New Refrigerants Evaluat

JAMA-JAPIA Consortiu

Tohru Ikegami(TOYOTA), Masahiro 

Kenta

Aoki

(

NISSAN), 

Kenji Iijima(VALEO THERMAL SYSTEM)

VDA Alternative 

Saalfelden

–

A
 Contents Contents

1234yf Evaluation

ProcedureFrameworkEvaluation ScheduleTest Vehicle / System SpecifTest ConditionsTest Results (DuPont & HoneFlammability Risk AssessmeSummary

LCCP Study

Comparison of R134a, 1234y
 The Purpose of 1234yf Evaluation The Purpose of 1234yf Evaluation 

ProcedureSTEP-1:1. Is a simple ‘Drop-in*’ possibl

- Cooling Performance and System Effi- Material Compatibility- Flammability Risk Assessment- Toxicity

2. If not possible, evaluate the iSTEP-2:1. Confirmation of Durability an2. Confirmation of a vehicle ma

* Drop-in

Only ‘Charge’ achanged to opt
 Framework of 1234yf Evaluation Framework of 1234yf Evaluation

Suppliers

(JAPIA)

DuPont /

Honeywell

•Cooling Per

Vehicle Test •A/C Power 

•Materials C•Cooling Ca•COP

System Bench Test

•Thermal Sta•Toxicity•Flammabilit

The Feasibility ofthe Refrigerant

STE

OEM’s (JAMA) Items

Refrigerant Suppliers : DuPont & HoneywellJAPIA : 7 Tier1 suppliers (Calsonic, Denso, Japan C

Mitsubishi Heavy Industr

JAMA : 12 OEM’s (Daihatsu, Hino, Honda, Isuzu, Ma

Mitsubishi Fuso, Nissan, Nissan Diese
 Evaluation Schedule (STEP Evaluation Schedule (STEP-1)

FlammabilityRisk Assessment

HosePermeability

MaterialTest

Dec

2007

ElastomerCompatibilityStability Test

Oct Nov

ToxicityVehicle TestSystem Bench TestEVENT

1234yf

1234yf/POE

1234yf

1234yf/PAG

1234yf

1234yf

2nd European Works

MAC conference

1234yf
 Test Vehicles Vehicles

Honda Zest 0.6L K-C

Mazda Axela 1.5-2.0L H/B 

0.6L K-C

Suzuki Every

Nissan Tiida 1.5-1.8L H/B 

2.4L SU

Mitsubishi Outlander

Nissan Sylphy 1.5-2.0L SED

Toyota GS430 4.3L SED

Vehicles Engine Typ
 A/C system Specifications A/C system Specifications

480g

(500g)

1.5ton

(Modified)

3.4mm

230x

185x55

2.8mm

560.5x

382.3x1

6.5

120

Fixed

rotary

Axela

1.5ton

(Modified)

2.0ton

(Serial)

1.5ton

(Modified) Capacity Expansion Valve

Fin pitch 3.0mm 3.1mm 2.6mm 

Fin pitch 3.55mm 2.8mm 3.196mm 

160 105 90 

Capacity (cm3)

1234yf

(R134a)

Size

(WxHxD

mm)

Size

(WxHxD

mm)

TYPE

560g

(500g)

---

420g

(450g)

