File In/With: - SI0389

New 819
Equipment YK Chillers - Mod H, G, F, D, C
Affected: YMC2 Chillers - Mod A and B
Service
Information Retrofit of R-134a YK System to R-513A

GENERAL NOTES ABOUT XP10 / R-513A

Opteon™ XP10 (R-513A) is a low global warming potential (GWP) hydrofluoro-olefin based (HFO) refrigerant
developed to replace R-134a in medium-temperature refrigeration systems. The R-513A is nonflammable under
normal conditions. However, when mixed with high concentrations of air or oxygen under elevated pressure, this
product can become combustible in the presence of an ignition source. This product should not be mixed with air
to check for system leaks.
The overall compressor performance (capacity and efficiency) will be similar when operating on R-513A versus
R-134a. Compressor suction and discharge pressures for R-513A will differ slightly from R-134a. The R-513A also
has lower compressor discharge temperature than R-134a. When the refrigerant selection is changed in the software,
this will change some default setpoints affected by this change. Because of the effects listed above it is advisable to
have a new chiller rating provided based on the original design operating conditions to provide a basis for compari-
son between the two refrigerants. This should always be done in advance of the refrigerant change to eliminate any
unwanted affects from affecting final performance.

RETROFIT OF R-134a CHILLERS TO R-513A

NOTE: R-22 Retrofit is not included in the SI)
The following detailed steps are the recommended procedure for retrofitting R-134a systems to R-513A. When in
doubt, follow F-gas Regulation / EN 378-4: 2017 throughout the whole process.
Before starting this retrofit please read through this document completely. Have all appropriate parts in
hand to avoid multiple trips back to the customer site.
1. Establish Baseline Performance with R-134a
Collect system performance data while R-134a refrigerant is in the system. Check for correct refrigerant charge
and operating conditions. The baseline data of temperatures and pressures at various points in the system
(evaporator, condenser, compressor suction and discharge, and condenser liquid subcool) at normal operating
conditions will be useful in noting any deficiencies in system operation and when optimizing operation of the
system with R-513A. A baseline refrigerant sample is also recommended to determine if there are any issue
prior to converting.
Work on this equipment should only be done by properly trained personnel who are qualified to work on this
type of equipment. Failure to comply with this requirement could expose the worker, the equipment and the building
and its inhabitants to the risk of injury or property damage.
The instructions on this service information letter are written assuming the individual who will perform this work
is a fully trained HVAC & R journeyman or equivalent, certified in refrigerant handling and recovery techniques, and
knowledgeable with regard to electrical lock out/tag out procedures. The individual performing this work should be
aware of and comply with all Johnson Controls, national, state and local safety and environmental regulations while
carrying out this work. Before attempting to work on any equipment, the individual should be thoroughly familiar
with the equipment by reading and understanding the associated service literature applicable to the equipment. If
you do not have this literature, you may obtain it by contacting a Johnson Controls Service Office.
Should there be any question concerning any aspect of the tasks outlined in this bulletin, please consult a
Johnson Controls Service Office prior to attempting the work. Please be aware that this information may be time
sensitive and that Johnson Controls reserves the right to revise this information at any time. Be certain you are
working with the latest information.

Product Technical Support

 SI0389 (819)

