Automotive Air Conditioning 2

Course objective and programme

On successful completion of this course you will be expected to effectively:
Understand the health and safety aspects relevant to working

with these systems

Understand the fundamental principles and operation of air conditioning systems and climate control Apply that understanding to a basic diagnostic process

Carry out servicing of these systems.

Environment

Ozone hole

UV Radiation

UV Radiation

1: CFC is released 2 :CFC rises into ozone layer 3 : UV releases CL from CFC

4 : CL destroys ozone 5 : Depleted ozone => more UV 6 : More UV => more skin cancer

Environmental damage potential

Global warming potential is in relation to CO2=1 Ozone depleting potential is in relation to other ozone destroying substances such as (R11 = 1) HFC R134a Ozone depleting potential = 0 Global warming potential = 1300 GWP will be limited in future to 150 (Directive 2006/40/EC) CFC R12. Classified as: High ozone depletion potential = 1 Big global warming potential (GWP = 8500)

Refrigerant CFC12 (CCl2F2):

CFC = Chloro Fluoro Carbon, completely halogenated chloroflourocarbon. Since it contains chlorine, it is very likely to cause ozone depletion. CFC 12, which is used as a refrigerant for automotive air Conditioners, is also subject to restriction as a substance which depletes the ozone.

F F C CL CL
Cause of ozone depletion

Role of ozone

Ultraviolet rays

Oxygen atom

Oxygen molecule

Ozone

Green house effect

Refrigerant HFC-134a
CH2FCF3
Carbon atom = 2

H F C
H

Hydrogen atom = 2
Fluorine atoms = 4

C
F

HFC = Hydro Fluoro Carbon, contains hydrogen elements. Since it does not contain chlorine, it does not cause ozone depletion.

F Gas Guidance from IMI as of 6th May 08

Date
4th July 2007

Regulation
Must stop using none refillable R134a containers (unless existing stock) Any technician working on A/C must have received some form of formalised training (in house training sufficient)

Action
Stop using them!

Solution
Brief all workshop staff as appropriate

4th July 2007 Providing this target was reached work on A/C can continue until July 2010 4th July 2008

Arrange training to Check ensure compliance training record of staff

Any technician working on AC without prior learning can only work under the supervision of someone who has. 1 year only. After that - until he must have completed a DEFRA approved qualification
You can no longer purchase R134a unless you are / or employ a DEFRA approved qualified technician

Check training records of staff

Arrange training / assessment to ensure compliance

Date still to be set

Check training records of staff

Arrange training assessment to ensure compliance

Type Approval

From the 1st January 2008, vehicle type approval will not be granted to vehicles fitted with an air conditioning system designed to contain R134a unless the leakage rate is 40g for a single evaporator and 60g for a double evaporator.

Kyoto Protocol
What is it?
The Kyoto Protocol is an amendment to the international treaty on climate change, - emission reduction of greenhouse gas emissions to the signatory nations.

The aim?
To stabilization of greenhouse gas concentrations in the atmosphere at a level that would prevent dangerous interference to the climate.

When did it happen?

As of December 1997, a total of 169 countries and other governmental entities have ratified the agreement (representing over 61.6% of emissions from all countries in agreement)

Montreal Agreement

What is it?
The Montreal Protocol on Substances that Deplete the Ozone Layer is an international treaty designed to protect the ozone layer by phasing out the production of a number of substances believed to be responsible for ozone depletion.

The aim? The treaty is structured around several groups of

halogenated hydrocarbons that have been shown to play a role in ozone depletion. All of these ozone depleting substances contain either chlorine or bromine (substances containing fluorine only do not harm the ozone layer). For each group of substances, the treaty provides a timetable on which the production of those substances must be phased out and eventually eliminated.

When did it happen?

The treaty was opened for signature on September 16, 1987 and entered into force on January 1st 1989. Since then, it has undergone five revisions, in 1990 (London), 1992 (Copenhagen), 1995 (Vienna), 1997 (Montreal), and 1999 (Beijing).

EC waste regulations
From 1991 it has been illegal to deliberately release R134a or R12 into the atmosphere. (Refer to section
33/34 of the Environmental Protection Act 1990 (EPA).

