Stay Away from Unapproved Flammable R22 Substitutes

At the risk of sounding like a broken record, I am once again talking about the dangers of unapproved, highly flammable R22 substitute refrigerants which are still easily available over the internet to anyone who wants to buy them. A quick Google search for R22 replacement refrigerant will list several places to buy these dangerous mixtures. The manufacturers market these under a variety of names. The EPA has listed many of them as specifically NOT approved for use. They include refrigerant products sold under the names R-22a, 22a, Blue Sky 22a refrigerant, Coolant Express 22a, DURACOOL-22a, EC-22, Ecofreeez EF- 22a, Envirosafe 22a, ES-22a, Frost 22a, HC-22a, Maxi-Fridge, MX-22a, Oz-Chill 22a, Priority Cool, and RED TEK 22a. The main component of all of these is propane.
 
It is true that the EPA has approved some flammable refrigerants for use in new systems with  lot of restrictions. However, the allowed use is for small refrigerators. The total allowable amount is very small, the systems must be new and specifically designed for flammable refrigerant. Refrigeration systems designed for flammable refrigerant meet strict safety standards, including non-sparking controls and labeling.  Class 3 flammable refrigerants are specifically NOT approved for use as a retrofit refrigerant for R22, or any other system designed for non-flammable refrigerant.

Every time a contactor or relay opens or closes they make a spark which is hot enough to ignite a flammable gas. If someone is losing refrigerant, their system has a leak. Continuing to add a flammable refrigerant on top of R22 will eventually create a flammable mixture. More worrying is that the flammable mixture will be leaking out somewhere.

As a practical matter, most recovery units are not designed to handle flammable refrigerants. Master Cool has just come out with one that is  specifically designed to safely handle flammable refrigerant. Even if you did not use any flammable refrigerant, are you certain that someone before did not add one of these flammable substitutes?

Here is a copy of some of the text from the EPA ruling

“ For retrofit residential and light commercial AC and heat pumps— unitary split AC systems and heat pumps, EPA is listing as unacceptable, as of January 3, 2017:
• All refrigerants identified as flammability Class 3 in American National Standards Institute (ANSI)/ American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) Standard 34–2013; and
• All refrigerants meeting the criteria for flammability Class 3 in ANSI/ ASHRAE Standard 34–2013. These include, but are not limited to, refrigerant products sold under the names R-22a, 22a, Blue Sky 22a refrigerant, Coolant Express 22a, DURACOOL-22a, EC-22, Ecofreeez EF- 22a, Envirosafe 22a, ES-22a, Frost 22a, HC-22a, Maxi-Fridge, MX-22a, Oz-Chill 22a, Priority Cool, and RED TEK 22a. “

Here is a link to the EPA ruling banning flammable refrigerant as a retrofit refrigerant. https://www.gpo.gov/fdsys/pkg/FR-2016-12-01/pdf/2016-25167.pdf

EPA Warns of Flammable Replacement Refrigerants

As the summer cooling season gets under way it is a good time to reiterate that flammable refrigerants should NOT be used as replacement for R-22 in existing systems. Some people are putting in R-290, which is simply propane.  A few have tried charging their systems with fuel grade propane. Not only is this dangerous, but fuel grade propane has lots of water contaminants and will screw up your systems, that is if it does not blow up. Yes, it is true that the EPA approved flammable refrigerants for a few very specific uses in systems with a very limited charge. However, these are NEW SYSTEMS ONLY! These systems are designed from the outset to handle a flammable refrigerant.

Your R-22 air conditioner of heat pump has many spark creating controls, such as relays and contactors. A leaky system recharged with a flammable refrigerant could have all the components for an explosion: fuel, oxygen, and an ignition source. The EPA has started fining companies for selling non-approved, propane based R-22 replacement refrigerants. Most have “22a” in their name. Unfortunately, there are still plenty of places to buy this stuff over the internet. A few other names include “Frosty Cool” and Eco-Freeze”. You should be wary of anyone that sells refrigerant directly to consumers over the internet.

I don’t believe regular HVACR wholesalers will have any of this stuff, and major refrigerant companies such as Honeywell, DuPont, or Arkema are not selling it either. They do each offer their own R-22 replacement solutions, none of which are flammable. Some legal replacement solutions have very small percentages of hydrocarbon components to improve oil return. Their hydrocarbon components are in such small quantities that they generally pose no threat of flammability. So what is the best thing to put in an R-22 system? R-22. Read more about the EPA actions and warnings here.

