AC Safety Testing for R32 and Other A2L Refrigerants Under IS 302 Part 2 Section 40:2025

R32 is already common in Indian split air-conditioners but it is in the A2L class: lower flammability and low burning velocity, but not zero risk. That changes how a product is built and tested. This article describes the inclusion of A2L refrigerant AC safety testing in IS 302 Part 2 Section 40:2025, the Indian standard for household air conditioners, heat pumps and dehumidifiers.

It includes charge, leak behaviour, ignition sources and the evidence worth assembling before you book ac testing services. It leaves energy performance and refrigerant selection aside.

What Does IS 302 Part 2 Section 40:2025 Add Over the Older Edition?

The Indian standard is a modified version of IEC 60335-2-40:2022. It replaces the 2018 edition. Anyone planning A2L refrigerant AC safety testing should review the leak-related requirements in IS 302 Part 2 Section 40:2025. The⁠se include refrig‌erant‌ leak detection, safety meas‌ures to reduce risk​s and c‍hec‌ks for​ ig‍nit‍ion‍ from hot surfaces. Th​e⁠ standard's exact‍ w‍ording matters‌ because Indi​an⁠ modification may change‍ som‌e requirements. Summaries of the 2022 IEC text also highlight refrigerant detection systems and ignition risks from relays and switching components.

This doesn’t mean that every existing model has to be retested. Retesting depends on the applicable clauses, product changes and the relevance of earlier reports. A gap check of existing reports against the new text is a sensible first step as 2026 compliance plans are finalised. Our guide to types of air conditioner testing covers the larger test families; this article sticks to the refrigerant side.

How Do Charge Limits, Leak Detection and Ventilation Checks Work?

A leak becomes a hazard when it becomes concentrated. Refrigerant mixes with room air and R32 vapour is heavier than air so it tends to settle low. What is important is how much can get away, at what volume and for how long it remains. So allowable charge depends on the type of appliance, the location of installation, the size of the room and the refrigerant itself. There is no one figure that works everywhere.

If charge alone doesn't solve the problem, a design could include refrigerant detection or other mitigation, such as a sensor that starts the fan to dissipate the leak. Which configuration is acceptable depends on the product, so you cannot simply copy one manufacturer's layout for another. The built appliance is evaluated in terms of airflow paths and sensor position. That’s why an A2L refrigerant leak test is rarely an isolated event; results are read against charge, enclosure design and installation conditions. The overall design is the basis for an R32 air conditioner safety test. The use of R32 alone does not constitute compliance.

How Are Hot Surfaces, Ignition Sources and Electrical Components Evaluated?

A2L refrigerant requires a pretty strong ignition source and the right mix, but a design still needs to limit the chance of hitting both. Assessment considers hot surfaces that could be in a leak path and at components near refrigerant carrying parts that could spark in normal use or on fault such as relays, switches, connectors and motors. Construction matters; how joints sit, how enclosures are ventilated and how a leak would travel through the unit all alter the picture.

Electromagnetic compatibility is a different issue. EMC testing for HVACR equipment looks at the disturbances a product emits and its immunity to them. It is not a substitute for leakage or ignition-safety assessment, nor does passing one have any bearing on the other.

Does the Same Standard Cover Heat Pumps and Dehumidifiers?

In theory, that’s true. The scope includes electric heat pumps, air conditioners and dehumidifiers, so the same questions about refrigerants apply. However, the specific requirements vary by appliance. The charge, the circuit layout, the airflow and the intended installation all change what an assessor has to look at and a small sealed dehumidifier circuit is a different one from a ducted system. Don’t think of heat pump safety testing and dehumidifier safety testing as copies of an AC test. Think of them as evaluations of the specific configuration.

How Does ACE Test Labs Support Refrigerant Safety Testing?

ACE Test Labs offers household appliances testing services to help manufacturers evaluate air conditioners and related appliances. Before contacting a NABL testing lab, identify the applicable standard edition, product configuration and refrigerant charge. Testing is for the product. Certification and BIS registration have their own processes.

Gather the following before contacting a lab:

• Refrigerant designation and total charge for the model

• Appliance type, intended application and installation conditions

• Circuit layout and any detection or mitigation features already fitted

• Current reports, drawings and component lists for that particular configuration

Conclusion: What Should Manufacturers Do Next?

In the 2025 edition, refrigerant safety is all about evidence: do charge, leak behaviour, detection arrangements and ignition controls exist and are they in line with the standard that applies. Review that evidence before fixing compliance plans, not after the sample reaches the lab. Efficiency is a different track that we cover in our note on energy efficiency testing.

Send your refrigerant type & charge and Ace Test Labs will map the tests.