The use of R12 is banned in the UK.

From 1st October 2000 it became illegal to trade R12.

From 1st October 2001 it became illegal to service systems containing R12.

Waste Product Legislation and Records

Used refrigerants are A/C waste products are controlled by legislation. It is not yet law, but it is good practice to keep records of the quantities of refrigerants which you use. Use the sheet provided and strap it to recycling machine. Records must therefore be kept about these waste products. If needing to dispose of refrigerant/contaminated refrigerant, BOC and other gas handling companies will take it and dispose of it in an environmentally sensitive manner. They will need a Waste Transfer Note before they will accept refrigerant.

Climate Change The refrigerants used in vehicle airconditioners affect the environment and contribute to ozone and greenhouse effect problems.

Ozone problem
Ozone (03) protects the Earth's surface against ultraviolet radiation by absorbing most of it Chlorine (Cl) atoms in refrigerants (e.g. R12) destroy the ozone layer if irradiated with ultraviolet light Greenhouse effect All refrigerant molecules contribute to atmospheric heating. They prevent the sun's rays reflected from the surface of the Earth from being re-radiated by the atmosphere (infrared radiation).

Chlorine released from type R12 (CFC 12) into the atmosphere damages the ozone layer
Both R12 and R134a are greenhouse gasses

Refrigerant properties
REFRIGERANT Molecular formula Molecular weight Boiling point (1atm,) Freezing point () R-134a CH2FCF3 102.03 -26.3 -108.0 R-12 CCL2F2 120.91 -28.9 -155.0

Critical temperature ()
Saturated vapor pressure

101.29
2.98 kg/ (0) 17.11 kg/ (60)

111.8
3.15 kg/ (0) 15.51 kg/ (60) 36.43 kcal/ 27.33 kcal/ 4.4 (0) 60)

Evaporation latent heat

47.04 kcal/ 33.18 kcal/

(0) (60)

Molecular size

4.2

Toxicity
Remaining time in the atmosphere Mineral oil solubility

Possible (burning)
8~11 Year Bad

No
95~150 Year Good

NOTE: Do not mix up refrigerants

Pressure and boiling point

Vapor pressure diagram R134a/R12

bar 45 40 35 30 25 20 15 10 5 0
-2 0 0

liquid

R134a R12

gaseous
20 40 60 80 10 0 C

Modification from R12 and R134a system

Component Condenser Compressor Compressor oil Hose material Desiccant High pressure switch Charging ports R-12 system Serpentine type NBR O-ring seals Mineral oil NBR hose Molecular sieve XH 5 27kg /cm2 SAE type R-134a system Parallel flow type H-NBR O-ring seals PAG Oil Hybrid type hose Molecular sieve XH 9/ XG 7 32kg /cm2 Quick connector and suction fitting adapter

NBR

: Nitrile Butadiene Rubber

*PAG : Polyalkalene Glycol ( Synthetic oil ) *HNBR : Hybrid Nitrile Butadiene Rubber

System overview
2 1

High pressure (gas)

High pressure (liquid) Low pressure (liquid) Low pressure (gas)

3
1. Compressor

2. Evaporator
3. Expansion valve 4. Dryer /Collecting tank 5. Condenser

Refrigerant properties

Refrigerant properties

5 4 6

1 7

Refrigerant properties

5 4 6

1 7 8

Swash plate compressor

Sucti Disch on arge valve valve S h af t

Discharge valve Suction valve

S w Pi as st h o pl n at e

Variable swash plate compressor

Piston Outlet chamber Swash plate

Inlet chamber

Shaft

Control chamber

Control valve

AC Regulations and Refrigerants Topics

Refrigerants the alternatives to R134a Regulation of the industry

Summary What does this mean for us!

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

Background The whole issue is about reducing emissions that contribute to the Greenhouse effect. R134a has a global warming potential (GWP)of 1300! This means for 1 Kg of R134a released into the atmosphere it is equivalent to 1.3 tonnes of CO2 Considering that by 2020 the European car-park will have 230 million cars with AC fitted.

