1、 SURFACE VEHICLE STANDARD J2842 MAY2015 Issued 2011-02 Revised 2015-05 Superseding J2842 FEB2011 R-1234yf and R744 Design Criteria and Certification for OEM Mobile Air Conditioning Evaporator and Service Replacements RATIONALE Need to update to include R-445A and update R-744 section based on use co
2、nditions from EPA final rule. 1. SCOPE The intent of this standard is to establish a framework to assure that all evaporators for R-744, R-1234yf, and R-445A mobile air conditioning (MAC) systems meet appropriate testing and labeling requirements. SAE J639 requires vehicle manufacturers to perform a
3、ssessments to minimize reasonable risks in production MAC systems. The evaporator (as designed and manufactured) shall be part of that risk assessment and it is the responsibility of the vehicle manufacturer to assure all relevant aspects of the evaporator are included. It is the responsibility of a
4、ll vehicle or evaporator manufacturers to comply with the standards of this document at a minimum. (Substitution of specific test procedures by vehicle manufactures that correlate well to field return data is acceptable.) As appropriate, this standard can be used as a guide to support risk assessmen
5、ts. With regard to certification, most vehicle manufacturers have established formal production part approval processes (PPAP) where compliance certification is established and formally documented. For an evaporator manufacturer of non-original equipment parts (or a vehicle manufacturer that does no
6、t have a formal part compliance certification process) then the certification described in this standard is the requirement to which those evaporators shall comply. In this case, the evaporator manufacturer or an independent institution shall complete the evaporator certification according to SAE J2
7、911. An example of the latter would be the completion of witness testing by the evaporator manufacturer with the submission of certification documents by the witness organization. Refrigerant R-152a was excluded from this standard because a secondary loop refrigerant system is required. This standar
8、d also does not apply to R-134a refrigerant evaporators because it is proven in use. _ 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 an
9、d 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 revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and
10、 suggestions. Copyright 2015 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO
11、PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standa
12、rds/J2842_201505 SAE INTERNATIONAL J2842 Revised MAY2015 Page 2 of 26 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publicatio
13、ns Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J639 Safety Standards for Motor Vehicle Refrigerant Vapor Compressions Systems SAE J1739 Potential Failure Mode and Effect
14、s Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA) SAE J2772 Measurement of Passenger Compartment Refrigerant Concentrations Under System Refrigerant Leakage Conditions SAE J2773 Standard for Refrigerant Risk Analysi
15、s for Mobile Air Conditioning Systems SAE J2911 Procedure for Certification that Requirements for Mobile Air Conditioning System Components, Service Equipment, and Service Technician Trainging Meet SAE J Standards 2.1.2 Related Publications The following publications are provided for information pur
16、poses only and are not a required part of this SAE Technical Report. ISO 13043 Road vehicles - Refrigerant systems used in Mobile Air Conditioning systems (MAC) - Safety requirements ISO/TS16949 Quality management systems - Particular requirements for the application of ISO 9001:2000 for automotive
17、production and relevant service part organizations VDA Band 3 Ensuring reliability of car manufacturers - Reliability Management (VDA volume 3.1, 3rd edition 2000) ANSI/UL 969-1991 UL Standard for Safety for Marking and Labeling Systems, UL 969 3. DEFINITIONS All physical dimensions and units are ex
18、pressed in SI units and all indicated pressures are assumed to be gauge pressure unless otherwise noted. 3.1 NORMAL USE This term represents the use of the vehicle during normal driving and does not address damage that may occur in a vehicle collision (this should be addressed in the vehicle risk as
19、sessment by the vehicle manufacturer). 3.2 DESIGN LIFE OF THE VEHICLE Many vehicle manufacturers interpret this term differently and may recognize differences based on local climate conditions. This standard uses 10 years and 6000 working hours in a moderately corrosive environment similar to Centra
20、l Europe as a normal design life 3.3 ORIGINAL EQUIPMENT OE Designation of products or components from a vehicle manufacturer, or contracted by a vehicle manufacturer, who complies with ISO/TS16949 standards. SAE INTERNATIONAL J2842 Revised MAY2015 Page 3 of 26 3.4 BURST PRESSURE The minimum pressure
21、 which causes a component to structurally fail or rupture, resulting in fluid leakage 4. TECHNICAL REQUIREMENTS 4.1 Introduction This standard establishes product and process design requirements, along with validation testing and acceptance criteria for evaporators intended for use with R-1234yf, R-
22、445A or R-744 refrigerants. Significant refrigerant leakage by the evaporator into the passenger cabin could potentially pose a health and safety risk to vehicle occupants. To ensure appropriate risk, evaporators and evaporator assemblies shall: Be designed, manufactured and tested to minimize evapo
23、rator leakage for the design life of the vehicle. Meet certification and documentation standards. Meet requirements for evaporator labeling to ensure compliance to this standard and proper handling in service. 4.2 Evaporators Used by Original Equipment OE Vehicle Manufacturers Evaporators installed
24、in new vehicles and made available for service through the distribution channels of the vehicle manufacturer or OEM supplier are considered original equipment OE evaporators. These OE evaporators shall comply with this standard as a minimum; substitution of specific test procedures, which correlate
25、well to field return data, by vehicle manufacturers is acceptable. Formal compliance certification and risk assessments have been established and documented. 4.3 Other Evaporators (From non-OE suppliers or used by vehicle manufacturers without formal certification and documentation processes) An eva
26、porator produced by a non-OE supplier (or used by a vehicle manufacturer without formal certification and documentation processes) may only be installed in vehicles, if the component shall fulfill the requirements described in this standard. Compliance to this standard shall be certified and documen
27、ted as described below. Certification of R-1234yf, R-445A and R-744 evaporators from non original equipment manufacturers shall meet the requirements of SAE J2911. This SAE J2911 qualified institution shall issue a “Certificate of Conformity”, stating that the examined evaporator meets the essential
