MackFri^® - 01a

MackFri^®- 01a
ASHRAE Name : R-401a
(53% HCFC-22 / 34% HCFC-124 / 13% HFC-152a)
The Blends for replacement of R-12.

Packing: 13.6 Kg. (30 lb.) Net nonrefillable Steel cylindersand individual neutral carton outside.
                 6.8 Kg. (15 lb.) Net nonrefillable Steel cylinders and individual neutral carton outside.

- Acceptable Substitutes for Class I (CFCs) Substances in Air Conditioning under the Significant New Alternatives Policy (SNAP) Program printed on December 18, 2000 as:
a) replacement for R-12 and R-500 in the Reciprocating Chillers (R, N)
b) replacement for CFC-114 in the Industrial Process AC (R, N)
c) replacement for CFC-12 and R-500 in the Residential Dehumidifiers (R, N)

- Acceptable Substitutes for Class I (CFCs) Substances in Commercial Refrigeration under the Significant New Alternatives Policy (SNAP) Program printed on December 18, 2000 as:
a) replacement for CFC-12 in the Cold Storage Warehouses (R, N)
b) replacement for CFC-12 in the Ref. Transport (R, N)
c) replacement for CFC-12 in the Retail Food Ref. (R, N)
d) replacement for CFC-12 in the Ice Machines (R, N)
e) replacement for CFC-12 in the Vending Machines (R, N)
f) replacement for CFC-12 in the Water Coolers (R, N)

- Acceptable Substitutes for Class I (CFCs) Substances in Non-Commercial Refrigeration under the Significant New Alternatives Policy (SNAP) Program printed on December 18, 2000 as:
a) replacement for CFC-12 in the Industrial Process Refrigeration (R, N)
b) replacement for CFC-12 in the Ice Skating Rinks (R)
c) replacement for CFC-12 and R-500 in the Household Refrigerators (R, N)
d) replacement for CFC-12 and R-500 in the Household Freezers (R, N)

(R) = Retrofit Uses
(N) = New Uses

Similar : SUVA MP39

Physical properties:

Physical State Gas at ambient temperatures Molecular weight   94.4        Boiling point atm,oF(oC)   -27     (-33.0)   Liquid Density at 77oF (25oC), lb/ft3 (kg/m3)   74.5     (1194)   Vapor Pressure of Satd. Liquid at 77oF (25oC), psia (kPa)   112.1     (772.9)   Heat Capacity of Liquid at 77oF (25oC), Btu/lb oF (kJ/kgK)   0.310     (1.3)   Heat Capacity of Vapor at 1 atm at 77oF (25oC), Btu/lb oF (kJ/kgK)   0.176     (0.737)   Thermal Conductivity of Liquid at 77oF (25oC), Btu/hr.ft oF (W/mK)   0.0517     (0.09)   Thermal Conductivity of Vapor at 1 atm (101.3 kPa), Btu/hr.ftoF (W/mK)   0.00688     (0.0119)   Critical Temperature, oF (oC)   226     (108)   Critical Pressure, psia (kPa)   668     (4604)   AEL/TLV, 8- or 12-hr TWA, ppm   1,000        ODP, CFC-12=1   0.028        GWP, CO2=1   973        ASHRAE Safety Classification   A1/A1        Refrigerant Cylinder Color, PMS Code   177

MackFri^®-01a (R-401a) CFC-12 Substitute - This is not a new molecule. This is a mixture of 3 old molecules (R-22, R-124 and R-152a) and this solution does not produce a new molecule. The toxicity of all 3 components and the ozone depletion have been known and tested for 30 years: R-124 (Chlorotetrafluoroethane) has an ozone depletion potential ODP of 0.026, R-22 (Chlorodifluoromethane) has an ozone depletion potential ODP of 0.034. Difluoroethane has no ozone depletion potential. All 3 components are currently registered with the EPA on an individual basis.
This blend contain hydrochlorofluorocarbons (HCFCs), chemicals currently regulated by law and scheduled for control beginning in 1996. It is mixture of HCFC-22, HFC-152a and HCFC-124.

MackFri^®-01a, is a suitable retrofit refrigerant for medium- and low-temperature R-12 systems, such as reach-in and walk-in -coolers, for supermarket display cases, water coolers, food and dairy display cases, beverage dispensers and vending machines, and home refrigerators. The use of MackFri^®-01a should be limited to applications where the evaporator temperature is above -10^oF (-23^oC).

MackFri^®-01a require no oil changes as they operate well in mineral oil (or alkylbenzene oil) found in CFC-12 systems. This refrigerant is all EPA SNAP acceptable for stationary applications and acceptable with use restrictions for the MVAC sector. Performance is equal to or often better than that of the original CFC-12 system.

