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SAE Air Conditioning Standards

Ward Atkinson

January 20, 2010
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Interior Climate Control

Standards Committee

Five Sub-Committees

Industry Experts

Develop Documents

Members

• Vehicle OEM/Tier

one Suppliers

• A/C System and

equipment

Suppliers

• Chemical

Industry
3

Interior Climate Control

Standards Committees

13 Members

Vehicle

Manufacturers

Vehicle

OEM

Steering

Committee Including

OEM

Steering

Committee

Members

17 Members

Vehicle

OEM

Committee

Including

Vehicle OEM

Steering

Committee

Members

Includes Tier

1& 2

Suppliers

28 Members

MAC

Suppliers

Committee Including

Vehicle OEM

Steering

Committee

Members

Includes Tier

1& 2

Suppliers

23 Members

Fluids

Committee

Including

Vehicle OEM

Steering

Committee

Members

Includes

Service

Industry and

Equipment

Suppliers

30 Members

Service

Committee
4

HFO-1234yf SAE Standards

(Under development or revision to be published in 2010)

 System Design

 5 - Documents

 Refrigerant

 1 - Document

 Service Equipment

 6 - Documents

 Service Fluids

 1 - Document

Technician

Requirements

 1- Document

SAE Certification

 A/C Components

 Service

Equipment

 Technicians
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HFO-1234yf SAE Standards

HFO-1234yf is a new

refrigerant

When industry lists

HFO-1234yf as a production

refrigerant:

HFO-1234yf will be designated

as R-1234yf and both

designations can be used
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SAE System Design Standards

 J639 Safety Standards for

Motor Vehicle Refrigerant

Vapor Compression Systems

 This document provides

design standards and safety

requirements for MAC

systems. Also included are

cautionary statements for

the mobile air conditioning

service industry to alert

service technicians to the

inadvisability and the

possible health and safety

effects associated with

venting refrigerant during

service.

 Master Document

referencing all MAC A/C

Standards

J2842 Certification for OEM Mobile Air

Conditioning Evaporator and Service

Replacements

J2845 Technician Training for Safe

Service and Containment of

Refrigerants

Vehicle Label
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SAE System Design Standards

J639 Provides requirements and

identifies SAE J Standard requirements

for MAC systems including:

 System design requirements

 FMEA J1739

 System operation J2772 - J2773

 System components J2064 - J2842 - J2844

 Service Equipment

J2843 - J2851 - J2888 - J2912 - J2913

 Technician Certification

J2845
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SAE System Design Standards

 J2772 Measurement of Passenger Compartment

Refrigerant Concentrations under system refrigerant

leakage conditions

 Provides a method of test for use in risk assessment.

 The purpose of this standard is to provide a procedure and

conditions to evaluate the refrigerant concentration in a

vehicle passenger compartment resulting from leakage of

refrigerant from a Mobile Air Conditioning system (MAC).

 J2773 R-744 and HFO-1234yf Refrigerant Standard

for Safety and Risk Analysis for use in Mobile Air

Conditioning Systems

 This standard describes the method to verify the risk of a

vehicle A/C system with alternative refrigerants in design,

production and assembly, operation and final scrapping.
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SAE System Design Standards

 J2842 HFO-1234yf and R-744 Design Criteria

and Certification for OEM Mobile Air

Conditioning Evaporator and Service

Replacements

 This standard is intended to minimize any

unnecessary exposure to persons, during normal

use or servicing of a mobile air conditioning system

using toxic or flammable refrigerants.
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 SAE J2064 R-134a and HFO-1234yf Refrigerant

Automotive Air-Conditioning Hose and Assemblies

 This SAE Standard covers hose and hose assemblies intended

for conducting liquid and gaseous R-134a and/or HFO-1234yf

refrigerant in automotive air-conditioning systems. The hose

shall be designed to minimize permeation of the refrigerant,

contamination of the system, and to be functional over a

temperature range of –30 to 125 °C.

New requirements for

field coupled hose

assemblies

10

SAE System Design Standards
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SAE Refrigerant Standard

 J2844 Refrigerant Purity and Container Requirements

for New HFO-1234yf Refrigerant Used in Mobile AirConditioning Systems

 The purpose of this SAE Standard is to establish the

minimum level of purity required and container specifications

for HFO-1234yf refrigerant used in mobile air-conditioning

(A/C) systems. The refrigerant shall meet all purity

requirements as identified in this Standard and shall follow

the sampling and analytical methods of testing described in

AHRI Standard 700-2006 and in future AHRI-700 Standards

that include HFO-1234yf.
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SAE Service Equipment Standards

 J2843 HFO-1234yf Recovery/Recycling/Recharging

Equipment for Flammable Refrigerants for Mobile AirConditioning Systems

 The purpose of this SAE Standard is to establish the specific

minimum equipment requirements for

recovery/recycle/recharge of HFO-1234yf that has been directly

removed from, and is intended for reuse in, mobile air

conditioning systems and system recharging of recycled or

virgin HFO-1234yf.