2. Check Lubricant (YK Chillers Only)

For YK's operating on R-134a, the POE lubricant currently in the system is suitable for use with R-513A. If
there are questions about the lubricant, or tests indicate it is contaminated or has a high acid number, then the
lubricant must be changed.
3. Lockout-Out Tag-Out
Follow all Lock-out/Tag-Out procedures prior to starting the retrofit. This will prevent anyone from starting the
chiller and possibly causing injury, death, or damage to the chiller.
4. Remove the R-134a Charge into Recovery Cylinders
Confirm that the evaporator has water flow while removing the refrigerant charge to prevent freezing and tube
damage.
Remove the entire R-134a refrigerant charge from the system into a recovery cylinder(s). Weigh the amount
removed to use as a guide for the quantity of R-513A to be charged into the system. Refer to YK Operation and
Maintenance Manual (Form 160.76-O1) or YMC2 Operations and Maintenance Manual (Form 160.84-OM1)
for further information.
5. Perform Other System Modifications (as needed)
• Fit new filter drier cores and drier in the eductor circuit plus a new oil filter. (This is good practice, but
not essential.)
• Change the R-134a liquid level sensor, the new R-513A part number is: 025-48615-006 (6.41” Insertion
Length), -008 (8.5” Insertion Length), -009 (9.5” Insertion Length), or -012 (12” Insertion Length). Refer to
Service Instructions (Form 50.40-M1) Installation, calibration and troubleshooting guide for level sensors.
• Install a new OptiView micro board (031-03630-001) into the control panel. If the OptiView panel already
has a 031-03630-001 board go, to the next step.
• If it has a 031-02430-001, -002, -003 or 031-01730-001 (OptiView Only) board, you will need to order
the conversion kit 331-02430-601 from Baltimore Parts. A Millennium single line control panel will re-
quire an OptiView upgrade kit. The OptiView upgrade kit part numbers can be found in the table below
and current kit pricing can be found from Baltimore Parts, or AOMS (from UL applications) or at https://
easyparts.johnsoncontrols.com (for CE applications in Europe).
OptiView Kit Description OptiView Kit Part Number
YK Style C - Electro-Mechanical Starter - High or Low Voltage 375-38121-101
YK Style C - Liquid-Cooled Solid State Starter Style A 375-38121-104
YK Style C - Liquid-Cooled VSD (Not Turbo-Modulator) 375-38121-107
YK Style D - Electro-Mechanical Starter - High or Low Voltage 375-38121-102 (Variable Orifice Actuator Barber Coleman)
YK Style D - Electro-Mechanical Starter - High or Low Voltage 375-38121-103 (Variable Orifice Actuator Belimo)
YK Style D - Liquid-Cooled Solid State Starter Style A 375-38121-105 (Variable Orifice Actuator Barber Coleman)
YK Style D - Liquid-Cooled Solid State Starter Style A 375-38121-106 (Variable Orifice Actuator Belimo)
YK Style D - Liquid-Cooled VSD (Not Turbo-Modulator) 375-38121-108 (Variable Orifice Actuator Barber Coleman)
YK Style D - Liquid-Cooled VSD (Not Turbo-Modulator) 375-38121-109 (Variable Orifice Actuator Belimo)
YK Mod E - with Optiview 031-01730-001 Microboard 331-02430-601
YK Mod E,F,G - with Optiview 031-02430-001,-002,-003 Microboard 331-02430-601
YMC2 Mod A 331-02430-610
YMC2 Mod B 331-02430-614

• Confirm software version Y.OPT.01.03.308 or Y.OPT.01.00C.308 or greater is loaded into the OptiView
Control panel.
• Select the refrigerant type to R-513A.

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6. Evacuate System and Check for Leaks

Ensure while evacuating any VSD equipped system that the VSD power is isolated at the VSD Isolator. To
remove air or other non-condensable gases and any residual moisture from the system, evacuate the system to
full vacuum (<1000 (500 preferred) microns [<29.88 in Hg vacuum] [<1.33 mbar]). If the system is not able
to hold vacuum, it may be an indication of a leak requiring appropriate repairs. After vacuum test, pressurize
the system with dry nitrogen, taking care not to exceed the system design maximum pressure, and check for
leaks. After leak tests are complete, release the nitrogen in a safe and controlled manner that does not represent
a danger to personnel. Ensure the Nitrogen is not released into an enclosed space, and that any area where
Nitrogen is released is adequately ventilated. Do not use mixtures of refrigerant and air to check for leaks, as
these mixtures can become combustible. After leak checking, remove residual nitrogen with a vacuum pump.
7. Charge System with R-513A
Prior to charging the unit, confirm water flow can pass through the evaporator. Charge the unit using weighing
/ refrigerant scales and a charging unit capable of transferring liquid from the cylinder to the chiller. Ensure all
service valves are open in the chiller allowing refrigerant (liquid or vapor) to flow to all parts of the system. Refer
to the chiller operations manual for further information.
Refrigerant R-513A is a blend, so it is important to remove liquid only from the charging cylinder. (If the cyl-
inder does not have a valve with a dip tube, invert the cylinder so that the valve is underneath the cylinder.)
The proper cylinder position is often indicated by arrows on the cylinder and the cylinder box. Once liquid is
removed from the cylinder, the refrigerant can be allowed to enter the refrigeration system as liquid or vapor
as desired. Refer to manuals for further information.

