New refrigerants R744 and R1234yf -

Service Technology Guide

 SN83.30-P-0001A

SN83.30-P-0001A New refrigerants R744 and R1234yf - Service Technology 26.07.2017

Guide

Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463

Dear reader Here, we will look into the technical background of

In this brochure, we would like to provide you with the
means to answer questions you may have in connection
with refrigerants R744 (carbon dioxide (CO2)) and R1234yf
(C3H2F4). The brochure should also support you in your
daily handling of Daimler car, off-road vehicle, smart and
van model series.
refrigerant systems. Special considerations are underlined
and relevant workshop appliances explained. Additionally,
this information should help you professionally process
customer queries on this topic.
Before carrying out a repair, consult the currently valid
Workshop Information System (WIS) documents.

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Replacing the previous refrigerant, R134a vehicle models will be equipped with safe air conditioning
The former refrigerant has significant potential to harm the systems filled with refrigerant R1234yf (C3H2F4). The air
climate, and, to define this with a uniform measurand, the conditioning system with refrigerant R744 (CO2) is
"Global Warming Potential (GWP)" unit is used. available for the E-Class only when equipped with
THERMOTRONIC (with code (581) automatic air
Mercedes-Benz is equipping the E-Class and S-Class with conditioning (AAC)).
an air conditioning system filled with refrigerant R744
(CO2) — they will be the first series production cars Refrigerant R744 (CO2) and refrigerant R1234yf are so far
globally to have this system. This is to fulfill the EU the only refrigerants, which comply with the future
directive, valid from 2017, which prescribes a "Global requirements of the EU directive for new vehicles with air
Warming Potential (GWP)" of <150 for refrigerants in cars conditioning systems.
and cars approved as commercial vehicles. All other
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Complex redevelopment for air conditioning systems Air conditioning systems with refrigerant R744 (CO2) work
with refrigerant R744 (CO2) with pressure 5 to 10 times higher than previous systems.
The implementation of refrigerant R744 (CO2) requires the The inner cross-sections must be adapted for high volume
redevelopment of all refrigerant circuit components, cooling capacity. This imposes particular demands on the
because the physical characteristics of a refrigerant must design and choice of material.
be taken into account when constructing the components.
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Possible modifications and relevant certifications Inerting systems (with refrigerant R1234yf): The vehicle
Modifications/conversions: Modification/conversion to the does not lose its General Operating Permit (GOP) if the
alternative refrigerant for existing air conditioning systems system stops working, but the inerting system (with
is currently not planned. refrigerant R1234yf) is relevant for certification.

Approval: Approval is only granted by fulfilling International
Organization for Standardization (ISO) standard ISO13043
(precautionary measures for risks). Thus, only safety
precautions especially adapted to these refrigeration
systems will make an approval possible.
Import/export: When importing to Europe, the use of a
refrigerant, which does not violate EU law, is an integral
part of the entire scope of the modification/conversion.
When exporting to other countries, the relevant local laws
apply and may entail modification/conversion.

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Note
This brochure is formed of the following documents.
 
Overview of refrigerants Page 3

Pkw / 1
SN83.30-P-0001A

R744 and R1234yf system Page 4

components in comparison
Design and principle of air Page 5
conditioning system with
R744 and R1234yf
Request to workshop Page 11
Air conditioning system Page 14
maintenance and testing
measures
Inerting system with R1234yf Page 16
Qualification for the handling Page 17
of refrigerants R744 and
R1234yf
Handling of refrigerants R744 Page 18
and R1234yf

