Get Working with air conditioner service station -> 2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal Guide for Volkswagen Scirocco SUV Third Generation (2008-2017)

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Note

♦ Replacement compressors c_lo_kntain a certain specified quantity

of refrigerant oil. On vehicles with two evaporators, a certain

amount of refrigerant oil may also have to be filled in the circuit

if necessary ⇒ Heating, air conditioning; Rep. gr. 00 ; Tech‐

nical data; Refrigerant oil .

♦ If the air conditioner compressor does not need to be renewed,

replenish the refrigerant oil accordingly up to the prescribed fill

level (empty or flush refrigerant oil and pour the prescribed

volume back into the air conditioner compressor or refrigerant

circuit) ⇒ “1.5 Renewing components”, page 79 and ⇒ Heat‐

ing, air conditioning; Rep. gr. 00 ; Technical data; refrigerant

oil .

– Completely reassemble the refrigerant circuit again ⇒ Heat‐

ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System

overview - refrigerant circuit (vehicle-specific workshop man‐

ual).

– Evacuate and charge the refrigerant circuit in accordance with

the specifications

⇒ “2.5 Evacuating refrigerant circuit”, page 140 ,

⇒ “2.6 Charging refrigerant circuit”, page 146 and ⇒ Heating,

air conditioning; Rep. gr. 00 ; Technical data .

– Bring the air conditioning system into operation in the prescri‐

bed manner ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐

erant circuit; Bringing air conditioning system into operation

after charging refrigerant circuit (vehicle-specific workshop

manual) and

⇒ “2.7 Bringing air conditioning system into service after

charging”, page 149

2.13

Filling contaminated refrigerant in a re‐

cycling cylinder for analysis, processing

or disposal

⇒ “2.13.1 Filling contaminated refrigerant in a recycling cylinder

using technical equipment”, page 161

⇒ “2.13.2 Filling undercooled contaminated refrigerant in a recy‐

cling cylinder”, page 164

2.13.1

Filling contaminated refrigerant in a re‐

cycling cylinder using technical equip‐

ment

Note

♦ Some manufacturers may provide accessory devices (extract‐

ing or disposal units) that they claim to be approved for the

extraction of gases of unknown composition. These devices,

however, have not been tested or approved by Volkswagen

so that we cannot draw any conclusions about their operation

or suitability.

♦ In order to be filled into an evacuated recycling cylinder without

any auxiliary equipment, the contaminated refrigerant must be

supercooled. The corresponding procedure has been ap‐

proved by Volkswagen and described accordingly

⇒ page 164 .

2. Working with air conditioner service station

161

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

CAUTION

Risk of explosion if non-approved equipment is used

Refrigerant of unknown composition may expand due to a

chemical reaction or overheating causing the used device to

burst.

lk

– Make sure to use only devices and accessories that have

been authorised and approved by the manufacturer for be‐

ing suitable for operation with gases of unknown composi‐

tion in accordance with the relevant rules and regulations.

– Always read the owner's manual of these devices before

using them.

– Make sure to comply with all instructions given in the re‐

spective owner's manual when using the devices.

CAUTION

Risk of explosion from overfilling refrigerant reservoirs.

Refrigerant can expand and cause reservoirs to burst if they are

overfilled.

– Use a refrigerant tank with safety valve.

– Never exceed the permissible fill level of the refrigerant tank.

CAUTION

Chemical reactions from contaminated refrigerant. Mixing

gases of unknown composition can cause different chemical

reactions.

Risk of injuries.

– Never mix together refrigerants of different origins.

Extract refrigerant of unknown composition from refrigerant circuit

and collect it in a recycling cylinder.

– Connect the extracting and charging unit to the refrigerant cir‐

cuit of the vehicle and to a recycling cylinder observing the

corresponding owner's manual.

– Operate the extracting and charging unit according the in‐

structions in the corresponding owner's manual.

– Monitor the extraction process using a suitable pressure

gauge.

Note

♦ You can use your own pressure gauge or the pressure gauge

of the air conditioner service station to monitor the extraction

process.

♦ As it will take some time until the entire contaminated refrig‐

erant has been extracted from the refrigerant circuit, make

sure that you do not switch off the extracting and charging unit

until the refrigerant circuit has been drained completely. To be

absolutely sure about this, watch the display of the connected

pressure gauge.

After the entire contaminated refrigerant has been extracted from

the circuit:

– Switch off unit.

– Close the manual shut-off valve of the recycling cylinder.

162

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

– Wait a certain amount of time (e.g. 20 minutes), then check if

pressure started building up again in the vehicle’s refrigerant

circuit.

