SAE J2842 R-1234yf and R744 Design Criteria and Certification

The purpose of the standard "SAE J2842 OEM mobile air conditioning evaporator and service replacements for R-1234yf and R-744 design criteria and certification," developed by the American Society of Automotive Engineers (SAE), is to establish a framework to ensure that all evaporators for R-744 and R-1234yf mobile air conditioning systems meet appropriate testing and labeling requirements. The SAE J639 standard requires vehicle manufacturers to conduct assessments to minimize reasonable risks in production mobile air conditioning systems. The evaporator (as designed and manufactured) must be part of this risk assessment, and it is the vehicle manufacturer's responsibility to ensure that all relevant aspects of the evaporator are included.

It is the responsibility of all vehicle or vaporizer manufacturers to at least comply with the criteria of this standard. (Variations of certain test procedures by vehicle manufacturers may be acceptable if they correlate well with field return data.) Where appropriate, this standard may be used as a guide to support risk assessments.

In terms of certification, most vehicle manufacturers have established formal production part approval processes through which compliance certification is established and officially documented. For a vaporizer manufacturer of non-original equipment parts (or a vehicle manufacturer without a formal part compliance certification process), the certification described in this standard is the requirement to which these vaporizers must comply. In this case, the vaporizer manufacturer or an independent agency will complete the vaporizer certification according to SAE J2911. An example of the latter would be the completion of witness testing by the vaporizer manufacturer and the submission of certification documentation by the witness agency.

This standard does not apply to R-134a refrigerant evaporators, as this refrigerant has been proven in use. R-152a is also excluded due to the requirement for a secondary loop refrigerant system.

SAE J2842 is a technical standard developed by SAE International that provides design criteria and certification requirements for evaporators used in mobile air conditioning systems using the refrigerants R-1234yf (hydrofluoroolefin) and R-744 (carbon dioxide). This standard is intended to address appropriate testing and labeling requirements to minimize risks associated with the use and service of these evaporators.

Vehicle manufacturers are required to conduct assessments to minimize reasonable risks in mobile air conditioning systems, including considering the evaporator as part of the overall system. Evaporator manufacturers must adhere to the standards outlined in SAE J2842. For non-OEM parts, or when a formal part compliance certification process has not been established, certification must be completed in accordance with SAE J2911.

The SAE J2842 standard is necessary because it addresses the safety, performance, and compatibility concerns associated with the use of newer refrigerants—specifically, R-1234yf (hydrofluoroolefin) and R-744 (carbon dioxide)—in mobile air conditioning systems. The reasons for this importance of this standard include:

• Ensures safety with flammable or high-pressure refrigerants: R-1234yf is mildly flammable. R-744 (carbon dioxide) operates at very high pressures. Evaporators must be designed and tested to minimize the risk of leaks, withstand the pressure, and prevent fire hazards in the event of a malfunction or accident.
• Protects end users and technicians: This standard provides testing and certification and helps prevent:
  • Dangerous leaks
  • Inconsistent part quality
  • Incorrect identification of spare parts

This standard increases safety for vehicle occupants and service technicians.

• Supports regulatory compliance: Automakers are switching to refrigerants with low global warming potential, such as R-1234yf and R-744, to meet environmental regulations. The SAE J2842 standard supports compliance by ensuring that evaporator components are tested to safely handle these refrigerants.
• Guides aftermarket and original equipment manufacturing standards: Ensures that non-OEM replacement parts meet the same performance and safety requirements as original parts. Prevents unsafe substitutions that could lead to system failure or injury.
• Supports industry consistency: Having a shared, authoritative standard ensures that manufacturers and suppliers are on the same page regarding design, test methods, and documentation. This is important as more vehicles worldwide switch to alternative coolants.

In short, the SAE J2842 standard is about ensuring human safety, protecting the environment, and enabling the industry to seamlessly transition to next-generation refrigerants without compromising quality or safety. This standard applies to evaporators or evaporator assemblies installed in the heating, ventilation, and air conditioning (HVAC) module for climate control in the passenger compartment of vehicles.

Our organization, which has been supporting businesses across all sectors for years through a wide range of testing, measurement, analysis, and evaluation activities, boasts a strong team of employees who closely follow global developments in science and technology and are constantly improving themselves. In this context, we also provide testing services in accordance with the "SAE J2842 OEM mobile air conditioner evaporator and service replacement R-1234yf and R744 design criteria and certification" standard.