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

Question: How long would you have to stop driving to compensate for the greenhouse effect, if you had a leak that caused complete loss of refrigerant?
Answer 6 months

The average loss from an AC unit is 57grams per year (based on a 750 gram charge) This can vary between 35 to 100 depending on the quality of components.

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

European Commission statement:
The objective is to make a significant contribution to the European Communitys Greenhouse gas emission reduction target under the Kyoto Protocol.

Proposal
Obligation to prevent and minimise leakage. Annual inspections for leakage. Recording of refrigerant amounts added and recovered. Training and certification of personnel involved in, leakage inspection, recovery, recycling, reclamation and destruction. The initial charge of an AC system after the 1st January 2008 must be with a refrigerant having a GWP of 150 or less

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

Enhanced R134a A GWP of 1300 A better refrigerant development The enhancement is also an engineering one, improved components and leak prevention. Improvement in hoses and pipework. Higher efficiency and fuel economy. Tighter controls and re-engineered components. Less refrigerant charge for the same or better results Is an option but due to high GWP will not be in the race. This system may be used in the transition period.

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

R744 ( CO2 )
A GWP of 1 Is the most suitable refrigerant for use as a heat source (Heatpump) for direct injection and diesel applications. New Sensor Technology Different Chemical Structure Different Gas Characteristics Higher System Pressures 7 to 10 times higher than current systems No direct emmisions Naturally occuring gas Higher cooling capacity Better COP (Coefficient of performance)

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

R152a
A GWP 130 Flammable Low Same pressure / temperature carachteristics as R134a Improved cooling performance and energy efficiency R134a components, lubricants and materials can be used Easy conversion from R134a to R152a. Current leak detection technology can be used. It is a HFC New service fittings required Current service stations can be used. May require a secondary loop system due to its flammability. Charge amount decreased by 30% Requires a safety system (discharge upon accident or leak)

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

The chart summarise the choice to be made using R134a as the baseline Choice Reduction rate Reduction rate of Additional Cost of Direct Indirect in Emissions emissions Enhanced 50% 25% 20 R134a R152a 95% 10% 15 Future R152a 95%+ 30%+ 40 R744 CO2 Future R744 CO2 100% 100% <20% 30%+ 40 to 180 ???

Both R152a and R744 systems are still being developed

Tuesday ,

AC Regulations and Refrigerants The alternatives to R134a

Timings Phase out of R134a starting in 2008 Quotas for VMs reducing by 20% per annum over 4 years Complete phase out by 2012

Tuesday ,

AC Regulations and Refrigerants The proposed regulations

Background
Certain EU countries have already introduced regulations, some more stringent than others. Sweden Mandatory training with testing and certification Holland STEG Certificate as Sweden but less time Other EU countries some have a certificate but very weakly policed reactive not pro-active Non EU some have, some not New members will have a lot of catching up to do

Tuesday ,

AC Regulations and Refrigerants The proposed regulations

What does this mean for the industry. Training agencies will have to offer the certificate training. A register of trained personnel needs to be kept. Policing concept will need to be developed cost and manpower intensive.

Tuesday ,

Air conditioning
End test Paperwork / review sheets Thank you for your attention

Tuesday ,

Legislation

F Gas - Timetable for action July 2006

Date
4th July 2007

Regulation
Manufacturers must cease production of disposable R134a containers ( existing stock can be supplied)

Action

Solution

Brief all workshop staff Old as appropriate disposable containers should be vacuumed and punctured

4th July 2007

Any technician working on A/C must have received some form of training

Check training Arrange training to record of staff ensure compliance Check training Arrange training / assessment to ensure records of compliance staff Check training Arrange training assessment to ensure records of compliance staff

4th July 2008

Any technician working on

A/C must have been trained and assessed to Defra approved standards

9th July 2009

You can no longer purchase R134a unless you are or employ a Defra approved qualified technician

Transportation of Refrigerants
Secure upright vessels against falling over and vessels lying on their side against rolling away!

Never throw pressure vessels!

Do not place vessels near to radiators! Do not heat vessels over 50C!

