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°
CLIMATE COMFORT
Heating

Air Conditioning

Split airconditioning Applied Systems

Refrigeration
Chapter 2: Handling R32 in the field

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Contents
1. Specifications of R32

2. Basics of flammability and explosions

3. Safety precautions during transport and storage of the unit/refrigerant vessel

4. Attention points during commissioning/repair/pump-down.

5. How to ensure a safe handling of R32

6. Special tools for R32

7. Conclusion

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1: Specifications of R32
1. R32 vs. other F-gases

2. Why R32

3. Flammability issue

4. Density of R32

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1.1. R32 vs. other F-gases

R32 R410A R22

Category HFC HFC HCFC

Formula CH2F2 CH2F2 / CHF2CF3 CHClF2

Composition - R32/R125 -
(Mixture Ratio wt%) (50/50 wt%)
Boiling temperature -51.7 -51.5 -40.8
(°C)
ODP*1 0 0 0.055

GWP*2 675 2100 1810

Refrigerant Oil*3 Synthetic oil Synthetic oil Mineral oil

(ether) (ether) (suniso)
*1: Relative ODP values based on R12=1
*2: Information from IPCC 4th Assessment Report
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1.1 R32 vs. other F-gases

R32 R410A R22

Flammability Slight flammability No flammability No flammability

(A2L) (A1) (A1)
Toxicity No No No

Pressure*3 1.6 1.6 1

*3: The pressure are relative values based on R22 as 1

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1.1 R32 vs. other F-gases

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1.2. Why R32

R32
ENVIRONMENT FRIENDLY REFRIGERANT
2500 3.50 3.25
3.08
2090 2027 3.00 2.80
2.68
2000 1810 1810
2.50
1500 -67% -77% 2.00 +5%
1.50
1000 +4% -29%
675 1.00 0.75
463 0.50
500 0.53
0.00
0 Cooling COP Charge (kg )
GWP CO2 eq. emission Performance (kW )

R22 R410A R32 R410A R32

Advantages of R32 over R410A

Lower GWP and CO2 eq. Emission

Higher Thermal Conductivity
Lower Viscosity (lower pressure drop)
Lower Density (lower refrigerant amount)
Single Component Refrigerant
(ease in handling)

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1.3. Flammability classification

Under ASHRAE 34 and draft ISO 817, R32 is a slightly flammable gas

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1.3. Flammability classification

Flammability classification of R32 = 2L

Propane R32

Class A: Non Toxicity* Class B: High Toxicity

Class 3: High Flammability A3 B3
A2 B2
Class 2: Lower Flammability
A2L B2L
Class 1: Non Flammability A1 B1
SAFETY GROUP

R410A / R22 Ammonia

*Class A signifies refrigerants for which toxicity has not been identified at concentrations less than
or equal to 400 ppm

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1.4. Density of R32

Density of a flammable gas is important to know:

GAS Density
R32 2,15
Iso-Butane 2,15
Natural Gas 0,6
Ammonia 0,8
R22 /
410A /
Acetylene 0,9

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1.4 Density of R32

1. Location determines explosivity/flammability

2. The further away from the leak, the lower the concentration

3. Lower parts of the room (ditch, cellar, gutter, manhole…) are a

higher risk  accumulation!

4. Close off prior to works and ensure ventilation

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2: Basics of flammability and explosions

1. Conditions for refrigerant ignition

2. Practical test on igniting or leakage of R32

3. Characteristics of a flammable gas: definitions

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2.1 Conditions for refrigerant ignition

A fire will be triggered by a flammable refrigerant if 3 conditions are met.
 Adequate measures must be taken to prevent such situation occurs.

Presence of oxygen

Occurrence of
refrigerant leakage Presence /contact of
ignition source

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2.2 Practical test on igniting or leakage of R32

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2.2 Practical test on igniting or leakage of R32

Burning speed test:

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2.2 Practical test on igniting or leakage of R32

igniting 30g propane

igniting 180g R1234yf

igniting 320g R32

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2.2 Practical test on igniting or leakage of R32

0g R32 400g R32 800g R32

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2.2 Practical test on igniting or leakage of R32

Simulating an R32 rapid leak from liquid line during brazing
 No explosion occurs, same result as R410A (due to oil)

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2.3 Characteristics of a flammable gas: definitions