2 Pkw /
 SN83.30-P-0001-01A

SN83.30-P-0001-01A Overview of refrigerants

Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463

Overview of refrigerants particularly quickly, enables A/C systems filled with CO2 to
provide a pleasant regulated temperature in the vehicle
Refrigerant R744
interior in a short period of time, despite a high thermal
Carbon dioxide (CO2) with designation R744 is a natural load.
refrigerant with a minimum influence on global warming.
The unit that defines the level of harmfulness for the Refrigerant R1234yf
climate is the "Global Warming Potential (GWP)". CO2 is Along with the refrigerant R744, the refrigerant R1234yf,
the reference variable here with a "Global Warming that was previously only produced on an industrial scale, is
Potential (GWP)" value of 1. From an ecological and the refrigerant that also fulfills the specifications of the EU
technical point-of-view, the refrigerant R744 is an ideal Directive.
refrigerant. It is chemically inactive, neither toxic nor Under certain circumstances, the refrigerant R1234yf
combustible, and it does not exhibit an ozone-depleting exhibits a different inflammation potential than the
potential. refrigerant R134a currently used in industry.
CO2 production does not require a complex procedure. It is Therefore, on vehicles, in which the refrigerant R1234yf is
generated in large quantities as a "residuary product" of used, specially developed safety devices are deployed
industrial and chemical production processes. CO2 does depending on the vehicle configuration involved.
not need to be recycled. The high cooling output, available
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Type plate
The model plate for the refrigerant used and the vehicle-
specific refrigerant quantity is located in a visible area of
the engine compartment.
 
Refrigerant use
R744 R1234yF
Model 213 All other Mercedes-Benz car model series such as smart,
In combination with Thermotronic (code 581 (Automatic air off-road vehicles, vans with car approval
conditioning)).
Not used in hybrid vehicles, Mercedes-AMG vehicles and
vehicles equipped with Thermatic (code 580 (Air
conditioning system)).
Model 217, 222
Series production scope, not used in hybrid vehicles and
Mercedes-AMG vehicles.

Refrigerant comparison
Properties R744 R1234yF R134a
"Global Warming Potential 1 4 1430
(GWP)" (see example at
foot of table)
System pressure in bar 100 10 10
(approx. values)
Safety group A1 A2 A1
"Global Warming Potential (GWP)" example: 1 kg R134a contributes to global warming as with 1430 kg CO2.

Pkw / 3
SN83.30-P-0001-02A

SN83.30-P-0001-02A R744 and R1234yf system

components in comparison

Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463

P83.30-5135-78

Comparison of system components

A/C with refrigerant R1234yf Air conditioning with refrigerant R744
Condenser with refrigerant collector (with desiccator Condenser (gas cooler) (1b)
cartridge) (1a)
Refrigerant compressor (A9) Refrigerant compressor (A9)
Refrigerant compressor with magnetic clutch (A9/7) Refrigerant compressor with magnetic clutch (A9/7)
Evaporator (2) Evaporator (2)
Thermostat-controlled expansion valve (constant throttle) CO2 expansion valve (Y148), electrical expansion valve
(5)
Elastic and rigid lines with internal heat exchanger (4) Accumulator with internal heat exchanger (3) (with drier)
Conventional connection technology (radial/axial elastomer Elastic and rigid lines High-pressure connection
seals) technology with metallic sealing system
Refrigerant pressure sensor (B12) (not illustrated) CO2 pressure/temperature sensor downstream of gas
cooler (B12/4)
- CO2 pressure/temperature sensor upstream of gas cooler
(B12/5)
- CO2 sensor (B98) in A/C housing under instrument panel
(not illustrated)

