DuPont Suva
REFRIGERANTS
Technical Information
Author: Barbara H. Minor, DuPont Fluoroproducts
R410A and R407C Design and Performance
A Literature Review
Abstract
In response to concerns about ozone depletion, refrigerant
HCFC-22 is being phased-out under the Montreal Protocol.
R410A and R407C have emerged as the leading HFC alterna-
tives to replace HCFC-22 in many applications. R407C was
designed to have similar pressure and operating performance
to HCFC-22, and is therefore intended for use in new equip-
ment without signicant design changes, or as a service
refrigerant for existing equipment. R410A was designed to
operate at higher pressure and to provide the opportunity for
reduced equipment size and increased energy efciency and
capacity. The purpose of this paper is to summarize industry
experience using these refrigerants in air conditioning ap-
plications from both a design and performance standpoint to
better understand issues and opportunities for using R410A
and R407C.
Introduction
Hydrouorocarbon (HFC) compounds have been essential
substitutes for ozone-depleting substances, an important
factor in the on-schedule implementation of the Montreal
Protocol. Two mixtures have been identied, extensively
studied, and determined to be viable alternatives to HCFC-
22, the current predominant refrigerant in air conditioning
applications. R-407C is a blend of HFC-32, HFC-125 and
HFC-134a (23/25/52 wt%) and was specically designed to
closely match HCFC-22 performance with minimal design
changes. R410A is a blend of HFC-32 and HFC-125 (50/50
wt%) specically designed for new equipment which could
take advantage of higher pressure and improved transport
properties to increase energy efciency.
In this paper, a literature review has been undertaken to
investigate and summarize performance data and design
improvements that have been realized for R407C and R410A
systems. Performance comparisons were primarily made
versus HCFC-22 at equal capacity. Performance data includes
both system testing and rigorous modeling work. The goal is
to help designers and equipment speciers assess perfor-
mance and to offer ideas to improve and optimize system
designs. Though this paper will not present exhaustive detail
of each test or design improvement, further information can
be found in the references.
1. R410A Design
R410A was designed to provide benet in energy efciency,
capacity and system size by increasing system pressure
and taking advantage of thermodynamic and transport
properties. Since R410A is a 50/50 weight percent blend of
HFC-32 and HFC-125, this near-azeotropic mixture is about
5060% higher pressure than R22. This blend offers several
advantages which have been exploited to improve system
designs lower viscosity, lower pressure drop, excellent heat
transfer, and the opportunity to design smaller equipment
due to higher pressure. Following are summaries of design
improvements made with R410A. Design improvements in
general focused on the compressor, heat exchangers and fan
systems.
Burns et al (1997) designed unitary R410A air conditioners in
7.014.0 kW capacity range. Several design changes were
implemented for 13 SEER (Seasonal Energy Efciency Ratio)
systems. To achieve standardization in manufacturing, the
evaporator design was not changed from R22. However, due
to the higher capacity and improved heat transfer of R410A,
the condenser size was reduced 1750%. Because R410A
was operating at higher pressure, noise level was expected to
be higher, but actual measurements determined noise level
to be about 2 dBa lower. This was attributed to lower com-
pressor displacement volume and increased shell thickness.
To achieve similar superheating and subcooling as R22, the
R410A short tube orice diameter was reduced 13% for a 13
SEER unit. It was also noted that cyclic losses and sensible
heat factors were very similar for R410A and R22.
2
Suzuki et al (1998) redesigned room air conditioners (duct-
free splits) using R410A to achieve higher energy efciency
than R22. The compressor was modied by redesigning
the scroll structure and discharge, achieving 50% efciency
improvement. A new inverter was developed with better dc
voltage control. More detailed scroll design information is pro-
vided in a paper by Ukai, Ito and Toda (1998). The indoor heat
exchanger had several modications including new external
ns and improvements to the air blowing system which in-
creased capacity about 15%. The outdoor unit was improved
by decreasing the diameter of the heat exchangers from 9.52
mm to 8 mm. A new fan was developed with larger diameter
blades as well as fewer blades to reduce fan power and pres-
sure loss. The layout of the heat exchanger was improved
by minimizing number of bends. Overall system COP for the
R410A system achieved was 5% higher than R22.
Zheng et al (1998) used a model to optimize R410A design at
different SEER ratings and compared system cost with R22.
By reducing heat exchanger size and increasing compres-
sor efciency, equipment savings of $13/unit for 11 SEER to
$50/unit for 14 SEER could be realized for a typical 3 ton a/c
system.