Do not heat vessels uncontrolled with a naked flame! Danger of micro-structure change in the vessel! (explosion hazard)
Seal empty vessels to prevent ingress of moisture! Protect from frost Make sure taps are set to closed during transportation

EC waste regulations
From 1991 it has been illegal to deliberately release R134a or R12 into the atmosphere. (Refer to section 33/34 of the environmental Protection Act 1990 EPA.
The use of R12 is banned in the UK. From 1st October 2000 it became illegal to trade R12. From 1st October 2001 it became illegal to service systems containing R12.

Connecting differences between R12 and R134a

Sometimes white stripes are found on the pipes. This means the system is R134a

R134a
Quick release thread

R12

Screw thread

Waste Product Legislation and Records

Used refrigerants are A/C waste products are controlled by legislation. Records must therefore be kept about these waste products. It is not law yet, but it is good practice to keep records of the quantities of refrigerants which you use. Use the sheet provided and strap it to recycling machine. If needing to dispose of refrigerant/contaminated refrigerant, BOC and other gas handling companies will take it and dispose of it in an envoronmentally sensitive manner. They will need a Waste Transfer Note before they will accept refrigerant.

Good working practice

Record Sheet on the Use of R134a Refrigerant when Servicing Vehicle Air-Conditioning Systems
Company: Device type: Quantity removed (grams) Quantity filled (grams) S tart date: End date: Author:

Item No.

Date

Registration Number

Difference (grams)

Comments

S ignature

Safety

Fluoroelastomer gloves
These are the only suitable gloves for safe workings on A/C systems

Do not use Fabric gloves Latex gloves etc

Safety goggles

Refrigerant will freeze the eyeball leading to blindness

Safety glasses do not provide sufficient protection

Safety precautions well ventilated area

Refrigerant is heavier than air it would stand in the bottom of a pit! In case of accidental leakage vent the workshop

Safety precautions do not allow the cylinders to over heat.

Keep well below 50C

General Occupational Safety

Wear suitable protective clothing (safety goggles, safety gloves)!

Avoid skin contact with liquid cryogen (risk of local cold burns the boiling point of R134a is -26.5C)!
Do not inhale cryogen vapours in high concentrations (they displace the oxygen in the air you breathe)! Do not expose refrigerant to smoke or fire as it will produce toxic gasses this can be detected by a pungent smell Provide adequate workplace ventilation if high concentrations are likely to occur! Prior to welding and brazing on AC systems, remove the cryogen and blow out any remaining traces with nitrogen!

First Aid

First-Aid Instructions
In case of contact with eyes or mucous membranes, wash immediately with copious amounts of flowing water and consult an eye specialist!

In case of skin contact, remove affected clothing immediately and wash skin areas with copious amounts of water!
If high concentrations of cryogen vapors are inhaled, immediately move the affected person into the fresh air and call for a doctor! In case of breathing difficulties administer oxygen. If the affected person's breathing is faint or has ceased altogether, bend his head backwards and provide mouth-to-mouth resuscitation! Trained and competent person only! Refer to Material Data Sheets in companies COSHH (Control of Substances Hazardous to Health) file all employees of a company employing more than 5 people should have seen these sheets and signed to say they have read them.

Fundamentals

Vehicle air-conditioners
Air-conditioners fulfill four requirements:
They remove heat from the air, thus lowering temperature. They remove dirt from the air pollen, carbon, large germs etc! They remove humidity from the air. The humidity (in the form of condensed water) is led to the vehicle underside and allowed to drop away. They transport the cooled and dried air to the vehicle interior.

Temperature change through flow of heat

Hot travels to cold until temperatures equalise.

3 Physical states and latent heat

To heat one gram of water by 1 C, 4.18 Joules of heat are needed (1 Joule = 1 Nm = 1 Ws KWh)

solid

liquid

gaseous

What happens in between 99C and 100C? what is latent heat?

State changes through altering temperature and pressure

Temperature effect:
Liquid into gas?

Pressure effect:
Liquid into gas?

Increase temperature
Gas into liquid?

Reduce pressure
Gas into liquid?

