12TMSS-0022 October 31, 2012

MAC Refrigerant Blend Cooperative Research Program

--- Update ---

Enrique Peral-Antúnez, RENAULT

[ Chair person ]

2 12TMSS-0022 October 31, 2012

Background

MRB CRP phase I : outcomes reminder

Phase II activities

Decision point for AC6

CRP Conclusions

Presentation Overview

3 12TMSS-0022 October 31, 2012

MRB Sponsors

4 12TMSS-0022 October 31, 2012

http://www.exponent.com/

creativethermalsolutions.com/

http://www.sceinc.com/

http://www.haifire.com/

http://www.ilkdresden.de/index.php?L=1 http://www.gradientcorp.com/index.html

Science and Strategies for Safe

Environments

Independent Labs

5 12TMSS-0022 October 31, 2012

CRP formed under rules of SAE in Feb 2011

OEM & Tier Ones involved

Chaired by OEM representative with SAE support

Engaged experts with refrigerant assessment experience

CRP focused on technical assessment of multiple factors

in parallel

Develop suggestions for future SAE standards

MRB considered two fluids, AC5 and AC6, in phase I

The team has agreed to moving with AC6 as the

best option after Phase II evaluation

CRP overview

6 12TMSS-0022 October 31, 2012

AC5 and AC6 have been extensively tested via a

rigorous CRP AC5 matches the LCCP performance of R-1234yf

AC6 needed further improvement in energy efficiency

AC6 offers reduced flammability

AC5 is ignition temperature with oil is also significantly higher than

R-1234yf

Systems components, lubricants and hoses are available for AC5

and AC6 systems

Project made remarkable progress in 7 months in 2011

Further work needed in order to allow final selection of preferred fluid

Compatibility with electrical compressors provides an opportunity

for these fluids for use with heat pump systems in electric vehicles

Open issues to be analyzed in phase II

Phase I outcomes reminder

7 12TMSS-0022 October 31, 2012

01 Flammability

02 Performance & efficiency

03 Selective Leakage issues

04 Compressor durability

05 Materials compatibility

06 Vehicle manufacturing issues

07 Service issues

08 FTA & Risk assessment

09 Suggestions for further J-Standards to SAE

ICCSC

Phase II activities

8 12TMSS-0022 October 31, 2012

INERIS result with Hot Body Ignition temperature for AC5/AC6 are similar and 100°C

higher than 1234yf, but there is a significant delay in

ignition with AC6

Ignition Sources Finalized table and assessed different blend

concentrations

Testing at 400 volt

Regional Codes Assessment region per region

Transport & handling (MSDS)

Service/Building

Will be discussed in TMSS-0025

01. Flammability

9 12TMSS-0022 October 31, 2012

AC5 AC6 R-1234yf

Blower resistor No

Ignition No

Ignitiono No

Ignition*

Blower module No

Ignition No

Ignition No

Ignition*

12 volt battery cable No

Ignition+0 No

Ignition+o No

Ignition+

Prolonged short of pierced battery cable

Ignition Ignition Ignition

Friction sparks No

Ignitiono No

Ignition No

Ignition

Ignition Source Test

* Based on previous testing at INERIS 0 Tests run with WCF composition + Short for 30 seconds

10 12TMSS-0022 October 31, 2012

AC5 AC6 R-1234yf

Wire-to-wire short No

Ignitiono No

Ignition No

Ignition*

Relay No

Ignition No

Ignition No

Ignition*

Headlight filament Ignition No

Ignitiono No

Ignition

Shorted out Low Voltage

PTC heater Ignition

No Ignitiono

Ignition*

400V spark Sufficient

energy Sufficient

energy Sufficient

energy

Ignition Source Test

* Based on previous testing at INERIS 0 Tests run with WCF composition

11 12TMSS-0022 October 31, 2012

Flammability summary

AC6 anticipated characteristics are as follows* :

USA EU

AC5/R-1234yf AC6 AC5/R-1234yf AC6

MAC system application

A2L A2L A2L A2L

Transport & handling [MSDS]

Flammable Non-

flammable Flammable

Non-flammable

Service Flammable Flammable Flammable Flammable

Building codes Flammable Flammable Flammable Reduced

flammability

May benefit from non-flammability

below 50C in implementation

(interpretation of Seveso directive)

