Bristol

Compressors, Inc.

Number:

124

Application Bulletin

HIGH TEMPERATURE RETROFIT FROM R22 TO R407C

Release EN Number C18811

Release Date 10/20/95

REVISIONS

D00905
E27204
L00910

2/9/96
10/17/97
2/21/03

Bristol Compressors, Inc.

Application Bulletin
No. 124

Release E/N:
Date:
Revision E/N:
Date:

C18811
10/20/95
L00910
2/21/03

Subject: High Temperature Retrofit from R22 to R407C

These are general guidelines only and in no way should they replace, contradict or otherwise take
precedence over any local, state or federal law or regulation pertaining to the recovery,
reclamation, and recycling of refrigerants.
With the phase-out of HCFCs, existing air conditioning/heat pump equipment will need to be
replaced with new equipment or retrofitted with new components (including the compressor) that
are approved for use with the new refrigerant and their lubricants. Using the procedures described
below, existing R22 systems can be retrofitted for use with R407C, allowing them to continue in
service for the remainder of their useful life. Bristol Compressors does not recommend the
changeover of HCFC refrigerants to HFCs in systems that are operating and have no leaks.
R407C is a zeotropic blend of refrigerants of the following composition:
R32
R125
R134a

23%
25%
52%

New High Temperature R407C Compressors are identified by the number 7 in the second digit
of the model number (example: H75B28QABC). These compressors are factory oil charged with
Polyol ester (POE) lubricant and employ an improved lubrication system which are required for
the new refrigerant .
For Bristols approved lubricant type and required oil charge amounts for use with R407C, refer to
the individual compressor model specification sheet. This information can be found on Bristols
website www.bristolcompressors.com. The use of any other lubricant may void the compressor
warranty.

Application Bulletin 124 - Page 2 of 13

Revision L00910

SYSTEM DESIGN
1.0 Refrigerant Metering Devices
The performance of each system is very dependent on the proper operation of each metering
device. Devices such as solenoid valves, capillary tubes, fixed orifice valves, and expansion
valves can perform differently if they are not correctly adjusted or properly sized. For example,
the port size of a valve may not be correct for the new refrigerant density. Each valve and
metering device manufacturer should be consulted, along with the system's manufacturer, to
ensure all components will work properly in the presence of the new refrigerant and lubricant.
2.0 Filter Driers
The proper selection of a system's filter drier is very important. Some filter driers may not be
suitable for R407C refrigerant and polyol ester lubricant. Therefore, the original equipment
manufacturer should be contacted for the proper filter drier selection. It is important to replace the
filter drier any time the refrigerant or lubricant in a system is changed. Specifically, Bristol
Compressors requires a new suction line filter drier be installed during any compressor
replacement. Maintaining good system performance, reliability and cleanliness is closely linked
to proper filter drier operation.
3.0 Controls
The proper operation of many types of air conditioning/heat pump equipment requires that the
control systems function correctly. The control system could be pressure controls, temperature
controls, timing devices, or sophisticated electronic controls. Changing to R407C refrigerant and
polyol ester lubricant in a system could adversely affect these control systems. Each equipment
manufacturer should be consulted to ensure each control system will operate correctly with the
R407C refrigerant/polyol ester lubricant combination. Changes most likely will have to be made
for continued good equipment performance. These changes could involve adjusting temperature
or pressure set points to new values or replacing the control system with a newly designed unit.
4.0

Explanation of R407C vs. R22 Condenser and Evaporator Temperature/Pressure

Graphs
Pressure versus temperature charts and graphs are included on pages 4 through 8 as a general
information guideline. More detailed specific saturated property tables can be obtained from the
chemical manufacturer and should be used when conducting system retrofits. The graphs are
intended to represent the pressures that R407C delivers versus R22 at the equivalent saturated
evaporator and condenser temperatures.
4.1

Explanation of refrigerant glide inherent to R407C

4.1.1 R407C has refrigerant glide. Glide is due to the different boiling and
condensing temperatures of the three components that make up R407C. This
means there is not a one to one relationship between pressure and temperature as
with R22. The saturated vapor and saturated liquid values are approximately
10F apart for a given pressure, whereas with R22 they are one and the same.
4.1.2 The temperature glide of this refrigerant should not cause any problems as long
as you keep in mind the following points about the relationship between
pressures and temperatures of the evaporator and condenser.

