Presentations for PowerPoint

Modern
Refrigeration
and Air
Conditioning
11 Equipment and
Instruments for
Refrigerant Handling
and Service
Learning Outcomes (1 of 2)
• 11.1-1 Identify and explain the use of the various types of refrigerant
cylinders and identify the regulatory body over each type.
• 11.2-1 Differentiate between the various types of pressure gauges and
explain/demonstrate the appropriate and safe use of each.
• 11.3-1 Compare various types of service valves and their positions.
• 11.4-1 Explain the purpose, construction, and operation of a gauge manifold.
• 11.5-1 Identify the various types of leak detection equipment and explain the
appropriate use of each.

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Learning Outcomes (2 of 2)
• 11.6-1 Demonstrate the care and use of a refrigeration vacuum
pump and how to change its oil.
• 11.7-1 Identify and demonstrate the use of various recovery
machines.

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Refrigerant Cylinders (1 of 2)
• Pressure release protective devices

Goodheart-Willcox Publisher

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Refrigerant Cylinders (2 of 2)
• Types of cylinders
• Storage cylinders
• Disposable cylinders
• Recovery cylinders

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Cylinder Regulations
• Prescribed by DOT
• Ensure technician safety
• Inspection and recertification
• Cylinders with corrosive or noncorrosive refrigerants: every 5 years

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Storage Cylinders
• 100-lb and 150-lb cylinders
• Used to charge refillable cylinders in shop
• Fitted with valve and cap
• Packing around valve makes it leak-proof
• Protective cap must be in place for moving or shipping

Worthington Cylinders

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Safety Note: Moving Heavy Cylinders
• Moving cylinders more than 35 lb (16 kg)
• Use a hand truck
• Secure the cylinder with a chain

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Disposable Cylinders
• Designed for one usage only
• Used to charge refrigerant into system
• Advantages
• Easy to handle
• Eliminate need to refill

Worthington Cylinders

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Disposing of Disposable Cylinders
• Before disposing of or recycling:
• Recover all refrigerant into approved recovery cylinder
• Evacuate cylinder down to atmospheric pressure
• Many refrigerant supply stores offer recycling
• Illegal to transport recovered refrigerant in disposable cylinder

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Code Alert: Disposable Cylinder Usage
• It is illegal to transport recovered refrigerant in a disposable
cylinder.
• Do not use disposable cylinders to store refrigerant removed from a
system.

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Recovery Cylinders
• Designed for storing recovered refrigerant
• Gray cylinder with yellow top
• Valves
• Gas—usually blue
• Liquid—usually red
• Read valve handles to identify valves

Manchester Tank

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Pressure Gauges
• Measure pressure of fluid in container
• Provide information about inside of refrigeration system
• Bourdon tube—operating element
• Retarder enables readings at higher pressures
• Available in several types and ranges
• Vacuum gauge
• Compound gauge
• High-pressure gauge
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Vacuum Gauge
• Measures lower-than-atmospheric pressure
• Digital scales
• microns
• psi
• in. Hg
• millibars
• pascals
• torr
• millitorr JB Industries

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Procedure: Cleaning a Thermistor
Vacuum Gauge
1. Fill the tube with cleaner.
2. Rock the tube gently
3. Empty the tube.
4. Repeat Steps 1–3 two or three times.
5. Clean with an alcohol rinse.
6. Clean the instrument dial cover with soap, water, and facial
tissues.
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Compound Gauge
• Measures positive pressure and
vacuum
• Low-side gauge
• Measures above and below
atmospheric pressure

Ritchie Engineering Co., Inc. – YELLOW JACKET Products Division

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High-Pressure Gauge
• Can read high-pressure values on continuous scale
• High-side gauge
• 0 psi to 500 psi or 800 psi (depending on refrigerant
scales)

