2. John Hill Technical Training john.hill@goodmanmfg.com
Ext.907

3. TECHNICAL SUPPORT

4. NAECA National Appliance Energy Conservation Act January 23, 2006
Minimum SEER – 13
Previously – 10
Minimum HSPF 7.7
Previously – 6.8

5. Montreal Protocol
Montreal Protocol on Substances that Deplete the Ozone Layer
No Production of R-22 Equipment in 2010

6. Montreal Protocol CFC Phase Out (R-12) HCFC Phase Out (R-22)
1991 – 100%
1996 – 0%
HCFC Phase Out (R-22)
1995 – 100%
2020 – 0%

8. Service Valves Service valves located at 90o angle.
Unobstructed access to gauge ports.
More room to maneuver tools.

9. Access to the Control/Electrical Panel
Two screws to remove the outside cover
Removable Panel
Contactor with lug connectors
Ground with lug connector
Room for field installed accessories

10. Super-heat and Sub-cooling charts
The super-heat and sub-cooling charts will be posted on the back side of the control door.

11. Access to the Condenser Coil
The 2006 units will come with 4 independent louver panels. They are easy to remove for quick accessibility to the condenser coil.

12. 2006 Product Line

13. 2006 Product Line

14. 2006 Product Line

15. INSTALLATION TIPS NO CAPILLARY TUBE EVAPORATORS
LINE SETS WITH ¼ LIQUID 5/8 SUCTION MUST BE LESS THAN 25 FT. IN LENGTH
EVAPORATORS WITH FLOWRATORS CHANGED TO THE PISTON SUPPLIED WITH NEW CONDENSORS
WHEN CHARGING SYSTEM USE SUPERHEAT OR SUBCOOLING METHOD
HEAD PRESSURE WILL BE LOWER THAN 10 SEER SYSTEM
HEAT PUMPS REQUIRE COMPLETE SYSTEM CHANGE OUT

16. INSTALLATION TIPS
USING A 13 SEER CONDENSER WITH A 10 SEER OR LESS EVAPORATOR MAY DEGRADE CAPACITY BY 6% TO 10%.
IN APPLICATIONS WHERE CAPACITY IS MARGINAL, IT MAY BE NECESSARY TO INCREASE THE CAPACITY OF THE CONDENSOR BY ½ TON.
IT IS IMPORTANT THAT WHEN DOING THIS , THAT THE ELECTRICAL SERVICE IS ADEQUATE FOR THE LARGER CONDENSOR. IT MAY ALSO BE NECESSARY TO INCREASE THE SIZE OF THE REFRIGERATION LINE SET.

17. Montreal Protocol/US Phase-Out
R-22 Phase-Out Timeline %
$20/lb
100
R-22 Cost
Montreal Protocol/US Phase-Out
% 1996 CAP
65% 50
$10/lb
35%
EU Phase-Out
10%
$2/lb
Explain current phase out of R22 units. Be sure to point out that time is running out on R22.
1999
2004
2010
2015
2020
No New Equip. EU
No New Equip. US

18. Why R-410a? R-22 Alternatives R-134a R-407c R-410a R-417b Propane
Carbon Dioxide
Several replacements for R-22 have been investigated by the refrigerant producers and equipment manufacturers. The three generally considered are R-134A, R-407C, and R-410A. Greenpeace has lobbied for the use of Propane as a refrigerant, but U.S. manufacturers have ruled this out as a safety concern. Japanese car manufactures are developing CO2 systems for possible use in automotive applications.
R-134A is a pure refrigerant, not a blend like the other alternatives.
This refrigerant has proven to be a near drop in for R-12 in automotive and some refrigeration applications. As a pure refrigerant, R-134A does not suffer from a condition known as fractionation. Fractionation can occur in some blends and allow one component to escape at a different rate than the others.

19. US New Refrigerant Transitions
Screw Chillers Ton
R-134A
R-22
R-410A
R-407C
Commercial 5 to 100 Ton
R-22
R-410A
R-410A
Residential 1.5 to 5 Ton
Explain how Transition in the next couple of years will be drastic.
R-22

20. Back Seat Service Valves
All “R” series models equipped with back seating service valves
RVP February 2003
Explain issues with this valves

21. R-410 Facts Ozone friendly- No Chlorine
Replacement for R-22, NOT a drop in!
Higher Pressure Range-50 to 75% higher than R-22
Requires Special Lubricants

22. Components that needed Redesigned for R410A
Compressor
Condenser coil
Filter Drier
Expansion device
Evaporator
Pressure switches
Cover the effects of higher pressures than R22 refrigerants.
Working pressures of a minimum of 610psi.

23. Compressors Copeland ZRS and ZPS Compressors
We will get further into these later in the program

24. Pressure Switches Pressure Switches have to be at higher settings
Low Pressure R410a=50psi
High Pressure R410a=610psi

25. Line Sets
Line Sets
New Line Sets are always recommended, but required if:
The previous system had a compressor burn out.
The existing line set has oil return traps.
The existing line set has been open to the atmosphere for an extended time.
The existing line set is larger than or smaller than the recommended line size for the Amana R-410a system.
The existing line set is damaged, corroded, or shows signs of abrasion/fatigue.
Very important that all understand this section

26. Special Tools Required
Differences in Saturation Pressures between R22 and R410a affects many of the tools the Technician must use when Charging and Servicing an R410A system.
Some of the tools used on R22 systems may be unacceptable for use on R410a systems.

27. Manifold Gauge Set
Standard Gauges and hoses cannot be used safely with R410a.
The High Side gauge should have a range of zero to 800psi.
The Low Side gauge should have a range from 30 inches vacuum to 250psi.
The Low Side gauge should also have a 500psi retardation feature. This slows the movement of the gauge needle at higher pressures.
Safety is a concern without the use of proper gauges and hoses.

