Module (s 101) شحن غاز التكييفrefrigerant recovering, vacuuming and gas charging-training -excerise_for apex_by eng. juma-getco

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioning
Refrigerant ‫وعملياته‬ ‫التبريد‬ ‫غاز‬
Recovering, Vacuuming and Gas Charging-Training
ClassAct SRS enabled.
Instructor: Eng. Juma Yousef Juma
Module: S-101

 Refrigeration Cycle.
 Gauge set and refrigerant
 Installing Gauges.
 Service ports and valves
 Refrigerant Types.
 Discharging,
 Evacuating and
 Recharging
 Superheat & Subcooling.
 Pressures of Refrigerants.
 Electronic Refrigerant Identifier Instrument.
Topics covered in this presentation:‫الفهرس‬

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioning ‫التكييف‬ ‫دائرة‬ ‫مكونات‬

Introduction ‫المقدمة‬-
Pressure tests (using the
service ports), can be made to
help determine faults.
Faults can occur
when the pressure
too high or too low.
The hot part of the A/C system
has high pressure.
The cold part of the
system has low
pressure.
Cold
Cool
Hot
Warm
Hot

1-A
The cold side of an A/C system
has low pressure.
Is this true or false?
Answer True or False.
Question

1-B
The liquid side of an A/C
system has low pressure.
Answer True or False.
Question

Gas vs. Liquid & High Pressure vs. LP

2
A) Over charge Refrigerant.
B) Charging Refrigerant in Liquid form.
C) Cooling Coil is chocked.
D) Oil film blocking heat transfer in the CC.
What might be wrong in A/C system,
When liquid found in LP-Service port?
Question
E) All of the above.

‫التبريد‬ ‫غاز‬ ‫أطوار‬ ‫تغير‬
Refrigerant Phase Change
Superheated
Vapor
Saturated Mixture
From 100% Sat-V to Mix. to Sat-L. @ Condenser
Subcooled
Liquid
From 100% Sat-L to Mix. to Sat-V. @ Evaporator

12
How a Manifold Gauge Set Works‫العمل؟‬ ‫كيفية‬
To Low Side To High Side
Center port for evacuation and
charging
High PressureLow Pressure
Gauge
Manifold
Close
right
handle
Close left
handle

Gauge Set ‫العداد‬ ‫تجهيز‬-
Low pressure
gauge
High pressure
gauge
Low side valve High side valve
Low pressure hose
connected to low
pressure service valve
High pressure hose
connected to high
Service hose connected
to oil supply tank
to charging station
Manifold
Gauge set connects
to service ports.

3
A) Black
B) White
C) Red
D) Blue
Which colour is associated with low
pressure on a gauge set?
Question

Personal Safety – ‫الشخصي‬ ‫التأمين‬
Wear safety glasses with side shield –
Chemical Splash goggles are the safest.
Note - ‫مالحظة‬
Wear leather or insulating Gloves when working with
pressure fittings or recovery equipment.
Work in well ventilated area to avoid asphyxiation.
Liquid refrigerant, when exposed to the air, quickly
evaporates and will instantly FREEZE Skin and can
blind you if it contacts your Eyes..

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioning ‫السالمة‬ ‫احتياطات‬ ‫كل‬ ‫رغم‬ ‫شخصيا‬ ‫لى‬ ‫حدث‬ ‫ما‬ ‫هذا‬:‫التبريد‬ ‫حرق‬
This once happen to me with all the precautions I
took: Freeze Burn

17
Installing Gauges
Compressor
Filter-Drier
Sight GlassTEV Receiver
Crack service valves to
read system pressures
EVAPORATOR
CONDENSER
Path of refrigerant
Hook up gauges
Gauge Manifold ‫العداد‬ ‫تركيب‬

Gauge Dials ‫الضغط‬ ‫عدادات‬-
High Pressure Gauge
Low Pressure Gauge
High side pressure gauge
displays pressure in bar (psi).
Low side pressure gauge displays
positive bar (psi) and negative
(mm-Hg - vacuum) pressure.
Note: Gauge shows 0 bar.

