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## UNITED STATES ENVIRONMENTAL PROTECTION AGENCY WASHINGTON, D.C. 20460 

# HE B 2 5 2015 OFFICE OF AIR AND RADIATION 

# Memorandum To: From: Subject: Date: Docket EPA-HQ-OAR-2013-0748

Gerald Wozniak and Dave Godwin EPA/Stratospheric Protection Division Derivation of Charge Limits for Room Air Conditioners February 25, 2015 

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This document describes how EPA derived the refrigerant charge limits for room air conditioners and heat pumps proposed in "Protection of Stratospheric Ozone: Listing of Substitutes for Refrigeration and Air Conditioning and Revision of the Venting Prohibition for Certain Refrigerant Substitutes." Source documents f'or calczrlations These charge limits are based upon calculations from formulas in Underwriters Laboratories (UL) standard 484, Room Air Conditioners. The formulas in Appendix F of the UL 484 standard in turn are based upon the international industry standard International Electrotechnical Commission (IEC) 60335-2-40, "Particular Requirements for Electrical Heat Pumps, Air Conditioners and Dehumidifiers" (2005). Kataoka, et al. (2000) first derived these formulas and discussed their technical basis. These formulas are empirically derived, considering molecular mass, lower flammability limit, refrigerant dispersion, leak rates, and the dimensions of the space that refrigerant leaks into. These formulas also were proposed to the IEC SC 61 D and International Organization for Standardization (ISO) TC86 SC1 WG1 joint working groups to assist in setting standards for using flammable refrigerants in air conditioning equipment and dehumidifiers (Kataoka et al., 2000). Formula used to establish limits for fixed units The formula in section 1.6 of appendix F,"Requirements for Charge Limits," of UL 484 is for fixed appliances with charge amounts m 1< M< m2, where M is the refrigerant charge amount in appliance in kg, ml is 4m 3 x the lower flammability limit (LFL) in kg/m 3 , and m2 is 26m 3 x LFL. The formula for the maximum allowable charge size for fixed appliances is as follows: Internet Address (URL) -http//wwwepa.gov

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# mrnax = 2.5 (LFL)4 h,
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Where, m,,, ax = the maximum allowable charge size allowed for the space, in kg, LFL = the lower flammability limit of the refrigerant in kg/m 3 , ho = the installation height of the indoor unit in m(0.6 m for an air conditioning (AC) unit on the floor, 1.0 m for an AC unit in a window, 1.8 m for a wall-mounted AC unit, and 2.2 m for a ceiling-mounted AC unit) A= the area of the room, in m 2 The formulas are based upon the conservative assumption that the ceiling of the room is 2.2 m(8 ft) high. The formulas are designed to prevent exceedance of 25% of the LFL. The formula in section 1.7 of appendix F of UL 484 is for non fixed factory sealed single package units (i.e., "portable room AC units") with charge amounts m 1< M< 2 x m 1. The formula for maximum allowable charge size for non-fixed units is as follows: mmax = 0.25 x A x LFL x 2.2 Where mn,a,, A and LFL mean as described above. EPA used the following methodology to derive the maximum allowable charge limits by means of the aforementioned equations. This approach included examining the charge limit with respect to the LFLs of different refrigerants, while taking into consideration variables such as the installation height (ho) of the AC unit and the area of the room. Source of values in the .

formula for maximum allowable charge size Lower Flammability Limit (LFL) values EPA used the following information in calculating the lower flammability limit on the basis of inass per unit volume (kg/m 3 ), abbreviated LFL,,,. Refrigerant IUPAC chemical Molar rnass LFLm in LFLv in % designation name or blend (kg/kmol) kg/m 3 v/v

com osition R-290 Propane 44.1 0.038 2.1% R-32 Difluoromethane 52 0.306 14.4% R-441 A 2901600/600a/170 48.44 0.04 1 2.05%

(60/30/5/5) 