Mastercool

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Care and Calibration of Gauges
• Causes of damage • Calibration
• Sudden release of high pressure into gauge • Calibrating equipment shows
• Fluctuating pressures 0 psi at sea level
• Calibrate gauges to read 0 psi
for elevation where they will
be used

Goodheart-Willcox Publisher

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Service Valves
• Provide easy access to system
• Ensure continued smooth operation
• Control access to service port
• Provide connection to system
• Taking readings
• Charging
• Evacuating
Courtesy of Sporlan Division – Parker Hannifin Corporation

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Front Seated and Back Seated Valves

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Mid-Position and Cracked Open Valves

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Service Valves: Low-Side and High-Side
Valves
• Low-side valves
• Suction line service valve
• Suction service valve (SSV)
• High-side valves
• Discharge service valve (DSV)
• Liquid line service valve
• Liquid receiver service valve (LRSV)
Mueller Industries, Inc.

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Service Valve Maintenance and
Operation
• Clean and oil valve stems before turning
• Reduce rusting by coating valve body with refrigeration lubricant
• Match wrench size to valve stem
• Maintain packing to prevent leaks
• Oil threads of service port

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Safety Note: Valve Cracking Tip
• Always use fixed wrench when cracking open a stuck valve.
• Valve can be quickly closed again if leak or breakage occurs.

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Procedure: Loosening a Stuck Service
Port Plug
1. Heat the outside of the service valve body with flame from a torch.
Be careful not to overheat the valve. This will cause the valve
body to expand and weaken the valve body’s thread grip on the
plug.
2. Use a wrench to gently turn and loosen the plug.

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Access Ports
• Small valve opening
• Schrader valve core
• Opened by depressing pin
• Pin springs back in place to minimize
refrigerant loss
• Provide convenient access to system
• Evaporator outlet
• Liquid line inlet Goodheart-Willcox Publisher

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Piercing Valves
• Pierce tubing to access system
• Provide access to systems
• Small hermetic systems
• Systems without access ports
• Designs
• Brazed on
• Bolted on
Sealed Unit Parts Co., Inc.

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Brazed-On Piercing Valves
• Used when there is good access to area of straight tubing
• Before installing
• Evacuate refrigeration system
• Remove valve core
• Check for nearby flammables or soft-soldered joints

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Procedure: Installing a Brazed-On
Piercing Valve (1 of 3)
1. Check to see if there is enough space around the tubing to install and operate
the piercing valve.
2. Check to see if a service hose can be easily attached where the piercing
valve will be placed.
3. Make sure the tubing used to install the piercing valve runs in a straight line
and is round without any dents or irregularities.
4. Clean both the saddle and tubing mating surface with clean sandpaper and
clean steel wool. Remove any dust with a clean cloth.
5. Remove the piercing valve steam and the gasket from the saddle.
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Procedure: Installing a Brazed-On
Piercing Valve (2 of 3)
6. If using a flux-coated filler rod, mount the saddle on the tubing. If not
using a flux-coated filler rod, apply clean, fresh brazing flux on the
saddle. Then mount the saddle on the tubing.
7. Check to see if there is enough room for using the valve in its
present location. If not, then find a more suitable location.
8. Using a torch, heat both the tubing and saddle until the filler rod
material flows around the saddle.
9. When finished brazing, inspect it carefully.
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Procedure: Installing a Brazed-On
Piercing Valve (3 of 3)
[Link] the brazed joint has cooled, install the piercing needle and
gasket.
[Link] the service hose and then back off the piercing valve stem
slightly to access the system.
[Link] for leaks to make sure the seal between the piercing valve
and tubing is airtight

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Procedure: Installing a Bolted-On
Piercing Valve (1 of 2)
1. Check to see if there is enough space around the tubing to install and
operate the piercing valve.
2. Check to see if a service hose can be easily attached where the piercing
valve will be placed.
3. Make sure the tubing used to install the piercing valve runs in a straight line
and is round without any dents or irregularities.
4. Clean the tubing area with a fine emery cloth or fine sandpaper.
5. Back out the valve’s piercing needle by rotating the stem counterclockwise.