*based on test data generated to date

12 12TMSS-0022 October 31, 2012

LCCP calculation AC5 and AC6 are similar to R1234yf

All much better than R134a

Blend tolerances investigations Vehicle pull down tests follow with reduced CO2

Heat pump performance – preliminary

results

02. Performance & Efficiency

13 12TMSS-0022 October 31, 2012

Life Cycle Analysis

Life Cycle Performance of AC5/AC6/R1234yf is similar, and

all are better than R134a

14 12TMSS-0022 October 31, 2012

Impact of Reduced CO2 on

Cool-down Performance [Drop-In]

Performance is sensitive to CO2 concentration

Performance of nominal concentration is similar to R134a

15 12TMSS-0022 October 31, 2012

Preliminary Heat Pump Performance

Initial concept testing yielded considerably higher capacities for the WGB fluid at low temperatures compared to R134a, and allowed operation at lower ambient temperatures

16 12TMSS-0022 October 31, 2012

CTS testing Selective Leakage rates are different for all

components of AC6

Leakage model Estimate of performance loss is 5% in 7 years with

improved hoses, while COP increases 20%.

Further system optimization still planned

03. Selective Leakage

17 12TMSS-0022 October 31, 2012

CTS testing

Actual selective leakage measured in a full system

18 12TMSS-0022 October 31, 2012

Impact of selective leakage on

performance

PAPER # 12TMSS-0066

Performance loss at high load is small, but improvement

should be made to achieve at least 10 years life with CO2.

19 12TMSS-0022 October 31, 2012

Tier one internal testing Denso

Sanden

Visteon

Doowon

ILK testing Dual loop testing with R134a side-by-side with AC6

Summary of results No significant issues discovered in these initial

screening tests

See TMSS-0023 for more detail

04. Compressor durability

20 12TMSS-0022 October 31, 2012

Permeation Testing Previous testing was at 90C

New results at 30-75C show more reasonable results

Oil testing Additional oil evaluated from sponsor

Results similar to previous oils tested

Miscibility of oils is better in AC5/AC6 than with R1234yf

Compatibility testing Confirmed issues with certain PA materials, similar to

those with R1234yf

Evaluated new oil from sponsor

More details in TMSS-0024

05. Material compatibility

21 12TMSS-0022 October 31, 2012

Technology identification Plan to add R744 to vehicle charge just prior to

charging vehicle

Prototype machine development Working with CINETIC to validate process …

Validation by physical testing Final validation part of Phase III

06. Vehicle manufacturing issues

22 12TMSS-0022 October 31, 2012

07. Service issues

Technology identification Plan to add R744 as needed to assure proper

concentration in vehicle

Prototype machine development Equipment Development is on-going

Validation by physical testing Planned in phase III

More detail in TMSS-0020

23 12TMSS-0022 October 31, 2012

08. Overall Risk Assessment

Conclusions

Use of AC6 in MAC systems poses an extremely low

level of risk for vehicle operators and repair workers The risks are lower than those estimated for R-1234yf

Based on Risk Assessment to date, AC6 could be

an appropriate alternative for R134a and R12 as MAC

refrigerants Increased risk due to flammability is very small

Hazard due to toxicity is equivalent or reduced

Environmental benefits (i.e., GWP, ODP, LCCP) are enhanced as

compared to R-134a and R-12

Newly collected data are consistent with and

support these prior conclusions

24 12TMSS-0022 October 31, 2012

Risk Comparison to Other Vehicle Events

Event Probability per vehicle

per operating hour

Probability of being in a police reported vehicle collision 5 x 10-5

Probability of vehicle collision due to vehicle brake failure 3 x 10-7

Probability of highway vehicle fire (any cause) 1 x 10-7

Probability of an airbag-related fatality associated with a vehicle collision 2 x 10-10 Probability of vehicle occupant/former occupant experiencing HF exposure above health

based limits associated with AC5 ignition/decomposition. 4 x 10-14

Probability of vehicle occupant/former occupant experiencing HF exposure above health

based limits associated with R-1234yf ignition/decomposition. 2 x 10-14

Probability of vehicle occupant being exposed to an open flame due to AC5 ignition 2 x 10-14 Probability of vehicle occupant/former occupant experiencing HF exposure above health

based limits associated with AC6 ignition/decomposition. 1 x 10-14

Probability of vehicle occupant being exposed to an open flame due to R-1234yf ignition 4 x 10-15

