Refrigeration System Setup: Refrigeration and Hvac Labvolt Series User Guide

Refrigeration System Setup
Refrigeration and HVAC
LabVolt Series
User Guide
Germany
Festo Didactic SE
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73770 Denkendorf
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Fax: +49 711 347-54-88500
did@festo.com
United States
Festo Didactic Inc.
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User Guide
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Canada
Festo Didactic Ltée/Ltd
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0000580301000000000100
Québec (Québec) G2N 2K7

Tel.: +1 418 849-1000
Toll Free: +1-800-522-8658
Fax: +1 418 849-1666
services.didactic@festo.com
Festo Didactic
en
www.festo-didactic.com 580301
Refrigeration and HVAC

User Guide
580301
Order no.: 580301
First Edition
Revision level: 04/2017
By the staff of Festo Didactic
© Festo Didactic Ltée/Ltd, Quebec, Canada 1996

Internet: www.festo-didactic.com
e-mail: did@de.festo.com
Printed in Canada
All rights reserved
ISBN 978-2-89289-347-2 (Printed version)
Legal Deposit – Bibliothèque et Archives nationales du Québec, 1996
Legal Deposit – Library and Archives Canada, 1996
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser’s site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser’s site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical
colleges, training centers, and universities, the right of use shall also include use by school and college
students and trainees at the purchaser’s site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this
available for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow
access by a wide variety of users, including those outside of the purchaser’s site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic.
Information in this document is subject to change without notice and does not represent a commitment on
the part of Festo Didactic. The Festo materials described in this document are furnished under a license
agreement or a nondisclosure agreement.
Festo Didactic recognizes product names as trademarks or registered trademarks of their respective
holders.
All other trademarks are the property of their respective owners. Other trademarks and trade names may
be used in this document to refer to either the entity claiming the marks and names or their products.
Festo Didactic disclaims any proprietary interest in trademarks and trade names other than its own.
Safety and Common Symbols
The following safety and common symbols may be used in this manual and on
the equipment:
Symbol Description
DANGER indicates a hazard with a high level of risk which, if not

avoided, will result in death or serious injury.
WARNING indicates a hazard with a medium level of risk which,

if not avoided, could result in death or serious injury.
CAUTION indicates a hazard with a low level of risk which, if not

avoided, could result in minor or moderate injury.
CAUTION used without the Caution, risk of danger sign ,

indicates a hazard with a potentially hazardous situation which,
if not avoided, may result in property damage.
Caution, risk of electric shock
Caution, hot surface
Caution, risk of danger. Consult the relevant user documentation.
Caution, lifting hazard
Caution, belt drive entanglement hazard
Caution, chain drive entanglement hazard
Caution, gear entanglement hazard
Caution, hand crushing hazard
Notice, non-ionizing radiation
Consult the relevant user documentation.
Direct current
© Festo Didactic 580301 III

Safety and Common Symbols
Symbol Description
Alternating current
Both direct and alternating current
Three-phase alternating current
Earth (ground) terminal
Protective conductor terminal
Frame or chassis terminal
Equipotentiality
On (supply)
Off (supply)
Equipment protected throughout by double insulation or

reinforced insulation
In position of a bi-stable push control
Out position of a bi-stable push control
IV © Festo Didactic 580301

Table of Contents
Preface ................................................................................................................. VII
Section 1 Refrigeration Instruments and Tools ........................................... 1

EXERCISE OBJECTIVE ......................................................................... 1
DISCUSSION ....................................................................................... 1
The Gauge Manifold .................................................................. 1
Compressed Gas Cylinder ........................................................ 2
Bubble Solutions........................................................................ 3
Ultrasonic Leak Detectors ......................................................... 3
Halide Leak Detector ................................................................. 4
Electronic Leak Detectors ......................................................... 5
Vacuum Analyser ...................................................................... 7
The Charging Cylinder .............................................................. 8
Digital Charging Scale ............................................................. 10
Section 2 Leak Detection ............................................................................. 13

EXERCISE OBJECTIVE ....................................................................... 13
DISCUSSION ..................................................................................... 13
PROCEDURE .................................................................................... 14
Procedure A – Leak detection using nitrogen ......................... 14
Procedure B – Leak detection using refrigerant and a
gauge manifold ........................................................................ 16
Procedure C – Leak detection using refrigerant and a
charging unit ............................................................................ 19
Section 3 Evacuating a Refrigeration System ........................................... 25

DISCUSSION ..................................................................................... 25
PROCEDURE .................................................................................... 26
Procedure A – Evacuating with a vacuum pump and a
gauge manifold ........................................................................ 26
Procedure B – Evacuating with a charging unit ...................... 28
Section 4 Charging a Refrigeration System ............................................... 29

DISCUSSION ..................................................................................... 29
High Side Charging ................................................................. 29
MP39 refrigerant blend ............................................................ 31
Temperature glide ................................................................... 31
© Festo Didactic 580301 V

Table of Contents
PROCEDURE .................................................................................... 32
Procedure A – Liquid charging using a charging scale ........... 32
Procedure B – Liquid Charging using a Charging Unit. .......... 33
Procedure C – Vapor Charging using a gauge manifold......... 35
Procedure D – Vapor Charging using the Vizi-Vapor.............. 36
Section 5 Refrigerant Recovery................................................................... 37

DISCUSSION ..................................................................................... 37
Liquid refrigerant recovery ....................................................... 37
Vapor refrigerant recovery ....................................................... 38
PROCEDURE .................................................................................... 39
Section 6 System Troubleshooting ............................................................. 41

DISCUSSION ..................................................................................... 41
PROCEDURE .................................................................................... 42
Appendix A Conversion Factors ..................................................................... 43
Appendix B Vapor Pressure of Refrigerants .................................................. 45
Appendix C Conversion Table ......................................................................... 47
Appendix D Troubleshooting Flowchart......................................................... 53
Appendix E Mechanical Service Analysis ...................................................... 57
Appendix F Electrical Service Analysis ......................................................... 61
VI © Festo Didactic 580301

Preface
The maintenance of refrigeration equipment is a very demanding task requiring
much care and precision. For this reason, a thorough knowledge of the different
techniques necessary to successfully service a system is a necessity.
The System Setup Manual allows familiarization with the different instruments
and techniques involved during refrigeration system setup. The manual is divided
into six sections, each section dealing with a specific topic. Each section includes
a discussion and one or several step by step procedures. The techniques
presented in this manual can be accomplished by the students, under the
instructor supervision, or as demonstrations.
The System Setup Manual introduces students to the techniques involving the
leak detection, evacuation, charge and refrigerant reclaiming of the refrigeration
training systems. The manual also contains troubleshooting techniques and
flowcharts as well as various appendices such as Conversion Factors, Pressure
of Refrigerants and Pressure Superheat Analysis.
We invite readers of this manual to send us their tips, feedback, and

suggestions for improving the book.
Please send these to did@de.festo.com.

The authors and Festo Didactic look forward to your comments.
© Festo Didactic 580301 VII

Section 1
Refrigeration Instruments and Tools
EXERCISE OBJECTIVE To become familiar with the instruments and tools required during installation or
servicing of a refrigeration system.
DISCUSSION Many test instruments and tools are needed when installing or servicing a
refrigeration system. In the following, a short description of some basic
instruments will be given. For more detailed explanation, refer to the
manufacturer instruction manual, or text books.
The Gauge Manifold
The gauge manifold is one of the most important tool used for verifying system
pressures, evacuating and charging a system, and many other purposes. The
gauge manifold consists of two gauges mounted on a manifold with hand valves.
These valves are used to isolate the common connection or to open it to the low
or high side connection of the manifold. Figure 1 shows a gauge manifold with
both valves (V100 and V101) closed and an isolated common connection.
COMPOUND HIGH PRESSURE
GAUGE GAUGE
V100 V101
LOW COMMON HIGH
Figure 1. Gauge Manifold with common connection isolated.
In this position the pressure applied on the low side connection of the manifold
can be read by the compound (suction) gauge. Similarly, the pressure applied on
the high side connection of the manifold can be read by the high pressure gauge.
Figure 2 shows a gauge manifold with the high pressure valve (V101) open to the
common connection.
© Festo Didactic 580301 1

Section 1 – Refrigeration Instruments and Tools  Discussion
V100 V101
LOW COMMON HIGH

Figure 2. Gauge Manifold with the high pressure valve open to the common connection.
To avoid introduction of contaminants into the system, the hose connections

must always be purged with refrigerant before connecting the manifold. Different
techniques must be used depending if the low pressure side is under vacuum or
not.
If the suction pressure side is above 0 kPa (0 psig), close both manifold valves.
Tighten hose connections to both service valves. Crack open the high pressure
manifold valve (V101) and the system high side service valve. Let the refrigerant
bleed through the discharge and common hose for a few seconds, then close the
high pressure valve (V101) on the gauge manifold. Repeat the same procedure
with the low pressure valves.
If the low pressure side is in a vacuum, all the purging must be done from the
high pressure service valve. Tighten the connection to the high pressure service
valve while leaving the low pressure and common hose connections loose. Crack
open both valves (V100 and V101) on the gauge manifold. Crack open the high
pressure service valve to allow refrigerant to bleed through the loose hose
connections. After few seconds, tighten all connections. Close both valves (V100
and V101) on the manifold and crack open the low pressure service valve.
Compressed Gas Cylinder
Inert gas are often required for high pressure test purposes. Dry nitrogen (N2) or
dry carbon dioxide (CO2) are the two gases recommended by refrigeration
components manufacturers. Typical pressure in a nitrogen cylinder is
about 2000 psig (14 MPa) and 800 psig (6 MPa) in a carbon dioxide cylinder.
Oxygen or acetylene should never be used for pressure testing since violent
explosion can result.
Figure 3 hows a high pressure test system with all the safety equipment required.
The system must include a pressure regulator, a cylinder pressure gauge, a
testing pressure gauge and a pressure relief valve. It is recommended that
pressure applied to a system under test never exceeds 1200 kPa (175 psig).
2 © Festo Didactic 580301

CYLINDER TESTING
PRESSURE PRESSURE
GAUGE GAUGE
CYLINDER
SAFETY PRESSURE HAND
VALVE RELIEF VALVE VALVE
NITROGEN
CYLINDER
PRESSURE CONNECTED
REGULATOR TO SYSTEM
Figure 3. High Pressure Test System.
Bubble Solutions
The leak detection method using bubble solutions is very common. A water-soap
solution is brushed over an area suspected of having a leak. If there is a leak,
bubbles will be formed indicating the exact location of the gas leak.
The method has the advantage of being easy to use and inexpensive.
Commercial bubble solutions for leak detection will give better results than the
water-soap solution for very small leaks because they provide stronger and
longer lasting bubbles. The bubble solution must always be cleaned after each
verification.
Ultrasonic Leak Detectors
When a pressurized gas is forced through a small opening, an ultrasound is

produced (sound above 20 kHz). An electronic leak detector is a device capable
to detect a sound above the human hearing range. The frequency response of
the detector is in the range of 20 kHz to 100 kHz.