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Procedure: Installing a Bolted-On
Piercing Valve (2 of 2)
6. Dab a little clean refrigerant lubricant on the tubing.
7. Mount the valve on the tubing and secure the valve body to the tubing.
8. Attach the service hose and rotate the piercing valve stem clockwise
into the tubing.
9. Back off the piercing needle slightly by turning the stem
counterclockwise.
[Link] for leaks to make sure the seal between the piercing valve and
tubing is airtight.
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Gauge Manifolds
• Components
• Compound gauge
• High-pressure gauge
• Minimum of three ports
• Minimum of two valves
• Uses
• Check pressures of low and high sides at same time
• Add or recover refrigerant
• Add oil
• Bypass compressor Imperial

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Purging Gauges and Hoses
• Removes vapors, dirt, or moisture from refrigerant hoses
• Releases contents into atmosphere
• Use quick-connect fittings to release as little refrigerant as possible

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Procedure: Purging a Gauge Manifold
and Hoses (1 of 2)
1. Make sure that the cylinder valve, the gauge manifold valves, and the
system service valves are closed. Service valves should be back
seated.
2. Connect the center service line of the gauge manifold to a refrigerant
cylinder containing the same refrigerant used in the system.
3. Remove the caps from the system service ports; loosely connect the
gauge manifold’s low- and high-side service links for purging.
4. Open low- and high-side valves on the gauge manifold.
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Procedure: Purging a Gauge Manifold
and Hoses (2 of 2)
5. Briefly crack open the cylinder valve on the refrigerant tank to
flush the gauge manifold and service line with refrigerant.
6. Close the cylinder valve and tighten the service line fittings at the
service ports.
7. The service valve can now be opened.

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Code Alert: Venting Refrigerants
• EPA allows technicians to release small amounts of refrigerants
during:
• Recovery
• Repair
• Purging
• Charging

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Valve Positions for Pressure Readings

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Valve Positions for Evacuation

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Valve Positions for Vapor Charging

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Valve Positions for Liquid Charging

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Refrigeration System Analyzer
• Measures pressure and temperature
• Programmed with saturation temperature for multiple refrigerants
• Includes digital connectivity
• Some troubleshooting capabilities

Ritchie Engineering Co., Inc. – YELLOW JACKET Products Division

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Leak Detection Devices
• Bubble solutions
• Fluorescent dyes
• Refrigerant dyes
• Halide torches
• Electronic detectors
• Ultrasonic detectors
Spectronics Corporation

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Tips for Detecting Leaks
• Check connections early in your search
• Look for oily or dusty areas
• Block off search area to eliminate wind or breezes
• Block bright lights when using color-changing methods
• Turn off nearby equipment when using ultrasonic detector
• Operate the system to build up pressure

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Code Alert: EPA Leak Repair Standard
• Section 608 of Clean Air Act states leak repairs are required:
• Within 30 days if a leaking system contains 50 lb of refrigerant.
• If the system has yearly leak rates at or above trigger levels.
• Trigger level is 35% for commercial and industrial systems.
• Trigger level is 15% for comfort cooling and other appliances.

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Thinking Green: Refrigerant Loss Logs
• Keeping accurate logs of customers’ refrigerant use and loss will
help technicians detect leaks early.
• The earlier a leak is detected and repaired, the smaller the
environmental impact of the leak.