Reduce temperature

Increase pressure

Temperature and pressure

Water boils

100C 21C 27C

1cm
Human comfort zone

Water freezes
Helium boils

0C

-26,3C
-176C -273C -236C

R134a boils Helium freezes

965km

Absolute Zero

Atmospheric pressure This 965 km belt of gas enveloping the earth exerts pressure that is measured in bar. Standard atmospheric pressure = 1.01325bar = 101325 Pa

Boiling point of liquids

The temperature at which a liquid boils, known as its boiling point, depends on its pressure. For example: cooling water in a cooling system with 0.8 bar overpressure first boils at 120 C (at 100 C under atmospheric pressure) Showing multiple boiling points depending on pressure illustrates the parabolic vapor pressure curve of the liquid being observed.

Water in a vacuum

Vapor pressure curves for water and R134a

liquid

gaseous

Operating principle

Air Conditioning - Components

Expansion Valve
Blower Compressor

Thermal Expansion Valve

Evaporator Filter/Drier

Fan

Condenser

Air Conditioning - Components

Fixed Orifice Tube

Accumulator

Compressor Blower

Orifice Tube

Evaporator

Fan

Condenser

Air Conditioning -

Workshop exercise 1

Split into conveniently sized groups and using the vehicles in the workshop, locate the components we have just described, on the actual cars. Compressor Condenser Filter drier TXV Evaporator (If possible)

Refrigeration circuit
Low pressure pressure low temp gas High pressure high

Lower pressure lower temp liquid

temp gas

1 - Fan 2 - Condenser

3 Reciever dryer
4 Expansion valve 5 Interier ventilation fan 6 - Evaporator 7 Low pressure service connector 8 High pressure service connector 9 - Compressor High pressure lower temp liquid

Air Conditioning

Compressors

Q. What is the function of the Compressor? A. To circulate the refrigerant around the system, via pumping action

Refrigeration cycle

Refrigeration cycle

High pressure high temp gas

Low pressure low temp gas High pressure lower temp liquid

Low pressure low temp liquid

Low pressure low temp gas

From Autodata
Typical example of aftermarket technical data - component location

Receiver dryer / modulator

Old New

Filter dryer
1 - Condenser connector A - Refrigerant (gaseous)

2 - Evaporator connector
B - Refrigerant (liquid) 3 - Filter dryer container a - Observation glass (if present) 4 - Fine filter (porous material) 5 - Filter sieve 6 - Solid material dryer (hygroscopic) 7 - Ascent tube

Usually change every 2 years

Familiarisation exercise

Test!

High pressure high temp gas

Low pressure low temp gas High pressure lower temp liquid

Low pressure low temp liquid

Low pressure low temp gas

Air-conditioner compressor

77

Electrics/Electronics

PAG Oil Polyalkyleneglycol Oil

Compressor 90ml

New compressors contain the full amount of oil required by the system. Therefore, when replacing the Condenser incl dryer 20ml compressor, first drain and measure the amount of oil Dryer cartridge 20ml contained in the old compressor. Then, drain the new compressor, and pour the same amount of oil as was Intake pipe in engine comp 20ml removed from the old compressor, plus 20 cm3, into the Pressure line from compressor to condenser none new compressor.
Pressure line in engine compartment 10ml Evaporator 40ml

These figures depend upon vehicle

Hygroscopic keep container sealed

Modern electronically controlled variable swash compressor

7-cylinder swash plate compressor Operates from 5% to 100%, maximum swept volume is 160 cm3 Compressor is belt driven by via a magnetic clutch

Note: The compressor drive command is not executed under a temperature of +2C

Swash plate type compressor

Swash plate type compressor

Compressor belt protection system

Some models only

Magnetic clutch

Sub-cool condenser

Condenser

Expansion valve

Expansion valve
H valve
1 - Diaphragm cover

a - Refrigerant flow from condenser

2 - Sealed-in refrigerant b - Refrigerant flow to evaporator 1 - Diaphragm a - Refrigerant flow from evaporator 4 - Valve (ball) d - Refrigerant flow to condenser 5 - Regulating spring P1 - temperature-dependent pressure of sealed-in refrigerant

P2 - evaporation pressure
P3 - regulating spring pressure

Evaporator

Pressure switch

3-way refrigerant switch

High/low and medium pressure
A - Medium pressure switch B - High/low pressure switch a Signal to DME (condenser blower drive) b - Signal directly via compressor relay (suppression of compressor function)