RefrigerantCharge

254x

205x38

198x

192x40

211x

293.1x38 Evaporator

623x

x407x16

615x

343x16

660x

Condenser 363.8x16

Fixed

scroll

Variable

piston

Variable

piston

Compressor

Vehicles GS430 Sylphy Outlande
 System bench test condition (GAR 

System bench test condition (GA

Compressor

speed

Air temperature

upstream of

condenser

Air velocity

upstream of

condenser

Set point air

downstream

from evaporator

Evaporator air

amount

Conditions

evaporator

entry

Remarks

min-1

°C m/s

°C

kg/min

1 9

0

0 60 1.5

2 9

0

0 1.5

3 1

80

0

2

4 25

0

0

3

5 400

0

4

6 1

80

0 45

2

3

5

6%

7 9

0

0 60 1.5

8 9

0

0 1.5

9 1

80

0

2

10 2500

3

11 4000

4

12 1800 45

2

3

5

6%

13 90

0 50 1.5

14 90

0 1.5

15 1800

2

16 2500

3

17 4000

4

18 1800 35

2

3

5

6%

20 90

0 40 1.5

22 90

0 1.5

24 1800

2

2

6 2500

3

2

8 4000

4

3

0 1800 25

2

3/1

0

44%

32 90

0 30 1.5

34 90

0 1.5

3

6 1800

2

3

8 2500

3

40 4000

4

42 1800 15

2

3/1

0

44%

72%

45°C/25%

33 35°C/25%

35°C/40%25°C/5

0%

15°C/80%

Max air flow

3

Max air

flow

Max air flow

72% 25

15

3/103/10

Series of

measurement

454535

45 oC Ev

Besidesbench fa60 oC Co

bench fa35 oC /25Use 40% Set poincompresInternal 

Fix type 

not majodifferent 9kg/min Max air vMedium 
 Vehicle Test Conditions (GAR Co

Vehicle Test Conditions (GAR Co

Driving cycle Test Condition

Chamber temperature : 40oCRelative humidity : 40%Solar load : 1,000 W/m2 

SOAK1 SOA

(min

Time)

Driving

Speed(km/h)

-60 

-150 (-120)

ENG SU

N

LIGHT

GEAR WIND

SPEED

(km/h)

HVAC

OPERATE

20

10

ON

OFF

P or N 

ON

OFF

ON

OFF 

DOOR

HOOD

T/GATE

OPEN

CLOSE

OPEN

CLOSE

COMP ON OFF

SOAK1 SOA

(min

Time)

Driving

Speed(km/h)

-60 

-150 (-120)

ENG SU

N

LIGHT

GEAR WIND

SPEED

(km/h)

HVAC

OPERATE

20

10

ON

OFF

P or N 

ON

OFF

ON

OFF 

DOOR

HOOD

T/GATE

OPEN

CLOSE

OPEN

CLOSE

COMP ON OFF

Blower Setting and Air Distribution:

Automatic and Manual HVAC Control:

Cooling : maxBlower : maxGrill outlet : “face level” openRecirculation : 100%

Based on Common Spec Book for evaluating Global Alternative R
 Material Test Conditions Material Test Conditions

3⁄4 Procedure : ANSI/ASHRAE97-1999 Sealed Glass Tube Me

the Chemical Stability of Materials for Use Wit

3⁄4 Test condition

 Thermal Stability Test

Catalyst   Al , Cu , FeOil:Ref. (Rate )   1 : 1

* Refrigetant   R134a , 1234yf

* Oil   PAG, POE

Test period   2 week

Moisture PPM <10 , 1000 , (10000)Temperature oC 175 , 200 * Oil : 

PAG

PAGPAG

POE

POEPOE

3⁄4 Procedure: JRAIA standard JRA20213⁄4 Test condition : Temp. : 80oC , Ref. charge amount: 0.6g/m

(Permeation was calculated with the difference between 

point and that of 96 hour point.)

3⁄4 Samples: Yokohama (use 2 types of discharge/suction lin

* 

*

 Permeation Test
 System bench test result (1234y

System bench test result (1234y

60708090

100110

Cooling Capacity [%]

 Cooling Capacity Test

Eva. air volume Max Max Max Max 

Every 87.5 91.3 95.9 107.8 

Zest 94.1 96.8 97.9 98.1 

Tiida 89.9 92.9 94.6 94.2 

Outlander 89.0 90.2 91.9 92.4 

Sylphy 103.8 104.0 103.3 102.7 

Axela 91.3 90.3 90.8 90.4 

GS430 89.3 92.3 95.7 93.6 

Comp. speed 900rpm 1800rpm 2500rpm 4000rpm 

Comparison of 1234yf and R134a (1234yf / 
 System bench test result System bench test result (1234y

(1234y

60708090

100110120

COP [%]

