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AC Valve Manual - User Guide - 10!21!13
AC Valve Manual - User Guide - 10!21!13
©Schrader International
ENGINEERED PRODUCTS DIVISION
Scope
This engineering guide contains application and
installation recommendations for refrigeration valves
and cores used in mobile AC systems.
Specifications
The principal Technical Specification that governs the
application of service and access ports for mobile AC
applications is Society of Automotive Engineers (SAE)
J-639. Other specifications that apply to particular
valve designs described in this standard are governed
by International Standards Organization (ISO), Tire &
Rim Association (TRA), Japan Refrigerant Association
(JRA), and American Refrigeration Institute (ARI).
Applications
The AC system has several access ports that are used
to monitor and service the A/C system. These ports
consist of a valve element inside a port that is usually
brazed to the A/C line. The valve usually consists of
self-sealing rubber element activated by a depressor
pin that opens and closes the A/C valve element.
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
2 SchraderInternational.com 1.800.288.1804
ENGINEERED PRODUCTS DIVISION
Section 1
AC VALVE APPLICATION
A1 AC System ports When used for assembly plant evacuation, the low
There are three distinct valve applications: high side side port usually utilized is the low side version of
service, low side service and access (both high and the Primary Seal Integrated Valve (two-piece valve)
low side). The exterior configuration of the service or the 8 mm Valve core (one-piece valve). Smaller
ports are defined by SAE J-639. valves such as the JRA core or standard core may be
used in this application if this fitting is not used for
A1.1 High side service assembly plant evacuation. The port exterior has a
The high side service port is a quick connect fitting design which allows a quick connection to the A/C
that provides access to the high pressure side of the charging unit. The quick connect design is specified by
AC system. Most AC systems are evacuated and filled SAE J-639, and there are different connection designs
from the high side service port in the assembly plant. for each refrigerant to assure that there is no cross
Accordingly, the high side service port should include contamination of refrigerant.
a high flow capacity valve element to assure that the
system can be evacuated to an appropriate vacuum A1.3 Switch port
level in the least time. Access ports are provided on both the high and low
side lines in AC systems for pressure and temperature
Valves usually utilized for the high side service port sensing. These access ports often include a standard
are the Primary Seal Integrated Valve (two-piece valve core between the sensing element and the
valve) and the 10 mm Valve core (one-piece valve). refrigerant. The standard core is normally utilized in
Smaller valves may be used in this application if the switch ports.
assembly plant processing allows sufficient time for
the appropriate vacuum level to be achieved in the A1.4 Coupler Mating
system with the lower flow rates cores. The high side The external configuration, and internal functional
service fitting exterior has a design which allows a dimensions, of the high and low side service ports
quick connection to the A/C charging head. The quick must meet the requirements of SAE J-639. The ports
connect design is specified by SAE J-639, and there may use any of the various valve cores described in
are different connection designs for each refrigerant this guide, which are chosen to meet specific vehicle
to assure that there is no cross contamination of and system requirements, and vehicle charging
refrigerant. needs. Ports are designed specifically for each core so
that the requirements of SAE J-639 are respected.
A1.2 Low side service
The low side service port is a quick connect fitting that A2 AC valves
provides access to the low pressure side of the AC Schrader supplies two types of AC valves: valve cores
system. This port is used to evacuate and fill the AC within a separate port (referred to as a one-piece
system in service conditions, although sometimes the valve), and integrated valve/port (referred to as a two-
AC system is evacuated and/or filled from the low side piece valve). Drawings of the various valves and cores
service port in the assembly plant. are shown in the following sections.
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
SchraderInternational.com 1.800.288.1804 3
ENGINEERED PRODUCTS DIVISION
A2.1.1 Primary seal R-134a High Side Primary Seal integrated valve
Both the high and low side Primary Seal valves are
excellent choices for ports used for evacuation and A2.2 Valve cores
fill. The Primary Seal charge valve has the valve Valve cores consist of machined brass bodies with
element permanently assembled into the port, which rubber seals that are screwed into a separate valve
provides a pre-tested and quality verified valve to the port. The core seal is attached to a pin which is
line manufacturer. This high flow valve is normally actuated when contacted by the coupler depressor.
used for high side charge port applications that The core is screwed into a port which is generally
function to evacuate and charge the vehicle. The fabricated of aluminum that is brazed or welded
internal seal is a hemispherical rubber poppet that onto the lines. An external seal on the core, made
fits into a conical sealing surface assuring robust of rubber or Teflon, provides leak-free attachment
sealing. The coupler depressor pin contacts the between the core and port.
rubber poppet directly for valve actuation. The SAE
port dimensions are produced on the valve body, and There are several styles of valve core available
the required seal location dimensions are machined with different performance parameters, these are
into the body yielding robust dimensions that are not described in the following paragraphs. Valve selection
affected by core assembly variability. The primary should be based on system application needs and
seal charge valve is available for both high side and valve core performance parameters. Information
low side charge valve applications, in several different below will assist in the correct selection.
refrigeration styles. The primary seal charge valves
are available with different rubber compounds for A2.2.1 The 10 mm core
various applications. The primary seal charge valve This high flow core is used only in high side charge
attaches to an adapter which is normally brazed into port applications where the high flow capability of
the AC line, the attachment between the charge valve this core can be of great value. Both the internal
and adapter utilizes an o-ring connection. and external seals are robust o-rings, which are
available with different rubber compounds for various
applications.
