New Refrigerants Evaluation Results - SAE International

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Mitsubishi Fuso, Nissan, Nissan Diesel, Subaru, Suzuki, Toyota) ... 160. Capacity. (cm3). 1234yf. (R134a). Size. (WxHxD mm. Size. (WxHxD mm. TYPE. 320g.
New Refrigerants Evaluation Results JAMA-JAPIA Consortium Tohru Ikegami(TOYOTA), Masahiro Iguchi(HONDA), Kenta Aoki(NISSAN), Kenji Iijima(VALEO THERMAL SYSTEM)

2008 SAE Alternative Refrigerant Systems Symposium Phoenix, Arizona – USA, 10-12 June 2008



Contents

1234yf Evaluation Procedure Framework Evaluation Schedule Test Vehicle / System Specifications Test Conditions Test Results (DuPont & Honeywell 1234yf) Flammability Risk Assessment Summary LCCP Study Comparison of R134a, 1234yf and R744

2



The Purpose of 1234yf Evaluation Procedure

3

STEP-1: 1. Is a simple ‘Drop-in*’ possible? - Cooling Performance, System Efficiency and Fuel Consumption - Material Compatibility - Flammability Risk Assessment - Toxicity * Drop-in

Only ‘Charge’ and ‘Expansion Valve’ were changed to optimize system performance.

2. If not possible, evaluate the influence. STEP-2: 1. Confirmation of Durability and Reliability. 2. Confirmation of a vehicle marketability.



4

Framework of 1234yf Evaluation

Items

The Feasibility of the Refrigerant

System Bench Test

Vehicle Test

DuPont / Honeywell

Suppliers (JAPIA)

OEM’s (JAMA)

STEP-1

STEP-2

•Thermal Stability •Toxicity •Flammability

•Cost

•Materials Compatibility •Cooling Capacity •COP

•System Durability and Reliability

•Cooling Performance •A/C Power Consumption •Fuel Consumption

•Vehicle Durability •Cooling Capability •NV

Main

Support

Refrigerant Suppliers : DuPont & Honeywell JAPIA : 7 Tier1 suppliers (Calsonic, Denso, Japan Climate System, Keihin, Mitsubishi Heavy Industries, Sanden, Valeo) JAMA : 12 OEM’s (Daihatsu, Hino, Honda, Isuzu, Mazda, Mitsubishi, Mitsubishi Fuso, Nissan, Nissan Diesel, Subaru, Suzuki, Toyota)



5

Evaluation Schedule (STEP-1) 2007

HFO-1234yf

Oct

System Bench Test Cooling Performance Fuel Consumption

Stability Test

w/POE w/PAG

Material Elastomer Compatibility Test Hose Permeability Flammability Risk Assessment Toxicity

Dec

2nd European W/S MAC conference

EVENT

Vehicle Test

Nov

2008 Jan

Feb

Mar

JSAE VDA Winter mtg

Apr

May Jun ARSS

Jul

Aug

Sep



6

Test Vehicles Vehicles

Engine

Type

Transmission

Toyota GS430

4.3L

SEDAN

A/T

Mazda Axela

1.5-2.0L

H/B

M/T

Nissan Sylphy

1.5-2.0L

SEDAN

A/T

Mitsubishi Outlander

2.4L

SUV

CVT

Nissan Tiida

1.5-1.8L

H/B

A/T

Honda Zest

0.6L

K-Car

A/T

Suzuki Every

0.6L

K-Car

A/T



7

A/C system Specifications Vehicles

GS430

Axela

Sylphy Outlander

Tiida

Zest

Every

TYPE

Variable piston

Fixed rotary

Variable piston

Fixed scroll

Fixed rotary

Fixed scroll

Fixed rotary

Capacity (cm3)

160

120

105

90

80

53.9

63.4

660x 363.8x16

560.5x 382.3x1 6.5

615x 343x16

623x x407x16

607x 340.8x16

405x 356.9x16

420x 320x16

3.55mm

2.8mm

2.8mm

3.196mm

2.8mm

2.6mm

2.8mm

211x 293.1x38

230x 185x55

198x 192x40

254x 205x38

207.8x 225x39

181.1x 221x38

199.4x 200x38

3.0mm

3.4mm

3.1mm

2.6mm

3.1mm

3.2mm

3.0mm

1.5ton

1.5ton

2.0ton

1.5ton

1.0ton

2.0ton

1.0ton

(Modified)

(Modified)

(Serial)

(Modified)

(Modified)

(Modified)

(Modified)

420g (450g)