The ultrasonic leak detector can be used as an initial leak detection tool when the
system is pressurized with an inert gas. The detector can also be used with
systems under vacuum. Most detectors of this type have a sensitivity adjustment,
a display panel to identify the strength of the signal and a earphone. Figure 4
shows a typical ultrasonic leak detector.
The ultrasonic leak detector is also useful to locate a source of noise in a

refrigeration system such as a vibrating tubing touching the cabinet.
Figure 4. Ultrasonic Leak Detector.
Halide Leak Detector
The Halide leak detector, as show in Figure 5, burns acetylene or propane gas
and produces an almost colorless flame. Air for combustion is drawn in through a
tube at the base of the burner. The flame burns through a small copper disc.
When the tube is held near a suspected leak, the refrigerant vapor present is
drawn into the hose and contacts the red hot copper disc. Any refrigerant
contacting the hot copper immediately changes the color of the flame. The flame
color can range from green for a slight leak to purple for a large leak.

SENSING
TUBE
COLORLESS
FLAME
VAPOR
INTAKE
FLAME
CONTROL
PROPANE
TANK
Figure 5. Halide leak detector.
Electronic Leak Detectors
The electronic leak detector is the most sensitive type of leak detector. However,
due to their sensitivity, they must not be used in areas contaminated by
refrigerant vapor. Also, it is important to minimize air draft to facilitate leak
detection. Many types of electronic leak detectors are available on the market.
Two principles of detection used are be based on the dielectric difference of
gases or on the thermic conductivity of different gases.
When turned on, the detector must be calibrated for the normal atmosphere (that
may already contain refrigerant vapor). Once done, the probe may be passed
slowly over surfaces suspected of leaking. The sensing probe, also called the
sniffer, should be positioned below the suspected leak since refrigerant is heavier
than air. Once a leak is found, the leak detector will emit a loud piercing sound
and an indicating light will flash. On some other detectors, when a leak is found,
the normal slow ticks of an audio signal will increase in frequency and a visual
signal will flash. Figure 6 shows a typical electronic leak detector.

Figure 6. Electronic Leak Detector. Vacuum Pump.
Once a refrigeration system has been pressure tested for leaks, the system
usually contains air, water vapor and other impurities. The best way to remove
these non-condensables is to draw them out using a high vacuum pump, as
shown in Figure 7. The pump must be able to pull a vacuum to
within 100 microns (0.1 mm Hg or 13,33 Pa) of a perfect vacuum. A micron is a
unit of measurement which equals one millionth of a meter, or 1/25 000 part of
one inch (0.00004").
On large commercial refrigeration units, the compressor is used to partially

evacuate the system. The compressor however, cannot completely evacuate the
system and a vacuum pump must also be used.
Although the compressor in smaller systems is capable of pulling a vacuum, a

vacuum pump is used, especially on new installations. On systems with hermetic
units, a vacuum pump must always be used. This is due to the fact that hermetic
systems depend upon the refrigerant vapor to cool the compressor motor
electrical insulation.
Foreign matter and moisture within the system would also damage the
compressor valves and contaminate the oil.
Water is removed from the system along with the air since pumping a vacuum
lowers the boiling point of the water. Under a 29 inch Hg (98.6 kPa) vacuum,
water boils at 25°C (77°F). The water in the system boils into vapor at this low
pressure and is removed from the system with the air.

PUMP
SUCTION
HOSE
POWER
PUMP CORD
EXHAUST
AND
HANDLE
DRIVE
MOTOR
OIL FILL
PLUG
TEST
PORT
BALLAST
VALVE
OIL
FILL
LEVEL
OIL DRAIN
PLUG
Figure 7. Vacuum pump.
A gauge manifold is normally used to connect the vacuum pump to the

refrigeration system to be evacuated. The pump is connected to the common
port of the gauge manifold while the high and low ports are connected to the
discharge and suction service valves of the refrigeration system respectively.
The gauge manifold valves being closed, open the service valves mid-way. Start
the vacuum pump and gradually open the gauge manifold valves. Continue
evacuation until desired vacuum is obtained.
The compound gauge of the manifold can be used to estimate the vacuum.
However, a vacuum analyser will provide a more accurate reading of the
vacuum.
The evacuation process completed, the system should be charged immediately.

Close both valves tightly on the gauge manifold. Remove the hose from the
pump outlet. Turn the pump power switch to off. Connect the hose to a charging
unit. Purge the hose before beginning to charge the system.
Always break the vacuum of the pump before storing it.
Vacuum Analyser
A good vacuum must be pulled to remove the humidity trapped in a refrigeration

system. The vacuum analyser permits to know when a good vacuum has been
reached and the moisture removed from the system. The analyser can also be
used to determine if a leak is present in the system.

The sensing element of the vacuum analyser gauge is generally a thermocouple

heated by a filament. As the air pressure is reduced, the temperature of the
filament rises since there is fewer air molecules to cool it down. The
thermocouple reads the temperature of the filament and this information is
displayed in terms of vacuum (microns) on the instrument display.
If the system has a leak, the desired vacuum will not be reached and the
pressure will rise steadily when the valve to the vacuum pump is closed. This rise
of pressure can be observed on the vacuum analyser display. A pressure
increasing and then stabilizing at a pressure corresponding to the water vapor
pressure at room temperature indicates that there is still moisture in the system.
The Charging Cylinder
To accurately measure and transfer refrigerant to a system, a charging cylinder

can be used. The charging cylinder is graduated to indicate the amount of
refrigerant in the cylinder, as shown in Figure 8.
The cylinder is equipped with a pressure gauge on the top of the cylinder to
indicate the pressure within the cylinder. Pressure graduations along the top of
the dial on the cylinder are set to the pressure in the cylinder. The amount of
charge can then be accurately determined by reading the graduations under the
appropriate pressure reading.
The charging cylinder has a charging valve at the bottom for filling the cylinder
with liquid refrigerant. A valve located at the top of the cylinder is used for
charging a system with refrigerant vapor.
Some charging cylinder are electrically heated to speed up the transfer process.
A pressure control valve and a thermostat must be used to provide adequate
safety.
A digital charging scale can be used to quickly and efficiently transfer refrigerant
to a system. This is also the most accurate method to charge a system.
To measure the weight of a refrigeration cylinder, the charging scale is first

switched on. The ZERO of the scale must then be adjusted. Once done, the
refrigerant cylinder is carefully installed on the centre of the platform on the
charging scale. The total weight of the cylinder plus the one of the refrigerant is
then displayed in pounds and ounces (or in kg).
For charging operation, it is preferable to adjust the zero of the scale while the
refrigeration cylinder is installed on the platform of the charging scale. Doing so,
the scale will display the amount of refrigerant transferred to the system.

70 80 90 100 110 120 130
GAUGE PRESSURE PSIG
SIGHT GLASS
INSIDE
CYLINDER
LEVEL OF
REFRIGERANT
IN CYLINDER
Figure 8. Charging Cylinder.

Digital Charging Scale
A charging scale can also be used during refrigerant recovery. The utilisation of a
charging scale insure that the recovery cylinder is not overfilled.
To measure the weight of a refrigeration cylinder, the charging scale is first

switched on. The ZERO of the scale must then be adjusted. Once done, the
refrigerant cylinder is carefully installed on the centre of the platform on the
charging scale. The total weight of the cylinder plus the one of the refrigerant is
then displayed in pounds and ounces (or in kg).
For charging operation, it is preferable to adjust the zero of the scale while the
refrigeration cylinder is installed on the platform of the charging scale. Doing so,
the scale will display the amount of refrigerant transferred to the system.
A charging scale can also be used during refrigerant recovery. The utilisation of a
charging scale insure that the recovery cylinder is not overfilled.
To charge a system, connect a hose between the refrigerant cylinder and the
common connection of a gauge manifold. Close both valves on the gauge
manifold. Connect the charging hoses on the suction and discharge service
valves on the refrigeration system, leaving the fittings loose. Open the manual
valve on the top of the refrigeration cylinder. Crack open both valves on the
gauge manifold. Let the refrigerant bleed through the loose connections for few
seconds. Tighten the connections.
Certain charging scale, as shown in Figure 9 are automatic. The refrigerant

cylinder is connected to the input port of the charging scale while the output port
is connected to the common port of the gauge manifold. These ports are simply
input and output ports of a solenoid valve that controls the transfer of refrigerant.
The scale can be programmed to transfer a certain quantity of refrigerant. When
the charging operation begins the solenoid valve opens, allowing the refrigerant
to be transferred between the refrigerant cylinder and the refrigeration system.
When the scale detects that the desired amount of refrigerant has been
transferred, the solenoid valve is automatically closed.

REFRIGERANT
CYLINDER
SCALE OUTLET
(TO MANIFOLD)
SCALE INLET
Figure 9. Automatic Charging Scale.
A heating blanket can be used to speed up the refrigerant transfer when the
refrigerant cylinder pressure and the refrigeration system pressure equalize.
Heating the cylinder will increase the refrigerant pressure and facilitate the
charging operation. Caution should be taken while using a heating blanket. It is
not recommended to use a heater blanket if the refrigeration cylinder is full. A
refrigerant cylinder must never be heated at temperatures above 125°F. The
system must not be left unattended when a heating blanket is used. The
refrigerant cylinder pressure must also be monitored.

Section 2
Leak Detection
EXERCISE OBJECTIVE To be able to test for leaks using different techniques.
DISCUSSION A refrigeration system is a closed system because it operates under pressure.

