[Rev02]
Procedure for Retrofitting R-22 Systems
with R-421A
written by Rick Roland, Engineer
Recovery and Vacuum
The removal or recovery of the R-22 refrigerant from the system is completely typical and should only
be done by an EPA certified technician. All recovered R-22 should be collected and returned to a quality
refrigerant reclaiming facility.
After the recovery, a vacuum pump should be connected to the system along with a micron gauge. The
micron gauge should be installed so that the vacuum can be isolated from the system while the micron gauge
still continues to measure the vacuum of the system. The vacuuming is complete when the vacuum pump is
isolated from the system and the maximum of 1000 microns is held by the system for a five minute period.
An important factor in the successful retrofit of a R-22 system to R421A is the installation of the correct
metering device. Two types of metering devices may be found in the typical system.
1) Thermal expansion valve TXV.
2) Fixed orifice metering device (Flowrater or Accurater) * see appendix A
Field experience has discovered that the proper metering device for this retrofit may be larger than the
device properly sized for R-22. i.e. on the typical (4) ton system, a (5) ton TXV or fixed orifice may be used.
For systems that have a fixed orifice, a selection of orifices should be acquired before starting the retrofit.
Having a selection of orifices will allow you to test and then make changes as needed. See Appendix A for a
chart of available fixed orifices and their recommended use. For systems with TXVs, be sure that the valve is
capable of controlling a system at least one ton larger than the system being retrofitted. This approach works
will for systems in the 1 to 5 ton range. For larger systems, refer to Appendix B or call the tech support “hot
line” for suggestions on valve sizing.
With the system and gauge set in a quality vacuum, estimate the amount of R-421A that will be
needed. Two methods work well to estimate the weight of the system charge.
1) Determine the amount of R-22 that was recovered from the system, assuming the system was
\fully charged. This will give you the weight of the charge for the system IF the system is to be
charged “pound for pound.”
2) Read the unit tag and check for the factory charge. This will work well for package units.
3) NOTE: When charging the system, stop at about 90% and evaluate the system.
Charging
With the System OFF and a “Choice” R-421A cylinder on a scale to track the weight added to the
system and the cylinder properly connected to the vacuumed system:
1) Open the tank valve
2) Open the high side gauge and allow (LIQUID) R421a to flow into the high side of the system.
3) Monitor the scale and add 90% of the calculated charge with this method.
4) At 90%, or as close as the system will allow, close the high side gauge.
Be sure that you have the ability to monitor the temperatures, pressures and amperage, in order to fill-in
the “Field Experience Report.”
Tel: (941) 637-6300 Fax: (941) 637-6323 Website: www.certifiedrefrigerant.com Page 1
Start The Sytem
Allow the system to stabilize for at least five minutes. A general goal for the system will be:
10 - 20 degrees of Super Heat
10 - 15 degrees of Sub Cooling
18 – 20 degree temperature drop across the indoor coil
Reduced high side pressure
Reduced Amperage draw
Refer to Appendix C to see where to monitor temperatures and how to calculate Super Heat, Sub Cooling, and
temperature drop over the indoor coil. All of these variables are considered when determining if the system is optimized.
It is possible that all of the variables may not be perfect, or in complete agreement, while the system is operating
optimally.
System Check
With 90% of the calculated charge in the system, collect data from the running system and fill-in the “field experience
report” sheet, this is very helpful in evaluating the system. Most likely with 90% of the charge in the system, the Super
Heat will be greater than recommended. If so, SLOWLY add refrigerant to the low side of the system.
CAUTION
Adding liquid at an excessive rate can slug the compressor and cause a catastrophic failure.
Add refrigerant, stop, wait 5 minutes for the system to stabilize and take new data until:
1) The system data is within range of the recommendations.
2) 100 % of the calculated charge has been added to the system.
Be Cautious do not continue past 110% of the charge. If the system data is within range, you are finished with the
retrofit.
If 100% of the calculated charge has been added, and the data is not within range, the metering device, TXV or fixed
orifice is not allowing the correct amount of refrigerant to flow. The Super Heat is the most important factor, if that
number is greater than the recommended 10 to 20 degrees; the flow of refrigerant may be too low. If this number is less
than 10 degrees, the flow of refrigerant may be too high.
Recommendations:
1) Adjust the TXV open or closed to change the refrigerant flow.
2) Change the fixed orifice one size up or down to increase or decrease the refrigerant flow.
