ServiceInformation Retrofit of R-134a YVAA and YVWA System to R-513A

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Equipment Affected:

YVAA and YVWA

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Product Technical Support

GENERAL NOTES ABOUT XP10 / R-513A Opteon™ XP10 (R-513A) is a low global warming potential (GWP) hydrofluoro-olefin based (HFO) refrigerant developed to replace R-134a in medium-temperature refrigeration systems. The R-513A is nonflammable under normal conditions. However, when mixed with high concentrations of air or oxygen under elevated pressure, this product can become combustible in the presence of an ignition source. This product should not be mixed with air to check for system leaks.

The overall compressor performance (capacity and efficiency) will be similar when operating on R-513A versus R-134a. Compressor suction and discharge pressures for R-513A will differ slightly from R-134a. The R-513A also has lower compressor discharge temperature than R-134a. When the refrigerant selection is changed in the software, this will change some default setpoints affected by this change. Because of the effects listed above it is advisable to have a new chiller rating provided based on the original design operating conditions to provide a basis for compari-son between the two refrigerants. This should always be done in advance of the refrigerant change to eliminate any unwanted affects from affecting final performance.

(source: 2015 The Chemours Company FC, LLC. R-513A Retrofit Guidelines to Replace R-134a)

RETROFIT OF R-134a CHILLERS (R-134a) CHILLERS TO R-513A (R-134a ONLY, NOTE: R-22 RETROFIT IS NOT INCLUDED IN THE SI)The following detailed steps are the recommended procedure for retrofitting R-134a systems to R-513A. When in doubt, follow F-gas Regulation / EN 378-4: 2017 throughout the whole process.

YVWA: It is necessary to replace the liquid level sensor. R-513A is included as a selectable option for refrigerant in the current version of the chiller control software. If the chiller in the field is an old one (produced before October, 31st 2017) then the software needs to be updated. The general set new points have been integrated in the software. The setpoints will change automatically if one selects R-513a in the control panel interface.

Work on this equipment should only be done by properly trained personnel who are qualified to work on this type of equipment. Failure to comply with this requirement could expose the worker, the equipment and the building and its inhabitants to the risk of injury or property damage. The instructions on this service bulletin are written assuming the individual who will perform this work is a fully trained HVAC & R journeyman or equivalent, certified in refrigerant handling and recovery techniques, and knowl-edgeable with regard to electrical lock out/tag out procedures. The individual performing this work should be aware of and comply with all Johnson Controls, national, state and local safety and environmental regulations while car-rying out this work. Before attempting to work on any equipment, the individual should be thoroughly familiar with the equipment by reading and understanding the associated service literature applicable to the equipment. If you do not have this literature, you may obtain it by contacting a Johnson Controls Service Office. Should there be any question concerning any aspect of the tasks outlined in this bulletin, please consult a Johnson Controls Service Office prior to attempting the work. Please be aware that this information may be time sensitive and that Johnson Controls reserves the right to revise this information at any time. Be certain you are working with the latest information.

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Before starting this retrofit please read through this document completely. Have all appropriate parts in hand to avoid multiple trips back to the customer site.

1. Establish Baseline Performance with R-134a

Collect system performance data while R-134a refrigerant is in the system. Check for correct refrigerant charge and operating conditions. The baseline data of temperatures and pressures at various points in the system (evaporator, condenser, compressor suction and discharge, evaporator vapor superheat, and condenser liquid subcool) at normal operating conditions will be useful in noting any deficiencies in system operation and when optimizing operation of the system with R-513A.

2. Check Lubricant

For YVWA operating on R-134a, the POE lubricant currently in the system is suitable for use with R-513A. If there are questions about the lubricant, or tests indicate it is contaminated or has a high acid number, then the lubricant must be changed. If there has been any event that may contaminate the oil, several oil changes may be required to bring the oil back into allowable limits.

3. Remove the R-134a Charge into Recovery Cylinders

Confirm that the evaporator has water flow while removing the refrigerant charge to prevent freezing and tube damage.

Remove the entire R-134a refrigerant from the system into a recovery cylinder(s). Weigh the amount removed to use as a guide for the quantity of R-513A to be charged into the system.

4. Perform Other System Modifications

• Fit new filter drier cores in the liquid line and drier in the eductor circuit plus a new oil filter. (Good practice but not essential) Oil filter drier cannisters must be changed with every oil change.

• Change the old liquid level sensor (325-44846-001), the new part number is: 025-44846-202 (June 2018: 7-8 weeks leadtime) Upgrade the IPU2 control software with the new chip using Form 201.28-NM1.1, page 120.

