Proposed Draft of CO2J2210 4/20/05 1

Proposed STANDARD CO2J2210 REV. 11 Revised: October 28, 2004 (Color code): CO2Jxxxx = New J-spec number needed

CO2Jxxxx = Revision to existing J-spec CO2 (R-744) Refrigerant Removal and R-744/R-134a Charging Equipment for Mobile Refrigerant Systems Foreword—These specifications are for equipment intended to provide controlled discharge, of R-744 only, and charging of R-744 or R-134a mobile refrigerant systems. Recovery of R-744 is not required, however, recovered oil separation is required and system charge accuracy is critical. R-744 is also considerably higher in vapor and operating pressures than R-12 or R-134a. 1. Scope—The purpose of this SAE standard is to provide equipment specifications for the removal (R-744 only), evacuation and charge of mobile refrigerant systems. This information applies to equipment used to service automobiles, light trucks, and other vehicles with similar R-744 or R-134a refrigerant systems. 2. References 2.1 Applicable Publications—The following publications form a part of the specification to the extent specified herein. Unless otherwise indicated, the latest revision of SAE publications shall apply. 2.1.1 SAE PUBLICATIONS—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J639—Safety Standards for Motor Vehicle Vapor Compression Refrigerant Systems SAE CO2J2196—Service Hoses for CFC-12 (R-12), HFC-134a (R-134a) and CO2 (R-744) Mobile Refrigerant Systems SAE CO2J2197CO2 (R-744) Service Hose and Equipment Fittings Mobile Refrigerant Systems Service Equipment 2.1.2 CGA PUBLICATION—Available from CGA, Crystal Gateway #1, Suite 501, 1235 Jefferson Davis Highway, Arlington, VA 22202. CGA S-1.1—Pressure Relief Device Standard Part 1—Cylinders for Compressed Gases 2.1.3 DOT SPECIFICATION—Available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. CFR 49, Section 173.304—Shippers—General Requirements for Shipments and Packaging J2683Refrigerant Purity and Container Requirements For Carbon Dioxide (CO2 R-744) Used In Mobile Air-Conditioning Systems 3. Specifications and General Description 3.1 The equipment shall be able to provide controlled discharge of a R-744 refrigerant system. Refer to section 6.2. 3.2 The equipment shall be suitable for use in an automotive service garage environment. 3.3 Equipment Certification—The equipment shall be certified that it meets this specification by Underwriters Laboratories, Inc. (UL) or by an equivalent independent nationally recognized testing laboratory. The laboratory shall maintain documentation of testing to this specification for each model certified, including all calibration data and equipment calibration dates for a period of 5 years. 3.4 Label Requirements for R-744—The equipment shall have a label “Design Certified by (Company Name) to meet SAE CO2J2210 for use only with R-744 (CO2).” The minimum letter size shall be bold type, 3 mm in height. 3.5 Label Requirements for R-134a—The equipment shall have a label “Design Certified by (Company Name) to meet SAE CO2J2210 for use only with R-134a.” The minimum letter size shall be bold type, 3 mm in height. 4. Safety Requirements

Proposed Draft of CO2J2210 4/20/05 2

4.1 The equipment shall comply with applicable federal, state, and local requirements on equipment related to the handling of R-744 or R-134a material. Safety precautions or notices, labels, related to the safe operation of the equipment shall also be prominently displayed on the equipment and should state "CAUTION—SHOULD BE OPERATED BY CERTIFIED PERSONNEL." The safety identification shall be located on the front near the controls. 4.2 The equipment shall comply with applicable safety standards for electrical and mechanical requirements. 4.3 Venting of R744 systems should be performed outdoors. Indoor venting is optional, provided the design of the equipment includes a provision to vent the refrigerant to the outdoors, as with a flow control valve and a hose. 4.4 The internal design of the R-744 equipment shall have a pressure relief device wherever in the refrigerant circuit liquid refrigerant could be trapped in any failure mode, such as solenoid valves not opening. The pressure relief valve setting shall be below the burst pressure of the circuit. 5. Operating Instructions 5.1 The equipment manufacturer shall provide operating instructions that include necessary maintenance procedures, and source information for replacement parts and repair. 5.1.1 The instruction manual shall include the following information on the lubricant removed. Only new lubricant, as identified by the system manufacturer, should be replaced in the mobile refrigerant system. Removed lubricant from the system and/or the equipment shall be disposed of in accordance with the applicable federal, state, and local procedures and regulations. 5.2 The equipment shall prominently display the manufacturer's name, address, the type of refrigerant it is designed to handle, a service telephone number, and any items that require maintenance or replacement that affect the proper operation of the equipment. Operation manuals shall cover information for complete maintenance of the equipment to assure proper operation. 6. Function Description 6.1 Prior to performing discharge, evacuation and charge functions, open any isolation valves that may be present in the vehicle system. 6.1.1 The instruction manual shall include a warning that any isolation valves shall be located and opened per the manufacturer’s recommended service procedures. 6.1.2 This is necessary to avoid unexpected and potentially dangerous pressures which could cause injury and/or damage equipment. 6.1.3 This is also necessary to insure complete discharge and evacuation which will allow accurate charging. 6.2 For R-744 Only: The equipment shall be capable of ensuring safe discharge of R-744 from the system being serviced by reducing the system pressure to atmospheric. It shall have a provision for ambient venting from inside a service shop, as described in 4.3. 6.2.1 The discharge flow rate shall be limited to prevent icing and explosive decompression of seals and o-rings. 6.2.2 The purpose of limiting the discharge rate is to prevent ice build-up and clogging of the service fitting which would prevent completion of the discharge per 6.2. 6.2.3 Elastomeric seals and o-rings can absorb R-744. If the refrigerant system pressure is reduced too rapidly, these components can explode due to escaping of the absorbed, high pressure gas, into the low pressure surrounding area. 6.3 All external flexible hoses shall meet SAE CO2J2196 for service hoses. 6.3.1 The external hose assemblies shall meet SAE CO2J2196 for fittings. 6.4 Service hoses shall have quick-couplers at the connection point to the system being serviced that meet SAE J2197, SAE CO2J2197 and J639. 6.5 The equipment shall be able to separate the lubricant during discharge of refrigerant and accurately indicate the amount removed in 10 ml (0.3 fl oz) units. 6.5.1 The purpose of indicating the amount of lubricant removed is to ensure that a proper amount of new lubricant is returned to the mobile refrigerant system for proper compressor lubrication.