 System Efficiency (COP) Test 

Eva. air volume Max Max Max Max 

Every 87.7 87.6 89.0 78.9 Zest 97.9 100.5 101 97.6 

Tiida 95.0 96.7 97.2 95.8 

Outlander 96.0 92.4 93.0 93.8 

Sylphy 110.1 107.6 107.8 105.0 

Axela 103.7 98.8 95.3 92.0 

GS430 92.2 86.4 88.6 93.3 

Comp. speed 900rpm 1800rpm 2500rpm 4000rpm 

Comparison of 1234yf and R134a (1234yf / 
-2

02468

0

5 10 15 20 25 30 35 40 45 50 55

Ti

m

e[min]

⊿T[deg-C]

GS

4

3

0

Ax

ela

O

utrander

Tiid

a

Ze

st

-2

02468

0

5 10 15 20 25 30 35 40 45 50 55

Ti

m

e[min]

⊿T[deg-C]

GS

4

3

0

Ax

ela

O

utrander

Tiid

a

Ze

st

Wors

e

Better

Pull Dow

n(32

k

m/h) Idle 64km/h

 Vent / Relative Temperature to R134a Head / Relative Temperature to R134a

Wors

e

Better

Pull Dow

n(32

k

m/h) Idle 64km/h

 Vehicle Test Results (1234yf) Vehicle Test Results (1234yf)

ZS

AE

O

T

ATG

ZS

AE

O

T

ATG
 Material Evaluation Results Material Evaluation Results (1234

(123

Total Acid Number mgKOH/g 2.19 0.87 21.4 22.3 High Moisture ppm 10

Total Acid Number mgKOH/g 1.15 0.54 0.1 0.21 

Low Moisture ppm 1Total Acid Number mgKOH/g 1.28 0.00 0.00 0.00 

Low Moisture ppm <

Condition 175deg

mgKOH/gppmmgKOH/gppmmgKOH/gppm

Condition 200deg

Total Acid Number 1.75 0.00 21.3 21.4 High Moisture 10

0.100.00

POE2

0.010.00

POE1

0.000.00

PAG2

Total Acid Number 0.82 Low Moisture 1Total Acid Number 0.03 Low Moisture <

Oil PAG1 

Ref. R134a 

PAG

PAG1:Serial PAG for PAG2:PAG (without e

additive 

POE

POE1:Serial POE for POE2:Serial POE for 

 Thermal Stability Test

ANSI/ASHRAE97-1999
 Material Evaluation Results Material Evaluation Results (1234

(123

 Elastomer Compatibility Test Test specificat

Material: for AC 

Elongation changeTensile strength changeHardness change(Duro-A)

Test condition PAG1(Serial PAG for MACs) + 1234yf Liquid a

Elongation changeTensile strength changeHardness change(Duro-A)

Test condition PAG1(Serial PAG for MACs) + 1234yf Gas at 1

HNBR

2

HNBR

1

EPDM

2

EPDM

1

Type of elastomers NBR IIR

Need to improve slightly but no fatal res

SatiDoe

Oil:PAG1 (Serial PAG for MACs)
 Material Evaluation Results Material Evaluation Results (1234

(123

 Elastomer Compatibility Test Test specificat

Material: for AC 

Elongation changeTensile strength changeHardness change(Duro-A)

Test condition POE1(Serial PAG for HV AC) + 1234yf Liquid an

Elongation change

Tensile strength changeHardness change(Duro-A)

Test condition POE1(Serial PAG for HV AC) + 1234yf Gas at 15

HNBR

2

HNBR

1

EPDM

2

EPDM

1

Type of elastomers NBR IIR

SatiDoe

Oil:POE1 (Serial POE for HV AC)

Need to improve slightly but no fatal res
 Material Evaluation Result Material Evaluation Result (1234

(1234y

 Permeation Test Result

1234yf 56.3 59.1 HFC134a 40.8 46.4 

Inner coat : 6-NylonInner rubber : IIROuter rubber : EPDM

Inner coat : 6-NylonInner rubber : IIROuter rubber : Cl-IIR

Discharge

Inner coating(2)

Discharge

Inner coating(1)

HOSEL=400mm

Permeation JRAIA standard JRA2021

Inner diameter Discharge inner coating (1) (ACH 77 11) 11.2mmDischarge inner coating (2) (ANESIS 11) 11.2mmSuction inner coating (ACH 87 15) 15.2mm

Annual Leakage will be 0.3g/year under 

(estimated by SAE-J272
 Outline of Flammability Risk Ass

......