Furuhama et al (1999) described design changes made to
residential duct-free split systems for R410A. First, the inter-
nal volume for a 2-cylinder rotary compressor was reduced by
30% and compressor dimensions optimized. Re-expansion
loss was minimized by reducing the top clearance volume
by 50%. Overall compressor efciency improved by 6%
versus R22. Indoor heat exchanger size was also optimized
for R410A and tube diameter was reduced 6.35 mm to
55.5 mm. Heat exchanger modication resulted in another
45% efciency improvement. Combined system efciency
improvements of 56% were demonstrated versus R22.
Keller (1999) discussed design changes and eld trials for
R410A air-to-air heat pumps. Several modications were
required to operate R410A at higher pressure and meet mini-
mum burst pressure requirements. These included increased
thickness of the compressor shell, accumulator, condenser
tubing, reversing valve and lter drier. Also addressed was an
issue of stratication of lubricant in the accumulator which
could result in excessive lubricant entrapment. This can occur
due to the miscibility and foaming characteristics of R410A
with polyol ester lubricants versus R22 with mineral oil or
alkyl benzene lubricants. The problem was solved with a des-
tratication device designed to ensure good oil return.
Nonaka et al (2002) made several improvements to their
R410A room air conditioner design to increase energy ef-
ciency. These include development of a gas injection cycle
using a gas-liquid separator. This reduced the amount of
vapor entering the evaporator thereby increasing enthalpy
difference and also the amount of total refrigerant being
circulated on the low side which reduced compressor work.
Heat exchanger performance was also improved by redesign-
ing internal spiral grooved tubes, including reducing external
pressure loss by lowering n height. The scroll compressor
design was modied to an asymmetrical scroll shape which
allows compression to start earlier than conventional designs.
Oil ow was also increased to improve sealability of the
compression chamber. Indoor and outdoor fan designs and
grills were also improved to optimize air ow. Over a two year
period, R410A system COP was increased 5% while system
weight was decreased 6%.
Hattori et al (2002) described changes to commercial air con-
ditioning systems in the range of 22 to 28 kW. Designing at
28 kW was more challenging due to higher R410A pressure,
but the problem was solved with a twin inverter rotary com-
pressor design. The two rotary compressors also weighed
50% less than an equivalent scroll compressor. Using two
inverter driven compressors eliminated the on/off losses
associated with xed speed compressors. To stabilize oil
ow to the twin compressors, they were designed to oper-
ate at similar speeds to each other regardless of load. Other
system improvements to fans, heat exchangers and blowers
contributed to a net overall COP improvement of 3040%
versus their R22 design, half of which was attributable to the
compressor modications.
2. R410A Performance
Since R410A has about 50% higher capacity than R22,
references were selected where the performance com-
parison was on an equal capacity basis to R22. References
consistently show equivalent or better energy efciency of
R410A systems versus R22 systems.
Linton et al (1996) tested R410A in a 10.5 kW residential
central heat pump using a scroll compressor versus R22 with
a reciprocating compressor. Since the R410A compressor
displacement was 66% of the reciprocating compressor, a
correction factor was used to compare on an equal capacity
basis. Over a range of conditions, the cooling COP of R410A
was 17% higher than R22 and the heating COP 07%
higher.
3
Bivens and Denison (1996) tested R410A versus R22 in two
residential split 8.0 kW heat pumps. One heat pump was
equipped with a reciprocating compressor, the other a scroll
compressor both with 33% less displacement than the R22
compressor. Average energy efciency ratios for R410A were
14% higher for cooling and 23% lower for heating versus
R22. Modeling was then used to investigate energy improve-
ment potential by recircuiting the heat exchangers. It was
found that recircuiting the evaporator from 4 to 3 circuits
and the condenser from 5 to 3 circuits could increase energy
efciency another 2%.
Pande, Hwang and Rademacher (1996) tested a 7.0 kW
split heat pump with a reciprocating compressor comparing
R410A and R22 and determining SEER and HSPF (Heating
Seasonal Performance Factor). Compressor displacement
was adjusted to give comparable capacities, though in reality
the resized compressors still demonstrated 46% higher
capacity for R410A versus R22. Overall, R410A SEER was
2.6% higher than R22 and HSPF was 12% lower.
Triebe et al (1999) evaluated R410A performance using a
test rig with a variable speed reciprocating compressor to
match R22 capacity. The heat source inlet temperature in the
evaporator was varied from 0C to 15C. The heat sink was
set at 28C. The evaporator was divided and instrumented
in four sections. In testing, R410A required a compressor
speed 38% lower than R22 due to its larger capacity. COP
for R410A varied from 6.8% to 13.5% higher than R22
depending on test conditions. The lower compressor speed
for R410A helped increase capacity due to reduced frictional
losses. R410A also showed 17% higher heat transfer coef-
cient in the rst section of the evaporator and 12% higher
in the second section.