Caution - ‫تحذير‬
Dangerous to connect Low side gauge (Blue Hose) to
the High side gauge (Red Hose) of the System
Gauges of refrigerant hoses not
connected to the System MUST have
SHUT OFF to avoid air contamination

4
A) psi
B) vacuum
C) bar
D) mm Hg
Which of the following is NOT a unit for
the measurement of pressure?
Question

Manifold Flow Control ‫بالغاز‬ ‫التحكم‬ ‫عداد‬-
Both valves can be
opened or closed for
pressure checking.
When the low valve is
open it allows flow from
the low side to the
centre hose.
When the high valve is
open it allows flow from
the high side to the
centre hose.
Both valves open to allow flow
from both sides.

Service Ports ‫الخدمة‬ ‫مرابط‬-
R-134a service port has a Quick
Detachable fitting (QD).
R-12 service port has a male
imperial service fitting.
Both types have Schrader valves.
Service port can be connected to: Charging station.
 Oil refill tank.
 System lines.
Dust caps must be fitted to the
Schrader valves when they are
not in use.
R-12 Service Port
Male thread fitting
Schrader valve
To charging
station
To system
R-134a Service Port
QD FittingTo system
Schrader valve
To charging
station

Notes - ‫مالحظات‬
• To avoid
contamination: every
type of refrigerant
must have different
styles of service
fittings.
• SAE J639 helps
standardize MVAC
system design,
implementation and
service including
refrigerant fittings
sizes.
This SAE Standard applies to refrigerant vapor compression systems that provide cooling
and/or heating for passenger cars, light trucks and commercial vehicles (on and off road) that
use automotive type mobile air conditioning [MAC] systems.

24
Recovery
Cylinder
Recovery
Unit
Vapor Recovery
Compressor
Filter-Drier Receiver
Gauge Manifold
Scales
Sight Glass
Start recovery
Now open high side
gauge valve
EVAPORATOR
CONDENSER
Open
valve
Refrigerant
now in tank
TEV

25
Recovery
Cylinder
Recovery
Unit
Recovery Completed ‫االسترداد‬ ‫عملية‬ ‫اكتمال‬-
Compressor
Filter-Drier
Receiver
Gauge Manifold
Scales
All refrigerant is recovered
when unit pulls a vacuum.
Sight Glass
System now ready for
removal, repair, etc.
EVAPORATOR
CONDENSER
TEV

Caution - ‫تحذير‬
Recycled Refrigerant can be contaminated with air
which is a “Non-Condensable Gas”
Up normal High Pressures
=
Air in the System

Refrigerant Types ‫التبريد‬ ‫غازات‬ ‫أنواع‬-
Two types of refrigerant are typically used
in automotives: R-12 & R-134a.
R-12 is a CFC and is no longer used in
new vehicles (stored in white container).
R-134a is an HFC and it has
replaced R-12.
R-134a is normally kept in a light
blue container.
R-12 and R-134a containers and service
port connections are different.
R-134a operating pressures are higher
than R-12.
Next >

5
A) R-12
B) R-134a
Which refrigerant is normally
kept in a light blue container?
Question

A) R-12
B) R-134a
Which refrigerant is normally kept
in a light blue container?
Colour Codes of Refrigerants ‫الترميز‬‫باأللوان‬

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioning ‫باأللوان‬ ‫الترميز‬

Most refrigerant is sold in Disposable
Containers.
Recycled or reclaimed refrigerant must be stored
tanks marked: DOT-4BA or DOT-4BW only
Disposable tanks are Not Used to recycle or reclaim
refrigerant.
Refrigerant tanks can be filled to a MAXIMUM of 60%
gross weight rating.
Empty disposable refrigerant containers must be
evacuated using a recovery machine.

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioningInspection Sight Glass ‫الزجاجية‬ ‫الفحص‬ ‫عين‬
It is used to visually inspect
the refrigerant.
The inspection sight glass can be
found in the accumulator (drier) or in
the refrigerant line.
Sight glass will show either:
 Clear
 Cloudy
 Bubbles (Foamy)
 Oil Streaked
Sight glass
Next >

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioningSight Glass for Refrigeration Condition:
Clear ‫صافية‬
Foam or ‫و‬ ‫رغوة‬
Bubbles ‫فقاقيع‬
‫الزيت‬ ‫خطوط‬
Oil Streaks
Clouded ‫غيمة‬
• System:
Okay
• Over-
Charge
• No
Refrigerant
• Low
Refrigerant
• Air maybe
in System
• Refrigerant
Maybe Low
• Oil maybe
streak as oil
circulates
• Desiccant
Breakdown
• Contaminated
System