Therefore it is necessary that the system be airtight for proper operation. A leak
on the high or low side of a refrigeration system, regardless of its size, will result
in a loss of refrigerant and eventually the system will fail. If a leak occurs and the
compressor operates at a pressure lower than atmospheric pressure, air and
moisture will be drawn into the system. The air and moisture if not removed may
cause permanent damage to the compressor.
After a system is assembled, it must be carefully tested to ensure that all joints
are leak proof. This can be done by applying a low pressure refrigerant vapor (35
to 210 kPa [5 to 30 psig]) to the system and listening for major leaks. If local
regulations prohibit release of refrigerant into the atmosphere, dry nitrogen (N2)
or dry carbon dioxide (CO2) can be used.
Once a small charge (35 to 210 kPa [5 to 30 psig]) is applied to the system, all
lines and connections are checked for audible leaks. If a leak appears at a flared
connection, the connection should be tightened. If the connection still leaks, the
flare is faulty and should be replaced. For a leak at a solder connection, the
system should be de-pressurized and the connection taken apart, cleaned, fluxed
and resoldered. The leak detection can then be repeated.This is a question.
Once the major leaks have been found and repaired, the system should then be
tested by building up the normal pressures in the high and low sides of the
system. Typical test pressure is approximately 1200 kPa (175 psig).
If the system is not already charged with refrigerant, it is more economical and as
effective to partially charge the system with 35 psig of refrigerant and use
nitrogen to bring up the system pressure to the desired test pressure. The
mixture nitrogen-refrigerant allows use of halide and electronic leak detectors.
Local regulations may prohibit release of refrigerant into the atmosphere.
Nitrogen alone should then be used for this test.
Oxygen or acetylene should never be used for pressure testing since violent
explosion can result. Compressed air must not be used to avoid introduction of
moisture in the system. Furthermore, R22 and MP39 refrigerants can explode
when mixed with air at pressures above 60 psig at ambient temperature.
Bubble solutions, ultrasonic leak detectors, halide leak detectors and electronic
leak detectors can be used to find the exact location of the leaks. Halide and
electronic leak detectors can only be used with refrigerant. If no leaks are found
at test pressures, the system is de-pressurized and a vacuum pump is used to
bring the system pressure to a vacuum. If the vacuum is maintained for a certain
period of time (typically 12 hours or overnight), the system is leak free and ready
for charging. Pressure leak testing helps to locate individual leaks while vacuum
testing is useful to determine if a system is leak free.

Section 2 – Leak Detection  Procedure
PROCEDURE Before leak tests ensure that the area is clear of vapors before beginning work. It
is also important to make certain that the area is well ventilated. In case of large
spill or leaks, the area must be evacuated and blowers or fans must be used to
circulate the air at floor level.
The following procedure has been divided in three sections. The first section
provides the necessary steps to perform leak detection when using nitrogen. The
last two sections use refrigerant for leak detection. The choice of the procedure
depends on the equipment available and local regulations. The sections are
identified as follow:
Procedure A – Leak detection using nitrogen

Procedure B – Leak detection using refrigerant and a gauge manifold
Procedure C – Leak detection using refrigerant and a charging unit
High pressure compressed gas must never be used in refrigerant system without
a pressure regulator and a pressure relief valve. Test pressure must not
exceed 1200 kPa (175 psig).
Procedure A – Leak detection using nitrogen
Inert gas are often required for high pressure test purposes. Dry nitrogen (N2) or
dry carbon dioxide (CO2) are the two gases recommended by refrigeration
component manufacturers. Oxygen or acetylene should never be used for
pressure testing since violent explosion can result. Compressed air must not be
used to avoid introduction of moisture in the system. Furthermore, R22 and
MP39 refrigerants can explode when mixed with air at pressures above 60 psig
at ambient temperature.
The following procedure uses nitrogen to build up pressure in the system trainer.
An initial leak detection is performed at a pressure of 105 kPa (15 psig). Once all
major leaks have been found and fixed, the pressure is increased to the system
test pressure. Leaks can be found using an ultrasonic leak detector or a bubble
solution.
Using nitrogen, it is possible to apply pressures well above safety level. For most
refrigeration system, the low pressure side components should never be exposed
to pressures exceeding 1200 kPa (175 psig). Using higher pressure can result in
rupture or distortions of the components. It is however acceptable to pressure
test the high pressure side to pressures exceeding 1200 kPa (175 psig).
However, the low pressure side components must be isolated from the rest of the
system. If test pressures are not known, it is recommended that pressure applied
to a system under test never exceeds 1200 kPa (175 psig).
If a leak appears at a solder connection, the system should be de-pressurized

and the connection taken apart, cleaned, fluxed and resoldered. The leak
detection can then be repeated. Once the system is leak free, the gas can be
released in the atmosphere.

1. Using a charging hose to connect the center port of the gauge manifold to
the output connection of the nitrogen high pressure test system, as shown in
Figure 3.
Be sure that your high pressure test system has all the safety equipment
required. The system must include a pressure regulator, a cylinder pressure
gauge, a system pressure gauge and a pressure relief valve.
2. Install the gauge manifold charging hoses on the compressor service valves
(blue hose – low pressure side; red hose – high pressure side).
3. Open the valves specified in the Leak Detection section of your refrigeration
system trainer Instruction Manual.
4. Crack open the service valves on the refrigeration system trainer.
5. Verify that the hand valve of the high pressure test system is closed then
open the nitrogen cylinder valve.
6. Adjust the high pressure test system pressure regulator for a pressure
of 105 kPa (15 psig).
7. Open the hand valve on the high pressure test system.
a
8. Listen for major leaks in the system.
A hissing sound indicates a leak.
9. Record the position of leaks.
a
10. Tighten or resolder connections where leaks are found.
The system must be de-pressurized before a leaking connection can be

resoldered.
11. Close the hand valve on the high pressure test system.
12. Adjust the pressure regulator on the high pressure test system for the
a
suggested test pressure.
If the system test pressure is not known, set the pressure regulator
to 1200 kPa (170 psig).

13. Open the hand valve on the high pressure test system.
14. Use a leak detector (bubble solution or ultrasonic leak detector) to locate the
leaks.
a
The system must be de-pressurized before a leaking connection can be

resoldered.
17. Close the hand valve on the high pressure test system.
18. Once all leaks have been repaired, close the system trainer service valves.
19. Carefully remove the charging hoses from the service valves on the system
trainer to de-pressurize the hoses.
20. Return all tools to their appropriate places.
a
Procedure B – Leak detection using refrigerant and a gauge manifold
If local regulations prohibit release of refrigerant into the atmosphere, use

Procedure A (leak detection using nitrogen).
When using refrigerant for leak detection, the same refrigerant that will be used
in normal operation must be selected. The system is first charged with low
pressure refrigerant vapor as shown in Figure 10. The refrigerant cylinder is
maintained in an upright position allowing only vapor into the system.
When major leaks have been found and fixed, the refrigerant cylinder is
positioned for a liquid charge a small quantity of refrigerant is transferred to the
refrigeration system trainer, at the discharge service valve. When the trainer
pressure reaches 410 kPa (60 psig), valve 101 on the gauge manifold is closed
and the system can be tested for leaks. The refrigerant must be reclaimed and
a
the system evacuated when the leak test is completed.
Do not use MP39 refrigerant for leak detection. The MP39 is a blend of three
refrigerants. To insure the proper blend composition in the refrigerant cylinder,
liquid only can be removed from the cylinder. The MP39 refrigerant cylinder
must be kept in the upright position for liquid charge. Use dry nitrogen (N2) for
leak detection.

LOW SIDE HIGH SIDE LIQUID

CHARGE
V100 V101
V102
VAPOR
CHARGE
CHARGING
HOSES REFRIGERANT
CYLINDER
Figure 10. Leak detection using a gauge manifold.
4. Open valves V100 and V101 on the gauge manifold.
5. Slowly open the refrigerant cylinder valve (V102). Observe the pressure
gauges on the refrigeration system trainer.
6. Close the refrigerant cylinder (V102) when the pressure on the low pressure
gauge reaches approximately 103.4 kPa (15 psi).

a
a
If system totally loses its pressure before all leaks have been found, repeat
procedure steps 5 to 8.The system must be depressurized before a leaking
connection can be resoldered.
11. Close valves V100 and V101 on the gauge manifold.
12. Position the refrigeration cylinder for a liquid charge.
Goggles and gloves should always be worn when working with refrigerant.
13. Open the refrigerant cylinder valve (V102).
14. Open the high side service valve on the refrigeration system trainer.
15. Slowly open valve V101 (high side) on the gauge manifold. Observe the
pressure gauges on the refrigeration system trainer.
16. Close valve V101 on the gauge manifold when the pressure in the
a
refrigeration system trainer reaches approximately 414 kPa (60 psi).
It may be difficult to reach a pressure of 414 kPa (60 psi) since the volume of
the refrigeration system trainer is greater than the volume of the refrigerant
cylinder. It then may be necessary to wrap a heater blanket around the
refrigerant cylinder to heat the refrigerant in the cylinder, and so increase its
pressure. However caution must be exercised since the charging cylinder may
explode if the heater is left on for a prolonged period of time.
17. If a heater blanket was used to increase the refrigerant cylinder pressure,
insure it has been switched off.
18. Obtain an electronic leak detector.

19. Point the nozzle of the probe at all joints, approximately 12mm (0.5 in.), away
a
from a joint. Slowly rotate the probe around the joint.
If the detector ticking increases, a leak gas been detected. If the leaking joint is
a flared connection, tighten immediately. If leaking still occurs, the connection
should be replaced. If a solder joint is leaking, mark the joint for later
identification and continue checking for leaks. The system must be de-
pressurized before an solder joint can be repaired.
a
20. Record the position of all leaks.
If the system pressure falls below 344.75 kPa (50 psi), before all joints have
been checked, repeat the previous steps and recharge to 414 kPa (60 psi).
21. Once all leaks have been detected and repaired, close valve V102 on the
refrigerant cylinder, and close the service valves on the compressor.
22. Remove the gauge manifold charging hoses from the compressor service
valves.
23. Return the leak detection equipment and all tools to their proper locations.
a
Procedure C – Leak detection using refrigerant and a charging unit
If local regulations prohibit release of refrigerant into the atmosphere, use

Procedure A (leak detection using nitrogen).
When using refrigerant for leak detection, the same refrigerant that will be used
in normal operation must be selected. The system is first charged with low
pressure refrigerant vapor as shown in Figure 11. The refrigerant cylinder is
maintained in an upright position allowing only vapor into the system.
When major leaks have been found and fixed, the refrigerant cylinder is
positioned for a liquid charge a small quantity of refrigerant is transferred to the
refrigeration system trainer, at the discharge service valve. When the trainer
pressure reaches 410 kPa (60 psig), valve 101 on the gauge manifold is closed
and the system can be tested for leaks. The refrigerant must be reclaimed and
a
the system evacuated when the leak test is completed.
Do not use MP39 refrigerant for leak detection. The MP39 is a blend of three
refrigerants. To insure the proper blend composition in the refrigerant cylinder,
liquid only can be removed from the cylinder. The MP39 refrigerant cylinder
must be kept in the upright position for liquid charge. Use dry nitrogen (N2) for
leak detection.