Application Bulletin 124 - Page 3 of 13

Revision L00910

a)

When specifying the evaporating and condensing temperatures use the

mean (or average of dew and bubble point) temperatures.

b)

When setting evaporator superheat, calculate it from the saturated vapor (or
dew point) temperature.

c)

When setting subcooling, calculate it from the saturated liquid (or bubble
point) temperature.

4.1.3 Specific examples: (Some interpolation between values may be required)

4.1.3.1

4.1.3.2

Set conditions to run a 45F evaporator, 130F condenser with 20F

superheat and 15 liquid subcooling.
a)

Find the 45F mean temperature from Table 1. The pressure

corresponding to this mean temperature is your suction pressure =
94.4 psia.

b)

Calculate the return gas temperature using the dew point

temperature at this pressure. Example: 50.59F + 20F superheat
= 70.59F return gas temperature.

c)

Find 130F mean temperature from Table 1. The pressure

corresponding to this mean temperature is your discharge
pressure = 339.4 psia.

d)

Calculate the liquid temperature using the bubble point

temperature at this pressure. Example: 126F - 15F subcool =
111F liquid temperature.

Determine the amount of superheat on a system that measures a suction

pressure of 68 psig at the bulb, and the temperature at the bulb reads
52F.
a)

Convert 68 psig to psia = 68 + 14.7 (atmospheric pressure) = 82.7

psia. Look up the dew point temperature from Table 1 at 82.7
psia. This value is 43.3F. Your superheat is 52F - 43.3F =
8.7F.

Application Bulletin 124 - Page 4 of 13

Revision L00910

R407C PRESSURE/TEMPERATURE TABLE

Saturated Liquid and Saturated Vapor Properties

PSIA

PRESSURE
PSIG

DEW POINT
F

MEAN TEMP
F

BUBBLE POINT
F

10

-4.7

-47.90

-54.48

-61.06

11

-3.7

-44.64

-51.18

-57.72

12

-2.7

-44.59

-49.61

-54.62

13

-1.7

-38.75

-45.24

-51.72

14

-0.7

-36.07

-42.53

-48.99

15

0.3

-33.53

-39.97

-46.40

16

1.3

-31.13

-37.54

-43.95

17

2.3

-28.84

-35.23

-41.62

18

3.3

-26.65

-33.03

-39.40

19

4.3

-24.56

-30.91

-37.26

20

5.3

-22.55

-28.89

-35.22

21

6.3

-20.62

-26.94

-33.25

22

7.3

-18.76

-25.06

-31.35

23

8.3

-16.96

-23.25

-29.53

24

9.3

-15.23

-21.50

-27.76

25

10.3

-13.55

-19.80

-26.05

26

11.3

-11.92

-18.16

-24.39

27

12.3

-10.34

-16.56

-22.78

28

13.3

-8.0

-15.01

-21.21

29

14.3

-7.31

-13.50

-19.69

30

15.3

-5.85

-12.03

-18.21

31

16.3

-4.44

-10.60

-16.76

32

17.3

-3.05

-9.20

-15.35

33

18.3

-1.70

-7.84

-13.98

34

19.3

-0.38

-6.51

-12.64

35

20.3

0.90

-5.21

-11.32

36

21.3

2.16

-3.94

-10.04

37

22.3

3.40

-2.69

-8.78

38

23.3

4.61

-1.47

-7.55

39

24.3

5.79

-0.28

-6.34

40

25.3

6.95

0.90

-5.16

45

30.3

12.44

6.44

0.43

50

35.3

17.47

11.52

5.57

TABLE 1
Application Bulletin 124 - Page 5 of 13
Revision L00910

R407C PRESSURE/TEMPERATURE TABLE (Page 2)