• For dual circuit the software version is: Y.WCS.31.04, the chip part number is 031-03476-030

• For single circuit the software version is: Y.WCS.41.04, the chip part number is 031-03476-040

• Select the refrigerant type to R-513A

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5. Evacuate System and Check for Leaks

Ensure while evacuating any VSD equipped system that the VSD power is isolated at the VSD Isolator. To remove air or other non-condensable gases and any residual moisture from the system, evacuate the system to full vacuum (<1000 (500 preferred) microns [<29.88 in Hg vacuum] [<1.33 mbar]). If the system is not able to hold vacuum, it may be an indication of a leak requiring appropriate repairs. After vacuum test, pressurize the system with dry nitrogen, taking care not to exceed the system design maximum pressure, and check for leaks. After leak tests are complete then release the Nitrogen in a safe and controlled manner that does not represent a danger to personnel, ensure that Nitrogen is not released into an enclosed space, and ensure any area where Nitrogen is released is adequately ventilated. Do not use mixtures of refrigerant and air to check for leaks, as these mixtures can become combustible. After leak checking, remove residual nitrogen with a vacuum pump.

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6. Charge System with R-513A

Prior to charging the unit ensure that you can confirm you have water flow passing through the evaporator at a flow rate as near to design as is possible. Charge the unit using weighing / refrigerant scales and a charging unit capable of transferring liquid from the cylinder to the chiller. Ensure all service valves are open in the chiller allowing refrigerant (liquid or vapor) to flow to all parts of the system.

Refrigerant R-513A is a blend, so it is important to remove liquid only from the charging cylinder. (If the cyl- inder does not have a valve with a dip tube, invert the cylinder so that the valve is underneath the cylinder.) The proper cylinder position is often indicated by arrows on the cylinder and the cylinder box. Once liquid is removed from the cylinder, the refrigerant can be allowed to enter the refrigeration system as liquid or vapor as desired.

WARNING: Do not charge liquid refrigerant into the suction line. This can cause irreversible damage to the compressor. Use the manifold gauges or a throttling valve to flash the liquid refrigerant to a vapor prior to entering the suction line.

YVWA chiller will require a similar charge size of R-513A as the original R-134a charge. The optimum charge will vary depending on the system design and operating conditions. The initial charge should be approximately 85% of the standard charge size for R-134a. After startup and adjustment, the final charge amount will be ap-proximately 97% of the R-134a charge.

7. Start Up System and Check Operation

Monitor and adjust liquid level sensor to 50% level of sight glass to achieve optimum discharge superheat sub-cooling. Monitor oil levels in compressor. Add oil as required to maintain proper levels. Expect the discharge superheat and sub-cooling to be the same as when the unit runs on R-134a.

8. Label System with New Refrigerant

Change the nameplate and labelling that was ordered in advance.

9. Provide customer with new documentation.

The process for refrigerant conversion of a YVAA will be similar between YVAA and YVWA. YVAA is an air-cooled condenser with microchannel coils that uses a refrigerant level switch that does not require to be changed or calibrated. The YVWA uses a level sensor that will require a calibration in a water cooled round tube condenser.

031-03476-010 is the software part number for YVAA chillers with a SD Card slot 3478 motherboards. There is currently no software available on the older 2478 motherboards.

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FREQUENTLY ASKED QUESTIONS• Is it necessary to change oil? Not necessary unless it’s contaminated.

• Why do I have to change the liquid level sensor? The new refrigerant requires new calibrations. The sensor cannot be adjusted on site which is why a new sensor with correct calibration is required.

• Which Liquid Level Sensor (LLS) needs to be replaced? The original part number for R-134a units is 325-44846-001. Number 3 and 46 in below schemes:

LD27127

46

3

46

• Where can I order the Liquid Level Sensor from? https://easyparts.johnsoncontrols.com

• What is the new Liquid Level Sensor part number that I need to order? 025-44846-202 (June 2018: 7-8 weeks leadtime)

• Do I need two sensors for two circuit units? Yes.

• Where can I order the new nameplate from? Nantes Factory. Or just have a sticker made to cover the R-134a with a new label stating R-513A wherever applicable on the unit.

• Do I have to change the software on site? Not always, you only need to change the software to conform to the software versions shown in this letter. From then on the R-513A option is available in the software.

• What are the part numbers for the software for units produced before October, 31st 2017: DOWNLOAD AND INSTALL THE LATEST SOFTWARE SUITABLE FOR YOUR CHILLER FROM THE SOFTWARE SITE http://firmware.eng.york.york.com/

For dual circuit the software version right now (Jan. 2018) is: Y.WCS.31.04, the chip part number is 031-03476-030

For single circuit the software version right now (Jan. 2018) is: Y.WCS.41.04, the chip part number is 031-03476-040

• How can I get revised documentation? EG and ICOM? Currently the R-513A option is available as SQ, so the ICOM and EG is not updated. If you have a project then please contact P&D or Product Management to help you prepare the documentation update.