Until 2010, R-22 was the most frequently used refrigerant in air conditioners and heat pumps. Because R-22 causes ozone depletion, the Environmental Protection Agency required manufacturers to phase out its use. In 2015, R-410A became the standard refrigerant used.
Out with R-22, In with R-410A
By January 1, 2010, there was a ban on the production and import of R-22. As a result, manufacturers of heat pump and air conditioning equipment redesigned their systems to accommodate R-410A, a chlorine-free refrigerant compared to R-22.
The phase out of R22 began in 2014-2015 and has progressed ever since. It fully culminated on January 1, 2020. According to the EPA, in 2019 the production of R22 dropped by 55% from 2018. On January 1, 2020 it ceased completely.
The pressure can become high enough for parts of the system to rupture. At the very least, leaks will occur. Mixing refrigerants is not an option either. This will contaminate the system, and the R22 will not evaporate under the higher suction pressure that R410A requires.
When you replace an air conditioner or heat pump and upgrade from R-22 to R-410A, the ideal solution is to replace your refrigerant lines. This is because the mineral oil used in R-22 systems is not compatible with the new R-410A refrigerant and oil.
How much will an R-22 to R-410A conversion cost? The actual cost will depend on many things, including where you live, but most of the time R-22 conversions start at around $2,000 and go up from there. The higher end of that range is somewhere around $4,500 to $4,600.
In 2010, the U.S. stopped the sale of newly manufactured residential air conditioning units and heat pumps that use R-22 because of its particularly harmful impact on the ozone layer when released into the air. On January 1, 2020, the U.S. Environmental Protection Agency (EPA) banned the production and import of R-22.
If you use R-22 in the same system as R-410a, the compressor is going to be trying to work two different fluids through the same coils as both refrigerants respond differently to different mechanical situations. As you might imagine, this isn't going to go well for your air conditioner or heat pump.
Understanding the Current HVAC Refrigerant Guidelines
Most HVAC brands have started to swap out their older AC and heat pump units over the year, preparing for the 2025 deadline, when they will have to completely stop the production of systems with R-410A.
When retrofitting an HVAC system, drain all existing refrigerant from the system before adding a new refrigerant. Never mix refrigerants, or "top off" a system running on R-22 with a 400-Series blend.
In 1987 an agreement called the Montreal Protocol was signed to begin the worldwide phase out of ozone-depleting CFCs and in 1992 HCFCs were added. In 2010, manufacturers were no longer able to produce new equipment designed with R22 and at the end of 2020, production and import of R22 will be eliminated.
R22 refrigerant is illegal to import and manufacturer in the U.S. But it's not illegal for anyone to buy R22 freon. And it's not illegal to sell it IF you have a license. As long as the stocks last, you will be able to continue purchasing R22 from specialized dealers and form your air conditioning company.
R410a was first introduced in 1991 and was put into large-scale production in 1995. It then became readily available in 2005 and became the industry standard on January 1st, 2013. This meant that by the time it became the primary refrigerant on the market, equipment had been produced with it for 18 years.
There should be a manufacturer's label on the air handler or the condenser containing the manufacture date. If it was made before 1996, then it is using R22. From that point until 2009, companies had a choice between R22 and R-410A. From 2010 onwards, the entire HVAC industry switched to R-410A.
Cooling systems shifting from R-410a to newer refrigerants like R-454B refrigerant and R-32 refrigerant will be implemented in 2025. These new coolants are engineered to be friendlier to the environment and meet updated regulations about global warming.
R-22 refrigerant prices range from $90 to $250 per pound. Since you'll need between 6 and 12 pounds to refill a home AC, costs can reach between $660 and $2,400 for a refill of R-22 refrigerant.
R-22 uses simple mineral oil, non-toxic, safe, stable, etc. while R-410a uses a somewhat exotic Poly o Ester (POE) oil typically found in jet turbine engines. The refrigerant used MUST match the oil present in the system, which is one reason why you can't replace the R-22 with R410a in a system.
R-454B has a lower GWP than previous refrigerants, meaning it has a much lower climate impact. Trane is phasing in the transition to R-454B in 2024, starting with the adoption of R-454B refrigerant in its residential products, beginning with the XR15 SEER2 heat pump.
ComStar's RS-53 (R470A) is the world's only drop-in retrofit replacement for existing R410a systems. At 909, RS-53 has a GWP that is effectively 56% lower than R410a. Additionally, RS-51 (R470B) has a GWP of 717 which is 80% lower than R404a, R507 and half of R448A and R449A.
To retrofit an R-22 system with R-410A system your line set must not be more than 25-50 feet in total distance. If the line set is longer than this, you will have to replace the line set with larger lines.
In fact, R410A can cool a room slightly faster with less energy. Efficient performance is a significant benefit of R410A. However, it works the same way as R22 in absorbing heat to provide cooling. But R410A doesn't make a room any colder than its predecessor.
If your HVAC system still uses R-22 or R-410A, you don't need to replace or stop using your system right away. The EPA's plan to phase out these harmful refrigerants stretches out into the next decade.
What Refrigerant Is In My Cooling System? On January 1, 2010, the Environmental Protection Agency (EPA) implemented a ban on the production and import of R22, except for continuing servicing needs of existing equipment. The EPA also banned the manufacture and installation of new R22 AC or heat pump systems.
You may just need some maintenance or redesign work. However, if the compressor has failed, especially on an older R22 air conditioner, it's often time to replace. The compressor is the heart of the system, and the investment to fix it may not be worth the cost.
R22 phaseout in 2020 means that it's completely illegal to manufacture or import R22 into the country. Recovered, recycled, or reclaimed R22 can still service existing HVAC systems, but chemical manufacturers can't produce new R22 refrigerants to service existing air conditioners and heat pumps.