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F I II: (Vapor Cycle)
F I II: (Vapor Cycle)
F I II: (Vapor Cycle)
I F I II I
(VAPOR CYCLE)
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ORDER NUMBER EA-AAC-1
AIRCRAFT AIRCONDITIONING
IVAPOR CYCLEJ
SECOND EDITION
1
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II. Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Refrigerant Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Refrigeration Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Receiver-dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Expansion Valve.................................. 7
a. Internally Equalized . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
b. Externally Equalized . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Compressor..... . ................................ 8
5. Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Manifold Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1. Visual Inspection .. .. . .. .. . .. . .. .. . . .. .. .. .. .. .. .. 14
2. Leak Test.............. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. Feel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Final Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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J INTRODUCTION:
] Only a short time ago, air-conditioning was considered a and repeats the cycle.
.! luxury for the automobile. But, because it increases the Servicing and maintaining aircraft air-conditioning
efficiency of the driver and gives the passengers such systems is one of the tasks being added to the respon-
comfort, it is fast being looked upon as a necessity. sibilities of the modern A & P mechanic. These systems
Air travelers who live in air-conditioned homes, work in are neither mysterious nor complex, but they do require
air-conditioned offices, and drive air-conditioned some knowledge of basic physics and an accumulation of a
automobiles are reluctant to fly in airplanes without this good many servicing facts in order to be ready when a cool
comfort producing system. job comes in hot.
\ There are two basic types of air-conditioning systems This book is arranged to present basic facts for you to
i installed in modern aircraft. One is the air-cycle system read and digest. At intervals throughout the course,
where the air is compressed, energy is extracted, and the questions are asked for you to check your progress. Be
air released. As it expands, it cools. The other system is sure to answer each question before going on to the next
i the vapor-cycle system. Here a liquid refrigerant under section. Much of the material builds on what has just been
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J• pressure is sprayed into a cooling coil. The refrigerant covered. Some of the words used may be new to you, so
evaporates and in so doing removes heat from the cabin. you will find them defined in the Glossary at the end of the
The heated vapor passes through a radiator-like heat book. All such words when first mentioned are marked
exchanger outside the airplane, where it gives this heat to with an asterisk (•).
the outside air. The refrigerant returns to its liquid state
SECTION 1:
The basic theory of refrigeration
Blower Assembly
Suction line
Di!K'harge line
Expansion Valve
liquid Hose
Fig. 1
The vapor-cycle air-conditioning system is similar to the to another, but it still exists. Heat will flow from an object
mechanical refrigerator we use to keep our food cold. A or material having more heat energy to any other object or
refrigerant* changes its state from a liquid* to a gas *. As material having Jess heat. A material that allows this heat
it does this, it absorbs heat from the cabin. This heat is to flow easily is a good conductor, and one which resists
takttn outside the airplane and given off to the air as the the flow of heat is called an insulator.
refrigerant returns to its liquid state. The refrigerant used in aircraft air-conditioning is a
liquid, under certain conditions. When this liquid is
surrounded by air having more heat energy than the
J A. TRANSFER OF HEAT refrigerant. heat passes from'the air into the refrigerant.
As heat energy is absorbed by the liquid, it changes its
Heat, we must remember, is a form of energy, and we state and becomes a gas. The air that has passed over the
can neither create nor destroy energy. We can transform coils and given up its heat is cooled. Cold is a term that
it, move it from one place to another, or from one material merely indicates an absence of heat.
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evaporator that it will completely evaporate* by the time it
QUESTIONS: reaches the end of the coiL The cabin blower blows air
over the evaporator coiis. Heat from the cabin is absorbed
1. Where does the heat come from that causes the refri- by the refrigerant in the evaporator where it changes its
gerant in an air-conditioning system to turn from a state to a vapor. This extraction of heat is the cooling
liquid to a gas? action we are looking for. Low-pressure vapor is drawn
into the compressor where its pressure is raised to around
2. What happens to the heat that is taken from the cabin? 200 psi and its temperature to around 200 degrees F. This
high-pressure, high-temperature vapor goes into the
condenser, a heat exchanger cooled by a flow of outside
air. Heat is extracted from the refrigerant. As it cools, it
condenses back into a liquid and flows into the
receiver-dryer, ready to repeat the cycle.
