## January 29, 2011 Orlando, Florida Ward Atkinson Bill Hill

1/31/2011 1

##  R - 134a

 

### System Stability  

### Equipment Status  

### Refrigerant Emissions 

##  R - 1234yf  

### Background on R - 1234yf  

### Refrigerant Properties  

### Timing  

### Service Issues  

### New Service requirements and Equipment 

##  Future of the R - 134a Fleet

1/31/2011 21/31/2011 3

## Industry Refrigerant

Purity Requirements

• ARI 700

• SAE J2776

1/31/2011 4

### Who Made It??
Does It Meet Industry Refrigerant Purity 

### Requirements? Reports of Some Cylinders Have contained Mixtures R- 12 & R - 152a R-22 & R - 142b
1/31/2011 5 CONTAINER AND SHIPPING CARTON IDENTIFICATION REQUIREMENTS  Refrigerant meeting these requirements identified in this document shall contain a marking on the container and shipping carton.  6.1.1 The label or imprint marking in bold type having a minimum height of 5 mm and shall state : “Meets SAE J2776 purity standard.”

Specification R134a-J2776 Volatile Impurities Including Other Refrigerants 0.5% by weight Unsaturated Compound Volatile Impurities 40 ppm by weight

Moisture 10 ppm by weight Returnable Cylinders CGA 660 Non - Returnable Cylinders CGA 167

Fitting 0.500 in x 16-2 g ACME - RH Tank External Color PMS 2975 Sky Blue

6 1/31/20117 

###  

## Impurities can result in catastrophic 

## results!!  

### Cost to you and to your customer!

1/31/2011

# Non - Condensables [Air]
 Air In The System Is A Common Condition  Excessive temperature/pressure drop in the condenser may be indicator of the problem  How to Purge Air  Draw a good vacuum  In large systems, the vacuum at the gauge may be mis - leading  Run purge cycle on recovered/recycled refrigerant cylinders often [R&R equipment]

1/31/2011 8 J2099 Recycled refrigerant 4.1.1.1 High Boiling Residues (Lubricant) - 500 ppm by weight, by gravimetric method, by AHRI Standard 700C-2008 4.1.1.2 Non -condensable Gases (Air) - 1.5% by volume , at 23.9 oC by gas chromatography, by AHRI Standard 700C-2008 4.1.1.3 Moisture - 50 ppm by weight, by Karl Fischer method or equivalent analysis, by AHRI Standard 700C-20081/31/2011 9 

###  Systems where compressor controls for 

### evaporator freeze are pressure based:  Poor performance as cutout will occur too early  Thermistor based systems will not be impacted 

###  Compressor cutout due to high pressure will occur too early resulting in potentially poor idle performance 

###  Control of cooling fans will shift, potentially resulting in unusual engine disturbance

# Impact Contaminated

Refrigerant  

## R - 1234yf in R- 134a systems  

### P/T Curve shifts  

### Automatic Air (NCG) purge cycle may 

### not work properly  

## Recycled refrigerant may be contaminated with R - 1234yf and air  

### Causing system control problems and higher pressures

10

# Refrigerant Oil

 

### Most of today’s compressors depend on 

### oil splash to lubricate critical bearing surfaces  

### Viscosity is critical  

### Amount is critical  Too little can result in compressor failure  Too much can result in poor performance and potential high pressures and relief valve opening  

### Mixing of oils can result in system failures  

### Mixing of PAG with POE oil in electric compressors can result in disabling the customer’s vehicle!!
1/31/2011 11

## Impact of Water and Temperature On Oil  

## Keeping Oil Dry is important  

### Change desiccant if system is exposed  

## With severe usage, oil may need replacement in lifetime due to acid creation

12 1/31/2011

ACID Number

TAN [Total Acid Number]

