Illegal Refrigerants: Why risk it?
Published: 09 August, 2019
Honeywell is urging garages to make sure they don’t source illegal refrigerants when dealing with air con systems this summer.
“Air conditioning is by far the most popular at-cost optional extra for UK car owners and drivers, “said Lee Hermitage, Marketing Director, Honeywell Fluorine Products Europe, Middle East and Africa. “It is not only a comfort perk – it is more often considered a safety feature, too. And rightfully so, since air conditioning can prevent drowsiness and help keep drivers alert. That all is good news for UK garages, because the more air conditioning units are in cars on British roads, the more maintenance they will require.For air conditioning to work, the system has to use a refrigerant and these refrigerants are subject to some pretty tough environmental requirements policed by the Environment Agency to limit emissions from air conditioning units in cars.”
Since January 2017, all new vehicles must be equipped with a low global-warming-potential refrigerant. In most cases this is R-1234yf. However, older vehicles are still equipped with R-134a.
Lee continued: “The first step when servicing car’s air conditioning system, is therefore to understand which refrigerant it contains, since it is illegal to service R-1234yf systems with R-134a.”
It is also essential to check if the product has been legitimately placed on the market: “Counterfeiting or smuggling are not words usually used when talking about refrigeration,” said Lee. “However, they became a reality of the industry lately. In the European Union, illegal products are estimated to make up 20% of the refrigeration market and create 20 million MT of CO2 a year – equivalent to the emissions of four million cars. According to the Environmental Investigation Agency’s study, 72% of users have been offered refrigerant in non-returnable containers, a clear sign of the refrigerant being illegal.
“With illegal products, users do not know what refrigerant really is in the container. Such unknown mixtures can represent a health hazard for technicians working with these refrigerants. An illegal product can also impact the performance of the air-conditioning system, ranging from increasing the fuel consumption to damaging the air-conditioning compressor.
There are consequences: “Being found to be in possession of these illegal products may mean fines are imposed and it may result in custodial sentences. While there is a lot of risk associated with illegal refrigerants, there are steps a business can take to make sure they never use these products.”
- Blast it! How to disinfect air con systems
With cars having been using their air con in full during the warmer months, Helen Robinson, Marketing Director at Euro Car Parts, wants to remind garages that cleaning air conditioning systems remains a good opportunity into the autumn and beyond.
“We’ve all done it – you turn on the air con after not using it for a few months, only to be greeted by a terrible smell. The reason behind this, however, is quite simple. Stagnant water droplets trapped in your dormant system are blasted out, leaving behind a foul odour and some nasty bacteria. While this is a common driver complaint, not every garage is taking the opportunity to upsell and provide a thorough cleaning and disinfection service. Fortunately, you can take three essential steps using products from Normfest that have been specifically designed and formulated to help these troubled drivers.
“The first step is to ‘bomb’ the system with Viro Dry Shot Plus, a powerful anti-bacterial cleaning agent. Using the product is simple – spray it directly into the air intake nozzles that are usually located in the passenger footwell. The spray then disperses throughout the air conditioning system for a thorough, quick and hygienic clean. Viro One Shot Plus eliminates microorganisms, prevents allergic reactions and leaves a lasting pleasant smell. A single can is enough for one application.
“In the second step, Viro Air Fresh Plus is sprayed directly into the air vents and gets to work on the air conditioner’s piping. Over time, a layer of dirt collects in the ventilation ducts and becomes a perfect breeding ground for bacteria and mould. Viro Air Fresh Plus eliminates these odour-causing particles with direct application, enabled by the included tube nozzle. It provides a long-lasting disinfection and leaves a pleasant citrus fragrance. One can contains enough spray for three applications.
“For the third and final step don’t forget the evaporator. For a complete clean, it is recommended that garages also use Viro Vaporizer to disinfect the air conditioner’s evaporator. A layer of dirt can accumulate on the evaporator fins over time, which provides ideal conditions for microorganisms to reproduce. The product cleans with high-pressure flushing, acting across the evaporator’s entire surface. It quickly kills bacteria and fungi and prevents their resettlement. The product is supplied with a 60-centimetre long tube with a rotary nozzle, helping the user to reach all corners of the evaporator. Viro Vaporizer contains enough spray for one air conditioning system. This final step completes the process, providing comprehensive protection against bacteria and bad odours.”
