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