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R-22A : An HVAC Disaster in the Making!

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  • R-22A : An HVAC Disaster in the Making!

    Thanks to the need to keep ourselves, our children and our grandchildren from getting skin cancer from over-exposure to Ultraviolet radiation from the sun, the laws regulating the use of CFCs (Chloro-Fluoro-Carbons) and HCFCs (Hydro-Chloro-Fluoro-Carbons) have been in effect for several decades now to cause the elimination, removal, recovery and recycling of these refrigerants. Their less offensive replacements however, while not being the great destroyer of the Ozone Layer, are nonetheless still regulated by the EPA and in conjunction with other legal limiters and restrictions because they are still classified as "Green House Gases". These realities have pretty much marginalized any of us who might imagine working on our own in-home HVAC problems and fixing things along the way as almost being out of the question.

    For the last few weeks, I've been cobbling together a raft of cooling fans that move with my family members from room to room like a troop of quartered soldiers while I've been cobbling together all the replacement parts and pieces to replace the dead air handler up in my attic. Naturally, since I cannot buy the parts I need without having to deal with the professional HVAC Parts Houses that often refuse to sell anything to lay persons, eBay and Craig's List have come in handy while finding replacements such as the 3 Ton Trane AH and a decent TVX to simplify the liquid line metering at the evaporator inside.

    It was during some of these searches that I came across what I thought would be an almost too-good-to-be-true replacement for the R-22 that leaked out of a weakened brazing point in the old, worn out and FUBARd evaporator coil. The stuff was called R-22A and was touted as being a more efficient refrigerant than the stock R-22 gas, and also had the added ability of keeping the compressor head pressure much lower and needed a fraction of the amount usually required. The last and probably most significant aspect of this R-22A was that it could be purchased without the need for a license, since the new gas was not regulated by the EPA. Well... so far, so good ...I thought...and so without further ado... I ordered the stuff from an eBay company. I mean just imagine... it uses the same equipment and gauges with no changes necessary in either the compressor fridge oil or physical hardware... Pretty Cool ...right? Wrong... Very Wrong...

    Some few days later... I started looking on some HVAC forums to get all the safety dope I wanted to know about the need to replace the various sections of Hi/Lo coolant lines in the attic and the importance of not allowing any air and moisture in the lines while brazing everything back together using Dry Nitrogen Gas to purge the system...when some of members mentioned something about "This NEW stuff called R-22A...Doesn't it have an additive that prevents or limits its COMBUSTION?..." I thought... You mean this sh*t burns? Uh Ohhh... Fire???!!! WTF???? So I read on for the reply as an experienced HVAC member was chuckling through his response by saying, "Yeah... but only if they sell you a Fire Extinguisher with each pound of the stuff..." So now I thought to myself, "Dammit, Bob... You Dumb-Ass!!! You should have done more research before flying off the handle and buying this stuff on impulse!"

    Well... after doing the Boo-Koo Research I should have started with... I found out what the deal was: R-22A is nothing more than a highly refined gas mixture of Propane and Butane fuel. Apparently, such Hydro-Carbon "HC" gas mixtures possess the same incredible ability to act as refrigerants that rival even the CFCs like R-12 and R-22... with the darker side being that should this gas ever escape its confinement in a cooling system under high compression, several very bad things can possibly happen.

    1.) If the escaping jet of R-22A is instantly exposed to an ignition source... the resulting flame will become a burning blow torch and eventually melt the copper tubing and spray flame up inside the open attic area.

    2.) If the escaping gas does not immediately ignite, since the gas is heavier than air, it can pool and pose a suffocation risk...or even pool and upon later accidental ignition...explode like a bomb and burn everything down around it.

    Needless to say...unless this stuff is being used in a limited industrial application, it has no place being used in either vehicles or especially occupied dwelling and business locations. As much as I would like the ease of its use to help my situation out... I WON'T be using it in my home. I'll have to pay a certified HVAC Tech with a 608-609 EPA license to re-charge the system with R-22. (Believe it or not...The Aussies regularly use this stuff in their cars!)
    Last edited by 60dgrzbelow0; 05-07-2010, 06:20 PM.

  • #2
    My instant thoughts are good catch on not using it in your home. Cars a/c systems are much smaller and much more open to worry about since they won't require as much as a home to run. I thought I had read somewhere that you could use R134a to replace R22 in window a/c and refrigerator units, so I was actually going to try charging our home a/c system with 134a once upon a time. I believe that some sort of chlorine gas has been used as a refrigerant in RV a/c units and refrigerator units (another suffocation hazard, not to mention I believe it's a corrosive to human skin as well). It makes sense about propane and butane as a refrigerant. Think about how cold your grill tank and butane lighter refill tank can get when used at a decent rate.
    -60v6's 2nd Jon M.
    91 Black Lumina Z34-5 speed
    92 Black Lumina Z34 5 speed (getting there, slowly... follow the progress here)
    94 Red Ford Ranger 2WD-5 speed
    Originally posted by Jay Leno
    Tires are cheap clutches...

