Freon™ HP80, HP81, 404A PUSH Bulletin HP62 H47122 Suva HP

User Manual: HP62

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Freon™ HP80, HP81,

and 404A

Refrigerants (R-402A, R-402B, and R-404A)

Properties, Uses,

Storage, and

Handling

Freon™ Refrigerants

Table of Contents

Introduction ...........................................................................1

Freon™ HP Refrigerants.......................................................................... 1

Uses .......................................................................................1

Physical Properties ...............................................................2

Chemical/Thermal Stability ..................................................2

Stability with Metals ................................................................................. 2

Thermal Decomposition......................................................................... 6

Compatibility Concerns If R-502 and Freon™ HP

Refrigerants Are Mixed ........................................................................... 6

Materials Compatibility ..................................................... 13

Elastomers ...................................................................................................13

Motor Materials ........................................................................................13

Desiccants ................................................................................................... 15

Refrigeration Lubricants ..................................................................... 15

Safety ................................................................................. 17

Inhalation Toxicity ....................................................................................17

Cardiac Sensitization ............................................................................17

Skin and Eye Contact ...........................................................................17

Spills or Leaks ............................................................................................ 17

Combustibility of Freon™ HP Refrigerants ..............................18

Air Monitors and Leak Detection ...................................... 19

Types of Detectors ................................................................................. 19

Nonselective Detectors ................................................................. 19

Halogen-Selective Detectors ....................................................19

Compound-Specific Detectors ................................................. 19

Fluorescent Additives .....................................................................19

Storage and Handling ........................................................ 20

Shipping Containers in the United States ..............................20

Bulk Storage Systems .......................................................................... 20

Converting Bulk Storage Tanks from R-502 to Freon™

HP Refrigerants ...................................................................................22

Material Compatibility Concerns .............................................22

Handling Precautions for Freon™ HP Refrigerant Shipping

Containers .................................................................................................... 22

Recovery, Recycle, Reclamation, and Disposal .............. 23

Recovery ........................................................................................................ 23

Recycle ........................................................................................................... 23

Reclamation ................................................................................................23

Disposal .........................................................................................................23

Freon™ Refrigerants

Introduction

Chlorofluorocarbons (CFCs), which were developed over

60 years ago, have many unique properties. They are low in

toxicity, nonflammable, noncorrosive, and compatible with

other materials. In addition, they offer the thermodynamic

and physical properties that make them ideal for a variety

of uses. CFCs are used as refrigerants; blowing agents in

the manufacture of insulation, packaging, and cushioning

foams; and cleaning agents for metal and electronic

components; as well as in many other applications.

However, the stability of these compounds, coupled with

their chlorine content, has linked them to depletion of the

Earth’s protective ozone layer. As a result, Chemours has

phased out production of CFCs and introduced acceptable

alternatives, such as the Freon™ HP refrigerant family.

Freon™ HP Refrigerants

The products designated as Freon™ HP refrigerants are

intended as replacements for R-502 in medium- and

low-temperature refrigeration systems. The Freon™ HP

refrigerant family contains two different types of refrigerants.

Both types involve the use of refrigerant blends to achieve

alternatives that will act very much like R-502 in

refrigeration systems.

The first type of blends incorporate the following

refrigerants in two compositions to optimize different

performance characteristics:

HCFC-22 HFC-125 Propane

Freon™ HP80 (R-402A), wt% 38 60 2

Freon™ HP81 (R-402B), wt% 60 38 2

In addition, Chemours has formulated a mixture based on

all-HFC refrigerants, which results in no ozone depletion

factor. This refrigerant is called Freon™ 404A (R-404A),

and its composition is:

HFC-125 HFC-143a HFC-134a

Freon™ 404A (R-404A), wt% 44 52 4

The individual components of the three mixtures are listed

in Table 1 to show their chemical names and formulae. In

addition, the physical properties of the Freon™ HP

refrigerants are listed in Table 3.

Uses

The Freon™ HP refrigerants can be used in virtually all

R-502-based applications, either as a result of retrofitting

existing equipment that uses R-502 or following development

of new equipment designed to use Freon™ HP products.

R-502 currently serves a wide range of applications in the

refrigeration industry. It is used widely in supermarket

applications, food service and warehousing, transport

refrigeration, cascade systems for very low temperatures,

and other assorted applications. It offers good capacity and

efficiency without suffering from the high compressor

discharge temperatures that can be seen with HCFC-22

single-stage equipment.

Freon™ HP80 and HP81, which contain HCFC-22, are each

formulated to optimize different performance characteristics.

Freon™ HP80 offers compressor discharge temperatures

equivalent to R-502, with improved capacity versus

R-502, and slightly lower theoretical efficiency.

Freon™ HP81 offers the highest efficiency versus R-502,

with slightly better capacity. However, the higher HCFC-22

content results in compressor discharge temperatures in

the range of 14 °C (25 °F) higher than that of R-502, which

makes Freon™ HP81 most suited for medium-temperature

systems such as ice machines.

Table 1. Refrigerant Information

Refrigerant Chemical Name Formula CAS No. Molecular Weight

HCFC-22 Chlorodifluoromethane CF2HCl 75-45-6 6.47

HFC-125 Pentafluoroethane CF3CHF2354-33-6 120.02

HFC-134a 1,1,1,2-Tetrafluoroethane CF3CH2F 811-97-2 102.0

HFC-143a 1,1,1-Trifluoroethane CF3CH3 420-46-2 4.08

HC-290 Propane C3H8 74-98-6 4.1

Freon™ Refrigerants

Freon™ 404A (R-404A) offers the best overall properties

when compared with R-502. Capacity and efficiency values

should be equivalent to R-502, and compressor discharge

temperatures may be up to 9 °C (14 °F) lower than R-502,

which may equate to longer compressor life and better

lubricant stability.

In addition, the heat transfer characteristics of all the

Freon™ HP products appear to be better than R-502, so

any loss of compression efficiency may be offset by

improvements in heat transfer.

Due to the differences in operating characteristics

described above, Freon™ HP80 and HP81 are typically

selected for different applications. Freon™ HP81 is preferred

where higher energy efficiency and capacity are needed and

higher discharge temperatures will not create operating

difficulties. Both Freon™ HP80 and Freon™ 404A (R-404A)

are full-range R-502 replacements, with Freon™ HP80

preferred for retrofitting of existing systems, and Freon™

404A (R-404A) preferred for new equipment. Freon™ 404A

(R-404A) can also be used for retrofitting existing

equipment where HFCs are desired. Table 2 shows markets

that currently use each of these refrigerants.