AND

Leakage Leakage

Ignition Source

......

Detail is describedIn next slide

AND

Outline of Flammability Risk Ass

Total probability of fire caus

refrigerant leakage in veh

OR 1234yf Risk Fault Tree was divided into three area in vehicle

1234yf Risk Assessment was cond

Member: DNV,JAMA,JAPIA,DuPo

Potential risk of fire

in Engine Room

<Refrigerant Leakage>

Condenser, piping, ...

<Ignition Source>

Exhaust manifold, ...

Potential risk of fire

in Passenger Cabin

<Refrigerant Leakage>

Evaporator, ...

<Ignition Source>

Smoking lighter, ...
 Outline of Flammability Risk Ass

1234y

- Flam- Auto - Mini

1 & 2: Data collected from JAMA / JAPIA3 & 4: Quantify the risk from HAZOP (haz

FMEA (Failure M

Probability of 

Ignition Source

occurrence

(Hot surface / spark 

generated area) 

Probability 

Refrigerant 

ignition so

(Velocity of diffu

distance of leak p

ignition sou

Outline of Flammability Risk Ass

Potential risk of fire

in Engine Room

AND

2 3 

Probability of 

Refrigerant Leak

(Probability of the leakage 

caused by AC cycle 

parts failure or Accident)

1

Parts failure causes slowleak mainly and Accidentcauses large leak mainly

Normal, Parts failureand Accident case arealso considered
 Result of Risk Assessment for Ig

Result of Risk Assessment for Ig

・Surface of light bulbs(680°C)

Refrigerant may not reachdue to its lens / hood.

・Combustion heater(400°C)

In case of accident, 

refrigerant may reach

Parts Temp...Freq. Mode, Tem

ExhaustManifold

Light Bulb

CombustionHeater

・・・・・・・・・・・・・・・

Normal case Parts fail

Result ofrisky parts

・Exhaust manifold(600°C)

In case of accident, 

refrigerant may reach.

Pick out some risky parts as ignition source. (ex

Æ Confirm whether fire occurs or not by 1234yf 
 Result of Flammability Risk Asse

Result of Flammability Risk Asse

 Estimated Risk

Insignificant Insignificant Few ignition source Trunk Room

Probability

Result of

Risk Assessment Case

Insignificant

84ppm

In case of

Accident

Could be ignited by smoking lighter

Could be ignited at exhaust manifold

Total 106ppm

0.01ppm Passenger Cabin

22ppm Engine Room

In case of

Normal / 

Parts failure

The estimated total risk of adoption of 123Confirmed that no ignite will occur even aSo that, the risk increase by 1234yf can b
 Summary 1234yf Evaluation Res

Under high load condition and with the saspecs with modified TXV, 

3⁄4Cooling Performance

Æ Slightly less but quite similar

3⁄4Material Compatibility

Æ No fatal result is found at this 

3⁄4Flammability Risk Assessment

Æ No fatal result is found at this 

3⁄4Toxicity Evaluation

Æ Only long term toxicity is now 

Summary 1234yf Evaluation Resu

1234yf has potential to be alternativ

< Next Step >

System reliability and Vehicle suitability 
LCCP Result from 

Kiwamu I

Tohru Ike

Kenta Ao

VDA Alternative 

Saalfelden – A
 Content Content

3⁄4LCCP is the best method to assess Gloaffect. Therefore JAMA is trying to selecrefrigerant by taking into account of LCC

Today’s contents s contents

3⁄4LCCP evaluation conditions LCCP evaluation conditions3⁄4LCCP Results including updated EO

LCCP Results including updated EO

3⁄4Summary Summary
 LCCP evaluation condition LCCP evaluation condition

Vehicle Test Vehicle Test

JAMA uses Vehicle Test Result to calculate “to AC system operation” .