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6.6 Prior to charging the R-744 refrigerant system, it shall be evacuated to an absolute pressure of 0.6 kPa or 0.006 atm for a minimum of 30 minutes. This is equivalent to a vacuum of 755.44 mm Hg (or 29.74 in Hg) or 4000 microns below 1 atmosphere. If the equipment includes a vacuum pump, it shall be capable of performing to this specification. 6.7 The equipment shall be able to dispense a specified charge to within a tolerance of ±14 g. (±0.5 oz.). 6.7.1 Means shall be provided to secure the CO2 container in position per Compressed Gas Association (CGA) pamphlet P-1, Safe Handling of Compressed Gases in Containers. 6.7.2 The R-744 refrigerant container shall be of a capacity that shall not exceed the R-744 safety regulations of Japan, the European Community or North America. 6.8 Refrigerant R-744 shall be charged in vapor phase only. 6.9 If the R-744 supply bottle is heated, it shall not be allowed to exceed 49 °C (120 °F) with no localized heating applied to any part of the supply cylinder. See figure 1. 6.9.1 Never apply flame or localized heat directly to any part of the cylinder. 6.9.2 A thermal safety device shall be included to disable the heating element should the temperature control device fail. Refer to UL60730-1 or EN60730-1. 6.9.2 Heating is a way of generating an adequate charging pressure level. 6.10 For R-744 Only: A pressure relief valve, located after the equipment’s charge control valve, shall open if the pressure exceeds 9 Mpa (1305 psig). See figure 1. 6.10.1 This valve shall be self-sealing and close again below 9 Mpa (1305 psig). 6.10.2 Integration of this valve between the equipment’s charge control valve and the vehicle will help to avoid overcharging of the refrigerant system. Overcharging can result in loss of refrigerant and oil to the atmosphere, potential injury, and damage to the compressor. 6.11 A check valve shall be located between the refrigerant system and refrigerant supply. See figure 1. 6.11.1 This valve protects the refrigerant supply from reverse flow from the refrigerant system which could result in over-pressurization of the supply bottle. 6.11.2 Another benefit of this valve is avoidance of refrigerant supply contamination. 6.12 The equipment shall be capable of continuous operation in ambient temperatures of 10 °C (50 °F) to 49 °C (120°F). 6.13 If the equipment uses semi-automatic or automatic control of the evacuation and recharge process, it shall not proceed or permit proceeding from evacuation to recharge until a vacuum decay test of the system has been performed and a satisfactory result obtained, to insure the system has out-gassed. 6.13.1 The equipment's automatic operation shall conform to SAE J2211, section 4.3.2, in that it shall be capable of reducing system pressure to a minimum of 102 mm (4 in) of Mercury below atmospheric pressure, then shut off the recycling unit for at least five minutes, and recheck A/C system pressure. If the pressure has risen above vacuum, the equipment shall repeat evacuation, and not permit recharging until system pressure remains stable at vacuum for two minutes. 6.13.2 An acceptable alternative is detection of the system vacuum with an automatic detection device prior to recharging.

Proposed Draft of CO2J2210 4/20/05 4

To Service Hoses and Couplers Check Valve 9 MPa Relief Valve (1305 psi)

∫ Charge Control Valve

Refrigerant Bottle If used, heater shall be regulated and contain a thermally activated fuse so as not to allow the refrigerant temperature to exceed 49 °C (120 °F).

Figure 1.

7. TestingEquipment shall be tested as noted in 7.1 through 7.11 For test validation, the equipment is to be operated according to the manufacturer's instructions. 7.1 If the Equipment has a weight scale, conduct equipment durability test per UL1963 sections 65.3 and 65.4. 7.1.1 Equipment shall retain a charge accuracy of ±14 g. (±0.5 oz.) per section 6.7. 7.2 Conduct equipment performance tests at 10 °C (50 °F) and 49 °C (120 °F). 7.3 Connect the equipment under test (EUT) to the test apparatus. See figure 2. 7.3.1 The test apparatus must be elevated above the EUT and positioned to allow oil separation/recovery by the EUT during discharge of the test apparatus. 7.3.2 R-744 will not necessarily transport the oil back to the EUT during discharge of the test apparatus. 7.4 Close V1 7.5 Evacuate the test apparatus to ≤ 0.006 atmosphere using EUT. 7.6 Carefully Open V1 until 20 g of polyolester oil has been transferred. 7.7 Per operating instructions, set EUT to charge 350 g of R-744. 7.8 When charge is complete, per EUT operating instructions, verify that TV weighs 370 g. 7.9 Discharge test apparatus through EUT. 7.10 Verify recovered oil is 20 ±10 g and TV is at atmospheric pressure. 7.11 Repeat test steps 7.5 - 7.10 five times.

Heat Band

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Service Hoses Vacuum/Pressure Oil Gauge/Transducer Reservoir

⁄ ⁄ V1

Figure 2.

Developed by the SAE Interior Climate Control Standards Committee

EUT

HIGH SIDE

LOW SIDE

SCALE

TV

Proposed revisions SAE J639 Rev 22 January 12, 2004 1 of 17

REV. Under revision Proposed J639 Draft 22 J639 January 12, 2004 MAR1999 Issued 1953-04 Revised 1999-03 Superseding J639 APR94 Safety Standards for Motor Vehicle Refrigerant Vapor Compression Systems Scope—This SAE Standard Practice is restricted to refrigerant vapor compression systems that provide cooling and/or heating for the passenger compartment. This document provides design standards for refrigerant containment and safety for these systems. Also included are cautionary statements for the mobile air conditioning service industry to alert service technicians to the inadvisability and the possible health and safety effects associated with venting refrigerant during service. It is not intended to restrict the use, or further development, of other types of refrigeration systems for passenger compartment cooling. Should other systems be found practical, this document may be amended or an additional standard safety practice created for such systems. This document addresses only CFC-12 (R-12), HFC-134a (R-134a), HFC152a (R-152a) a flammable gas and carbon dioxide (R-744) refrigerants. To prevent system contamination all refrigerants used in mobile air conditioning vapor compression systems require unique service fittings. The unique service fittings minimize the potential for system refrigerant contamination during service activity. References Applicable Publications—The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE Publications concerning refrigerant vapor compression systems shall apply. SAE PUBLICATION—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAEJ2197—HFC-134a (R-134a) Service Hose Fittings for Automotive Air-Conditioning Service Equipment ASHRAE PUBLICATION—Available from ASHRAE, 17191 Tullie Circle NE, Atlanta, GA 30329-2305. ASHRAE 34 and Safety Classification of Refrigerants 3. Definitions: 3.0 A mechanical vapor compression refrigerant system (also referred to simply as a refrigerant system) is used for conditioning the airflow for a passenger compartment of a motor vehicle. An A/C system is designed for working in cooling mode only. A Heat Pump system is designed for working in cooling and heating modes. 3.1 These Systems can consist of: a. A pump or compressor that raises the pressure of the refrigerant vapor and, in so doing, also raises its temperature. b. An outdoor heat exchanger for rejecting heat to the ambient environment in an A/C system Or an outdoor heat exchanger for absorbing heat from the ambient environment or other energy source in a heat pump system.