Table 2. Freon™ HP Refrigerant Market Applications

Product Medium Temperature Low Temperature

Freon™ HP81 Ice Machines

Food Service

Vending

Supermarket

To Be Determined

Freon™ HP80 Supermarket

Transport

Supermarket

Transport

Food Service

Freon™ 404A (R-404A) All

Physical Properties

General physical properties of the Freon™ HP refrigerants

are shown in Table 3. Pressure enthalpy diagrams for

Freon™ HP refrigerants are shown in Figures 1–6.

Additional physical property data may be found in other

Chemours publications.

Chemical/Thermal Stability

Stability with Metals

Stability tests for refrigerant with metals are typically

performed in the presence of refrigeration lubricants. Results

of sealed tube stability tests available for R-502/mineral oil

and alkylbenzene lubricants have shown long-term stability in

contact with copper, steel, and aluminum in actual refrigeration

systems. Mineral oils, alkylbenzene, mixtures of mineral oil/

alkylbenzene and polyol esters (POE) are all possible

candidates for use with Freon™ HP80 and HP81; POEs are

proposed lubricants for use with Freon™ 404A (R-404A).

The method followed was generally the same as ASHRAE 97

with several minor modifications. A 3-mL volume of

refrigerant/lubricant solution was heated in the presence of

copper, steel, and aluminum coupons in an oven for 14 days at

175 °C (347 °F). Both the neat lubricant and a mixture of

lubricant and refrigerant (50/50 volume ratio) were tested.

Visual ratings were obtained on both the liquid solutions and

the metal coupons after the designated exposure time. The

visual ratings range from 0-5, with 0 being best.

After the visual ratings were obtained, sample tubes were

opened and the lubricant and refrigerant (if present) were

analyzed. The lubricant was typically checked for halide

content and viscosity, while the refrigerant was examined

for the presence of decomposition products. Table 4

summarizes typical data for Freon™ HP refrigerants. Visual

ratings are listed for the neat lubricant, the lubricant/

refrigerant solution, and the three metals that were present

in the lubricant/refrigerant solutions. Viscosity was

determined on the unused lubricant, the tested neat

lubricant, and the lubricant tested in the presence of

refrigerant. Decomposition products were determined in

some cases. Typical measurements for decomposition

products are in the low parts per million (ppm) range.

Freon™ HP81 tests with various lubricants indicate it has

adequate chemical stability with these lubricants. In addition,

we believe that HP80 will have similar behavior due to the

same refrigerants being used in the formulation. Freon™

404A (R-404A) tests with common POE lubricants indicate

that chemical stability of Freon™ 404A (R-404A) with

common metals used in refrigeration systems is acceptable.

Note: Lubricant/refrigerant combinations shown throughout

this report are for the purposes of comparing the stability and

compatibility of different lubricants with the Freon™ HP

products. No recommendation is made or implied that these

combinations will operate successfully in refrigeration systems.

Freon™ Refrigerants

Table 3. General Property Information

Physical Property Unit Freon™ HP80 (R-402A) Freon™ HP81 (R-402B) Freon™ 404A (R-404A)

Molecular Weight, avg. g/mol 101.55 94.71 97.6

Boiling Point (1 atm) °C (°F) –49.2 (–56.5) –47.4 (–53.2) –46.5 (–51.6)

Freezing Point (1 atm) °C (°F) N/A N/A N/A

Critical Temperature °C (°F) 75.5 (167.9) 82.6 (180.7) 72.1 (161.7)

Critical Pressure kPa (psia) 4135 (599.7) 4445 (644.8) 3732 (541.2)

Critical Density kg/m3 (lb/ft3) 541.7 (33.82) 530.7 (33.13) 484.5 (30.23)

Liquid Density at 25 °C (77 °F) kg/m3 (lb/ft3) 1151 (71.86) 1156 (72.14) 1048 (65.45)

Density, Saturated. Vapor at -15 °C (5 °F) kg/m3 (lb/ft3) 19.93 (1.24) 16.90 (1.05) 18.20 (1.14)

Specific Heat, Liquid at 25 °C (77 °F) kJ/kg·K (Btu/lb·°F) 1.3 (0.328) 1.34 (0.320) 1.53 (0.367)

Specific Heat, Vapor at 25 °C (77 °F) (1 atm) kJ/kg·K (Btu/lb·°F) 0.755 (0.181) 0.725 (0.173) 0.870 (0.207)

Vapor Pressure at 25 °C (77 °F) kPa (psia) 1337 (194.0) 1254 (181.9) 1255 (182.0)

Heat of Vaporization at Boiling Point kJ/kg (Btu/lb) 194.0 (83.5) 210.0 (90.3) 202.1 (87.0)

Thermal Conductivity at 25 °C (77 °F)

Liquid

Vapor (1 atm)

W/m·K (Btu/hr·ft·°F)

6.91E-2 (4.00E-2)

1.266E-2 (7.32E-3)

7.35E-2 (4.25E-2)

1.205E-2 (6.96E-3)

6.83E-2 (3.94E-2)

1.346E-2 (7.78E-3)

Viscosity at 25 °C (77 °F)

Liquid

Vapor (1 atm)

Pa·s

1.38E-4

1.29E-5

1.45E-4

1.28E-5

1.28E-4

1.22E-5

Flammability Limit in Air (1 atm) vol% None None None

Ozone Depletion Potential (CFC-12 = 1.0) 0.02 0.03 0.0

Halocarbon Global Warming Potential (CFC-11 = 1.0) 0.63 0.52 0.94

TSCA Inventory Status Reported/Included? Yes Yes Yes

Inhalation Exposure Limit* ppm (8- and 12-hr TWA) 1000 1000 1000

*The exposure limit is calculated based on the Chemours Acceptable Exposure Limit (AEL) for each component of the refrigerant blend. AEL is an airborne inhalation exposure limit

established by Chemours that specifies time-weighted average (TWA) concentrations to which nearly all workers may be repeatedly exposed without adverse effects during an 8- or

12-hr workday and a 40-hr work week.

Thermal Decomposition

Like R-502, Freon™ HP refrigerants will decompose when

exposed to high temperature or flame sources.

