Revised SAE J-2727

SAE Interior Climate Control 

Standards Committee

Presentation to the

European Commission

20 October 2006

SAE Working Group (Updating J272

Ward Atkinson Ward Atkinson

-SAE

Jim Baker - SAE

Tohru Ikegami - JAMA

Peter Nickels Peter Nickels

- ACEA
Mobile A/C Systems HFC-1

R fi tE i i R

e

f

rigeran

t

E

missions

• SAE J2727 R134a Mobile Air Conditioning 

SAE J2727 R134a Mobile Air Conditioning 

Leakage Standard was published June 200

• Since then, y the international A/C industr

y h

– Determined emissions from vehicles in – Established laborator

y tests for emissio

• A/C system components• Assembled A/C systems in a mini-she

– Analyzed available laboratory and f

data to calibrate results

October 20, 2006 
Mobile A/C Systems HFC-1

R fi tE i i R

e

f

rigeran

t

E

missions

• Emission data has been anal

yzed f

– ACEA fleet vehicles– JAMA fleet vehicles– ACEA Laboratory testing– SAE I

-MAC Cooperative Research P

MAC Cooperative Research P

• This information has been used to 

SAE J2727 HFC SAE J2727 HFC

-134 M bil Ai 134a 

M

obile Air 

Conditioning System Emission Ch

October 20, 2006 
ACEA and JAMA HFC-134a 

Fleet Vehicles Refri

gerant Emis

ACEA and JAMA A/C HFC-134a Fleet 

2025

r

ACEA Fleet

15

ssions Grams/yea JAMA Fleet

5

10

HFC-134a Emis

0

ABCDEFGH I JKLMNOPQR

October 20, 2006 

Production ACEA & JAMA Field Test Vehicles

JAMA Fleet ACEA Fleet
SAE J2727 SAE J2727

• EC and other environmental authorities need 

methods to certify that HFC-134a emissions new vehicles are less than required by law 

• The emissions of selected individual compon

systems assembled for laboratory and vehictesting do not account for defective parts or testing do not account for defective parts or

improper assembly. 

• J2727 does account for defective parts and i

J2727 does account for defective parts and i

assembly. So, the average emission for test will be less than the SAE J2727 emission. 

October 20, 2006 
What We Have Learned

• Vehicle systems can be classified as:

– Design Intent Design Intent (DI)

= average components, 

average components, 

assembled & checked with laboratory-quadetectors

• JAMA reports DI refrigerant emissions from ex

assembled systems 

– Normal Production (NP) = average compo

production assembled and tested to hold prior to charging prior to charging

(some expected to have leakage due to production va

• Average emissions of (NP) vehicles will alwa

hi h th f hi

g

her than 

from (DI) vehi l b f d

hi

cles 

because o

f ad

leakage due to possible improper componenassembly and variation in part quality

October 20, 2006 
What We Have Learned

• Field evaluation of Normal Production (NP) sys

production would be difficult because the low fproduction would be difficult because the low f

of improperly assembled systems would requirof very large numbers of vehicles 

• Field evaluation of new type vehicles can only 

conducted after the vehicles are in production.

• So, laboratory and vehicle field testing of new t

systems must be performed with (DI) systems. 

October 20, 2006 
Revised 2006 J-2727

• Based upon laboratory testing and vehicle us

– mini-shed test results of properly assembled systems

• incorporating both standstill and dynamic A/C system 

incorporating both standstill and dynamic A/C system 

– applied a vehicle usage profile to correlate lab results to 

• Correlated to vehicle field testing Correlated to vehicle field testing

– JAMA controlled field test results of 78 vehicles with 22 

systems 

– ACEA t ll d fi ld t t lt f 40 hi l ith 10 

ACEA con

troll

e

d fi

eld

tes

t results o

f 40 vehi

cles with 10 

systems

• Ad

j p usted s

preadsheet to account for

– design-intent system emissions

AND

– assembl

y and 

qualit

y variations of com

ponents 

October 20, 2006 

y qy p

• by including the potential for improper assembly and 

leakage for each type of system component.
SAE J2763 Mini-Shed

Test Cycle Test Cycle

Complete Modified CARB Cycle

Thursday- Monday Ambient Profile Monday Ambient Profile

5060

Thursday Monday Ambient Profile

5060

Thursday Monday Ambient Profile

50603040

mp(°C)

