There are estimated to be between 60,000 and 100,000 air conditioning systems in the UK still reliant on R22. With the ban on the use of new R22 for topping up systems coming into force at the beginning of January, that is a lot of buildings exposed.
The phase-out effectively makes plant running on R22 obsolete. Despite a chorus of warnings from the industry in the run-up to the ban - that there would be insufficient supplies of reclaimed R22 to meet demand, end users have been slow to bite the bullet and invest in new plant.
The coincidence of the R22 phase-out with the economic downturn hasn’t helped, with the resultant widespread freezes on capital spending and investment.
Now, however, SANYO Air Conditioners has developed a new solution that enables rapid conversion of existing R22 systems to new high efficiency R410A systems at dramatically reduced cost. The company’s R22 Renewal system uses existing refrigerant pipework to speed up installation and cut replacement costs by around 30 per cent.
It also delivers significant on-going savings in running costs for end users, due to the increased energy efficiency of R410A equipment. This has COPs (Coefficient of Performance) of up to 4.0 compared with just 2.5 and below for older R22 systems.
SANYO Renewal can be used with both existing SANYO systems and virtually all types of R22 systems from other leading manufacturers. On most installations, existing wiring can also be used. Any flare connections are replaced to upgrade the system to allow connection to new system components.
With PACi split systems, installers carry out a simple oil test to establish that the system has not been subject to a burn-out or is contaminated by dirt. Pipework is also checked to ensure it is not damaged and that wall thicknesses are within acceptable guidelines.
For VRF systems, checks are also carried out on pipe lengths and branch networks to ensure they meet current design criteria. Existing indoor and outdoor units are then replaced with current products from SANYO’s range.
The approach has been carefully engineered to take account of the different operating pressures of the refrigerants involved.
SANYO’s Graham Wright says: "In relation to split systems, engineers carry out a pipe work check to see if the system has the correct wall thickness and pipe runs to accommodate the working pressures of R410A. In practice, this means that some older systems may not be able to be changed, however the vast majority of systems will be suitable for conversion with R22 Renewal.
"In relation to VRF systems, for some time now SANYO units have been able to reduce the maximum working pressure to ensure that the system is as efficient as possible. We have effectively been able to reduce system pressures to the same as that in older R22 systems, without losing any capacity from the outdoor unit, by adjusting basic controls within the system.”
Where split systems are being replaced, the outdoor unit is selected from the company’s Classic, Standard or Elite ranges, depending on the level of efficiency required. In the case of VRF systems, any of the company’s range of two-pipe or three-pipe options can be applied.
Bob Cowlard, SANYO’s sales and marketing general manager, says: “The arrival of R22 Renewal is great news for both contractors and end users. There is a huge amount of R22-based equipment out there. With the ban on use of virgin R22 for service top-up coming into force at the end of 2009, people with R22 systems are seriously exposed.”
He added: “R22 Renewal enables R22 plant to be quickly replaced with modern, high efficiency air conditioning, saving around a third or more on replacement costs and delivering significant ongoing savings in energy costs. It is a win-win for all concerned, including the environment.”
For installers, no special training is required to carry out Renewal conversions. Refrigerant is reclaimed in the normal way, while on VRF installations the suitability of pipework is confirmed by a SANYO distributor or the manufacturer.
The Renewal approach can be used with all existing equipment that meets SANYO’s pipework criteria. It can also be applied to existing R407C systems.
SANYO is launching R22 Renewal across Europe to coincide with the implementation of the EU-wide phase-out in the use of virgin R22 for top up.
Mr Cowlard says: “R22 is still a mainstay for much of the installed base of air conditioning. The ban has been a long time coming, but many end users have so far failed to grasp the nettle.
“However, it is highly risky not to take action, in the hope of obtaining sufficient reclaimed R22 to keep systems running. The truth is that there simply won’t be sufficient to go round, and the cost – where it is available – is likely to rise dramatically.
He added: “Renewal offers a practical, cost-effective solution – that is quick and effectively future-proofs end users against uncertainty. With energy costs predicted to rise year-on-year for the foreseeable future, the costs of conversion should pay for themselves many times over.”
R22 Renewal can be also used to replace R407C systems, providing end users and installers with a further option.