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    • #3
      On the periphery of this repair...and since I like having more than just a thumb-nail sketch when it comes to doing anything that has the slightest hint of hazard associated with it (with this present situation a lesson for me to keep my guard up better in the future) I glommed this HVAC book by Audel off of eBay (Circa 1984...but very relevant to the basics and even deeper aspects of HVAC repair and builds) for two dollars, just to "Better Prepare...For the Repair" and on page 169, Theo. Audel describes a surprising and bewildering array of chemicals and gases that all share their common utility for use as refrigerants... with varying degrees of hazard associated with the use of each one under a given set of HVAC conditions. These include Ammonia, Methyl Chloride, Ethyl Chloride, Carbon Dioxide, Sulfur Dioxide and something that sounds suspiciously similar to "R-22A" he calls "FREEZOL" which is a flavor of Isobutane... (For all intents and purposes: High Octane Butane). This list would not be complete without a proper nod to all the myriad flavors of Dupont's homegrown "Freon" family with number variations too numerous to list here. But if the one you (Pocket-Rocket) mentioned for A/C use in Trailers, etc...Methyl Chloride, it can be especially dangerous because it is non-irritating in the local confined atmosphere and therefore provides no warning that there might be an insidious leak somewhere... making anybody's vacation a problem if they cannot wake up to hit the open road.
      Attached Files
      Last edited by 60dgrzbelow0; 05-09-2010, 05:53 PM.

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      • #4
        i imagine the "FREEZE-12" stuff on ebay is likely the same R-22A stuff... never would have thought...
        1995 Monte Carlo LS 3100, 4T60E...for now, future plans include driving it until the wheels fall off!
        Latest nAst1 files here!
        Need a wiring diagram for any GM car or truck from 82-06(and 07-08 cars)? PM me!

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        • #5
          Now if you get some balloons and some paper bags I'll bet you could make a nice BOOM!!! I wouldn't use that anywhere!! Luckily I've got a friend in the HVAC Bizz that has it for the home.. Another friend is in the auto AC trade and has that...
          GOOD Catch Bob,,,
          Tom...

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          • #6
            Sounds like good stuff to use in a potato cannon
            Past Builds;
            1991 Z24, 3500/5 Spd. 275WHP/259WTQ 13.07@108 MPH
            1989 Camaro RS, ITB-3500/700R4. 263WHP/263WTQ 13.52@99.2 MPH
            Current Project;
            1972 Nova 12.73@105.7 MPH

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            • #7
              And the idiots in the E.U. were actually trying to fit Co2! Anybody for a 1500-2000psi refrigeration system on board?

              If you ain't rock and roll, you must be driving a Honda

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              • #8
                I take back my chlorine comment. It was Ammonia they use in RV applications (besides the chassis a/c that runs off the engine like a car).
                -60v6's 2nd Jon M.
                91 Black Lumina Z34-5 speed
                92 Black Lumina Z34 5 speed (getting there, slowly... follow the progress here)
                94 Red Ford Ranger 2WD-5 speed
                Originally posted by Jay Leno
                Tires are cheap clutches...

                Comment


                • #9
                  Gotcha, P-R... God... Ammonia... Who would have thought that stuff would work?

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                  • #10
                    This link is topical and perfect in its way relating to the problem of fixing or upgrading home HVAC systems:



                    Interestingly enough... I finally found a 1-4-1 replacement for R-22 called "R-421A" made by a company called RMS up in Georgia and called commercially: "Choice R-421A". Its their proprietary binary HCF flavor (Zeotropic) that is a blended refrigerant that is well matched in performance with R-22 and which is also "Non-Explosive, Non-Flammable and has Low-Toxicity"...and that beats my R-22A experiment right into the ground for hitting all my required safety hazard requirements. The only remaining question is: Does it require an EPA 608 - 609 License(s) to purchase? And I'll find the answer to THAT question when I call them on Monday coming. The other "cool" part is that is comes ready with its own oil in solution and will not require any retro-fitting to the existing R-22 based Heat Pump Split System that I am trying to get up and running.
                    Last edited by 60dgrzbelow0; 05-14-2010, 06:17 PM.

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                    • #11
                      I thought about replacing my fridge, with a newer E* model, but it's got R12 and never hardly runs. My Mom's fridge runs non-stop..... Hmmm More efficient compressor and less efficient gas... worth my trouble and cost? probably not....

                      There is a HVAC alarm system computer at work that has a .wav file (sound file) that plays "WARNING CHLORINE GAS LEAK" on it.... Makes me wonder if they use chlorine gas in the system... great, WWI poison gas in the HVAC system...!! lol
                      sigpic New 2010 project (click image)
                      1994 3100 BERETTA. 200,000+ miles
                      16.0 1/4 mile when stock. Now ???
                      Original L82 Longblock
                      with LA1, LX9, LX5 parts
                      Manifold-back 2.5" SS Mandrel Exhaust. Hardware is SS too.

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                      • #12
                        These videos will amply prove my concerns about using R-22A and all other similar Propane-Butane gas mixtures for any king of AC installation as a fire and explosion hazard. Please!!!! Please NEVER USE THIS STUFF as a replacement for your non-flammable HVAC refrigerants!!!