4 Pkw /

SN83.30-P-0001-03A Design and principle of air
conditioning system with R744
and R1234yf
Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463
Comparison of A/C systems with refrigerant R744 and
A/C systems with refrigerant R1234yf
In principle, a refrigerant circuit with refrigerant R744
(carbon dioxide (CO2)) is similarly structured to that of an
air conditioning system operating with refrigerant R1234yf.
Function principle of A/C system with refrigerant R744
The refrigerant R744 is compressed in the refrigerant
compressor (A9) or in the refrigerant compressor with
magnetic clutch (A9/7) to a maximum of 130 bar. The heat
produced by this is dissipated into the environment via the
condenser (gas cooler), and the compressed refrigerant
R744 is cooled or, at temperatures below 30 ℃,
condensed.
The refrigerant mass flow is then cooled further in the
internal heat exchanger before being throttled in the CO2
expansion valve (Y148) (electrical expansion valve) and
flowing into the evaporator at low pressure. There the
refrigerant begins to evaporate. The necessary heat for the
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Differences in system components
The structure of the refrigerant circuit with refrigerant
R134a is identical to the refrigerant circuit with refrigerant
R1234yf.
Compared to the refrigerant circuit with refrigerant R1234yf,
there are significant differences in the refrigerant circuit
with refrigerant R744 in terms of the pressure, the
temperature of the refrigerant after compression, the
properties of the refrigerant, the arrangement of the
components and the connection technology used.
While in an A/C system with refrigerant R1234yf the
refrigerant reservoir (collector) is situated on the high-
pressure side, the accumulator (with drier) in the A/C
system with refrigerant R744 is located on the low-pressure
side.
The volume in A/C systems with refrigerant R744 is
considerably lower because only approx. 350 g of
refrigerant R744, for example, is required, compared to
approx. 630 g of refrigerant in a conventional charge with
refrigerant R134a or refrigerant R1234yf.
Due to the high pressure of the A/C system with refrigerant
R744, the line cross sections are smaller.
Pkw /
SN83.30-P-0001-03A
evaporation process of the refrigerant R744 in the
evaporator is taken from the air flowing past, which is
cooled. This cooled air stream cools the vehicle interior.
After the evaporator, the refrigerant R744 has a pressure of
only 30 to 50 bar and a temperature from slightly over
0 to 15 ℃.
The refrigerant R744 now flows through the accumulator
(with drier) and then enters the internal heat exchanger to
absorb heat. The accumulator (with drier) buffers the
refrigerant R744 from various operating states and contains
a refrigerant reservoir.
In the internal heat exchanger, the refrigerant R744 heats
up and is then drawn in and compressed again by the
refrigerant compressor (A9) or by the refrigerant
compressor with magnetic clutch (A9/7). The circuit starts
again from the beginning.
The accumulator (with drier) and internal heat exchanger
may be separate or combined in a single component.
In A/C systems with refrigerant R1234yf, thermostat-
controlled expansion valves are used as the flow-control
elements.
In A/C systems with refrigerant R744, the refrigerant mass
flow is regulated by the CO2 expansion valve (Y148)
(electrical expansion valve).
The refrigerant compressor (A9) or the refrigerant
compressor with magnetic clutch (A9/7) of the A/C system
with refrigerant R744 requires only approx. 1/5 of the
displacement previously required. Its aluminum housing is
manufactured by a specially developed pressure die
casting process which guarantees the required
leaktightness combined with high component strength.
The refrigerant compressor (A9) or the refrigerant
compressor with magnetic clutch (A9/7) of the A/C system
with refrigerant R744 is controlled with an electrical
differential pressure valve; the refrigerant compressor (A9)
or the refrigerant compressor with magnetic clutch (A9/7) of
the A/C system with refrigerant R1234yf uses a suction
pressure valve for this.
Service connections are installed on the high-pressure and
low-pressure sides for Service to empty and fill the
refrigerant circuit. These are geometrically designed
according to a Society of Automotive Engineers (SAE)
standard to avoid confusion between the high-pressure and
5
SN83.30-P-0001-03A

low-pressure sides, and also with other refrigerants

(e.g. R134a).
 

Schematic diagram of refrigerant

circuit with refrigerant R744
1 Condenser (gas cooler)
2 Evaporator
3 Accumulator (with drier)
and internal heat
exchanger
A9 Refrigerant compressor
A9/7 Refrigerant compressor
with magnetic clutch
Y148 CO2 expansion valve
A Line (from refrigerant
compressor (A9) or
refrigerant compressor
with magnetic clutch
(A9/7) to condenser (gas
cooler))
B Line (from accumulator
(with drier) and internal
heat exchanger to
refrigerant compressor
(A9) or refrigerant P83.30-5119-76
compressor with magnetic
clutch (A9/7))
C Line (from evaporator to
accumulator (with drier)
and internal heat
exchanger)
D Line (from accumulator
(with drier) and internal
heat exchanger to
evaporator)
E Line (from condenser (gas
cooler) to accumulator
(with drier) and internal
heat exchanger)