480g (500g)

450g (500g)

560g (500g)

450g (450g)

400g (400g)

320g (340g)

Compressor

Size

Condenser

(WxHxD mm

Fin pitch Size

Evaporator

(WxHxD mm

Fin pitch

Expansion Valve

Capacity

Refrigerant Charge

1234yf (R134a)

45 45 60 45 45 50 35 35 40 25 25 30 15 15

m/s 1.5 1.5 2 3 4 2 1.5 1.5 2 3 4 2 1.5 1.5 2 3 4 2 1.5 1.5 2 3 4 2 1.5 1.5 2 3 4 2

kg/min

3

Max air flow

3

56%

3

Max air flow

3

56%

3

Max air flow

3

56%

3/10

72%

3/10

44%

3/10

72%

3/10

44%

Remarks



Conditions evaporator entry

Air velocity upstream of condenser

Air temperature upstream of condenser

℃ 60

Evaporator air amount

min-1 900 900 1800 2500 4000 1800 900 900 1800 2500 4000 1800 900 900 1800 2500 4000 1800 900 900 1800 2500 4000 1800 900 900 1800 2500 4000 1800

Set point air downstream from evaporator

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 22 24 26 28 30 32 34 36 38 40 42

Compressor speed

System bench test condition (GAR common spec) 8

Series of measurement



45 oC Evaporator entry is few cases. Besides, this condition is severe for some bench facilities.

45℃/25%

60 oC Condenser entry is severe at some bench facilities. Omit this test condition.

35℃/25%

35 oC /25% humidity is severe at some bench. Use 40% instead of 25%.

35℃/40%

25℃/50%

15℃/80%

Set point 10 adapts only external variable compressor. Internal type is impossible. Fix type uses variable thermo switch but it’s not major. And it seems not crucial to compare different refrigerants for fix type compressor. 9kg/min is large for air volume of a small car. Max air volume uses test data. Medium air flow depends on each ratio



System bench test result (1234yf)



Cooling Capacity Test

Cooling Capacity [%]

110

9

Condenser 45ºC Evaporator 35ºC/40% Comparison of 1234yf and R134a (1234yf / R134a) Average 95.0% Max-Min cut (93.8%)

100 90 80

On-off

70 60

Comp. speed

900rpm

1800rpm

2500rpm

4000rpm

1800rpm

Eva. air volume

Max

Max

Max

Max

56%

GS430

89.3

92.3

95.7

93.6

95.6

Axela

91.3

90.3

90.8

90.4

92.7

Sylphy

103.8

104.0

103.3

102.7

104.6

Outlander

89.0

90.2

91.9

92.4

92.6

Tiida

89.9

92.9

94.6

94.2

94.2

Zest

94.1

96.8

97.9

98.1

95.7

Every

87.5

91.3

95.9

107.8

97.8



System bench test result (1234yf)



System Efficiency (COP) Test 120

10

Condenser 45ºC Evaporator 35ºC/40% Comparison of 1234yf and R134a (1234yf / R134a)

COP [%]

110

Average 95.9% Max-Min cut (95.4%)

100 90 80

On-off

70 60 Comp. speed

900rpm

1800rpm

2500rpm

4000rpm

1800rpm

Eva. air volume

Max

Max

Max

Max

56%

GS430

92.2

86.4

88.6

93.3

93.8

Axela

103.7

98.8

95.3

92.0

97.4

Sylphy

110.1

107.6

107.8

105.0

109.9

Outlander

96.0

92.4

93.0

93.8

93.4

Tiida

95.0

96.7

97.2

95.8

96.7

Zest

97.9

100.5

101

97.6

96.7

Every

87.7

87.6

89.0

78.9

89.4



11

Vehicle Test Conditions (GAR Common Spec)

< Cooling Performance > SOAK1 - 150 (- 120)

SOAK2 - 60

VEHICLE TEST 0

30

45

55

64

32 0

WIND SPEED (km/ h)

64

32 20

10

0

ON OFF

ENG COMP

ON OFF

GEAR SUN HVAC LIGHT OPERATE

Blower Setting and Air Distribution: Automatic and Manual HVAC Control: Cooling : max Blower : max Grill outlet : “face level” open Recirculation : 100%

Driving cycle Driving Time Speed(km/ h) (min)

Test Condition Chamber temperature : 40ºC Relative humidity : 40% Solar load : 1,000 W/m²

P or N

3rd

P or N

• ¦2nd or EQUV

ON OFF ON OFF

(REC,MAX COOL,FACE,FAN MAX)

