Get Air conditioning system Working with air conditioner service station -> 2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal Guide for Volkswagen Sharan VAN Second Generation (2010-2023)

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Note

♦ Replacemencompressors c_lo_kntain a certain specified quantity

of refrigeranoil. On vehicles with two evaporators, a certain

amounof refrigeranoil may also have to be filled in the circui

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

nical data; Refrigeranoil .

♦ If the air conditioner compressor does noneed to be renewed,

replenish the refrigeranoil accordingly up to the prescribed fill

level (empty or flush refrigeranoil and pour the prescribed

volume back into the air conditioner compressor or refrigeran

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

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

oil .

– Completely reassemble the refrigerancircuiagain ⇒ Heat‐

ing, air conditioning; Rep. gr. 87 ; Refrigerancircuit; System

overview - refrigerancircui(vehicle-specific workshop man‐

ual).

– Evacuate and charge the refrigerancircuiin accordance with

the specifications

⇒ “2.5 Evacuating refrigerancircuit”, page 140 ,

⇒ “2.6 Charging refrigerancircuit”, 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‐

erancircuit; Bringing air conditioning system into operation

after charging refrigerancircui(vehicle-specific workshop

manual) and

⇒ “2.7 Bringing air conditioning system into service after

charging”, page 149

2.13

Filling contaminated refrigeranin a re‐

cycling cylinder for analysis, processing

or disposal

⇒ “2.13.1 Filling contaminated refrigeranin a recycling cylinder

using technical equipment”, page 161

⇒ “2.13.2 Filling undercooled contaminated refrigeranin a recy‐

cling cylinder”, page 164

2.13.1

Filling contaminated refrigeranin a re‐

cycling cylinder using technical equip‐

men

Note

♦ Some manufacturers may provide accessory devices (extract‐

ing or disposal units) thathey claim to be approved for the

extraction of gases of unknown composition. These devices,

however, have nobeen tested or approved by Volkswagen

so thawe cannodraw any conclusions aboutheir operation

or suitability.

♦ In order to be filled into an evacuated recycling cylinder withou

any auxiliary equipment, the contaminated refrigeranmusbe

supercooled. The corresponding procedure has been ap‐

proved by Volkswagen and described accordingly

⇒ page 164 .

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

CAUTION

Risk of explosion if non-approved equipmenis used

Refrigeranof 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 thahave

been authorised and approved by the manufacturer for be‐

ing suitable for operation with gases of unknown composi‐

tion in accordance with the relevanrules 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 refrigeranreservoirs.

Refrigerancan expand and cause reservoirs to bursif they are

overfilled.

– Use a refrigerantank with safety valve.

– Never exceed the permissible fill level of the refrigerantank.

CAUTION

Chemical reactions from contaminated refrigerant. Mixing

gases of unknown composition can cause differenchemical

reactions.

Risk of injuries.

– Never mix toher refrigerants of differenorigins.

Extracrefrigeranof unknown composition from refrigerancircui

and colleciin a recycling cylinder.

– Connect the extracting and charging unito the refrigerancir‐

cuiof the vehicle and to a recycling cylinder observing the

corresponding owner's manual.

– Operate the extracting and charging uniaccording 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 iwill take some time until the entire contaminated refrig‐

eranhas been extracted from the refrigerancircuit, make

sure thayou do noswitch off the extracting and charging uni

until the refrigerancircuihas been drained completely. To be

absolutely sure abouthis, watch the display of the connected

pressure gauge.

After the entire contaminated refrigeranhas been extracted from

the circuit:

– Switch off unit.

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

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

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

pressure started building up again in the vehicle’s refrigeran

circuit.

Note

lk

If pressure started building up in the refrigerancircuidue to

evaporation of refrigerant, fill the refrigeranresponsible 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 refrigeranmusbe 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 ito the recycling cylinder.

♦ If iis nopossible 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 amoun

of refrigeranthawas filled in the recycling cylinder. This is

permissible as only the amounof refrigeranfrom a vehicle is

filled in a recycling cylinder.

– Take the recycling cylinder to a suitable location for storage

until iis ready to be collected by the gas processing / gas

disposal company.

– Fill outhe data sheefor the recycling cylinder (R-cylinder) if

the refrigeranis contaminated, and firmly attach ito 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 shee

⇒ page 169 .

– Evacuate the refrigerancircuiwith the air conditioner service

station for aleas1 hour

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

2. Working with air conditioner service station

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Note

♦ Subsequenevacuation results in the lasremnants of conta‐

minated refrigerant, which could still be in the refrigeranoil,

being removed aan absolute pressure of less than 10 mbar.

♦ If, after the unihas been switched off, a pressure thais higher

than the maximum permissible pressure for the function

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

builds up in the refrigerancircuit, release this pressure (drain

refrigerant) into the workshop extraction unit.

♦ The nexsteps depend on the complainwith the refrigeran

circui

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

2.13.2

Filling undercooled contaminated refrig‐

eranin a recycling cylinder

Note

♦ To ensure thathe contaminated refrigeranis filled automat‐

ically withousupporting equipmeninto an evacuated recy‐

cling cylinder, the cylinder musbe supercooled.

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

container and dry ice.

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

2

lk

directly to a gaseous state a-78°C.