Decomposition may produce toxic and irritating

compounds, such as hydrogen chloride and hydrogen

fluoride. The decomposition products released will irritate

the nose and throat. Therefore, it is important to prevent

decomposition by following Chemours Safety Data Sheet

(SDS) recommendations for handling and use.

Compatibility Concerns If R-502 and Freon™ HP

Refrigerants Are Mixed

R-502 and Freon™ HP refrigerants are chemically

compatible with each other; this means that they do not

react with each other and form other compounds. However,

when the different refrigerants are mixed by accident or

deliberately, they will form mixtures that can be very

difficult to separate. Therefore, mixtures of R-502 and

Freon™ HP refrigerants cannot be separated in on-site

recycle machines or in the typical facilities of an off-site

reclaimer. These mixtures will have to be disposed of by

incineration.

Also, mixtures of R-502 and Freon™ HP refrigerants will have

performance properties different from either refrigerant

alone. These properties may not be acceptable for your

systems. Therefore, we do not recommend mixing R-502

and Freon™ HP refrigerants in any system. First remove the

R-502 properly (see Recovery discussion) and then charge

the new refrigerant.

Freon™ Refrigerants

Figure 1. Freon™ 404A (R-404A) Pressure–Enthalpy Diagram (SI Units)

Freon™ Refrigerants

Figure 2. Freon™ 404A (R-404A) Pressure–Enthalpy Diagram (ENG Units)

Freon™ Refrigerants

Figure 3. Freon™ HP80 (R-402A) Pressure–Enthalpy Diagram (SI Units)

Freon™ Refrigerants

Figure 4. Freon™ HP80 (R-402A) Pressure–Enthalpy Diagram (ENG Units)

Freon™ Refrigerants

Figure 5. Freon™ HP81 (R-402B) Pressure–Enthalpy Diagram (SI Units)

Freon™ Refrigerants

Figure 6. Freon™ HP81 (R-402B) Pressure–Enthalpy Diagram (ENG Units)

Freon™ Refrigerants

Materials Compatibility

Because Freon™ HP refrigerants will be used in many

different applications, it is important to review materials of

construction for compatibility when designing new equipment,

retrofitting existing equipment, or preparing storage and

handling facilities. Because Freon™ HP products have been

designed as refrigerants, the compatibility data

summarized here will include materials commonly used in

refrigeration applications.

Elastomers

Compatibility results for Freon™ HP81 (R-402B) and Freon™

404A (R-404A) were developed with five different polymer and

lubricant combinations. It was assumed that Freon™ HP80

(R-402A) compatibility would be similar to Freon™ HP81.

Recognize that these data reflect compatibility in sealed

tube tests, and that refrigerant compatibility in real systems

can be influenced by the actual operating conditions, the

nature of the polymers used, the compounding formulations

of the polymers, and the curing or vulcanization processes

used to create the polymer. Polymers should always be

tested under actual operating conditions before reaching

final conclusions about their suitability.

The rankings shown in Table 5 are based on duplicate

samples of each polymer subjected to aging at 150 °C

(302 °F) for 30 days in various lubricant/refrigerant

combinations. Physical properties of the test samples were

determined before and after aging. The resulting ratings are

based on 1 being best and 5 being worst for the purposes

of comparison. The factors included in the overall

assessment of compatibility included:

• Visual observations of material changes due to aging

• Changes in weight and volume of the samples due to aging

• Changes in hardness of the samples due to aging

• Changes in flexural properties of the samples due to aging

• Recovery of weight and flexural properties after

refrigerant evaporation

The compounds tested were:

• PTFE (Teflon™, commercial-grade skived sheet, from

Tex-O-Lon Mfg. Co.)

• Neoprene W (from Precision Rubber Co.)

• HNBR (hydrogenated nitrile butadiene, N1195 from

Parker Seal Co.)

• EPDM (ethylene propylene diene, commercial grade,

from Kirkhill Rubber Co.)

• NBR (BUNA N, nitrile butadiene, from Parker Seal Co.)

Lubricants tested:

• Mineral Oil, Suniso 3GS, Witco Corporation

• Alkylbenzene, Zerol 150 TD, Shrieve Chemical Products Inc.

• Polyol Ester, Icematic SW32, Castrol

• Polyol Ester, Arctic EAL22, Mobil Chemical

Motor Materials

In hermetic and semi-hermetic compressors, the

compressor motor is normally cooled by direct contact with

refrigerant returning from the evaporator. As a result, the

motor must be compatible with the refrigerants and

lubricants used in the refrigeration system.

Accelerated aging tests were conducted with combinations

of refrigerants, lubricants, and motor materials using sealed

tube tests prepared according to ANSI/ASHRAE 97-1989.

After aging, the materials in the tubes were inspected

visually and microscopically and tested physically and

chemically to determine property changes.

Materials tested, and a summary of test results, are

described below.

Polyethylene Terephthalate (PET), Mylar®

PET film is used as phase and slot insulation in hermetic

motors. Visual inspection of sealed tubes after aging in

refrigerant environments revealed no extracts with

refrigerant alone (R-502, Freon™ HP81, or Freon™ 404A

[R-404A]), but varying degrees of cloudiness and light

precipitates when lubricants were present.

PET weight change on aging was small (<5%) and occurred

with R-502/lubricant and HP81/lubricant combinations.

Weight gain with Freon™ 404A (R-404A)/ester lubricants

was 2% or less.

PET flexibility after aging was determined by a bend test.

The results show excellent retention of flexibility on aging

at 135 °C (275 °F). There is definite loss of flexibility when

PET is aged in R-502/mineral oil or R-502/alkylbenzene at

150 °C (302 °F). This loss of flexibility does not occur

when PET is aged in HP81 or Freon™ 404A (R-404A) with

ester lubricants at 150 °C (302 °F).