IMPORTENT SAFETY INFORMATION.
Do not work in high concentrations of refrigerant vapors. Always maintain adequate ventilation in the work area. Do not breathe vapors. Do not breathe lubricant mists from leaking systems. Ventilate the area well after any leak before attempting to repair equipment.
Do not use handheld leak detectors to check for breathable air. These detectors are not designed to determine if the air is safe to breathe. Use oxygen monitors to ensure adequate oxygen is available to sustain life.
Do not use flames or torches to search for leaks. Also do not use flames in high concentrations of refrigerant. Open flames release large quantities of acidic compounds in the presence of all refrigerants, and these compounds can be hazardous. Also do not use torches as leak detectors. Old halide torches look for chlorine, which may not be present with new refrigerants. Use an electronic leak detector designed to find the refrigerants you are using.
If you detect a visible change in the size or color of a flame when using torches to repair equipment, stop work immediately and leave the area. Ventilate the work area well and stop any refrigerant leaks before resuming work. These flame effects may be an indication of very high refrigerant concentrations, and continuing to work without adequate ventilation may result in injury or death.
Note: Any refrigerant can be hazardous if used improperly. Hazards include liquid or vapor under pressure, and frostbite from the escaping liquid. Overexposure to high concentrations of vapor can cause asphyxiation and cardiac arrest. Please read all safety information before handling any refrigerant. Refer to the appropriate Material Safety Data Sheet (MSDS) for more safety information about each refrigerant.

LUBRICANT AND FILTER DRIER INFORMATION.
Lubricants
Lubricant selection is based on many factors, including compressor wear characteristics, material compatibility, and lubricant/refrigerant miscibility that can affect oil return to the compressor. Before starting a retrofit, consult the compressor manufacturer to determine the correct lubricant for your compressor. Other information sources are lubricant manufacturers, and system manufacturers.
Either alkylbenzene (AB) lubricants and mineral oil lubricants can be used with MackFri^®-01a service refrigerants.
To provide optimum oil return, a single compressor lubricant change from mineral oil to AB lubricant using the same viscosity is recommended. This process will normally replace 50-80% of the existing mineral oil, and satisfies the recommendations and requirements of most compressor manufacturers.
Field experience has shown that MackFri^®-01a work successfully with the existing mineral oil in many unitary and other close-coupled systems where oil return is not a concern such as reach-in coolers, point-ofpurchase display units, vending machines, beverage dispensers, and domestic refrigerators. An oil change may be necessary, however, in systems that have poor oil return if the evaporator is distant from the compressor, the evaporator is below the compressor, or if there are low line velocities.
Filter Drier
Change the filter drier during the retrofit. This is a routine practice following system maintenance. There are two types of filter driers commonly used, solid core and loose filled. Replace the drier with the same type you are using now. The drier label will show which refrigerants can be used with that drier.