# R- 134a Equipment Status

13

# Current EPA Requirements

For R- 134a J2788 Recovery/recycle Charging 

# Equipment Requires 95% refrigerant recovery in 

# less than 30 minutes Requires accurate measurement of refrigerant recovered and charged

14

## SAE R - 134a J Standard Recovery/Recycle



## Equipment Certification Status
 J2210 HFC- 134a (R - 134a) Recovery/Recycling Equipment for Mobile Air- Conditioning Systems  Standard superseded all R - 134a R/R equipment must meet J2788 requirements  Certified J2210 equipment cannot be sold as new (EPA reg.) All new R&R equipment must be certified to J2788  Certified J2210 equipment can be used to service MAC systems  J2788 HFC- 134a (R - 134a) Recovery/Recycling Equipment and Recovery/Recycling/Recharging for Mobile Air- Conditioning Systems  J1770 Automotive Refrigerant Recovery/Recycling Equipment Intended For Use With Both R12 and R134a  Standard --- Canceled does not meet J2788 performance requirements 15

# SYSTEM REFRIGERANT

EMISSIONS

16

## Minnesota Leakage Data



# Type of System Profile

Results same as in 2009 submissions Multiple Evaporator Includes:

• Second Evaporators

• Cooler box 17

# Vehicle Model Profile 2009
-2010

5% Less SUV/crossover Models in 2010

18

# System Refrigerant Leak



# Rates  Vehicle OEMs choose the refrigerant charge by 

### adding a reserve charge above the minimum charge needed for performance  Time to service is based on the loss of this 

### reserve refrigerant [range from: 100 to 350 gram]  System Service may not be required for 6 to 10 years or more based on J2727 emission rates  

### Recent Service History Suggests Less Required Servicing of The Refrigerant Circuit

19

# System Refrigerant Leak Rates

20

# 2010 MAC System Refrigerant 

# Profile – Charge - Leak Rates

21 23 oz

38 oz

## • 1993 MACS Survey R - 12 systems requiring service being on the road for 3 to 5 years represented 1.7 – 17.8% of fleet serviced 

### • 2001 MACS Survey R - 134a systems requiring service being on the road for 3 to 5 years represented 0.0 – 6.3% of fleet serviced 

## Reduced Service



# Requirements Due To System Refrigerant 

# Leakage

22

# Estimated MAC R
- 134a Model



# Leakage Rates In 2001 EU estimated that MAC system

Avg. leakage was 67 g/yr Average: Single/multiple Evaporators 

### 2009 Data  

### MAC Fleet system Avg. leakage 15.1 g/yr  

### 366 Vehicle - Models 

### 2010 Data  

### MAC Fleet system Avg. leakage 14.6 g/yr  

### 379 Vehicle – Models 

### 2011 Data  

### MAC Fleet system Avg. leakage 11.9 g/yr  

### [preliminary] 50 Vehicle - Models 23

# MAC System Refrigerant Emissions  

## Current production refrigerant leakage rates are reaching:  

### Reliable production capabilities
 

## Refrigerant emission of less than 12 grams/yr
 Are technically difficult for reliable vehicle assembly  Are costly for the consumer and offer minimal value for the environment

24

# The Future R - 1234yf

2526



### Life Cycle Impact of R - 1234yf

Direct emissions: The greenhouse gas emissions resulting from the direct emission of the refrigerant. Indirect emissions: The greenhouse gas emissions (CO2) resulting from the power needed to run the air conditioning system. The majority of total GHG emissions come from this, especially for low GWP fluids

.