B. BASIC VAPOR-CYCLE OF REFRIGERATION
2
A. REQUIREMENTS
B. COMPONENTS
SECTION Ill:
From .:ondenser
Aircraft Airconditioning
Systems and Components Sight glass
~ l-
~ l- Blowers
Condenser Receiver-dryer
REFRIGERATION CYCLE
The compressor and expansion valve divide the high and low sides of the
system-
Fig. 2
6
the entire system operation. Water will also react with will be added. A smaller amount of refrigerant will be
refrigerant to form hydrochloric acid which is highly metered into the coils.
corrosive to the metal in the system.
b. Externally equalized expansion valve:
2. Expansion valve
Systems having larger evaporators have a noticeable
The thermal expansion valve is the control unit pressure drop across the evaporator caused by the
opposition to flow of the refrigerant. This pressure drop is
which meters just the right amount of refrigerant into the
evaporator to evaporate completely by the time it reaches compensated by increasing the flow of refrigerant into the
evaporator. A constant pressure is thus maintained across
the end of the coils. The opening or orifice in the valve is
controlled by the heat load* in the airplane cabin. There the evaporator, which allows the temperature-sensing
are two types of thermal expansion valves, the internally function of the valve to meter refrigerant as a function of
equalized valve and the externally equalized valve. the superheat, or the heat load, in the cabin.
receiver-dryer
External
equilizer line
port
To evaporator Outlet
Fig. 4
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J The internally equalized expansion valve is used
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on systems having small evaporators. This valve is
Externally equalized expansion valve compensates lor the pressure drop
controlled by the amount of superheat* in the evaporator. across a large evaporator.
Fig. 5
A capillary tube* filled with a gas and sealed, connects
into the diaphragm chamber above the valve. The end of 3. Evaporator
the capillary is coiled into a bulb and attached to the
discharge of the evaporator. Coiling this tube allows a The actual cooling umt m an air·conditioning
greater area to be held in intimate contact with the system is the evaporator. This unit consists of one or more
evaporator, and a more accurate measurement of the circuits of copper tubing arranged in parallel between the
temperature can be made. If the liquid refrigerant
completely evaporates before it reaches the end of the
evaporator, it will continue to absorb heat and become
. superheated. It is still very cold to touch, but it is
·; considerably warmer than it would be if it had not
absorbed this additional heat. The expansion valve is
1 adjusted to a given value of super heat. When the
J pressure of th.e refrigerant vapor reaches this value, the
valve pushes down against the superheat spring and opens
to allow more refrigerant to enter the evaporator. A bal·
17. What two units divide the high side and the low side of
Pressure in Pressure in
an air-conditioning system? discharge line cylinder holds
holds discharge inlet valve
valve closed. dosed.
18. What is the condition of the refrigerant as it leaves the
evaporator? Piston on Piston on
downstroke upstroke
a. High-pressure liquid
b. Low-pressure liquid
c. High-pressure vapor
d. Low-pressure vapor
6. Service Valves
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8. Back seated • Normal operation
Fig. 9
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a. Compressor isolation service valves
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Compound Gage High-Pressure Gage
MANIFOLD SET
The most useful piece of air-conditioning servicing equipment.