Proposed revisions SAE J639 Rev 22 January 12, 2004 2 of 17

c. An expansion device or other refrigerant metering device that regulates the refrigerant flow in the refrigerant cycle and/or controls refrigerant pressure. d. A passenger compartment (indoor) heat exchanger acting in an A/C system in cooling mode as an evaporator, wherein the liquid refrigerant vaporizes, because of the heat it absorbs from the air passing over the evaporator surface, Or – An indoor heat exchanger acting as a gas cooler or condenser and rejecting heat to the passenger compartment in a heat pump system in heating mode. Or – A secondary loop indoor heat exchanger acting as a cooling/heating core operating with a non-evaporative cooling media. A chiller heat exchanger is utilized with the secondary loop system where the non-evaporative heat transfer fluid is cooled with the primary refrigerant. This isolates the passenger compartment airflow from the primary refrigerant. e. The system may require sensors, wiring, hoses, tubing, connections, a means of driving the compressor and the evaporator blower, a means of cooling the condenser or gas cooler, and non-evaporative heat transfer fluid circulating pump. f. A refrigerant storage device(s), which may also contain desiccant material for moisture adsorption. g. An internal heat exchanger that transfers heat from the high-pressure to the low-pressure side of the refrigerant system. h. Mode selecting valves to switch a Heat Pump System between cooling and heating modes 3.2 A pressure relief device is a pressure, not temperature, actuated valve or rupture membrane designed to automatically relieve pressure in order not to exceed the maximum pressure. The maximum pressure is defined for each refrigerant in this standard. 3.3 Burst Pressure: ASHRAE ???? Requires information 4. Refrigerants 4.1 Refrigerants contained in components that are directly exposed to the passenger compartment or air handling system, including blends of refrigerants, both in their original composition and in compositions created as a result of normal refrigerant system operating conditions, shall be of low toxicity, nonflammable, and non-explosive as defined in the American Society of Heating, Refrigeration, and Air Conditioning Engineers, Inc., Standard ANSI/ASHRAE 34. 4.2 Refrigerants not meeting the guidelines of 4.1 shall meet the following criteria. 4.2.1 Rationale: Existing systems are considered safe from the perspectives of toxicity and flammability. The following would provide assurance of comparable conditions. 4.2.2 For refrigerants contained in components that are located within the passenger compartment, or in direct contact with passenger compartment airflow (e.g., evaporators and associated lines and fittings), system design shall be such that neither a harmful nor a flammable condition will result from a release of refrigerant or combustion products descendant from the refrigerant into the passenger compartment. Applicable threshold concentrations shall be those identified by recognized cognizant authorities for toxicity and flammability.

Proposed revisions SAE J639 Rev 22 January 12, 2004 3 of 17

4.2.3 Discharge of system refrigerant, to meet 4.2.2., in the case of an accident or significant leak/release into the passenger compartment. 4.2.3.1 Because uncontrolled refrigerant discharge can occur due to (1) an imminent crash situation and in (2) the case of a significant leak from the heat exchanger or piping in the HVAC case, a rapid controlled refrigerant system discharge device is both preferred and acceptable. 4.2.3.2 Rapid refrigerant discharge device controls requiring electric power, in case of an vehicle accident and electrical power is interrupted, discharge must occur while such vehicle electrical power is available. 4.3 System design shall be such that neither a harmful nor a flammable condition will result from a release of the system refrigerant charge or combustion products descendant from the refrigerant into the air space of an enclosure used to house the vehicle (i.e. garage). Applicable threshold concentrations shall not exceed those identified by recognized cognizant authorities for toxicity and flammability 5. Safety Practices—The following safety practices are required for all refrigerant systems covered by this specification: 5.1 Refrigerant Sensing Devices Sensing devices (e.g. pressure, temperature) mounted on a component or line/hose of the refrigerant system, and in direct contact with the refrigerant, shall have the following characteristics: 5.1.1. Components that can be removed while the system is still under pressure shall use a female thread and the fitting where the connection is made shall have a male thread with a valve core. 5.1.2. Components that cannot be removed while the system is still under pressure shall use a male thread and the fitting where the connection is made shall have a female thread. Replacement of the component requires complete removal of the refrigerant from the system. If the system still contains pressure, the component shall have sufficient thread length so that a small, controlled refrigerant release, alerting the servicing personnel, will occur before total mechanical separation. 5.2 Refrigerant High Pressure Circuit The high-pressure side of the A/C-System is defined as the refrigerant system from the compressor discharge chamber to the expansion device inlet chamber. 5.2.1 The refrigerant high-pressure side shall have a pressure relief device located in 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. The discharging of refrigerant from all pressure relief devices shall be directed or shielded so as to minimize its release toward personnel servicing or repairing the vehicle. 5.2.2 Unused components (those components not previously subjected to fatigue stresses) on the high-pressure side of the system shall have an ultimate burst pressure not less than two times the maximum pressure. Additional, refrigerant-specific, requirements are noted in the applicable refrigerant section(s).

Proposed revisions SAE J639 Rev 22 January 12, 2004 4 of 17

5.2.3 To prevent unnecessary discharge of refrigerant during operation, the system shall have a means to limit the compressor operation before a pressure relief device will vent refrigerant. 5.3 Refrigerant Low Pressure Circuit The low-pressure side of the A/C-System is defined as all parts of the refrigerant system not included in the definition of 5.2. 5.3.1 Unused Components (those components not previously subjected to fatigue stresses) on the low-pressure side of the system shall have an ultimate burst pressure not less than two times the maximum low side pressure. For refrigerants with critical temperature above 54°C, the maximum low side pressure is defined as the refrigerant’s saturation pressure at 54°C (129F). For refrigerants with critical temperatures below 54°C, see the specific refrigerant section(s) for maximum low side pressure. This prevents bursting of the component under all operating and climatic conditions. 5.3.2 Components designed for the low-pressure side in cooling mode that are used in heating mode, on the high-pressure side of the refrigerant system shall have an ultimate burst pressure not less than two times the maximum heat pump operating pressure. 5.3.3 The pressure relief device, if required, shall be vented outside of the passenger and baggage compartments and air-circulating system for the passenger compartment. The discharge of all pressure relief devices shall be directed or shielded so as to minimize direct release toward personnel involved in servicing/or repair activity. 5.4 Refrigerant System Service Fittings (Ports) 5.4.1 The system shall have a low side and a high side service fitting. To prevent connection of a low-pressure container or service equipment to the high-pressure side of the system, service fittings for the high-pressure side refrigerant circuit shall be mechanically dissimilar from the low-pressure side service fitting. The service fittings shall not be similar to those of other refrigerants identified in this standard. 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 average leakage rate of tube connections of the refrigerant circuit. 5.4.2 CFC-12 (R-12) service fittings are included for reference purposes for conversion of service fittings, via adapters, for retrofit to HFC-134a. 5.4.3 Quick release service charge couplings used in conjunction with fittings in Figures 3 through 8 shall have a pressure relief feature to prevent coupling blow-off during installation and removal. The coupler depressor shall provide a self-alignment feature. 5.4.3.1 Charge couplings used in conjunction with fittings in Figures 3 through 8 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 9), 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.

Proposed revisions SAE J639 Rev 22 January 12, 2004 5 of 17

5.4.3.2 For 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. 5.1 Compressor Design All compressor housing(s) components which enclose reciprocating, rotating or orbiting components such as pistons, vanes, scrolls, shafts, drive plates, linkages, swashplates, wobble plates, connecting rods etc, whose motion is proportional to the drive shaft rotation speed, shall be constructed of materials that are demonstrated capable to withstand internal catastrophic mechanism component fatigue fracture, or other worse case failure without causing rupture or fragmentation of the housings wall, while under typical operating system pressures. This shall be demonstrated by means of worse case destructive testing; the housing(s) wall may breach by crack or permanent deformation, losing pressure during this test, but must not eject component or housings fragments of any kind. The worse case test shall be determined using FMEA analysis techniques during the development of the compressor, identified to pose the greatest severity to safety. 6.0 HFC-134a Refrigerant 6.1 The refrigerant system shall have a self-sealing pressure relief device as identified in 5.2. In no case shall the maximum release (blow off) pressure be greater than 4.14 MPa (600 psig). 6.2 To 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 5.4.1. No external threads shall be allowed on the fittings in Figures 3 and 4. 6.3 Charge couplings used in conjunction with fittings in Figures 3 & 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 7), has a pin location at breach of seal of 6.1 mm to 7.1mm from the face of the fitting. (Breach of seal means when valve starts to open.) Minimum depressor travel shall 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 7—PIN CONVEX RADIUS OF 1.9 mm 6.4 For 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. 7. HFC-152a Refrigerants 7.1 The system shall have a self-sealing pressure relief device as identified in 5.2. In no case shall the maximum release (blow off) pressure be greater than 4.14 MPa (600 psig). 7.2 Design of service fittings Figures 7 and 8