Note

lk

If pressure started building up in the refrigerant circuit due to

evaporation of refrigerant, fill the refrigerant responsible for this

increase in pressure into the recycling cylinder.

– Remove the charge hose and adapter from the recycling cyl‐

inder, and seal the connection of the recycling cylinder with

the sealing cap.

– The paperwork required for analysis, processing (or disposal)

of contaminated refrigerant must be filled in completely (dis‐

posal record, acceptance certificate etc.).

Note

♦ All of the information and documents for analysis, processing

(or disposal) can be obtained from your gas processing / gas

disposal company.

♦ Included with the recycling cylinder is a form. Kindly fill this in

accordingly and attach it to the recycling cylinder.

♦ If it is not possible to weigh the recycling cylinder before and

after filling with contaminated refrigerant, the fill volume speci‐

fied for the vehicle in question can be quoted as the amount

of refrigerant that was filled in the recycling cylinder. This is

permissible as only the amount of refrigerant from a vehicle is

filled in a recycling cylinder.

– Take the recycling cylinder to a suitable location for storage

until it is ready to be collected by the gas processing / gas

disposal company.

– Fill out the data sheet for the recycling cylinder (R-cylinder) if

the refrigerant is contaminated, and firmly attach it to the re‐

cycling cylinder.

Note

♦ In the “Other comments” section, details can be provided re‐

garding e.g. who is to receive the analysis results and in which

way.

♦ Example for recycling cylinder (R-cylinder) data sheet

⇒ page 169 .

– Evacuate the refrigerant circuit with the air conditioner service

station for at least 1 hour

⇒ “2.5 Evacuating refrigerant circuit”, page 140 .

2. Working with air conditioner service station

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Note

♦ Subsequent evacuation results in the last remnants of conta‐

minated refrigerant, which could still be in the refrigerant oil,

being removed at an absolute pressure of less than 10 mbar.

♦ If, after the unit has been switched off, a pressure that is higher

than the maximum permissible pressure for the function

“Evacuate” to be started on the air conditioner service station

builds up in the refrigerant circuit, release this pressure (drain

refrigerant) into the workshop extraction unit.

♦ The next steps depend on the complaint with the refrigerant

circuit

⇒ “2.3 Performing gas analysis of refrigerant”, page 134 .

2.13.2

Filling undercooled contaminated refrig‐

erant in a recycling cylinder

Note

♦ To ensure that the contaminated refrigerant is filled automat‐

ically without supporting equipment into an evacuated recy‐

cling cylinder, the cylinder must be supercooled.

♦ To cool down the evacuated recycling bottle, use an insulated

container and dry ice.

♦ Dry ice is solid carbon dioxide (CO ) that changes from a solid

2

lk

directly to a gaseous state at -78°C.

♦ Most of the gases used as refrigerant have only a low vapour

pressure at very low temperatures (less than 0.6 bar absolute

pressure at -50°C). When an extremely cooled recycling cyl‐

inder is connected to a refrigerant circuit, the refrigerant liq‐

uefies in the cold recycling cylinder and the pressure in the

refrigerant circuit drops below ambient pressure

⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17 .

♦ Commercially available recycling cylinders are usually made

of common mild steel. These are not always suitable for low

temperatures (down to -78°C in this case), which is why only

recycling cylinders suitable for this application should be used

and why the cylinder should be allowed to reach ambient tem‐

perature slowly (e.g. by placing the insulated container with

recycling cylinder in a secure, well-ventilated location where

the dry ice can evaporate safely).

Special tools and workshop equipment required

♦ Extraction unit - VAS 581 007- ⇒ Electronic parts

catalogue (ETKA)

♦ At least 10 kg of commercially available dry ice (pellets or

granules)

♦ Evacuated recycling cylinder from gas supplier for contami‐

nated R1234yf refrigerant, which is suitable for very low tem‐

peratures (e.g. with a permissible fill capacity greater than

3.0 kg).

♦ Commercially available bottle adapter with seal (for connect‐

ing charge hose to recycling bottle, internal W 21.8 x 1/14 LH

left-hand thread and M 12 x 1.5-6G in accordance with SAE

J639)

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

♦ Commercially available charge hose for R1234yf refrigerant

with seals (2m charge hose with external M12 x 1.5-6G thread

in accordance with SAE J639)

♦ Commercially available low-pressure service coupling in ac‐

cordance with SAE J639

Note

Dry ice evaporates at ambient temperature even from the insu‐

lated container (about 20 to 30% per day depending on the

ambient conditions). Therefore, only order the dry ice once all of

the necessary tools are ready and the measures can be per‐

formed immediately after receipt of the dry ice (e.g. do not order

the dry ice on a Friday if work is not going to be carried out at the

weekend).

