Get Air conditioning system -> 2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal Guide for Volkswagen Touran 4 Door Second Generation (2015-2022)

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

♦ On a new air conditioner com‐

pressor filled with more than

150 cm³, pour out as much re‐

frigerant oil as possible before

flushing.

♦ Reason: The oil volume to be

displaced in one work step may

be restricted depending on the

version of air conditioner service

station .

Note

If the clean refrigerant oil is poured

out of a new air conditioner com‐

lk

pressor into a clean container and

this is subsequently sealed air-tight,

the refrigerant oil can be re-used to

top-up the refrigerant oil volume in

the circuit.

6 - Refrigerant line

❑ For connection of air conditioner compressor to adapter ⇒ Item 7 (page 157)

❑ Use a refrigerant line e.g. with part number 7L6 820 721 BF to set-up the flushing circuit ⇒ Electronic

parts catalogue

7 - Adapter for connection on high pressure side of air conditioner compressor

❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105

❑ From adapter case VW/Audi passenger vehicle set

8 - Charging hose of flushing device for refrigerant circuits

❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐

ameter) to inlet of flushing device for refrigerant circuits.

9 - Flushing device for refrigerant circuits

❑ Different versions and different design of flushing devices for refrigerant circuits ⇒ Electronic parts cata‐

logue (Tools; Workshop equipment/tools; Air conditioning/heating)

❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).

❑ Depending on the layout of the air conditioner service station and the flushing device for refrigerant

circuits, there may be a service coupling for refrigerant circuits fitted at the outlet and in some cases at

the inlet of the flushing device. If a service connection with a valve is installed to the outlet of the flushing

device, this valve must be opened completely when the service coupling is connected. If the valve is not

opened completely, it restricts the refrigerant flow.

❑ If there is a connection for a service coupling fitted at the inlet of the flushing device, the inlet must be

adapted to allow for the refrigerant hose coming from the vehicle to be connected directly.

Note

A service coupling and a valve in the

inlet of the flushing device restrict

the refrigerant flow from the vehicle

into the flushing device.

10 - Refrigerant hose of air conditioner service station

❑ From the low pressure side of the air conditioner service station (normally coloured blue) to the outlet of

the flushing device for refrigerant circuits.

2.12

Cleaning refrigerant circuit

– Perform preparatory measures for cleaning (flushing with

R1234yf refrigerant)

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

⇒ “1.6.2 Preparations for cleaning refrigerant circuit (flushing

with R1234yf refrigerant)”, page 94

– Check the refrigerant volume in the air conditioner service sta‐

tion . There must be at least 6 kg of R1234yf refrigerant ⇒

Operating instructions of air conditioner service station .

– Empty container for used oil of air conditioner service station

⇒ Operating instructions of air conditioner service station .

– Connect the supply hose (high pressure side) of the air con‐

ditioner service station with an adapter to the low pressure line

leading to the air conditioner compressor (line with larger di‐

ameter)

⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105 .

– Connect the return hose (low pressure or suction side) of the

air conditioner service station to the outlet of the flushing de‐

vice for refrigerant circuits.

– Connect the inlet of the flushing device for refrigerant circuits

with an adapter to the high pressure line leading to the air

lk

conditioner compressor (line with smaller diameter)

⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105 .

♦ Principle circuit diagrams for various flushing circuits

⇒ “1.6 Cleaning refrigerant circuit”, page 92

♦ Adapters for setting up flushing circuits

⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105

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

Note

♦ The components are almost always flushed against the direc‐

tion of refrigerant flow when the air conditioning system is in

operation. (Exception: electrically-actuated air conditioner

compressor) ⇒ page 92 .

♦ When flushing, contaminants from the refrigerant circuit enter

the flushing device for refrigerant circuits and the air condi‐

tioner service station and are retained in the filters and dryers

installed within. Depending on the contamination, these com‐

ponents must be renewed at shorter intervals than prescribed

as per the operating instructions of the air conditioner service

station or flushing device for refrigerant circuits ⇒ Operating

lk

instructions of air conditioner service station .