6 Pkw /
 SN83.30-P-0001-03A

Overview of temperatures and pressures

Ite Line Temperature and pressure in line
m
Line From refrigerant compressor (A9) or refrigerant compressor with 30...160 ℃; 50...130 bar
(A) magnetic clutch (A9/7) to condenser (gas cooler)
Line From accumulator (with drier) and internal heat exchanger to refrigerant 0...30 ℃; 30...50 bar
(B) compressor (A9) or refrigerant compressor with magnetic clutch (A9/7)
Line From evaporator to accumulator (with drier) and internal heat exchanger 0...15 ℃; 30...50 bar
(C)
Line From accumulator (with drier) and internal heat exchanger to evaporator 5...35 ℃; 50...130 bar
(D)
Line From condenser (gas cooler) to accumulator (with drier) and internal 5...55 ℃; 50...130 bar
(E) heat exchanger

Sealing system for interfaces with refrigerant R744

11 Male part
12 Female part
13 Positioning pin
14 Retainer
15 Metal sealing washer
16 Spring element
17 Special screw

P83.30-5120-81

Sealing system for interfaces with refrigerant R744
The sealing system for interfaces in the refrigerant circuit
was designed in accordance with German Industrial
Standard (DIN) specifications and has been specially
developed for the refrigerant R744.
The metal sealing washer (15) used must be stable and
absolutely gas-tight in the specified pressure and
temperature range, which places particular demands on
material and composition. The retainer (14) consists of a
hard component and a soft component and has also been
designed with the strict requirements in mind to keep the
gap between the male part (11) and the female part (12)
free of fluids.

Pkw / 7
SN83.30-P-0001-03A

Single-evaporator system with

refrigerant R744, shown on model
222
1 Condenser (gas cooler)
2 Evaporator
3 Accumulator (with drier)
and internal heat
exchanger
7 High-pressure limiting
element
8 Low-pressure limiting
element
9 Low-pressure side
service port
10 High-pressure side
service port
A9 Refrigerant compressor
A9/7 Refrigerant compressor
with magnetic clutch
B10/6 Evaporator temperature
sensor
P83.30-5121-76
B12/4 CO2 pressure/
temperature sensor
downstream of gas
cooler
B12/5 CO2 pressure/
temperature sensor
upstream of gas cooler
B14 Outside temperature
sensor
N22/1 Climate control system
control unit
Y148 CO2 expansion valve

8 Pkw /
 SN83.30-P-0001-03A

2-evaporator system with

refrigerant R744, in model 222
1 Condenser (gas
cooler)
2 Evaporator
2/1 Rear climate control
evaporator
3 Internal heat
exchanger
3/1 Accumulator (with
drier)
7 High-pressure limiting
element
8 Low-pressure limiting
element
9 Low-pressure side
service port
10 High-pressure side
service port
A9 Refrigerant
compressor
P83.30-5122-76
A9/7 Refrigerant
compressor with
magnetic clutch
B10/6 Evaporator
temperature sensor
B10/11 Rear climate control
evaporator
temperature sensor
B12/4 CO2 pressure/
temperature sensor
downstream of gas
cooler
B12/5 CO2 pressure/
temperature sensor
upstream of gas
cooler
B14 Outside temperature
sensor
N22/1 Climate control system
control unit
Y148 CO2 expansion valve
Y148/2 Rear air conditioning
CO2 expansion valve

Pkw / 9
SN83.30-P-0001-03A

Single-evaporator system with

refrigerant R744, shown on model
213
1 Condenser (gas cooler)
2 Evaporator
3 Accumulator (with drier)
and internal heat
exchanger
7 High-pressure limiting
element
8 Low-pressure limiting
element
9 Low-pressure side
service port
10 High-pressure side
service port
A9 Refrigerant compressor
A9/7 Refrigerant compressor
with magnetic clutch
B10/6 Evaporator temperature
sensor
P83.30-5123-76
B12/4 CO2 pressure/
temperature sensor
downstream of gas
cooler
B12/5 CO2 pressure/
temperature sensor
upstream of gas cooler
B14 Outside temperature
sensor
Y148 CO2 expansion valve

10 Pkw /
 SN83.30-P-0001-05A

SN83.30-P-0001-05A Request to workshop

Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463

Air conditioning service unit for R134a

P83.30-5125-11

Air conditioning service unit for refrigerant R134a
The minimum requirements needed for air conditioning
service units for refrigerant R134a to meet the Mercedes-
Benz standard are described in document WS83.00-
P-0031B in the Workshop Information System (WIS) to
support retail with procurement measures. Important here
is that, in addition to meeting the appropriate Society of
Automotive Engineers (SAE) standard, air conditioning
service units for refrigerant R134a are able to process
various oils, and accessories for cleaning a vehicle's air
conditioning system can be ordered at the same time.