                        A video of a hydrocarbon refrigerant demonstration which went horribly wrong

                        This is the ABC news report on the gases that are not approved for automobiles by the EPA's SNAP program



                        Okay... It's literally been weeks since I've had the chance to do anything other than work on my HVACs which was like going through the Mike Holmes "Holmes on Homes" procedure of looking deeper into the old duct work and HVAC hardware and finding out that in addition to learning HVAC from scratch... I had to add sheet metal cutting/shaping/bending/taping and insulation abilities to my mechanical acumen as well in order to put things right again. I got my hands on a pristine Trane 3 Ton air handler for $275.00 and tidied it up before installing the unit by cleaning the blower blade unit and aluminum taping the the inside of the two air chambers with 4" Nashua tape. With a solid nod to the original problem I am addressing here, I finally came back around to using R-22 in the system and did all my own work from start to finish. I am happy to report that with the ambient temps staying in the high 90s... we are finally Cool as Moose Dipped in Penguin Juice. I know what everyone is thinking ..."Bob...why not just call an HVAC specialist and get it done quicker?" Well ...it would have cost me around $5,000.00 to have them do it all...and since I am perfectly capable learning how to do new things... I bought the best HVAC books and read them all cover-to-cover...invested in the best pro tools( refrigerant scale, manifold gauges, SilFos solder, Dry Nitrogen bottle and regulator, O/A torch kit, HVAC copper line site fittings, tube insulation, thermostat 7/18 wire, metal and duct tape, right angle metal snips...and a brand new Thermostatic Expansion Valve and Voila... My system is running perfectly "Beer-Can-Cold" with proper readings for Sub-Cooling and Super-Heat...and finally... I know exactly everything that is going on with the system and what needed repair to keep me from air conditioning half of my my attic! I would recommend that anyone slender and fit enough and able to contort themselves enough to make a trip up into their own attics and be surprised at how many air duct leaks you will find that are costing you a small fortune in exaggerated electric bills. If anything goes awry in the future... I can diagnose and fix the works on my own, too. Oh... and I also finally fixed the busted AC unit in my 93' Z-28 while I was at it...and not a moment too soon! )

                        If anybody wants to see the images of all this... let me know and I'll create an album in my public photobucket and post them all there. Oh and one last "Thank You" goes to a guy named "Dr. Zarkloff" (if this guy is NOT related to or the twin brother of the actor from Arachnophobia...Jeff Daniels...I'll eat my Flat Hat!) for all of his great (and often funny) HVAC instructional and educational videos on YouTube. Thanks to the books and to him... I was able to get everything repaired or replaced by the numbers and get the job done right. Here is a link to his page for any and all folks in need of this kind of help!

                        What is my channel about? I make videos about air conditioning and post them on youtube for the World to see.
                        Last edited by 60dgrzbelow0; 06-12-2010, 07:01 AM.

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                        • #13
                          Congrats on your successful foray into the world of artificial environment. Lends a new respect to what the NASA boys have to contend with outside of the atmosphere, eh?

                          If you ain't rock and roll, you must be driving a Honda

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                          • #14
                            By the By... Caveat Emptor...

                            You can't work on AC units without getting grounded on the rules and laws involved with the use of Ozone Depleting Refrigerants and their acceptable replacements... but trust me... in the war to "Keep Your Cool"... the list of gases that can and often are used in refrigeration units of all kinds is just staggeringly long. Only certified HVAC Techs with either a 608 or 609 license(s) are allowed to purchase and install or evacuate closed HVAC systems and the fines and penalties are heavy for messing around with this stuff if you are not so licensed.

                            And a just a word or two for all of us car enthusiasts about automotive HVAC issues... in 2012...the EPA will say Bye-Bye to the manufacture and sale of R-134A... so unless you want to have to invest in converting your legacy HVAC systems over to using refrigerants that are "Green Friendly", but require re-fitting of systems to handle the higher compressor head pressures necessary for cooling...it might be a good idea to stock up on some cans of R-134A or the synthetic substitutes for it while the prices are still relatively low. Don't be surprised of the stuff starts to cost $50.00 a can in 2013...assuming the Mayan Calendar prediction for the End of Days in 2012 proves wrong... and we are all still here.
                            Last edited by 60dgrzbelow0; 06-12-2010, 07:02 AM.

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                            • #15
                              So, Bob. I'm in a similar boat as you were. The compressor in my outside unit has gone kaput. Can you give me a basic run down of what you bought, and where? I'm wanting to do mine myself so I can save some green. I've got a good job now (yay! ) but I don't want to just blow money I can save for other things since I can do it myself. I've got copper sweating experience, so that part is the least of my concern, it's the rest of the stuff, like sourcing the refrigerant, ect. Thanks!
                              -60v6's 2nd Jon M.
                              91 Black Lumina Z34-5 speed
                              92 Black Lumina Z34 5 speed (getting there, slowly... follow the progress here)
                              94 Red Ford Ranger 2WD-5 speed
                              Originally posted by Jay Leno
                              Tires are cheap clutches...

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