Fig. 11
A. MANIFOLD SET
3. Manifold
QlJESTIONS:
Fig.13
l air, refrigerant, and water vapor is pumped out of the air-conditioning and commercial service is the propane
system. In order to remove the water, the pressure in the burner type detector. A small propane torch heats a
system is dropped as low as possible. At this low reaction plate red hot. A "sniffer tube" attaches to a
pressure, the water turns into a vapor and is drawn from low-pressure point in the tester. The open end of the tube
the system. The vacuum pump used for this operation is held below any fitting or point suspected of leaking.
must produce an extremely low pressure. The flow is of (R-12 is heavier than air and will settle downward.) Any
little consequence. A typical pump used for evacuating refrigerant that leaks out is drawn up into this tube and
air-conditioning systems pumps about 0.8 cubic foot of air passes over the reaction plate. The flame normally burns
per minute, and will evacuate the system to about 29.62 light blue, but the presence of any R-12 will cause the
inches of mercury, gage pressure. At this pressure, water flame to change color radically to green or purple. The
will boil at temperatures as low as a plus 45 degrees F. torch type leak detector is definitely NOT RECOM-
and the vapor will be drawn out. MENDED for use with an aircraft air-conditioning system
because of the danger of the open flame in the aircraft.
The most acceptable type of leak detector for use in
QUESTION: aircraft is the electronic type. This is an electronic
oscillator* that produces an audible tone. The presence of
48. What is the purpose of a vacuum pump in servicing an R-12 will cause the frequency to increase to a high-pitched
air-conditioning system? squeal. This type detector is recommended because of its
safety and its sensitivity. It is possible to detect leaks as
small as one half ounce per year.
D. LEAK DETECTOR
The continued operation of an air-conditioning system QUESTIONS:
i is dependent upon the system maintaining its charge of
.. j refrigerant. A tiny leak will soon lose all the charge. 49. Name two types of leak detectors recommended for
Naturally a tiny leak of a colorless, odorless gas is difficult use with aircraft air-conditioning systems.
to find. Without the aid of a leak detector, this would be
difficult indeed. SO. What will be the indication of a leak when using an
Of the several types ofleak detectors, the most simple is electronic leak detector?
a soap solution. A relatively thick solution is made of soap
chips and water. This is applied with a paintbrush to any 51. Would you look above or below a fitting for a
1 part of the system where a leak is suspected. Bubbles will
refrigerant leak?
\ indicate the presence of a leak.
. A common type leak d.....tector used in automotive
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SECTION V:
Ai rcond itioning
system servicing
Understanding the operation of an aircraft air-condi- A complete absence of cooling with no bubbles in the sight
tioning system and the purpose of each component makes glass could mean there is no refrigerant in the system. In
servicing the system easy. Actually there is not a great order to find the leak that caused the loss of refrigerant,
deal involved in maintaining these systems. Inspections, the following procedure should be followed:
and an occasional replacement of refrigerant or a
component is the main work the A&P will have to do. Let's a. Connect the manifold set into the system with
look at the service requirements: both the high and low side valves closed.
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Sehrader valve
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The manifold set connects across the expansion valve for entry into both
the low and high sides of the system.
fig. 14
3. Performance Test b. All of the lines and components in the high side
of the system should be warm.
A test to determine exactly how the system is
functioning is performed using the manifold set and a c. All of the lines and components in the low side of
thermometer. the system should be cool.
a. Connect the manifold set into the system and d. If the atmospheric conditions are especially
and leave both valves closed. humid, the amount of cooling will be reduced
because of the water that condenses on the
b. Run the engine somewhere around 1250 RPM evaporator. Changing water from a vapor into a
and set the air-conditioning controls for liquid and then into a solid as it freezes gives off
maximum cooling. heat. This heat goes into the refrigerant and
decreases the amount of heat the refrigerant can
c. Insert the thermometer into the evaporator as take from the air in the cabin.
near the coils as possible. Have the blower
operating at low or medium speed.
QUESTIONS:
d. After the system has operated for a few minutes,
the low side gage should read between 20 and 30 52. What could be indicated by an oil seepage at a fitting
psig, and the high side gage should read in the in a refrigeration system?
range of 225 to 300 psig. The evapora-
53. What is indicated by bubbles in the refrigerant as seen
tor temperature should be around 40 to SO de-
in the sight gtass in the receiver-dryer?
grees F.