20

Te

Determines the emis

0

10

0 10 20 30 40 50 60 70 80 90 100 

rate in grams/year foyear round usage

October 20, 2006 

Dynamic operation Time(hr)
SAE & ACEA Use Comparable Tes

Temperature and Field Correlation Fa

• SAE laboratory rate to customer usage profile 

– 5 months use under mini-shed conditions (31C)– 7 m

o t s use at a a e age te pe atu e o 5C n

t

h

s use at

an 

a

v

e

rage te

mpe

ratu

r

e

of 5C

• where emissions are ~ 0.18 of mini-shed emissions 

(pressure)

2

– 12 months use: 5 months @ 31C + 7 months @ 5C = 16C Av

• Average J2763 mini-shed test temperature is 31

– Compares to Armines mini-shed test temperature 

• C l ti ti f t i i Correlation equation 

for cus

tomer usage emissi

5/12 (x) + 7/12 (0.18x) = 0.522x x= mini-shed em

• Correlation factor to convert mini Correlation factor to convert mini

-shed emission

shed emission

random customer field usage emissions is 0.522 

compares to Armines correlation factor of 0.526 at 3

October 20, 2006 

Same correlation 
J2727 Standard J2727 Standard

• Standard spreadsheet determine

Standard spreadsheet determine

mobile air conditioning system 

refrigerant emissions in grams prefrigerant emissions in grams p

year by accounting for 

– Individual refrigerant components Individual refrigerant components– Compressor type including Europe

compressor adaptor plate compressor adaptor plate

• Belt driven• Electric motor driven

October 20, 2006 
SPTT

October 20, 2006 
J2727 Accuracy

• J2727 spreadsheet is intended to accurately pr

y

p yp

emissions from a randomly chosen fleet of (NP

• J2727 spreadsheet includes emissions from (D

plus emissions from improper assembly

– when modified to eliminate assembly variati

when modified to eliminate assembly variati

spreadsheet can predict emissions from (DI

tested in the laboratory and in vehicles (DI-e

October 20, 2006 
Predicted J2727 A/C Systems Em

vs.

“DI

” Estimated JAMA Fle

Estimated JAMA Fle

"DI" System Mini-shed Emissions 

vs. J2727 Emissions For JAMA Fleet 

2520

J2727

1015

rams/year

5

G

“DI” Estimate

0

ABCDE FGH I J KLMNOPQRS 

Production JAMA Field Test Vehicles

October 20, 2006 

Production JAMA Field Test Vehicles

Estimated "DI" Mini-shed System J2727 Predict
Estimated “DI” Systems vs. JAM

"DI" Estimate vs. JAMA Fleet

2520

“DI” E ti t

15

ams/year

DI”

E

stima

t

e

5

Gr10a

0

ABCDE FGH I J KLMNOPQR

P d ti JAMA Fi ld T t V hi l

JAMA Fle

October 20, 2006 

Pro

duction JAMA Fi

eld

Test V

ehi

cles

"DI" Estimated System JAMA Field Test Fleet 
JAMA Test Fleet Compar

JAMA Fleet - J2727 and "DI" Estimated Emission

2520

“DI” Estimate

J2727

15

ams/year

5

Gr10

0

ABCDEFGH I JKLMNOPQR

P d ti JAMA Fi ld T t V hi l

JAMA Fleet

October 20, 2006 

Pro

duction JAMA Fi

eld

Test V

ehi

cles

J2727 Emissions JAMA Fleet DI Estimated 
Emissions Of “DI” and ACEA Tes

vs. J2727 Production System Ra

ACEA Fleet Vehicled Emissions 

vs. "DI" Estimates and J2727 System Emissions

J2727

202515

ms/Year

“DI” Estimate

5

10

Gram

0

A BCDEFGH 

ACEA Fleet

October 20, 2006 

ACEA Field Test Vehicles

J2727 EP ACEA Test Fleet Vehicle Emissions Estimated DI Sys
SAE Test Support Standa