Proposed revisions SAE J639 Rev 22 January 12, 2004 6 of 17

8. Carbon Dioxide -744 Refrigerant 8.1 Pressure levels 8.1.1 The maximum pressure on the high-pressure side shall not exceed 17.6 MPa (2550 psig). The maximum pressure on the low-pressure side shall not exceed 13.2 MPa (1915 psig). 8.1.2 The system shall have a pressure relief device on both high and low pressure sides. In no case shall the maximum release (blow off) pressure be greater than the specified maximum pressure 8.1.3 Unused components (those components not previously subjected to fatigue stresses) of the system, which may be subject to tensile strength reduction as a consequence of temperature or pressure (i.e. compressor outlet chamber, gas cooler, and connecting piping between these components) shall have an ultimate burst pressure greater than two times its maximum pressure at the highest component operating temperature. 8.1.4 In addition, components of the system which may be subject to tensile strength reduction as a consequence of temperature or pressure shall be tested as follows. 8.1.4.1 The components shall be exposed to the appropriate system operating conditions to simulate the specified refrigerant system life (temperature, pressure, pressure cycling, vibration, corrosion) to simulate vehicle usage. 8.1.4.2 The burst pressure shall not be less than 1.5 times the maximum pressure when tested at the highest component operating temperature after exposure to these conditions. 8.1.5 Adjacent cavities internal to the compressor which are exposed to a pressure difference during system operation (high-side pressure adjacent to low-side pressure), shall be burst tested at worse case conditions as follows: cavities exposed to the high-side pressure shall be burst tested at twice the maximum high-side pressure, 35.2 MPa (5100 psi) while the adjacent low- side pressure cavity is maintained at a pressure not to exceed the maximum low-side pressure, 26.4 Mpa (1915 psi). This test applies separately to both: (1) the discharge chamber adjacent to the suction chamber and (2) the crankcase chamber adjacent to the discharge chamber. The test shall be conducted at the highest component operating temperature. 8.2 Pressure Relief Device The device on the high-pressure side shall have a red identification color. The device on the low-pressure side shall have a blue identification color. The high pressure and low-pressure devices shall not be interchangeable. If threaded, the devices shall have male metric thread sizes, M10x1 for high pressure and M9x1 for low pressure. 8.3 Design of Service Fittings 8.3.1 High side fitting shall be located downstream of the gas cooler outlet. (A/C operation mode only) The high side fitting shall be located only on the higher-pressure side of the

Proposed revisions SAE J639 Rev 22 January 12, 2004 7 of 17

refrigeration cycle regardless of operating mode. The low side fitting shall be located only on the lower pressure side of the refrigeration cycle regardless of operating mode. The high side fitting shall be larger diameter than the low side fitting. 8.3.2 The quick connect service couplers shall have a separate and distinct action (screw, lever, etc) to open and close the service valve in addition to the coupler quick connect attachment to the valve housing. Also, the service coupler must not uncouple from the service valve with the valve open. 8.3.3 The service-fitting cap must not pose a safety hazard (projectile, harmful spray of

refrigerant, etc) when removed. 8.3.4 The external service fitting design is found in figures 5 and 6. 9.0 Cautionary requirements 9.1 Cautionary Statements [Common to all refrigerants]—For all refrigerants, the safe handling procedures should be followed as designated by the refrigerant manufacturer’s Material Safety Data Sheet (MSDS). 9.1.0 Lubricants. Use only the lubricant specified for service by the original equipment manufacturer for the refrigerant system. Use of incorrect lubricant (type/viscosity) may result in premature failure of compressor. 9.1.1 Additional health and safety information may be obtained from lubricant and refrigerant manufacturers. 9.1.2 Cautionary statements are provided to alert the mobile A/C industry to the inadvisability and the possible health and safety effects associated with venting refrigerant into the workspace. It is intended that these cautionary statements (or equivalent language) be minimum required for inclusion in all publications dealing with the servicing of refrigerant mobile A/C systems. 9.1.3 Caution: Avoid breathing A/C refrigerant and lubricant vapor or mist. To remove refrigerant from the A/C system, use service equipment designed for recovery that are certified to meet the requirements of the appropriate SAE Standards. 9.2 HFC-134a Refrigerant 9.2.1 Caution—To remove HFC-134a (R-134a) from the A/C system, 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). When retrofitting, 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). 9.2.2 Caution—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. Combustion may produce toxic products. Stop engine during charging / emptying the AC system. 9.3 HFC-152a Refrigerants

Proposed revisions SAE J639 Rev 22 January 12, 2004 8 of 17

9.3.1 Refrigerant System charging should only be done with charging equipment certified to meet the appropriate SAE J Standards. To remove refrigerant from the A/C system, use service equipment certified to meet the requirements of SAE Standards for HFC-152a (R-152a). 9.3.2 Caution— HFC-152a (R-152a) is a flammable refrigerant. Do not pressure test or leak test HFC-152a (R-152a) service equipment and/or vehicle A/C systems with compressed air during repair or modification. Mixtures of R152a and air, can be combustible inside and outside the vehicle A/C system. These mixtures, if ignited, may cause injury or property damage. Combustion may produce toxic products. Stop engine during charging / emptying the AC system. 9.3.3 When servicing the system appropriate grounding procedures shall be used. 9.4 Carbon Dioxide R-744 Refrigerant 9.4.1 Carbon Dioxide R-744 Refrigerant System charging should only be done with charging equipment certified to meet the appropriate SAE J Standards due to high system pressure. Stop engine during charging / emptying the AC system. 10. Additional requirements 10.1 A plainly legible and durable nameplate 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 that is not normally replaced during service as a result of repair or vehicle accident damage (i.e. do not attach to radiator support, hood). The nameplate or tag shall include identification of the refrigerant, shall indicate; if flammable, potentially toxic, the lubricant type, and the amount of refrigerant charge. If flammable the label shall include the symbol in 10.5 red in color. The nameplate or tag shall contain 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 CONTAINS REFRIGERANT XXX UNDER HIGH PRESSURE-TO BE SERVICED ONLY BY QUALIFIED PERSONNEL” (XXX should be replaced by actual refrigerant type.) 10.2 The vehicle owner’s manual shall include, or reference, identification of the refrigerant, shall indicate if; flammable, potentially toxic, the lubricant type, and the recommended amount of refrigerant charge, or the owner’s manual shall contain information where this information can be found on the vehicle or from another source. 10.3 SAE J1739 - Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA), and Potential Failure Mode and Effects Analysis for Machinery

Proposed revisions SAE J639 Rev 22 January 12, 2004 9 of 17

(Machinery FMEA) shall be applied to the design and development of mobile air conditioning refrigerant systems. 10.4 SAE J1739 - Potential Failure Mode and Effects Analysis (FMEA) shall be applied to the development of service equipment and technician service procedures. 10.5 Flammable Symbol