Indirect emissions [related to fuel consumption] are much more than the direct emissions! 26 Why Another Refrigerant Change ? R - 134a GWP 1430 R - 1234yf GWP 4

# R- 1234yf  

## Unstable Compared To R - 134a  

## Short Environmental Lifetime (3-4 days)  

## Mildly Flammable  

## Requires Professional Handling  

### New Lubricants  Belt driven compressor systems  c/o POE for Electric compressor systems  

### Important for life of system:  Minimize Residual Air [not to exceed 1.5%]  Minimize Moisture [replace desiccant more often]
27

# R - 1234yf MAC Systems  

### R - 1234yf is less efficient when dropped into a R- 134a system  Requires system changes to retain same level of performance  Heat exchangers - compressor changes - refrigerant controls  

### Industry wants only certified technicians to service systems  

### New SAE Standards cover equipment and 

### technician procedures  

### Professionally servicing R - 1234yf is similar to proper servicing of R - 134a systems

28

# REFRIGERANT PROPERTIES

2930 

### Impact of Accidental Mixing HFO- 1234yf + R134a

What will happen if HFO - 1234yf is accidentally mixed with HFC - 134a?

• Minimal pressure effect, but will alter P -T relationship for servicing

• Potential impact on R/R/R segments (ease of separation, ARI 700 purity specs )

• Contamination of HFO- 1234yf by R - 134a can be misinterpreted as AIR by automated equipment

• Need proper service training, unique service fittings for HFO - 1234yf vehicles Education & Training is needed to prevent mixing of HFC- 134a and

HFO- 1234yf during servicing 30

###  New specification for R - 1234yf  Increased requirements  Additional requirements may be added as mass production of refrigerant begins  Use of refrigerant not to SAE/AHRI specifications will cause system failures! Specification R- 134a-J2776 R- 1234yf-J2844 Volatile Impurities Including Other Refrigerants 0.5% by weight 0.5% by weight Unsaturated Compound Volatile Impurities 40 ppm by weight NA Moisture 10 ppm by weight 25 ppm by weight High boiling residue 0.01% by volume Acidity 1 ppm by weight HCl Non -condensables 1.5% gas phase by volume at 23.9 ° C. Returnable Cylinders CGA 660 TBA Non - Returnable Cylinders CGA 167 TBA Fitting 0.500 in x 16-2 g ACME- RH quick couple service fitting External Color PMS 2975 Sky Blue white with a red band on the shoulder 1/31/2011 31

###  Different than R - 134a, but new oil can be 

### used for R - 134a, but R134a oil cannot be used for R1234yf  What is different?  More inhibitor  Change in miscibility 

###  J2941 R - 1234yf Compressor Lubricant for 

### Aftermarket (Service) is under development

1/31/2011 32

# Main Considerations for R
- 1234yf

lubricant design

• Chemical stability (thermal, oxidative, hydrolytic variables?)



### • Refrigerant / lubricant miscibility & impact on viscometrics

• Electrical insulation properties



### • Applicability to current R - 134a systems

33

##  Air  

### Air needs to be controlled in MAC systems or supplemental additives will be needed for service  Vacuum levels below 28 in Hg are recommended per SAE Standard J2843 

##  Moisture  

### Moisture should not be introduced to MAC systems Good system practices prevent problems
34

# Flammability

35



## R - 1234yf 

## R - 134a

Propane36 

### Ineris Potential Ignition Sources for R - 1234yf

Cherry Red Manifold Match or Butane Lighter Difficult to ignite R- 1234yf due to high Minimum Ignition Energy37



## Future use of R - 1234yf

• New 2012 Vehicles in European Market

• New Vehicles in US Market to utilize fuel Credits

• GM announcement production in 2013 MY

37

###  International Vehicle Producers (Import 

### common models to U.S. New 2012 Models)  Meet U.S. and Europe Requirements using R- 1234yf or  Use R- 134a in U.S. Market R - 1234yf in European Market 

###  Providing U.S. Fuel Credits for some vehicles using R- 1234yf

38 38

# Honeywell and DuPont Will begin supplying the 

# refrigerant in the fourth quarter of 2011 for new 

# vehicle builds

1/31/2011 3940 1/31/2011 R- 1234yf Cost???

30 pound Cylinder

4041 

## R - 1234yf SAE Standards Summary

• How do the standards compare to R- 134a?