CAUTION

Risk of frost-bite and suffocation from dry ice.

lk

Frost-bite on the skin and other body parts possible and risk of

suffocation in gaseous state.

– Wear protective gloves.

– Wear protective goggles.

– Only work with dry ice in well ventilated areas.

– Never work in or near cellars or other low lying areas.

CAUTION

Risk of explosion from incorrectly stored dry ice.

As dry ice evaporates, pressure builds up in the container. Un‐

suitable containers could burst.

– Only transport and store dry ice in dedicated containers.

Refilling refrigerant using a supercooled recycling cylinder

•

All requisite tools, equipment and a sufficient quantity of dry

ice ready

– Remove seal on recycling cylinder and unscrew sealing cap

from connection.

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Note

♦ Sealed recycling cylinders from your gas supplier usually

come pre-evacuated.

♦ Should the recycling cylinder not be evacuated, evacuate it as

necessary using a vacuum pump or an air conditioner service

station .

♦ Recycling cylinders are clearly marked as such and, unlike

refrigerant cylinders, do not have a non-return valve thereby

making them suitable for filling.

♦ Recycling cylinders are designed for international use, which

is why the “O” on the handwheel means “Open” (cylinder valve

= open) and not “0” (zero = closed).

♦ If an absolute pressure greater than 100 mbar but less than

900 mbar is measured in the recycling cylinder, evacuate the

recycling cylinder using a vacuum pump (or an air conditioner

service station ) (residual pressure less than 50 mbar)

⇒ “2.5 Evacuating refrigerant circuit”, page 140 .

♦ If an absolute pressure greater than 900 mbar is measured in

the recycling cylinder, this could be due to a number of rea‐

sons. The manual shut-off valve was opened and not closed

properly or the recycling cylinder had previously been used to

store refrigerant and then was not evacuated properly

⇒ “2.10 Emptying air conditioner service station”, page 154

(evacuate recycling cylinder). The recycling cylinder is leaking

(return the recycling cylinder to the supplier).

lk

– Connect a vacuum metre (or air conditioner service station )

to the recycling cylinder.

– Carefully open the manual shut-off valve of the recycling cyl‐

inder to check the vacuum and then check the vacuum in the

cylinder.

– If necessary, evacuate the recycling cylinder with the air con‐

ditioner service station .

Note

♦ Should there be any air trapped in the recycling cylinder, it can

be evacuated using an air conditioner service station for

R1234yf. To do this, unscrew the low pressure service cou‐

pling from the charge hose of the air conditioner service station

and connect the charge hose directly to the recycling cylinder

adapter for the extraction device (for R1234yf refrigerant) - dry

ice box .

♦ If air is trapped in the recycling cylinder and there is no air

conditioner service station for R1234yf available, the recycling

cylinder can also be evacuated with an air conditioner service

station for R134a using a relevant flushing container and

adapter -VAS 6338/38- along with the charge hose from ex‐

traction device (for R1234yf refrigerant) - dry ice box .

•

Residual pressure in the recycling cylinder less than 10 mbar

absolute pressure.

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Note

♦ Recycling cylinders are pre-evacuated by the supplier, though

it is not always possible to ensure that the vacuum will remain

intact in storage.

♦ To reliably determine the type and scope of the contamination

of the refilled refrigerant during analysis of the contaminated

refrigerant, the recycling cylinder must be evacuated before

refilling to a residual pressure less than 50 mbar.

– Switch off ignition.

– Ensure that the workplace is well ventilated. Switch on addi‐

tional workshop extraction systems if fitted.

– Connect the charge hose with a suitable adapter to the evac‐

uated recycling cylinder.

CAUTION

Risk of explosion from overfilling refrigerant reservoirs.

Refrigerant can expand and cause reservoirs to burst if they are

overfilled.

– Use a refrigerant tank with safety valve.

– Never exceed the permissible fill level of the refrigerant tank.

lk

Note

♦ Since contaminated refrigerant is only filled into a recycling

cylinder from a vehicle in the following work routine, there is

no danger of a recycling cylinder being overfilled with a fill vol‐

ume exceeding 3.0 kg.

♦ If contaminated refrigerant is filled into a recycling cylinder e.g.

from an air conditioner service station , measures must be

taken to ensure that the recycling cylinder is not overfilled due

to the larger volume. Use a recycling cylinder with an appro‐

priate permissible fill capacity and when refilling ensure by

means of weighing that the maximum permissible fill volume

is not exceeded.