Chin and Spatz (1999) modeled a 12 kW split system air
conditioner which incorporated improved heat transfer
coefcients for R410A (+55% evaporating and +15%
condensing). The number of heat transfer units (NTU) and
effectiveness of the heat exchangers for R410A and R22
were calculated assuming cross-ow heat conguration. At
the design condition of 35C ambient temperature, energy
efciency of R410A was 2% higher than R22. At average op-
erating condition of 28C, energy efciency was 5% higher.
3. R407C Design
Since R407C was specically designed to match R22 pres-
sure characteristics and performance, there were fewer
references citing design changes implemented for R407C.
References primarily focused on use of brazed plate heat
exchangers and other investigations of counter-ow circuitry
to take advantage of R407C temperature glide.
Chitti and Bivens (1998) evaluated brazed plate heat exchang-
ers with R407C. Brazed plate designs facilitate implementa-
tion of counter-ow congurations. A 12.4 kW capacity indus-
trial chiller with brazed plate heat exchangers and scroll com-
pressor was evaluated under many test conditions. R407C
had an average of 5.6% higher cooling capacity and 0.3%
higher energy efciency compared with R22. Since R407C is
not an azeotropic mixture, circulating composition was also
evaluated, but did not change signicantly (25.1/25.9/49.0
wt% R32/R125/R134a versus nominal 23/25/52 wt%).
Suzuki et al (1998) designed packaged central air conditioners
with R407C. A new scroll compressor was developed with
higher efciency and low noise by optimizing the variable
turning mechanism radius of the turning scroll. The outdoor
heat exchanger heat transfer area and the fan diameter
were increased. For condensation, the air ow was directed
opposite to the refrigerant to take advantage of R407C tem-
perature glide. Performance tests indicated R407C energy
efciency was 6% higher than R22 in cooling mode and
equivalent in heating mode.
Marques and Domanski (1998) used a computer model to
evaluate the benet of using counter-ow heat exchangers
to take advantage of R407C temperature glide and achieve
glide matching. They studied several different counter-ow
and cross counter-ow congurations for the condenser
and evaporator. Counter-ow provided the most benet.
The predicted COP improvement was 7.1% in cooling mode
and 3.6% in heating mode versus R407C using cross-ow
conguration.
Bailly and Jurkowski (1999) studied chillers tted with brazed
plate heat exchangers versus tubular heat exchangers. The
system used R407C and a polyol ester oil. The cooling capac-
ity was 710% higher with brazed plate heat exchangers, the
rejected heat from the condenser was up to 5% higher and
the power consumption was 7% lower. Overall, the energy
efciency (EER) was up to 16% higher than R407C using a
tubular design.
4
4. R407C Performance
R407C was designed to match as closely as possible R22
pressure and performance to allow a smooth transition with
minimal designed changes and retrots of existing equip-
ment. References below show these parameters have been
met with performance within about 5% of R22.
Bivens and Denison (1996) tested R407C versus R22 in two
residential split 8.0 kW heat pumps. One heat pump was
equipped with a reciprocating compressor. The other heat
pump used a scroll compressor and an accumulator. The
energy efciency ratio during cooling and heating was 35%
lower for R407C versus R22. A computer model was then
used to investigate the impact of using counterow heat
exchangers to take advantage of R407C temperature glide.
Improvements of 57% in energy efciency were predicted.
Using a liquid-suction heat exchanger (LSHX) could provide
an additional 2% improvement.
Linton et al (1996) tested R407C in a 10.5 kW residential
central heat pump using a reciprocating compressor. To ap-
proximate cross counter-ow, the evaporator was inverted.
The relative cooling capacity and COP in the original evapora-
tor conguration ranged from 46% lower than R22. When
the evaporator was inverted, the cooling capacity was 4%
lower to 1% higher and the COP was 14% lower than R22.
However, inverting the evaporator resulted in a heating per-
formance penalty of 38% capacity and 79% efciency.
Biancardi et al (1997) evaluated effect of fractionation of
R407C in an 8.6 kW heat pump with a scroll compressor.
During the tests, 25% of the refrigerant charge was leaked
then relled, repeating three times. A total of two cooling
mode and four heating mode tests were conducted. System
leaks were performed when the heat pump was operating
and also when idle. Results showed the circulating refrigerant
composition stayed close to the initial composition in each
test. The worst case composition change occurred during va-
por side leaks when the system was idle, but the impact on
capacity and energy efciency was determined to be small.
