This summer, HARDI has been warning contractors and technicians not to substitute R-410A for R-454B in systems designed for the newer refrigerant. A recent Reddit post has provided firsthand field evidence of why this matters.
In their post, the Reddit user explained how they retrocharged a rooftop unit, originally built for R-454B, with R-410A due to supply shortages. While the unit powered on and ran, the building wasn’t cooling. The data supplied by the user’s Fieldpiece gauge explained why the system wasn’t cooling and how R-410A was damaging the equipment.
What Did the Data Say?
The technician posted a screenshot showing suction pressure at 178 psig and an indoor coil temperature of 82 °F. On the high side, the liquid pressure was 364 psig, with the outdoor coil reading 95°F.
In a unit designed for R-454B, which operates at slightly lower pressures, seeing such a large pressure/temperature mismatch should be alarming. The refrigerant/equipment discrepancy is the root of the problem.
What’s Going Wrong Inside the System?
Refrigerants are engineered to operate within specific pressure and temperature ranges. R-410A operates at higher pressures than R-454B, and when used in a system not designed for it, the components are pushed beyond their limits.
The evaporator coil, which should be significantly colder than the indoor air temperature in order to absorb heat from the air, instead becomes too warm. In this case, the evaporator coil was in the low 60s, about 20 degrees warmer than it should have been. Meanwhile, the condensing side of the unit struggles to reject heat efficiently. The system is circulating refrigerant, but the space doesn’t get cooler since it is not transferring heat properly.
Why Substitution Is Tempting — and Why It’s a Mistake
It’s understandable why some technicians might consider using R-410A when R-454B isn’t available. Both refrigerants, when operating properly, run at similar pressures, and the system may seem to operate normally at first.
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But the thermodynamic differences between them are significant. The elevated pressures and mismatched metering in a system designed for a different refrigerant led to poor performance, higher energy costs, and long-term damage to the equipment. What seems like a quick fix can become a headache that can be expensive to remedy.
Long-Term Risks of Running the Wrong Refrigerant
Running R-410A in an R-454B system stresses the compressor, coils, valves, and piping. These parts aren’t rated for the higher pressures, which can lead to premature wear, reduced efficiency, and even sudden failure. The expansion valve, calibrated for R-454B, restricts flow and starves the evaporator, preventing the unit from properly cooling and causing increased wear on the components.
Despite the system appearing to run, it delivers little to no cooling and consumes more energy in the process. Over time, this mismatch increases the risk of leaks and ruptures, posing safety concerns for both technicians and building occupants.
The Right Refrigerant Isn’t Optional: Don’t Make a Costly Mistake
R-410A should never be used as a substitute for R-454B. Even if the system powers on, it won’t cool properly and will likely suffer premature failure.
The Reddit post offers a real-world example of what HARDI has been warning about all season: refrigerant mismatches compromise performance, damage equipment, and create safety risks. Technicians should always use the correct refrigerant and follow manufacturer specifications to ensure reliable, efficient cooling.
This article was republished with permission from hardinet.org.