4

Servicing of
HFC based
Air-conditioners
Training Material Reference

Servicing of HFC Based Air-conditioners - 2012.ppt

Target Group

Trainers and Technicians

Duration of the Session

30 minutes

Purpose of the Session

To train the participants for systematic servicing procedures for HFC based appliances/air

conditioners.

Terminal Performance Objectives

At the end of session the participants should understand the following:

(a) Recovery of HFC-refrigerants

(b) Steps for servicing of HFC based appliances / air conditioners.

(c) Why leakages are happening in RAC system.

(d) Importance of drawing proper vacuum

(e) Charging procedure of HFC refrigerants.

Key Message being delivered through this Session

As HFCs are having high GWP and we need to recover the refrigerants instead of releasing

the same in the environment. HFCs are most commonly used refrigerants in place of HCFC

(e.g. R410A) for various appliances including domestic and small capacity commercial air-

conditioners. As mineral oils are not compatible with HFCs, POE oils are used. POE oils are

hygroscopic in nature. The HFC systems are also very sensitive to contaminations. Thus,

there is a need to upgrade the servicing procedure and facilities

Tools & Equipments (if any) required for the session

Reference may be made to the practical session, to be conducted later, where special tools

and equipments will be explained and used.

4
Servicing of HFC based appliances
Servicing of HFC Based Appliances

HFCs are the most commonly used refrigerants in place of HCFCs in case of domestic
and commercial air-conditioning appliances. This session will discuss the step-by-step
procedure for servicing of HFC based appliances.
Steps of Servicing *

For good servicing, following step-by-step procedure should be followed to service the HFC
based appliances as also described in detail and followed during the practical.

HFC Servicing Steps

1 Recover HFC into cylinder using recovery machine and piercing valve
2 De-braze filter and the old process tube. Braze new “T” process tube and also braze
six inch copper charging pipe. Flush and clean refrigeration system with Nitrogen
3 Do the necessary repair work in the appliances as required. System should not be
open for a longer duration.
Use XH-7 or XH-9 filter drier preferably with double mouth (only in case of commercial
appliances)
4 Choke testing: Flushing using oxygen free dry nitrogen to ensure nitrogen flows freely
out from suction process tube and the “T” process tube / filter drier process tube.
5 Leak test with Nitrogen and soap solution, Release Nitrogen to atmosphere
6 Evacuate to lowest pressure, Check if vacuum holds
7 Charge HFC or HFC blend
8 Pinch and seal both process tubes
9 Run unit & check for its performance

* In this slide only give bullets point’s narration but not the whole narration of the bullet as
each of the important steps are described in the following slides and guidelines.
4 Recovery of HFC Refrigerant
Servicing of HFC Based Appliances

HFCs are global warming gases. It is advised to recover the refrigerant pure or
azeotropics in a cylinder rather than venting out in the atmosphere. This gas can be
reused after recycling or reclamation.
To recover the HFC, the following tools items are needed:
• Piercing valves or piercing pliers,
• A good recovery machine (preferably oil-less compressor) and
• A recovery cylinder.
Photograph shows fixing of piercing pliers on a copper tube. It is advised to make sure
that the plier is fixed tightly enough so that there is no leakage of refrigerant.
For subsequent steps, as described in the practical procedures, the Piercing pliers /
valve is removed and an extension tube with a Hand shut off valve is brazed at the
other end.
Cleaning and Flushing

Cleaning & flushing is an important step of proper servicing practice. All synthetic oils are
hygroscopic and must not be exposed to ambient conditions for extended periods of time.
HFC and POE combination is very sensitive to contaminations and therefore proper cleaning
& flushing of system is required. Once the old filter is removed, the system needs to be
properly flushed & cleaned of micro-particles.
Following is advised for cleaning and flushing the system.
• Always use dry nitrogen at about 5-10 bar (72-145 psig). The Nitrogen cylinder must
be fitted with two stages regulator. It is a must to have proper regulator.
• Use Hexane/ methylene dichloride (MDC) where chemical cleaning is required. 141b
is also an ozone depleting substance. There should be no traces of liquid Hexane/methylene
dichloride, after the cleaning is done.
• Atmospheric air contains moisture, which is detrimental to the system. Use of air
should be totally avoided specially with HCs & HFCs.
• Petrol contains impurities that can contaminate the system. Never use petrol for
cleaning.
While doing de-brazing, if the system is based on R-32 refrigerant extra care has to be taken
like HC de-brazing.
4 Repair the System
Servicing of HFC Based Appliances

