Revised SAE J-2727SAE Interior Climate ControlStandards CommitteePresentation to theEuropean Commission20 October 2006SAE Working Group (Updating J2727)Ward Atkinson-SAEWardAtkinsonJim Baker - SAETohru Ikegami - JAMAPeter Nickels-ACEAPeterNickelsMobile A/C Systems HFC-134aR fi tE i iRefrigerantEmissions•SAE J2727 R134a Mobile Air Conditioning SystemSAEJ2727R134aMobileAirConditioningSystemLeakage Standard was published June 2005•Since then,the international A/C industryhas:y–Determined emissions from vehicles in use–Established laboratorytests for emissions from:•A/C system components•Assembled A/C systems in a mini-shed–Analyzed available laboratory and fielddata to calibrate resultsOctober 20, 20062Mobile A/C Systems HFC-134aR fi tE i iRefrigerantEmissions•Emission data has been analyzed from:–ACEA fleet vehicles–JAMA fleet vehicles–ACEA Laboratory testing–SAE I-MAC Cooperative Research ProgramMACCooperativeResearchProgram•This information has been used to reviseSAE J2727 HFC134 M bil AiSAEJ2727HFC-134aMobileAirConditioning System Emission ChartOctober 20, 20063ACEA and JAMA HFC-134aFleet Vehicles Refrigerant EmissionsACEA and JAMA A/C HFC-134a Fleet2025

rACEA Fleet15

s sions Grams/yeaJAMA Fleet510

HFC-134a Emi s0ABCDEFGH I JKLMNOPQRSTUVOctober 20, 20064Production ACEA & JAMA Field Test VehiclesJAMA FleetACEA FleetSAE J2727SAEJ2727C•Eand other environmental authorities need testmethods to certify that HFC-134a emissions fromnew vehicles are less than required by law•The emissions of selected individual components orsystems assembled for laboratory and vehicletesting do not account for defective parts ortestingdonotaccountfordefectivepartsorimproper assembly.•J2727 does account for defective parts and improperJ2727doesaccountfordefectivepartsandimproperassembly. So, the average emission for test systemswill be less than the SAE J2727 emission.October 20, 20065What We Have Learned•Vehicle systems can be classified as:–Design Intent(DI)=average components, properlyDesignIntentaveragecomponents,properlyassembled & checked with laboratory-quality leakdetectors•JAMA reports DI refrigerant emissions from expertlyassembled systems–Normal Production(NP)= average components,production assembled and tested to hold a vacuumprior to chargingpriortocharging(some expected to have leakage due to production variation)•Average emissions of(NP)vehicles will always behi h th f(DI)hi l b f dditi lhigherthanfromvehiclesbecause ofadditionalleakage due to possible improper componentassembly and variation in part qualityOctober 20, 20066What We Have Learned•Field evaluation of Normal Production(NP)systems inproduction would be difficult because the low frequencyproductionwouldbedifficultbecausethelowfrequencyof improperly assembled systems would require testingof very large numbers of vehicles•Field evaluation of new type vehicles can only beconducted after the vehicles are in production.•So, laboratory and vehicle field testing of new typesystems must be performed with(DI)systems.October 20, 20067Revised 2006 J-2727•Based upon laboratory testing and vehicle use–mini-shed test results of properly assembled systems•incorporating both standstill and dynamic A/C system operationincorporatingbothstandstillanddynamicA/Csystemoperation–applied a vehicle usage profile to correlate lab results to vehicles•Correlated to vehicle field testingCorrelatedtovehiclefieldtesting–JAMA controlled field test results of 78 vehicles with 22 differentsystemsACEA t ll d fi ld t t lt f 40 hi l ith 10 diff t–ACEAcontrolledfieldtestresults of40vehicles with10differentsystems•Adjusted spreadsheet to account forp–design-intent system emissionsAND–assemblyandqualityvariations of componentsOctober 20, 20068y qy p•by including the potential for improper assembly and relatedleakage for each type of system component.SAE J2763 Mini-ShedTest CycleTestCycleComplete Modified CARB CycleThursday-Monday Ambient ProfileMondayAmbientProfile5060ThursdayMondayAmbientProfile5060ThursdayMondayAmbientProfile50603040