In conclusion, Helen added: “Disinfecting a vehicle’s air conditioning is not just about removing bad smells. It is important to periodically remove the build-up of bacteria, dirt and dust within the system to avoid discomfort, allergies and health complications. This simple three-step process could be combined with a re-gas and a new cabin filter for a complete system rejuvenation. It presents a great opportunity for garages to upsell and provides a service that directly benefits customers – solving a common driver complaint.”
- Keep cool as air con heats up
As we move towards through summer, motorists are dropping the dial across the spectrum on their climate control systems.
According to Adam White, Workshop Solutions Director at Euro Car Parts, repairers can make the most of the opportunity if they are properly equipped: “The key to profitability is offering the right services and performing them efficiently, in terms of both time and cost. By those measures, air conditioning is one of the most profitable service areas a workshop can be involved in – given the right expertise and equipment. Unfortunately, air con work is sometimes overlooked by garages who fail to see the potential profits it could bring to their business. With summer here, there are lucrative opportunities for those who are prepared.
“Air con is a key growth area for UK garages. A lot of customers that visit a workshop have some form of issue with their air con system and the average job takes just five minutes. It’s easy to see why air conditioning remains one of the most profitable services that workshops can offer. If you want to make the most of the summer rush, now is the perfect time of year to invest in quality equipment.”
As many workshops will know, automotive air conditioning systems use one of two specific gas types; either R134A or 1234YF. Adam observed: “Perhaps the most important decision for a workshop is whether to use a dual gas or double single gas setup. This will likely be dictated by the size of the business or the amount of air con servicing undertaken. The primary advantage of a dual gas machine is that you only require one unit to cater for both R134A and 1234YF, meaning less occupied space and reduce costs. The alternative is two separate machines, one for each gas. Having two machines is more expensive but it allows you to service two vehicles at once and offers greater opportunity for revenue-generation.
“Workshops should ideally have the capability to cover both 1234yf and R134a systems. We aim to support the independent aftermarket in any way we can. Our latest Workshop Solutions brochure outlines the profitability of air con servicing and is well worth a read. New machines only require a hands-on time of around five minutes, with the total air-con service time taking between 45 minutes to an hour. This effectively gives you an additional pair of hands in the workshop – an hour of labour that can be used and charged elsewhere.”
Adam continued: “Autoclimate’s products cover most of the UK market and it offers a support service that can fix 72% of the issues workshops encounter over the phone, minimising downtime. For the remaining problems, the company has 18 dedicated air con repair specialists committed to performing on-site repairs within three working days. For peace-of-mind, all its air con machines are eligible for a five-year warranty package with included annual servicing.”
Adam concluded: “Whether you are considering investing in your workshop’s first air con machine or a seasoned veteran looking to upgrade, make sure that you evaluate the market to find one that best suits your requirements. The Workshop Solutions brochure is a great source of information and advice on how to maximise workshop profitability. The latest issue provides interesting insights into air-conditioning, including comparisons of popular models and useful finance examples.”
- Limited spaces still available for first REPXPERT Academy LIVE event
The first REPEXPERT Academy LIVE training day is set to take place on Saturday 16 November at Lincoln College. Spaces are still available, but techs are urged to book now to avoid disappointment. Doors open at 9.30am, and the day runs until 4pm.
- New ADAS seminar from Snap-on
Snap-on is offering a new seminar about ADAS. The event is accredited by the Institute of the Motor Industry (IMI) and gives attendees an overview of ADAS and how the various systems must now be considered part of their everyday work.
- Engine management: Past and future
I have long accepted that nothing stands still for long in this industry. Just when you think you have a grasp of the subject something is sure to upset it. Nothing illustrates this more than powertrain diagnostics. Initially this was called fuel injection, and later became engine management. Now I’m afraid it’s even more complex.
