MACS February 2018Ward Atkinson

2-20-18F-am

The Future Part I

R-134a systemsExpect fewer models having it

R-134a SNAP July 2015 change of status listing for new vehicles after 2020 has been challenged in US court

Restricted use may be implemented by California and some states

R-1234yf systemsExpect more models being offered by OEMs

Trend in 2016MY indicated 2.2 million R-1234yf were producedResulting in 13% of those new cars having the new refrigerant

Expect it’s use in HD trucks and off-road equipment

R744 (Carbon Dioxide) Systems

First experimental systems were demonstrated in 1998Development being done in Europe

Limited number of production R-744 systems (2-3 models)

Only available on low volume production vehicles in Europe

Vehicles will not be exported outside EU communities

SAE Interior Climate Control Standards CommitteeHas stopped all development on SAE R-744 standards

Several published SAE J Standards address limited R-744 requirements

Currently there is limited information covering R-744System performance or durability

R-152a Secondary Loop System Development

First experimental systems demonstrated in 2007Had comparable occupant comfort to other systems

SL-Loop MACs use refrigerant to chill a fluid (coolant)It’s circulated inside cooling coil replacing refrigerant evaporator

Has reduced charge of flammable refrigerant

Can be used for heating pump mode

Advantages for chilled coolant:Requires less system refrigerant for single/dual systems

Eliminates refrigerant distribution problems in cooling coil

Can provide extended cooling time on idle stop engines

Can Cool batteries and/or second rear cooling unit

Direct

expansion

systemAndersen et al., 2014

Secondary

loop

systemAndersen et al., 2014

Cooling Comfort

level

S-LR-134a

Part II

R-134aSNAP July 2015 change of status listing for new vehicles after 2020 has been challenged in US court

Restricted use may be implemented by California and some states

Can be used to service production built R-134a systems

Low GWP Refrigerants

R-152a Flammable refrigerant ASHRAE A2 rating

R-744 (Carbon Dioxide)

R-1234yf Mildly Flammable refrigerant ASHRAE A2L rating

All refrigerants:Can be used in new production vehicles with system design use restrictions

EPA allows vehicle OEMs to generate emission credits

Not Acceptable For Servicing

Hydrocarbons

Rule on using HC refrigerant in MACS is they are an unacceptable substitute in the United States, including U.S. territories.

Under SNAP program, EPA listed all flammable refrigerants, except those specifically listed as acceptable subject to use conditions (i.e., R-152a or HFO-1234yf) as unacceptable for use in new and retrofit MVAC systems at 40 CFR part 82 subpart G appendix B.

In General HC containers are listed in Safety Data Classification -- as Extremely flammable gas Liquefied gas -- Contains gas under pressure; may explode if heated

EPA GuidelinesAll shops performing service on motor vehicle air conditioning systems for consideration are covered by the EPA regulations.

Charging systems is considered to be performing service.

EPA allows OEMs to generate greenhouse gas emission credits by using R-1234yf or other acceptable lower Global Warming Potential (GWP) refrigerants.

Use of refrigerant other than R-1234yf in a vehicle originally certified for its use could be considered “tampering with a vehicle emissions-control device.”

This is because:1. The A/C system, designed to meet EPA greenhouse standards, is an emission-

related device.

2. As such, tampering with it in any way that increases emissions is a violation of the Clean Air Act.

A person or shop who engages in such tampering could be assessed civil penalties under Title II of the Clean Air Act.

Refrigerant

cost

trends

With more

use of

R-1234yf

Will R-134a

cost

increase?

Mildly Flammable compared to other refrigerants and chemical used in vehicles and

service facilities Part III

Refrigerant Service OverviewUnlike R-134a, R-1234yf is flammableCharging a leaking system without leak detection, vacuum and pressure testing (SAE charge equipment procedure) can result in issues:

Safety

Liability

EPA 609Compliance

R-1234yf

Notification

R-134a 12 oz. R-1234yf 8 oz.

R-1234yf 12 oz.