1. Explosion limits (LEL-UEL)

2. Minimum Ignition Energy (MIE)

3. Auto ignition temperature (AIT)

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2.3.1 Explosion limits (LEL – UEL)

• Every flammable gas needs oxygen to burn

• ‘Explosion’ depends on circumstances in which gas is ignited

• How much oxygen is typical for each gas

• ‘Explosion Limit’ implies ‘an explosion’ which is not always the case

• Better is ‘Flammable Limits’

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2.3.1 Flammable limits (LFL – UFL)

Lower Upper
Flammable Flammable
Limit Limit

Too lean Too rich

LFL UFL
100 % air LEL UEL 0 % air
0 % gas 100 % gas

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2.3.1 Flammable limits (LFL – UFL)

Flammable limits of a few gasses

GAS LFL-UFL
R32 14-31

Iso-butane 1,8-8,4

Natural gas 5-15,8

Ammonia 15-30

R22 /

410A /

Acetylene 2,3->80

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2.3.1 Flammable vs. explosions

1. The sudden release of energy (combustion) that causes a sharp
pressure rise (=damage)

2. Reaction: CH4 + 2O2 = CO2 + 2H2O + E (heat)

3. HEAT = expansion of gasses

4. Do the gasses have room to expand?

YES: little/less build-up of pressure
NO: build-up of pressure

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2.3.1 Flammable vs. explosions

• Small volume of flammable mixture in large room does not lead to
sharp pressure rise

• Compares to ‘unconfined’ explosion

• Burning velocity vs. ‘violent’ combustion

• R290: 46 cm/s, R-717: 6,8 cm/s R-1234yf: 1,5 cm/s
• R32: 6,7 cm/s (= very slow!)
• Hydrogen: 312 cm/s

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2.3.2 Minimum ignition energy (MIE)

1. MIE is typical for a gas

2. Amount of energy is expressed in Joules

3. 1 J = lift 0,1 kg to a height of 1m

Type Energy
Mechanical spark (steel tool drops on concrete floor) < 0,6 mJ
ESD of a person (can just be felt) 1 mJ
Maximum ESD of a person To 30 mJ
ESD Spark 3J
Open flame >10 J

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2.3.2 Minimum ignition energy (MIE)

MIE of R32 compared to that of other gasses

GAS MIE (mJ)

R32 >15-100
Iso-Butane 0,25
Natural Gas 0,28
Ammonia 680
R22 /
410A /
Acetylene 0,017
Hydrogen 0,011

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2.3.3 Auto ignition temperature (AIT)

1. Temperature by which a gas will self ignite

GAS AIT
(°C)
2. AIT is typical for a gas
R32 648
Iso-Butane 460
3. No sparks, flames or other ignition sources Natural Gas 670
required
Ammonia 651
R22 /
4. Attention: Hot surface by welding flame can 410A /
easily reach 648°C! Acetylene 305

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3. Safety precautions during transport and storage of the
unit/refrigerant vessel

1. Calculation of the minimum required ventilation in a van

ATTENTION
2. Storing refrigerant vessels POINT 1

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3.1 Calculation of the ventilation in the van

ATTENTION
POINT 1

DAIKIN

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3.1 Calculation of the ventilation in the van

• 1,26 kg = 0,585 m³ pure gas
ATTENTION
POINT 1

• LFL = 14%

• 0,585 m³ pure gas makes 4,2 m³ flammable mixture (theoretically

perfect)

• Let’s stay under LFL safety factor 4

• 4*4,2 = 16,8m³ - 4,2 = 12,6 m³ fresh air

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3.1 Calculation of the ventilation in the van

ATTENTION
POINT 1

Solution:
 R32 heavier than air = LOW ventilation (at the bottom)!
 Permanent ventilation when driving
 No smoking

Remark:
Installer should already take same
precaution for transporting acetylene
for brazing.

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3.2 Storing refrigerant vessels

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3.2. Storing refrigerant vessels

• R32, being a high-pressure gas, is supplied in a highly safe pressure vessel.
To protect pressure vessels from dropping, being knocked down, impacts,
and rolling.

• R32 is, according to ASHRAE 34 and draft ISO 817, a slightly flammable
gas.

• Likewise other high-pressure gases, R32 should be stored in accordance

with the standards established by laws and regulations or MSDS.