• Developed new Standards in conjunction with refrigerant evaluation, addressing system design, equipment and technicians

NEW Revised

# R - 1234yf Issues  

## Service Equipment Refrigerant Cylinders  

### Container size and type due to A2L 

### Classification and high refrigerant cost still under review [30 or 20 pound size cylinders]  

### White body red top shoulder  

### Containers have quick couple fitting with safety feature [low side MAC system service fitting under review]

1/31/2011 42 

## Returnable cylinder

# R- 1234yf Issues Refrigerant is Classified ASHRAE A2L  

## Servicing MAC systems with lower cost SNAP listed refrigerants  

### System and service equipment contamination  

## Cylinder Handling/storage [In repair shop]  

### Federal Hazardous Act Sale of products  

### National Building Code UBC- BOCA- SBCCI Storage 15 pounds or more [Flammable]

43

# R- 1234yf Shop Equipment

Requirements  

## New Service Equipment  

### J2843 R- 1234yf Recovery/Recycling/Recharging Equipment  

### J2912 R- 1234yf Refrigerant Identification Equipment  

### J2913 R- 1234yf Refrigerant Electronic Leak Detectors

44 1/31/2011

# Timing For New R - 1234yf

Service Equipment  

### If International vehicle manufacturers produce 

### only R- 1234yf vehicles for U.S. and EU  Vehicle dealers will require equipment in 2012  

### Any vehicle manufacturer producing R - 1234yf 

### MAC systems for U.S. fuel credits  Vehicle dealers will require equipment in 2012  

### Normal Independent MAC Service Operations 3 to 5 years later  Based upon out of warranty MAC systems  

### Body/collision shops when R- 1234yf is introduced by Vehicle OEMs

4546 

## J2843 R- 1234yf Recovery Recycle Charging Equipment  

### Ventilation of Equipment Enclosure  2 Intake grills to maintain 6 air change per hour flow to maximize cross flow within the cabinet  

### Equipment will have contaminated 

### refrigerant identification feature  

### Refrigerant Charging Procedure Process  1 st. Vacuum decay leak rate check  2 nd. Partial refrigerant charge for pressurization and leak rate test  

### The MAC system cannot be charged without successfully meeting both leak 

### rate test requirements

# Shop Service Equipment Cost
 

### Current R - 134a Equipment  Recovery/Recycling/Recharging Equipment  $2,600 -- $4,500  Refrigerant Identification Equipment  $600 -- $1,500  Refrigerant Electronic Leak Detectors  $250 -- $600  

### Shop Equipment Cost Range  $3,450 -- $6,600 plus support equipment/tools  

### R - 1234yf Equipment Cost Will Be Higher!

47 1/31/2011

# New R - 1234yf Standards  

## SAE J2842 Requirements for 

# leaking evaporator replacement  

## SAE J2845 Certified Technicians  

## SAE J2911 Certification of  

## Service equipment  

## Components  

## Technician Programs  

## J639 Includes R - 1234yf

48

# J2842 Leaking R- 1234yf Evaporators  

### J2842 R - 1234yf and R744 Design Criteria and Certification for OEM Mobile Air 

### Conditioning Evaporator and Service Replacements  No leaking evaporators may be repaired or reworked in the vehicle assembly process or in service  An evaporator from a vehicle air conditioning system shall not be repaired or removed from any (including salvage) vehicle air conditioning system with the intention of using it again in the same or a different vehicle

49 Required Evaporator Label50



# J2845 SAE Technician Requirements  

### J2845 Technician Training for Safe Service and Containment of Refrigerants Used in Mobile A/C Systems (R -744 and R - 1234yf)  Technician training is required to ensure that recommended procedures are used for service and repair of mobile air conditioning systems using R-744 and R- 1234yf.  Technician must be trained  Recognize which refrigerant is being handled  Handle it safely  Equip with the essential information, proper equipment and tools, which are unique to these refrigerants51 