PRESSURE
GAUGE GAUGE
MANIFOLD
PORTABLE CART
HIGH
SIDE
V104
LOW SIDE
LIQUID
CHARGE
V100
V101
CHARGIN
CYLINGER
V103
HOSE STORAGE V102

RACK
VACUMM PUMP
SWITCH
V105
HEATER SWITCH V106 VAPOR
CHARGE
CHARGING
HOSES
V107
REFRIGERANT
CYLINGER
VACUUM
PUMP
Figure 11. Leak Detection using a Charging Unit.
4. Open the refrigerant cylinder valve (V102) and then the charging unit valves
a
V106, V100, V101, and V107, in that order.
Some charging units do not have a valve V107. If this is your case, ignore the
setting of this valve in the procedure.
5. Slowly open valve V105 on the charging unit.

6. Observe the pressure gauges on the refrigeration system trainer.
7. Close valve V105 when the refrigeration system pressure reaches

approximately 103.4 kPa (15 psi).
a
a
If system totally loses its pressure before all leaks have been found, repeat
procedure steps 5 to 9.The system must be depressurized before a leaking
connection can be resoldered.
12. Close the refrigerant cylinder valve (V102) and the charging unit valves
V100, V101, V106, and V105.
13. Position the refrigeration cylinder for a liquid charge.
Goggles and gloves should always be worn when working with refrigerant.
14. Open high side service valve.
15. Open the refrigerant cylinder valve (V102) and the charging unit valve V106.
16. Observe the liquid rising in the charging cylinder. When refrigerant level
is 25mm (1 in.) from the bottom of the cylinder, close valve V106.
17. Switch on the charging unit heater. Allow refrigerant to heat up for
a
approximately 15 minutes.
It may be difficult to reach a pressure of 414 kPa (60 psi) since the volume of
the system trainer is greater than the volume of the charging cylinder. Heating
the refrigerant in the cylinder increases its pressure.

18. Observe the pressure gauge on the charging cylinder. When the pressure
reaches 414 kPa (60 psi), open charging unit valves V101 and V107.
19. Slowly open charging unit valve V105. Observe the pressure gauges on the
refrigeration system trainer.
20. Close valve V105 on the charging unit when the system pressure reaches
approximately 414 kPa (60 psi).
21. Switch off the charging unit heater. The system trainer now contains a
pressure of 414 kPa (60 psi).
The charging cylinder may explode if the heater is left on. If liquid is left in the
cylinder, a high pressure will build up, possibly causing an explosion.
22. Obtain an electronic leak detector.
23. Point the nozzle of the probe at all joints, approximately 12 mm (0.5 in.),
a
away from a joint. Slowly rotate the probe around the joint.
If the detector ticking increases, a leak gas been detected. If the leaking joint is
a flared connection, tighten immediately. If leaking still occurs, the connection
should be replaced. If a solder joint is leaking, mark the joint for later
identification and continue checking for leaks. The system must be de-
pressurized before an solder joint can be repaired.
a
24. Record the position of all leaks.
If the system pressure falls below 344.75 kPa (50 psi), before all joints have
been checked, repeat the previous procedure steps and recharge to 414 kPa
(60 psi).
25. Once all leaks have been detected and repaired, close the service valves on
the compressor.
26. Open all the valves on the charging unit except V104.
27. Slowly open valve V104 to de-pressurize the charging cylinder. Stand clear
a
of V104 outlet when opening, as liquid may exhaust.
Local regulations may prohibit the discharging of refrigerant into the

atmosphere. The refrigerant must therefore be recaptured in a holding
container using a recovery unit.

28. Disconnect the charging hoses from the refrigeration system trainer and
place them on the hose storage rack.
29. Return the charging unit and all tools to their proper locations.

Section 3
Evacuating a Refrigeration System
EXERCISE OBJECTIVE To be able to evacuate a refrigeration system.
DISCUSSION Once a refrigeration system has been pressure tested for leaks, the system
should be evacuated since it usually contains air, water vapor and other
impurities. The best way to remove these impurities is to draw them out using a
high vacuum pump, as shown in Figure 7. The pump must be able to pull a
vacuum to within 100 microns of a perfect vacuum. A micron is a unit of
measurement which equals one millionth of a meter, or 1/25 000 part of one
inch (0.00004").
On large commercial refrigeration units, the compressor is used to partially

evacuate the system. The compressor however, cannot completely evacuate the
system and a vacuum pump must also be used.
Although the compressor in smaller systems is capable of pulling a vacuum, a

vacuum pump is used, especially on new installations. On systems with hermetic
units, a vacuum pump must always be used. This is due to the fact that hermetic
systems depend upon the refrigerant vapor to cool the compressor motor
electrical insulation.
Foreign matter and moisture within the system would also damage the
compressor valves and contaminate the oil.
Water is removed from the system along with the air since pumping a vacuum
lowers the boiling point of the water. Under a 29 inch Hg (3.2 kPa) vacuum, water
boils at 25°C (77°F). The water in the system boils into vapor at this low pressure
and is removed from the system with the air.
An effective way to eliminate moisture in a system consists first to evacuate the

system with a vacuum pump. The system is then charged at 70 kPa (10 psig)
with dry nitrogen and evacuated again using a vacuum pump. This procedure is
repeated three times to exhaust over 99% of moisture.
Triple evacuation is normally recommended for all field installation systems

because of the higher degree of contamination compared to laboratory or
production line environment. Following this procedure, the system must be
evacuated twice to 1500 microns, and the last time to 500 microns, or the limit of
the vacuum pump’s ability. If the system is to be charged with R-134a refrigerant,
a vacuum of 200 microns must be reached.

Section 3 – Evacuating a Refrigeration System  Procedure
PROCEDURE The following procedure has been divided in two sections. The first section
provides the necessary steps to evacuate a refrigeration system using a vacuum
pump and a gauge manifold. The second section provides the necessary steps to
evacuate a refrigeration system using a charging unit. The sections are identified
as follow:
Procedure A – Evacuating with a vacuum pump and a gauge manifold

Procedure B – Evacuating with a charging unit
Procedure A – Evacuating with a vacuum pump and a gauge manifold
1. Crack open the service valves on the compressor to discharge the system to
a
atmosphere.
Local regulations may prohibit the discharge of refrigerant into the atmosphere.
The refrigerant must therefore be recaptured into a holding container using a
recovery unit.
2. Open the valves specified in the Evacuating the Refrigeration System section
of your refrigeration system trainer Instruction Manual.
3. Connect the center charging hose (yellow) from the gauge manifold to the
vacuum pump inlet port as shown in Figure 12. Connect the high (red) and
low (blue) side charging hoses from the gauge manifold to the service valves
on the system trainer. (Red hose to the high side service valve on the trainer,
blue hose to the low side service valve.)
4. Open valves V100 and V101 on the gauge manifold.
5. Turn on the vacuum pump. Open the ballast valve on the vacuum pump by
turning the valve two turns counterclockwise. Close the valve after 10
a
seconds or until the system pressure has reached 1000 - 3000 microns.
Opening the ballast valve purges a small amount of atmospheric air through
the exhaust changer. This extra volume of air mixes with the vapor from the
refrigerant system, preventing vapor from being condensed and helps vapor to
be exhausted in vapor form.
6. Observe the compound gauge on the system trainer.
7. When the gauge reading has maintained a vacuum of approximately 100 kPa
(30 in. Hg) for several minutes, close valves V100 and V101 on the gauge
manifold and turn off the vacuum pump.

GAUGE
MANIFOLD
LOW SIDE HIGH SIDE
V100 V101
BLUE RED
YELLOW
CHARGING
HOSES
VACUUM PUMP
a
Figure 12. Evacuating with a vacuum pump and a gauge manifold.
If available, use a vacuum analyser to measure the vacuum in the system. For
R12, R22 and MP39, a vacuum of 500 microns must be reached. For R134a, a
vacuum of 200 microns must be reached.
8. If the system is not to be charged immediately following the evacuation

procedure, close the service valves on the trainer.
9. Disconnect the charging hoses form the refrigeration system trainer service
valves.
10. Remove the charging hose from the pump inlet and cap the port.
11. Return the equipment to their appropriate places.

Procedure B – Evacuating with a charging unit
1. Crack open the service valves on the compressor to discharge the system to
a
atmosphere.
Local regulations may prohibit the discharge of refrigerant into the atmosphere.
The refrigerant must therefore be recaptured into a holding container using a
recovery unit.
2. Open the valves specified in the Evacuating the Refrigeration System section
of your refrigeration system trainer Instruction Manual.
3. Connect the charging hose from the gauge manifold to the service valves on
the system trainer. (Red hose to the high side service valve on the trainer,
blue hose to the low side service valve).
4. Close all valves on the charging unit, except valves V100, V101 and V107.
Plug in the charging unit.
5. Turn on the vacuum pump and open V103. Open the ballast valve on the
vacuum pump, by turning valve two turns counterclockwise. Close the valve
after 10 seconds or until the system pressure has reached 1000 - 3000
a
microns.
Opening the ballast valve purges a small amount of atmospheric air through
the exhaust changer. This extra volume of air mixes with the vapor from the
refrigerant system, preventing vapor from being condensed and helps vapor to
be exhausted in vapor form.
6. Observe the compound gauge on the system trainer.
7. When the gauge reading has maintained a vacuum of approximately 100 kPa
(30 in. Hg) for several minutes, close valve V103 on the charging unit and
a
turn off the vacuum pump.
If available, use a vacuum analyzer to measure the vacuum in the system. For
R12, R22 and MP39, a vacuum of 500 microns must be reached. For R134a, a
vacuum of 200 microns must be reached.
8. If the system is not to be charged immediately following the evacuation

procedure, close the service valves on the trainer. Close the charging unit
valves V100 and V101.
9. Disconnect the charging hoses form the refrigeration system trainer service
valves.
10. Return the charging unit to its proper location.

Section 4
Charging a Refrigeration System
EXERCISE OBJECTIVE • To be able to charge a refrigeration system.

