G. Oil - A general term that applies to a family of synthetic oils based
on the chemistry of Poly-alkyline glycols. The primary application of P.A.G.
oils will be for automotive air conditioning.

• Alkyl Benzene Oil - A synthetic refrigeration oil commonly known as Zero.

• Mineral Oil - Refrigeration oil currently in use but is not compatible with
most of the alternative refrigerants. Refrigerant conversions often require. a
procedure for the removal of existing mineral oil because of the
incompatibility with alternative refrigerants.
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 COMPATIBILITY
• Assure oil is compatible with refrigerant.
• Assure refrigerant is compatible with equipment components.
• Assure recovery unit is compatible with refrigerant and oil.

KNOW WHAT REFRIGERANT, OIL, AND

COMPONENT MATERIAL YOU ARE
WORKING WITH
(Look at unit name plate)

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Suggested Oil Guide

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RETROFIT EXAMPLE

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 HFC-134a retrofit for CFC-12
• Check system. Includes leak detection and identifying other
part failures.
• Remove R-12 from the system
• Lubricant removal
• Retrofit part replacement. (Seals/O-rings, hose material,
compressor, desiccant, condenser, refrigerants controls,
lubricant.)
• Install service ports
• System labels
• System evacuation
• Charge system with R-134a
• Leak check system
• Check system operation

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HFC-134a AS RETROFIT FOR R-12

• HFC-134a is a leading candidate in replacing CFC-12 in

refrigerators and freezers.
• Benefits
 R- 134a is ideal non-flammable, zero-ODP replacement for
R-12.
 HFC-134a is an environmentally acceptable alternatives that
is low in toxicity, non-corrosive and compatible with other
materials.
 Energy consumption of the HFC-134a refrigerator equalled
that of CFC-12.
 Thermal performances met national standards.
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HFC-134a AS RETROFIT FOR R-12
• Problems:
• Studies show from 1% less to 7% higher energy consumption
than CFC-12.
• Immiscible with mineral oils traditionally used with R-12.
• HFC-134a has very low solubility and mineral oil does not mix
well in HFC-134a, which could contribute to the following
problems:
 Poor oil return back to the compressor, resulting in possible
compressor failure
 Fouling of expansion valves and heat exchanger surfaces,
leading to reduced system performance

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HFC-134a AS RETROFIT FOR R-12
• PAGs have to be used, but revealed an inherent and
significant problem, namely high hygroscopicity.

• Improved lubrication and better handling characteristics

achieved with use of synthetic polyol ester oils.

• Synthetic polyol ester lubricants are well suited for use with
R-134a.

• Problems regarding accurate cleaning of the old system,

redesign of the compressor and matching of each component

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 OILS CHANGE PROCEDURE
• Where possible, use OEM-recommended oil type, charge size,
and viscosity.
• The oil change procedure is as follows:
 The mineral oil is drained from the compressor.
 The compressor is filled with polyol ester oil and run for 24 hr or more.
 A longer run time provides better flushing of the oil from the system.
 A sample of the oil is removed and tested for contamination levels of mineral oil &
metal wear.
 The system is again drained, refilled, and run with fresh polyol ester oil for 24 hr or
longer. Contamination levels are once again determined.
 This procedure is repeated, if necessary, until mineral oil contamination is under
5 percent (usually 2 or 3 oil changes total).
 The system may then be evacuated of R-12 and charged with R-134a, assuming
that all necessary modifications have been made.
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 Material Compatibility
• R-134a and polyol ester lubricants tested for a variety of factors, such as
material swell, material shrinkage, hardening, elasticity changes, refrigerant
permeation
• In general, the following applies:
• (1) Metals. R-134a and polyol esters are compatible with all metals typically
found in airconditioning systems.
• (2) Plastics. R-134a and polyol esters are compatible with most plastics found
in R-12 systems.
 Acrylics and celluloses should not be used with R-134a.
• (3) Elastomers (seals, gaskets, o-rings, etc.). R-134a and polyol esters are
compatible with many elastomers found in R-12 systems.
 Adiprene L and Viton A should not be used with R-134a. Because Buna
S and butyl rubber exhibit borderline characteristic changes, their use
with R-134a is not recommended.
 Styrenated butadiene (SBR) exhibits a high swell with polyol ester and
is not recommended for use with the lubricant.
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 Equipment Modifications
• Check the compatibility before being converted to another type of refrigerant --
compressors, expansion valves, hot gas valves, condensor coils, evaporator coils,
filter-driers, capillary tubes, pressure switches, and system piping.

• Centrifugal R-12 compressors often experience significant capacity loss as impeller

design and rotational speed are exactly matched to the properties of R-12.
Replacement of the impeller and/or pulley is usually required to regain lost
capacity.

• Reciprocating R-12 compressors in systems operating above evaporator

temperatures of 6.7 ° C usually experience equivalent performance with R-134a.

• No piping material or diameter changes are required when retrofitting with R-134a
because its physical characteristics are similar to those of R-12.

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 Equipment Modifications
• Some expansion valve manufacturers may recommend replacing the
expansion valves because of somewhat higher operating pressures with R-
134a.
• The solenoid valves, pressure switches, and hot gas valve for the R-12
system were found to operate satisfactorily with R-134a
• Filter driers were replaced with an R-134a-compatible type.
• No compressor modifications were required.
• Capacity
• At evaporator temperatures over 6.7 °C, R-134a exhibits an equivalent
capacity compared with R-12.
• Some systems running at these temperatures may show slightly higher
capacities with R-134a because of its higher heat of vaporization (ability of
a liquid to absorb heat prior to vaporizing to a gas).
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