SAE-J639-2002.pdf

SAE Technical Standards Board Rules provide that: “ This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243 TO PLACE A DOCUMENT ORDER; (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS http:/www.sae.org Copyright 1999 Society of Automotive Engineers, Inc. All rights reserved.Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 RECOMMENDED PRACTICE Submitted for recognition as an American National Standard J639 REV. MAR1999 Issued1953-04 Revised1999-03 Superseding J639 APR94 Safety and Containment of Refrigerant for Mechanical Vapor Compression Systems Used for Mobile Air-conditioning Systems 1.Scope This SAE Recommended Practice is restricted to mechanical vapor compression refrigerant systems that provide cooling for the occupant s compartment. This document provides guidelines for refrigerant containment and safety for a mobile air-conditioning (A/C) system. It is not intended to restrict the use of, or further development of, other types of refrigeration systems for passenger compartment cooling. Should other systems be found practical at some future time, this document may be amended or an additional recommended safety practice drawn up for other types of systems. This document only addresses CFC-12 (R-12) and HFC-134a (R-134a) refrigerants. To prevent mobile A/C system refrigerant contamination, all other alternate refrigerants considered for automotive use require unique service fittings. 2.References 2.1Applicable Publications The following publication forms a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE Publications shall apply. 2.1.1SAE PUBLICATION Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE 1732 HFC-134a (R-134a) Refrigerant Recovery Equipment for Mobile Automotive Air-Conditioning Systems SAE J2197 HFC-134a (R-134a) Service Hose Fittings for Automotive Air-Conditioning Service Equipment SAE J2209 CFC-12 (R-12) Refrigerant Recovery Equipment for Mobile Automotive Air-Conditioning Systems 2.1.2ASHRAE PUBLICATION Available from ASHRAE, 17191 Tullie Circle NE, Atlanta, GA 30329-2305. ASHRAE 34-1997 Number Designation and Safety Classification of Refrigerants 3.Components A mechanical vapor compression refrigeration system for cooling the passenger compartment of a motor vehicle consists of: a.A pump or compressor which raises the pressure of the refrigerant vapor and in so doing also raises its temperature. b.A condenser where the compressed refrigerant vapor is cooled and liquefied by passing outside air over its surface to absorb heat from the refrigerant. c.An expansion valve or other liquid refrigerant metering device regulates the flow of refrigerant to the evaporator. SAE J639 Revised MAR1999 -2- d.An evaporator, wherein the liquid refrigerant vaporizes because of the heat it absorbs from the air passing over the evaporator surface. e.A blower unit which circulates air over the evaporator where the air is cooled and then delivered to the passenger compartment. The air which is supplied to the evaporator unit may come from the passenger compartment (recirculated air), from the outside of the vehicle (outside air), or as a mixture of recirculated and outside air. f.A system of controls which may be manual, automatic, or part manual and part automatic. The control elements may control evaporator air flow delivery, temperature in the passenger compartment, the amount of outside or recirculated air introduced, maximum refrigerant pressure within the system, and similar items. g.In addition, the system may require wiring, tubing, connections, air ducts, a means of driving the compressor and the evaporator blower, a means of cooling the condenser, and other components. h.A refrigerant storage device (container) that may also contain desiccant material for moisture removal. Depending upon the system design, the device may be located in the high pressure circuit, identified as a receiver drier, or located in the low pressure circuit, identified as an accumulator drier. 4.Refrigerants Refrigerants, including blend refrigerants, both in their original composition and in compositions created as a result of normal mobile A/C operating conditions, must be of low toxicity, nonflammable, and nonexplosive as defined in the American Society of Heating, Refrigeration, and Air Conditioning Engineers, Inc., Standard ANSI/ASHRAE 34-1997 including Addenda 34a-o, 34q-z, 34ab, and 34ae. 5.Safety Practices The following safety practices are recommended: 5.1For safety, a self-sealing pressure-sensitive, relief device shall be located on the high-pressure side of the compressor or immediately adjacent to the compressor discharge port. The device shall be vented outside of the passenger and baggage compartments and air-circulating system for the passenger compartment. In no case shall the release (blow off) pressure be greater than 4136 kPa. 5.2To prevent unnecessary discharge of refrigerant during operation, the system shall have a device which limits the compressor operation before the pressure relief device in 5.1 will vent refrigerant. 5.3Components on the high-pressure side of the system shall have an ultimate bursting pressure not less than two times the release pressure specified in 5.1. 5.4To avoid the connection of a low-pressure container or service equipment to the high-pressure side of the system, any service fitting which connects into the high-pressure side refrigerant passage shall be mechanically dissimilar from the low-pressure side service fitting. The service fittings shall be located for easy access. High-side and low-side service fittings, including protective or sealing caps, shall provide containment of the refrigerant equal to the design intent “point“ leakage rate of the system. The CFC-12 (R-12) service fittings are included for reference purposes. The reference information for the CFC-12 (R-12) service fittings is also required to provide conversion fittings when retrofitting to HFC-134a (R-134a). 