15

Evacuation &
Charging Unit -
Maintenance
Training Material Reference

Evacuation & Charging Unit - Maintenance - 2012.ppt

Target Group

Trainers and Technicians

Duration of the Session

30 minutes

Purpose of the Session

Trainers are informed of the necessity of maintenance of the evacuation and charging station.

How the maintenance can lead to the long life of the machine and good image of the project.

Trainers must be able to explain to the technician about the safety during the vacuum pump

slide in chapter 4 Servicing of HFC blend based air-conditioners”.

Terminal Performance Objectives

At the end of the session, participants should know

a) General maintenance of the vacuum pump or charging station

b) How to maintain the valves

c) General maintenance of pressure gauges

d) How to check the motor and pump.

Key Message being delivered through this Session

To make the refrigeration system fully without non-condensable gases we need a good

vacuum pump. Vacuum pump will wok perfectly only when we will follow the regular check

up of the pump, regular change of oil and remove the faults if any comes during operation.

Tools & Equipments (if any) required for the session

It will be preferable to have a vacuum pump in the session.

15 Evacuation & Charging Unit - Maintenance
Evacuation & Charging Unit - Maintenance

This is the title slide and trainer must understand the importance of the maintenance of
the evacuation and charging (E&C) station. If the E&C is not well maintained then the
technician will not achieve the desired vacuum.

Why Evacuation?

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.
Evacuation and charging station

This slide shows the view of different evacuation and charging stations available in the market.

Evacuation and charging station

This slide shows the view of different evacuation and charging stations available in the market.
15 Evacuation and charging station - view
Evacuation & Charging Unit - Maintenance

This slide shows the back view of evacuation and charging station. There are so many
flare joint and connectors which need regular check up to achieve the proper level
of vacuum. Whenever some oil traces are there trainers must check by filling the dry
nitrogen pressure.

The filter drier is also seen in the picture and it is always advised to replace the filter
drier as per manufacturers’ recommendation.

Evacuation and charging station - view

Four way manifold has been shown in this slide. This kind of valve is fiitted on the front
panel in different ways, either as a single one or the circuit of valve made with internal
arrangements. For the maintenance of these kind of arrangements has been discussed
separately component wise in the coming slides.
Importance of Maintenance

Every running machine has a life span. If we want to run the evacuation and charging station
for longer years then first we must learn the importance of maintenance.

For getting the optimum performance we should follow the monthly check up schedule or
as recommended by the manufacturer. Trainer must feel that during the training if all the
equipment works well, the image of the project will be high. Any breakdown of the equipment
can give bad name to the project. Moreover with regular maintenance schedule we can
increase the life of the equipment and can save money and time both.

General Maintenance

This slide gives the insight of generalize maintenance of the machine. We can check the
evacuation and charging station visually for any kind of oil traces on vacuum pump cover,
drain plug etc. If the vacuum pump has been dismantled then change the “O” rings. Always
check the oil level of the vacuum pump before start. If it is less add it and if it is above the level
then remove it. Operates the valve if it is given in the system for smooth operation. If it tighten
with lot of pressure then check the stem of valve and do the required repair or replacement.
Also check the glass of the gauges are perfect or broken. If broken then replace the same.
15 Valve’s Maintenance
Evacuation & Charging Unit - Maintenance

This slide explain you the reasons for valve maintenance. When the gland is leaked or
there is leakage through valve seat or flare fitting is leaky, that means the valves need
our attention.

Trainers can maintain the valves by cleaning, some minor repair like polishing or
changing the damaged ‘O’ rings. If the seat is damaged then better to replace the valve
or connector. If the spindle is not moving freely inside, then check the spindle and if
play exist then replace the spindle or complete valve.

Gauges

This slide explain you the reasons to check for errors. Always check the zero errors on
gauge. If the traces of oil are on the gauge connector or glass is broken.

This thing must be followed strictly that when the gauge error is there, do not remove
the needle from the gauge and re-fix the same to zero. Do the setting by rotating the
screw clock wise or anti-clock wise. If the traces of oil are there on gauge adopter then
check the same and replace it. If the glass of the gauge is broken then replace it.
Check Pump and the motor

Before starting any vacuum pump check the sight glass for oil level and if the oil has changed
the colour from the original one or has become darkish brown, then it need the change of oil.

Check Pump and the motor

Remove the cover of the vacuum pump only after draining the oil from it. Clean the magnetic
filter and refix the same in original position. Replace the oil with recommended vacuum pump
oil and strict instruction is “Do not use mineral or polyester oil” as replacement.

After replacing the oil check the running of the pump. If during job of vacuum, vacuum pump
trips off then check the capacitance of capacitor or the bush of the motor shaft. Replace if you
visualize the scratches on the bush or shaft. But before removal of shaft, drain the oil in new
tray and keep it pack until refilling.
15 Oil change in vacuum pump
Evacuation & Charging Unit - Maintenance

Trainers must follow the following sequence to change the vacuum pump oil.

a) open the oil-in plug at the top and open the oil-out plug at bottom to collect the old
oil in drain tray.

b) remove the cover of vacuum pump and clean the magnetic filter.

c) refix the magnetic filter, check the “O” ring between the wall of pump body and cover.
If the new O ring is damaged or formed a shape due to heat, then replace the same.

d) Close the drain plug

e) Pour the measured quantity of fresh oil as recommended by manufacturer via oil-in
plug. And watch at the oil level indicator.

f) Do not under charge or overfill the oil which can lead to poor suction of vacuum pump.

g) Always wear personal protective equipment during work.

Safety Issues

Important safety instructions have to be followed during the maintenance of equipment.

Never open the valve of milli-bar gauge during the maintenance of vacuum pump as pressure
can lead to damage of the gauge. Never use any spanner while tightening the flexible hose
pipe or charging line.

When the vacuum pump is going to start definitely open the blast facility of the vacuum
pump for four to five minutes. It will save the oil to run for the longer time without any major
contamination.