Freon™ Refrigerants

Table 4. Stability of HP Refrigerants with Metals and Lubricants

Freon™ HP81 with Various Lubricants

Property HP81 with Mineral Oil, Suniso 3GS HP81 with Alkylbenzene, Zerol 150 TD HP81 with Polyol Ester, Castrol Icematic SW32

Viscosity of Neat Oil at 40 °C

(104 °F), (mm)2/s (cSt) ND ND 29.6

Stability Tests/Visual Ratings

Neat Oil 0 ND 1, H

Oil/Refrig 1, G, H 2, P 0

Copper 0 2, T 0

Iron 0 0 1, T

Aluminum 0 0 0

Viscosity Change

% Change Neat ND ND 5.0

% Change w/Refrig ND ND –13.3

Decomposition Analysis

(F-), ppm ND ND 7

(Cl-), ppm ND ND 7

(Values for Freon™ HP80 assumed to be comparable)

Freon™ 404A (R-404A) with Various Lubricants

Property

Freon™ 404A (R-404A) with

Mineral Oil, Suniso 3GS

Freon™ 404A (R-404A) with

Alkylbenzene, Zerol 150 TD

Freon™ 404A (R-404A) with Polyol

Ester, Castrol Icematic SW32

Freon™ 404A (R-404A) with

Polyol Ester, Mobil Arctic EAL22

Viscosity of Neat Oil at 40 °C

(104 °F), (mm)2/s (cSt) ND ND 29.6 23.7

Stability Tests/Visual Ratings

Neat Oil 0 0 1, H 0

Oil/Refrig 1, G 2, P, G, H 0, G 1, G

Copper 0 2, T 0 0

Iron 0 1, T 1, T, P 0

Aluminum 0 0 0 0

Viscosity Change

% Change Neat ND ND 5.0 ND

% Change w/Refrig ND ND ND ND

Visual Ratings: Stability Ratings: 0 to 5

ND = Not Determined 0 = Best

G = Gel 3 = Failed

T = Tarnish 5 = Coked

H = Haze

P = Precipitate

Freon™ Refrigerants

Table 5. Relative Ranking of Polymer/Refrigerant/Lubricant Compatibility

Refrigerant/Lubricant

Polymer

PTFE HNBR Neoprene W EPDM NBR

R-502 Neat 2 4 2 2 1

R-502/Mineral Oil 2 4 4 5 2

R-502/Alkylbenzene 2 4 2 5 2

HP81 (R-402B) Neat 2 4 2 2 2

HP81 (R-402B)/Mineral Oil 2 4 4 5 2

HP81 (R-402B)/Alkylbenzene 2 4 2 5 2

HP81 (R-402B)/Castrol Ester 2 4 2 2 5

HP81 (R-402B)/Mobil Ester 2 4 2 1 5

404A (R-404A) Neat 2 1 1 2 1

404A (R-404A)/Mineral Oil 2 2 4 5 2

404A (R-404A)/Alkylbenzene 2 2 3 5 2

404A (R-404A)/Castrol Ester 2 4 2 1 5

404A (R-404A)/Mobil Ester 2 4 2 1 5

(1 → 5; best → worst)

Polyesterimide Enameled Motor Wire, Amide-Imide

Overcoated (NEMA NW 35C)

No extracts or precipitates were observed on aging the

enameled wire in any of the lubricant/refrigerant

combinations. No blistering, crazing, or cracking was

observed after aging. Retention of flexibility was confirmed

by 1x bend tests of the wire after aging.

Dacron®/Mylar®/Dacron® Lead Wire (Belden 14 AWG)

After aging of D-M-D samples in refrigerant/lubricant

environments, contents of the tubes were inspected for

particulates, the tubes were cooled and opened, and the

lead wire samples were subjected to bend tests. Minimal

particulates or extracts were observed after aging. PET

embrittlement, ranging from slight loss of flexibility to

shattering, was observed when specimens were bent 135

degrees. The degree of embrittlement appeared to be a

factor of the lubricant, rather than the refrigerant. All D-M-D

samples were embrittled in the presence of mineral oil or

alkylbenzene lubricants. Good flexibility was seen after aging

with polyol esters in the presence of all refrigerants.

Summary

In summary, ester-based lubricants appear to cause much

less effect on common motor materials than mineral oils or

alkylbenzene lubricants. In all cases, the results appeared

to be better than R-502 with lubricants commonly used

with R-502.

Desiccants

In refrigeration systems, keeping the refrigerant and

lubricant free of moisture is very important. Dryers filled

with moisture-absorbing desiccant are typically used to

prevent moisture accumulation. A desiccant used with

R-502, UOP’s (formerly Union Carbide Molecular Sieve)

4A-XH-5, is not generally compatible with highly fluorinated

refrigerants such as Freon™ HP products. However,

compatible molecular sieve desiccants, such as XH-9, have

been developed. For loose-filled and solid core dryers, new

desiccants are available that are also compatible with the

new refrigerants and lubricants. Be sure to tell your parts

wholesaler what refrigerants you plan to use when

specifying the dryer for your system.

Refrigeration Lubricants

Most compressors require a lubricant to protect internal

moving parts. The compressor manufacturer usually

recommends the type of lubricant(s) and proper viscosity

that should be used to ensure acceptable operation and

equipment durability. Recommendations are based on

several criteria, which can include lubricity, miscibility,

compatibility with materials of construction, thermal

stability, and compatibility with other lubricants. It is

important to follow the manufacturers’ recommendations

for lubricants to be used with their equipment.

Freon™ Refrigerants

R-502

w/mineral oil

08+37+06–

sesahp 2sesahp 2

(inversion)

w/alkylbenzene

08+72–06–

esahp 1sesahp 2

Freon™ HP81 (R-402B)

Freon™ HP80 (R-402A)

w/mineral oil

08+86+06–

sesahp 2sesahp 2

(inversion)

w/alkylbenzene

08+61+06–

esahp 1sesahp 2

w/polyol ester

–60+80

1 phase

w/mineral oil

27+56+05–

sesahp 2sesahp 2

(inversion)

w/alkylbenzene

27+66+05–

sesahp 2sesahp 2

(inversion)

w/polyol ester

–50+72

1 phase

Freon™ 404A (R-404A)

w/mineral oil

08+25+06–

sesahp 2sesahp 2

(inversion)

w/alkylbenzene

08+75+06–

sesahp 2sesahp 2

(inversion)

w/polyol ester

–60+80

1 phase

Current lubricants used with R-502 have at least partial

miscibility with R-502, which eases the problems of

designing systems to allow lubricant return back to the

compressor. Many refrigeration systems take advantage of

this miscibility when considering lubricant return.

Note: Field experience has shown that Freon™ HP81 works

successfully with mineral oil in many small hermetic

systems where oil return is not a concern.

Refrigerants such as Freon™ HP products, with little or no

chlorine present in them, may exhibit less miscibility with

common lubricants used with R-502. Although many R-502

systems operating at low temperatures allow for reduced

miscibility with the lubricant, it is important to know that the

lubricants used with Freon™ HP refrigerants will return to the

compressor using existing equipment designs.