Restart and retest the system until the system parameters are within specification. This procedure is repeated until the
data is within range. The job of retrofitting a system will become easy with experience. Soon you will know the metering
device need and percentage weight for the average system and quickly go to those settings.
Congratulations for making R-421A your retrofit “choice.”
Enjoy the environmental benefits along with the better system pressures and reduced current draws achieved with R-
421A
Appendix A: Orifice Selection Flowrater
Appendix B: Suggested Valve Sizing
Appendix C: System diagram illustrating refrigerant flow, points of temperature reading
Appendix D: Pressure / temperature chart for R-421A with Superheat calculation example
Certified Refrigerant Services, Inc. 5481 Williamsburg Drive - Punta Gorda, Floria 33982 Page 2
Appendix A: Fixed Orifice Selection (courtesy Parker & Johnstone Supply) [Rev02]
MFG # ForUseWith Order #
B1789852 .............. CK18-I,CPE18J, CPKEI8-1 ................................................. B11-933
B1789855 .............. CK18-1, CKJ18-I ................................................................. B12-443
B1789859 .............. CK24-I, CKi24-1, CPE24-1, CPKE24-1 .............................. B11-934
B1789862 .............. CK24-l .................................................................................. B12-444
B1789865 .............. CK3O-1, 0030-1, CPE3O-1, CPKE3O-I - ........................... B11-935
B1789868 .............. CPKE3O-1, CPJ3O-1 .......................................................... B12-445
B1789871 .............. CPE36-I ............................................................................... B71-936
B1789873 .............. CK3G-1/3, CKJ36-l .............................................................. B12-446
B1789874 .............. CKT36-1, CPKE36-1 ........................................................... B12-447
B1789878 .............. CK42-1, CKJ42-l, CPKE42-I ............................................... B12-448
B1789880 .............. CK48-1, CK49-l, CKi48-1, CPE42-1, CPH42-1 ................. B1I-937
B1789882 .............. CKT48-1, CPE48-1, CPKE48-I ........................................... B1I-938
B1789890 .............. CKJ6O-1 .............................................................................. B11-939
B1789893 .............. CPKE6O-1 ........................................................................... B12-449
Appendix B: (courtesy Emerson Climate Technologies & Johnstone Supply)
Tel: (941) 637-6300 Fax: (941) 637-6323 Website: www.certifiedrefrigerant.com Page 3
Appendix C: Figure 1 – System Diagram of Refrigerant Flow & Points for Temperature Reading
Appendix D: Figure 2 R-421A P/T Chart
Example Superheat Calculation
T1 = Actual Suction Line Temperature = 55° (example purposes)
Using the chart below (Figure 2) R-22 or R-421A this example system has
a suction pressure of 69 psig at a Saturated Vapor Temperature of 40°F.
Measure the actual temperature at T1 and subtract the saturated vapor
temperature:
T1 - SVT = superheat
55° - 40° = 15° (superheat)
Actual Line Temperature _______________
Saturated Vapor Temperature _______________
Superheat = _______________
Certified Refrigerant Services, Inc. 5481 Williamsburg Drive - Punta Gorda, Floria 33982 Page 4
System Data Sheet [Rev02]
Be Sure To Record R-22 System Information Before R-421A Retrofit
Customer Name: _____________________________Address__________________________________________
Type of System/Location:_______________________________________________________________________
Equipment Mfg.:_______________________________________ Compressor Mfg.:____________________
Model Number: _______________________________________ Model Number:______________________
Serial Number: _______________________________________ Serial Number: ______________________
R-22 Recovery Cylinder Beg.Wt: _______lbs. Original Lubricant:
R-22 Recovered Ending Wt: _______lbs. Type/Mfg.:__________________________
R-22 Amount Removed: _______lbs. Charge Size: ________________________
Notes:________________________________________________________________________________________
_____________________________________________________________________________________________
Evaporator Mfg:________________________________________
Drier Type: Loose fill Solid Core
Model Number: ________________________________________
Expansion Device (check one): Fixed Orifice Size:________ Expansion Valve
If Expansion Valve: Manufacturer:__________________________Model Number:_______________
Location of Sensor:_________________________
Other System Controls:___________________________________________________________________________
R-421A Cylinder Beginning Wt: _______lbs.
R-421A Cylinder Ending Wt: _______lbs.
R-421A Added Amount: _______lbs.
Tel: (941) 637-6300 Fax: (941) 637-6323 Website: www.certifiedrefrigerant.com Page 5
Certified Refrigerant Services, Inc. 5481 Williamsburg Drive - Punta Gorda, Floria 33982 Page 6