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
4 SchraderInternational.com 1.800.288.1804
ENGINEERED PRODUCTS DIVISION
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
SchraderInternational.com 1.800.288.1804 5
ENGINEERED PRODUCTS DIVISION
A3.1 Core selection that residual moisture has been removed. The
Table 1 is a summary of the key performance evacuation port must allow a sufficient flow rate to
parameters for various AC valves. These parameters evacuate the AC system to the required low pressure,
should be considered together with the relative valve within the allocated plant process cycle time. Chart
capability shown in table 2 below when considering 1 is a summary of test data of evacuation trials
the selection of an AC valve for each system conducted on a typical mobile AC system using an
application. assembly plant evacuation system. The evacuation
Among the most critical requirements for the charge pressure was monitored within the AC system; time to
port is supporting fast evacuation of the AC system. A achieve 20 mm Hg was recorded for various Schrader
low residual pressure in the vehicle system assures valves and cores.
Service Access ✔ ✔ LS
Integrity Flow
10 mm Core B ++ +++
8mm Core ++ ++ ++
JRA Core ++ + +
Standard Core ++ B B
B Denotes baseline values for relative strength
Table 2. Valve Performance Parameters
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
6 SchraderInternational.com 1.800.288.1804
ENGINEERED PRODUCTS DIVISION
EVACUATION TIME
50
Standard Core
45
40
TIME TO 20mm Hg (sec)
35
30
JRA Core
25
Primary Seal
20
8mm Core
15 10mm Core
Open Port
10
0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
2
FLOW AREA (in )
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
SchraderInternational.com 1.800.288.1804 7
ENGINEERED PRODUCTS DIVISION
Section B
AC VALVE INSTALLATION
B1 Valve installation in the TRA & ISO specifications. These industry
Appropriate procedures must be employed for specifications recommend an installation torque of 2 –
effective assembly of AC cores and valves. Installation 5 in. lbs. [0.23 – 0.56 Nm]; this recommendation does
torque, lubrication and cleanliness are three areas not allow for the greater robustness offered by the
of particular interest that should be addressed in Schrader “positive stop” core which allows for greater
procedure development. These procedures will differ torque.
for the various valves so it is important to have verified
procedures for each valve and core type. B1.1.1 Torque driver:
It is strongly recommended that valve cores be The proper tooling must be utilized in installing valve
“started” by hand to minimize cross-threading. The cores into their ports. The recommended torque for
small thread size and fine pitch of valve cores makes valve cores is very low for most automated drivers;
these threads susceptible to cross-threading. See damaged cores or inconsistent installation torque
section B1.5 for critical quality evaluations that are is a common processing issue. It is important that
recommended following installation. appropriate driver equipment be selected and
properly adjusted, and that capability assessment
B1.1 Installation torque of installed torque be made to assure that cores are
Each valve core will have a different installation torque being installed effectively. Schrader has found that
recommendation because the thread size is unique for equipment such as the Deprag Minimat and Mountz
each core. Torque of the integrated valve to its adapter E-Driv BF series drivers have provided capable
will be different for the high and low side version. torque control for the low torque required when
used in accordance with recommended practices. It
Std. Core: 0.36 – 0.67 Nm / 3 – 6 in-lbs is recommended that core driver speed be carefully
JRA: 0.56 – 1.13 Nm / 5 – 10 in-lbs controlled as the small size and low torque required
8mm: 1.13 – 2.26 Nm / 10 – 20 in-lbs for core driving are very difficult to control if the driver
10mm: 1.70 – 3.40 Nm / 15 – 30 in-lbs operates at high speed.
Primary Seal (HS): 9.5 – 13.6 Nm / 7 – 10 ft-lbs
Primary Seal (LS): 6.8 – 9.5 Nm / 5 – 7 ft-lbs Selection of torque driver for the integrated
valves is less of a problem because the recommended
All torque recommendations are for dry threads. installation torque is greater, and there are a greater
If lubricants are used the installer should develop dry variety of capable commercial drive systems available.
vs. lubricated correlation.
It is important that the torque be monitored B1.1.2 Driver tip
during the installation process if possible, and that Utilization of a proper valve core driver tip is essential
assessment of installation torque be taken in the to minimize damage to the valve core during the
“installed” direction. Breakaway torque is not an installation process. The design of the driver bit tip
accurate way to verify the installation torque due to should have a radius on the edges which contact the
variability in material, surface friction, and surface core, and if the driver bit is introduced onto the core
conditions. while spinning, a radius leading surface to allow
Note that the installation torque recommended seating on the core.
above for the standard core differs from that specified The driver bit must have a central bore with
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
8 SchraderInternational.com 1.800.288.1804
ENGINEERED PRODUCTS DIVISION
sufficient clearance to assure the bit does not contact of that seal as well. When this occurs the leak test is
the external spring on the 8mm, 10mm, and JRA rendered ineffective.
cores. This is particularly critical for the JRA core b. Lubricant applied, or migrating to, the threads
which has a light spring that is vulnerable to damage may reduce the coefficient of friction at the threads.
from the driver bit. This will increase the amount of torque transferred to
the core body, and may cause core failure within the
recommended torque value.
It is recommended that the lubricant used is the
same as the refrigerant oil used in the system, so that
chemical compatibility between the lubricant and the
seal is assured.
B1.3 Cleanliness
Contamination is the greatest enemy of AC system
durability, and of AC valve robustness. All surfaces
of the AC port must be carefully cleaned to assure
a leak tight assembly. Machining debris and braze
flux contamination are common causes of surface
contamination that have caused defective assembly
performance, these must be removed from the ports
prior to core assembly. Use of the Primary Seal
integrated valve reduces the potential for thread and
braze flux contamination.
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
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ENGINEERED PRODUCTS DIVISION
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ENGINEERED PRODUCTS DIVISION
B4.3 Contamination
Contamination is the greatest enemy of AC valve
integrity, and may be introduced at every stage in its
life cycle.
Due to the variety of operating conditions or applications, the customer is responsible to perform their own
testing to insure performance, safety and warning requirements for the intended application.
SchraderInternational.com 1.800.288.1804 11
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