54. How much refrigerant pressure is normally
recommended for performing a leak test?
SS. What is a normal range of pressure on the low side
4. Feel Test gage and on the high side gage when the system is
operating properly?
a. There should be no appreciable temperature
difference betweeen the inlet and the outlet side 56. Will an air-conditioning system cool better when the
of the receiver-dryer. They should both be humidity is high, or when it is low?
warm.
15
B. PURGING THE SYSTEM C. CHECKING COMPRESSOR OIL
Any time the system is to be opened, all of the The compressor is sealed into the refrigeration system
refrigerant must be purged. and the oil is in the compressor crankcase. In order to
check the oil, the system should be operated for at least
1. Connect the manifold set into the system with both fifteen minutes, then completely evacuated. With no
valves closed. pressure on the system, remove the oil filler plug from the
compressor and use a special oil dipstick made according
2. Place a clean rag over the end ofthe center hose and to drawings furnished by the compressor manufacturer. A
open both high and low side valves slowly. Be sure that range of oil level is indicated in the compressor service
the valves are not open so much that the refrigerant manual. It should not be allowed to go below the minimum
escapes fast enough to expel oil with the vapor. level, and should not be filled above the maximum.
Purging should be done in an area where there is no Be sure that only the oil recommended by the
danger of breathing the vapors. R-12 vapor is nontoxic, manufacturer is used in the compressor. The oil container
but it will displace oxygen we need and will cause should be kept tightly capped at all times that it is not
suffocation. When both gages read zero, the system is being used. After the proper amount of oil has been added
purged and may be opened. Any time a system is opened, to the system, the filler plug should be replaced and the
all of the lines must be capped to prevent the entry of system charged.
water vapor, dirt, or foreign matter.
D. EVACUATING THE SYSTEM
QUESTION: Any time an air-conditioning system has been opened,
it must be evacuated before recharging. Evacuating
57. Why should the valves be opened only a small amount simply means "pumping the system down" by attaching a
when purging an air-conditioning system? vacuum pump to the system and lowering the pressure so
any water in the system will t urn into a vapor and be drawn
20 30
10
Vacuum
45°F 0.30 in. Hg. ABS 29.62 in. Hg. vacuum Inches of Meteury
Gage Pressure
t.o.ering the pressure in the syslem by drawing a high vacuum causes all
of the water to vaporiu and be drawn out.
Fig. 15
16
Receiver-dryer
Discharge line sight glass
Condenser
Suction line
\'>-::!:.
J
~.~._----- _J_ -
- - - - - - - - - - - - - - - -I- -
r.:====:lJ::
Schrader
valve
fitting
v \Cj! 0 I
Evaporator
Fig. 16
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out. Water, as we know, will boil at 212° F. at standard 5. After about fifteen minutes, the system should be
sea level pressure of 29.92 inches of mercury, absolute (0 down to around 25 inches of mercury, gage
I inches of mercury, gage pressure, or vacuum). If the pressure.
pressure is lowered to 27.99 inches of mercury, gage
pressure (vacuum), it will boil at 100° F. At 29.40 inches it 6. Pump the system down for, at the very least,
will boil at 60° F. If we evacuate to 29.88 inches, water will 30 minutes; longer, if possible.
boil at 0° F.
7. Close both manifold valves, remove the vacuum
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1. With the manifold set installed in the system,
connect the inlet of a refrigeration vacuum pump to
pump, and replace the protective caps on the pump
fittings.