• Cool, dark place that is well-ventilated, with a temperature of 40ºC or lower;

Implementation of fall-prevention devices, etc.

 Exact instructions for storing R32 in a safe way should be obtained from
refrigerant supplier

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4: Attention points during commissioning/repair/pump-down.

1. Emission during vacuuming ATTENTION

POINT 2

2. Emission during disconnecting gauge hose ATTENTION

POINT 3

ATTENTION
3. Emission during connecting/disconnecting hoses POINT 4

ATTENTION
4. Full accidental release POINT 5

5. Air sucked in during pump down ATTENTION

POINT 6

6. What can happen if incorrect refrigerant is used

7. R 32 blocked inside the refrigerant circuit during repair ATTENTION

POINT 7

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4.1 Attention for emission during vacuum

ATTENTION

•
POINT 2
Evacuation of the air of the system
• GSL could be (slightly) open => gas expands and is being sucked in by
BP. Emission of gas by VP but pump will shut down because there is
no low pressure.
iu
EX…?
ou

SVL
OPEN

SVG

Emission too low for EX-risk, density will quickly be below LFL.
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4.2 Emission during disconnecting pressurized gauge hose

ATTENTION

•
POINT 3
System is operational
• Blue flexible hose accidentally still pressurised with R32

iu
Blue flexible hose
pressurised with R32 ou

SVG

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4.2 Emission during disconnecting pressurized gauge hose

Blue flexible hose pressurised with R32 => Emission of R32 to

atmosphere ATTENTION
POINT 3

 If gas, influence can be neglected as it will quickly blend below LEL

iu
EX…?
ou
Blue flexible hose
filled with liquid R32

SVG

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4.2 Emission during disconnecting pressurized gauge hose

 If liquid, this is approximately 32g of R32 ATTENTION

 This equals 104l of theoretical EX mixture POINT 3

 Moderate ventilation advised

iu
EX…?
ou
Blue flexible hose
filled with liquid R32

SVG

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4.3. Emission during connecting/disconnecting hoses

• Always brief moment

ATTENTION
POINT 4

• Estimated release of R32: 21g

• Estimated flammable mixture: 70l

• Low ventilation advised when working

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4.4 Full accidental release

• Very rare
ATTENTION
POINT 5

• 1,26 kg of R32 (full charge of unit) is released

Solution:
 12,6 m³ of fresh air required! (see transportation)
 Reaction: start to ventilate immediately!
 Avoid all flames/hot surfaces
 Leave the room until all gas is escaped

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4.5. Air sucked in during pump down

Possible causes:
• Pumping down too long causes under pressure ATTENTION
POINT 6

• Flare joints can leak with under pressure

• Leak = drawing air in the system.

When commissioning afterwards, the air will mix with R32 

Flammable mixture  ignition will cause internal explosion!

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4.5. Air sucked in during pump down

 Explosion leads to high internal pressure
ATTENTION
POINT 6
High pressure could lead to rupture of system

Rupture = flame jet (and) or shrapnel

 Injuries!

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4.5. Air sucked in during pump down

Air (Oxygen) must be ATTENTION
POINT 6
avoided at all times inside any
refrigerant circuit.

• It is strongly advised to
measure the saturated
pressure/temperature when a
unit has been pumped down or
when there is any doubt that air
might have entered the system.

• Use the pressure/temperature

graph to verify that any other
gas has entered the system or

 check manifold
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4.6. What happens if incorrect refrigerant was used?

1. If an R32 unit was charged with R22

The chlorine content in the R22 damages the refrigerant oil. Degradation of
refrigerant.
This oil reduces lubrication and can cause compressor to be damaged.

2. If an R22 unit was charged with R32

R32 has higher pressure than R22; therefore, in terms of pressure resistance of
the machine, incorrect refrigerant charge can cause a very dangerous situation.
In addition, the lack of compatibility between R32 and mineral oil (SUNISO oil)
reduces oil return performance, on top of R32 and the oil separating into two
layers inside the compressor hindering proper oil supply to the bearing, which
causes poor lubrication. This can result in the compressor overheating.

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4.6. What happens if incorrect refrigerant was used?

3. If an R32 unit was charged with R410A or vice versa

R32 units and R410A units are optimized to their respective refrigerant
properties;
therefore charging them with the unintended refrigerant prevents proper
operation.