WARNING: Do not charge liquid refrigerant into the suction line. This can cause irreversible
damage to the compressor. Use the manifold gauges or a throttling valve to flash the liquid
refrigerant to a vapor prior to entering the suction line.

The chillers will require a similar charge size of R-513A as the original R-134a charge. The optimum charge
will vary depending on the system design and operating conditions. The initial charge should be approximately
85% of the standard charge size for R-134a. After startup and adjustment, the final charge amount will be ap-
proximately 97% of the R-134a charge.
8. Start Up System and Check Operation
Monitor and adjust the liquid level sensor to 50% level of sight glass to achieve the rated discharge superheat
and approach temperature in the evaporator and condenser. Expect the discharge superheat and approach tem-
peratures to be the same as when the unit operated on R-134a.
When the unit is shutdown, the refrigerant charge level must be checked after the pressure and temperature
have equalized between the condenser and evaporator. This may take 4 hours or more after the compressor and
water pumps are stopped. The level should visible in the sight glass. Monitor oil levels in compressor. Add oil
as required to maintain proper levels.
9. Label System with New Refrigerant
Change the chiller nameplate and labelling.
10. Provide customer with new documentation.
(Source: These R-513A Retrofit guidelines were developed by The Chemours Company FC, LLC.)

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FREQUENTLY ASKED QUESTIONS

• Is it necessary to change oil? Not necessary unless it’s contaminated.
• Why do I have to change the liquid level sensor? The new refrigerant requires new calibrations. The sensor
cannot be adjusted on site which is why a new sensor with correct calibration is required.
• Which Liquid Level Sensor (LLS) needs to be replaced? Item numbers 48 and 108 in the below graphic.
YK Chillers - Mod H, G, F, D, C (Item 48, 108)

48
108

YMC2 Mod A (Item 36) YMC2 Mod B (Item 136-15)

36

136-15
LD27114

• Where can I order the Liquid Level Sensor from? Contact your local Johnson Controls service office.
• What is the new Liquid Level Sensor part number that I need to order? 025-48615-006, -008, -009 or
-012. This is based on the original R-134a insertion probe length.
• Where can I order the new nameplate and label kit from? Baltimore Parts. The R-513A label kit part
number is 335-26652-000. These stickers need to replace the R-134a labels with a new labels stating R-513A
wherever applicable on the unit. The nameplate part number can be found on the lower right corner of the
current chiller nameplate. This will come blank and information will have to be added to the new nameplate.
• Do I have to change the software on site? Not always. The software may need to be changed for LDxxxxx units
manufactured before January 1, 2017. The R-513A option is available in software on units manufactured after
January 1, 2017.

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• How can I get revised documentation? EG and O1 Manual? Currently the R-513A option is available
as SQ, so the O1 and EG is not updated. Send an email request along with the chiller PIN to BE-ChillerSer-
viceLiterature@jci.com. If you have a project then please contact P&D or Product Management to help you
prepare the documentation update.
• Can R-22 YK units be converted? No. R-513A is not a viable conversion solution. The unit will not meet
performance or capacity.

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