A/C System

Components
and
Operation
II
 Objectives
 System Components & Operation
 Evaporator
 Expansion Valve

 Orifice Tube

 Lines & Switches

 Refrigeration Cycle
 A/C Components
 Evaporator
 Heat exchanger
 Located inside the vehicle air ducting
 removes heat from the air entering the

passenger compartment (cold)

 Change of state takes place
 Low-pressure liquid changes into low-pressure
vapor
 A/C Components
 As low pressure liquid flows through
the evaporator, it takes on heat from
the passing air and begins to boil
 Boiling of refrigerant changes it from
a liquid to a vapor
 This process aids in removing
moisture from the cabin air
 Evaporator Flow
IN

OUT
 A/C Components
 Two abnormal conditions can exist in the evaporator:
 Flooding

 Too much refrigerant is allowed into the evaporator

 Not enough room is left for expansion during

vaporization
 Pressure build-up occurs and poor cooling results

 Excess liquid refrigerant from lack of vaporization

leaves the evaporator and enters the compressor where

it can damage the reed valves
 A/C Components
 Abnormal evaporator conditions:
 Starving

 Too little refrigerant is allowed into the evaporator

 Vaporization occurs too quickly and very little heat is

taken on
 Poor cooling and elevated humidity levels occur
 A/C Components
 Metering device
 High-pressure liquid changed into a low- pressure

liquid
 Hot on the high-pressure side, cold on the low-

pressure side
 Two basic types

 Thermostatic expansion valve

 Fixed orifice tube
 A/C Components
 Expansion Valve
 Separates the high and low sides

 Used in systems with a receiver-drier

 Meters the amount of liquid refrigerant that enters

the evaporator
 Maximum opening
approximately .008”
 A/C Components
 Contains a sensing bulb that is connected or in
contact with the evaporator
 Refrigerant is sealed in the bulb and expands when

heated
 The expansion pushes on the spring-loaded valve

to open the passage

 A/C Components
 Warm evaporator
temperatures cause the
expansion valve to open
up an allow additional
refrigerant into the low
side
 A/C Components
 Block Valves
 Internally equalized expansion valve that uses
exiting refrigerant from the evaporator to sense
temperature and adjust inlet flow on the other side
of the valve
 A/C Components
 Block Valves
 Internal equalization of
the expansion valve
allows for smoother
operation and less erratic
cooling
 A/C Components
 Orifice Tube
 Separates the high and
low sides
 Meters the amount of
liquid refrigerant into the
evaporator based on a
difference of pressure
between the high and
low sides
 A/C Components
 Orifice Tube
 High pressure liquid is
metered into the
evaporator as a low
pressure liquid
 The sudden drop in
pressure super-cools the
refrigerant
 A/C Components
 Orifice Tube
 A screen catches any
foreign material in the
system and keeps it from
entering the compressor
 Orifice tubes are color
coded for size and vary
from 0.047-0.067
A/C Components
 Orifice Tube
 An orifice tube is only
used in systems with an
accumulator
 Since the orifice is fixed,
most systems cycle the
compressor clutch to
control system pressure
and refrigerant flow
 A/C Components
 Hoses and lines
 Suction line
 Low-pressure, cool vapor; connects evaporator to the
compressor (larger line)
 Discharge line
 High-pressure, hot vapor; connects the compressor to the
condenser (smaller line)
 Liquid line
 High-pressure, hot liquid; connects the condenser to the
metering device (expansion valve or orifice tube)
 Hoses and Lines
 Early R12 hoses used
layers of reinforced
rubber
 Mineral oil acts as a
barrier on the original
R-12 hoses to keep
refrigerant from seeping
through
 Hoses and Lines
 R-134a uses barrier hoses
 R-134a hoses must use compression fittings
 Replacement hoses on both R-134a and R-12
systems should be of the barrier design
 Hoses and Lines
 R134a contains smaller
particles than R12 in its
composition which can
penetrate older lines
without a nylon barrier
 Hoses on vehicles made
prior to 1992 should be
replaced when
retrofitting to R134a
 Pressures
 High side
 160-220 psi (average)
 Prevents refrigerant from boiling
 Moves heat to the condenser
 Pressurizes refrigerant back to the evaporator
 Low side
 15-35 psi (average)
 Sudden loss of pressure at the metering device
 Allows refrigerant to absorb heat in the evaporator
 Moves heat to the compressor for refrigerant pressurization
 Pressure Switches
 High Side
 Cuts power to the
compressor clutch when
the high side pressure
exceeds or falls below a
predetermined amount
 Engages secondary
cooling fan when
pressure reaches a
predetermined amount
 Pressure Switches
 Low Side
 Cuts power to the
compressor clutch when
the low side pressure
falls below a
predetermined amount
 Cycles compressor
clutch based on pressures
leaving the evaporator
 Refrigerant
States
 Compressor
discharge to
condenser inlet
 High-pressure/high-
temperature vapor
 Change from a vapor
to a liquid in the
condenser (heat
removed)
 Refrigerant
States

 Condenser to
metering valve
 High-pressure liquid
 Refrigerant
States
 Metering device to
evaporator inlet
 Low-pressure liquid
 Small volume of
refrigerant metered
into large volume
 Change from liquid
to vapor in
evaporator (absorbs
heat)
 Refrigerant
States

 Evaporator outlet to
compressor suction
 Low-pressure, high-
temperature vapor
(superheated)
 Changes from low to
high pressure vapor
in the compressor
Manifold
Gauges
 Manifold Gauges
 Low-Side Gauge
 Measures both pressure
and vacuum
 Typical low-side
pressure is 15-35 psi
 Pressures will vary
depending on ambient
temperature; may reach
80 psi on a hot day
 Manifold Gauges
 High-side Gauge
 Measures pressure from
the compressor outlet
 Typical high-side
pressure is 160-220 psi
 Temperature may reach
280-300 psi on a hot day
Manifold Flow
 Manifold Gauges
 Hoses
 High side – Red
 Low side – Blue
 Service Hose – Yellow
 R12 Gauge connections
 Make sure that both valves are closed on the
gauge set before connecting lines to the system
 Insure that gauges are zeroed
 R12 Gauge Connections
 Remove the dust caps
and connect the red hose
to the high side and the
blue hose to the low
side
 Thread on as quickly as
possible so that minimal
refrigerant is lost
 R134a Gauge Connections
 Make sure that both valves are closed on the
gauge set before connecting lines to the system
 Insure that gauges are zeroed
 R134a Gauge Connections
 Remove dust caps and
hook quick-connect
fittings to the high and
low pressure sides
 Once connect, turn hand
valve clockwise to
depress Schrader valve
and lock connections
A/C Performance Test