Air conditioning service units for

refrigerant R1234yf

P83.30-5126-75

Pkw / 11
SN83.30-P-0001-05A
Air conditioning service unit for refrigerant R1234yf
Specific air conditioning service units for refrigerant
R1234yf are necessary for work to air conditioning systems
with refrigerant R1234yf. A selection of approved air
conditioning service units for refrigerant R1234yf and the
relevant order information can be found in the Electronic
Parts Catalog (EPC) under number W 000 588 10 82 00.
Air conditioning service combined units, which can process
refrigerant R134a and refrigerant R1234yf, are also listed
here.
These air conditioning service units for refrigerant
R1234yf,or air conditioning service combined units for
refrigerant R134a and refrigerant R1234yf, have been
developed and tested for refrigerant circuit according to the
Air conditioning service units for refrigerant R744
Air conditioning service units for refrigerant R744
Specific air conditioning service units for refrigerant R744
are necessary for work to air conditioning systems with
refrigerant R744. A selection of approved units and the
relevant order information can be found in the EPC under
number W 000 588 09 82 00. These air conditioning
service units for refrigerant R744 have been developed and
tested for refrigerant circuit according to the Mercedes-
Benz standard by Team Workshop Appliance Product
Technology in cooperation with those responsible for repair
technology and systems development.
A high degree of quality when constructed (e. g.
compliance with certain SAE standards and securing
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Hydrogen gas trace instrument
The criteria catalog serves to support retail with
procurement measures. The hydrogen gas detection unit
can usually be sourced from manufacturers of approved
leak testers or selected on the open market based on the
12
Mercedes-Benz standard by Team Workshop Appliance
Product Technology in cooperation with those responsible
for repair technology and systems development. A high
degree of quality when constructed (e. g. compliance with
certain SAE standards and protection classes) is required
alongside, among others, the need for high accuracy in
refrigerant dosing (tolerance range of ±15 g) and a practical
implementation of gas analysis.
i
We wish to state explicitly that service work to Mercedes-
Benz and smart vehicles with air conditioning systems with
refrigerant R1234yf must only use the air conditioning
service units recommended in retail.
P83.30-5127-81
measuring equipment against damage) is required
alongside, among others, the need for high accuracy in
refrigerant dosing (tolerance range of ±10 g) and an
operating pressure of up to 140 bar. The amount of time
spent on the filling process is optimized by determining the
discharge rate of the carbon dioxide (CO2) gas cylinder
and using the vehicle's own refrigerant compressor (A9) or
refrigerant compressor with magnetic clutch (A9/7).
i
We wish to state explicitly that service work to Mercedes-
Benz vehicles with air conditioning system with refrigerant
R744 must only use the air conditioning service units
recommended in retail.
criteria catalog. The criteria catalog only describes the
minimum requirements for fulfilling the Mercedes-Benz
standard. Therefore, there is no exigent reference to the
equipment or devices of specific manufacturers.
Minimum requirements:
Pkw /
 SN83.30-P-0001-05A

• The measuring range comprises at least 10 to 500 ppm. • The hydrogen gas detection unit provides the user with
• Measurement display: Hydrogen concentration is given acoustic feedback regarding hydrogen concentration.
in an increment ≤ 10 ppm.
• The measuring tip is attached to a flexible extension
(gooseneck).