♦ The filter in the flushing device for refrigerant circuits should

be changed (depending on the type and severity of contami‐

nation in the flushed refrigerant circuits) after about 5 to 10

flushing cycles (flushed vehicles). If a heavily contaminated

refrigerant circuit is flushed (the refrigerant oil from the refrig‐

erant circuit is black and viscous or there are large amounts

of swarf in the refrigerant circuit), renew the filter after flushing

this refrigerant circuit. After such heavy contamination of the

refrigerant circuit, it is a good idea to flush the system again

after replacing the filter.

♦ Depending on the type of contamination, deposits (old refrig‐

erant oil and friction dust from the air conditioner compressor)

will gather in the sight glass of the rinsing device for refrigerant

circuits. If necessary, clean this sight glass after flushing and

flush the refrigerant circuit through again to make sure it is

clean (one pass is sufficient in this instance).

♦ Liquid refrigerant cannot be routed through the expansion

valve, restrictor and desiccant bag of certain receivers at the

necessary rate. Therefore remove these components and re‐

place them with adapters if applicable ⇒ page 92 and ⇒

Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;

System overview - refrigerant circuit (vehicle-specific work‐

shop manual).

♦ Adapters to connect air conditioner service station and to

bridge certain components of the refrigerant circuit

⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105 .

Perform flushing (the procedure runs automatically as per the

program in the air conditioner service station ⇒ Operating in‐

structions of air conditioner service station )

– Switch on the air conditioner service station ⇒ Operating in‐

structions of air conditioner service station .

– Select the flushing program on the air conditioner service sta‐

tion ⇒ Operating instructions of air conditioner service station .

– Flush the refrigerant circuit (duration approx. 1 to 1.5 hours for

one flushing cycle with 4 cycles) ⇒ Operating instructions of

air conditioner service station .

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

Note

♦ Flushing procedure

⇒ “1.6.3 Refrigerant circuit cleaning procedure”, page 96 .

♦ Perform flushing as instructed in the operating manual of the

air conditioning service station ⇒ Operating instructions of air

conditioner service station .

♦ Depending on the type of air conditioning service station , the

used oil tank has a capacity of about 125 cm ³of refrigerant

oil. If a system with a greater amount of refrigerant oil has to

be flushed, it may be necessary to empty the used oil tank after

the first flushing process of a flushing cycle.

♦ Observe the refrigerant flowing back into the air conditioning

service station from the refrigerant circuit. Once the refrigerant

flows clear and completely colourless through the inspection

window of the flushing device for refrigerant circuits in the air

conditioning service station , the refrigerant circuit is cleaned.

♦ When flushing, the whole amount of refrigerant oil from the

refrigerant circuit is washed out (except for a very small

amount, e.g. in the evaporator, but this is negligible).

♦ Where contamination is particularly high, it may be necessary

to carry out the flushing process twice (two flushing cycles with

4 flushing processes each).

– At the end of the flushing process, check the inspection win‐

dow or windows of the flushing device for refrigerant circuits.

If dirty, clean as per the instructions of the flushing device for

refrigerant circuits or air conditioner service station and per‐

form the flushing process again ^lt^ko be safe (running through

once over a period of approx. 30 min. is sufficient) ⇒ Operating

instructions air conditioner service station .

– Check the pressure in the refrigerant circuit. There must be no

overpressure in the refrigerant circuit (evacuate twice briefly if

necessary).

– Remove the connections to the air conditioning service station

from the refrigerant circuit of the vehicle (there should be no

overpressure in the refrigerant circuit)

– Renew these vehicle-specific components (restrictor and res‐

ervoir, expansion valve and receiver / dryer cartridge in the

reservoir) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refriger‐

ant circuit; System overview - refrigerant circuit (vehicle-spe‐

cific workshop manual) and ⇒ Electronic parts catalogue .

– Depending on the complaint, renew the air conditioner com‐

pressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant

circuit; System overview - refrigerant circuit (vehicle-specific

workshop manual) and ⇒ Electronic parts catalogue or drain

the remaining refrigerant oil from the removed air conditioner

compressor ⇒ “1.5 Renewing components”, page 79 and fill

with the requisite amount of fresh refrigerant oil again ⇒ Heat‐

ing, air conditioning; Rep. gr. 00 ; Technical data (vehicle-

specific workshop manual) and ⇒ Heating, air conditioning;

Rep. gr. 00 ; Technical data; Refrigerant oil .

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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

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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.

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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 .

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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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♦ 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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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 system -> 2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal for Your Volkswagen Touran 4 Door Second Generation (2015-2022)

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