CAUTION

Chemical reactions from contaminated refrigerant. Mixing

gases of unknown composition can cause different chemical

reactions.

Risk of injuries.

– Never mix together refrigerants of different origins.

2. Working with air conditioner service station

167

lk

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

– Connect the service coupling for R1234yf refrigerant -5- to the

charge hose -4-.

– Connect the charge hose -4- with cylinder adapter -3- (and

seal -2-) to the recycling cylinder -1-.

– Place the spacer -6- in the insulated container -7-.

– Cover the base of the insulated container -7- with dry ice.

– Place the recycling cylinder -1- in the insulated container -7-

extraction device (for R1234yf refrigerant) - dry ice box .

– Pour the remainder of the dry ice in the insulated container

-7-.

– Cool down the recycling container -1- with dry ice (for approx.

15 minutes).

– Connect the recycling cylinder -1- via the service coupling

-5- to the connection of the air conditioner service station (or

the vehicle's refrigerant circuit).

– Open the manual shut-off valve of the recycling cylinder -1-.

Note

Recycling cylinders are designed for international use, which is

why the “O” on the handwheel means “Open” (cylinder valve =

open) and not “0” (zero = closed).

– Connect a pressure gauge to the refrigerant circuit (or use the

pressure gauge of the air conditioner service station ) and

check the pressure in the refrigerant circuit.

– Carefully open the service coupling -5- on the charge hose for

the recycling cylinder and allow the refrigerant to flow out

slowly into the recycling cylinder -1-.

– Wait until the refrigerant in the recycling cylinder -1- has liq‐

uefied (watch the display on the connected pressure gauge).

Note

♦ You can use your own pressure gauge or the pressure gauge

of the air conditioner service station to monitor the extraction

process.

♦ As soon as the displayed pressure is less than 0.3 bar after

approx. 60 minutes, it is safe to assume that the whole refrig‐

erant in the recycling cylinder is liquefied.

♦ Complete evaporation of the contaminated refrigerant from the

refrigerant circuit takes some time. After 60 minutes, it is safe

to assume that the whole refrigerant has evaporated.

– Close the service coupling -5- and manual shut-off valve of the

recycling cylinder -1-.

– Remove the charge hose -4- and cylinder connecting piece

-3- from the recycling cylinder -1- and close the recycling cyl‐

inder with the cap.

– The paperwork required for analysis, processing (or disposal)

of contaminated refrigerant must be filled in completely (dis‐

posal record, acceptance certificate etc.).

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Note

♦ All of the information and documents for analysis, processing

(or disposal) can be obtained from your gas processing / gas

disposal company.

♦ Included with the recycling cylinder is a form. Kindly fill this in

accordingly and attach it to the recycling cylinder.

♦ If it is not possible to weigh the recycling cylinder before and

after filling with contaminated refrigerant, the fill volume speci‐

fied for the vehicle in question can be quoted as the amount

of refrigerant that was filled in the recycling cylinder. This is

permissible as only the amount of refrigerant from a vehicle is

filled in a recycling cylinder.

– Move the insulated box -7- with recycling cylinder -1- and dry

ice to a secure, well ventilated area outside the building.

– Open the lid of the insulated box -7- or remove and allow the

dry ice to evaporate.

Note

Do not take the recycling cylinder -1- out of the insulated container

-7- until the dry ice has evaporated and the recycling cylinder has

adjusted to ambient temperature.

– Remove the recycling cylinder -1- from the insulated container

-7-.

lk

– Take the recycling cylinder -1- to a suitable location for storage

until it is ready to be collected by the gas processing / gas

disposal company.

– Evacuate the refrigerant circuit with the air conditioner service

station for at least 1 hour

⇒ “2.5 Evacuating refrigerant circuit”, page 140 .

Note

♦ Subsequent evacuation results in the last remnants of conta‐

minated refrigerant, which could still be in the refrigerant oil,

being removed at an absolute pressure of less than 10 mbar.

♦ The next steps depend on the complaint with the refrigerant

circuit

⇒ “2.3 Performing gas analysis of refrigerant”, page 134 .

– Fill out the data sheet for the recycling cylinder (R-cylinder) if

the refrigerant is contaminated and firmly attach it to the recy‐

cling cylinder -1-.

Note

In the “Other comments” section, details can be provided regard‐

ing e.g. who is to receive the analysis results and in which way.

Example for recycling cylinder (R-cylinder) data sheet

2. Working with air conditioner service station

169

Working with air conditioner service station -> 2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal for Your Volkswagen Scirocco SUV Third Generation (2008-2017)

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