R22 Renewal

With the end of R22 in almost touching distance it is more important than ever to consider the future of your existing equipment.

Current Panasonic equipment has been designed with this in mind because we know that there are many sites where it would be difficult if not impossible to replace existing pipe work.

Our renewal system is designed to allow new energy efficient R410a systems to be used with old R22 piping and works differently depending upon which range you are using RAC, PACi or VRF

RAC Products

RAC products are very simple to change over using the procedure below.

  • Check the capacity of the system you are replacing. The new system should be the same capacity
  • Check that the pipe length does not exceed the allowable pipe length of the new system
  • It is possible that the pipe size of one or both of the existing pipes will be larger than the new unit. Don't worry if it is only one size larger but consult us if it is more than one size larger.
  • Operate the existing system, in forced cooling for a minimum of 10 minutes for a single split or 30 minutes for a multi split if the system is still functional
  • After operating for this period, perform a pump down operation
  • If the unit is not functional then recover the refrigerant and oil then thoroughly flush the pipework with Pro Flush or similar. We stock Pro Flush kits and replacement fluid
  • Check that the pipe thickness is at least 0.8mm. If it is not then the pipe cannot be reused
  • Check the pipe is both dry, clean and leak free. If you have not already done so flush the pipes with Pro Flush if you are in any doubt
  • Remove any Pro Flush residue
  • Use a cotton bud to take an oil swab and compare the colour to the chart below
  • Cut the existing flare and nut from the pipe
  • If the pipe is larger than the new units pipe connections then use a reducer to connect to the indoor and outdoor unit
  • Remake the flares using an R410a compatible concentric flare kit
  • Connect to the indoor and outdoor units using a torque wrench to the torque shown in the manual that comes with the new system
  • Carry out a strength and leak test as usual then evacuate to hold below 1 Torr (1,000 micron) for 15 minutes
  • Commission as normal

PACi Products

For PACi products the procedure is slightly more complicated but this is compensated for by the facility in a PACi system to set the outdoor unit to work with a maximum working pressure of 33 Bar (outdoor unit option code 4B, accessed using a maintenance remote controller connected to the outdoor unit and the setting changed from 0000 to 0001)

Firstly check the existing unit and select one that is the same capacity then check the pipe lengths are within the limitations of the new system. Then check the existing pipework for leaks, damage or corrosion.

For single split systems the pipe lengths allowed will vary depending upon the size of pipe, which will often differ from the new system. Use the chart below. This also gives guidance on additional gas charge

For multi systems also see the table below

Then follow the chart below

To limit the operating pressure to 33 Bar then follow the instructions below

Connect a CZ-RTC2 controller to the outdoor unit terminal RC (blue 3 pin connector on the PCB) using a service checker connector cable. We normally stock both of these items.

Then follow the procedure below to change option code 4B from the factory setting of 0000 to 0001. Remember to use the SET button to confirm the selection.

ECOi and ECOG Products

Always contact us and discuss an VRF renewal project.

The procedure is actually very similar to a PACi renewal with the following exceptions

  • We will need a full schematic of the existing pipe work with accurate lengths and pipe sizes along with full indoor and outdoor model references in order to decide whether it is permissible to proceed.
  • It is more important than ever to ensure the pipework is clean and undamaged due to the long distances involved
  • Do not proceed if there has ever been a burnout. Do an oil test
  • The procedure for changing option code 4B in an ECOi is similar to that shown for the PACi except that the controller connects directly to the terminals used in the outdoor unit to link additional outdoor units to the control line, so there is no requirement for the special connection plug. You only need to change the setting of the master unit
  • If you have an ME1E81 2 pipe VRF then the 4B setting is factory set at 0002 and should be changed to 0000
  • For ECOG option code 4B can be changed using the standard outdoor unit PCB which has a display and setting switches supplied with it
  • A VRF Renewal kit CZ-SLK2 and sight glass should be fitted into the pipe work. Fit shut off valves either side in order to allow the sight glass and drier to be replaced if necessary.
  • A different flow chart applies, shown below