DOOR

OPEN CLOSE

HOOD T/ GATE

OPEN CLOSE

Based on Common Spec Book for evaluating Global Alternative Refrigerants (GAR) V2.0



Vehicle test results (1234yf Cooling Performance) 12



Vent / Relative Temperature to R134a 10 Pull Down(32km/h)

Idle

64km/h

T [ºC]

8 6 4

GS430 Axela Sylphy Outlander Tiida Zest Every

Worse

2 0 -2

Better

0

5

10 15 20 25 30 35 40 45 50 55 Time [min]

Time (min)

10

30

45

55

GS430

-0.6

-0.6

1.0

-1.2

Axela

0.3

0.4

2.6

0.5

Sylphy

2.2

2.1

2.3

1.7

Outlander

0.0

0.1

0.3

-0.6

Tiida

1.6

0.8

2.1

-0.1

Zest

-0.2

-0.2

1.9

1.0

Every

1.6

1.6

0.9

-0.2

Average

0.7

0.6

1.6

0.2 T [ºC]

Head / Relative Temperature to R134a 10 Pull Down(32km/h)

8 T [ºC]



T [ºC]

Idle

64km/h

6 4

GS430 Axela Sylphy Outlander Tiida Zest Every

Worse

2 0 -2

Better

0

5

10 15 20 25 30 35 40 45 50 55 Tim e [m in]

Time (min)

10

30

45

55

GS430

0.1

0.1

0.7

-0.4

Axela

0.2

1.6

1.8

2.3

Sylphy

2.4

2.8

2.1

2.1

Outlander

-1.3

0.0

-0.4

-0.1

Tiida

2.5

1.9

2.2

2.2

Zest

2.1

1.7

2.2

1.0

Every

1.9

-0.2

0.5

2.3

Average

0.8

0.9

1.2

0.9



13

Vehicle Test Conditions (GAR Common Spec)

< Fuel Consumption Performance > Driving cycle (New European Driving Cycle)

Test Condition Chamber temperature [ºC]

15

25

35

Time (min)

Relative humidity [%]

80

50

40

Driving Speed (km/h)

PRE- CONDITION

Enthalpy [kJ/kg] 36.6 50.3 71.4 No

No

No

CITY Until Stable

-1

0

HIGHWAY 13

25

35

Evaporator setting [ºC]

5

5

10 10

Grill outlet

Face

Face

Face

Outside Air

100% 100% 100%

HVAC OPERATE

8

OFF

SUN LIGHT

5

ON

GEAR

15

OFF

COMP

Chamber temp.

ON

ENG

Blower Setting and Air Distribution: Automatic and Manual HVAC Control:

Fan voltage [%]

VEHICLE TEST

Wind Speed (km/h)

Solar load

1min IDLE

Shift Position: D ON OFF ON

FRESH, FACE, Teva(5 or 10 deg.C), FAN(5 or 8 or 10V)

OFF

Based on Common Spec Book for evaluating Global Alternative Refrigerants (GAR) V3.0

20



NEDC (CITY)

105 100

115 Worse Better

Cooling Performance

100.3

98.9

Worse

99.8

Better

95 90 85

15ºC

25ºC

35ºC

T = 1234yf V.T. R134a V.T. (V.T. vent temperature)

110 105

T

115 Consumption ratio (%)

(F.C. fuel consumption)

105

2 1 0 -1 -2

Worse Better

100.1

100 95

Cooling Performance

2 1 0 -1 -2

90 85

15ºC

25ºC

Axela

Cooling Performance

98.7

Worse

Outlander Tiida Zest Average

Better

90 85

35ºC

99.4 100.4

100 95

Worse

Better

Worse Better

100.7

98.9

NEDC (OVERALL)

Consumption ratio (%) = 1234yf F.C. (L/100km) / R134a F.C. (L/100km)

110

T

2 1 0 -1 -2

NEDC (HIGHWAY) Consumption ratio (%)

110

T

115 Consumption ratio (%)

14

Vehicle test results (1234yf Fuel Consumption)

15ºC

25ºC

35ºC

Note: Only 2 vehicle’s data are available at 15C due to the facility limit.

Negligible influence on fuel consumption when 1234yf is applied



15

Material Test Conditions

 Thermal Stability Test  Procedure : ANSI/ASHRAE97-1999 Sealed Glass Tube Method to Test the Chemical Stability of Materials for Use Within Refrigerant Systems  Test condition Temperature

ºC

Moisture

PPM

Test period * Oil * Refrigetant

175 , 200