Proposed revisions SAE J639 Rev 22 January 12, 2004 10 of 17

FIGURE 1—CFC-12 (R-12) LOW-PRESSURE SERVICE VALVE FITTING

Proposed revisions SAE J639 Rev 22 January 12, 2004 11 of 17

FIGURE 2—CFC-12 (R-12) HIGH-PRESSURE SERVICE VALVE FITTING

Proposed revisions SAE J639 Rev 22 January 12, 2004 12 of 17

FIGURE 3—LOW SIDE FOR HFC-134a (R-134a) SERVICE VALVE FITTING

Proposed revisions SAE J639 Rev 22 January 12, 2004 13 of 17

FIGURE 4—HIGH SIDE FOR HFC-134a (R-134a) SERVICE VALVE FITTING

Proposed revisions SAE J639 Rev 22 January 12, 2004 14 of 17

FIGURE 5 LOW SIDE FOR CO2 (R-744) SERVICE VALVE FITTING

FIGURE 6 HIGH SIDE FOR CO2 (R-744) SERVICE VALVE FITTING

Proposed revisions SAE J639 Rev 22 January 12, 2004 15 of 17

FIGURE 7 LOW SIDE FOR HFC-152a Refrigerant SERVICE VALVE FITTING

FIGURE 8 HIGH SIDE FOR HFC-152a Refrigerant SERVICE VALVE FITTING

Proposed revisions SAE J639 Rev 22 January 12, 2004 16 of 17

FIGURE 9 —PIN CONVEX RADIUS OF 1.9 mm Content R134a

High Side Valve

R134a Low Side Valve

R152a High Side Valve

R152a Low Side Valve

CO2 High Side Valve*

CO2 Low Side Valve*

OD 16.0 +- 0.15mm

13.0 +- 0.15mm

16.1+0; -0.2 mm

14.1+0;-0.2 mm

18.1+0, -0.2

16.6+0, -0.2

Pin Location at Breach of Seal

6.1 - 7.1 mm 6.1 - 7.1 mm 10.2 +0; -0.75 mm

10.2 +0; -0.75 mm

5.5 - 4.5mm*

5.5 – 4.5mm *

Coupling Depression Location

7.8 - 8.3 mm 7.8 - 8.3 mm 11.9 - 12.4 mm 11.9 - 12.4 mm 8.0 mm max*

8.0 mm max *

Min Coupling Clearance

18.4 mm 19.4 mm 24 mm 24 mm 27 mm

31 mm

* Note: Alternatives to the traditional pin style valve for CO2 are in development at Visteon and Schrader. 11. Notes 11.1 Marginal 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

Proposed revisions SAE J639 Rev 22 January 12, 2004 17 of 17

revision of the report. PREPARED BY THE SAE INTERIOR CLIMATE CONTROL STANDARDS COMMITTEE Relationship of SAE Standard to ISO Standard The SAE Interior Climate Control Committee will propose this standard as an ISO standard after approval. Application—This document is restricted to mechanical vapor compression refrigerant systems. Reference Section SAEJ2197—HFC-134a (R-134a) Service Hose fittings for Automotive Air-Conditioning Service Equipment ASHRAE 34 Number Designation and Safety Classification of Refrigerants SAE J1739 - Potential Failure Mode and Effects Analysis in Design (Design FMEA) Developed by the SAE Interior Climate Control Standards Committee

SURFACE VEHICLE STANDARD

SERVICE HOSES FOR CFC-12 (R-12), HFC-134a (R-134a) and CO2 (R-744) Mobile Refrigerant Systems

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. Copyright © 2003 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 PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvc@sae.org SAE WEB ADDRESS: http://www.sae.org

Issued Proposed Draft Revised Date Cancelled Date Superseding J2196 Date Jun92

® J2196

ISSUED PropDft xxxxxxx

Proposed STANDARD Revised October 28, 2004 (rev. 12) Issued 1992-06 Reaffirmed 1997-03, 2002-06 and 2003-03 Superseding J2196 JUN92 (Color code): CO2Jxxxx = New J-spec number needed CO2Jxxxx = Revision to existing J-spec Foreword - This Reaffirmed Document has been changed to reflect the new SAE Technical Standards Board Format and support for CO2 refrigerant systems. Scope – This SAE Standard covers reinforced rubber, reinforced thermoplastic, or otherwise constructed hose, or hose assemblies. These hoses are for conducting liquid and gaseous refrigerants from mobile refrigeration systems to service equipment and for internal use in service equipment. 1.1 The hose shall be designed to minimize permeation of refrigerants and contamination of refrigerant passing there through and to be serviceable over a temperature range of -30 to 95°C (-22 to 203°F). Hose working pressure shall be at least 3.4 Mpa, for R-12 and R-134a, and 16 Mpa for R-744. The minimum burst pressure shall be at least 5 times the working pressure. 2. References 2.1 Applicable Publications - The following publications form a part of this specification to the extent specific herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE PUBLICATIONS - Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J51-Automotive Air-Conditioning Hose SAE J513-Refrigerant Flare Fittings SAE J639-Safety Practices for Mechanical Vapor Compression Refrigeration Equipment or System used to Cool Passenger Compartments of Motor Vehicles SAE CO2J2197-Service Hose Fittings SAE J2210-HFC-134a Recycling Equipment for Mobile Air-Conditioning Systems SAE CO2J2210-CO2 (R-744) Refrigerant Removal and R-744/R-134a Charging Equipment for Mobile Refrigerant Systems ARI PUBLICATIONS - Available from Air Conditioning and Refrigeration Institute, 1501 Wilson Boulevard, Sixth Floor, Arlington, VA 22209. ARI 720 - Refrigerant Access Valves and Hose Connectors.

SAE JXXXX Issued Proposed Draft XXXXXXX

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ASTM PUBLICATIONS - Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. ASTM D 380-Methods of Testing Rubber Hoses. Check with UL. 3. Definitions 3.1 High-Side Service Hose - A hose connected between the vehicle high-side service port and the manifold gauge set or equipment. For R-12, it includes a l/4 female refrigeration flare(FFL) nut on both ends and a shutoff device within 30 cm of the end connected to the serviced system or equipment. For R-134a, it includes a high-side coupling, as defined in SAE J639 and a shutoff device within 30 cm of the connection to the serviced system or equipment, and a 1/2 ACME female nut on the other end. A 14mm. male thread fitting in lieu of crimped on high side coupling is optional. For R-744, it includes a 3/8 BSPP 60 degree external cone seat female swivel fitting with internal BSPP 1/4-19 thread on both ends. A 1/4-19 BSPP 60 degree female thread fitting in lieu of crimped on high side coupling is optional. 3.2 Low-Side Service Hose - A hose connected between the vehicle low-side service port and the manifold gauge set or equipment. For R-12, it includes a 1/4 female refrigeration flare (FFL) nut on both ends and a shutoff device within 30 cm of the end connected to the serviced the system or equipment. For R-134a, it includes a low-side coupling, as defined in SAE J639 and a shutoff device within 30 cm of the connection to the serviced system or equipment, and a 1/2 ACME female nut on the other end. A 14mm. male thread fitting in lieu of crimped on low side coupling is optional. For R-744, it includes a 3/8 BSPP 60 degree external cone seat female swivel fitting with internal BSPP 1/4-19 thread on both ends. A 1/4-19 BSPP 60 degree female thread fitting in lieu of crimped low side coupling is optional. 3.3 Utility Hose - A hose connected between the manifold gauge set and the service equipment (vacuum pump, charging equipment, recovery/recycling unit). For R-12, it includes a 1/4 FFL nut on both ends and a shutoff device within 30 cm of the end connected to the serviced system or equipment. For R-134a, it includes a 1/2 ACME female nut on both ends and a shutoff device within 30 cm of the connection to the serviced system or equipment. For R-744, it includes a 3/8 BSPP 60 degree external cone seat female swivel fitting with internal BSPP 1/4-19 thread on both ends. 3.4 Internal Hose -A hose connected between components within the service equipment. It should be a wrench-tight connection or equivalent. 3.5 Charge Coupling, used with R-134a - The female connector intended to be used with the vehicle service fittings (ports) as identified in SAE J639. 3.6 The 1/2 ACME Female Nut For R-134a - The 1/2 ACME thread reduces the chance of cross threading R-134a service hoses resulting in leakage and safety concerns. 3.7 The 3/8 BSPP 60 degree external cone seat female swivel fitting with internal BSPP 1/4-19 thread - Was established for connecting service hoses to R-744 refrigerant system service equipment, as defined in CO2J2210, and couplers, as defined in J639, to prevent cross contamination of refrigerants. After consideration of existing fittings for refrigerants along with manufacturing and safety concerns, it was determined that possible cross threading could occur. Establishment of the 3/8 BSPP 60° female swivel fitting is intended to reduces the chance of cross threading service hoses resulting in leakage and safety concerns. 4. Hose Assembly Construction 4.1 R-12 Hose 4.1.1 No color, fitting restrictions, or shutoff device requirements shall apply to internal hoses. 4.1.2 High-side service hoses, low-side service hoses, and utility hoses shall be constructed with 1/4 FFL nuts on both ends and shall have a shutoff device within 30 cm of one end of the hose.