♦ Mosof the gases used as refrigeranhave only a low vapour

pressure avery low temperatures (less than 0.6 bar absolute

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

inder is connected to a refrigerancircuit, the refrigeranliq‐

uefies in the cold recycling cylinder and the pressure in the

refrigerancircuidrops below ambienpressure

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

♦ Commercially available recycling cylinders are usually made

of common mild steel. These are noalways 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 ambientem‐

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 equipmenrequired

♦ Extraction uni- VAS 581 007- ⇒ Electronic parts

catalogue (ETKA)

♦ At leas10 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 refrigeranR1234yf - General information - Edition 07.2017

♦ Commercially available charge hose for R1234yf refrigeran

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 aambientemperature even from the insu‐

lated container (abou20 to 30% per day depending on the

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

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

formed immediately after receipof the dry ice (e.g. do noorder

the dry ice on a Friday if work is nogoing to be carried ouathe

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 transporand store dry ice in dedicated containers.

Refilling refrigeranusing a supercooled recycling cylinder

•

All requisite tools, equipmenand a sufficienquantity of dry

ice ready

– Remove seal on recycling cylinder and unscrew sealing cap

from connection.

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Note

♦ Sealed recycling cylinders from your gas supplier usually

come pre-evacuated.

♦ Should the recycling cylinder nobe evacuated, evacuate ias

necessary using a vacuum pump or an air conditioner service

station .

♦ Recycling cylinders are clearly marked as such and, unlike

refrigerancylinders, do nohave 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 no“0” (zero = closed).

♦ If an absolute pressure greater than 100 mbar buless 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 refrigerancircuit”, 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 noclosed

properly or the recycling cylinder had previously been used to

store refrigeranand then was noevacuated 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, ican

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 connecthe 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 relevanflushing 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.

166

Rep. gr.87 - Air conditioning system

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Note

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

iis noalways possible to ensure thathe vacuum will remain

intacin storage.

♦ To reliably determine the type and scope of the contamination

of the refilled refrigeranduring analysis of the contaminated

refrigerant, the recycling cylinder musbe evacuated before

refilling to a residual pressure less than 50 mbar.

– Switch off ignition.

– Ensure thathe 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 refrigeranreservoirs.

Refrigerancan expand and cause reservoirs to bursif they are

overfilled.

– Use a refrigerantank with safety valve.

– Never exceed the permissible fill level of the refrigerantank.

lk

Note

♦ Since contaminated refrigeranis 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 refrigeranis filled into a recycling cylinder e.g.

from an air conditioner service station , measures musbe

taken to ensure thathe recycling cylinder is nooverfilled due

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

priate permissible fill capacity and when refilling ensure by

means of weighing thathe maximum permissible fill volume

is noexceeded.

CAUTION

Chemical reactions from contaminated refrigerant. Mixing

gases of unknown composition can cause differenchemical

reactions.

Risk of injuries.

– Never mix toher refrigerants of differenorigins.

2. Working with air conditioner service station

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167

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

– Connect the service coupling for R1234yf refrigeran-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 refrigerancircuit).

– 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 no“0” (zero = closed).

– Connect a pressure gauge to the refrigerancircui(or use the

pressure gauge of the air conditioner service station ) and

check the pressure in the refrigerancircuit.

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

the recycling cylinder and allow the refrigeranto flow ou

slowly into the recycling cylinder -1-.

– Wait until the refrigeranin 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, iis safe to assume thathe whole refrig‐

eranin the recycling cylinder is liquefied.

♦ Complete evaporation of the contaminated refrigeranfrom the

refrigerancircuitakes some time. After 60 minutes, iis safe

to assume thathe whole refrigeranhas 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 refrigeranmusbe filled in completely (dis‐

posal record, acceptance certificate etc.).

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Air conditioning systems with refrigeranR1234yf - 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 ito the recycling cylinder.

♦ If iis nopossible 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 amoun

of refrigeranthawas filled in the recycling cylinder. This is

permissible as only the amounof refrigeranfrom 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 notake the recycling cylinder -1- ouof the insulated container

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

adjusted to ambientemperature.

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

-7-.

lk

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

until iis ready to be collected by the gas processing / gas

disposal company.

– Evacuate the refrigerancircuiwith the air conditioner service

station for aleas1 hour

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

Note

♦ Subsequenevacuation results in the lasremnants of conta‐

minated refrigerant, which could still be in the refrigeranoil,

being removed aan absolute pressure of less than 10 mbar.

♦ The nexsteps depend on the complainwith the refrigeran

circui

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

– Fill outhe data sheefor the recycling cylinder (R-cylinder) if

the refrigeranis contaminated and firmly attach ito 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 shee

2. Working with air conditioner service station

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Data sheefor R-cylinder if refrigeranis contaminated

Service contac

Dealership contact:

Email address:

Customer information:

Surname, firsname:

Street:

Town/city:

Vehicle model

Identification

Vehicle identification

number:

Mileage:

Gas analysis performed

on:

Information abouR-cylinder

Cylinder number:

Cylinder weighwith

contents:

(gross weight)

Fill volume

(neweight)

lk

Other comments

2.14

Checking pressures

⇒ “2.14.1 General information on checking pressures in the re‐

frigerancircuit”, page 170

⇒ “2.14.2 Pressures and temperatures in refrigerancircuit”, page

173

⇒ “2.14.3 Checking pressures in the refrigerancircuiwith the

ignition switched off”, page 176

⇒ “2.14.4 Checking pressures with air conditioning system switch‐

ed on - vehicles with mechanical air conditioning compressor”,

page 183 .

⇒ “2.14.5 Checking pressures with air conditioning system switch‐

ed on - vehicles with electrical air conditioning compressor”, page

205

2.14.1

General information on checking pres‐

sures in the refrigerancircui

Note

Work on the refrigerancircuithainvolves the air conditioner

service station can usually be carried ouwithouthe need to de-

energise the high-voltage system.

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Rep. gr.87 - Air conditioning system

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Air conditioning system Working with air conditioner service station -> 2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal for Your Volkswagen Sharan VAN Second Generation (2010-2023)

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