 J2851 HFO-1234yf Refrigerant Recovery Equipment for

Mobile Automotive Air-Conditioning Systems

 The purpose of this SAE Standard is to provide minimum

performance and operating feature requirements for the

recovery of HFO-1234yf refrigerant to be returned to a

refrigerant reclamation facility that will process it to the

appropriate ARI 700 Standard or allow for recycling of the

recovered refrigerant by using SAE J2843 certified equipment.
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SAE Service Equipment Standards

 J2888 HFO-1234yf Service Hose, Fittings and Couplers

for Mobile Refrigerant Systems Service Equipment

 The purpose of this SAE Standard is to establish specific but

unique fittings, couplers, and hoses for service equipment

used in maintaining HFO-1234yf systems. This is necessary to

avoid cross mixing of refrigerant and lubricants from other

refrigerant systems. This standard applies only to systems

specifically designed to use HFO-1234yf.

 J2099 Standard of Purity for Recycled HFC-134a

(R-134a) and HFO-1234yf (R-1234yf) or Use in Mobile

Air-conditioning Systems

 The purpose of this SAE Standard is to establish the minimum

level of purity required for on-site recycled HFC-134a (R-134a)

and HFO-1234yf (R-1234yf) removed from, and intended for

reuse in, mobile air-conditioning (A/C) systems.
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SAE Service Equipment Standards

 J2912 HFO-1234yf Refrigerant Identification

Equipment for Use with Mobile Air

Conditioning Systems

 The purpose of this SAE Standard is to establish

criteria for refrigerant identification equipment

intended for use with or without recycling

equipment when removing refrigerant from Mobile

Air-Conditioning (A/C) Systems or from refrigerant

containers prior to charging a mobile A/C system.

 J2913 HFO-1234yf Refrigerant Electronic

Leak Detectors, Minimum Performance

Criteria

 The purpose of this SAE Standard is to establish

minimum performance criteria for a modern class

of electronic probe- type leak detectors intended

for use in automotive air conditioning systems with

HFO-1234yf a A2 flammable refrigerant.
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SAE Service Fluids Standards

 J2670 Stability and Compatibility Criteria for

Additives and Flushing Materials Intended for

Use in R-134a and HFO-1234yf Vehicle AirConditioning Systems

 The purpose of this standard is to provide testing

and acceptance criteria to evaluate the stability and

compatibility of chemicals, including flushing

materials and additives (e.g., to enhance

lubrication, durability, cooling performance, energy

performance, prevent/fix leaks) intended for use in

either R-134a or HFO-1234yf vehicle air

conditioning systems using belt-driven

compressors.
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SAE Technician Requirements

 J2845 Technician Training for Safe Service and

Containment of Refrigerants Used in Mobile A/C

Systems (R-744 and HFO-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

HFO-1234yf. The technician must be trained to recognize

which refrigerant is being handled, how to handle it safely

and be equipped with the essential information, proper

equipment and tools, which are unique to these

refrigerants
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SAE Certification Standard

 SAE J2911 Procedure For Certification

That Requirements For Mobile Air

Conditioning System Components,

Service Equipment and Service

Technicians Meet SAE J Standards

 The purpose of this Standard is to certify that

the requirements of an SAE J Standard for MAC

system components, service equipment and

service technician qualification are met.

Certification provides a means to assure a

customer or a Regulatory Agency that the

equipment delivers the advertised

performance.
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SAE Surface Vehicle

Recommended Practice [Developed by Industry]

 SAE J1739 [Issued July 1994 Revised June 2009] Potential Failure

Mode and Effects Analysis in Design (Design

FMEA), Potential Failure Mode and Effects Analysis

in Manufacturing and Assembly Processes

(Process FMEA), and Potential Failure Mode and

Effects Analysis for Machinery (Machinery FMEA)

 This document introduces the topic of potential Failure

Mode and Effects Analysis (FMEA) and gives general

guidance in the application of the technique.

