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