# J2911 SAE Certification Standard  

### Procedure For Certification That 

### Requirements For Mobile Air Conditioning System Components, Service Equipment and Service Technicians Meet SAE J Standards  Purpose of this Standard  Certify the requirements:
 MAC system components
 Service equipment
 Service technician qualification  Certification provides a means to assure a customer or a Regulatory Agency that the equipment delivers the advertised performance Certification Results Will Be Posted on SAE Web

# SAE System Design Standards  

### J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compression Systems  Provides design standards and safety requirements for MAC systems  Cautionary statements for the mobile air conditioning service industry 

###  

## Master Document referencing all MAC 

## A/C SAE Standard s

5253 

# Vehicle Label Requirements

J2842 Certification for OEM Mobile Air Conditioning Evaporator and Service Replacements J2845 Technician Training for Safe Service and Containment of Refrigerants J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compression Systems

##  Leakage rate comparison to R - 134a is 

## different for different material types  Purity of the refrigerant, moisture and air in the system can affect the result 

## more than in the case of R - 134a  Cost to recharge the system will be much higher so leakage rate will be very important to the OEMs and to the customer!!

1/31/2011 54SAE International CRP1234
-2 Final Meeting, Dresden, September 15/16, 2008 Hose Permeation Comparison to R134a baseline

R - 134a R - 1234yf

# Future Of R - 134a Fleet

56

###  EPA has been petitioned to eliminate R - 134a  

### Possible Replacement Refrigerants  All SNAP Listed  System and service equipment damage  

### Safety Issues with R - 1234yf in systems designed 

### for R - 134a  Cooling performance loss of 10 to 15%  Potential compressor durability/oil miscibility issues  

### SNAP currently listed Refrigerants are lower cost than expected R - 1234yf cost  Likely use to service R - 1234yf systems

1/31/2011 57

###  EPA does not test any refrigerants for:

 System cooling performance  System durability  System and service equipment damage  Oil and elastomer compatibility  Flammability 

###  At present time the vehicle OEMs have only tested R - 152a, R - 134a, R -744 and R - 1234yf for:  System cooling performance  System durability 

###  At the present time only the service equipment OEMs have developed equipment for R - 134a and R - 1234yf

1/31/2011 581/31/2011 59R- 134a Dec. 2010 $6.33/lb

1/31/2011 60

# Retrofitting of R- 12 Fleet To

R - 134a  

## MACS Service Field Surveys 

# Indicated  

## Less that 10% of R - 12 Fleet Was Retrofitted to R - 134a  

## Retrofitting use of other SNAP listed and Hydrocarbon Refrigerants were 

## found in less that 3% of the R - 12 Fleet  

## With Adequate Supply of R - 12 Retrofit Was Not A Major Success

61

# Retrofitting of R- 12 Fleet To

R - 134a Two types of retrofitting  

### Type I Retrofit Vehicle manufacturer’s recommended procedure  

### Type II Retrofit  New service fittings  New label  High - pressure cutout 

### switch

62 

### 38% Did not 

### Meet EPA Retrofit Requirements

###  Cooling Performance Change  Expansion Valve Calibration Is Different  Refrigerant Pressure Controls Settings [9 PSIG spread]

1/31/2011 63 Evaporator Pressure/32F [PSIG]

• R - 134a 27.8

• R - 1234yf 31.464 

# Future Challenges  

## Introduction of R - 1234yf in new vehicles  

## Refrigerant cost considerably higher  Potential to re-charge with some other refrigerant due to high cost  

## Cannot be vented at service  

## Requires all new service equipment  

## Current EPA SNAP rule allows listed refrigerants  

## To service R- 134a and potentially 

## R - 1234yf MAC systems65



# Lessons Learned



# -The Future  

## The MAC change from R - 134a to 

# R - 1234yf will be much more expensive for the consumer and industry  

## Use of other EPA listed refrigerants should be avoided  

# Higher costs for:  

## Refrigerant  

## Service Equipment66 1/31/2011