PSIA

PRESSURE
PSIG

DEW POINT
F

MEAN TEMP
F

BUBBLE POINT
F

55

40.3

22.14

16.23

10.32

60

45.3

26.48

20.62

14.76

65

50.3

30.56

24.74

18.92

70

55.3

34.40

28.63

22.85

75

60.3

38.04

32.31

26.57

80

65.3

41.50

35.80

30.10

85

70.3

44.79

39.13

33.47

90

75.3

47.94

42.32

36.69

95

80.3

50.96

45.37

39.78

100

85.3

53.85

48.30

42.75

105

90.3

56.64

51.13

45.61

110

95.3

59.33

53.85

48.37

115

100.3

61.93

56.49

51.04

120

105.3

64.44

59.03

53.62

125

110.3

66.87

61.50

56.12

130

115.3

69.23

63.89

58.54

135

120.3

71.52

66.21

60.90

140

125.3

73.74

68.47

63.19

145

130.3

75.91

70.67

65.42

150

135.3

78.02

72.81

67.59

155

140.3

80.07

74.89

69.71

160

145.3

82.08

76.93

71.78

170

155.3

85.95

80.87

75.78

180

165.3

89.64

84.62

79.60

190

175.3

93.19

88.23

83.27

200

185.3

96.59

91.70

86.80

210

195.3

99.86

95.03

90.20

220

205.3

103.01

98.25

93.48

230

215.3

106.05

101.35

96.65

240

225.3

109.00

104.36

99.71

250

235.3

111.84

107.27

102.69

260

245.3

114.60

110.09

105.58

270

255.3

117.28

112.83

108.38

280

265.3

119.88

115.50

111.11

290

275.3

122.41

118.09

113.77

TABLE 1
Application Bulletin 124 - Page 6 of 13
Revision L00910

R407C PRESSURE/TEMPERATURE TABLE (Page 3)

PSIA

PRESSURE
PSIG

DEW POINT
F

MEAN TEMP
F

BUBBLE POINT
F

300

285.3

124.88

120.62

116.36

310

295.3

127.27

123.08

118.89

320

305.3

129.61

125.49

121.36

330

315.3

131.89

127.83

123.77

340

325.3

134.12

130.13

126.13

350

335.3

136.29

132.37

128.44

360

345.3

138.41

134.56

130.70

370

355.3

140.49

136.71

132.92

380

365.3

142.52

138.81

135.09

390

375.3

144.51

140.87

137.22

400

385.3

146.46

142.89

139.31

410

395.3

148.37

144.87

141.37

420

405.3

150.24

146.81

143.38

430

415.3

152.08

148.73

145.37

TABLE 1

Application Bulletin 124 - Page 7 of 13

Revision L00910

Saturated Properties of R407C and R22

Pressure vs. Temperature Graph
Condenser Pressure vs. Temperature
345
335
325

R22

315

R407C SAT VAPOR

305

R407C SAT LIQUID

295
285
275
Pressure (Psia)

265
255
245
235
225
215
205
195
185
175
165
155
145
135
125
80

90

100

110

120

Condenser Temperature (F)

FIGURE # 1

Application Bulletin 124 - Page 8 of 13

Revision L00910

130

Saturated properties of R407C and R22

Pressure vs. Temperature Graph
Evaporator Pressure vs. Temperature
120
R22
R407C SAT VAPOR
100

R407C SAT LIQUID

Pressure (Psia)

80

60

40

20

0
-20

-10

10

20

30

40

Evaporator Temperature (F)

FIGURE # 2

Application Bulletin 124 - Page 9 of 13

Revision L00910

50

5.0 Maximum Continuous Current (MCC) Data

Extensive testing has been done at maximum continuous current (MCC) test conditions with
R407C and R22 refrigerant on many different displacement compressors. The MCC values of the
compressors did not change from the published R22 values when R407C refrigerant was utilized.
6.0 Retrofit Procedure
Summarized below are the recommended procedures for retrofitting an R22 system to R407C:
6.1