Probability of vehicle occupant being exposed to an open flame due to AC6 ignition 5 x 10-17

25 12TMSS-0022 October 31, 2012

Risk Comparison to Other Workplace Events

Event Probability

Non-fatal recordable Injury at work (all occupations, per working hour) 2 x 10-5 Probability an AC service technician is struck by object resulting in lost work

days (per working hour) 2 x 10-6

Probability of a fatal fall at the workplace (all occupations, per working hour) 2 x 10-9

Probability of AC service technician exposure to an open flame due to AC5

ignition (per hour of vehicle service) 9 x 10-17

Probability of AC service technician exposure to an open flame due to R-

1234yf ignition (per hour of vehicle service) 5 x 10-17

Probability of AC service technician exposure to an open flame due to AC6

ignition (per hour of vehicle service) 5 x 10-19

26 12TMSS-0022 October 31, 2012

09. SAE J-Standards Standard Number/Title Action Plan

J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compression Systems •New Fitting/Cautions on blend

J1658 Alternate Refrigerant Consistency Criteria for Use in Mobile Air-Conditioning Systems •Update and assign a new number

J2064 R-134a and R-1234yf Refrigerant Automotive Air-Conditioning Hose and Assemblies •No update needed right now

J2099 Standard of Purity for Recycled R-134a and R-1234yf or Use in Mobile Air-conditioning

Systems •Simply update to reference new refrigerant

J2297 ULTRAVIOLET LEAK DETECTION: STABILITY AND COMPATIBILITY CRITERIA OF

FLUORESCENT REFRIGERANT LEAK DETECTION DYES FOR MOBILE R-R-134a and R-R-1234yf

(HFO-R-1234yf) AIR-CONDITIONING SYSTEMS •Simply update to reference new refrigerant

J2670 Stability and Compatibility Criteria for Additives and Flushing Materials Intended for Use in

R-R-134a and R-R-1234yf Vehicle Air-Conditioning Systems •Simply update to reference new refrigerant

J2772 Measurement of Passenger Compartment Refrigerant Concentrations under system

refrigerant leakage conditions •Simply update to reference new refrigerant

J2773 Standard for Refrigerant Risk Analysis for Mobile Air Conditioning Systems •Simply update to reference new refrigerant

J2842 R-1234yf and R744 Design Criteria and Certification for OEM Mobile Air Conditioning

Evaporator and Service Replacements •Simply update to reference new refrigerant

J2843 R-1234yf Recovery/Recycling/Recharging Equipment for Flammable Refrigerants for Mobile

Air-Conditioning Systems •New standard under development

J2844 R-1234yf New Refrigerant Purity and Container Requirements Used in Mobile Air-

Conditioning Systems •New standard under development

J2845 Technician Training for Safe Service and Containment of Refrigerants Used in Mobile A/C

Systems (R-744, and R-1234yf) •New standard under development

J2851 R-1234yf Refrigerant Recovery Equipment for Mobile Automotive Air-Conditioning Systems •New standard under development

J2888 R-1234yf Service Hose, Fittings and Couplers for Mobile Refrigerant Systems Service

Equipment •Simply update to reference new refrigerant

J2911 Certification Requirements For Mobile Air Conditioning System Components, Service

Equipment, and Service Technicians to Meet SAE J Standards •Simply update to reference new refrigerant

J2912 R-1234yf Refrigerant Identification Equipment for Use with Mobile Air Conditioning Systems •New standard under development

Work to begin in Interior Climate Control Standards

Committee once all IP issues are disclosed and

resolved

27 12TMSS-0022 October 31, 2012

Team’s agreement for AC6 validation

Reduced flammability compared to R-1234yf

Potentially higher capacity

Future use in heat pump systems :

Temperature glide larger than currently used

refrigerants

Slightly higher pressure fluid than R-134a

Refrigerant Conclusion in phase II

28 12TMSS-0022 October 31, 2012

Additional activities have been identified for

further assessment Further FTA assessment based on the current situation

Further heat exchanger optimization

New hose materials development

Worst case refrigerant composition testing

Validate Factory Fill and Service Equipment test

procedures

Support for SNAP submission

New partners are welcome to join in Phase III

A separate CRP is proposed to investigate in more

detail heat pump cycle with blend refrigerants

CRP Phase III

29 12TMSS-0022 October 31, 2012

MRB Sponsors