m p(°C)20

TeDetermines the emission0100 10 20 30 40 50 60 70 80 90 100 110 120rate in grams/year foryear round usageOctober 20, 20069Time(hr)Dynamic operationSAE & ACEA Use Comparable TestTemperature and Field Correlation Factor•SAE laboratory rate to customer usage profile–5 months use under mini-shed conditions (31C)–7 monthsuseatanaveragetemperatureof5Ct s use at a a e age te pe atu e o 5C•where emissions are ~ 0.18 ofmini-shed emissions based on(pressure)2–12 months use: 5 months @ 31C +7 months @ 5C = 16C Avg. Annual•Average J2763 mini-shed test temperature is 31C–Compares to Armines mini-shed test temperature of 30CC l ti ti f t i i•Correlation equationfor customer usage emissions5/12 (x) + 7/12 (0.18x) = 0.522x x= mini-shed emission rate•Correlation factor to convert mini-shed emissions toCorrelationfactortoconvertminishedemissionstorandom customer field usage emissions is0.522compares to Armines correlation factor of0.526at 30COctober 20, 200610Same correlation factorJ2727 StandardJ2727Standard•Standard spreadsheet determinesStandardspreadsheetdeterminesmobile air conditioning systemrefrigerant emissions in grams perrefrigerantemissionsingramsperyear by accounting forIndividual refrigerant components–Individualrefrigerantcomponents–Compressor type including Europeancompressor adaptor platecompressoradaptorplate•Belt driven•Electric motor drivenOctober 20, 200611PipeConnectionsService portsPRV – SwitchesTransducerTXVHoseAssembliesH teaExchangersBeltCompressorEuropeAdaptor PlateOctober 20, 200612J2727 Accuracy•J2727 spreadsheet is intended to accuratelypredictyp ypemissions from a randomly chosen fleet of(NP)vehicles•J2727 spreadsheet includes emissions from(DI)systemsplusemissions from improper assembly–when modified to eliminate assembly variations thewhenmodifiedtoeliminateassemblyvariations,thespreadsheet can predict emissions from(DI)systemstested in the laboratory and in vehicles(DI-estimate).October 20, 200613Predicted J2727 A/C Systems Emissionsvs.“DI”Estimated JAMA FleetEstimatedJAMAFleet"DI" System Mini-shed Emissionsvs. J2727 EmissionsFor JAMA Fleet2520J27271015

r ams/year5

G“DI” Estimate0ABCDE FGH I J KLMNOPQRS TUVProduction JAMA Field Test VehiclesOctober 20, 200614ProductionJAMAFieldTestVehiclesEstimated "DI" Mini-shed SystemJ2727 PredictionsEstimated “DI” Systems vs. JAMA Fleet"DI" Estimate vs. JAMA Fleet2520“DI” E ti t15

a ms/yearDI”Estimate510

Gr a0ABCDE FGH I J KLMNOPQRS TUVP d ti JAMA Fi ld T t V hi lJAMA FleetOctober 20, 200615ProductionJAMAFieldTestVehicles"DI" Estimated SystemJAMA Field Test Fleet AverageJAMA Test Fleet ComparisonJAMA Fleet - J2727 and "DI" Estimated Emissions2520“DI” EstimateJ272715

a ms/year510

Gr0ABCDEFGH I JKLMNOPQRSTUVP d ti JAMA Fi ld T t V hi lJAMA FleetOctober 20, 200616ProductionJAMAFieldTestVehiclesJ2727 EmissionsJAMA FleetDI Estimated EmissionsEmissions Of “DI” and ACEA Test Fleetvs. J2727 Production System RatingACEA Fleet Vehicled Emissionsvs. "DI" Estimates and J2727 System EmissionsJ2727202515

m s/Yea r“DI” Estimate510

Gra m0ABCDEFGH I JACEA FleetOctober 20, 200617ACEA Field Test VehiclesJ2727 EPACEA Test Fleet Vehicle EmissionsEstimated DI System EmissionsSAE Test Support StandardsJ2762Method for removal of refrigerant from R134amobile air condtioning system to quantifiedcharge amountJ2763Test procedure for determining R134a leakagerates of Mobile Air conditioningsstems in a MiniyshedJ2764Test procedure for determining R134a leakagerates of Mobile Air conditioning components in aratesofMobileAirconditioningcomponentsinaMini-shedOctober 20, 200618J2762 Refrigerant RecoveryJ2762RefrigerantRecoveryMethod forMethodforremoval ofrefrigerant fromrefrigerantfromR134a mobile airconditioningsystem toquantified chargequantifiedchargeamountCurrentlyin draft statusOctober 20, 200619Mini-Shed Facility Test Results•The SAE I-MAC program Mini-Shed testprocedure was validated in two different testprocedurewasvalidatedintwodifferenttestfacilities using the same 4 productionsystems in each facilitysystemsineachfacility–Ford F150–DCX Minivan Dual System–Toyota Camry–GM "W" car•Both facilities measured emission levels ofless that 10 grams/yr for all systemsOctober 20, 200620Mini-shed Facility Test ResultsSAE I-MAC Mini-shed Test FacilityEmission Comparision vs. "DI" Emission Rating2520