R-1234yf

Compared

to other

products

SAE

CRP1234

Data

R-1234yf Compared to other

products

SAE

CRP1234

Data

R-1234yf, is a mildly flammable refrigerant, and there are some safety procedures that should be considered when working on the system

Service equipment and procedures must meet R-1234yf requirements

Equipment must meet SAE J2843 standards

Today's systems are using reduced chargeCan be sensitive to over and under charge

Important to identify and fix leaking systems for Safety reasons

Re-charge process requires: Vac./hold -- Press./hold procedure before re-charging

MACS Published a Manual in 2016

Procedures that should be considered when working with R-1234yf

The manual covers:Regulatory Issues

Servicing Contaminated R-1234yf Systems

R-1234yf Service Equipment

Component Issues

Evaporator Temperature Off-Set

Handling and Storage of R-1234yf Refrigerant

R-1234yf Storage Information

Technicians must use refrigerant handling equipment that has been certified by the EPA or an independent standards testing organization approved by EPA to certify equipment.

Listed on

Internet

Retrofitted

R-134a

Recovery

Charging

machine

There are no procedures to retrofit CFC-12 or R134a R&R charge equipment for servicing A2L R-1234yf flammable refrigerant

Safety requirements in SAE J2843 for R-1234yf Electrical Components shall comply with:

ANSI/ISA 12.12.01 Motors

Solenoids

Cabinet ventilation (Air exchange in cabinet)

Refrigerant Identification equipment to ID contamination required

Before R-1234yf can be charged into system: System processing features assure that the system does not

have a major leak : Vacuum check and hold

Pressure check and hold

To Assure proper MAC operation refrigerants should not be mixed or changed

Part IV

Evaporator controlPressure controlled compressor’s -- cycling or variable displacement can be affected.

Air temperature sensing may not have the same affect.

Contamination of air, R-134a or another refrigerant with R-1234yf may result in evaporator freeze-up, reducing system airflow and warmer panel air temps’

Without use of Ref. Identification, at recovery, your service equipment can become contaminated.

Expansion Valve/Other refrigerant controlsRefrigerant system contamination may result in improper operation of other controls.

MACS February 2018Ward Atkinson Bill Hill

Part V 2-7

C 2017 Mobile Air Conditioning Society Worldwide

Servicing MAC Systems with RefrigerantIndustry has developed SAE standards for service equipment and service procedures using large cylinders

Remove the entire refrigerant charge

Evacuate system and install known amount of refrigerant

Currently there is no SAE procedure for servicing A/C systems using small cans of refrigerant

MACS has developed a recommended practiceThis is a general overview

Many variables may exist between systems

Variables include actual amount of refrigerant in system and transferred into system

Reduced refrigerant charge systems require factory charge amounts

Many less than 1Kg (2.2 lbs.)

Servicing A/C SystemsIt is important to charge an A/C refrigerant system accurately.

Newer systems use less refrigerant and exact charge amount may be critical for proper operation and durability.

Use of SAE J2843 R-1234yf listed recovery and charging service equipment provides proper processing of the A/C system.

This includes:Refrigerant Identification

Refrigerant recovery.

Vacuum leak and pressure check process prior to charging.

For R-1234yf, electrical equipment for flammable refrigerants is required.

Use of SAE J2788 R-134a listed recovery and charging service equipment does not haveVacuum leak and pressure check process

For R-134a flammable electrical equipment is not required

J 2843 Equipment Pre-Charge Leak Testing Vacuum Phase Check

To detect the possibility of a gross system leak (>0.3 g/s) prior to charging, shall perform the following sequence:

Evacuate the A/C system to at least .011 MPa A (3.32 in Hg absolute)

Evacuation must operate for a minimum of 5 min, and must reach and hold at or below .011 MPa A (3.32 in Hg absolute) during evacuation for at least 3 min.

Evacuation process shall be halted upon meeting the above conditions and the system isolated from the vacuum source (vacuum pump).