Pkw / 13
SN83.30-P-0001-06A

SN83.30-P-0001-06A Air conditioning system

maintenance and testing
measures
aDanger Risk of explosion when using Wear safety glasses and AS83.00-Z-0001-02A
a forming gas with incorrect protective gloves. No smoking
mixing ratio. Risk of suffocation or open flames. Work in well-
due to inhalation of forming gas. ventilated rooms only.
Risk of injury due to bursting of
high-pressure hoses.

Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463

Maintenance • Service 26: (Only) ECE every 125,000 km

Maintenance is specified as follows: • Engine compartment: Evacuate and refill the A/C
• Air conditioning systems with refrigerant R1234yf are refrigerant.
maintenance free.
• Air conditioning systems with code 1U6 (Refrigerant
R744) as follows:
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Diagnosis
The diagnosis scopes are created as for air conditioning
systems with refrigerant R134a. Basically, all electronic
component part can be diagnosed.
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Fill-level inspection for an extended period of time, e.g overnight (idle state of
The fill level is determined by the air conditioning service refrigerant circuit). The pressure of the refrigerant circuit or
unit for refrigerant R744 as well as by air conditioning the gas bottle alone does not provide any indication about
service unit for refrigerant R1234yf through completely the actual residual quantity of refrigerant in the refrigerant
draining the refrigerant circuit. Theoretically the fill level can circuit or the gas bottle!
be calculated through diagnosis if the vehicle is not moved
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Leak test with forming gas i
Additional workshop appliances are required for the After a leak test the forming gas must be completely
method used for searching for leaks and the leak test with evacuated from the refrigerant circuit, as any residue by the
the aid of forming gas (95 % nitrogen, 5 % hydrogen). The air conditioning service unit will be detected as
leak tester, which operates with forming gas (95 % contamination for refrigerant R744 as well as by the air
nitrogen, 5 % hydrogen), can be used to conduct pressure conditioning service unit for refrigerant R1234yf, whereby a
tests of the refrigerant circuit. It is equipped with service filling with refrigerant R1234yf is then no longer possible!
couplings for the 3 different types of air-conditioning
i
systems (with refrigerants R134a, R1234yf and R744).
To completely evacuate the forming gas, the valves of the
The additional hydrogen gas detection unit is used to service connection for the refrigerant circuit have to remain
localize leakages. open sufficiently long.
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Warning and safety information operator's manual must be carefully read by each user
The warning and safety information on the air conditioning before using it for the first time. The user may only conduct
service unit for refrigerant R1234yf and in the operator's the maintenance operations expressly permitted by the
manual must always be observed by the user. The manufacturer and as described in the operator's manual.

14 Pkw /

The warning and safety information on the air conditioning
service unit for refrigerant R744 and in the operator's
manual must always be observed by the user. The
operator's manual must be carefully read by each user
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Inerting system (air conditioning systems with
refrigerant R1234yf)
The inerting system is not maintenance relevant. The
pressure medium reservoir is a "T1 component part"
(classification code hazardous materials) or hazardous
material. It may only be handled by trained personnel, as
Pkw /
SN83.30-P-0001-06A
before using it for the first time. The user may only conduct
the maintenance operations expressly permitted by the
manufacturer and as described in the operator's manual.
with an airbag. The connection points are safety relevant.
After working procedures are conducted on the system, the
system must be tight again.
System continuity must be assured not only after a frontal
impact. The system may need to be checked even in the
event of a side impact.
15
SN83.30-P-0001-08A
SN83.30-P-0001-08A Inerting system with R1234yf
Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463
Inertization system
1 Inert gas lance
2 Inert gas line
3 Inert gas cartridge
Inertization system
The inerting system is a newly developed safety system for
the refrigerant R1234yf. The refrigerant R1234yf has a
different ignition potential from the refrigerant R134a used
previously and from the refrigerant R744.
Depending on the vehicle configuration and on the
arrangement of the components relative to each other in
the engine compartment, and because of the higher
exhaust gas temperatures in gasoline engines compared to
diesel engines, a safety (inerting) system is installed which
has been developed specifically for the use of refrigerant
R1234yf.
In the event of a severe frontal impact, the system ensures
that the resulting refrigerant/air mixture in the engine
compartment is separated from hot engine parts. In
addition, these parts are effectively cooled.
16
P83.30-5124-79
4 Electrical wiring harness
N2/10 Supplemental restraint system control unit
This is done by a pressurized cartridge (3) of inert gas
(argon). The targeted release of inert gas (argon) at the
appropriate hot spots can counteract the potential ignition
of the refrigerant R1234yf.
Like the airbags, seat belt tensioners etc., the inerting
system is activated in the event of a crash by the
Supplemental Restraint System control unit (N2/10). The
inert gas cartridge (3) containing the inert gas (argon) at
high pressure is then opened pyrotechnically, i.e. by means
of a rapid burn-off process.
The pressure forces the inert gas (argon) through the open
cap into the connected inert gas line (2) and on via the inert
gas lance (1) onto the hottest components in the engine
compartment (the exhaust gas turbocharger and partly the
exhaust manifold). The components are thus shielded from
inflammable mixtures of air and gaseous refrigerant
R1234yf and are actively cooled.
Pkw /