Low pressure opening < 2 bar; closing again > 2.6 bar

High pressure opening approx. 26 bar; closing again 20 to 21 bar

Anti-frosting devices (thermistor)

Evaporator temperature sensor

Evaporator temperature sensor

Electrical circuitry

Electrical system overview

Principle of air conditioner electrical circuit

Servicing

Correct installation techniques

ND 8 oil to be used to help seal joints

Correct installation techniques

Normal gauge pressures

Performance testing
A/C turned on and set to max cool
Engine speed 1500 RPM Blower speed full Recirculate selected

6-10 C (depends upon temp of the day)

Doors open

Working practices pre and post A/C service

Lines and service valves

Quick-release connectors on the service unit
Dont vent refrigerant!
Make sure taps are unscrewed before and after connection! Clean connections before connecting onto vehicle

 Clean the service valves on the vehicle before connecting the recycling machine prevent contamination Close all shut-off hand valves before connecting the filling system to the AC system! Before disconnecting the filler from the AC system, ensure that the process is complete! Do not expose the filling system to moisture and never use it in a wet environment!

Using recycling machines

Remember to empty the pipes after every service. Refer to Koolkare Blizzard operators manual.
If refilling A/C machine bottle with refrigerant only fill to around 75% capacity to ensure enough space for the first vehicle evacuation

A service best practice

1. Make sure engine has been running and A/C has been operating 2. Visual inspection of machine and vehicle pipes secure, no visual leaks etc vacuum pump oil O.K.

3. Recover pipes before fitting to vehicle.

4. Clean hi and low pressure connections on the car.

5. Fit and carry out procedure recovery to refill procedure. Put in the specified amount of refrigerant.
6. Vacuum down should last for 30 mins and vac hold 10 mins. In the demo and the assessment 7 mins and 0 mins will be sufficient.

A service best practice

7. Once procedure has been complete 8. Close taps and remove hi pressure connector from vehicle. 9. Start the vehicle 10. Open red valve and then blue valve slowly wait for the gauge pressures to equalize. Close the taps on the machine and turn the engine off. 11. Now remove the low connector from the vehicle and recover both the pipes. 12. Fit the pipes on to the connections on the side of the machine and job done!

Troubleshooting with manifold gauges normal operation

Low pressure side High pressure side

2kg/cm2

15kg/cm2

Under these conditions, the liquid refrigerant will evaporate in the evaporator and will therefore absorb heat energy at this point result is efficient cooling

Fault finding

Evaporates here therefore absorbs heat energy here. Correct!!

Fault finding

Evaporates here therefore absorbs heat energy here. Wrong!!

Leak detection

Electronic leak detection (Sniffer)

Dye kit
Specs Low pressure adaptor Dye

Lamp

Remover

Gun

Ultra-violet dye

Dye with ultra-violet enhancement

Dye without ultra-violet enhancement

Ultra-violet dye

Oxygen free nitrogen

This is the only legal method of pressurising an A/C system to detect leaks. You must not vent refrigerant to atmosphere and if you had a substantial leak that is exactly what you would be doing if you re-gassed a leaking system!

A Refrigerant Identifier

An identifier such as this will enable accurate identification of: R134a R12

R22
HCs Air

In rare cases it has been know for propane / butane to be used as a refrigerant.

Other equipment Refrigerant identifier

Fault finding

Temp / pressure chart

practice

Practice

1300 - 1345

1345 - 1430

1430 - 1515

1515 - 1530

1530 - 1615

Red

Exercise 1 fan operation

Exercise 2 rec machine use pressure observations Exercise 1 fan operation

Exercise 3 rec machine use pressure switch operation Exercise 2 rec machine use pressure observations Exercise 1 fan operation

BREAK

Exercise 4 temperature sensing Exercise 3 rec machine use pressure switch operation Exercise 2 rec machine use pressure observations Exercise 1 fan operation

Blue

Exercise 4 temperature sensing Exercise 3 rec machine use pressure switch operation Exercise 2 rec machine use pressure observations

BREAK

Yellow

Exercise 4 temperature sensing Exercise 3 rec machine use pressure switch operation

BREAK

Green

Exercise 4 temperature sensing

BREAK