Carry out the necessary repair – what so ever the equipment requires. Use only XH-7,
XH-9, 3A filter driers for HFC appliances (in case of small commercial machine based
on HFCs) as these filter drier contain the right grade of molecular sieves desiccants
specially developed for HFC. Also fix “T” with copper tube before filter of air conditioner.
Also braze a process tube with a hand shut-off valve to the “T” joint.

Choke testing

After due repairs, it is necessary to flush the system and particularly ensure that no
choking has taken place due to improper brazing of filter, particularly at the capillary
end.
For this, introduce nitrogen at 5 bar through the hand shut-off valve on the filter process
tube and see if nitrogen flows freely out from the suction process tube. This will ensure
that there are no chokes due to brazing at the capillary-filter joint.
After this, introduce oxygen free dry nitrogen at 5 bar through suction process tube and
see if nitrogen flows freely through the filter process tube. This ensures that the filter /
condenser joint are not choked.
Why does leak occur?

Refrigerant leaks are caused by material failure. The mechanism that creates the material
failure is normally attributable to one or more of the following factors:
1. Vibration – Vibration is a significant factor in material failure and is responsible for
“work hardening” of copper, misalignment of seals, loosening of securing bolts to flanges, etc.
2. Frictional wear – There are many cases of frictional wear causing material failure, and
they vary from poorly-fixed pipe work to shaft seals.
3. Incorrect material selection – In a number of cases, inappropriate materials are selected
e.g., certain types of flexible hoses have a known leakage rate, and materials that are known
to fail under conditions of vibration and transient pressure and temperature changes are
used.
4. Poor quality control – Unless the materials used in the refrigeration system are of a
high and consistent standard, changes in vibration, pressure and temperature will cause
failure.
5. Poor connections – Poorly made connections, either brazed joints, flare connections,
or not replacing caps on valves, can allow refrigerant to escape.
6. Corrosion – Exposure to a variety of chemicals or the weathering can result in a variety
of different corrosion modes, which decays the construction material resulting in pitting of
pipes.
7. Accidental damage – Accidental mechanical impacts to refrigerant-containing parts
can happen under many circumstances, and therefore it is appropriate to ensure that all parts
of the system are protected against external impacts.
Refrigeration systems are designed to operate adequately with a fixed charge of refrigerant. If
it has been determined that a system has insufficient refrigerant, the system must be checked
for leaks, then repaired and recharged
4 Pressure Testing and Leak Detection
Servicing of HFC Based Appliances

This slide shows the line connection to fill the nitrogen pressure to check the leakage in
the circuit. Pressure testing should be done after repairs using oxygen free dry nitrogen
(OFDN).

Pressure Testing and Leak Detection

The test pressure can be 1.5 times the working pressure. In case of air conditioners,
it may be about 20 bars. Depending on the refrigerant, the test pressure varies, for
instance for R410 it needs to be around 43 bar. Procedure for leak testing is similar to
HCFCs. Use soap solution for leak testing. Apply soap solution on each joint with the
help of a brush and look for leakage, if any. But be sure to wipe off all the joints with
dry cloth before the next step i.e. evacuation takes place. The given pressure is to be
monitored over a period of time in order to check for a fall in pressure.
Different Methods – Leak detection

Leak Detection with Fluorescent Dyes

If small concentrations of fluorescent dye is placed in the refrigerant and allowed to disperse
throughout the system, then the system can be examined visually with an ultraviolet light for
any evidence of leaks. This method will only be effective on high pressure lines (points) of
the systems. Ultra-violet lamp is a method commonly used in large systems where accessing
all joints and connections by soap solution or electronic detectors is difficult. By adding an
additive dye to the refrigerant, the leak will glow yellow green colors when pointed by the
ultra-violet lamp.