Monitor vacuum level for 5 min; if vacuum decay exceeds 51 mm Hg/min (2.0 in Hg/min) during this time, the charging refrigerant process shall be aborted

J 2843 Equipment Pre-Charge Leak Testing Pressure Test Phase Check

If vacuum level holds, charge 15% of the total system refrigerant charge indicated on the vehicle SAE J639 label for the purpose of pressurized leak testing

With 15% of the system charge installed, perform a pressurized leak test, as follows:

HVAC blower motor on low

A/C switch off

Air distribution mode set to “floor”

Insert an SAE J2913-compliant electronic leak detector, set to high [maximum] sensitivity (4 grams/year leak rate) into the center of a floor duct outlet, as far as possible

If the detector alarms, an evaporator leak is indicated and it shall be repaired

Using Low Side Pressure Gauges to Indicate Refrigerant Charge Amount

Low side system pressure can identify:

System off:

Can identify VERY low charge when amount is below saturation.

System operating:

Can identify VERY low charge or an overcharged condition.

System refrigerant overcharge :

At cooler temperatures, a system overcharge may not be evident at time of service.

System compressor may shut off on hot day.

Conclusions system pressure:

Gauge reading does not accurately indicate the amount of refrigerant in the system

Refrigerant system “full” gauge ranges:

Some have suggested that a wide range of low side system pressure readings can identify amount of refrigerant in a system.

Below are two examples:Green range is “full” (25 - 55 psig)

Blue range is “full” (25 - 45 psig)

Issues to Consider if you Suspect a System Refrigerant Charge Issue when Charging :

“Top Off” is just a “guess and hope the problem get’s fixed” approach.

To properly service an A/C system, the following equipment is needed:

Refrigerant Identification

Equipment to recover all refrigerant in the system.

Vacuum pump to process the system for recharge (for R-1234yf, pump shall meet the standard for Electrical Equipment for Hazardous Locations). ANSI/ISA 12.12.01

Gauges and hoses

An accurate weight scale

Part VI

Refrigerant Purchase Starting January 1, 2018

Anyone can purchase Small Cans (2 lbs. or less) equipped with self sealing valves of:

R-134a

R-1234yf

Only certified 608 or 609 technicians can purchase larger containers (more than 2lbs.) of:

R-134a

R-1234yf

Only certified 609 technicians can purchase containers (less than 20 lbs.) of:

R-12 (CFC12).

California Air Resources Board (ARB) in 2009 adopted a regulation requiring a self-sealing valve on containers less than 2 pounds of automotive refrigerants with a GWP value greater than 150.

This regulation affects retailers who sell the product, and companies that package, distribute, or market the small cans of refrigerant, and the consumers who recharge MVAC systems using this product.

Effective January 1, 2018, EPA 608 rule requires can top to have a seal added for both R-134a and R-1234yf refrigerants.

An aerosol can containing R–134a or R-1234yf refrigerant, oil, leak and sealant to charge MVAC systems:

Shall have a self-sealing valve

Shall have the unique fittings required by the SNAP use conditions for MVAC refrigerants.

Questions

Part VII

What small cans require seal top?

Seal top are required for:An aerosol can containing HFC–134a or HFO-1234yf -refrigerant - oil - leak sealant, used to recharge MVAC systems

Seal top is not required when:HFCs is a propellant to inject additives and not used as a refrigerant, to recharge MVAC systems

Currently no Federally required return program for small cans of MVAC refrigerant. Currently only Calf. has a refrigerant small can return program

“Distributors and wholesalers must keep refrigerant sales records and verify purchasers are (or employ) 608 or 609 certified technicians” a container designed to hold two pounds or more of refrigerant

Adapters for Small Cans

Caution: Use proper ½” Acme “Seal” or “Pierce”top adaptors

Part VIII

R-1234yf 8 oz./12 oz. and R-134a 12 oz. cans are same size and have Acme 1/2” thread.

R-1234yf is Left hand thread

R-134a is Right hand thread

Never attach small cans to A/C high side service port.

The maximum pressure can is designed for is 100 psig.

Flat Surface Seal

Look-alike “pierce top” can adapters may damage seal top cans. (There may be no marking to ID adaptor type.)

LH ½” Acme

R-1234yf

12 oz. pierce

top can

LH ½” Acme R-1234yf

8 oz. seal can

RH ½” Acme

R-134a pierce

top can RH ½”

Acme

R-134a

12 oz.

seal

can

Adapters for Small Cans

V I AQ

VIAQ

Part IX

V I A QUnder Clean Air Act EPA has issued Light-Duty Vehicle Greenhouse Gas Emission and Corporate Average Fuel Economy Standards.