Different compressor and equipment manufacturers will

recommend lubricants to use with their equipment and

Freon™ HP products. It would be difficult to summarize all

possible lubricant candidates that may be screened by

various equipment manufacturers. In addition, there will be

continuing research and development of new lubricants

that we may not have tested because the market for

alternative refrigerants continues to stimulate other market

areas. Review your system needs with the equipment

manufacturer, Chemours distributor, certified refrigeration

service contractor, or other qualified party. Never assume

the current lubricant in your refrigeration system will be

acceptable with the Freon™ HP refrigerant you intend to

use. Always review system components for compatibility

with the new refrigerant and possibly a new lubricant.

Table 6 shows a summary of miscibility tests done with a

50/50 volume mixture of refrigerant and lubricant over a

wide range of temperatures, with visual inspection for

phase separation as the tubes are slowly warmed. This

table does not show that any refrigerant/lubricant

combination is acceptable, only whether the two appear to

be miscible at the conditions shown.

Table 6. Miscibility Summary

Note: All temperatures in °C

Freon™ Refrigerants

Safety

Users must have and understand the applicable Freon™ HP

refrigerant Safety Data Sheets (SDS).

Inhalation Toxicity

Freon™ HP refrigerants pose no acute or chronic hazard

when they are handled in accordance with Chemours

recommendations and exposures are maintained below

recommended exposure limits, such as the Chemours

acceptable exposure limit (AEL) of 1,000 ppm, 8- or 12-hour

time-weighted average (TWA).

An AEL is an airborne exposure limit established by

Chemours that specifies time-weighted average for

airborne concentrations to which nearly all workers may be

repeatedly exposed without adverse effects. The AEL for

Freon™ HP refrigerants is the same level as the threshold

limit value (TLV) established for HCFC-22 and calculated

for R-502 based on the TLVs for the components.

However, like R-502, exposure above the recommended

exposure limit to the vapors of Freon™ HP refrigerants by

inhalation may cause human health effects that can include

temporary nervous system depression with anesthetic

effects such as dizziness, headache, confusion, loss of

coordination, and even loss of consciousness. Higher

exposures to the vapors may cause temporary alteration of

the heart’s electrical activity with irregular pulse,

palpitations, or inadequate circulation. Death can occur

from gross overexposure. Intentional misuse or deliberate

inhalation of Freon™ HP refrigerant vapors may cause death

without warning. This practice is extremely dangerous.

A person experiencing any of the initial symptoms should

be moved to fresh air and kept calm. If breathing is difficult,

administer oxygen. If not breathing, administer artificial

respiration. Call a physician.

Cardiac Sensitization

As with many other halocarbons and hydrocarbons,

inhalation of Freon™ HP refrigerants followed by

intravenous injection of epinephrine, to simulate human

stress reactions, results in a cardiac sensitization response.

In humans, this can lead to cardiac irregularities and even

cardiac arrest. The likelihood of these cardiac problems

increases if you are under physical or emotional stress.

Freon™ HP refrigerants can cause these responses well

above the AEL, but the effect level varies with people and

has not been fully determined.

If you are exposed to very high concentrations of Freon™

HP refrigerants, move immediately from the area and seek

medical attention as a precaution. Do not attempt to

remain in the area to fix a leak or perform other duties—the

effects of overexposure can be very sudden.

Medical attention must be given immediately if someone is

having symptoms of overexposure to Freon™ HP

refrigerants. Do not treat the patient with drugs such as

epinephrine. These drugs could increase the risk of cardiac

problems. If the person is having trouble breathing,

administer oxygen. If breathing has stopped, administer

artificial respiration. Call a physician.

Skin and Eye Contact

At room temperature, Freon™ HP refrigerant vapors have

little or no effect on the skin or eyes. However, in liquid form,

they can freeze skin or eyes on contact, causing frostbite. If

contact with liquid does occur, soak the exposed areas in

lukewarm water, not cold or hot. In all cases, seek medical

attention immediately.

Always wear protective clothing when there is a risk of

exposure to liquid refrigerants. Where splashing of refrigerant

may occur, always wear eye protection and a face shield.

Spills or Leaks

If a large release of vapor occurs, such as from a large spill

or leak, the vapors may concentrate near the floor or in low

elevation areas, which can displace the oxygen needed for

life, resulting in suffocation.

Evacuate everyone until the area has been well ventilated.

Re-enter the area only while using self-contained breathing

apparatus. Use blowers or fans to circulate the air at floor

or low levels.

Always use self-contained breathing apparatus or an

air-line respirator when entering tanks or other areas where

vapors might exist. Use the buddy system (a second

employee stationed outside the tank) and a lifeline. Refer to

the Safety Data Sheet for the specific Freon™ HP

refrigerant you plan to use.

Freon™ HP refrigerants have virtually no odor and, therefore,

can be extremely difficult to detect in enclosed areas.

Frequent leak checks and the installation of permanent

leak detectors may be necessary for enclosed areas or

machinery rooms. Refer to ASHRAE Standards 15 and 34

for machinery room requirements.

Freon™ Refrigerants

To ensure safety when using Freon™ HP refrigerants in

enclosed areas:

1. Route relief and purge vent piping outdoors, away from

air intakes.

2. Make certain the area is well ventilated at all times; use

auxiliary ventilation, if necessary, to remove vapors.

3. Make sure the work area is free of vapors prior to

beginning any work.

4. Install air monitoring equipment to detect leaks.

Combustibility of Freon™ HP Refrigerants

Freon™ 404A (R-404A), HP80, and HP81 are not

flammable in air at temperatures up to 100 °C (212 °F) at

atmospheric pressure. However, mixtures of R-404A,

HP80 or HP81 with high concentrations of air at elevated

pressure and/or temperature can become combustible in

the presence of an ignition source. Freon™ 404A (R-404A),

HP80, and HP81 can also become combustible in an

oxygen enriched environment (oxygen concentrations

greater than that in air). Whether a mixture containing

Freon™ 404A (R-404A), HP80 or HP81 and air, or Freon™

404A (R-404A), HP80 or HP81 in an oxygen enriched

atmosphere becomes combustible depends on the inter-

relationship of 1) the temperature 2) the pressure, and 3)

the proportion of oxygen in the mixture. In general, Freon™

404A (R-404A), HP80 or HP81 should not be allowed to

exist with air above atmospheric pressure or at high

temperatures, or in an oxygen enriched environment. For

example: R-404A, HP80 or HP81 should NOT be mixed

with air under pressure for leak testing or other purposes.