I find myself fortunate to have been there at the beginning; Bosch l Jetronic, a 25 pin ECU with if I recall correctly, only 13 pins occupied. No serial diagnostics, no specific tools. So why was I fortunate? Consider my reflection on diagnostics back in the late 1970s and see if they are still applicable today.
Firstly, you had to understand what the system had to achieve, what components it had at its disposal, what role they played and how they interacted within that system.
The next challenge was measurement values; what to expect under a variety of conditions, and what equipment was required to access this information. This all seems so straightforward now, but in those days it was a little like Columbus sailing across the ocean. He knew it was wet, he needed a boat, he knew which way west was, despite this being blasphemy in the eyes of the Pope, and so set off without a clue as to what was out there.
Hardly a logical diagnostic process, however I was writing the rule book and did understand the meaning of the words test don’t guess. So, what’s changed that undermines these basic principles?
Acessibility
With even the most basic of vehicles now relying on a level of technology that makes accessibility almost impossible, OE manufacturers totally forbid any intrusion within the wiring loom and I am sure this explains the why design and manufacture precludes access as a high priority. However, we are brave, and have the Starship Enterprise at our disposal for our journey of discovery.
The problem is one of integration. Systems don’t function in isolation any more, and Columbus now has to map the Americas and Australia at the same time. In order to conduct an accurate assessment of a function it must be in its natural environment and be observed when functioning normally.
Complexity
This is not restricted to a physical state. It also includes software, algorithms, and predictive response, correction or adaptive action. Systems now change their mode of operation based on environmental influences, affected by a very wide range of changing influences. Cylinder select or dynamic stability comes to mind. The driver selects an option from a long list of choices, engine, transmission, and chassis. I used to say that for a function to occur it must have a command followed by response. In today’s world, the command may be a software decision followed by a constantly changing response, stratified and homogenous fuelling, infinitely changing camshaft timing and variable valve lift to name a few.
Test options
Manufacturers are driven by non-intrusive process dictated by guided diagnostics. Pre-determined test plans more often or not end with a pass or fail result, foregoing any data reveal. Is this due to a control of process and cost, or a mistrust in their techs? Actual evaluation of circuits, voltage, current or complex profile is getting ever more difficult. Attachment of gauges in order to measure pressure and flow is often restricted by sealed transit hoses or internal ducting within castings. Serial data has become so much, more powerful and trustworthy, however it does not and will not replace the functions available from an oscilloscope. Specialist mechanical tools and assembly techniques prohibit casual examination, due to cost or the ever more common single fitment parts.
Data extraction
This may lie in a multitude of directions; Physical extraction, camshaft timing, fuel quantity per stroke via the serial port or fuel pressure rise time via the scope. We are forced to monitor not just a physical value, but not how the PCM is adjusting or adapting a value. How do we know the parameters of operation when VMs are removing more and more data in favour of the pass-fail flags from a software automated test profile?
SENT
Rieve gauche, no not a walk along the Left Bank, but a completely new protocol for data and diagnostic transmission. SENT has been developed specifically for automotive applications, rather than being a black-market hooky copy from other engineering developments. SENT stands for single edge nibble transmission, and is a uni-directional out-only data line to the PCM. SENT is essentially a serial interface, used predominantly with throttle position, air mass and temperatures. The basic unit of time is the tick, with a minimum data unit nibble. 0Data transmission speeds over fast or slow channels, where bitrate can also vary: 1xtick= 3us. In essence it is very similar to a single channel can transmission, where the function includes synchronisation, calibration, CRC and checksum.
How am I to challenge the authenticity of data? For example, sensor error may come from power or ground discrepancies, range error, environment influences, calibration error or simply a genuine condition fault. Its design is of course intended to provide an autonomous diagnostic platform via the serial port, excluding any assessment by the techs.
Full circle
What does this mean for the industry? I suspect it will go full circle back to the 1970s, when part swapping was the norm for Christopher Columbus frauds.