Provides fuel economy credits for various Air Conditioning technologies.

One credit is for increased use of re-circulation air mode:

When Ambient is over 24C (75F.).

Does not have a requirement for vehicle cabin air quality

Does not define what is meant by recirculated air and how much outside air may be allowed.

Cabin air quality may result in: Safety and health issues for both younger/older drivers.

Alertness concerns may hinder ability to operate a vehicle safely.

V I A QIndustry Indoor Air Quality standards exist for commercial passenger aircraft, homes and buildings.

Vehicle cabin air contamination can result from these 4 sources 1. From occupant breathing carbon dioxide levels can build up in the

cabin.

2. Vehicle body design - construction, operating on the road, can encounter exhaust fumes entry into the cabin.

Door, window, tail light, trunk seals

Door handles and water drains

Body structure, pinch welds, connected body panel surfaces

3. Release of Volatile Organic Compounds, “new car smell” odors from plastic material in the vehicle cabin can be harmful.

4. Collection of foreign materials/moisture retention in evaporator housing can result in undesirable odors.

V I A QSeveral SAE Technical papers have addressed cabin air quality

These issues have reached public awareness including “Class Action Activity”.

There is international activity on Automotive Vehicle Interior Air Quality (VIAQ) including:

ISO International Standards Organization -- OICA International auto industry -- ACEA European auto industry -- UN United Nations --- SAE International -- VDA German Association of the Automotive Industry -- USCAR

China, Korea and Japan have or are preparing to enforce new VIAQ regulations.

OEMs have developed performance based VOC methods and standards.

A/C max. cooling recirculated air modeCurrently no standards exist for cabin Out Side Air exchange for air quality

V I A QCurrent regulatory A/C system operation should consider maintaining cabin air quality for safe operation of the vehicle.

Recirculation air feature should provide a fixed outside air bleed to maintain cabin air quality

And/or an override feature to provide a timed 100% recirculation mode when encountering:

Tunnel passage

High contamination of local environments

Default recirculation mode next vehicle restart should not be allowed

Prevent recirculation mode to occur in cold weatherCan result in window fogging occurring

V I A Q

Solution to clean inside of glass -- Equal parts of the following:

Isopropyl alcohol

White vinegar

Water

Added aftermarket

window tinting may

increase VOC

window film issue

2014 Operation 4 years 45,000

miles hard surface roads in

US SW city

Questionable VOC removal by

filter?

Replacement

V I A Q

As noted before: A/C systems using recirculated air mode for

EPA fuel economy credits may result in vehicle cabin contamination and poor air quality

Consumer use of A/C system in OutSide Air mode can provide cabin air exchange and improved VIAQ

Except when encountering: Tunnel passage

High contamination of local environments

MACS 2018 FIELD SURVEY

Microchannel heat exchangers used in MAC systems

for:

Condensers

Evaporators

Part X

Condenser Failure Road damage, holes, stones, road, trash

Corrosion

Mechanical breakage

Integrated receiver dryer

Evaporator Failure Entry of foreign material - dirt, tree/plant

droppings Do cabin air filters reduce foreign material entry?

Corrosion

Mechanical breakage

How will it impact your future operation? Part XI

How will you service the marketplace?

Only A/C system service?

New technologies

More Electric compressors

Do you want to service EV’s Power Train??

Electric vehicles are more complex

New technical procedures and training

New capital investments

Vehicles on US roads in 2015 US 263.6 million

In 2016 542,000 electric vehicles on road in US

Sales of Over

10,000 Units

Electric Vehicle Charging Station Locations In the United States Excluding private stations

16,551 electric stations

45,396 charging outlets

At the request of Members, the following overview information is provided for unique vehicle air conditioning

applications

Since these applications are complex Regulatory confirmation is advised

R1234yf Motor vehicle air conditioning (newly manufactured medium- duty passenger vehicles).

Motor vehicle air conditioning (newly manufactured heavy-duty pickup trucks).

Motor vehicle air conditioning (newly manufactured complete heavy-duty vans only).