Ambient 35 25 15RH% 50 50 80Solar [W/m2] 850* 500 100

Target temperature setting+ 22 22 22

For manual AC: FC

1/2 of heatercontroller

3/4 of heatercontroller

Air Intake REC OSA OSAFan Speed High 2nd 1stDrive ScheduleAir Output VENT VENT VENT

Agreed proposal: vehicle

Fixed speed Idle / 40km/hr / 100km/hr

Agreed TEST Condition between JAMA&SAE Agreed TEST Condition between JAMA&SAE

From these test results, we take into account 9Driving Schedule 9Ambient Condition9AC Operation Timefor each Cities (i.e. Phoenix, Frankfurt, Tokyo, etc)
Parameters for Calculation

 LCCP evaluation condition LCCP evaluation condition

3⁄4Following values are used for LCCP calculation. 

(agreed value in JULY/07 with GM) 

GWP=1410 (R134a), 4 (1234yf), 1(CO2)

Leakage during chargein plant

Annular regularleakage

Annual irregularleakage

S

ervice

Phoenix

3.5 g/life 10 g/yr 16 g/yr 41 g

Toky

o

3.5 g/life 10 g/yr 13 g/yr 44 g

Frankfurt

3.5 g/life

7 g/yr 16 g/yr 40 g

Direct emission

T

otal quivalent CO2 of

R

efrigerant produce

d

A/C s

yste

m manufacturing

and end of life

Transportation energy per year

Phoenix

12.2kg/file(R134a)

8.0kg/life(Others) 73 kg/life 54.4 kg/yr 

Toky

o 73 kg/life 29.4 kg/yr 

Frankfurt 73 kg/life 38.6 kg/yr 

Indirect emissio

n

12.2kg/file(R134a)

8.0kg/life(Others)

12.2kg/file(R134a)

8.0kg/life(Others)

3⁄4Cooling Capacity is adjusted by calculation.
 LCCP evaluation condition LCCP evaluation condition

Parameters for Calculation

Direct emission in End of Life

Direct emission value is Under discussion.

3⁄4Japan Market Japan Market

44g Î 91g Official data of JAMA (fro

3⁄4USA Market USA Market

According to GM’s invest(Assuming original charg

46g Î 288g

3⁄4EU Market EU Market

45g Î ??? NO DATA has been prov

(Awaiting for information f
CO2 (R744) characteristics CO2 (R744) characteristics

3⁄4GWP=1 (R134a=1410)3⁄4Natural material3⁄4System pressure is very high (6-7times high

3⁄4Compressor load is higher than R134a due t

Cooling capa 

IHX

P

[Mpa]

Cooling

Capa

Load

(R134a)

>>

(CO2)

Cooling

Capa

Load
1234yf characteristics

1234yf

R134a

1234yf characteristics

3⁄4GWP=4 (R134a=1410)3⁄4Similar characteristics with R134a as refrigera

3⁄4Evaporating heat is less than R134a and Comp

R134a.

P

[Mpa]

i [kJ/kg]

Cooling

Capa

Load

(R134a)

>

(1234

yf)

Cooling

Capa

Load
 LCCP Result LCCP Result - Compact Car Compact Car -

Vehicle specifications and AC component specif

-

3⁄41234yf has same component as R134a system.3⁄4R744 system has higher specification than R134a 

<Car Specification>

Model: NISSAN TIIDA/VERSA

Engine:1.5L L4 Petrol Engine

None None 

Internal Heat

Exchanger

Cooling Fan 120W x 1 Same part as R

618W x 337H x 16D Same part as R

Condenser or

Gas cooler size

Evaporator size 201W x 198H x 36D Same part as R

Same part as R

Fix Volume Rotary type Compressor spec

R134a 1234yf 

<Component Specification>
 LCCP Result LCCP Result - Compact Car Compact Car -

Result with Original EOL Direct Emission EOL Direct Emission

3⁄41234yf has better environmental performance than 3⁄4CO2 system is worse in hotter region.

Note1: R744 system has higher specification (ECV & IHX) as listed in the prev

Note2: Cooling Capacity is adjusted by calculation.