Compatibility. Consult the original equipment manufacturer of the system components

for their recommendation on the following:
-

Plastics compatibility
Elastomers compatibility
Lubricant (viscosity, manufacturer, additives)
Solid core driers: Check with drier manufacturer for recommendation

6.2

If compressor has failed:

a. Determine reason for system/compressor failure and correct
b. Recover refrigerant (see step 6.4)
c. Remove compressor (see step 6.5)
d. Measure lubricant remaining in compressor - should be greater than 95% of
original charge to minimize removal efforts in step (e)
e. Assure removal of residual levels of original lubricant (must be less than 5%)
- Purge system heat transfer components using high pressure inert gas (e.g.,
nitrogen)
- Disconnect and purge line sets, or any other component that could trap
lubricant (e.g., oil separator, valves, etc.)
- Large system/long line sets may require up to three (3) oil changes after
replacing compressor
f. Go to 6.6

6.3

If compressor has not failed:

a. Run at reference condition and record on data sheet (see Appendix 2) which will be
used to confirm R407C charge requirement
b. Run system at a high flow condition (highest suction pressure) for 10 - 15 minutes
for optimum lubricant pick-up/return to compressor
e. Go back to step 6.2, item (b) through (f)

6.4

Remove R22 charge. Remove refrigerant and collect in a recovery cylinder using a
recovery device capable of pulling 10 - 20 in. Hg vacuum. If the correct R22 charge
size for the system is not known, weigh the amount of refrigerant removed. The initial
quantity of R407C charged in the system will be determined from this weight.

6.5

Remove compressor. The compressor must be removed from system since it will not
be compatible with HFCs/POE lubricant.

6.6

Replace filter drier. Replace filter drier with one approved for use with R407C
refrigerant/polyol ester lubricant.

6.7

Install compressor. Using normal service practices, install compressor approved for
R407C refrigerant/polyol ester lubricant.
Application Bulletin 124 - Page 10 of 13
Revision L00910

CAUTION: Do not leave compressor or system open to atmosphere for longer

than 15 minutes maximum. Polyol ester lubricants are at least 100 times more
hygroscopic (ability to absorb moisture) than mineral oils. It is almost impossible
to remove the moisture absorbed by the lubricant even with heat and vacuum.
6.8

Leak check system. Use normal service practices. If a leak detector is used, consult the
leak detector manufacturer for units sensitivity to R407C.

6.9

Evacuate. Use normal service practices to remove air and other non-condensables in
the system, evacuate to at least 200 microns.

6.10 Charge system with R407C. To ensure that the proper refrigerant composition is
charged in the system, it is important that liquid only be removed from the charging
cylinder. Once removed from the cylinder, R407C can be charged to the system as
vapor as long as all of the refrigerant removed from the cylinder is transferred to the
system.
Due to the liquid density difference of R407C versus R22, the refrigeration system will
requires less weight of R407C than R22. The optimum charge will vary depending on
the operating conditions, size of the evaporator and condenser, size of receiver (if
present), and length of pipe or tubing runs in the system. For most systems, the
optimum charge will be 85 - 90% by weight of the original R22 charge. It is
recommended that the system be initially charged with about 85% by weight of the
original R22 charge (refer to section 6.4).
Add the initial charge to the liquid line of the system with the compressor not running.
When the system and cylinder pressures are equal, start the compressor and meter the
remainder of the refrigerant into the suction line of the system. Since some
compressors may be damaged if liquid refrigerant enters the suction side of the
compressor, it is important to charge the refrigerant slowly into the suction line to
allow it to vaporize before it enters the compressor. A throttling valve can be used to
ensure that the liquid is converted to vapor prior to entering the system.
6.11 Charge adjustment. Allow the system to run until conditions stabilize. Add additional
R407C in small amounts until the system conditions reach the desired levels (refer to
data recorded in step 6.3). Be sure to charge by evaporator/condenser temperatures
since the pressures will be higher at the temperatures equal to R22. Total charge
should not exceed original R22 charge levels.
6.12 Label components and system. After completion of retrofit, label the system and the
converted components to identify the type of refrigerant and lubricant, so proper
service will be performed in the future.
Attached is a Retrofit Checklist (Appendix 1) for R407C to assist you in the retrofit
process and a System Data Sheet (Appendix 2) to record the system operating
conditions for your records.