r“DI” Estimate1015

Grams/YeaDelphi5Creative Thermal Solutions0Ford F150 DCX Minivan DualSystemToyota Camry GM "W" carTest Facilities and RatingOctober 20, 200621TestFacilitiesandRatingDelphiCTS"DI" RatingJ 2763 Mini-Shed A/CSt L tystemLayoutCondenserHeatexchangerCompressorEvaporatorOctober 20, 200622Leak rate generatorGas analyzerJ2763 Mini-ShedDelphi Test FacilityyTest AnalyzerChamberSlideRailsTestFixtureOctober 20, 200623J2763 Mini-ShedCreative Thermal Solutions Test FacilityCreativeThermalSolutionsTestFacilityOctober 20, 200624Summary•Emissions from mini-shed testing comparefavorably withpredictions based on (DI)-favorablywithpredictionsbasedon(DI)estimates.•(DI)estimates are within a few grams of the-estimatesarewithinafewgramsoftheaverage emissions measured in field testingTh 2006 i d J2727 ( d h t) ill•The2006revisedJ2727(spreadsheet)willaccurately predict emissions from randomlyselectedproduction assembled systemsyOctober 20, 200625Addressing IssuesSubmitted by the ECSubmittedbytheECTheECsubmittedanumberofquestionstotheSAEC sub tted a u be o quest o s to t e SICCC J2727 Working Group, regarding the proposedrevised standard.The J2727 Working Group has resolved these concernsin the revised J2727 document.The revised J2727 was passed by SAE TechnicalCommittee members on 9 October 2006The revised J2727 document has been sent for ballot tothe SAE Motor Vehicle Council, with , final approvalexpected by Nov. 9th, 2006October 20, 200626expectedbyNov.9,2006Addressing IssuesSubmitted by the EC•The methodology used to pass from the rating figure toSubmittedbytheEC•Themethodologyusedtopassfromtheratingfiguretog/year is not clear.The factor (0.522) to correlate laboratory data to fleet testresults is based on annual customer usage.It is the same correlation factor as used by ACEA•The factor 0 522 is generally applicable to allThefactor0.522isgenerallyapplicable,toallcomponents, but that factor is only used in the templateto correlate fittings and the compressorThe factor 0.522 is applied to all rigid pipe fittings, hosesand compressors.October 20, 200627Addressing IssuesSubmitted by the EC•It is not known if the outputs from the study carried outbyARMINEShavebeentaken intoaccount.SubmittedbytheECby S a e bee ta e to accou tJ2727 correlates well with ARMINES data.•Correlation factor between real fleet leakage and systemleakage is not definedleakageisnotdefined.J2727 correlated to JAMA Fleet and ACEA Fleet results•Quality of the different components is not taken intoaccount.Variations in quality have always been accounted for inthe assigned leakages within the spreadsheetTh d f d t i ti f th ti fi i•The procedurefordetermination ofthe ratingfiguresisnot known.J2727 now only expressly provides emissions in/October 20, 200628gramsyear.Addressing IssuesSubmitted by the EC1- Current requirements of SAE 2727 cannot be directly adopted by the EC,as the aim of the SAE standard is the definition of a rating systemSubmittedbytheECastheaimoftheSAEstandardisthedefinitionofaratingsystembased upon the technology used and it is not intended for theevaluation of refrigerant emissions from MACs.J2727 directly provides g/yr2- The translation of SAE scores to grams (as stated in yourcommunication) is only a first step before the EC can consideraccepting the requirements of SAE J2727. A correlation to g/year(drivingconditions)should be established and the test methodologyg ) gyhas to be compatible.The revised J2727 is now correlated to field testresults and driving conditions. Test methods comparable to Armines.3- The application of SAE 2727 in the EU would imply a kind of autocertification of the MAC system by the car or systems manufacturercertificationoftheMACsystembythecarorsystemsmanufacturer.But, as you know, we have type-approval here in Europe so theprocedure will need to be changed.The EC type approval J2727spreadsheet can be certified by third party review.October 20, 200629Conclusion•The 2006 revised J2727(sreadsheet)willp )predict emissions from randomly selectedproduction assembled A/C systems•ACEA, CLEPA, JAMA and SAE recommend thetimely acceptance by the EC of J2727 as antimelyacceptancebytheECofJ2727asanalternative type approval under the MACRegulationOctober 20, 200630