RETROFIT OF CFC-12 TO MackFri^®-01a.
The following detailed discussion is the recommended procedure for retrofitting R-12 systems to MackFri^®-01a.
1. Establish baseline performance with CFC.
Before making any hardware changes, compare current system operating data with normal operating data. Correct any deficiencies and record final data as a performance baseline. Collect system performance data while the old 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, superheat and subcool, etc.) at normal operating conditions will be useful when optimizing operation of the system with the MackFri^®-01a refrigerant. A System Data Sheet is included at the back of this document to record baseline data.
2. Remove CFC from the system into a recovery cylinder.
The existing R-12 charge should be removed from the system and collected in a recovery cylinder using a recovery device capable of pulling 10-15 inHg vacuum (30-35 kPa). If the recommended existing charge size for the system is not known, weigh the amount of refrigerant removed. The initial quantity of MackFri^®-01a refrigerant to charge to the system can be determined from this figure. The charge must be collected in a recovery cylinder.
DO NOT VENT THE REFRIGERANT.
(Skip steps 3 and 4 if AB lubricant is already in the system or if not changing the mineral oil; see Lubricants section for more information.).
3. Drain mineral oil from the system and measure the volume removed.
One quick oil change ensures that adequate mineral oil has been removed from the system (see Lubricants section for additional information). If mineral oil is the existing lubricant, it will have to be drained. This may require removing the compressor from the system, particularly with small hermetic compressors that have no oil drain port. In this case, the lubricant should be drained from the suction port on the compressor, which will remove most of the lubricant. Remember that most of the mineral oil must be removed from the system before adding the alkylbenzene lubricant.
Larger systems may require drainage from additional points in the system, particularly low spots around the evaporator, which will remove 50-80% of the lubricant. In systems with an oil separator, any lubricant present in the separator should also be drained. In all cases, measure the volume of lubricant removed from the system. Most of the existing oil can be drained from the compressor crankcase, but particular attention also should be paid to low spots around the evaporator where lubricant often collects. The mineral oil also should be drained from oil separators and/or suction accumulators.Record this information on the Retrofit Checklist for R-12 Systems (see page below). Compare this volume with the compressor/system specifications to ensure that the majority of lubricant has been removed. Consult the compressor manufacturer for recommendations on allowable residual mineral oil in AB or POE lubricant. If poor system performance is noted on start-up, an additional lubricant change may be required. Our experience is that this occurs in less than 1% of retrofits.
4. Add AB lubricant; use the same volume as removed in Step 3.
In most cases, the lubricant replacement will be AB or perhaps POE. Charge the compressor with the same volume of new lubricant as the amount you removed from the system in step 3. Use a lubricant viscosity and grade recommended by the compressor manufacturer for the MackFri^®-01a refrigerant you are using; or use a similar viscosity to the mineral oil you removed if compressor information is not available. A typical viscosity is 150 SUS or ISO 32 for many compressors.
5. Measuring Existing Lubricant
Measure and record the volume of lubricant removed from the system. Compare this amount with the amount recommended by the manufacturer to ensure that the majority of lubricant has been removed. This volume also will be used as a guide to determine the amount of alkylbenzene lubricant to add in the next step.
6. Recharge Compressor with Alkylbenzene Lubricant
Add to the compressor the same volume of alkylbenzene lubricant as the volume of mineral oil drained in step 5. In small systems with short refrigerant lines, the mineral oil may have sufficient miscibility with MackFri^®-01a to achieve adequate oil return to the compressor. However, We recommend using a commercially available alkylbenzene oil of the same viscosity grade as the mineral oil, typically 150 SUS, to ensure optimum performance. Check with the compressor manufacturer for the correct viscosity grade.
7. Reinstall the Compressor
If the compressor was removed to drain the oil, reinstall the compressor following the standard service practices recommended by the manufacturer.
8. Evaluate the Expansion Device
Most CFC-12 systems with expansion valves will operate satisfactorily with MackFri^®-01a or MackFri^®-01b. If the system uses a capillary tube, it will need to be replaced with one of greater restriction to achieve satisfactory performance over the complete range of design conditions. We recommend consulting with the equipment manufacturer before replacing the capillary tube. If the manufacturer's information is not available, the suggested approach is to replace the capillary tube with one of the same diameter, but about 50 percent longer. For example, if the CFC- 12 system's capillary tube is 40 inches (1.0 meter) long, its optimum length for MackFri^®-01a hould be approximately 60 inches (1.5 meters). It may be easier and more effective, however, to replace the capillary tube with a properly sized expansion valve. In most cases, the unit can be operated with the original capillary tube by undercharging the unit with a MackFri^®-01a and MackFri^®-01b blend. Operation may be satisfactory if the ambient conditions are expected to be relatively constant. If operation is expected over a wide range of condensing temperatures, unsatisfactory performance may result at both high- and low-condensing temperatures. The potential problems could include liquid floodback and motor overload at high-condensing temperatures, as well as a loss of liquid seal entering the capillary tube at low-condensing temperatures.
9. Replace the filter/drier.
It is routine practice to replace the filter/drier following system maintenance. Replacement driers are available that are compatible with MackFri^®-01a refrigerants. See above of this manual for additional information on driers. Following system maintenance, a recommended service practice is to replace the filter drier. There are two types of filter driers commonly used in refrigeration equipment - loose-fill and solid-core. Many, but not all, of the standard loose-fill and solid-core driers used with CFC-12 are compatible with MackFri^®-01a and MackFri ^® - 01b.
10. Evacuate system and check for leaks.