Application Bulletin 124 - Page 11 of 13

Revision L00910

Appendix 1
Checklist for R407C Retrofit
1. Consult the original equipment manufacturer of the system components for their
recommendation concerning compatibility and their retrofit procedures in order to
sustain warranty
2. If compressor is operable, run high flow condition (highest suction pressure for 10 - 15
minutes to maximize oil return to compressor).
3. Remove R22 charge from system (need 10-20 in. Hg vacuum to remove charge). Use
recovery cylinder --Do not vent to atmosphere-4. Replace filter drier with new filter drier approved for use with R407C.
- Loose fill driers: Use XH7 or XH9 desiccant or equivalent.
- Solid core driers: Check with drier manufacturer for recommendation.
5. Replace compressor with one approved for usage with R407C.
- Measure and record oil remaining in old compressor
- Residual lubricant should be less than 5% by weight of the total lubricant used in
system
6. Leak check system.
7. Evacuate with vacuum pump using normal service practices (200 microns minimum).
8. Charge system with R407C.
- Initially charge 85% by weight of original equipment manufacturer specified R22
charge.
- Amount of refrigerant charged: _______
9. Start up equipment and adjust charge until desired operating conditions are achieved.
- If low on charge, add in increments of 2 - 3% of original R22 charge.
- Amount of refrigerant charged:
_______
10. Total Refrigerant Charged (add 8 and 9)
_______
- Should not exceed original R22 charge level
11. Label components and system for type of refrigerant (R407C) and lubricant (polyol ester
oil).
12. Conversion is complete!!

Application Bulletin 124 - Page 12 of 13

Revision L00910

Appendix 2
SYSTEM DATA SHEET
Type of System/Location:
Equipment Mfg.:

Compressor Mfg.:

Model No.:

Model No.:

Serial No.:

Serial No.:
Original Lubricant:
Type/Mfg.:
Charge Size:
New Lubricant:
Type/Mfg.:
1st Charge Size:
2nd Charge Size:
Additional Charge Size:

Drier Mfg.:

Drier type (check one):

Model No.:

Loose Fill:
Solid Core:

Condenser Cooling Medium (Air/Water):

Expansion Device (check one):

Capillary Tube:
Expansion Valve:

If Expansion Valve:
Manufacturer:
Model No.:
Control/Set Point:
Location of Sensor:
Other System Controls (e.g.: head press control); Describe:
(circle units used where applicable)

R22 Data

R407 Data

Date/Time
Refrigerant
Charge Size Lb.
Ambient Temperature (F/C)
Relative Humidity
Compressor:
Suction Temperature (F/C)
Suction Pressure psig
DischargeTemperature (F/C)
Discharge Pressure psig
Indoor Temperature (F/C)
Evaporator:
Refrigerant Inlet Temperature (F/C)
Refrigerant Outlet Temperature (F/C)
Coil Air/H 2O In Temperature (F/C)
Coil Air/H 2O Out Temperature (F/C)
Refrigerant Temperature @ Superht. Ctl. Pt. (F/C)
Condenser:
Refrigerant Inlet Temperature (F/C)
Refrigerant Outlet Temperature (F/C)
Coil Air/H 2O In Temperature (F/C)
Coil Air/H 2O Out Temperature (F/C)
Exp. Device Inlet Temperature (F/C)
Motor Amps
Run/Cycle Time
Comments:

Application Bulletin 124 - Page 13 of 13

Revision L00910