SN83.30-P-0001-09A Qualification for the handling of
refrigerants R744 and R1234yf
Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463
Range of "Global Training" courses
The handling of the refrigerants R744 and R1234yf is being
incorporated into the existing range of training and
accreditation courses offered by "Global Training". It can
therefore be booked through the familiar channels for retail
operations.
The Chemicals Climate Protection Ordinance (EC
307/2008) requires a certificate of competence (DE
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Training content
Design and function of air conditioning system with new
refrigerant R744.
Design and function of air conditioning system with
refrigerant R1234yf.
Performing a professional diagnosis on refrigeration
systems with the appropriate air conditioning service unit
for refrigerant R744 or R1234yf (evacuating, leak testing,
filling, pressure testing).
Pkw /
SN83.30-P-0001-09A
243487) for work on passenger car air conditioning
systems.
The certificate of competence is the requirement for
participation in the training courses for air conditioning
systems with refrigerants R744 and R1234yf in Mercedes-
Benz vehicles.
This course is aimed at maintenance, repair and system
technicians.
Performing a professional diagnosis on the air conditioning
system with XENTRY Diagnosis.
Describing the new features of the air conditioning system
in model 213 and in model 222 with respect to design and
function.
Overview of the additional functions of the air conditioning
system in hybrid vehicles.
17
SN83.30-P-0001-10A
SN83.30-P-0001-10A Handling of refrigerants R744
and R1234yf
aDanger Risk of fire due to ignition of
R1234yf refrigerant on hot
components. Risk of poisoning
caused by inhaling overheated
refrigerant vapors. Risk of
injury to skin and eyes caused
by contact with escaped
R1234yf refrigerant and when
working on pressurized parts.
Risk of explosion due to
formation of ignitable
refrigerant/air mixtures
Model 117, 156, 166, 172, 176, 190, 205, 213, 217, 222, 231, 238, 242, 246, 253, 292, 415, 447,
453, 461, 463
Work safety
Safety information on the refrigerants R744 and R1234yf
and on working on high-pressure systems is published in
the Workshop Information System (WIS).
Risks and safety precautions
The relevant risks associated with the refrigerant R744
(carbon dioxide (CO2)) in production and Service are:
• Flying fragments of components and detachable parts,
fragments of fittings.
• Escaping refrigerant R744 with high kinetic energy due
to the high pressure.
• Inhalation of high refrigerant R744-/CO2 concentrations.
The design and location of the components are intended to
prevent vehicle users or technicians from being exposed to
hazards in the course of proper use, maintenance, repair
and scrapping of the vehicle.
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Notes on handling refrigerant R1234yf
The refrigerant R1234yf is colorless and odorless. At
normal temperatures it is not toxic. The refrigerant R1234yf
is inflammable and in certain mixing ratios with air it can
ignite. The refrigerant R1234yf may only be used in air
conditioning systems which are approved for the refrigerant
R1234yf. The refrigerant R1234yf may not be mixed with
other refrigerants (e.g. R134a).
The refrigerant R1234yf does not contain any
chlorofluorocarbons (CFCs). The refrigerant R1234yf does
not damage the earth's ozone layer. It has a GWP (Global
Warming Potential) of 4. Nevertheless, the refrigerant
R1234yf may only be extracted by experts with suitable
extraction and recycling equipment. Contaminated
refrigerant R1234yf must not be extracted using the air
18
Never perform welding work on AS83.00-Z-0007-01A
or near a closed air conditioning
system. No smoking or open
flames. Wear safety glasses
and protective gloves. Work
only in well ventilated rooms.
Carry out repair work on the air
conditioning system circuit only
after the system has been
evacuated.
The components of the systems are developed for the
maximum permissible operating pressure. They must