 These events are risks as a result of installations contradictory

to the code of good practice.

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4.7. Danger of R 32 blocked inside the refrigerant circuit during
repair
ATTENTION
POINT 7

Problem:
R32 can be locked up in the system even after evacuation (e.g. blocked
expansion valve).
Always verify if refrigerant might be trapped inside the refrigerant
circuit.

Caution: using a flame on a pipe under

pressure can lead to flame jet (severe
burns) or explosion of pipe.
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4.7. Danger of R 32 blocked inside the refrigerant circuit
during repair
ATTENTION
POINT 7

 Recover the refrigerant to verify the recovered quantity with the charged
quantity.
 Flush with nitrogen gas for brazing + check if flow comes through
 Always cut out the parts that need to be repaired.
 If cutting out the parts is impossible, then puncture the pipe

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4.8. Maximum allowable charge

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4.8. Maximum allowable charge

Model R32 charge, kg for Min. floor area, m2 / R32 charge, kg for Min. floor area, m2 /
7.5m piping ft2 for 7.5m piping 20m piping ft2 for 20m piping
xxxxx 0.4 0.15 / 1.61 0.61 0.35 / 3.77

Whereas:

M : R32 Charge
LFL : Low Flammable Limit
ho : Indoor unit Height

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5: Safe handling of R32

1. Overview

2. What you need to remember

3. R32: what if

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Attention point Safety Prevention R32 vs R410A? PUBLIC

problem?

1 Transport in a van Concentration Ventilation Same

of R32

2 Emission during vacuuming Concentration No risk Same

of R32
3 Emission during Concentration Ventilation Same
disconnecting R32 of R32
pressurized gauge hose
4 Emission during Concentration Ventilation Same
connecting/disconnecting of R32
hoses
5 Full accidental release Concentration Ventilation Same
of R32
6 Air sucked in during pump Flammable AVOID  check Check manifold
down mixture of R32 with manifold
& O2
7 R32 blocked inside the Flammable AVOID  flush with Same
refrigerant circuit during mixture of R32 nitrogen + check if
repair & O2 flow or cut out parts
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5.2. What you need to remember for R32

1. At all times, avoid a mixture between LFL and UFL.
 Through safe handling (avoid leaks)
 Through ventilation (avoid concentrations)

2. Check-check-check
 Check if there is air in the system (manifold)
 Check if there is still refrigerant in the system (weighing and cutting parts)

3. VENTILATE if an unsafe situation occurs (thus reducing the

concentration and avoiding risk of flammability)

4. Perform works according to F-gas regulation and code of good

practice
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5.3. R32: what if (essential Word document)

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6: Special tools for R32 (different from R410A)

1. Gauge manifold

2. Electronic leak tester

3. Recovery pump
Tooling R410A R32
Manifold Normal Different scale but solution
can be found
Scale Normal Normal
Vacuum pump Normal Normal
Leak detector Normal Different
Recovery unit Normal Different
Ventilation Recommended Necessary (fan)
Warnings Blue marks (see p16) Blue+Red marks (p16)

Recovery bottle 40 bar, right thread 48 bar, left thread

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6.1 Gauge manifold for R32

Special manifold for R32 is

supplied by Panimpex.
See appendix for more detailed
information

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6.2 Electronic leak tester for R32

Electronic leak tester for

R32 is supplied by
Mastercool.
See appendix for more
detailed information

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6.3 Recovery pump for R32

Recovery pump for R32 is

supplied by Mastercool.
See appendix for more detailed
information

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6.4. Adapter piece left thread to right thread

In case it cannot be obtained locally, DENV has a small quantity
of adapter pieces in SPP stock.

All flammable gas cylinders have left thread. This adapter piece
converts left thread to right thread, for use of manifolds.

SPP number = 999005P

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7. Conclusion
1. Technically, installation of R32 unit is the same as R410A
2. Tooling is slightly different
Tooling R410A R32
Manifold Normal Different scale but
solution can be found
Scale Normal Normal
Vacuum pump Normal Normal
Leak detector Normal Different
Recovery unit Normal Different
Ventilation Recommended Necessary (fan)
Warnings Blue marks (see p16) Blue+Red marks (p16)

Recovery bottle 40 bar, right thread 48 bar, left thread

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