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Leak Testing Expansion valve

Evaporator

Condenser

Compressor

Low pressure gauge High pressure gauge Refrigeration manifold gauge set

Nitrogen cylinder

Fig. 1

Procedure for leak testing in a room air condition unit Connect the compressor and nitrogen cylinder to the refrigeration gauge set as shown in the above figure (Fig.1). Then open the valve of the nitrogen cylinder and after that open the high pressure side valve in the refrigeration manifold. Charge the dry nitrogen up to 150 psi. When high pressure side gauge indicates the 150 psi close the both refrigeration manifold valve and the nitrogen cylinder valve. Then apply liquid soap solution in the welded areas. If soap bubbles are generating from that areas it means there is a leakage in those welded areas. If not the welded joint are in leak proof condition. Then let the nitrogen gas free from the system. If there is a leakage in the system braze the joints again and carry on the above steps. Evacuation

Expansion valve

Evaporator

Condenser

Compressor

Non-return valve

Low pressure gauge High pressure gauge Refrigeration manifold gauge set

Vacuum pump Fig. 2

Nitrogen cylinder

Procedure of evacuation in a room air condition unit First check the oil level in the vacuum pump and make sure it is in appropriate level. Then assemble the compressor and the vacuum pump to the refrigeration manifold gauge set as shown in the above figure (Fig.2). After that switch on the vacuum pump and then open the low pressure side valve (left hand side valve). Vacuum the system up to 29.2 Hg mm below atmospheric pressure. (The pressure can read from the low pressure side gauge) After vacuuming the system switch off the vacuum. After 15 minutes check the pressure indication of the vacuum pump and make sure that the system is vacuum state and leak proof. Expansion valve

Gas charging

Evaporator

Condenser

Compressor

Low pressure gauge High pressure gauge Refrigeration manifold gauge set

Refrigerant cylinder

Fig. 3 Procedure of gas charging in a room air condition unit First assemble the compressor and the refrigerant cylinder to the refrigeration manifold gauge set as shown in the above figure (Fig.3). Then switch on the air condition unit. After switching on the unit, open the shutoff valve of the refrigerant cylinder and then the low pressure side valve of the refrigeration manifold gauge set. Charge the refrigerant gas up to appropriate pressure (60 psi for R22). Then shut off the refrigerant cylinder shut off valve and the refrigerant manifold valve. Disconnect the refrigerant manifold from the air condition unit.

Refrigerant Recovery and Recharge of A Room Air Conditioner

Name: Index No: Field: Date of sub:

Manawadu U.E. 080298N ME 03/03/2012

Discussion
1. Schematic diagram of air conditioning system

2. Components causing High and Low pressures on refrigerant High Pressure: Compressor Low Pressure: Expansion valve 3. Condition of the refrigerant at specific locations Compressor inlet Compressor outlet Low pressure dry saturated or superheated vapor High pressure superheated vapor

Evaporator inlet Evaporator outlet Expansion valve outlet Condenser inlet Condenser outlet

Low pressure mixture of liquid and vapor Low pressure dry saturated or superheated vapor Low pressure mixture of liquid and vapor High pressure superheated vapor High pressure saturated or sub cooled liquid

Expansion valve inlet High pressure saturated or sub cooled liquid

4. Precautions taken when handling N2 As Nitrogen can displace Oxygen when it is leaked in to a closed space, difficulties in breathing can occur. Following precautions have to be taken; Air pressure should be monitored Air pressure should not exceed industry standards Use equipment having no defects

5. Instruments used in the leak test: Refrigeration manifold pressure gauge to monitor standard pressures Vacuum pump to evacuate refrigerant Soap solution to check gas leaks

6. Evacuation is necessary; Moisture and air inside the tubes should be removed from the system and otherwise this will reduce the refrigeration effect Impurities due to welding should be removed from the system and otherwise they can cause blocks in the lines 7. Symptoms of an undercharged system Cooling effect will be reduced Compressor will run under-loaded Low discharge pressure of the compressor Low suction pressure of the compressor

8. Symptoms of an overcharged system Compressor overheated

Compressor running overload Cooling effect is changed Sound of the compressor changes from normal

9. Possible faults in an AC system Compressor blown due to overload Compressor motor windings are blown Condenser fan is not working due to lose contacts, dust Strainer is blocked Capillary tubes are blocked due to dust Thermo stat is not functioning properly Condenser fan motor winding are blown Condenser fins are damaged

10. Precautions taken when charging gas; Refrigerant should be same type that used before Refrigerant cylinder should be in vertical position Make sure that refrigerant manifold gauges are working properly Flush the manifold tubes from the refrigerant to make that no air is entering to the system