By Stan Johnson | Master HVAC Technician & Educator
If your AC system was built before 2010, it likely uses R-22 refrigerant—a now-phased-out chemical that’s expensive and environmentally harmful. Modern systems rely on R-410A, a more efficient but higher-pressure alternative. After 20+ years in HVAC, I’ve helped hundreds of homeowners navigate this transition—some saving thousands, others learning costly lessons the hard way.
This guide breaks down:
⚖️ Key differences between R-22 and R-410A
💰 Cost impacts of sticking with an old system
🔄 When to retrofit vs. replace your AC
⚠️ Safety and legal considerations
Let’s clear the air on refrigerants.
🔍 R-22 vs. R-410A: Key Differences
| Feature | R-22 (Freon) | R-410A (Puron) |
|---|---|---|
| Status | Phased out (Banned in 2020) | Current standard |
| Pressure | Lower (~150 PSI) | Higher (~400 PSI) |
| Efficiency | Lower (SEER max ~10) | Higher (SEER 16+) |
| Environmental Impact | Ozone-depleting (ODP=0.05) | Ozone-safe (ODP=0) |
| Cost Per Pound | 150 (Limited supply) | 90 |
| Compatibility | Older systems only | Requires special equipment |
Pro Tip: Never mix R-22 and R-410A—it creates dangerous pressures and ruins compressors.
If you’re unsure about safe handling or compatibility, explore our refrigerant management guide for detailed advice.
💰 The True Cost of an R-22 System
1. Refrigerant Prices Are Sky-High
2010: $5/lb
2024: 150/lb (If you can find it)
2. Repairs Get More Expensive
Leak repair + recharge: 2,500 (vs. 1,200 for R-410A)
Parts scarcity: Many R-22 compressors are no longer made
3. Efficiency Penalty
R-22 systems are 30-50% less efficient than modern units
Example: A 3-ton R-22 unit costs $300+/year more to run than an R-410A equivalent
Real-World Case: A homeowner spent 6,000 replacement two years later.
♻️ Can You Convert R-22 to R-410A?
Retrofitting is Rarely Worth It
✔ Required Changes:
New compressor
High-pressure coils
TXV valve upgrade
Flushing all lines
✔ Cost: 5,000 (Often more than a new system)
When Retrofit Might Make Sense:
Commercial systems with expensive ductwork
Recent R-22 units (Under 5 years old when phased out)
Pro Verdict: 90% of homeowners should replace, not retrofit.
⚠️ Safety & Legal Notes
1. Only EPA-Certified Techs Can Handle Refrigerant
Fine for illegal handling: $37,500 per violation
2. R-22 Can’t Be Topped Off Without Fixing Leaks
EPA Requirement: Must repair leaks >15% per year
3. Disposal Must Be Done Properly
Recover all refrigerant before scrapping old units
For step-by-step instructions on proper pressure checks and maintenance, refer to the refrigerant pressure checks guide.
🔄 Transitioning to R-410A: What to Expect
New System Requirements:
✔ Thicker copper lines (Handles higher pressure)
✔ Different oil type (POE vs. mineral oil)
✔ Updated service ports (Different fitting sizes)
Performance Benefits:
✔ Higher SEER ratings (Up to 26 vs. R-22’s max ~10)
✔ Better humidity control
✔ Lower operating costs
📉 The Future: R-410A Being Phased Out Too
New Refrigerants Coming:
R-454B (Replacing R-410A by 2025)
R-32 (Common globally, flammable)
Pro Tip: If buying a new system now, ask about R-454B-ready models.
Final Thought: Don’t Wait Until Crisis Hits
As I tell my clients:
*"Patching an R-22 system is like repairing a VCR—eventually, you’ll need to upgrade anyway."*
Action Steps:
Check your unit’s data plate (Lists refrigerant type)
Start saving for replacement if still on R-22
Get a load calculation before buying new
Still running R-22? Share your upgrade plan below!
Stay cool and compliant,
Stan Johnson
HVAC Pro Tips YouTube | EPA 608 Certified