SAE ICCC Standards references J1739 in:

 Design requirements such as in J639

 Service Equipment Requirements
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HFO-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

• Added 5 new standards

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   Ne w Fie ld

Couple d

 


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HFO-1234yf SAE Standards

Summary

Current Status of 15

SAE J Documents

SAE Document Status Committee Type

J639 Safety Standards for Motor Vehicle

Refrigerant Vapor Compression Systems OEM 28 Day

J2064 R134a and HFO-1234fy Refrigerant

Automotive Air-Conditioning Hose and

Assemblies

MAC 28 Day

J2065 Desiccant Testing for Vehicle Air

conditioning Systems Fluids

J2099 Standard of Purity for Recycled HFC-134a

(R-134a) and HFO-1234yf (R-1234yf) or Use in

Mobile Air-conditioning Systems

Fluids 28 Day

J2670 Stability and Compatibility Criteria for

Additives and Flushing Materials Intended for

Use in R-134a and HFO-1234yf Vehicle AirConditioning Systems

Fluids 28 Day

J2772 Measurement of Passenger Compartment

Refrigerant Concentrations under system

refrigerant leakage conditions

OEM 14 Day

J2773 HFO-1234yf and R744 Refrigerant Standard

for Safety and Risk Analysis for use in Mobile Air

Conditioning Systems

OEM 28 Day

J2842 HFO-1234yf and R744 Design Criteria and

Certification for OEM Mobile Air Conditioning

Evaporator and Service Replacements

OEM &

MAC 28 Day

J2843 HFO-1234yf

Recovery/Recycling/Recharging Equipment for

Flammable Refrigerants for Mobile AirConditioning Systems

Service 14 Day

J2844 HFO-1234yf New Refrigerant Purity and

Container Requirements Used in Mobile AirConditioning Systems

Fluids 14 Day

J2845 Technician Training for Safe Service and

Containment of Refrigerants Used in Mobile A/C

Systems (R-744, and HFO-1234yf)

Service 28 Day

J2851 HFO-1234yf Refrigerant Recovery

Equipment for Mobile Automotive AirConditioning SystemsService 28 Day

J2888 HFO-1234yf Service Hose, Fittings and

Couplers for Mobile Refrigerant Systems Service

Equipment

Service 14 Day

J2911 Certification Requirements For Mobile Air

Conditioning System Components, Service

Equipment, and Service Technicians to Meet SAE

J Standards

MAC &

Service 28 Day

J2912 HFO-1234yf Refrigerant Identification

Equipment for Use with Mobile Air Conditioning

Systems

Service 28 Day

J2913 HFO-1234yf Refrigerant Electronic Leak

Detectors, Minimum Performance Criteria Service 28 Day
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SAE Interior Climate Control

Standards Committee

All standards are planned to be

published in first quarter of 2010

Many States reference SAE J639

 Some are:

 Arizona-Idaho-Kansas-North DakotaOklahoma-Texas

 Compliance requires:

 MAC System Design Requirements

 MAC Servicing Requirements
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U.S. NCCTI Report October 12, 2001

In the Executive Summary of

Technologies to Reduce

Emissions of Non-CO2

Greenhouse Gases and Black

Carbon National Climate Change

Technology Initiative the

following graph covers the

emissions of HFC-134a
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 EPA Inventory of U.S. Greenhouse Gas Emissions

and Sinks 1999 and 2000 indicated emission levels for

HFC-134a in 1992.

 HFC-134a systems first production MY1992 and full

production MY1995

 Refrigerant R&R was mandatory

 New HFC-134a systems required minimal refrigerant

for service in 1993 –1998

 In 1998, an unexplained HFC-134a emissions,

accountable to MAC service industry, of an additional

14,000 equivalent metric tonnes of carbon dioxide or

31 million pounds of HFC-134a

 HFC-134a was used to service the CFC-12 fleet

U.S. NCCTI Report October 12, 2001
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 EPA Inventory of U.S. Greenhouse Gas Emissions

and Sinks 1999 and 2000 indicated emission levels for

HFC-134a in 1992.

 HFC-134a systems first production MY1992 and full

production MY1995

 Refrigerant R&R was mandatory

 New HFC-134a systems required minimal refrigerant

for service in 1993 –1998

 In 1998, an unexplained HFC-134a emissions,

accountable to MAC service industry, of an additional

14,000 equivalent metric tonnes of carbon dioxide or

31 million pounds of HFC-134a

 HFC-134a was used to service the CFC-12 fleet

Mobile A/C HFC-134a Emissions

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

92 93 94 95 96 97 98 99 00

Year

M

etric

T

o

n

n

e

EPA Service R134a Fleet

31 Million Pounds

Graph 1

Used to service R-12

MAC fleet

U.S. NCCTI Report October 12, 2001

1995 All

New

MAC use

R-134a
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SAE Interior Climate Control

Standards Committee

SAE J2727 HFC-134a Mobile Air

Conditioning System Emission Chart

 Estimates the annual refrigerant

emissions rate (grams per year) from new

production A/C systems

Compliance Required

 Currently Required in California

Minnesota

 Future Federal Requirement
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SAE J2727 HFC-134a Mobile Air