SAE JXXXX Issued Proposed Draft XXXXXXX

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4.1.3 A valve core depressor shall be provided on the same end of the hose as the shutoff device. In most cases, valve core pins on the male fittings are located per ARI Standard 720 refrigerant access valves and hose connectors, but other locations have been used. 4.1.4 Adapters will be used to account for different high-side vehicle service fittings per SAE J639. 4.1.5 Colors for various hoses shall be: 4.1.5.1 Low-Side Service Hose - Solid blue is preferred with optional black with continuous blue stripe. 4.1.5.2 High-Side Service Hose - Solid red is preferred with optional black with continuous red stripe. 4.1.5.3 Utility Hose - Solid yellow or solid white is preferred with optional black with yellow or white continuous stripe. 4.1.5.4 Additional marking as noted in Section 6. 4.2 R-134a Hose 4.2.1 No color, fitting restrictions, or shutoff device requirements shall apply to internal hoses. 4.2.2 High-side service hose and low-side service hose shall be constructed with the charge coupling on one end, a 1/2 ACME female nut per SAE J2197 on the other end, and a shutoff device within 30 cm of the charge coupling end. Charge couplings for high and low-side shall meet the requirements and be compatible as defined in SAE J639. 4.2.3 Utility hose shall have 1/2 ACME female nut per SAE J2197 on both ends and a shutoff device within 30 cm of one end. The end with the shutoff device shall also include a valve core depressor compatible with SAE J2197. 4.2.4 Colors for various hoses shall be: 4.2.4.1 Low-Side Service Hose - Solid blue with black stripe. 4.2.4.2 High-Side Service Hose - Solid red with black stripe. 4.2.4.3 Utility Hose - Solid yellow with black stripe. 4.2.4.4 See Figure 1 for stripe and marking detail.

SAE J2196/ R134a

SAE J2196

HFC-134a PRINTING & STRIPE 3mm MINIMUM REPEAT I.D. SPACING 30cm MAXIMUM MANUFACTURER ASSEMBLER INFORMATION 180 DEGREE

CFC-12

FIGURE 1 – SERVICE HOSE

SAE JXXXX Issued Proposed Draft XXXXXXX

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4.3 R-744 Hose 4.3.1 No color, fitting restrictions, or shutoff device requirements shall apply to internal hoses. 4.3.2 High-side service hose and low-side service hose shall be constructed with the service coupling or 3/8 BSPP 60° external cone seat female swivel fitting with internal BSPP 1/4-19 thread fitting on one end, and a 3/8 BSPP 60° external cone seat female swivel fitting with internal BSPP 1/4-19 thread fitting on the other end per SAE CO2J2197. Service couplings for high and low-side shall meet the requirements and be compatible as defined in SAE CO2J639. 4.3.3 See Figure 2 for marking detail.

FIGURE 2 – CO2 SERVICE HOSE

5. Hose Identification 5.1 The hose shall be identified with "SAEJ2196" marking. For R-134 refrigerant, "SAEJ2196/R134a" marking is required. For R-744 refrigerant, "SAEJ2196/R744(CO2)" marking is required. 5.2 On R-134a hoses, the refrigerant designation is associated with the stripe and identified in Figure 1. 5.3 Manufacturer’s and assembler identification shall be located on the external surface of the hose 180 degrees from the refrigerant marking as identified in Figure 1. 5.4 The external hose identification should be durable for the life of the hose. 5.4.1 The printed information and stripe as required shall be 3 mm minimum in height, and shall be repeated, not to exceed a distance of 30 cm between start and end of the identification. 5.5 On R-744 hoses, the refrigerant designation is identified in Figure 2. 5.6 Manufacturer’s and assembler identification shall be located on the external surface of the hose 180 degrees from the refrigerant marking as identified in Figure 2. 5.7 The external hose identification should be durable for the life of the hose. 5.7.1 The printed information as required shall be 3mm minimum in height, and shall be repeated, not to exceed a distance of 30 cm between start and end of the identification. 6.Testing - The test procedure described in the current ASTM D 380, shall be followed whenever applicable. 6.1 Test Conditions 6.1.1 The temperature of the testing chamber shall be maintained at 23°C ± 2°C (73°F ±4°F). 6.2 Refrigerant Containment – This section R-12 and R-134a hoses only 66..22..11 TTeesstt hhoossee aasssseemmbblliieess sshhaallll nnoott ppeerrmmiitt rreeffrriiggeerraanntt lloossss ooff mmaarrkkeedd rreeffrriiggeerraanntt ((RR--1122,, RR--113344aa)) aatt aa rraattee ggrreeaatteerr tthhaann 11..00 kkgg//mm22//yyeeaarr ((00..22 llbbss//fftt22//yyeeaarr)) wwhheenn tteesstteedd aatt 4499°°CC ±± 22°° ((112200°°FF ±± 44°°FF)).. 6.2.2 The containment test is designed to measure, by loss of mass, the rate of refrigerant loss. 6.2.3 The apparatus required consists of canisters with internal volumes of 475 to 1000 cm3 and a 21 MPa minimum burst pressure with appropriate fittings to connect to the hose assemblies, halogen detector, circulating air oven capable of maintaining uniform test temperature throughout the test periods, and a weight scale capable of mass measurements to 0.1 g accuracy.