Leak Detection by Oil Stains

A trained service technician can identify a badly leaking refrigeration system by the presence
of oil stains on the outside of the equipment. If refrigerant leaks out, lubricant oil leaks out as
well, but it doesn’t evaporate rapidly and remains on the outside of the equipment and pipes,
identifying the leaks area.

Leak detection with Electronic Leak Detector

Electronic refrigerant detectors contain an element sensitive to a particular chemical
component in a refrigerant. The device may be battery or AC-powered and often has a
pump to suck in the gas and air mixture. Often, an audible “ticking” signal, and/or visible
flashing indicating lamp increases in frequency and intensity as the sensor analyses higher
concentrations of refrigerant, which guide the operator that the source of the leak is closer.
Many refrigerant detection devices also have varying sensitivity ranges that can be adjusted.
Many modern refrigerant detectors have selector switches for switching between refrigerant
types e.g. hydrochlorofluorocarbons (HCFCs), HFCs or HCs. When using electronic
refrigerant detectors in a workshop, always ensure good ventilation since sometimes it gives
false signals due to other refrigerants being present in the surrounding area.
4
Servicing of HFC Based Appliances

Evacuation – Why and what equipment?

Evacuation is very important to remove non-condensable gases and moisture. HFC

systems need deep vacuum (500 microns or lower) because of hygroscopic nature of
polyol ester oil. A two-stage vacuum pump, capable of pulling vacuum between 20-50
microns at blank off is required. A micron gauge capable of reading between 5 to 5000
microns is required to make accurate measurement of the vacuum.
Evacuation – 1st step

First make proper connections to the vacuum pump (or the manifold) using adequate hose
connected to the process tube or suction and discharge valves (as the air-conditioner is
designed). Then switch on the vacuum pump and open the valves. Run the pump and
evacuate till the gauge shows the lowest vacuum at which it holds steady. This level should
be around 500 microns or preferably lower.

After that, close the valve to isolate the vacuum pump from the manifold and observe the rise
in pressure (vacuum holding). The pressure should not rise beyond 1500 microns (the lower
the better) in 5 to 10 minutes. This is an indication that most of the moisture is expelled. Of
course lower readings like stabilization at 500 microns or so are even better and welcome. In
case the pressure increase is greater, then the system should be evacuated once again and
the vacuum holding repeated.

In the absence of a micron vacuum gauge, the vacuum pump should be run at least half an
hour after the Bourdon type vacuum gauge reading shows -30”/ -760 mm/ 0 millibar (This
value is for locations at sea level; please correct for altitude at other locations above sea
level)
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Servicing of HFC Based Appliances

Evacuation – 2nd step

After the vacuum gauge shows the vacuum, then close the valve as shown in the figure
and remove the micron gauge. Then attach the charging cylinder with valve in close
position. Again run the vacuum pump for two minutes with high side valve in open
position to remove the non condensable from the charging hose. By doing this there will
be no need to purge the refrigerant from the charging hose.
Recommended Evacuation – R410A

As this is the new refrigerant in the market and needs to follow lot of good practices including
deep vacuum. The following is the methodology for performing vacuum for R-410A air-
conditioners.
Step 1: Evacuate the system to 1000 microns from both service valves. To measure the
vacuum a vacuum gauge must be used at all times - do not use a system manifold gauge.
Step 2: Break the vacuum with oxygen free dry nitrogen (OFDN) to 14 PSIG
Step 3: Evacuate to 500 microns
Step 4: Repeat Step 2
Step 5: Evacuate to the lowest pressure that the pump will achieve (200 microns for a
minimum of 1 hour)
Step 6: The rise test must then be carried out for a minimum of 5-10 minutes
4
Charging by weight
Servicing of HFC Based Appliances

Following charging method should be followed:

• Charge always in a well evacuated system.