withstand the burst pressure, which corresponds to at least
12 times the maximum permissible operating pressure. The
systems are equipped with pressure limiting valves which
are triggered when the maximum permissible operating
pressure is exceeded. With these, the refrigerant R744
should escape without posing a hazard to persons.
Personnel working on the system should know the location
of the pressure limiting valves.
Nobody should be underneath the vehicle when the system
is being filled with refrigerant. The vehicles may only be
filled with the permissible quantity of refrigerant R744.
Systems with the refrigerant R744 can be drained in the
workshop when normal ventilation in the work areas is
guaranteed.
conditioning service unit for refrigerant R1234yf. Special
aids must be used which are intended only for extracting
contaminated refrigerant R1234yf from air conditioning
systems with refrigerant R1234yf.
Procurement of the alternative refrigerants
The refrigerants R744 and R1234yf of the required purity
are freely available commercially in all the relevant
markets.
Storage and disposal
The refrigerant R744 does not to be specifically disposed
of. The service units certified by Mercedes Benz dissipate
the refrigerant R744 into the environment at a harmless
rate.
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The refrigerant R1234yf can be reprocessed and reused
with the air conditioning service unit. Contaminated
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Potential risks
• Fire hazard
• Risk of asphyxiation
• Risk of injury
• Risk of explosion
• Risk of poisoning
Fire hazard
The refrigerant R1234yf is highly flammable and in certain
mixing ratios with air it can ignite. In the event of a fire,
hazardous decomposition products such as, e.g. hydrogen
fluoride, acyl halide, carbon monoxide (CO) and CO2 can
be produced and released.
Risk of asphyxiation
At high concentrations of refrigerant R1234yf there is a risk
of asphyxiation.
Risk of injury
Compressed refrigerant R1234yf is present in the lines and
components of the air conditioning system. Even after the
air conditioning system has been evacuated, overpressure
may still be present when detaching the plug connections
of the air conditioning system.
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First-aid measures
• In the event of contact with eyes
• With the eyelid wide open, thoroughly rinse for at
least 10 min with flowing water. Seek medical
attention immediately.
• In the event of skin contact
• Use water to defrost body parts iced-up by cold fluid,
then carefully remove clothing. Rinse with plenty of
water and wash contaminated clothing before
reusing. Seek medical attention immediately.
Pkw /
SN83.30-P-0001-10A
refrigerant R1234yf must be disposed of via the process of
the refrigerant manufacturer.
Risk of explosion
Ignitable mixtures may form in combination with refrigerant
vapors.
Risk of poisoning
The refrigerant R1234yf can decompose when overheated.
The resulting substances are toxic and should never be
inhaled. Avoid contact with skin.
Consequently:
• Change contaminated clothing immediately.
• Open radiant heaters must not be operated.
• Prior to performing repair work on the refrigerant circuit
and on components of the air conditioning system,
always extract the refrigerant R1234yf from the entire
system.
• In order to protect the workshop personnel and the
atmosphere, evacuation of refrigerant R1234yf directly
into the environment is prohibited.
• Even after the system has been evacuated,
overpressure may still be present when unfastening
plug connections of the air conditioning system.
Therefore, unfasten the plug connections carefully, so
that the pressure can reduce slowly.
• In the event of ingestion
• Rinse out mouth thoroughly with water. Seek
medical attention immediately.
• In the event of unconsciousness
• Keep and transport affected persons in the recovery
position. If breathing is arrested, bend head towards
neck and perform artificial respiration. Summon
medical attention immediately.
19
SN83.30-P-0001-10A

20 Pkw /