# For R-290 and R-32, the LFL m values are listed in Appendix B of UL 484. For R-441 A, EPA used the LFL as a percentage of volume per volume from A.S. Trust & Holdings' SNAP submission (2.05%) and calculated the LFL n , from the LFL, using the following formula: LFL,„ =(MM/24.4) x LFL, x 1000

# Where,

LFL m =lower flammability limit in kg/m 3 (0.041), MM = molecular mass in kg/mol (0.04844), LFL, =lower flammability limit as a percentage volume (0.0205), 24.4 = conversion factor, I mole of a gas per 24.41iters at standard temperature (32°F, 0°C) and pressure (1 atmosphere, 101.325 kPa), based on the ideal gas law, 1000 = conversion factor, 1000 liters per m 3 

# Installation Height (ho) values Appendix F in the UL 484 standard sets four installation heights for a fixed uiiit: 0.6 m for an AC unit on the floor, 1.0 m for an AC unit in a window, 1.8 m for a wall-mounted AC unit, and 2.2 m for a ceiling-mounted AC unit. In terms of detennining if concentrations are small enough to remain below the LFL if the refrigerant is released, a greater compressor height ho corresponds with better mixing of the refrigerant throughout a room. For example, a release of refrigerant near the ceiling will be more thoroughly mixed and there will be lower concentrations than if the same refrigerant charge is released close to the floor. UL 484 does not utilize an installation height factor in the determination of maximum charge for portable units. EPA established the tables of proposed charge limits with ho values that correspond to the following room air conditioner types:

• ho=0.6 m: packaged terminal air conditioners (PTACs), packaged terminal heat pumps (PTHPs), and portable air conditioners (all units on or near floor) • ho=1.0 m: window AC units • ho=1.8 m: wall-mounted AC units • ho=2.2 m: ceiling-mounted AC units

# Correlation ofAC unit capacdty and room area

After determining the LFL m and installation heights the EPA used approximation of appropriate capacities for cooling a given area. The capacities for cooling a given area of a room is based upon the foliowing table from EnergyStar 2014: Area To Be Cooled (ft 2 ) 

# Capacity Needed (B'1'll;s/hour) 100 up 

# to 150 5,000 150 up to 250 6,000 250 aap to 300 7,000 300 up to 350 8,000 350 up to 400 9,000 400 up 

# to 450 10,000 450 up to 550 550 up to 700
— 

# 700 up to 1,000 12,000 14,000 18,000 1,000 up to 1,200 

# 21,000 1,200 up to 

# 1,400 23,000 1,400 up to 1,500 24,000 1,500 up to 2,000 30,000 2,000 up to 2,500 34,000 

# EPA used the correlations below in associating capacity with room area. We used a conversion factor of 0.092903 m 2 /ft 2 . EPA established the tables of proposed charge limits with respect to the minimum area required for a maximum charge that correspond to the room air conditioner type.

# ~ Area To Be Cooled I

range (ft Z ) min (ftz) max (ft 2 ) min (m 2 ) max (m 2 ) Capacity 

# (BTU/hr) 100 up to 150 100 150 9.3 13.9 5,000 150 up to 250 150 250 13.9 23.2 6,000 250 up to 300 250 300 23.2 27.9 7,000 300 up to 350 300 350 27.9 32.5 8,000 350 up to 400 350 400 i 32.5 37.2 9,000 400 up to 450 400 450 37.2 41.8 10,000 450 up to 550 550 up to 700 450

550 550

700 41.8

51.1 51.1

65.0 12,000

14,000 700 up to 1,000 700 1.000 65.0 92.9 18,000 1,000 up to 1,200 1000 1,200 92.9 111.4 21,000 1,200 up to 1,400 1200 1,400 111.5 130.1 23,000 1,400 up to 1,500 1,500 up to 2,000 1400 1500 1..500

2,000 130.1

139.4 139.4

185.8 24,000

30,000 2,000 up to 2,500 2000 2,500 185.8 232.3 34,000 

# Sources of uncertaint ipacity value EPA's EnergyStar program website also suggests some adjustments to capacity to address additional factors that may increase or decrease cooling capacity needed for a room: • If the room is heavily shaded, reduce capacity by 10 percent. • If the room is very sunny, increase capacity by 10 percent. • If more than two people regularly occupy the room, add 600 BTUs for each additional person. • If the unit is used in a kitchen, increase capacity by 4,000 BTUs. The calculations used to derive the charge sizes in EPA's proposed rule do not adjust for these additional factors.

