MAC Refrigerant Blend Cooperative Research Program --- Update --- Enrique Peral-Antúnez, RENAULT [ Chair person ]

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1 MAC Refrigerant Blend Cooperative Research Program --- Update --- Enrique Peral-Antúnez, RENAULT [ Chair person ] 12TMSS-0022 October 31, 2012

2 Presentation Overview Background MRB CRP phase I : outcomes reminder Phase II activities Decision point for AC6 CRP Conclusions 2 12TMSS-0022 October 31, 2012

3 MRB Sponsors 3 12TMSS-0022 October 31, 2012

4 Independent Labs Science and Strategies for Safe Environments creativethermalsolutions.com/ TMSS-0022 October 31, 2012

5 CRP formed under rules of SAE in Feb 2011 OEM & Tier Ones involved CRP overview 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 5 12TMSS-0022 October 31, 2012

6 Phase I outcomes reminder 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 6 12TMSS-0022 October 31, 2012

7 01 Flammability 02 Performance & efficiency 03 Selective Leakage issues 04 Compressor durability 05 Materials compatibility 06 Vehicle manufacturing issues 07 Service issues Phase II activities 08 FTA & Risk assessment 09 Suggestions for further J-Standards to SAE ICCSC 7 12TMSS-0022 October 31, 2012

8 01. Flammability 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 TMSS-0022 October 31, 2012

9 Ignition Source Test AC5 AC6 R-1234yf Blower resistor Ignition Ignition o Ignition* Blower module Ignition Ignition Ignition* 12 volt battery cable Ignition +0 Ignition +o Ignition+ Prolonged short of pierced battery cable Ignition Ignition Ignition Friction sparks Ignition o Ignition Ignition * Based on previous testing at INERIS 0 Tests run with WCF composition + Short for 30 seconds 9 12TMSS-0022 October 31, 2012

10 Ignition Source Test AC5 AC6 R-1234yf Wire-to-wire short Ignition o Ignition Ignition* Relay Ignition Ignition Ignition* Headlight filament Ignition Ignition o Ignition Shorted out Low Voltage PTC heater Ignition Ignition o Ignition* 400V spark Sufficient energy Sufficient energy Sufficient energy * Based on previous testing at INERIS 0 Tests run with WCF composition 10 12TMSS-0022 October 31, 2012

11 Flammability summary AC6 anticipated characteristics are as follows* : USA EU AC5/R-1234yf AC6 AC5/R-1234yf AC6 MAC system application Transport & handling [MSDS] A2L A2L A2L A2L Flammable Flammable nflammable nflammable Service Flammable Flammable Flammable Flammable Building codes Flammable Flammable Flammable *based on test data generated to date May benefit from non-flammability below 50C in implementation (interpretation of Seveso directive) Reduced flammability 11 12TMSS-0022 October 31, 2012

12 02. Performance & Efficiency 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 12 12TMSS-0022 October 31, 2012

13 Life Cycle Analysis Life Cycle Performance of AC5/AC6/R1234yf is similar, and all are better than R134a 13 12TMSS-0022 October 31, 2012

14 Impact of Reduced CO2 on Cool-down Performance [Drop-In] Performance is sensitive to CO2 concentration Performance of nominal concentration is similar to R134a 14 12TMSS-0022 October 31, 2012

15 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 15 12TMSS-0022 October 31, 2012

16 03. Selective Leakage 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 16 12TMSS-0022 October 31, 2012

17 CTS testing Actual selective leakage measured in a full system 17 12TMSS-0022 October 31, 2012

18 Impact of selective leakage on performance Performance loss at high load is small, but improvement should be made to achieve at least 10 years life with CO2. PAPER # 12TMSS TMSS-0022 October 31, 2012

19 04. Compressor durability Tier one internal testing Denso Sanden Visteon Doowon ILK testing Dual loop testing with R134a side-by-side with AC6 Summary of results significant issues discovered in these initial screening tests See TMSS-0023 for more detail 19 12TMSS-0022 October 31, 2012

20 05. Material compatibility 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 TMSS-0022 October 31, 2012

21 06. Vehicle manufacturing issues 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 21 12TMSS-0022 October 31, 2012

22 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 TMSS-0022 October 31, 2012

23 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 23 12TMSS-0022 October 31, 2012

24 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 Probability of vehicle occupant/former occupant experiencing HF exposure above health based limits associated with AC5 ignition/decomposition. Probability of vehicle occupant/former occupant experiencing HF exposure above health based limits associated with R-1234yf ignition/decomposition. 4 x x Probability of vehicle occupant being exposed to an open flame due to AC5 ignition 2 x Probability of vehicle occupant/former occupant experiencing HF exposure above health based limits associated with AC6 ignition/decomposition. 1 x Probability of vehicle occupant being exposed to an open flame due to R-1234yf ignition 4 x Probability of vehicle occupant being exposed to an open flame due to AC6 ignition 5 x TMSS-0022 October 31, 2012

25 Risk Comparison to Other Workplace Events Event Probability n-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 Probability of AC service technician exposure to an open flame due to R- 1234yf ignition (per hour of vehicle service) 5 x Probability of AC service technician exposure to an open flame due to AC6 ignition (per hour of vehicle service) 5 x TMSS-0022 October 31, 2012

26 09. SAE J-Standards Standard Number/Title J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compression Systems J1658 Alternate Refrigerant Consistency Criteria for Use in Mobile Air-Conditioning Systems J2064 R-134a and R-1234yf Refrigerant Automotive Air-Conditioning Hose and Assemblies Action Plan New Fitting/Cautions on blend Update and assign a new number update needed right now J2099 Standard of Purity for Recycled R-134a and R-1234yf or Use in Mobile Air-conditioning Systems 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 Work to begin in Interior Climate Control Standards Committee once all IP issues are disclosed and resolved 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 J2772 Measurement of Passenger Compartment Refrigerant Concentrations under system refrigerant leakage conditions J2773 Standard for Refrigerant Risk Analysis for Mobile Air Conditioning Systems J2842 R-1234yf and R744 Design Criteria and Certification for OEM Mobile Air Conditioning Evaporator and Service Replacements Simply update to reference new refrigerant Simply update to reference new refrigerant Simply update to reference new refrigerant Simply update to reference new refrigerant Simply update to reference new refrigerant 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 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 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 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 Simply update to reference new refrigerant J2912 R-1234yf Refrigerant Identification Equipment for Use with Mobile Air Conditioning Systems New standard under development 26 12TMSS-0022 October 31, 2012

27 Refrigerant Conclusion in phase II 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 27 12TMSS-0022 October 31, 2012

28 CRP Phase III 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 28 12TMSS-0022 October 31, 2012

29 MRB Sponsors 29 12TMSS-0022 October 31, 2012

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