J2762

Method for removal of refrigerant fro

mobile air condtioning system to qu

charge amount

J2763

Test procedure for determining R134a 

rates of Mobile Air conditionin

g y s stem

shed

J2764

Test procedure for determining R134a 

rates of Mobile Air conditioning comporates of Mobile Air conditioning compo

Mini-shed

October 20, 2006 
J2762 Refrigerant Reco

J2762 Refrigerant Reco

Method for Method for

removal of 

refrigerant from refrigerant from

R134a mobile air 

conditioning

system to 

quantified charge quantified charge

amount 

Currentl

y in draft status

October 20, 2006 
Mini-Shed Facility Test Re

• The SAE I-MAC program Mini-Shed tes

procedure was validated in two differeprocedure was validated in two differe

facilities using the same 4 production 

systems in each facility systems in each facility

– Ford F150– DCX Minivan Dual S

ystem

– Toyota Camry– GM "W" car

• Both facilities measured emission leve

less that 10 grams/yr for all systems

October 20, 2006 
Mini-shed Facility Test Re

SAE I-MAC Mini-shed Test Facility 

Emission Comparision vs. "DI" Emission Rat

2520

r

“DI” Estimate

1015

Grams/Yea

Delphi

5

Creative Therma

0

Ford F150 DCX Minivan Dual

System

Toyota Camry G

Test Facilities and Rating

October 20, 2006 

Test Facilities and Rating

Delphi CTS "DI" Rating
J 2763 Mini-Shed A/C 

St L t ys

tem 

Layou

t

Condenser

Heat 

exchanger

Compressor

Evaporator

October 20, 2006 

Leak rate generator Gas analyzer
J2763 Mini-Shed 

Delp y hi Test Facility

Test AnalChamber

Slide 

Test RailsFixture

October 20, 2006 
J2763 Mini-Shed 

Creative Thermal Solutions TesCreative Thermal Solutions Tes

October 20, 2006 
Summary

• Emissions from mini-shed testing compa

favorably with favorably with predictions based on (DI) predictions based on (DI)estimates.

• (DI)-estimates are within a few grams of t

estimates are within a few grams of t

average emissions measured in field test

• Th 2006 i d J2727 ( d h t) 

The 2006 revised J2727 ( spreadsheet) w

accurately predict emissions from randoselected p y roduction assembled systems 

October 20, 2006 
Addressing Issues 

Submitted by the EC Submitted by the EC

Th

e C sub tted a u be o quest o s to t e 

 E

C submitted

a n

u

mber 

of questio

n

s to

t

h

e

ICCC J2727 Working Group, regarding the prrevised standard.

The J2727 Working Group has resolved these c

in the revised J2727 document.

The revised J2727 was passed by SAE Technic

Committee members on 9 October 2006

The revised J2727 document has been sent for 

the SAE Motor Vehicle Council, with , final apexpected by Nov. 9th, 2006

October 20, 2006 

expected by Nov.

9 , 2006
Addressing Issues 

Submitted by the EC

• The methodology used to pass from the rating fi

Submitted by the EC

• The methodology used to pass from the rating fi

g/year is not clear. The factor (0.522) to correlate laboratory data to 

results is based on annual customer usage. 

It is the same correlation factor as used by A

• The factor 0 522 is generally applicable to all The factor

0.522 is generally applicable, to all

components, but that factor is only used in the teto correlate fittings and the compressor

The factor 0.522 is applied to all rigid pipe fittingand compressors. 

October 20, 2006 
Addressing Issues 

Submitted by the EC

• It is not known if the outputs from the study car

by ARMINE

S h

a

v

e been ta

k

en into accou

n

t. 

Submitted by the EC

by S a e bee ta e to accou tJ2727 correlates well with ARMINES data.

• Correlation factor between real fleet leakage and 

leakage is not defined leakage is not defined. 

J2727 correlated to JAMA Fleet and ACEA Fleet 

• Quality of the different components is not taken 

account.

Variations in quality have always been accounted the assigned leakages within the spreadsheet

• Th d f d t i ti f th ti fi 

The proce

dure 

for 

d

e

termination o

f the rating fig

not known.J2727 now only expressly provides emissions in 

/

October 20, 2006 

grams year. 
Addressing Issues 

Submitted by the EC

1- Current requirements of SAE 2727 cannot be directly adopte

as the aim of the SAE standard is the definition of a rating s

Submitted by the EC

as the aim of the SAE standard is the definition of

a rating s

based upon the technology used and it is not intended for tevaluation of refrigerant emissions from MACs. J2727 directly provides g/yr

2- The translation of SAE scores to grams (as stated in your 

communication) is only a first step before the EC can consiaccepting the requirements of SAE J2727. A correlation to g

( g ) 

drivin

g conditions

) should be established and the test met

has to be compatible. The revised J2727 is now correlated tresults and driving conditions. Test methods comparable to 

3- The application of SAE 2727 in the EU would imply a kind of 

certification of the MAC system by the car or systems manucertification of the MAC system by the car or systems manu

But, as you know, we have type-approval here in Europe so procedure will need to be changed. The EC type approval J2

spreadsheet can be certified by third party review. 

October 20, 2006 
Conclusion

• The 2006 revised J2727 (p ) s readsheet) wil

predict emissions from randomly selecteproduction assembled A/C systems 

• ACEA, CLEPA, JAMA and SAE recommen

timely acceptance by the EC of J2727 as timely acceptance by the EC of J2727 as 

alternative type approval under the MAC Regulation 

October 20, 2006