• To become familiar with the MP39 refrigerant blend.
• To understand the concept of temperature glide.
DISCUSSION Once a system has been completely evacuated, it is ready to be charged with
refrigerant. The system can be charged with refrigerant using one of two
methods: the high side or liquid charge; and the low side or vapor charge.
The high side, or liquid, method of charging is usually used when charging a new
or completely evacuated system. This method requires less time to completely
charge the system. The low side, or vapor, method of charging is usually used
when adding small amounts of refrigerant to a system (topping up).
Since CFC refrigerants were linked to depletion of the earth’s ozone layer,
replacement refrigerants were introduced as alternatives. The R-12 refrigerant
primarily used in residential and automotive refrigeration is now replaced by the
R-134a refrigerant in new designs. The thermodynamic properties of the R-12
and R-134a are very similar. Furthermore, since the R-134a does not contains
chlorine, it is considered safe for the ozone layer. Refrigerant R-134a is not
compatible with the mineral oil used for R-12. Systems designed for R-134a use
polyolester oil. This type of oil absorbs humidity very quickly. It is then important
to avoid keeping a refrigerant system using R-134a exposed to atmosphere for a
prolonged period of time.
Another replacement refrigerant for the R-12 is the MP-39 blend. Because this
refrigerant is a blend, special precaution must be taken when charging a system.
For the same reason, a temperature glide exists in the evaporator and
condenser. A good understanding of the properties of this refrigerant is then
essential.
High Side Charging
The high side, or liquid, method of charging is usually used when charging a new
or completely evacuated system. This method requires less time to completely
charge the system.
The system is charged on the high side, usually at a point where the liquid
passes through the compressor discharge line into the condenser, such as at the
compressor discharge service valve. The refrigerant cylinder is inverted for a
a
liquid charge, as shown in Figure 13.
For the MP39 refrigerant, the cylinder must not be inverted for liquid charge.

Section 4 – Charging a Refrigeration System  Discussion
A strainer and drier are usually placed in a line through which all refrigerant will
pass. This prevents any contaminants in the refrigerant from entering the
refrigeration system.
When charging on the high side of a system, it is very important that liquid
refrigerant not be allowed to reach the low pressure side of the compressor. The
liquid is not compressible, and therefore, the compressor valves, and even the
bearings and rods, may be damaged if the compressor should be operated. To
prevent this, the compressor should not be running while charging.
GAUGE
MANIFOLD
LOW SIDE HIGH SIDE
V100 V101
REFRIGERANT
CYLINDER
LIQUID
CHARGE
V102
CHARGING
HOSES
CHARGING
SCALE
Figure 13. High side method of charging.Low Side Charging.
The low side, or vapor, method of charging is usually used when adding small
amounts of refrigerant to a system (topping up). With this method, the refrigerant
cylinder is maintained in an upright position allowing only vapor into the system,
as shown in Figure 10. A charging line is installed on the low side of the
a
refrigeration system, usually through a compressor suction service valve.
Refrigeration System Trainers using MP39 refrigerant must use a Vizi-Vapor

charger for vapor charging. Refer to the “MP-39 refrigerant blend” section.

Section 4 – Charging a Refrigeration System  Discussion
During the charging procedure, the compressor is running, drawing the vapor out
of the cylinder. The low side method of charging has the advantage of preventing
dirt, oil and scale contaminates from entering the system since contaminates
cannot be transported in refrigerant vapor. The simplest way to check for
sufficient refrigerant charge is to watch for bubbles through the sight glass in the
liquid line. Bubbles indicate insufficient refrigerant charge.
Another method of checking refrigerant charge is by comparing the design

pressures for the system to the actual pressures of the system. Low pressures
indicate insufficient charge. High pressures indicate too much charge.
MP39 refrigerant blend
The MP39 refrigerant blend is a mixture of three refrigerants: HCFC-22 (53%),

HFC-152a (13%) and HCFC-124 (34%). This blend is not true azeotrope since
a
the composition of the blend changes as it changes state.
An azeotropic blend is a mixture of refrigerants acting as a single refrigerant

and having constant maximum and minimum boiling points.
Special precaution must be taken when charging a system using MP39

refrigerant. With this type of refrigerant, the vapor composition in the refrigerant
cylinder differs from its liquid composition. For this reason, it is important that
liquid only be removed from the refrigerant cylinder to insure correct blend
composition. Improper handling of the refrigerant can have adverse and
unpredictable effect on the system performance.
When using a charging unit, the MP39 refrigerant must be transferred in liquid
phase in the charging cylinder and then the entire contents of the charging
cylinder must be transferred to the refrigeration system. The transfer to the
refrigeration system can be performed in vapor or liquid phase as long as the
entire contents of the cylinder is transferred.
The most convenient and accurate method of charging a refrigeration system

with MP39 refrigerant is to use a charging scale. The refrigerant is measured by
weight and transferred to the refrigeration system in liquid phase directly from the
refrigerant cylinder. The method has also the advantage to minimize risks of
contamination.
Once the refrigeration system has been charged in liquid phase, it is possible to
adjust the charge of refrigerant using a Vizi-Vapor charger. Using this charger,
liquid refrigerant is transferred from the refrigerant cylinder to the charger and, in
vapor phase, from the charger into the low side of the refrigeration system,
without the danger of liquid slugging. The section Vapor charging using the Vizi-
Vapor in the following procedure explains how to use the charger.
Temperature glide
The MP39 is a near azeotropic refrigerant. Its boiling point temperature changes
as the refrigerant changes states. The explanation for this is simple. As the liquid
refrigerant blend is heated, the refrigerant with the lowest boiling point
temperature begins to form vapor. The temperature at which this refrigerant
begins to evaporate corresponds to the bubble point of the blend. While the first
refrigerant evaporates, the composition of the blend changes as the percentage

Section 4 – Charging a Refrigeration System  Procedure
of this refrigerant increases in the vapor phase and reduces in the liquid phase.
The temperature increasing, the refrigerants in liquid phase continue to
evaporate until the refrigerant with the highest boiling point is fully evaporated.
When this happens, the blend reaches its dew point. The difference between the
bubble point and dew point temperatures is called the temperature glide. The
temperature glide for the MP39 refrigerant is about 4-5°C (8-10°F). As a result,
the boiling point of the blend increases between the inlet and outlet of the
evaporator while the condensing temperature decreases for the condenser.
PROCEDURE
Refrigeration Systems using MP39 refrigerant requires special care. Please read
carefully the section "MP39 blend refrigerant" in the DISCUSSION before
charging the system.
a Refrigeration Systems using R134a require charging hoses compatible with

this refrigerant. Hoses designed for R12 and R22 will leak if used with R134a.
The following procedure has been divided in four sections. The choice of the
section depends on the equipment available and the charging method required.
The sections are identified as follow:
Procedure A – Liquid charging using a charging scale

Procedure B – Liquid charging using a charging unit
Procedure C – Vapor charging using a gauge manifold
Procedure D – Vapor charging using a Vizi-Vapor
Procedure A – Liquid charging using a charging scale
a
1. If not already done, evacuate the trainer.
Goggles and gloves should always be worn when working with refrigerants.
2. Position the refrigerant tank for a liquid charge as shown in Figure 13.
The MP39 refrigerant cylinder must not be inverted for liquid charge. It is
important that liquid only be removed from the cylinder.
3. Connect the charging hoses to the service valves on the trainer.
4. Open the refrigerant cylinder valve (V102).
5. Refer to your refrigeration training system instruction manual to know the

quantity of refrigerant required for charging. Follow the instructions provided
with your charging scale and program the quantity of refrigerant required for
charging. Charging hoses must be purged before proceeding with next step.

6. Once the charging hose has been purged, open the high side service valve
a
and proceed with the liquid charge.
If the system does not charge totally with liquid refrigerant, a heater blanket
wrapped around the refrigerant cylinder may be used to complete the transfer.
It is also possible to complete the charge using the vapor charge method.
7. Close the compressor high side service valve on the refrigeration system
trainer. Wait at least 10 to 15 minutes before turning on the refrigeration
system trainer.
8. Turn the evaporator and the condenser fans to “HIGH” and turn on the
a
compressor. Allow the system to operate for 5 minutes.
If the condenser is water-cooled, open valves to let water flow in the

condenser.
9. If equipped with one, observe the refrigeration system trainer liquid indicator.
a
If bubbles appear, the system is not fully charged.
If the system is not fully charged, the vapor charge, or low side charging
method, must be used for topping up the system.
Procedure B – Liquid Charging using a Charging Unit.
a
1. If not already done, evacuate the trainer.
Goggles and gloves should always be worn when working with refrigerants.
a
2. Position the refrigerant tank for a liquid charge as shown in Figure 11.
For next procedure, insure valve V105 is closed.
The MP39 refrigerant cylinder must not be inverted for liquid charge. It is
important that liquid only be removed from the cylinder.
3. Open valves V102 and V106 on the charging unit.
4. Crack open valve V104 on the charging unit to allow refrigerant to enter the
a
cylinder.
Refer to your Refrigeration System Trainer instruction manual to know the

quantity of refrigerant required for charging.

5. Close valve V104 when the required quantity of refrigerant has entered the
a
cylinder. Then close valve V106.
Align the charging cylinder with the sight glass to the required pressure setting
(graduations along the top). The amount of refrigerant in the cylinder is
indicated in the sight tube. Close the appropriate valves when the amount of
refrigerant in the sight tube aligns with the required setting (vertical
graduations).
6. Close the valves specified in the Charging the Refrigeration System Trainer
section of the Instruction Manual for your system.
7. Close all charging unit valves, except valve V101.
8. Connect the charging hoses to the service valves on the trainer compressor.
a
Slowly open valve V105 and then V107 on the charging unit.
Charging hoses must be purged before proceeding with next step.
9. Once the charging hose has been purged, open the high side service valve.
Observe the charging cylinder. When the system has been charged, close
valves V105 and V107 on the charging unit. Close service valve on the
a
trainer.
If the quantity of refrigerant required for charging exceeds the charging

cylinder capacity, repeat procedure steps 3 through 9. If the system does not
charge totally with liquid refrigerant, it may be necessary to turn on the
charging unit heater or complete the charge using the vapor charge method.
10. Wait at least 10 to 15 minutes before turning on the refrigeration system

trainer.
a
compressor. Allow the system to operate for 5 minutes.
If the condenser is water-cooled, open valves to let water flow in the

condenser.
12. If equipped with one, observe the refrigeration system trainer liquid indicator.
a
If bubbles appear, the system is not fully charged.
The vapor charge or low side charging method must be used for topping up
the system.