28、 safety requirements covering design, manufacture and testing; follows appropriate conformity assessment procedures, and carries the necessary labels and other information. Details of certificate are found in Appendix D. 4.3.1 Responsibility for Certification The manufacturer shall supply documentat
29、ion to SAE as described in SAE J2911 that includes the information listed in the following sections. The manufacturer shall provide an appropriate number of evaporators that are representative of the evaporator production being certified and the intended HVAC system. 4.3.2 Documentation Submission a
30、nd Certification Submission The manufacturer shall complete and submit form SAE J2842 Appendix D as the actual certification document. 5. EVAPORATOR DESIGN AND CERTIFICATION REQUIREMENTS The evaporator in this standard is defined as a component (the evaporator core body and permanently attached line
31、s and fittings) installed in the heating, ventilation and air conditioning (HVAC) module intended for climate control of the passenger compartment of a vehicle. The evaporator assembly in this standard is defined as a component assembly (with removable attaching lines, fittings or devices) installed
32、 in the heating, ventilation and air conditioning (HVAC) module intended for climate control of the passenger compartment of a vehicle. The evaporator or the evaporator assembly shall be treated as the component specified in this standard according to each section. SAE INTERNATIONAL J2842 Revised MA
33、Y2015 Page 4 of 26 5.1 Evaporator Design 5.1.1 Evaporator Design Requirements and Design Best Practices The evaporator is located within the heating, ventilation and air conditioning (HVAC) module and is connected to the refrigerant circuit. Substandard evaporator design, damage or misuse during ass
34、embly, shipping or service may increase potential risks to vehicle occupants. The requirements specified in this standard contain an approach for design, assembly to the HVAC housing, production quality and production testing of the assembly. Other relevant manufacturing and transportation practices
35、 such as storage, packaging and shipping shall be documented and retained by the manufacturer. Evaporators shall be designed appropriately for all vehicle operational conditions (AC on or off) as well as vehicle off (storage and soak) as would be expected over the lifetime of a vehicle. The evaporat
36、or shall have appropriate corrosion behavior and protection to meet this specification or the equivalent based on evaporator field return data. Evaporators as assembled in an HVAC module must include consideration of forces and torques from the assembly and disassembly of attaching lines and compone
37、nts. Any attaching tubing/pipe or other components in the evaporator assembly must withstand anticipated production, transport and assembly forces on those components without degradation of the refrigerant retention characteristics from those specified in this standard. Any tubing or piping used in
38、the assembly may be strengthened with brackets, connecting flanges, etc. to protect them from potentially damaging mechanical loads resulting from assembly operations, handling or transportation that would degrade the refrigerant retention characteristic of the assembly. See 5.7 for the allowable le
39、ak rate of an evaporator assembly. Material composition should comply with local or national environmental rules and requirements (e.g., banned and regulated substances). The materials for the evaporator shall be suitable for the maximum and minimum operating temperature and pressure ranges listed i
40、n SAE J639. Evaporator designs must have adequate material resistance to any chemical reactions with the refrigerant and lubricant (including normal degradation of both over time) to meet this standard and shall be capable of operating without significant degradation of the refrigerant retention cha
41、racteristics from those specified in this standard under the anticipated working temperature and pressure cycles, for the life of the vehicle. This includes exposure to a deep vacuum (for charge extraction and filling). The design specifications of the evaporator shall include considerations for cha
42、nges in material properties due to ageing based upon assembly, shipping, expected usage, exposure to corrosion and storage to achieve evaporator life targets. If the evaporator or evaporator assembly, including mating or attaching parts, are assembled from different materials, then galvanic corrosio
43、n must be considered in the validation/certification process. 5.1.2 Evaporator Manufacturing Requirements The evaporator production process covers the manufacturing and testing of the evaporator or the assembly of the evaporator and other parts as it is delivered for further assembly or distribution
44、. Robust manufacturing processes are required to ensure evaporator designs appropriately minimize potential risks to vehicle occupants. Design and process Failure Mode and Effects Analysis (FMEA) must be completed for evaporators used in a MAC system using R-744, R-1234yf, or R-445A. The evaporator
45、manufacturing process must take into account and insure the following: All critical characteristics coming from the Design-FMEA (on the complete evaporator assembly and on each component in the assembly) must be addressed; All critical characteristics coming from Process-FMEA (on process parameters)
46、 must be addressed. All design and process critical characteristics shall be included in the quality control plan for the evaporator. SAE INTERNATIONAL J2842 Revised MAY2015 Page 5 of 26 5.2 Pressure Strength and Endurance 5.2.1 Burst Requirements Evaporators shall meet or exceed specific minimum bu
47、rst pressure requirements as defined in the latest published version of SAE J639. For new evaporator, these values shall be a minimum of 2 times the maximum low-side refrigerant gauge pressure. 5.2.2 Burst Pressure For R-744 MAC systems increase the pressure 1.0 MPa/s up to 50% of the minimum burst
48、pressure and afterwards by 0.1 MPa/s until the minimum burst pressure is achieved. The evaporator must hold this pressure for 1 min without rupture or structural failure. Continue adding 0.1 MPa/s until the actual burst pressure is reached. For R-1234yf and R-445A MAC systems increase the pressure 1
49、00 kPa/s up to 50% of the minimum burst pressure and afterwards by 10 kPa/s until the minimum burst pressure is achieved. The evaporator must hold this pressure for 1 min without rupture or structural failure. Continue adding 10 kPa/s until the actual burst pressure is reached. The values obtained for burst pressures shall be recorded and documented. As actual burst pressure is achieved, no fra