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Glossary:
'
This glossary of terms is provided to give a ready reference inches of mercury: A measurement of pressure, normally
to the meaning of some of the words with which you may used for pressures below atmospheric. One inch of
not be familiar. These definitions may differ from those of mercury is equal to approximately one half pound per
standard dictionaries, but are more in line with standard square inch.
shop usage.
latent heat: The amount of heat required to change the
state of a material without changing its temperature.
ambient air temperature: The temperature of the air
surrounding a person or object. latent heat of evaporation: The amount of heat absorbed
by a substance when it changes from a liquid to a vapor
boiling point: The temperature at which a liquid changes without changing its temperature.
to a vapor.
latent heat of condensation: The amount of heat given off
·;
British thermal unit ·- Btu: The amount of heat required when a substance changes from a vapor to a liquid
I to raise the temperature of one pound of water one without changing its temperature.
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I degree Fahrenheit .
latent heat of fusion: The amount of heat which must be
calorie: The amount of heat required to raise the removed from a substance to change it from a liquid to a
temperature of one pound of water one degree Celsius solid without changing its temperature.
(Centigrade).
liquid: A fluid which will assume the shape of the
can tap valve: A valve which is fastened onto a small can container in which it is held, but will not expand to
of refrigerant. It punctures the can seal and controls the completely fill the container.
flow of refrigerant.
capillary tube: A small tube of definite inside diameter orifice: A hole of specific size used to meter a fluid.
and length used to meter a fluid.
phosgene: A colorless gas with an unpleasant odor which
charging stand~ A handy and compact arrangement is produced when Refrigerant-12 is passed through an
of air-conditioning service equipment, containing open flame. It causes severe respiratory irritation.
a vacuum pump, manifold set, and a method of
measuring and dispensing the refrigerant. pressure, absolute: Pressure measured from a vacuum.
Absolute pressure is quite often expressed in inches of
cold: The absence of heat. mercury.
condensation: The process of changing a vapor into a pressure, ambient: The pressure of the air surrounding
liquid. a body.
desiccant: A material used in a receiver-dryer to absorb
. )
I moisture from the refrigerant.
pressure, differential: A pressure which is referenced
from another pressure .
electronic oscillator: An electronic device which emits pressure, gage: Pressure referenced from ambient
an audible tone. This device is used in a leak pressure.
detector. When a leak is detected, the tone changes.
reed valve: Thin leaf-type valve located in the valve plate
evaporate: To change from a liquid to a vapor. of a reciprocating compressor to control the inlet and
outlet ofthe refrigerant.
I freezing point: The temperature at which a liquid will
.! change into a solid. refrigerant: A fluid which is used in an air-conditioning
system to absorb heat from the cabin and carry it outside
gas: A fluid which will assume the shape of the container the airplane where it can be transferred to the outside
in which it is placed and will expand to fill all of the air.
··
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container.
Refrigerant 12: Dichlorodifluoromethane, a chemical·
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beat load: The amount of heat which the air-conditioner
is required to remove from an airplane cabin.
compound used in most aircraft air-conditioning
systems. Commonly referred to simply as R-12.
19
relative humidity: The ratio of the amount of water vapor temperature: A measurement of heat intensity.
in the air to the amount of water vapor required to
saturate the air at the existing temperature. thermostat: An air-conditioning control which senses the
temperature of the evaporator coil and causes the
saturated vapor: The condition of the vapor above a system to cycle to maintain the proper temperature
liquid in which no further vaporization can take place of the cooling air.
without an increase in its temperature.
ton of refrigeration: A measure of the cooling capacity of
sensible heat: Heat added to a substance which causes a an air-conditioning system. It is the same cooling effect
change in the temperature of the substance. as would be had by melting one ton of ice in 24 hours. It
is equal to 12,000 Btu of !)eat energy absorbed in one
silica gel: A desiccant used as a drying agent in hour.
air-conditioning systems. It has the ability to absorb a
large amount of water. vacuum: A negative pressure, or pressure below atmos-
pheric. It is usually expressed in inches of mercury.
specific heat: The amount of heat required to raise the
temperature of a pound of substance one degree vapor: The gaseous state of a material.