Procedure C – Vapor Charging using a gauge manifold.
Refrigeration System Trainers using MP39 refrigerant must use a Vizi-Vapor

charge for vapor charging. Refer to the next procedure.
a
1. Position the refrigerant cylinder for vapor charge, as shown in Figure 10.
Before charging the system with vapor, the charging unit must be free of all
liquid refrigerant.
2. If not already done, connect the charging hoses to the compressor service
valves on the refrigeration system trainer. Open the refrigerant cylinder valve
a
(V102) and the gauge manifold V100.
Purge the low-side charging hose.
compressor. Allow the system to operate for 5 minutes before proceeding
with vapor charging.
4. Slowly open the suction side service valve. If present in your system,
observe the liquid line sight glass carefully as compressor operates. Once all
bubbles disappear, close the compressor service valve and valve V102. The
a
system is now fully charged.
If the pressure in the refrigerant cylinder is lower than the pressure on the
suction side, the system will not receive a charge. Use the heater blanket (or
place the refrigerant cylinder in a bath of warm water) to increase the
refrigerant temperature and pressure in the cylinder.
5. Close the refrigerant cylinder valve (V102) and the gauge manifold valve
V100. Disconnect the charging hoses from the compressor service valves.
Keep hands clear of refrigerant vapor.
6. If the trainer is not going to be used, turn off the evaporator and condenser
a
fans, compressor and power mains supply.
If the condenser is water-cooled, shut-off the water supply.

a
Procedure D – Vapor Charging using the Vizi-Vapor.
The following method of charging can only be performed if your charging

station is equipped with a Vizi-Vapor.
1. After liquid charging, close valve V107 and V101 on the charging unit.
2. If not already done, close the high side service valve on the trainer.
3. Slowly open valve V100 on the charging unit. After refrigerant appears in the
Vizi-Vapor, adjust the valve on the top of the Vizi-Vapor until a fine vapor
a
spray is provided.
a
Purge the low-side charging hose.
When charging a refrigeration system using this method, the applied charge
should be a very fine vapor since the compressor cannot compress a liquid.
a
4. Open the suction side service valve on the trainer.
Ensure the compressor and fans are in operation.
5. If present on your system, observe the liquid indicator in the liquid line. Once
all bubbles disappear the system is fully charged. Close suction service
valve.
6. Remove the charging hoses form the trainer and return them to the storage
rack.
7. If you are using a charging unit, de-pressurize it through valve V104. Close
all charging unit valves.
8. If the trainer is not going to be used, turn off the evaporator and condenser
a
fans, compressor and power mains supply.
If the condenser is water-cooled, shut-off the water supply.

Section 5
Refrigerant Recovery
EXERCISE OBJECTIVE To be able to recover refrigerant from a disabled refrigeration system using a
refrigerant recovery unit.
DISCUSSION Many countries in the world have passed legislation to prohibit release of CFC
refrigerants in the atmosphere. These refrigerants must now be recovered and
recycled.
The recovery process consists to remove a refrigerant from a system and store it
in an external container. The refrigerant is not processed in any way. Specialized
recovery machines are available on the market. The model 3445 Refrigerant
Recovery System can be used for this purpose.
With the model 3445 Refrigerant Recovery System, the refrigerant can be
recovered in vapor or liquid form. Independently of the recovery method chosen
(liquid or vapor), vapor only must enter the suction port of the refrigerant recovery
system. A compressor enclosed in the unit provides the pumping power to
a
recover refrigerant from the disabled system.
Insure that the compressor oil used in the Refrigerant Recovery System is
compatible with the refrigerant to be recovered.
A disposable cylinder cannot be used for recovery. Use of these cylinders can
result in serious hazard. Recovery cylinders available on the market must comply
with Department of Transportation (DOT) regulations. The recovery cylinders
must never be filled over 80% of their capacity. This can be verified by using a
charging scale.
Liquid refrigerant recovery
It is much faster to recover refrigerant in liquid form than vapor. For this reason, it
is preferable to recover the refrigerant in liquid form first. For this purpose, a
recovery cylinder with two ports must be used. If such recovery cylinder is not
available, the refrigerant must be recovered in vapor form only. The setup shown
in Figure 14 allows recovery of refrigerant from a system using the liquid transfer
method.

Section 5 – Refrigerant Recovery  Discussion
VAPOR
SIDE
REFRIGERATION
RECOVERY SYSTEM
VAPOR
DISABLED
UNIT LIQUID
SIDE
SUCTION
HIGH PRESSURE
VAPOR
LIQUID
VAPOR
LIQUID
SIGHT
GLASS
Figure 14. Refrigerant recovery in liquid form.
The Refrigerant Recovery System pumps the refrigerant in vapor form from the
recovery cylinder and pressurize the disabled unit. The pressure differential
created between the disabled unit and the recovery cylinder transfers the liquid
refrigerant in the recovery cylinder. Once all the liquid has been removed, the
remaining refrigerant must be recovered in vapor form.
VAPOR
REFRIGERATION
SIDE
RECOVERY SYSTEM
VAPOR
DISABLED
UNIT
SUCTION
HIGH PRESSURE
LIQUID
VAPOR
LIQUID
(SHUT)
Figure 15. Refrigerant recovery in vapor form.
Vapor refrigerant recovery
Figure 15 shows the setup required for recovery of vapor refrigerant from a
system. The recovery procedure is very similar with the evacuation procedure of
a system. The suction input port of the recovery unit is connected to the low side
service valve of the disabled unit. Once all hoses have been purged the recovery
unit is turned on. The refrigerant is pumped in vapor form from the disabled unit
and transferred in liquid form to the recovery cylinder.

Section 5 – Refrigerant Recovery  Procedure
Once the recovery is completed, the service valve must be closed and the
disabled unit should sit for at least five minutes. If the system pressure rises
above 70 kPa (10 psig) it may be necessary to start the recovery again.
PROCEDURE Since recovery procedure vary with each manufacturer please refer to the
instruction manual supplied with your refrigerant recovery unit.
To allow complete refrigerant recovery, the refrigeration system trainer valves

must be opened as specified in the instruction manual for your refrigeration
system trainer, under the section Evacuating the Refrigeration System.
The recovery cylinder must not be filled over 80% of its capacity. Overfilling the
cylinder could create hazardous conditions.

Section 6
System Troubleshooting
EXERCISE OBJECTIVE To be able to troubleshoot a refrigeration system for electrical or mechanical

faults using troubleshooting flowcharts.
DISCUSSION A service technician must have a thorough knowledge of the fundamentals of

refrigeration cycles before becoming competent at troubleshooting and repair.
The problem in a refrigeration system must be located before dismantling the
system. This keeps the cost of servicing to a minimum and assures proper
operation of the unit after repair and assembly is complete.
When a faulted refrigeration system is first approached by the technician, he

must observe the system temperatures or pressures to determine a possible
source of the problem. Once a general area is determined, the fault can be pin
pointed to a specific device by taking various voltage readings.
Electrical component failure is the main cause of refrigeration breakdown. In

refrigeration systems some electrical faults are more obvious than others. Many
electrical faults occur as a result of component failure, poor or corroded
connections, or open windings on compressor motors. Most faults can be found
and repaired before any damage is caused, either to the system or space being
refrigerated if the condition is detected immediately. However, under certain
circumstances, damage to the system components and items begin refrigerated
are possible. Typical faults in a refrigeration system are:
• power supply failure
• evaporator fan and circuit failure
• condenser fan and circuit failure
• pressure controller failure
• temperature controller failure
A fault in any part of a refrigeration system will usually show up as an

unsatisfactory temperature or operating condition. To find faults quickly and
easily in a system, typical designed operating points should be know. These
include:
• the temperature of the evaporator and condenser during the normal
operating cycle.
• the head pressure and suction pressure during the normal operating cycle.
The operating conditions can be compared to the designed conditions in the

system when a fault is suspected. A large variation in the system temperatures or
pressures from the designed conditions can assist in determining the area of
difficulty.

Section 6 – System Troubleshooting  Procedure
The sequential troubleshooting method based on the use of a troubleshooting

flowchart can help to determine the cause of a problem. This flowchart aids the
service technician in performing the appropriate test and in drawing logical
conclusions about the results of the test. A typical flowchart is provided in
Appendix D.
A similar troubleshooting technique is based on troubleshooting charts having

three columns. The first column describes the problem, the second the probable
cause, and the last column the remedy. Several troubleshooting charts may be
required to cover most typical problems of a system. Appendices E and F provide
typical flowcharts for mechanical and electrical service analysis.
PROCEDURE 1. Set the refrigeration system trainer for normal operation mode.
2. Switch on the trainer.
3. If the system seems functioning normally, record system pressures and

temperatures.
4. Compare your readings with designed conditions.
5. If a fault is suspected, list the symptoms and use the troubleshooting charts
to troubleshoot the system.