Refrigerants should not be exposed to open flames or

electrical heating elements. High temperatures and flames

can cause the refrigerants to decompose, releasing toxic

and irritating fumes. In addition, a torch flame can become

dramatically larger or change color if used in high

concentrations of many refrigerants including R-500 or

R-22, as well as many alternative refrigerants. This flame

enhancement can cause surprise or even injury. Always

recover refrigerants, evacuate equipment, and ventilate

work areas properly before using any open flames.

Based on the above information, the following operating

practices are recommended.

• Do Not Mix with Air for Leak Testing

– Equipment should never be leak tested with a

pressurized mixture of R-404A, HP80 or HP81 and

air. Pressurized mixtures of dry nitrogen and R-404A,

HP80 or HP81 can be used for leak testing.

• Bulk Delivery and Storage

– Tanks should be evacuated prior to initial filling and

should never be filled while under positive air pressure.

– Tank pressure should never be allowed to exceed the

tank manufacturer’s maximum allowable working

pressure when filling with R-404A, HP80 or HP81.

Relief devices on either the tanks or the supply system

should be present and in good operating condition.

– Tank pressures should be monitored routinely.

– Air lines should never be connected to storage tanks.

• Filling and Charging Operations

– Before evacuating cylinders or refrigeration

equipment, any remaining refrigerant should be

removed by a recovery system.

– Vacuum pump discharge lines should be free of

restrictions that could increase discharge pressures

and result in the formation of combustible mixtures.

– Cylinders or refrigeration equipment should be

evacuated at the start of filling and should never be

filled while under positive air pressure.

– Filled cylinders should periodically be analyzed for air

(nonabsorbable gas or [NAG]).

• Refrigerant Recovery Systems

Efficient recovery of refrigerant from equipment or

containers requires evacuation at the end of the

recovery cycle. Suction lines to a recovery compressor

should be periodically checked for leaks to prevent

compressing air into the recovery cylinder during

evacuation. In addition, the recovery cylinder pressure

should be monitored and evacuation stopped in the

event of a rapid pressure rise, indicating the presence of

air. The recovery cylinder contents should then be

analyzed for NAG, and the recovery system leak checked

if air is present. Do not continue to evacuate a

refrigeration system that has a major leak.

• Combustibility with Chlorine

Experimental data have also been reported that indicate

combustibility of HCFC-22 (a component of HP80 and

HP81) in the presence of chlorine.

Freon™ Refrigerants

Air Monitors and Leak Detection

Service personnel have used leak detection equipment for

years when servicing equipment. Leak detectors exist not

only for pinpointing specific leaks, but also for monitoring

an entire room on a continual basis. There are several

reasons for leak pinpointing or area monitoring, including:

• Conservation of refrigerant

• Protection of employees

• Detection of fugitive or small emissions

• Protection of equipment

Leak detectors can be placed into two broad categories:

leak pinpointers and area monitors. Before purchasing a

monitor or pinpointer, several criteria should be considered,

which include sensitivity, detection limits, and selectivity.

Types of Detectors

Using selectivity as a criterion, leak detectors can be

placed into one of three categories: nonselective, halogen-

selective, or compound-specific. In general, as the specificity

of the monitor increases, so will the complexity and cost.

A different technology that can be employed to find leaks

is by using a dye or other additive that is placed in the

refrigeration system and emitted with the leaking

refrigerant and lubricant.

A detailed discussion of leak detection is given in the

Chemours technical bulletin, “Leak Detector Guidance for

Freon™ Refrigerants."

Nonselective Detectors

Nonselective detectors are those that will detect any type

of emission or vapor present, regardless of its chemical

composition. These detectors are typically quite simple to

use, very rugged, inexpensive, and almost always portable.

However, their inability to be calibrated, long-term drift, and

lack of selectivity and sensitivity limit their use for area

monitoring.

Some nonselective detectors designed for use with R-502

may have a much lower sensitivity when used with Freon™

HP refrigerants. However, newly designed detectors with

good sensitivity for HFCs are now available. Be sure to

consult with the manufacturer before selecting or using a

nonselective detector with Freon™ HP refrigerants.

Halogen-Selective Detectors

Halogen-selective detectors use a specialized sensor that

allows the monitor to detect compounds containing

fluorine, chlorine, bromine, and iodine without interference

from other species. The major advantage of such a

detector is a reduction in the number of nuisance alarms—

false alarms caused by the presence of some compound in

the area other than the target compound.

These detectors are typically easy to use, feature higher

sensitivity than the nonselective detectors (detection limits

are typically <5 ppm when used as an area monitor and

<1.4 g/yr [<0.05 oz/yr] when used as a leak pinpointer), and

are very durable. In addition, due to the partial specificity of

the detector, these instruments can be easily calibrated.

Compound-Specific Detectors

The most complex detectors, which are also the most

expensive, are compound-specific detectors. These units

are typically capable of detecting the presence of a single

compound without interference from other compounds.

With Freon™ HP refrigerants, using compound-specific

detectors may be difficult because the different mixtures

often contain similar types of compounds. In an area where

different refrigerant mixtures are used, these detectors

may offer more specificity than is needed for normal leak

management. Discuss these issues with the equipment

manufacturers before making a purchase decision.

Fluorescent Additives

Fluorescent additives have been used in refrigeration

systems for several years. These additives, invisible under

ordinary lighting, but visible under ultraviolet (UV) light, are

used to pinpoint leaks in systems. The additives are typically

placed into the refrigeration lubricant when the system is

serviced or charged. Leaks are detected by using a UV light

to search for additive that has escaped from the system.

Recent innovations in dye technology have allowed

fluorescent additives to be used with HFCs and new

refrigerant mixtures. However, before adding additives to a

system, the compatibility of the specific dye with the

lubricant and refrigerant should be tested.

Freon™ Refrigerants

Storage and Handling

Shipping Containers in the United States

Freon™ HP refrigerants are liquefied compressed gases.

According to the U.S. Department of Transportation (DOT),

a nonflammable compressed gas is defined as a

nonflammable material having an absolute pressure greater

than 40 psia at 21 °C (70 °F) and/or an absolute pressure

greater than 104 psia at 54 °C (130 °F). See Table 7 for

the appropriate DOT designation.