6
A) Liquid level
B) Bubbles
C) Streaks of oil
D) Cloudy
Which of the following would you not
expect to see in an inspection sight
glass?
Question

The refrigerant must be
discharged when the system
needs to be opened.
A charging station
(recovery unit) is used
to remove refrigerant.
The charging station can connect
to the gauge set or directly to the
low and high service valves. Both
valves will be open when
recovering the refrigerant.
The recovered refrigerant is
recycled and can be used to
recharge the system.
Discharging the System‫الغاز‬ ‫منظومة‬ ‫تفريغ‬
The refrigerant is normally
recovered slowly and controlled
by the charging station.
Low
pressure
valve
open
High pressure
valve open
Refrigerant
recovery
Charging
station Next >

7
A) Removing extra pressure from the system
B) Removing excess refrigerant from the system
C) Removing all the refrigerant from the system
D) Removing the gauge set from the system
What is meant by 'discharging' the A/C system
Question

The vacuum created causes
any moisture to boil at
room temperature.
The system must be
evacuated when it has
been discharged/opened or
moisture is in the system.
A vacuum pump removes
any air and moisture left
in the system.
Both the high and low pressure
valves are normally opened.
Evacuating the System ‫الغاز‬ ‫منظومة‬ ‫تفريغ‬
Low
pressure
valve
open
High pressure
valve open
Charging
station

8
A) A vacuum pump
B) A compressor
C) A supply of compressed air
D) A source of distilled water
What is used to evacuate an A/C system?
Question

40
Single Evacuation ‫أحادي‬ ‫تفريغ‬-
• What is evacuation?
Pulling a vacuum on a system
• Why?
To remove air and moisture
• How long do you evacuate?
To 500 microns

41
Single Evacuation
Compressor
Filter-Drier
Receiver
Gauge ManifoldStart Pump and open valves on
Gauge Manifold
Continue Vacuum to 500
microns
Wait 5 min. to see if
proper vacuum
remains
Sight Glass
Shut off pump valve
Turn off pump
500
Vacuum Pump
EVAPORATOR
CONDENSER
System Ready for
Charging
TEV

42
Multiple Evacuation ‫المراحل‬ ‫متعدد‬ ‫تفريغ‬
(Deep Vacuuming ‫العميق‬ ‫التفريغ‬- )
For systems with lots of moisture:
1. Pull a vacuum to 1000 microns
Break vacuum with nitrogen
2. Pull a second vacuum to 1000 microns
Break vacuum with nitrogen
3. Pull a third vacuum to 1000 microns
If system holds vacuum start charging

43
Multiple Evacuations: Step 1
Compressor
Filter-Drier
Vacuum Pump
EVAPORATOR
CONDENSER
ReceiverSight Glass
Start pump and
open valves on gauge
Evacuate to 1000
microns
1000
Shut off valve at
pump
TEV

44
Multiple Evacuations : Step 1
Compressor
Filter-Drier
Nitrogen
removes
moisture
Vacuum Pump
1000
NITROGEN
Close valve to pump,
open valve to nitrogen
EVAPORATOR
CONDENSER
ReceiverSight Glass
Break vacuum to about 2 psig
TEV

45
EVAPORATOR
Compressor
NITROGEN
CONDENSER
Close valves to nitrogen tank
Filter-Drier
ReceiverSight Glass
Pull 2nd vacuum to 1000
microns
Vacuum Pump
1000
Run compressor 5 seconds
Open valve to pump
NEVER start a compressor in a
vacuum
TEV

46
Compressor
Filter-Drier
Vacuum Pump
1000
NITROGEN
EVAPORATOR
CONDENSER
ReceiverSight Glass
Break vacuum with
nitrogen
TEV

47
EVAPORATOR
Multiple Evacuations: Last Step
Compressor
NITROGEN
CONDENSER
Filter-Drier
ReceiverSight Glass
Pull 3rd vacuum to 1000
microns
Vacuum Pump
1000
System Ready for
Charging
TEV

Air is lighter than refrigerant.
The recycling process will remove air by Filter Drier
To purge air from a stored tank slowly vent the top of
the cylinder into a recycle/recovery machine.
Refrigerant tanks can be filled to a MAXIMUM of 60%
gross weight rating.
Empty disposable refrigerant containers must be
evacuated using a recovery machine.