Use normal service practices. To remove air or other noncondensables in the system, evacuate the system to near full vacuum (29.9 inHg vacuum [500 microns] or less than 10 kPa). Attempting to evacuate a system with the pump connected to only the low side of the system will not adequately remove moisture and non-condensibles such as air. Use a good electronic gauge to measure the vacuum. An accurate reading cannot be made with a refrigeration gauge.
Do not use mixtures of air and refrigerant under pressure to check for leaks; these mixtures can be combustible.
11. Charge with MackFri^®-01a refrigerant. Remove liquid only from charging cylinder.
The proper cylinder position for liquid removal is indicated by arrows on the cylinder and cylinder box. Once liquid is removed from the cylinder, the refrigerant can be charged to the system as liquid or vapor as desired. Use the manifold gauges or a throttling valve to flash the liquid to vapor if required. In general, the refrigeration system will require less weight of the MackFri^®-01a refrigerant than of R-12. The optimum charge will vary depending on the system design and operating conditions, but for most systems the best charge size will be 75-90% by weight of the original R-12 charge. In retrofits of R-500 systems with MackFri^®-01b, the refrigeration system will require a slightly larger charge, about 105% of the original R-500 charge. For best results:
It is recommended that the system be initially charged with about 75% by weight of the original charge. For replacing R-500 with MackFri^®-01b, start with 100% by weight of the R-500 charge.
Add the initial charge of MackFri^®-01a refrigerant to the high-pressure side of the system (compressor not running) until the system and cylinder pressures equalize. Then connect to the low-pressure side of the system, start the compressor, and load the remainder of the refrigerant slowly to the suction side of the system. You should be removing liquid from the charging cylinder, and therefore should charge slowly to allow the refrigerant to flash (vaporize) before entering the compressor suction and avoid compressor damage.
When charging the system with either MackFri^®-01a or MackFri^®-01b, it is important to remember that these products are blends and not azeotropes. For this reason, special charging procedures are required to ensure optimal system performance. It is essential when using either MackFri^®-01a or MackFri^®-01b that the system be liquid-charged by removing only liquid from the cylinder. Never charge the system with vapor from a MackFri^®-01a and MackFri^®-01b blends cylinder. Vapor-charging a MackFri^®-01a and MackFri^®-01b blends will result in the wrong refrigerant composition and may result in a loss of system performance. The cylinders for both products are equipped with dip tubes to facilitate liquid-removal with the cylinder in the upright position. A throttling valve should be used to control the flow of refrigerant to the suction side to ensure that the liquid is converted to vapor prior to entering the system.
Note: To prevent compressor damage, do not directly charge liquid into the suction line of the unit.
12. Start up system, adjust charge size. Label system for the refrigerant and lubricant used.
Start the system and let conditions stabilize. If the system is undercharged, add more MackFri^®-01a refrigerant in small amounts (still removing liquid from the charging cylinder) until the system conditions reach the desired level. See the pressure-temperature charts in this bulletin to compare pressures and temperatures for the MackFri^®-01a refrigerant you are using. MackFri^®-01a refrigerants are more sensitive to charge size than CFCs. System performance will change quickly if the system is overcharged or undercharged. Sight glasses in the liquid line can be used in most cases as a guide, but system charge should also be determined by measuring system operating conditions (discharge and suction pressures, suction line temperature, compressor motor amps, superheat, etc.). Attempting to charge until the sight glass is clear may result in overcharging the refrigerant. Please read “How to Determine Suction Pressure, Superheat and Subcool.”
Systems being charged with MackFri^®-01a or MackFri^®-01b require a smaller charge size than those using CFC-12. The charge typically will be about 90 percent by weight of the original CFC-12 charge with expansion-valve or optimized capillarytube systems. If the original capillary tube is used, it will generally be necessary to undercharge the system to prevent liquid floodback to the compressor.
We recommend initially charging the system with 75 percent by weight of the original CFC-12 charge. For mediumtemperature refrigeration applications, if the original CFC-12 charge was 100 pounds (50 Kg), initially charge 75 pounds (37.5 Kg) of MackFri^®-01a. The same procedure is used for MackFri^®-01b.
13. Check System Operation
Start the system and let conditions stabilize. If the system is undercharged, add additional MackFri^®-01a and MackFri^®-01b in increments of 5 percent by weight of the original CFC-12 charge. For example, if the original charge was 100 pounds (50 Kg), charge in increments of 5 pounds (2.5 Kg). Continue until desired operating conditions are achieved. Compressor suction pressures for MackFri^®-01a after stabilization should be within about 1 psi (5 to 10 KPa) of normal system operation with CFC-12 for most medium-temperature systems.
Compressor discharge pressures typically will be about 10- 20 psi (75-150 kPa) higher than normal system operation with CFC-12. For MackFri^®-01b, the suction pressure will be close to that of CFC-12 at low evaporator temperatures -20^oF (-29^oC), but may be as much as 8 or 9 psi (60 kPa) higher at medium temperatures 25°F (-4^oC). The discharge pressure may be as much as 70 psi (450 to 500 kPa) higher when exposed to extreme ambient conditions.
It may be necessary to reset the high pressure cutout to compensate for the higher discharge pressures of the MackFri^®-01a Blend system. This procedure should be done carefully to avoid exceeding the recommended operating limits of the compressor and other system components. The use of an expansion device not optimized for the system, such as the original capillary tube, will make the system more sensitive to charge and/or operating conditions. As a result, system performance will change more quickly if the system is overcharged (or undercharged) with MackFri^®-01a and MackFri^®-01b.
To avoid overcharging, it is best to charge the system by first measuring the operating conditions (including discharge and suction pressures, suction line temperature, compressor amps, superheat) instead of using the liquid-line sight glass as a guide.
14. Label Components and System
After retrofitting the system with an MackFri^®-01a Blend, label the system components to identify the type of refrigerant (MackFri^®-01a and MackFri^®-01b) and alkylbenzene lubricant (by brand name) in the system. This will help ensure that the proper refrigerant and lubricant will be used to service the equipment in the future.