EPA Announces R-22 Allocations for 2015 - 2020

The EPA has released their R-22 allocations for 2015 – 2020, and it looks like the days of free-flowing R-22 are about to come to an abrupt end. To put things in perspective, the R-22 allocation for this current year, 2014, was 51 million pounds. The allocation for 2015, coming up in a few months, is 22 million pounds. That is just over 43% of the 2014 allocation. From there the cutbacks are more gradual with a reduction of approximately 4 million pounds each year until 2020 when the allocation is 0. Trying to figure out R-22 prices has been a bit difficult these last few years. They have spiked twice but then gone back down as supply increased. This time look for the high prices to last  because there will be no turning the tap back on this time. The main question remaining is how long demand for R-22 will continue. Although there is still a very large installed base of R-22 air conditioning equipment, it is starting to get old. As older equipment fails and supplies tighten, it will be increasingly difficult financially to keep an older R-22 system operating. I remember with R-12 and other CFCs, prices climbed high enough to kill demand. A local wholesaler took a bath on a large quantity of 502 just to get rid of it because nobody wanted it at the “market” price. Consider that a dry ship unit costs about the same as a 410A builder grade, but you still have to buy the refrigerant. It is conceivable that a dry ship unit charged with R-22 at inflated prices would be as expensive as replacing both the condenser and evaporator with a builder grade 410A system. Who would want to keep their old system if it costs as much as a system with current technology, higher efficiency, and a refrigerant that is still available? To read more about the EPA's ruling, check out

https://www.federalregister.gov/articles/2014/10/28/2014-25374/protection-of-stratospheric-ozone-adjustments-to-the-allowance-system-for-controlling-hcfc

R22 Phase Out

If you are at all involved in the HVAC/R trade, you know that new equipment may not be manufactured or imported beginning January 1, 2010. This imminent date has most of us at least a little apprehensive about the future. Right now, all the details and rules have not been firmly established. In most people’s minds, the date a unit is “manufactured” is when it is made in the factory. The EPA has proposed a rule change that would set the date of “manufacture” as the date of final charge. For split systems, this would be when the unit is installed. Adopting this rule change would effectively mean that R-22 split systems could not be installed beginning January 1, 2010. This would make inventory of existing R-22 systems essentially worthless on January 1, 2010.

AHRI has launched a site dedicated to monitoring the issues regarding the HCFC phase out and passing on information to the industry: www.phaseoutfacts.org.

Another good web site to keep an eye on is the EPA site devoted to the HCFC phase out: www.epa.gov/ozone/title6/phaseout/hcfcfaqs.html

Although R-22 will continue to be available for servicing existing systems, the amount of new R-22 available will be substantially less than is available this year, see EPA web site for details
www.epa.gov/ozone/title6/phaseout/hcfc.html

R-22 systems will still be with us for some time since the majority of the current installed base of air conditioning systems use R-22. However, R-22 systems represent the past; R-410A air conditioning systems represent the future. All HVAC/R training labs should have a full complement of R-410A systems. We need to prepare our students for the future, not the past. The training materials you use should support training using the refrigerants of the future, including R-410A. Fundamentals of HVAC/R includes extensive coverage of R-410A. We don’t just talk about R-410A in Unit 23 Refrigerants and Their Properties, but throughout the book whenever specific refrigerant pressures and temperatures are mentioned in examples. In Unit 17 Refrigeration System Components and Operation, the refrigeration cycle diagram uses R-410A as the refrigerant. Unit 27 Refrigerant System Evacuation and Charging uses R-410A for many specific examples of charging charts and operating specifications. Specific details of handling zeotropic refrigerants like R-410A are given in Unit 26 Refrigerant Management and the EPA. In all, 14 units have specific examples of working with and using R-410A refrigerant. R-22 has certainly not been left out. There are still plenty of examples and details using R-22. After all, we will be working on R-22 systems for several years to come. If you have not already moved towards incorporating R-410 your curriculum, now is the time to take the first step. If you are looking for materials that will help your students meet the challenges of the future, please take a look at Fundamentals of HVAC/R.