Table 7. DOT Designations

DOT Proper Shipping

Name

(HP80/81)

Compressed Gas N.O.S. (Contains

Pentafluoroethane and

Chlorodifluoromethane)

(404A [R-404A]) Compressed Gas N.O.S. (Contains

Pentafluoroethane and Trifluoroethane)

Hazard Class (All) Nonflammable Gas

DOT/IMO Hazard Class (HP80/81) 2

(404A [R-404A]) 2.2

UN/NA Number (All) UN 3163

DOT Labels (All) Nonflammable Gas

DOT Placard (All) Nonflammable Gas

A list of the different types of containers that can be used

to ship Freon™ HP refrigerants in the United States, along

with their water capacities, dimensions, DOT specifications,

and net weights, are provided in Table 8. All pressure relief

devices used on the containers must be in compliance with

the corresponding Compressed Gas Association (CGA)

Standards for compressed gas cylinders, cargo, and

portable tanks.

The 15-lb, 30-lb, and 123-lb cylinders designed for

refrigerant applications will be painted the colors shown in

Table 8, with labels that bear the name of the product in the

same color. For clarification, the colors are:

Freon™ HP80 PMS 461 Light Brown

Freon™ HP81 PMS 385 Green Brown

Freon™ 404A (R-404A) PMS 021 Orange

Disposable cylinders, known as a Dispos-A-Can® (or DAC),

fit into a box with the measurements given in Table 8. When

used to ship Freon™ HP refrigerants to the stationary

refrigeration market, the cylinders will have the same outlet

fittings as cylinders of R-502.

The 123-lb cylinders are equipped with a nonrefillable liquid

vapor CGA-660 valve. With this two-way valve, refrigerant

can be removed from the cylinder as either vapor or liquid,

without inverting the cylinder. The vapor valve handwheel is

located on the top of the valve assembly. The liquid handwheel

is on the side of the valve and attached to a dip tube

extending to the bottom of the cylinder. Each is clearly

identified as vapor or liquid.

The 4,400-gal cylinder is known as an ISO tank. The

dimensions referenced in Table 8 represent the frame in

which the container is shipped. The tank itself has the same

length of 20 ft and an outside diameter of approximately

86 in. ISO tanks are used for export shipments of

refrigerants from the United States.

The general construction of a one-ton returnable container

is shown in Figure 7. Note that one end of the container is

fitted with two valves. When the container is turned so that

the valves are lined up vertically, the top valve will discharge

vapor and the bottom valve will discharge liquid. The valves

are protected by a dome cover. The valves are Superior

Type 660-X1-B1.

One-ton containers are equipped with two fusible plugs in

each end. The fusible metal in the plugs is designed to start

melting at 69 °C (157 °F) and completely melt at 74 °C

(165 °F). Containers should never be heated to temperatures

higher than 52 °C (125 °F). One spring-loaded pressure

relief valve is also located in each end of the container.

Bulk Storage Systems

Chemours sells storage systems, at cost, to their

refrigeration customers. The systems are prefabricated,

tested, and ready to install on site. The units are designed

to optimize economy, efficiency, and safety in the storage

and dispensing of Chemours refrigerants. The delivered

systems include all components, such as storage tank,

pumps, piping, valves, motors, and instrumentation, as an

integrated unit. All systems are equipped with dual pumps

to provide an installed spare. The units are skid-mounted

and require only placement on a concrete pad and

connection to electrical and process systems.

A typical bulk storage system is shown in Figure 8. Your

Chemours marketing representative can arrange for

guidance on site selection, purchase, installation, start-up,

and maintenance.

Freon™ Refrigerants

Filter

To Service

Check Valve

1" Pipe

Back

Pressure

Regulator

Pump Motor

2" Pipe

Ball Valve

Thermometer

Tank

Flow Indicator

Liquid Level

Gauge

Pressure

Gauge

Internal Safety

Relief Valves

Manway

Relief Valves

Vapor

Equalizing

Line

Liquid Fill Line

Excess Flow Valves

Flange

FEED System

Table 8. Specifications of Shipping Containers for Freon™ HP Refrigerants

Container Dimensions DOT Spec. Net Weight (lb) Color Code

15-lb Dispos-A-Can®7.5" x 7.5" x 14.5" 39 (HP81 Only) 13 PMS 385/Green Brown

30-lb Dispos-A-Can®10" x 10" x 17" 39 (HP80) 27 PMS 461/Light Brown

(404A [R-404A]) 24 PMS 021/Orange

123-lb Cylinder 55" H x 10" OD 4BA300 (HP81) 110

(404A [R-404A]) 100

4BA400 (HP80) 110

1,682-lb ton Cylinder 82" L x 30" OD 110A500W

5,000 gal Tank Truck MC-330 or -331 40,000

4,400 gal ISO 8' x 8.5' x 20' (frame) 51

170,000 lb Rail Car 114A340W

Figure 7. One-Ton Returnable Container

Figure 8.Typical Bulk Storage System

Freon™ Refrigerants

Converting Bulk Storage Tanks from R-502 to Freon™ HP

Refrigerants

Before switching any R-502 storage system to Freon™ HP

refrigerants, the existing storage equipment must be

checked to verify that it is adequate. Storage tanks built to

the specifications of the American Society of Mechanical

Engineers (ASME) Pressure Vessel Code are required to

have a metal nameplate indicating each tank’s maximum

allowable working pressure (MAWP). This rating must be

320 psig or higher for use with all Freon™ HP refrigerants.

In addition, the set pressure of the tank relief device must

also be checked and changed if necessary. This relief

setting cannot be higher than the maximum working

pressure listed on the nameplate, however.

We recommend that storage tanks be completely emptied

of all R-502 liquid and vapor before introducing the HP

refrigerant. In general, converting a storage tank to HP

refrigerant requires:

1. Removing all R-502 from the storage tank, lines, and

equipment.

2. Evacuating the storage tank to 25–29 in of vacuum and

purging with compressed dry nitrogen gas.

3. Making necessary repairs to the tank after initial

evacuation and purging.

4. Repeating Step 2 until R-502 and moisture levels are

within acceptable limits.