Cleaning and filtering refrigerant
while servicing the unit

Photo of refrigerant being
cleaned and filtered

‫التكييف‬ ‫منظومة‬ ‫في‬ ‫التبريد‬ ‫غاز‬ ‫شحن‬ ‫إعادة‬
Recharging the System
1) Recharge by Weight Method.
2) Recharge by Superheat Method.

The charging station is
normally used to measure and
refill the system with the
correct amount of refrigerant.
The high pressure valve is
closed, and the low pressure
valve is opened.
The vacuum draws
refrigerant into the system.
The system pressures must be
checked after charging.
Recharging the System ‫الشحن‬ ‫إعادة‬-
The amount of refrigerant to
be added is measured by
weight (pounds or grams),
and is normally found on an
A/C label under the bonnet.
High pressure
valve closed
Low
pressure
valve
open
Charging
station

9
When recharging an A/C system, both valves on
the gauge set must be open fully.
Is this true or false
Question

10
When recharging an A/C system, Must charge
Refrigerant in Vapor Status only.
Question

Position of Cylinder ‫الغاز‬ ‫أسطوانة‬ ‫وضعية‬
Turn over for
liquid
Being a pure refrigerants, R134a, R12 and R22 Vapor only.
The blends like R401A, R409A, R410A and all in the 400 series of refrigerants
must be charges as a liquid.
While 500 series like R502 and R507 act nearly like pure refrigerants and can
be charged either way.

56
Charging the System ‫الغاز‬ ‫شحن‬ ‫إعادة‬-
Assumptions for the following slides:
System is clean and in a vacuum
Compressor is off
Procedure:
1. Charge by liquid through high side
Shut off discharge valve when pressures equalize
2. Start compressor
3. Finish charging through low side
All blended refrigerants must be charged by liquid

57
EVAPORATOR
Charge System
Compressor
CONDENSER
Filter-Drier
ReceiverSight Glass
Scales
Use refrigerant scale
Refrigerant tankCharge liquid through high
side
Compressor is OFF
Open tank valve
Purge
hose
TEV

58
EVAPORATOR
Charge System
Compressor
CONDENSER
Filter-Drier
ReceiverSight Glass
Scales
Close off high side
valve
Start compressor
Open low side valve and
charge by liquid
Monitor compressor amps
while charging liquid
Monitor head pressure
System now charged to
“present conditions” on TEV
system
Check sight glass
Note: Refer to manufacturer’s manual for
proper charging of critically charged
systems and units with flooded
condensers
TEV

59
EVAPORATOR
Remove Gauges Properly
Compressor
CONDENSER
Filter-Drier
ReceiverSight Glass
Scales
while unit is running
Shut off tank
Back seat
discharge valve
Open high
side valve
Back seat
suction valve
Now,
remove gauges
Purge high side
vapor into low side
TEV

Possible Recharging Errors‫الشحن‬ ‫أخطاء‬
It can cause inadequate cooling, faster refrigeration cycle and low
system pressures.
This occurs when too much refrigerant is in the system.
It produces inadequate cooling and liquid will not turn into vapour. This
causes high system pressures and a constant running compressor.
Moisture in the system can cause corrosion.
The moisture can freeze causing erratic operation and unexpected
system pressures.
Undercharge
Overcharge
Water Moisture
This occurs when there is not enough refrigerant in the system.

Moisture is a primary cause of
contamination-related problems of
HVAC System
Cautions - ‫تحذيرات‬
Moisture in refrigerant will cause:
* Ice forming in evaporator, expansion valve or orifice.
* Degradation of lubricating oil.
Acid formation.
* Corrosion of metals.
* Increase Discharge Head Pressure and case
Compressor failure.
Must ensure charged refrigerant is Super Dry

Charging liquid
in R22 System
will increase the
suction
pressure and
prevent
evaporation of
full charge
casing sufficient
cooling
performance.

Take 3 Cylinders of
R22, when one get
cold and pressure
drop, use 2nd then
3rd, back to 1st.
Otherwise charging
will take hours,
forcing Technician
to charge liquid to
finish the job.