Appendix A
Conversion Factors
Imperial Unit Conversion Metric Unit
Category X =
(Symbol) Factor (Symbol)
Energy Btu X 1055 = J
X 1.055 = kJ
H.p. X 0.746 = kW
Tons X 3.51 = kW
Refrig.
Energy / Btu/hr. X 0.000293 = kWh
Time X 0.293 = Wh
Length In. X 25.4 = mm
X 2.5 = cm
X 0.025 = m
ft. X 0.30 = m
yd. X 0.9 = m
mi. X 1.6 = km
Mass oz. X 28.35 = g
lb. X 0.453 = kg
ton (2000 lb.) X 907 = kg
grain X 0.0000648 = kg
X 0.0648 = g
Pressure psi X 6.9 = kPa
in. w.g. X 0.25 = kPa (w.g.)
in. Hg. X 3.4 = kPa (Hg)
Temperature (°F – 32°) X 5/9 = °C
Velocity fpm X 0.00508 = m/s
mph X 1.6 = km/h
X 0.45 = m/s
Volume ft.3 X 0.03 = m3
yd.3 X 0.76 = m3
pt. X 0.47 = l
qt. X 0.95 = l
gal. X 3.8 = l
Volume &
Time cfm X 0.0005 = m3/s
Air: (0.000472)
X 1.7 = m3/h
Liquid: cfm X 0.472 = l/s
gpm X 0.06 = l/s

Appendix B
Vapor Pressure of Refrigerants

Temperature R-134a MP391 R-22
°F kPa (Psi) kPa (Psi) kPa (Psi)
0 43.5 (6.3) 44.1 (6.4) 165.5 (24)
5 60.7 (8.8) 57.6 (9.0) 194.4 (28.2)
10 80.1 (11.6) (75.5) (11.8) 226.2 (32.8)
20 124.2 (18.0) 115.8 (18.1) 296.5 (43.0)
30 176.7 (25.6) 163.8 (25.6) 378.5 (54.9)
40 238.1 (34.5) 220.1 (34.4) 472.3 (68.5)
50 309.9 (44.9) 284.8 (44.5) 579.2 (84.0)
60 392.7 (56.9) 359.0 (56.1) 700.5 (101.6)
70 488.0 (70.7) 443.5 (69.3) 837.1 (121.4)
80 596.3 (86.4) 540.2 (84.4) 990.1 (143.6)
90 719.2 (104.2) 649.0 (101.4) 1161.1 (168.4)
100 857.9 (124.3) 771.8 (120.6) 1350.7 (195.9)
110 1013.2 (146.8) 908.8 (142.0) 1561.0 (226.4)
120 1186.5 (171.9) 1061.8 (165.9) 1792.0 (259.9)
130 1379.1 (199.8) 1232.0 (192.5) 2046.4 (296.8)
140 1591.0 (230.5) 1419.5 (221.8) 2325.7 (337.3)
150 1824.9 (264.4) 1627.5 (254.3) 2630.4 (381.5)
1ForMP39 refrigerant, mean evaporator temperature is approximately 2.2°C (4°F)
below saturated vapor temperature.

Appendix C
Conversion Table
Table 1. Conversion from SI/Metric units to U.S. customary units.
To convert from to Multiply by
Density kg/m3 lb/ft3 6.243 × 10-2
Heat transfer rate W BTU/h 3.412
Force N lbf 2.248 × 10-1
Length m ft 3.281
Mass kg lb 2.205
Pressure Pa in Hg (60°F) 2.961 × 10-4
Pa lbf/in2 (psi) 1.450 × 10-4
Specific weight N/m3 lbf/ft3 6.366 × 10-3

9
Temperature °C °F 𝑇𝑇𝐹𝐹 = 𝑇𝑇𝐶𝐶 + 32
5
9
K °F 𝑇𝑇𝐹𝐹 = (𝑇𝑇𝐾𝐾 − 273.15) + 32
5
Velocity m/s ft/s 3.281
Viscosity (dynamic) N∙s/m2 lbf∙s /ft2 2.089 × 10-2
Volume flow rate L/min ft3/s 5.886 × 10-4
L/min gal/min (gpm) 2.642 × 10-1
m3/s ft3/s 35.31
m3/s gal/min (gpm) 1.585 × 104

Appendix C Conversion Table
Table 2. Conversion from U.S. customary units to SI/Metric units.
To convert from to Multiply by
Density lb/ft3 kg/m3 16.02
Heat transfer rate BTU/h W 0.293
Force lbf N 4.448
Length ft m 3.048 × 10-1
Mass lb kg 4.536 × 10-1
Pressure in Hg (60°F) Pa 3.377 × 103
lbf/in2 (psi) Pa 6.895 × 103
Specific weight lbf/ft3 N/m3 1.571 × 102

5
Temperature °F °C 𝑇𝑇𝐶𝐶 = (𝑇𝑇𝐹𝐹 − 32)
9
5
°F K 𝑇𝑇𝐾𝐾 = (𝑇𝑇𝐹𝐹 − 32) + 273.15
9
Velocity ft/s m/s 3.048 × 10-1
Viscosity (dynamic) lbf∙s /ft2 N∙s/m2 47.88
Volume flow rate ft3/s L/min 1.699 × 103
gal/min (gpm) L/min 3.785
ft3/s m3/s 2.832 × 10-2
gal/min (gpm) m3/s 6.309 × 10-5

Low Suction Pressure ... High Superheat

Typical Faults Probable Cause Counter Measure
A. Expansion valve limiting flow
Pressure difference across valve Undersize liquid line. Replace with proper size of line.
too small.
Excessively low condensing Increase head pressure.
temperature.
Gas in liquid line. Pressure drop in line. Check for proper line size. Clean
strainers, replace filter-driers.
Increase head pressure.
Insufficient charge in system. Add refrigerant charge.
Valve restricted. Pressure drop trough Use expansion valve with
evaporator. external equalizer.
Moisture, wax, oil or dirt Check for wrong oil type.
plugging valve orifice. Change oil. Install filter-drier.
Valve orifice too small. Replace with proper valve size.
Superheat adjustment too high. Incorrect valve setting. Adjust to proper operating
superheat.
Filter screen clogged. Wrong type of oil. Change oil type.
Dirt in lines. Clean filter screens.
B. Restriction in system other than expansion valve
Strainers clogged or too small. Dirt or filings present in system. Clean strainers or replace with
proper size.
Solenoid valve not operating Faulty wiring. Check electrical connections
properly. and control operation.
Plugged lines. Lines too small. Clear or replace lines.
Oil in lines blocking refrigerant Wrong type of oil in system. Purge and recharge system,
flow. using proper oil.
Low Suction Pressure ... Low Superheat

Poor distribution of refrigerant in Liquid short-circuiting through Clean suction line and clamp
evaporator. favoured passages, causing remote bulb to free draining line.
valve to be throttled before all Balance evaporator load
passages receive sufficient distribution.
refrigerant.
Compressor oversized or running Wrong size pulley. Replace compressor or pulley.
too fast.
Uneven or inadequate evaporator Poor air distribution or brime Balance load distribution by
loading. flow. providing correct air or brine
distribution.
Evaporator capacity too small. Evaporator too small or Replace evaporator or install oil
capacity reduced by oil build-up separator.
in evaporator.
High Suction Pressure ... High Superheat

Unbalanced system with load in Oversized evaporator with an Balance system components for
excess of design conditions. undersized compressor and a load requirements.
high load on evaporator.
Compressor capacity too small. Undersized compressor. Replace compressor.
Evaporator capacity too large. Oversized evaporator. Replace evaporator.

High Suction Pressure ... Low Superheat

Compressor capacity too small. Undersized compressor. Replace compressor.
Valve superheat setting too low. Improper valve adjustment or Adjust or replace valve.
wrong size of valve.
Liquid flood back in evaporator. Expansion valve seat eroded or Clean or replace damage valve.
held open by foreign material or Install a filter-drier to remove
debris. foreign debris.
Ruptured diaphragm or bellows Replace valve power assembly.
in automatic expansion valve.
Valve stuck in open position. Moisture freezing valve in open Thaw valve and install filter-drier
position. to remove moisture.
External equalizer line plugged. Dirt or wax build-up. Clear or replace line.
Fluctuating Suction Pressure

Incorrect superheat at Improper valve setting or valve Adjust or replace valve.
evaporator. size.
Improper remote bulb location Clamp remote bulb to free
or installation. draining suction line.
Trapped suction line. Suction line not free draining. Install P Trap for a free draining
suction line.
Flood Back or liquid refrigerant. Poorly designed liquid Replace faulty liquid distributor
distribution device or uneven or install proper load distributing
evaporator loading. device.
Condenser cooling device Faulty fan wiring or faulty water Check wiring or replace water
cycling. regulator in water cooled regulator.
condensers.
Fluctuating Discharge Pressure

Insufficient charge. Improper charging during initial Check system for leaks and add
set-up or presence of lead. sufficient charge to system.
Condenser cooling mechanism Faulty cooling fan wiring or Check wiring or replace faulty
cycling. faulty fan control. fan control.
Faulty condensing water Replace water regulating valve.
regulating valve on water
cooled units.
Inadequate or fluctuating main Check water circuit for
water supply to system. restrictions.
Rapid cycling of compressor. Improper adjustment of Adjust cut-out pressure setting
discharge pressure controller. and differential pressure setting.

High Discharge Pressure

Insufficient cooling air circulation Faulty fan circuit, or clogged Check fan motor, wiring and fan
over air cooled condenser. condenser cooling fins. controls. Clean cooling fins.
Overcharge of refrigerant. Improper charging during initial Purge small amounts of
set-up. refrigerant until desired charge
obtained.
Air or non-condensable gases in Improper evacuating and, Purge and recharge system.
condenser. charging of system.
Condenser or liquid receiver too Faulty system design. Replace with proper
small. components.
Insufficient cooling in water Inadequate supply of water to Check for restriction in water
cooled condenser. condenser, faulty water circuit, replace regulating valve,
regulating valve, or cooling or increase rate of water flow
water above design through condenser.
temperature.

Appendix D
Troubleshooting Flowchart
Figure 16.

Appendix D Troubleshooting Flowchart
Figure 17.

Appendix D Troubleshooting Flowchart
Figure 18.

Appendix E
Mechanical Service Analysis
Low Suction Pressure ... High Superheat

Compressor Will Not Start
Thermostat setting is above the Thermostat set too high. Reset thermostat below room
room temperature. temperature.
Starter overload cuts out. High head pressure. Reset starter overload and
determine cause of high head
pressure.
Pressure switch contacts remain Defective pressure switch. Repair or replace pressure
open regardless of pressure. switch.
Pressure switch contacts open. Loss of refrigerant charge. Check system for leaks; repair
leaks and recharge system.
Electrical system operating; Compressor frozen. Repair or replace compressor.
adequate voltage at the
compressor.
Compressor Short-Cycles
Thermostat differential too close. Defective thermostat. Replace thermostat.
Compressor cycles on low- Improper setting of low- Reset low-pressure switch
pressure switch. pressure side of pressure differential.
switch.
Compressor cycles on low- Low refrigerant charge. Check system for leak; repair
pressure switch. leaks and add refrigerant.
Compressor cycles on overload. Defective overload. Replace overload.
Compressor cycles on low- Dirty or iced evaporator. Clean or defrost evaporator.
pressure switch.
Compressor cycles on low- Evaporator blower and motor Tighten or replace belts.
pressure switch. belts slipping.
Compressor cycles on low- Dirty or plugged air filters. Clear or replace filters.
pressure switch.
Compressor Runs Continuously
High dry-bulb or wet-bulb Excessive load. Check for excessive outside air,
temperature in conditioned and moisture.
area.
Higher than normal head Noncondensable gases in the Purge system.
pressure. system.
Lower than normal temperature Thermostat setting too low. Reset thermostat.
in refrigerated area.
Higher than normal head Dirty condenser. Clean condenser.
pressure.
Higher than normal head Condenser blower or motor belts Tighten or replace belts.
pressure. slipping.
Lower than normal suction Low refrigerant charge. Check system for leaks; repair
pressure. leaks and add refrigerant.
Higher than normal head Overcharge of refrigerant. Purge and remove excess
pressure. refrigerant.
Pressure equalizes when the Compressor valves leaking Replace valve plate assembly or
system is turned off. complete hermetic compressor.
Lower than normal suction Metering device or strainer Clean expansion valve or
pressure. plugged. strainer.

