January 29, 2011

Orlando, Florida

Ward Atkinson

Bill Hill

1/31/20111
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 2
1/31/2011 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

1/31/20115
 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

1/31/2011 6
7

 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-2008
1/31/2011 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 

1/31/2011 12 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
Single 

system

Leak rate 

G/yr Charge Grams % Loss/yr

Average 14.1 658.9 2.3

High 25.7 1220 4.3

Low 7.2 360 0.9

2010 MAC System Refrigerant 

Profile – Charge - Leak Rates

21

23 oz

Dual 

system

Leak rate 

G/yr Charge Grams % Loss/yr

Average 19.2 1088.4 1.9

High 28.2 1900 3.1

Low 11.0 685 0.8

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 

25
26

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

29
30

Impact of Accidental Mixing

HFO-1234yf + R134a

Vapor Pressure

0

0.5

1

1.5

2

2.5

3

3.5

-40 -20 0 2 0 4 0 6 0 8 0

Temperature (C)

Pressure (MPa)

R-134a

HFO-1234yf

50/50 Blend

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-134a R-1234yf

Propane
36

Ineris Potential Ignition Sources for R-1234yf

Cherry Red Manifold

Match or Butane Lighter

Difficult to ignite R-1234yf due to 

high Minimum Ignition Energy 
37

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 39
40 1/31/2011

R-1234yf Cost???

30 pound 

Cylinder

40
41

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

Documents R-134a HFO-1234yf

J639   

Refrigerant Purity   

Measurement 

Compartment 

Concentrations

 

Risk Analysis  

Evaporator Design  

Refrigerant 

Recovery   

Recycle Charging 

Equipment   

Leak Detectors   

Refrigerant 

Identification   

Technician and 

Equipment

Certification 

Technician 

Training  

Hose Assemblies

 

 New 

Field 

Coupled 

 
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

1/31/2011 44
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

45
46

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!

1/31/2011 47
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 Label
50

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 refrigerants
51

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 Standards

52
53

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 54
SAE International CRP1234-2 Final Meeting, Dresden, September 15/16, 2008

Hose Permeation Comparison to R134a baseline

100h240h500h100h240h500h100h240h500h100h240h500h100h240h500h100h240h500h

R134a HFO1234yf R134a HFO1234yf R134a HFO1234yf

High Temp-hose High Temp-hose Suction hose

g/(cm2*a)

Permeation Comparison

R-134a / R-1234yf Hoses

Chloroprene

[Neoprene]

Chloroprene

[Neoprene]

Polyamide

[Nylon]

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 58
1/31/2011 59
Refrigerant Cost 2009 vs. 1997

$0

$5

$10

$15

$20

$25

FRIGC FR-12 FREEZONE

RB-276

GHG-X-4

#Auto

FrostChill-It R414A

ICOR #Hot

ShotKar

KoolR-414B

Freeze-12 GHG 

#McCoolR406A

R-134a R-12

Refrigerants Cost per pound (Wholesale volume)

2009 1997

R-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 20 

25 

30 

35 P r e s s u r e P S I G

Type Of Refrigerant

FRIGC 

R401C

R134a

Freezone

IKON-12

R1234yf

Pressure For 32 F. Evaporator Core

Surface Temperature

reftype

R-1234yf

Evaporator 

Pressure/32F

[PSIG]

• R-134a 27.8

• R-1234yf 31.4
64

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 systems
65

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 Equipment
66 1/31/2011