SAE J2196/ R744 (CO2)

SAE JXXXX Issued Proposed Draft XXXXXXX

- 5 -

6.2.4 TEST SAMPLE PREPARATION 6.2.4.1 Four hose assemblies, having a free hose length of 1 m, are to be tested. 6.2.4.2 Three of the hose assemblies shall be used for determining the loss of refrigerant and the fourth assembly shall be run as an empty plugged blank to be used as the reference for determining the mass loss of the other hoses. 6.2.4.3 Measure the free length of hose in each assembly at zero gauge pressure to the nearest 1 mm. Connect each of the four hose assemblies to a canister and obtain the total mass of each test unit including end plugs to the nearest 0.1 g. 6.2.4.4 Load three of the test hose assemblies with 0.6 g of liquid refrigerant per cm3 of each test hose volume to a total variance of ± 5 g. 6.2.4.5 Check the loaded test hose assembly with a halogen detector at a sensitivity of 11 g/year to be sure that they do not leak. Any suitable method for safely loading may be used. 6.2.5 TEST PROCEDURE 6.2.5.1 Weigh the test samples and record the mass (weight) of each sample. 6.2.5.2 Place the three loaded and one blank (uncharged) test units in the air oven at the specified temperature (49°C/120°F) for a period of 30 min ± 5 min drive off moisture. 6.2.5.2.1 Do not bend the test sample hose in a curve with a diameter smaller than 20 times the outside diameter of the hose while in the oven. 6.2.5.3 Remove the loaded test sample units from the oven and weigh. 6.2.5.4 Check the test samples for leakage and weigh all samples not less than 15 min or more than 30 min after removal from the oven. 6.2.5.5 Weigh the samples and compare the mass as recorded in 6.2.5.1 to determine if the test samples have lost the test refrigerant charge. 6.2.5.6 If the samples contain a refrigerant charge, use the mass recorded in 6.2.5.5 as the original mass for future weight loss comparison. Place the test samples back in the air oven, within 1 h after completion of 6.2.5.6, at the specified temperature for 24 h. At the end of the 24 h period, remove the test samples, weigh and record the data in the same manner as previously specified, and return the test samples to the oven. If a loss of 20 g or greater occurs, discontinue the test, check for leaks, and repeat the procedure as defined in 6.2.5.2. 6.2.5.7 The first 24 h period is considered the preconditioning period. If the test samples as checked in 6.2.5.9 have not leaked, consider this recorded mass as the initial mass value. 6.2.5.8 Return the samples to the oven for 72 h. Remove the samples from the oven and weigh and record the mass in the same manner as previously described. 6.2.5.9 Calculate the 72 h mass loss and determine the effusion rate by subtracting the corresponding mass of the blank from that of the loaded test sample unit. Express the refrigerant loss rate in kg/m2/year.

SAE JXXXX Issued Proposed Draft XXXXXXX

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Calculate the rate of loss of refrigerant mass for the

loaded test sample unit as follows: 6.3 Refrigerant/Oil (Lubricant) Exposure 6.3.1 Three 457 mm long samples of the hose assembly are required for this test. The hose shall remain intact for this test. 6.3.2 The hose shall be filled to 70% capacity with a mixture of 95% refrigerant and 5% refrigerant lubricant. 6.3.2.1 Testing for R-12 hoses shall use SUNISO 5GS oil or equivalent. 6.3.2.2 Testing for R-134a hoses shall use ICI products lubricant (PAG) EMKAROX RL 118 or equivalent. 6.3.2.3 Testing for R-744 shall use ICI products lubricant or alternative. Alternative may be an OE selected oil including a mixture or series of tests using PAG or POE. 6.3.3 The hose assemblies containing the refrigerant/lubricant mixture shall be immersed in IRM 903 at 80°C (176°F) for 168 h. 6.3.4 Immediately following the exposure test, the test sample shall withstand, without failure, the tensile test of the assembly required in 6.8 and the burst pressure in 6.7.

SAE JXXXX Issued Proposed Draft XXXXXXX

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6.4 Vacuum Test 6.4.1 The test sample hose shall have a free length of 610 mm. 6.4.1.1 The collapse of the hose shall not exceed 20% of the original outside diameter when subjected to reduced pressure vacuum) of 1000 pm of Hg (microns) absolute for 2 min. 6.4.1.2 Bend the test hose assembly to a “U" shape with the inside radius at the base of the “U” being 20 times the nominal size of the hose. 6.4.1.3 Apply a reduced pressure (vacuum) of 1000 pm absolute to the bent hose assembly for 2 min. At the end of the 2 min period, while the hose is still under reduced pressure, measure the outside diameter of the hose at the base of the "U" to determine the minimum diameter in any plane. 6.5 Aging Test 6.5.1 The test sample hose shall show no cracks or other disintegration when tested as specified after aging at 95°C ± 2°C (203°F ± 4°F) for 168 h. 6.5.2 The test sample hose, which had been used for vacuum testing in 6.4, shall have a length of 610 mm. 6.5.3 Fill the interior of the hose with nitrogen to atmospheric pressure and cap the open ends. 6.5.4 The hose assembly shall be wrapped around a mandrel (metal tube) having a diameter 20 times the nominal hose size as defined in Chart 1 of 5.1. 6.5.5 Place the test sample in the air circulation oven for the time and temperature defined in 6.5.1. 6.5.6 After removal from the oven, allow the hose assembly to cool to room temperature, then remove it from the mandrel and lay in a straight length, and examine the hose for external cracks or other disintegration. 6.5.7 Load the hose with nitrogen to 2.4 MPa (348 psi) for R-12 and R-134a and 11 MPa (1595 psi) for R-744. 6.5.8 Place the hose assembly under water. 6.5.8.1 Inspect after 5 min and report any bubbling from the hose assembly as evidence of cracking or disintegration. 6.6 Cold Test 6.6.1 The hose shall show no evidence of cracking or breaking when tested as specified. 6.6.2 The test sample hose shall have a length of 457 mm. 6.6.3 Fill the interior of the hose with the appropriate refrigerant to 70% of capacity at room temperature (24°C/75°F) and plug the open ends. 6.6.4 Place the test sample in an air circulation oven at 70°C ± 2°C (158°F ± 4°F) for 48 h. 6.6.5 Remove the hose assembly from the oven and allow it to cool to room temperature. 6.6.6 Place the hose assembly in a straight position along with a mandrel (metal tube), having a diameter 20 times the nominal hose size as defined in Chart 1 of 5.1, in a cold chamber at - 30°C ± 2°C (86°F ± 4°F) for 24 h. 6.6.7 After 24 h, without removing the test material from the cold chamber, bend the hose through 180 degrees over the mandrel at a uniform rate within a time period of 4 to 8 s. 6.6.8 Remove the hose assembly from the cold chamber and allow to warm to room temperature. 6.6.9 Place the hose assembly under an internal hydrostatic pressure of 2.4 Mpa (348 psi) for R-12 and R 134a and 11 MPa (1595 psi) for a 5 min period. 6.6.10 Inspect and report any leakage from the hose assembly as evidence of cracking or disintegration. 6.7 Bursting Strength 6.7.1 For R-12 and R-134a the minimum bursting strength for all hose assemblies shall be 17.2 MPa (2494 psi) and 80 MPa (11,600 psi) for R-744. Perform hydrostatic test per ASTM D 380 using the "Straight Bursting Test Method." 6.8 Tensile Test of Hose Assembly

SAE JXXXX Issued Proposed Draft XXXXXXX

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6.8.1 The minimum force required to pull the hose adapter and separate the hose from the coupling shall not be less than 534N (120 lbs.). 6.8.2 The test hose shall have a minimum free hose length of 300 mm. 6.8.3 The hose assembly shall be mounted to a test apparatus having a crosshead speed not to exceed 25 mm per minute.