• Charging should be done slowly and gradually, so that no liquid goes into the
compressor.
• Charging should be done by weighing accurate mass of charge; this is essential for
good working of the appliance.
• In case of over-charged system, excess charge should not be vented out. It is better
to recharge after evacuation.
• Charge the same weight of refrigerant in the system, as recommended by the
appliance manufacturer instead of charging by feel (To ensure good cooling
performance and low energy consumption)
Charging by volume

It uses a glass tube liquid level indicator, which allows a technician to transfer refrigerant into a
system and measure the amount on a scale. Some cylinders are electrically heated to speed
up the evaporation and maintain pressure in the cylinder. This process of electrically heating
cylinder is usually done with an electrical insert. It is extremely important that a pressure
control relief valve and thermostat be used to provide the required temperature and pressure
safety controls. The system has a pressure gauge and hand valve on the bottom for filling the
charging cylinder liquid refrigerant into a system. It also has valve at the top of the cylinder.
This valve is used for charging refrigerant vapour into the system.
4
Charging with HFCs Blend
Servicing of HFC Based Appliances

Refrigerant blends are simply a mixture of different refrigerant components. If the

blend is a zeotropic mixture (i.e. R4xx) and it is charged as vapour, the refrigerant
with the highest vapour pressure will be charged at a higher proportion than the other
component(s). Charging as a liquid is the only way to guarantee that the blend is charged
within its intended composition. Refrigerant can be “bomb” charged into the liquid line.

Fractionation of a refrigerant blend (separation of the individual components) can occur

by removing the refrigerant from the cylinder as a vapour instead of a liquid. This can
potentially lead to both safety and performance issues. As such, it is recommended
charging all blends in liquid phase only. But one care must be taken that after charge do
not start the machine immediately. Give sometime to refrigerant to settle in the system.
Charging with HFCs Blend

When a blended refrigerant passes through a sight-glass it will tend to flash inside the larger
capacity of the glass. However, it does re-integrate as a blended liquid after passing through.
This ensures you have full stream of liquid o the expansion device (TEC).

Do not over charge the HFC blends by watching the sight glass. As the technicians normally
feel that clear glass means the charge is final. But in case of blends small bubbles can be
seen but do not mismatch that refrigerant is low or under charge. So better is charge the
refrigerant by weight.
4 Avoid overcharging!!
Servicing of HFC Based Appliances

In case of undercharging a relatively low condensing pressure exists. But normally

when technician do charge by feel and if refrigerant is charged the condensing pressure
rises until a given liquid level is obtained in the receiver. While the receiver is being filled
the pressure remains constant. Once the receiver is full, refrigerant backs up into the
condenser, the useful condenser area is reduced and the condensing pressure rises
further. The caution is “Avoid Overcharging”

Sealing Process Tube

After completing the charging, the process tube should be sealed. It is advised that
crimping be done twice in perpendicular direction and the crimping tool should remain
on the line till the process tube is sealed by brazing. Brazing may be done using either
oxyacetylene gas or LPG gas.
Once again leak testing using soap solution/ electronic leak detector should be carried
out without operating the system. If the system is running during this test, in case of
leak the soap solution will enter the system due to low pressure at the suction side.
In case of split air-conditioners where the process tube is not there but the service
valves are there after complete charge close the valve properly and put the valve cap.
After closing the cap check for leakages.
Checking Proper Operation

As a final step, the air conditioner should be switched on and the following parameters must
be verified for ensuring proper operation:

• Grill temperature; The return air temperature and grill temperature difference must be
in-between 10 degree Centigrade to 15 degree centigrade depending upon wet bulb
temperature.
• the compressor current;
• Check the air-conditioner for extra vibrations. If the vibrations are there then remove those
vibrations by anti-vibrating pads.

Evaluation Questions
1. What are the steps to be followed in the servicing of HFC based appliances?

2. Why should the HFC refrigerants be recovered?

3. What are the precautions to be observed while servicing HFC based appliances?

4. What are the advantages of using oxygen free dry nitrogen (OFDN) for flushing and

pressure testing?

5. If extra vibration you notice – what will you do as remedial measures?