Tip - ‫توجيه‬
Amazon.com: Robinair (10994) Heater Blanket
You can use the Heater Blanket to heat
the cold cylinder and enable Technician
to fully charge system faster and by
using one cylinder only

65
Removing Gauges ‫الغاز‬ ‫عدادات‬ ‫إزالة‬-
While the unit is running, return as much refrigerant
to the system as possible:
• Close Valves (Unit and Gauge).
• Release Gas from high pressure hoses.
• Remove HP Hose.
• Remove low pressure side Hose of the unit

11
A) Undercharging
B) Overcharging
What causes the liquid not to turn into a vapour?
Question

To measure SH & SC: Need Temp. & Press.

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioning ‫المبرد‬ ‫و‬ ‫المحمص‬ ‫الغاز‬
Superheat or Subcooling

Superheat & Subcooling Meter ‫عداد‬
Fieldpiece Instruments testo 550 Refrigeration Gauge

SH/SC Gauge
Low pressure
gauge
High pressure
gauge
Low side valve High side valve
Low pressure hose
connected to low
High pressure hose
connected to high
to oil supply tank
to charging station
Manifold
Gauge set connects
to service ports.

Select Refrigerant ‫التبريد‬ ‫غاز‬ ‫اختيار‬-
R-22 R-410a

Compare to Ultimate Condition @ 35’C:
R-22 R-410a
 R-410A
1
30
1
30
3
92
 R-410a
130
psig
128
psig
372
psig
Sensible
Temperature Above
45° F
Sensible
Temperature Above
111° F
Sensible
Temperature
Above 44° F
 R-410A
1
30
1
30
3
92
 R-22
72
psig
70
psig
250
psig
Sensible
Temperature Above
45° F
Sensible
Temperature Above
111° F
Sensible
Temperature
Above 44° F

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioningFill the Performance Form for full
Evaluation:
R-22 R-410a

‫العدد‬ ‫اختيار‬
Right
Tools

‫موقعيه‬ ‫أعمال‬
Site Work

Total Readings to
ensure cooling
performance

‫التكييف‬ ‫غازات‬
Refrigerants for Air Conditioning
Pressures - ‫الضغوط‬

R-22 Standing Pressure – ‫التوقف‬ ‫حالة‬ ‫الضغط‬
Low Suction Pressure – ‫المنخفض‬ ‫السحب‬ ‫ضغط‬
High Discharge Pressure – ‫المرتفع‬ ‫الدفع‬ ‫ضغط‬
150 Psi
60 to 70 Psi
250 to 300 Psi

255 Psi
110 to 120 Psi
450 to 500 Psi

R-407c Standing Pressure – ‫التوقف‬ ‫حالة‬ ‫الضغط‬
180 Psi
75 Psi
0 Psi

R-134a Standing Pressure – ‫التوقف‬ ‫حالة‬ ‫الضغط‬
85 Psi
50 to 55 Psi
340-345 Psi

180 Psi
30 to 80 Psi
- Psi

40 Psi
-1 to -2 hg
52 to 75 Psi @ 115’F

125 Psi
65 Psi
162 to 215 Psi

240 Psi
110 Psi
- Psi

R-1234yf Standing Pressure – ‫التوقف‬ ‫حالة‬ ‫الضغط‬
0 Psi
0 Psi
115 to 160 Psi @ 115’F

R-1234ze Standing Pressure – ‫التوقف‬ ‫حالة‬ ‫الضغط‬
0 Psi
0 Psi
82 to 120 Psi @ 115’F

Refrigerants CAN NOT be mixed
Some combinations of refrigerants (and Oils) will
clog and ruin recovery and recycling machines.
Mixed Refrigerants are inefficient (Poor Cooling).
Each type of refrigerant uses a different lubricating
Oil, mixed refrigerants wear our Compressors.
Some combinations of refrigerants are flammable.

Use the Electronic
Refrigerant Identifier
before recovering, recycling and charging any refrigerants.

3. Climate Control Systems ServiceAutomotive–Heating&AirConditioningBy Eng. Juma Yousef Juma
jumayjuma@gmail.com +971-50-4948385

Module (s 101) شحن غاز التكييفrefrigerant recovering, vacuuming and gas charging-training -excerise_for apex_by eng. juma-getco

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