HFO-1234yf MVAC systems must adhere to all of the safety requirements of SAE J639 (adopted 2011), including requirements:

Flammable refrigerant warning label

High pressure compressor cutoff switch

Pressure relief devices

Unique fittings.

Connections with refrigerant containers for professional servicingFittings must be consistent with SAE J2844 (revised October 2011).

Manufacturers must conduct Failure Mode and Effect Analysis (FMEA) as provided in SAE J1739 (adopted 2009). Manufacturers must keep the FMEA on file for at least three years from the date of creation.

Additional training for service technicians recommended

Trucks -- Up fitter's Tie-In auxiliary A/C systems Vehicle that are manufactured by vehicle OEM without any MAC system.

R-134a SNAP July 2015 change of listing status for new vehicles after 2020 has been challenged in US court

Restricted use may be implemented by California and some states

R-1234yf Mildly Flammable refrigerant ASHRAE A2L rating

Can be used in new production vehicles, direct expansion, with system design use restrictions

MAC system components shall be subject to SNAP Use Restrictions and section 609 requirements and meetindustry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)

Light-Duty Vehicle Passenger car and Trucks (Van –SUV) -- Up fitter's Tie-In auxiliary A/C systems

Passenger cars –Vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Extended Body (Limousine) adding additional cooling unit(s) shall use the refrigerant type as installed by the OEM in the front MAC system.

When modifying, vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Added system components shall be subject to SNAP and section 609 system design use restrictions requirements and meet industry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)

HD pickup trucks -- HD complete Vans --- SUV less 14,000 GVW

Up fitter's Tie-In auxiliary A/C systems Vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Adding additional cooling unit(s) shall use the refrigerant type as installed by the OEM in the front MAC system.

When modifying vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Added system components shall be subject to SNAP and section 609 system design use restrictions requirements and meet industry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)

LD Vehicle Passenger car and Trucks (Van –SUV) Light truck -- Vans --- SUV less 14,000 GVW

Vehicle that are manufactured by vehicle OEM without any MAC system.

R-134a SNAP July 2015 change of listing status for new vehicles after 2020 has been challenged in US court

Restricted use may be implemented by California and some states

R-1234yf Mildly Flammable refrigerant ASHRAE A2L rating

Can be used in new production vehicles, direct expansion, with system design use restrictions

MAC system components shall be subject to SNAP and section 609 requirements and meet industry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)

Vehicle Classifications:

Limousine extended passenger cars and light trucks

Class 2b and 3 HD incomplete vans.

December 2016 (SNAP Rule 21) HFO-1234yf cannot be used in incomplete vans.

In rule (81 FR at 22867; April, 18, 2016), EPA stated:

Incomplete HD vans, at this time, EPA does not have information on all potential vehicle conversions that could be made by secondary manufacturers or the impact those conversions may have with regard to the SNAP criteria.

EPA is not including these vehicle types in this proposed action but is interested in receiving information on this topic

Only R-134a can be used in these vehicles

HD Pickup Trucks -- Up fitter's Tie-In auxiliary A/C systems

Vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Up fitter's Tie-In auxiliary A/C systems or additional cooling unit(s) shall use the refrigerant type as installed by the OEM in the front MAC system.

When modifying vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Added system components shall be subject to SNAP and section 609 system design use restrictions requirements and meet industry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)

LD Vehicle Passenger car and Trucks (Van –SUV) -- Up fitter's Tie-In auxiliary A/C systems

Passenger cars –Vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Extended Body (Limousine) adding additional cooling unit(s) shall use the refrigerant type as installed by the OEM in the front MAC system.

When modifying, vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Added system components shall be subject to SNAP and section 609 system design use restrictions requirements and meet industry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)

LD pickup truck – HD complete Vans --- SUV less 14,000 GVW

Up fitter's Tie-In auxiliary A/C systems Vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Adding additional cooling unit(s) shall use the refrigerant type as installed by the OEM in the front MAC system.

When modifying vehicles manufactured with R-134a or R-1234yf shall not be retrofitted with any other refrigerant.

Added system components shall be subject to SNAP and section 609 system design use restrictions requirements and meet industry standards for that refrigerant.

Refrigerant circuit components (e.g.. Hose assemblies –Evaporators)