5.4.1To prevent mixing of CFC-12 (R-12) and HFC-134a (R-134a) refrigerants in mobile A/C systems, Figure 1 illustrates the low-pressure fitting and Figure 2 illustrates the high-pressure fitting for CFC-12 (R-12). Figure 3 illustrates the low-pressure fitting and Figure 4 illustrates the high-pressure fitting for HFC-134a (R-134a). The internal threads are optional for sealing caps as required in 5.3. No external threads shall be allowed on the fittings in Figures 3 and 4. SAE J639 Revised MAR1999 -3- FIGURE 1 CFC-12 (R-134A) LOW-PRESSURE SERVICE VALVE FITTING SAE J639 Revised MAR1999 -4- FIGURE 2 CFC-12 (R-12) HIGH-PRESSURE SERVICE VALVE FITTING SAE J639 Revised MAR1999 -5- FIGURE 3 LOW SIDE FOR HFC-134a (R-134a) SERVICE VALVE FITTING SAE J639 Revised MAR1999 -6- FIGURE 4 HIGH SIDE FOR HFC-134a (R-134a) SERVICE VALVE FITTING SAE J639 Revised MAR1999 -7- 5.4.1.1Charge couplings used in conjunction with fittings in Figures 3 and 4 shall have a relief feature to prevent coupling blow-off during installation and removal. The coupler depressor shall have a concave radius and shall provide a self-alignment feature. The coupling depressor travel, that depresses the valve core (which shall have a pin convex radius of 1.9 mm, Figure 5), has a pin location at breach of seal of 6.1 mm to 7.1 mm from the face of the fitting. (Breach of seal means when valve starts to open.) Minimum depressor travel must be 7.8 mm. To prevent core pin damage due to over-travel, the maximum coupling depression location shall not exceed 8.3 mm from the face of the fitting noted in Figures 3 and 4. Charge couplings shall open the service hose to flow according to the mandatory dimensioned features shown in Figures 3 and 4. FIGURE 5 PIN CONVEX RADIUS OF 1.9 mm 5.4.1.2For clearance during installation, the service fitting access coupler shall have a minimum inside diameter of 16.20 mm for the high side and 13.20 mm for the low side. 6.Cautionary Statements As with all refrigerants, the safe handling procedures should be followed as designated by the chemical manufacturers Material Safety Data Sheets (MSDS). Cautionary statements are provided to alert the mobile A/C industry to the inadvisability and the possible health and safety effects associated with (a) venting HFC-134a (R-134a) systems into the work space, and (b) using compressed air for leak detection in HFC-134a (R-134a) systems during repair or modification. It is intended that these cautionary statements (or equivalent language) be recommended for inclusion in all publications dealing with the servicing of HFC-134a (R-134a) mobile A/C systems. 6.1Caution Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, and throat. To remove HFC-134a (R-134a) from the A/C sy stem, use service equipment designed for HFC-134a (R-134a) recovery/recycling certified to meet the requirements of SAE J2210 HFC-134a (R-134a) recovery/ recycling equipment or SAE J1732 HFC-134a (R-134a) recovery equipment. To remove CFC-12 (R-12) from the A/C system, use service equipment designed for CFC-12 (R-12) recovery/recycling certified to meet the requirements of SAE J1990 CFC-12 (R-12) recovery/recycling equipment or SAE J2209 recovery equipment. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. SAE J639 Revised MAR1999 -8- 6.2Caution Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle A/C systems with compressed air during repair or modification. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. 7.Design Practice 7.1A plainly legible and durable name plate or tag shall be mounted in the engine compartment, where it can be easily seen. It should be mounted on a body structure part or vehicle component, not normally replaced during service as a result of repair or vehicle accident damage. The name plate or tag shall include identification of the refrigerant, lubricant type, and the recommended amount of refrigerant charge. The name plate or tag shall show the name and address of the refrigeration system manufacturer or the merchandiser responsible for design compliance with this document. It shall also reference appropriate repair practices. The plate or tag shall also state: CAUTION SYSTEM TO BE SERVICED BY QUALIFIED PERSONNEL. 7.2The type of the refrigerant, lubricant type, and the recommended amount of refrigerant charge, shall be identified in the vehicle owner's manual. 8.Notes 8.1Marginal Indicia The change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions have been made to the previous issue of the report. An (R) symbol to the left of the document title indicates a complete revision of the report. PREPARED BY THE SAE INTERIOR CLIMATE CONTROL STANDARDS COMMITTEE SAE J639 Revised MAR1999 Rationale Not applicable. Relationship of SAE Standard to ISO Standard Not applicable. Application This document is restricted to mechanical vapor compression refrigerant systems. Reference Section SAE 1732 HFC-134a (R-134a) Refrigerant Recovery Equipment for Mobile Automotive Air- Conditioning Systems SAE J2197 HFC-134a (R-134a) Service Hose Fittings for Automotive Air-Conditioning Service Equipment SAE J2209 CFC-12 (R-12) Refrigerant Recovery Equipment for Mobile Automotive Air-Conditioning Systems ASHRAE 34-1997 Number Designation and Safety Classification of Refrigerants Developed by the SAE Interior Climate Control Standards Committee