Practical No -03

Refrigerant Recovery and

Recharge of a Room Air
Conditioner
Refrigeration and Air Conditioning

ME 4382

Semester 7
University of Moratuwa
Sri Lanka

Name : M.P.C. Wijayabandara

Index No. : 170695X
Date of submission : 06/02/2022
Due date of submission : 06/02/2022

1
Abstract

Refrigerants play a major role in human life. In this practical, their effect on human life is
discussed. The maintenance aspect of AC systems is discussed and the procedures that are
followed in maintenance are described. The precautions to be taken while handling the
refrigerants and other involved gasses are clearly stated. The symptoms of faulty systems and
possible electrical and mechanical faults of AC systems are discussed.

Introduction

The standards of human life has grown to a point that personal comfort has now become an
essential need. With the increase of atmospheric temperature, the need to regulate and maintain a
satisfactory atmosphere for the comfort of humans has risen. Refrigeration and Air conditioning
plays a major role in this regard. This field is widely applied in animal farms, manufacturing
plants, mining setups as well.
By 1916 hydrocarbons (HC) were introduced as refrigerant with the excellent thermodynamic
properties despite their flammability. Expect for large commercial plants, this was substituted by
nonflammable hydrofluorocarbons (HCFC)s, developed in 1930. In 1974 scientists Melina and
Rowland discovered that HCFC is an ozone depletion substance. Induced by the Montreal
Protocol, the refrigerant manufacturers developed non ozone depleting substance such as HFC s,
which contain no chlorine. However, HFC has a higher value of global forming potential (GWP).
Therefore, conversion of room air conditioner from HCFC and HFCs to HCs is a mean of
contributing to protect the environment.
The Environmental Protection Agency (EPA) has prohibited refrigeration technicians from
intentionally venting refrigerants that harm the environment under Section 608 of the Clean Air
Act. Section 608 mandates that technicians recover refrigerants containing CFCs, HCFCs, and
HFCs instead of venting them. Apart from the legal requirements, there are other important
reasons to recover refrigerants. It’s beneficial for the environment as it reduces the volume of
harmful refrigerants entering the atmosphere. As supplies of R-22 continue to diminish, HVAC/R
businesses can sell the refrigerant they recover to reclamation companies, adding to their
revenues.

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Objectives
• To develop awareness on refrigerants
• To Familiarize with the AC systems and accessories
• To obtain hands on experience in recovering and recharging of a refrigerant
• To understand the correct practice of handling the refrigerant and the equipment
• To develop an understanding on interpretation between theory and practice

Apparatus

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 Procedure
Recharging a refrigerant
Leak testing procedure

1. Keep the V1 valve closed and V2, valve open.

2. Open the N2 cylinder valve and allow N2 gas to enter to the system, until the system pressure is
not exceeding 150 psi.
3. Then close the N2 cylinders valve and V2 valve.
4. Check the entire system for leaks by using a soap solution.

If no leakages are found, release the pressurized N2 gas to outdoor by opening the valves V1 , and V2.

Evacuating procedure

1. Disconnect the N2 cylinder and connect the Vacuum Pump to the specific place.
2. Keep the V1, valve open and V2 valve closed.
3. Start the Vacuum Pump and run until the pressure reaches 30 in Hg. Run the Vacuum pump at
least 15 min. Sometimes three cycles may have to be controlled.
4. Close the V1, valve and stop the Vacuum Pump.
5. Disconnect the Vacuum line.

Charging procedure

1. Disconnect the Vacuum Pump and connect the Refrigerant Gas Cylinder to the specific place.
2. Open the cylinder valve and purge the hose.
3. Keep the valve V2 closed and open refrigerant cylinder valve and V1 and allow the refrigerant to
enter to the system.
4. Open the cylinder valve and V1 and allow the refrigerant to enter into the system.
5. Start the compressor
6. Keep on adding the refrigerant in to the system until the correct charge (pressure) is reached.
7. When the suction pressure is 65 psi, close the cylinder valve and valve V1.
8. Disconnect the gas cylinder.

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Discussion
1. Schematic of Air Conditioning System

Sub cooled or High pressure

Saturated Saturated Vapor/
Liquid Superheated Vapor

Low pressure
Saturated or
Subcooled
Liquid Low pressure
Saturated Vapor/
Superheated Vapor

2. Components that cause the refrigerant to have high and low pressures

• The compressor and expansion valve causes the pressure changes.

• The compressor increases the pressure and the expansion valve reduces it.

3. Precautions taken when handling dry N2

• Setting the pressure gauges with accurate operating conditions. With the reading, it is
critical to keep the pressure at optimum pressure values.

• Using appropriate containers when storing

• Preventing oxygen deprivation to avoid vaporization, which can be lethal if inhaled.

• Liquid nitrogen should be handled in well-ventilated areas

4. Instruments used to do the leak test and reasons

• Soap water – bubbles form in case of leak, visible to notice

• N2 gas – to pressure the circuit

5. Why evacuation is necessary?

• In case of a leak repair, or another faulty component in the circuit, technicians

evacuate the system of refrigerant (recover) to engage in the maintenance task.
Additionally, evacuation prevents refrigerant from mixing with atmospheric air which
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 is an ecological benefit.

6. Symptoms of an Undercharged system

• When the system lacks gas, the cooling effect noticeably reduced. In cars, we notice
better cooling in less heated environments and no cooling in the afternoon.

7. Symptoms of an Overcharged system

• Overcharging will result in high discharge pressure and poor cooling will occur.

8. Faults that occur in Mechanical and Electrical system

• Bad thermostat resulting in non-stop running of compressor

• Compressor issues like cavitation

• Tube blockages, leakages

• Bad sensors, open circuits

9. Precautions taken while charging the refrigerant

• Double check the cylinder connections

• Read the system Refrigerant type

• Ensure there are no leakages or blockages

Conclusion
Refrigerants play a major role in day-to day life. Although they can be toxic and bad for inhaling they
are very useful to humans. Therefor safe application of Refrigerants are essential. There are certain
requirements in maintaining air conditioners / refrigerators such as gas charging, recovery and leak
testing. Detailed and safe procedures are followed while carrying out those tasks to avoid any injury
or health risk. There are various techniques used for leak testing but the most common of all, the soap
water method is discussed here. The procedure for gas evacuation and recharge are methods to be
followed with extreme caution. N2 gas must be handled with caution. There are certain symptoms
such as lack of cooling effect which occurs in a system when its under or overcharged. There are
electrical and mechanical failures that occur in AC systems additionally to refrigerant leak or tube
blockage.

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References

[1]A. Hilton, "Nitrogen Gas Safety Precautions: What You Need to Know", Ecscorrosion.com,
2022. [Online]. Available: https://www.ecscorrosion.com/blog/nitrogen-gas-safety-
precautions#:~:text=Take%20Safety%20Precautions&text=Always%20leave%20the%20door%20to
,oxygen%20level%20drops%20below%2019.5%25. [Accessed: 06- Feb- 2022].

[2]“How to Detect a Refrigerant Leak in Your HVAC System,” Clemmer Services Heating & Air
Conditioning, Sep. 18, 2018. https://www.clemmerservicesinc.com/blog/how-to-detect-a-refrigerant-
leak-in-your-hvac-system (accessed Jan. 06, 2022).

[3] “System Evacuation Training | Vacuum Training for Air Conditioning,” www.trutechtools.com.
https://www.trutechtools.com/air-conditioning-system-evacuation-training.html (accessed Jan. 06,
2022).