Appendix E Mechanical Service Analysis
System Short of Capacity

Lower than normal head and Low refrigerant charge. Check system for leaks; repair
suction pressures. leaks and add refrigerant.
Lower than normal suction Incorrect superheat setting of Adjust superheat setting to
pressure. the expansion valve. −12°C (10°F).
Lower than normal suction Defective expansion valve. Repair or replace expansion
pressure. valve.
Higher than normal head Air or noncondensable gases in Purge system.
pressure. the system.
pressure.
Higher than normal head Condenser blower and motor Tighten or replace belts.
pressure. belts slipping.
Higher than normal head Overcharge of refrigerant. Purge and remove excess
Pressure equalize rapidly when Compressor valves leaking. Replace valve plate assembly or
the system is turned off. the complete hermetic
compressor.
Lower than normal suction Expansion valve or strainer Clean expansion valve or
pressure. plugged. strainer.
Higher than normal head Condenser air short circuiting. Remove obstructions or causes
pressure. of short circuiting air.
Head Pressure too High
Higher than normal head Overcharge of refrigerant. Purge or remove excess
Higher than normal head Air or noncondensable gases in Purge system.
pressure. the system.
pressure.
Higher than normal head Condenser blower and motor Tighten or replace belts.
pressure. belts slipping.
Higher than normal head Condenser air short circuiting. Remove obstructions or causes
pressure. of short circuiting air.
Head Pressure too Low
Sight glass indicates bubbles or Low refrigerant charge. Check system for leak; repair
liquid level valve on receiver leaks and add refrigerant.
indicates shortage of refrigerant.
Lower than normal head Compressor valves leaking. Replace valve plate assembly or
pressures and pressures the complete hermetic
equalize rapidly when system is compressor.
turned off.
Suction Pressure too High
Compressor runs continuously Low refrigerant charge. Check system for leaks; repair
and capacity is low. leaks and add refrigerant.
Lower than normal head Expansion valve is stuck in open Repair or replace expansion
pressure. position. valve.
Lower than normal head Incorrect superheat setting of Adjust superheat setting to
pressure. expansion valve. −12°C (10°F).

Appendix E Mechanical Service Analysis
Suction Pressure too Low

Typical Faults Probable cause Counter Measure
Sight glass indicates bubbles or Low refrigerant charge. Check system for leaks; repair
liquid level valve on receiver leaks and add refrigerant.
indicates shortage of refrigerant.
Suction line is warm, expansion Expansion valve or strainer Clean expansion valve or
valve or strainer may be showing plugged. strainer.
frost, and system capacity is low.
Suction line is warm and system Incorrect superheat setting of Adjust superheat setting to
capacity is low. the expansion valve. −12°C (10°F).
System capacity is low and Stratification of cool air in Increase air velocity through
temperature of return air is low. conditioned area. supply grilles.
Compressor is Noisy
Noticeable knock in compressor. Worn or scored compressor Replace the compressor.
bearings.
Abnormally cold suction line, high Expansion valve is stuck in Repair or replace expansion
suction pressure, and lower than open position or is defective. valve.
normal head pressure.
Higher than normal head Overcharge of refrigerant or air Purge system.
pressure. and noncondensables in
system.
Oil sight glass in compressor is Overcharge of oil. Remove excess oil.
completely filled during operation.
Abnormally cold suction line and Liquid refrigerant flooding back Repair or replace expansion
high suction pressure. to compressor. valve.
Noticeable transmission of Shipping or hold down bolts Loosen compressor hold down
vibration from compressor to rest nor loosened or removed. bolts so compressor is freely
of unit; compressor held firmly in floating in mountings.
mounting.
Oil level below midpoint of the oil Lack of oil. Add oil.
sight glass in compressor during
operation.
Rapid equalization of the Broken compressor valves. Replace valve plate assembly or
pressures when compressor the complete hermetic
stops. compressor.
Compressor Loses Oil
Visual inspection or suction line Incorrect superheat setting of Rerun trapped portion of suction
indicates long trapped portions of expansion valve. line; locate traps as
line. recommended in installation
instructions.
Presence of oil at piping joints or Leaks in systems leaking. Repair leaks and add refrigerant
connections. and oil as required.
Lower than normal suction Shortage of refrigerant. Check system for leaks; repair
pressure. Sight glass indicates leaks and add refrigerant.
bubbles or liquid level valve on
receiver indicates shortage of
refrigerant.
Lower than normal suction Expansion valve or strainer Adjust superheat setting to
pressure. plugged. −12°C (10°F).

Appendix F
Electrical Service Analysis

Compressor and condenser fan motor will not start
No voltage at disconnect switch Power failure Call power company
Voltage on line side of disconnect Fuse blown Replace blown or defective fuse.
switch but not on unit side
Thermostat set above the room Defective thermostat Repair or replace the
temperature thermostat.
Compressor contactor or starter Faulty wiring Check wiring and make
and fan relay do not energize necessary repairs.
Compressor contactor or starter Defective controls Check and replace defective
and fan relay do not energize controls.
Starter overload tripped Low voltage Reset and check for cause of
tripping.
Dual pressure, control contacts Defective dual pressure control Replace the control.
remain in open position
Compressor will not start, but condenser fan runs
No voltage at compressor Faulty wiring to compressor Check compressor wiring and
repair.
Voltage is available at Defective compressor motor Replace the compressor.
compressor; but an open winding,
or stuck compressor prevents
operation
Overload contacts remain in open Defective compressor overload Replace overload.
position (single-phase only)
Starting capacitor does not Defective starting capacitor Replace capacitor.
indicate rated capacitance (single-phase only)
Condenser fan motor will not start, but compressor runs
Relay contacts do not make when Defective fan relay Repair or replace relay(s).
coil is energized
No voltage at fan motor Faulty wiring to fan motor Check fan motor wiring and
repair.
Voltage available at motor Defective fan motor Replace fan motor.
Condenser fan motor runs, but compressor hums and will not start
Inadequate voltage at Low voltage Check line voltage; determine
compressor the location of the voltage drop.
Inadequate voltage at Faulty wiring Check wiring and make
compressor necessary repairs.
Adequate voltage available at Defective compressor Replace compressor.
compressor
Higher than normal head High head pressure Check head pressure and
pressure complete operation of system to
remove the cause of high-
pressure condition.
No voltage from one phase to Failure of one phase (three- Check fuses and wiring.
ground phase only)
Starting capacitor does not Defective start capacitor Replace capacitor.
indicate rated capacitance (single-phase only)
Potential relay contacts do not Defective potential relay Replace potential relay.
close for starting (single-phase only)

Appendix F Electrical Service Analysis
Compressor starts, but cycles on overload

Inadequate voltage at Low voltage Check line voltage; determine
compressor the location of the voltage drop.
Inadequate voltage at Faulty wiring Check wiring and make
compressor necessary repairs.
Running capacitor completely Defective running capacitor Replace the capacitor.
dead (single-phase only)
Overload is breaking contact Defective overload Replace overload.
under normal operating
conditions
Unequal phase voltages Unbalanced line (three-phase Check wiring; call power
only) company.
Evaporator fan motor will not start
No voltage at disconnect switch Power failure Call power company.
Voltage on line side of disconnect Fuse blown Replace blown or defective fuse.
switch but not on unit side
Evaporator fan relay(s) do not Faulty wiring Check wiring and make
energize necessary repairs.
Voltage available at motor Defective fan motor Replace fan motor.
Relay contacts do not make when Defective fan relay Repair or replace relay(s).
coil energize

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Refrigeration System Setup

Refrigeration and HVAC

Refrigeration System Setup

Québec (Québec) G2N 2K7

Refrigeration System Setup

By the staff of Festo Didactic

© Festo Didactic Ltée/Ltd, Quebec, Canada 1996

DANGER indicates a hazard with a high level of risk which, if not

WARNING indicates a hazard with a medium level of risk which,

CAUTION indicates a hazard with a low level of risk which, if not

CAUTION used without the Caution, risk of danger sign ,

Caution, risk of electric shock

Caution, hot surface

Caution, risk of danger. Consult the relevant user documentation.

Caution, lifting hazard

Caution, belt drive entanglement hazard

Caution, chain drive entanglement hazard

Caution, gear entanglement hazard

Caution, hand crushing hazard

Notice, non-ionizing radiation

Consult the relevant user documentation.

© Festo Didactic 580301 III

Both direct and alternating current

Three-phase alternating current

Earth (ground) terminal

Protective conductor terminal

Frame or chassis terminal

Equipment protected throughout by double insulation or

In position of a bi-stable push control

Out position of a bi-stable push control

IV © Festo Didactic 580301

Section 1 Refrigeration Instruments and Tools ........................................... 1

Section 2 Leak Detection ............................................................................. 13

Section 3 Evacuating a Refrigeration System ........................................... 25

Section 4 Charging a Refrigeration System ............................................... 29

© Festo Didactic 580301 V

Section 5 Refrigerant Recovery................................................................... 37

Section 6 System Troubleshooting ............................................................. 41

Appendix A Conversion Factors ..................................................................... 43

Appendix B Vapor Pressure of Refrigerants .................................................. 45

Appendix C Conversion Table ......................................................................... 47

Appendix D Troubleshooting Flowchart......................................................... 53

Appendix E Mechanical Service Analysis ...................................................... 57

Appendix F Electrical Service Analysis ......................................................... 61

VI © Festo Didactic 580301

We invite readers of this manual to send us their tips, feedback, and

Please send these to did@de.festo.com.

© Festo Didactic 580301 VII

Refrigeration Instruments and Tools

The Gauge Manifold

LOW COMMON HIGH

Figure 1. Gauge Manifold with common connection isolated.

© Festo Didactic 580301 1

LOW COMMON HIGH

To avoid introduction of contaminants into the system, the hose connections

Compressed Gas Cylinder

2 © Festo Didactic 580301

Figure 3. High Pressure Test System.