# Proposed charge limits

Table A below illustrates the maximum design charge sizes (kg) for window air conditioners with an installation height equal to I m for different cooling capacities. Table B illustrates the maximum design charge sizes (kg) for PTACs, PTHPs and portable air conditioning units with an installation height equal to 0.6 m. Table C illustrates the maximum design charge sizes (kg) for wall mounted AC units with an installation height equal to 1.8 m. Table D illustrates the maximum design charge sizes (kg) for ceiling-mounted AC units with an installation height equal to 2.2m. Table E illustrates the maximum design charge sizes (kg) for portable room AC units. These tables clearly indicate that charge sizes will slightly increase as a result of the installation height of the unit. For example, the charge size of 1.73 kg for R-32 in Table A(the lowest installation height) is much smaller than the charge size of 3.82 kg for R-32 in Table D (the highest installation height). It is also important to note that these charge sizes were derived with respect to the minimum room area for a given capacity and thus these calculations are based on a conservative analysis. For example, if the maximum room area was considered, it would yield a slightly higher maximum design charge size. The UL standard indicates that the formula used above is for appliances with charge sizes in a given range of m 1 and m2. As indicated on page 1 of this memo, m2 is 26 m 3 x LFL for fixed units, and m2 is 2 x ml for portable units.. Therefore, the calculations of allowable charge size, shown in Tables A through E, must be checked to ensure the values remain below m2. Although this limit is not reached in Tables A and B, it is reached in Tables C, D and E; those values are marked with an asterisk (*). Specifically, these maximum charge limits will apply and supersede those in the Tables C, D and E: • In Table F, for R-32, for capacities >= 18,000 BTU/hr: 7.956 kg. • In Table F, for R-290, for capacities = 34,000 BTU/hr: 0.988 kg. • In Table F, for R-441 A, for capacities = 34,000 BTU/hr: 1.066 kg. • In Table G, for R-32, for capacities >= 12,000 BTU/hr: 7.956 kg. • In Table G, for R-290, for capacities >= 24,000 BTU/hr: 0.988 kg. • In Table G, for R-441 A, for capacities >= 23,000 BTU/hr: 1.066 kg. • In Table H, for R- 3 2, for capacities >= 7,000 BTU/hr: 2.448 kg. • In Table H, for R-290, for capacities >= 7,000 BTU/hr: 0.304 kg. • In Table H, for R-441 A, for capacities >= 7,000 BTU/hr: 0.328 kg.Incorporating these results, Tables F, G, and H present the maximum charge size limits for wallmounted, ceiling-mounted, and portable rooni air conditioners, respectively.

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# References

Energy Star, "Properly Sized Room Air Conditioners." Available at http://www.energystar.gov/?c=roomac.pr properly sized 

# ; accessed May 8, 2014. IEC 60335-2-40, "Particular Requirements for Electrical Heat Pumps, Air Conditioners and Dehumidifiers." 2005. Kataoka, O., Yoshizawa, M. and Hirakawa, T. 2000. Allowable charge calculation method for flammable refrigerants. International Refrigeration and Air Conditioning Conference, Purdue University, West Lafayette IN, USA. 2000. Available online at http://docs.lib.purdue.edu/cgi/viewcontent.cgi?artic1e=1505&context=iracc UL 484, Room Air Conditioners. Appendix F, "Requirements for Charge Limits." 8` h Edition. August 2012.