Phoenix

0

500

1000150020002500300035004000

CO2eq. emission [kg]

Direct emission

R134a 1234yf R744 R134a

There is some direct emission,but it very small(only 1.3kg for 1234yf / 0.33kg for R744

Indirect emission

1234yf R744 R134a 1234yf R74

Athens Tokyo 

HOT 
BASE data for LCCP calculation

<Compact Car> <Compact Car>

Compressor Load Comparison

3⁄4R134a (Fixed Vol. COMP) < 1234yf (Fixed Vol. CO

IDLE 40 km/h 100 km/h IDLE 40 km/h 100 km/h 

AMB=15degC AMB=25degC 

R134a = 1234yfR134a <

< R744

R134a = 1234yfR134a <

< R744

R134a

1234fy

R744

0

0.20.40.60.8

1

LOAD [kw] 1.2

1.41.61.8

2

GOOD BAD
 LCCP Result LCCP Result - Compact Car Compact Car -

Result with Updated Updated EOL Direct Emission (Unde

EOL Direct Emission (Unde

3⁄4Almost no affect to 1234yf and R744 with Updated 3⁄4There is some impact to R134a. 

Note1: R744 system has higher specification (ECV & IHX) as listed in the prev

Note2: Cooling Capacity is adjusted by calculation.

0

500

1000150020002500300035004000

R134a 1234yf R744

CO2eq. emission (kg)

Original EOL direct emission

Updated EOL direct emission

0

500

1000150020002500300035004000

CO2eq. emission (kg)

Phoenix 

R
None None 

Internal Heat

Exchanger

Cooling Fan 100W + 160W Same part as R

660W x 363.8H x 16D Same part as R

Condenser or

Gas cooler size

Evaporator size 293.1W x 211H x 38D Same part as R

Same part as R

External Control

Variable

Displacement type

Compressor spec

R134a 1234yf 

Model: LEXUS GS430Engine:4.3L V8 Petrol Engine

<Component Specification>

Vehicle specifications and AC component specif

 LCCP Result LCCP Result - Luxury car Luxury car -

3⁄41234yf has same component as R134a system.3⁄4R744 system has higher specification than R134a 

< Car Luxury car >
 LCCP Result LCCP Result - Luxury car Luxury car -

0

10002000300040005000600070008000

R134a 1234yf R744

CO2 emission [kg]

Direct emission

-

Result with Original EOL Direct Emission EOL Direct Emission

3⁄41234yf has better environmental performance than other 2 3⁄4CO2 system is worst within these 3 refrigerants. (more obv

Note1: R744 system has higher specification (IHX) as listed in the previous paNote2: Cooling Capacity is adjusted by calculation.

Indirect emission

R134a 1234yf R744 R134a 1234yf R

Phoenix Athens Tokyo 

HOT 
BASE data for LCCP calculation

<Luxury Car> <Luxury Car>

Compressor Load Comparison

3⁄4R134a (ECV) < 1234yf (ECV) < CO2 (ECV&IHX)

4.50

Idle 40 km/h 100 km/h Idle 40 km/h 100 km/

AMB=15degC AMB=25degC 

R134a

1234fy

R744

R134a = 1234yfR134a <

< R744

R134a < 1234yfR134a < R744

BAD

0.501.001.502.00

LOAD [kw]

4.003.503.002.500.00

GOOD
 LCCP Result LCCP Result - Luxury car Luxury car -

Result with Result with Updated EOL Direct Emission (TBD) EOL Direct Emission (TBD)

3⁄4Almost no affect to 1234yf and R744 with Updated 3⁄4There is some impact to R134a, but R134a system 

Note1: R744 system has higher specification (IHX) as listed in the previous paNote2: Cooling Capacity is adjusted by calculation.

0

10002000300040005000600070008000

R134a 1234yf R744

CO2eq. emission (kg)

Phoenix

0

10002000300040005000600070008000

CO2eq. emission (kg)
 Summary of LCCP Summary of LCCP

3⁄41234yf has the lowest impact to Global Warmin

(R134a, R744 and 1234yf) without high spec syste

Î1234yf system has further potential to be les

Up impact with high spec system such as EC

3⁄41234yf LCCP result is always best regardless w

Î 1234yf can be global solution.

3⁄4In order to evalutate Global Warming Up Impac

JAMA is going to keep collabolation with GM aup LCCP methodology.
 Conclusion Conclusion 

Based on our investigations, we concSTEP-1 Evaluation:

We found no fatal concern at this time Flammability and Toxicity

STEP-2 Evaluation:

System durability and reliability will b

individual JAMA members

1234yf has the potential to be a G
Toward the global s

Thank you for your a

END