5. Refilling the system with Freon™ HP refrigerant.

This is a simplified outline of what is actually a lengthy

procedure. Your Chemours marketing representative can assist

in obtaining the equipment, instrumentation, and technical

assistance to safely and effectively make the conversion.

Material Compatibility Concerns

Most metal components suitable for use with R-502 are

also compatible with Freon™ HP refrigerants. These include

standard grades of carbon steel, aluminum, and copper.

Some elastomeric or nonmetallic components suitable for

R-502 may not be adequate with the new refrigerants.

Therefore, all elastomeric or nonmetallic components

throughout the system must be identified and their

compatibility with Freon™ HP refrigerants verified. For

complete reliability, any component that cannot be properly

identified should be replaced.

In a fluorocarbon storage system, elastomers are most

commonly found in:

• Packing and seats of manual valves

• Pressure relief device seats

• Flange and manway gaskets

• Mechanical pump seals

• Wet-end pump gaskets and O-rings

• Filter O-rings

• Sight-glass gaskets

• Back-pressure regulator diaphragms and O-rings

Handling Precautions for Freon™ HP Refrigerant

Shipping Containers

The following rules for handling HP refrigerant containers

are strongly recommended:

• Use personal protective equipment such as side shield

safety glasses, gloves, and safety shoes when handling

refrigerant containers.

• Avoid skin contact with refrigerants, as they may cause

frostbite.

• Never heat a container to temperatures higher than 52 °C

(125 °F).

• Never apply direct flame or live steam to a container or valve.

• Never refill disposable cylinders with anything. The

shipment of refilled disposable cylinders is prohibited by

DOT regulations.

• Never refill returnable cylinders without Chemours consent.

DOT regulations forbid transportation of returnable

cylinders refilled without Chemours authorization.

• Never use a lifting magnet or sling (rope or chain) when

handling containers. A crane may be used when a safe

cradle or platform is used to hold the container.

• Never use containers as rollers, supports, or for any

purpose other than to carry refrigerant.

• Protect containers from any object that will result in a

cut or other abrasion in the surface of the metal.

• Never tamper with the safety devices in the valves or

containers.

• Never attempt to repair or alter containers or valves.

Freon™ Refrigerants

• Never force connections that do not fit. Make sure the

threads on the regulators or other auxiliary equipment

are the same as those on the container valve outlets.

• Keep valves tightly closed and valve caps and hoods in

place when the containers are not in use.

• Store containers under a roof to protect them from

weather extremes.

• Use a vapor recovery system to collect refrigerant

vapors from lines after unloading.

Recovery, Recycle, Reclamation, and Disposal

Responsible use of Freon™ HP refrigerants requires that

the product be recovered for re-use or disposal whenever

possible. Chemours purchases used refrigerant for

reclamation through its distributor networks in the United

States, Canada, and Europe. In the United States, all

Freon™ HP products will be accepted as part of this

program. Recovery and re-use of refrigerant makes sense

from an environmental and economic standpoint. In

addition, the U.S. Clean Air Act prohibits known venting of

CFC, HCFC, and HFC refrigerants during the maintenance,

servicing or disposal of refrigeration equipment.

Recovery

Recovery refers to the removal of refrigerant from

equipment and collection in an appropriate container. As

defined by the Air Conditioning and Refrigeration Institute

(ARI), recovery does not involve processing or analysis of

the refrigerants. Freon™ HP refrigerants may be recovered

from refrigeration equipment using permanent on-site

equipment or many of the portable recovery devices now

available in the marketplace. The portable devices contain a

small compressor, an air-cooled condenser, and may be

used for vapor (and in some cases, liquid) recovery. At the

end of the recovery cycle, the system is evacuated

thoroughly to remove vapors. In the United States, the

Environmental Protection Agency (EPA) sets standards for

recovery equipment. Before purchasing a specific recovery

unit, check with the manufacturer to be sure that it

contains proper materials of construction and lubricant for

the refrigerants you intend to recover.

Due to the fact that Freon™ HP products are not azeotropes,

it is important that all refrigerant is removed from a system

during recovery or recycle. It is always recommended that

refrigerant transfers be made liquid phase whenever possible

to minimize composition changes in the products.

Recycle

Refrigerant recycle refers to reducing the contaminant

levels in used refrigerants by passing the refrigerants

through devices that separate out or reduce the amount of

lubricant, water, acidity and particulates. Recycle is usually

a field or shop procedure with no analytical testing of

refrigerant. Freon™ HP refrigerants may be recycled using

many of the devices now available. In the United States, the

EPA sets standards for these devices. Recycle is already

standard practice in many portions of the commercial

refrigeration industry. Consult with the manufacturer before

specifying a recycle device for any refrigerant.

If you routinely recycle Freon™ HP refrigerants through

several cycles, we recommend that you have the

composition of the refrigerant checked periodically. This

will prevent loss of performance in the unlikely event that

the composition has shifted.

Reclamation

Reclamation refers to the reprocessing of used refrigerant

to new product specifications. Quality of the reclaimed

product is verified by chemical analysis. In the United

States, Freon™ HP refrigerants are included in Chemours

refrigerant reclamation program. Contact Chemours or one

of our authorized distributors for further information.

Reclamation offers advantages over on-site refrigerant

recycling procedures because recycling systems cannot

guarantee complete removal of all contaminants. Putting

refrigerants that do not meet new product specifications

into expensive equipment may cause damage.

Disposal

Disposal refers to the destruction of used refrigerant.

Disposal may be necessary when the refrigerant has

become badly contaminated with other products and no

longer meets the acceptance specifications of Chemours

or other reclaimers. Although Chemours does not presently

accept severely contaminated refrigerant for disposal,

licensed waste disposal firms are available. Be sure to

check the qualifications of any firm before sending them

used refrigerants.

Freon™ Refrigerants

For more information on the Freon™ family of refrigerants, or other refrigerant products, visit freon.com or call (800) 235-7882.

The information set forth herein is furnished free of charge and based on technical data that Chemours believes to be reliable. It is intended for use by persons having technical skill, at

their own risk. Because conditions of use are outside our control, Chemours makes no warranties, expressed or implied, and assumes no liability in connection with any use of this

information. Nothing herein is to be taken as a license to operate under, or a recommendation to infringe, any patents or patent applications.

trademarks of The Chemours Company.

Replaces: H-47122-5

C-11260 (4/17)

Freon™ HP80, HP81, 404A PUSH Bulletin HP62 H47122 Suva HP

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