SAE J2196 Reaffirmed MAR97 Rationale—Not applicable. Relationship of SAE Standard to ISO Standard—Not applicable. PREPARED BY THE SAE INTERIOR CLIMATE CONTROL STANDARDS COMMITTEE

TABLE 1 – USE THE TTITLE STYLE TAG FOR THE TITLE AND INSERT TABLE BELOW

FIGURE 1—USE THE FIGTITLE STYLE FOR THE FIGURE TITLE

ONCE THE GRAPHIC IS INSERTED, CLICK ON THE GRAPHIC TO HIGHLIGHT AND APPLY THE FIGURE STYLE TAG

PREPARED BY THE SAE XXXX (USE THE PREPAREDBY STYLE TAG)

SAE JXXXX Issued Proposed Draft XXXXXXX

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Rationale

The heading above uses the Rationale style tag. This paragraph is the Body style tag. The Body style tag should be used for all paragraphs in the rationale statement.

Relationship of SAE Standard to ISO Standard

The heading above is the Relationship style tag. This paragraph is the Body style tag.

Reference Section (RefSectionHead style tag)

SAE J551—The RefItems style tag is used to list the documents.

Developed By (DevelopedBy style tag)

Sponsored By (SponsoredBy style tag)

SURFACE VEHICLE STANDARD

CO2 (R-744) SERVICE HOSE AND EQUIPMENT FITTINGS FOR MOBILE REFRIGERANT SYSTEMS SERVICE EQUIPMENT.

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. Copyright © 2003 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 PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvc@sae.org SAE WEB ADDRESS: http://www.sae.org

Issued Proposed Draft Revised Date Cancelled Date Superseding JXXXX Date

Proposed

® JXXXX

ISSUED PropDft xxxxxxx

October 28, 2004 (Color code): CO2Jxxxx = New Jspec number needed

CO2Jxxxx = Revision to existing Jspec Forward: The purpose of this SAE Standard is to establish specific fittings for service equipment used in servicing CO2 (R-744) mobile refrigerant systems. This is necessary to avoid cross mixing of refrigerants, lubricants and leak detection dyes from other types of systems. This is also necessary to prevent connection of equipment designed for low pressure systems to a high pressure R-744 system. 1. Scope

1.1 This SAE Standard covers fittings intended for connecting service hoses, per SAE CO2J2196, from Mobile Refrigerant Systems to service equipment such as manifold gauges, vacuum pumps and refrigerant removal and charging equipment. (Figure 1) This fitting is physically different in size and connection thread type from current known fittings used in R-12 or R-134a service equipment or mobile refrigerant systems. It is a known standard type of fitting which provides the strength required for safe handling of high pressure gases. Its size difference will also reduce the potential of cross-threading service hoses on R-12 and R-134a refrigerant storage containers and service equipment. 2. References

2.1 Applicable Publications: The following publications form a part of this specification to the extent specified herein. The latest issues of SAE Publications shall apply.

2.1.1 SAE PULICATIONS- Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE CO2J2196- Service Hose for Mobile Refrigerant Systems SAE CO2J2210- CO2 (R-744) Refrigerant Removal and R-744/R-134a Charging Equipment for Mobile Refrigerant Systems 3. Specification and Application Description

3.1 3/8 BSPP 60 degree internal cone seat Male Fitting with external BSPP 1/4-19 Pipe Thread (Figure 2)

SAE JXXXX Issued Proposed Draft XXXXXXX

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3.1.1 This connection shall be used on all R-744 service equipment including the service coupler hose connections, manifold gauge hose connections, utility hose connection to the vacuum pump, and refrigerant removal and charging equipment as defined in SAE CO2J2210. 4. Functional Description

4.1 The high-pressure, low-pressure and utility hose assemblies shall meet SAE CO2J2196 requirements and will be terminated at both ends with a 3/8 BSPP 60° external cone seat female swivel fitting with internal BSPP 1/4-19 thread.

4.2 Refrigerant system service equipment including manifold gauge assemblies, high side and low side couplers, refrigerant removal and charging equipment, and stand-alone vacuum pumps shall include 3/8 BSPP 60° internal cone seat male fittings with 1/4-19 BSPP external thread connections. (Figure 2)

4.3 Both male fittings and female fittings must be reusable a minimum of 10 times at the recommended tightening torque.

4.4 The recommended tightening torque for brass fittings is 17.6±2.7 Nm (13 ±2 ft.-lbs). The recommended tightening torque for steel fittings is 25.8±2.7 Nm (19 ±2 ft.-lbs).

FIGURE 1 – R-744 SERVICE EQUIPMENT

HOSE CONNECTIONS TOMANIFOLD GAGE ANDREMOVAL - CHARGING EQUIPMENT:¼ - 19 BSPP 60° CONE

SERVICE HOSE

TO VEHICLE

DETAIL OF OPTIONAL:¼ - 19 BSPP 60° CONE

TO SERVICE EQUIPMENT:¼ - 19 BSPP 60° CONE

SAE JXXXX Issued Proposed Draft XXXXXXX

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FIGURE 2 - 3/8 BSPP 60° internal cone seat male fitting with 1/4-19 BSPP external thread connection shown. (BSPT external thread with 60° internal cone seat is optional)

PREPARED BY THE SAE XXXX (USE THE PREPAREDBY STYLE TAG)

SAE JXXXX Issued Proposed Draft XXXXXXX

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Rationale

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Relationship of SAE Standard to ISO Standard

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Reference Section (RefSectionHead style tag)

SAE J551—The RefItems style tag is used to list the documents.

Developed By (DevelopedBy style tag)

Sponsored By (SponsoredBy style tag)

SURFACE VEHICLE STANDARD

Refrigerant Purity and Container Requirements For Carbon Dioxide (CO2 R-744) Used In Mobile

Air-Conditioning Systems February 2004

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. Copyright © 2003 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 PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvc@sae.org SAE WEB ADDRESS: http://www.sae.org

Issued Proposed Draft Revised Date Cancelled Date Superseding JXXXX Date

® J2683

ISSUED PropDft xxxxxxx

Foreword—The purpose of this SAE Standard is to establish the minimum level of purity required and

container specifications for Carbon dioxide (CO2) refrigerant use in, mobile air-conditioning (A/C) systems.

1. Scope—This SAE Standard applies to Carbon Dioxide R-744 refrigerant used to service motor vehicle passenger air-conditioning (A/C) systems designed to use CO2 (R-744). Hermetically sealed, refrigerated cargo systems are not covered by this document. 2. References 2.1 Applicable Publications—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 PUBLICATIONS—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE Jxx—Criteria for Refrigerant Identification Equipment for Use with Mobile Air-Conditioning Systems SAE Jxx—Recommended Service Procedure for the Containment of CO2 (R-744) 3. Purity Specification—The refrigerant referred to in this document shall not exceed the following

levels: 3.1 Purity 99.5% 3.2 Moisture—Maximum Impurity (Mole%) 120 ppm (Dew Point colder than -40°F) 4.0 Container Requirements and Identification (Capacity up to 95 Pounds) 4.1 Standard Valve Outlet Connection CGA 320 ( For 0-3000psi) 4.2 UN Number: UN 1013 4.3 DOT Identification: Carbon Dioxide 4.4 Hazard Class / Division: 2.2 4.5 DOT Label: Non-Flammable Gas 4.6 CAS Number: 124-28-9 5. Notes 5.1 Marginal 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 JXXXX Issued Proposed Draft XXXXXXX

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