Fahrenheit.
vapor pressure: The pressure exerted by the vapor above
superheat: Heat energy added to a gas after evaporation a liquid which prevents the release of additional vapor at
has been completed. any specific temperature.
20
Aircond it ion ing (Vapor-Cycle)
FINAL EXAMINATION
STUDENT ....................................... .
6. Where is the high side service valve connected into
GRADE ........................................ . the system for servicing?
3. Care must be taken to avoid breathing R-12 vapors 9. The appearance of bubbles in the sight glass is an
because: indication of:
a. They will prevent your getting the oxygen you a. A partial charge of refrigerant:
need.
b. A full charge of refrigerant.
b. R-12 vapors are actually phosgene gas.
c. No refrigerant.
c. 63 to 72 degrees F. b. Condenser.
c. Evaporator.
13. At what RPM should the engine be run for
performing an operational test on an aircraft having d. Compressor.
an engine driven compressor?
a. 1250 RPM.
18. What does the thermostat control on an air-con-
b. Idle RPM. ditioning system in which the compressor is belt
driven from the engine?
c. High speed cruise RPM.
a. The opening of the expansion valve.
c. SO psi.
19. If the two lines connected to the expansion valve are
essentially the same temperature, it would indicate
15. What would cause the evaporator fins to ice up? that the valve is:
16. When a leak test is performed, where should the a. On every 100 hour inspection.
probe be held relative to the suspected leak?
b. Any time the system has been discharged.
a. Above the point.
c. It is a sealed system, so it does not need to be
b. Below the point. checked.
22
Answers to study questions:
1. From the air in the cabin. 27. The pressure drop across the evaporator.
2. It is taken outside the airplane and given off to the 28. Low side.
outside air.
29. Reed type valves.
3. Liquid.
30. Compressor bleed air.
4. Sprays liquid refrigerant and starts the evaporation
process. 31. A magnetically actuated clutch m the compressor
drive pulley.
5. Evaporator.
32. High side.
6. Condenser.
33. An interlock switch on the throttle retracts the
7. It condenses back into a liquid. condenser when the throttle is fully open.
14. Flood with much cool water, apply clean mineral oil, 40. The center fitting of the manifold is opened to the
and rinse with boric acid solution. side of the open valve.
15. Phosgene gas. 41. At the compressor inlet, or the discharge side of the
expansion valve.
16. A highly refined mineral oil. 42. At the compressor discharge, or at the
.J ' receiver-dryer.
17. The compressor and the expansion valve.
43. A can tap valve is screwed onto the can. This valve
18. (d) Low-pressure vapor. attaches to the service hose.
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19. (c) High-pressure vapor. 44. Weight.
.) 23. The desiccant absorbs moisture from the system. 48. Pressure in the system is lowered to a point that all of
water will turn into a vapor and be drawn out.
24. A sight glass in the receiver-dryer.
49. (a) Soap solution.
25. The heat load in the airplane cabin.
(b) Electronic oscillator-type tester.
, 26. The expansion valve would not be able to meter
I refrigerant as a function of the evaporator discharge so. The pitch of the tone will increase in the presence of
... J temperature (superheat). R-12.
23
51. Below. 59. Water will boil at low temperature when the pressure
is lowered. Water vapor will be pulled out with the
52. A possible refrigerant leak. air as the system is evacuated.
53. Low refrigerant supply. 60. This condition would indicate a blocked system.
(b) High side 225 to 300 psig. 63. At this temperature and pressure all liquid R-12 will
vaporize before it gets into the compressor.
56. Low.
64. There will be no more bubbles in the sight glass.
57. This will prevent the loss of refrigerant oil.
2. b.
3. a.
4. b.
S. d.
6. a.
)
l 7. b.
8. a.
9. a.
10. c.
11. b.
12. a.
13. a.
14. c.
15. c.
16. b.
. i 17. d.
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18. b.
I 19. b.
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20. b.
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