Volkswagen Golf / Golf GTI / Jetta. Manual - part 1004

 

2. Definition of terms and explanatory notes

 

2.1 Charging systems

 

2.1.1 Charging systems are systems for filling mobile 
compressed-gas vessels. The charging system includes 
the premises and facilities concerned.

 

2.4 Charging systems requiring a permit

 

Charging systems requiring a permit are ones used to 
transfer compressed gases to mobile compressed-gas 
vessels for supplying to third parties.

 

5 Charging systems not requiring a permit are ones used 
for transferring compressed gases to mobile compressed-
gas vessels for internal use only.

 

TRG 401 (installation of charging systems)

 

Does not apply to vehicle manufacturers or workshops.

 

TRG 402 (operation of charging systems)

 

2. Employees and employee instruction

 

2.1 Charging systems are only to be operated and 
maintained by personnel

- Aged 18 and above 

- Possessing the necessary technical knowledge 

- Who can be relied on to work diligently 

 

2.2 Supervised work may also be performed by personnel 
not satisfying the requirements stipulated in item 2.1, points 
1 and 2.

 

2.3 Employees are to be given instruction on the following 
topics before beginning work and at regular, appropriate 
intervals, however at least once a year:

- Hazards specifically associated with handling compressed 
gases 

- Safety regulations, particularly the applicable TRG 

- Procedures in the event of malfunction, damage and 
accidents 

- The use of fire-extinguishing and protective equipment  

- Operation and maintenance of the charging system on the 
basis of the instructions for use. 

 

Laws and regulations

13/2/2005

 

Charging (a separate TRG applies to vessels from 
other countries and their charging)

 

A compressed-gas vessel is only to be filled with the 
compressed gas declared on it and the quantity must 
comply with the stipulated pressure, weight or volume data 
(refer to g15, Para. 2, pressure vessel regulations).

2. In the case of vessels approved for use with several 
types of compressed gas, the compressed gas with which it 
is to be filled and - if the compressed gas has a tc  ≥ -10   
C (tc = critical temperature) - the maximum permissible 
charging weight in line with TRG 104 No. 3.3 must be 
marked on the vessel prior to connection for filling. 

3. Compressed-gas vessels marked with the maximum 
permissible charge pressure in bar at 15   C must be filled 
manometrically. If, at the time of filling, the temperature is 
not 15   C, the pressure corresponding to the prevailing 
temperature must be established; it must be ensured that 
the permissible charge pressure at 15   C is not exceeded 
in the compressed- gas vessel. The charged vessels are to 
be checked by way of random pressure measurements to 
determine possible overfilling. 

 

4. Compressed-gas vessels on which the maximum 
permissible capacity is indicated by the net weight (filling 
weight, permissible weight of fill) in kilograms must be filled 
gravimetrically. The vessels are to be weighed during filling 
and subsequently subjected to a weight check on special 
scales to establish possible overfilling. Scales used for this 
purpose must be calibrated.

5. Under certain conditions, gases with a tc  ≥ +70   C 
may be transferred volumetrically from compressed-gas 
vessels with a maximum volume of 150 l to compressed-
gas vessels with a volume of max. 1000 ccm. The 
stipulations of the TRG apply to the transfer of liquefied gas 
to cylinders used by workmen. 

 

6. Vessels in vehicles for

(1) Gases with tc ≥ +70   C (refer to TRG 101 Annex 3) 

(2) Industrial gas mixtures with tc ≥ +70   C (refer to TRG 
102 Annex 1 Groups 3) or 

 

Liquefied extremely low-temperature compressed gases 
(refer to TRG 103) may, contrary to item 4, be filled 
volumetrically if the charging system and/or the vessels 
is/are equipped with devices for measuring or limiting the 
volume of the charge and with the exception of motor 
vehicle vessels as per item 3 for measuring the 
temperature of the charge. When filling volumetrically, it 

Laws and regulations

13/2/2005

 

must be ensured that the permissible charge weight 
indicated on the vessel is not exceeded. To determine 
possible overfilling, the filled containers are to be checked 
gravimetrically on a calibrated scale or provided that the 
pressurized gases are not highly toxic volumetrically. 
Volumetric checking requires the use of appropriate 
equipment with completely separate charging and checking 
devices.

 

7. Charging and check measurements are to be performed 
by different people. Check measurements must be 
performed immediately upon completion of the filling 
process.

 

8. Overfilled vessels must be drained immediately and in a 
safe manner until the permissible fill is attained. The 
compressed-gas fill is then to be determined again.

 

9. Items 4 to 7 do not apply to vessels for liquefied, 
extremely low-temperature compressed gases which are 
neither flammable nor toxic; this does not affect the 
provisions of road traffic legislation.

10. When filling compressed gas vessels with liquefied 
gases at charging temperatures  ≤ -20   C, the 
compressed gas vessel (if the vessel material has not been 
tested for temperatures ≤ -20   C) is not to be released 
from the charging system for transportation until the vessel 
wall temperature is ≥ +20   C. 

 

Recycling and refuse law

 

Converting R12 refrigerant circuit to R134a refrigerant 
circuit and servicing (retrofit)

Note: 

- For environmental reasons and on account of the 
corresponding legislation, refrigerant R12 can no longer be 
manufactured or supplied. Refrigerant R134a has been 
developed as a replacement for R12.  

- Air conditioning systems developed and designed for 
refrigerant R12 cannot however simply be charged with 
refrigerant R134a. To ensure trouble-free operation of the 
air conditioning system even after conversion, various 
components of the refrigerant circuit must be replaced.  

- A precise description of the conversion procedure and 
information on the servicing of converted refrigerant circuits 
can be found in 

 Repair Manual: Air conditioner with 

refrigerant R12 Parts 2 and 3 . 

 

Keeping refrigerant records

Laws and regulations

13/2/2005

 

The environmental statistics law requires records to be kept 
on the use of refrigerants.

Consequently, motor vehicle workshops may well have to 
provide the relevant local authorities with information on 
their use of refrigerant. It is therefore advisable to keep 
records 

 HSO Environment Vol. 2-2. 43.2 

Recycling and refuse law

 

 

Legislation on the handling and disposal of refrigerants and 
refrigerant oils is contained in the BIMISCH (German 
Immission Protection Law) and the Recycling and Refuse 
law.

 Environment Vol. 2 and Vol. 3 

Disposal of refrigerant and refrigerant oil

 

 

Refrigerant

 

Refrigerants intended for disposal are to be transferred to 
marked recycling containers, observing the permissible 
filling quantity.

 

Refrigerant oil

 

Used refrigerant oils from systems employing halogenated 
hydrocarbons are to be disposed of as waste subject to 
special supervision. They are not to be mixed with other 
oils or substances. Proper storage and disposal must be 
ensured in line with local regulations.

 

German technical, work safety and accident prevention 
regulations can be obtained from

 

Beuth-Verlag GmbH

 

Burggrafenstr. 6

 

10787 Berlin

 

Carl Heymanns Verlag KG

 

Luxemburger Str.449

 

50674 Köln

 

(addresses in other countries can be obtained from the 
relevant authorities)

R12 refrigerant circuit, converting to R134a 

Laws and regulations

13/2/2005