Wei, Lin and Wang (1997) conducted a drop-in test of R407C
in a 3.5 kW duct-free split air conditioner. The unit was
equipped with a rotary compressor and capillary tube. It was
tested at standard, overload and low temperature conditions.
Overall the cooling capacity was 3% lower for R407C versus
R22 and the COP 4% lower.
Vaisman (1998) conducted a computational comparison using
a model equipped with condenser and evaporator units and a
rotary compressor. At 95F ambient, R407C cooling capacity
was 3.8% higher and COP 1.6% lower. At 104F, capacity
was 2.8% higher and COP 10.7% lower.
Triebe et al (1999) evaluated R407C performance using a
test rig with a variable speed reciprocating compressor to
match R22 capacity. The heat source inlet temperature in the
evaporator was varied from 0C to 15C. The heat sink was
set at 28C. The evaporator was divided and instrumented in
four sections. In testing, R407C required a compressor speed
17% greater than R22. COP for R407C varied from 3.8% to
6.8% lower than R22 depending on test conditions. In the
rst evaporator section, heat transfer coefcients were simi-
lar for R407C and R22. In the second section, R407C was 7%
lower and 6% lower in the third section.
Gopalnarayanan et al (2000) conducted R407C drop-in tests
using a 12.3 kW, 12 SEER R22 heat pump equipped with
a reciprocating compressor and TXVs for both cooling and
heating. The indoor heat exchanger was parallel cross ow
in cooling mode and counter cross ow in heating mode.
The outdoor unit was cross ow at all times. The only change
during the drop-in test was to replace the mineral oil lubricant
with polyol ester and refrigerant charge size optimization.
The R407C charge was 6% lower than R22. Several condi-
tions were measured to allow an SEER and HSPF (heating
seasonal performance factor) value to be determined. R407C
had equivalent cooling mode SEER compared with R22 and
about 3% lower HSPF.
Figure 1. LCCP Analysis Atlanta
5
Kim, Shin and Kim (2001) studied a residential window air
conditioner with a rotary compressor and investigated the
effect of using a liquid suction heat exchanger. In the baseline
case, the cooling capacity of R407C was 15% lower than
R22 and the energy efciency 5% lower. They attributed
this to a lower average evaporating temperature and higher
compression ratio. When a liquid suction heat exchanger
was used, R22 energy efciency increased 2% and R407C
increased 13%.
Rakesh et al (2003) conducted an exergy analysis using a 0.5
kW heat pump water chiller test stand. A semi-hermitic recip-
rocating compressor designed for R22 was used. The exergy
efciency of the refrigerant cycle was 46% lower for R407C
than R22. The exergy efciency of the compressor was about
57% lower. They concluded new R407C heat pump chiller
systems could be designed to achieve higher energy efcien-
cy than R22 provided the compressor was redesigned.
In summary, R407C energy efciency and capacity in drop-in
tests is on average 5% lower than R22. With design improve-
ments such as counter-ow heat exchange, performance can
be equivalent or better than R22. Impact of R407C fraction-
ation has minimal impact on performance even after leaking
and recharging several times.
5. LCCP Analysis
Results of this literature review have been used to update
an LCCP (Life Cycle Climate Performance) analysis by A. D.
Little (2002). A baseline 12 SEER R22 air conditioning system
in the Atlanta area was chosen to do this analysis. A. D. Little
assumptions of a 2%/yr refrigerant leak rate, end-of-life loss
of 15% and average electrical generation rate of 0.65 kg CO2 /
kWh were used. However, A. D.
Little assumed electrical consump-
tion of R22, R407C, R410A and CO2
were equal. Brown, Kim and Doman-
ski (2002) report energy efciency
losses for CO2 in stationary could
be 40% or more compared to R22.
Therefore, energy use compared to
R22 was adjusted for the analysis
as follows: equivalent usage for
R407C equipment, 2% less energy
use for R410A, and a 40% increase
in energy use for CO2. Results in
Figure 1 show comparable LCCP for
R22 versus R410A and R407C and
signicant environmental benet for
these HFC alternatives versus CO2
systems.
Conclusions
R410A and R407C have been extensively studied by the
HVAC&R industry in many regions of the world and found
to be effective and efcient alternatives to HCFC-22 in air
conditioning and heating systems. Designers have been able
to take advantage of excellent R410A performance character-
istics to design high efciency systems which demonstrate
reduced environmental impact. And R407C has proved to be
a good match for current HCFC-22 designs which is facilitat-
ing the transition away from HCFCs.
Acknowledgements
I would like to acknowledge Don Bivens and Dave Bateman
for their assistance compiling literature references for this
review.
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