28. Manifold Gauge Set

29. Refrigerant Hoses
The 600psi rating of standard hoses is NOT adequate for R410a.
Hoses need to be rated for a 800psi working pressure, with a 4000psi bursting rating.
5 to 1 safety margin is necessary to prevent dangerous hose ruptures.

30. Vacuum Pumps
Pumps used with CFC and HCFC charged systems may also be used on R410a systems as long as the pump is capable of attaining a vacuum of level of at least 250 Microns.
Will cover proper evacuations further in program

31. Leak Detectors
Leak detectors should be checked to see that they are designed to properly detect R410a.
The detector should have adjustable sensitivity to allow leaks to be pinpointed in areas where background vapor might cause false readings.

32. Two Stage Compressor Features: High Efficiency Quiet Operation
Scroll Technology
No Shut-Down to Shift Capacity

33. Copeland Scroll™ UltraTech Two-Stage Modulation Scheme
Bypass
Ports Closed
Bypass
Ports Open
100% Capacity
67% Capacity

34. R-410a It’s a Blended Refrigerant. 50% R-32 and 50% R-125.
This blend is a near-azeotrope, not a true azeotrope like R-502.
A true azeotrope is a mixture that maintains its composition through both the liquid and vapor phase.

35. R-410a
For a near-azeotrope, the individual refrigerants evaporate or condense at different temperatures.
The differences between these boiling points with mixed refrigerants is called
“ TEMPERATURE GLIDE”
Pose question as to what would happen with a high glide to get reaction.

36. R-410a
When temperature glide is high the refrigerants can separate during evaporation or condensation.
This changes the composition of the resulting vapor and liquid.
This separation is called:
“FRACTIONATION”

37. R-410a Fractionation is very low.
R410a does not significantly separate in the system and the composition of the refrigerant has very minor changes if a leak occurs.
But the fact that some fractionation occurs, means that charging techniques must be adjusted.
The temperature glide of R410a is very low, thus it acts very much like a single refrigerant.

38. R-410a
Another significant difference between R410a and R22 is its saturation pressure range.
R410a has a higher pressure range curve than R22.
Remember, R410a is a near azeotrope that is subject to some fractionation. At any specific temperature it has a higher vapor pressure when saturated.
Example:
85 ambient 200/75
85 ambient 315/125

39. Cylinders
Most R410a cylinders have an internal dip tube which allows the feeding of liquid when the cylinder is in an upright position. They must be inverted for for vapor flow.
Color is rose(pink).
The cylinder has to have minimum cylinder pressure requirement of 400 psig rating (DOT 4B400 or DOT 4BW400)

40. Lubrication
The chemistry of R410a makes it incompatible with mineral based lubricants.
Mineral oils typically used with R22 has relativity low Miscibility with with R410a.
Miscibility is the ability of an oil to dissolve uniformly in refrigerant in either the liquid or vapor state.

41. Lubrication
The preferred lubricants are the Polyolester or ester based oils.
Commonly known as POE oils.
POE oils are miscible with with any mineral oil traces that might be in the system.
While miscible, it is very important to remove as much mineral oil, particulates, and moisture from existing line sets as possible.

42. Lubrication The POE oils are more Hygroscopic than mineral oils.
This means that they absorb moisture very rapidly.
Exposure to the atmosphere must be limited.
The oil will break down into acid and alcohol
Keep the system closed

43. Lubrication
Any moisture absorbed by into POE oils cannot be removed with a vacuum pump-Only a new drier will work!
Break a recovery vacuum with Nitrogen!
Keep all systems closed until any component replacements are ready for installation.

44. Brazing Should be using at least 2% silver alloy
Always wear glasses and gloves.
Always purge with nitrogen when brazing.
Protect the service valves with wet rags or heat sink material.
Scale will get you with POE oils.
POE’s are also an excellent solvent-will strip old copper and scale!

45. Evacuation Ask for someone to explain this chart to get participation.
Discuss use of micron gauges, ask for hands of those who practice this.

46. Evacuation
Alternate method, but creates more time on job

47. Recovery Yes, you still have to recover the refrigerant.
R410a does not readily biodegrade, care should be taken to avoid any releases to the environment.
The recovery machines used for R410a must be designed to prevent cross contamination between oils and refrigerants..
Use machines certified for use with R410a.

48. Recovery
Preferred type is an oil-less compressor model with a pump down feature for removal of all refrigerant from the machine after each use.
If an oil bearing compressor is used, the machine should be restricted to R410a refrigerant. The machine must use ester based oil.
How many are set up already? Ask for hands

49. Charging Charge through the suction side of the system.
Use a commercial-type metering device in manifold hose to allow liquid to vaporize.
Follow your typical sub-cooling and superheat procedures to arrive at the correct charge.

50. Charging Single Stage
Explain chart

51. Charging RSG Set unit to operate at low stage cooling
Operate for 10 minutes.
Check and record low stage liquid pressure at the service valve.
Set thermostat to operate at high stage.
Check and record high stage liquid pressure at service valve.
Explain that since 2 stage-procedures are different

52. Charging RSG
The high stage pressure should be noticeably higher than the low stage liquid pressure.
If the pressures are identical, the compressor did not switch from low to high stage.
Verify wiring and t-stat settings.
Verifying unloader is working

53. Charging RSG
Run the unit on low stage and make the final charge adjustments on low stage.
Do not adjust charge to change sub-cooling on high stage. Charge adjustments must only be made under low stage cooling.

54. For technician use to refer to only

55. Complete chart in the I/O and Service manual