Conditioning System Emission Chart

Annual refrigerant emissions rate (14.1grams [0.49oz] per

year) from new production A/C systems

Refrigerant Leakage

Single Evaporator System 2009 MN Data

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

22.0

24.0

26.0

Acura

Audi

Bentley

BMW

Buick

Cadillac

Chevrolet

Chrysler

Dodge

Ford

GMC

Honda

Hummer

Hyundai

InfinityJaguar

Jeep

Kia

Land Rover

Lexus

Lincoln

Mazda

Mercedes

Mercury

Mini

Mitsubishi

Nissan

Pontiac

Porsche

Range Rover

Rolls Royce

Saab

Saturn

Scion

Subaru

Suzuki

Toyota

Volvo

VW

Grams Loss /year

Fleet Average Loss

14.1 Grams/yr

(0.49 oz./yr)

Average of A/C systems

offered by vehicle

product line

Some GM Data reported in pounds

and converted to grams

wa 01-09
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Future Challenges

Introduction of HFO-1234yf in new

vehicles

Refrigerant cost considerably higher

Cannot be vented at service

Requires all new service equipment

Current EPA SNAP rule allows SNAP

listed refrigerants

To service R-134a and potentially

HFO-1234yf MAC systems
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Current SNAP Listed Refrigerants

 15 SNAP Listed

 9 Contain HCFC’s!

 None can be vented

 All require unique fittings

 Can be used for retrofitting

 12 For HFC-134a systems

 13 For HFO-1234yf systems

 There are no SAE MAC

System Retrofit

procedures

 SAE Recovery/recycle

Equipment Standards for

only HFC-134a and

HFO-1234yf refrigerants

Refrigerant USE

Retrofit

Use New

MAC

Contains

HCFC's

FRIGC/FR-12

R-416A X X Yes

Free Zone/ RB-276 X X Yes

Ikon 12 X X No

R-406A/GHGGHG, GHGX3, GHG-12, McCool,

Auto frost X3

X X

Yes

GHG-HP X X Yes

GHG-X4 R-414A Auto

Frost, Chill-it, Autofrost

X4

X X

Yes

Hot Shot, Kar Kool

R-414B X X Yes

Freeze 12 X X Yes

GHG X-5 X X Yes

GHG-HP (HCFC Blend

Lambda) X X Yes

SP34E X X No

RS-24 R-426A X X No

HFC-134a X X No

HFC-152a X No

CO2 X No
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Future Challenges

Contamination potential for MAC systems

and service equipment

 Only recovery-recycle equipment will be

available for HFC-134a and HFO-1234yf

refrigerants

 No certified R&R equipment designs exist for the other

listed SNAP refrigerants

No information on MAC system cooling

performance or material compatibility for

other SNAP listed refrigerants if used in

HFC-134a or HFO-1234yf system
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Lessons Learned

The Future

The MAC change from CFC-12 to HFC-134a

was expensive for the consumer and

industry

The laissez-faire use and atmospheric

loading of HFC-134a has resulted in the

current World action to eliminated its future

use

 Normal MAC HFC-134a direct refrigerant

emissions is less than 5% over the MAC

system lifetime

 Vehicle tail pipe emissions for MAC energy use

[cooling] results in greater lifetime emissions
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Lessons Learned

The Future

The high atmospheric HFC-134a

loading is the result of refrigerant

mis-use/mis-handling

EPA controlled sale and use of

CFC-12

EPA did not control sale of

HFC-134a
32

Lessons Learned

The Future

The MAC change from HFC-134a

to HFO-1234yf will be much more

expensive for the consumer and

industry

Higher costs for:

Refrigerant

Systems

Service Equipment
33

Lessons Learned

The Future

The HFC-134a world fleet is large

 Refrigerant is required to retire the world

HFC-134a fleet

 Retrofitting the HFC-134a fleet is not

acceptable

HFC-134a has been used in MAC

systems since 1992

What is the future for MAC systems?

 Current direct expansion type systems?

 Secondary loop systems?

 Multiple new refrigerants?
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Lessons Learned

The Future

EPA must revise the list of all

SNAP MAC listed refrigerants

and control their sale and use

SNAP List should only include

refrigerants which have been

evaluated by industry and where

SAE standards are established
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Lessons Learned

The Future

Refrigerants evaluated by industry

 HFC-134a - HFO-1234yf – HFC-152a – R-744

[carbon dioxide]

 Without SNAP revisions/controls:

 Lower cost refrigerants will be used to service

HFO-1234yf MAC systems

 System contamination

 Damage to MAC systems and service equipment

will occur

Most contain POTENT ODS or

GREENHOUSE GASES
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