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Bubble Solutions
• Soap and water or patented solution
• Brushed over tubing and connections
• Vapor causes bubbles to form
• Advantages
• Low-cost, easy method of leak detection
• Most reliable test in presence of urethane
• Disadvantage
• Larger leaks may blow through without bubbling Refrigeration Technologies

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Dye-Based Leak Detection
• Refrigerant dye
• Injected into system
• System returned to normal operation
• Visually inspected for dye at various points
• Fluorescent dye
• Uses fluorescent dye and ultraviolet light
• No false alarms
SPX Corporation

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Halide Torch Leak Detection
• Principle
• When halogen refrigerant contacts flame, flame becomes light green
• Works for all halogenated refrigerants
• Procedure
• Halide torch burns fuel gas near copper plate
• Rubber hose siphons air from areas of suspected leaks
• Green flame indicates refrigerant leak

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Electronic Leak Detectors
• Electronic sensors determine presence of leak
• Very sensitive—can detect tiny leaks
• Often battery-powered
• Exercise care not to damage sensing tip

SPX Corporation

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Safety Note: Explosive or Flammable
Vapors
• Do not use halide torches or electronic leak detectors in areas
containing explosive or flammable vapors.

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Ultrasonic Leak Detectors
• Detect the sound a vapor makes as it leaves pressurized system
• Handheld devices
• Amplify sound and play through headphones
• LEDs or other type of indicator

Photo Courtesy of INFINICON

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Vacuum Pumps
• Vapor pumps used to create vacuums for evacuating system before
charging
• Specifications
• Ultimate vacuum
• Free air displacement

Ritchie Engineering Co., Inc. – YELLOW JACKET Products Division

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Safety Note: Vacuum Pumps Used with
Flammable Refrigerants
• Make sure that the vacuum pump is UL-rated for use with A2L
refrigerants

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Types of Vacuum Pumps
• Single-stage pumps
• Single pump mechanism
• Used in triple evacuation method
• Two-stage pumps
• Two pumps mechanisms connected in series
• Used in deep-vacuum method
Two-Stage Vacuum Pump

Ritchie Engineering Co., Inc. – YELLOW JACKET Products Division

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Oil in Vacuum Pumps
• Purpose
• Lubricate pump
• Provide fluid seal for air, gases, and contaminants as they enter the
pump
• Replacement
• Replace oil frequently
• Check sight glass for oil level and quality
• Test pump or change oil before each system evacuation
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Procedure: Testing a Vacuum Pump (1
of 2)
1. Using a tee fitting, connect an electronic vacuum gauge between the
vacuum pump and the center port of a gauge manifold.
2. Close the low- and high-side gauge manifold valves.
3. Start the vacuum pump, allowing the pump to run enough to pull a
vacuum of approximately 500 microns.
4. Turn off the vacuum pump. Wait 2 to 3 minutes, allowing the vacuum
pressure to rise.
5. Pull another vacuum down to 500 microns.
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Procedure: Testing a Vacuum Pump (2
of 2)
6. Watch the reading.
7. If it rises, check for leaks at the hose fitting.
8. If a pump will not pull down to high vacuum, change the oil.
9. Always follow manufacturer’s direction.

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Refrigerant Recovery Management
Equipment
• Recovery―a unit that removes the refrigerant
• Recovery/Recycle―a unit that removes and filters the refrigerant
• Reclaim―a unit that processes refrigerant to a pure state, in
accordance with EPA regulations

Bacharach, Inc.

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Code Alert: Refrigerant Recovery and
Recycling
• Section 608 of Clean Air Act requires refrigerant to be recovered
and recycled.
• Technicians must evaluate HVACR equipment to established
vacuum levels when opening equipment for service.

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Code Alert: Equipment Certification
• Recovery equipment must be certified by an EPA-approved testing
organization.
• Certification ensures equipment can achieve required vacuum
levels.

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Refrigerant Recycling
• Process of cleaning refrigerant for reuse
• Separate out oil
• Pass through filter-driers
• Recycled refrigerant
• Returned to system following repair
• Used in another system belonging to same owner
• Cannot be sold
Ritchie Engineering Co., Inc. – YELLOW JACKET Products Division

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Refrigerant Reclaiming
• Reprocessing recovered refrigerant to be chemically pure
• Analyzed at approved testing facility
• Must meet AHRI Standard 740 for purity
• Reclaimed refrigerant use
• Can be charged back into any unit designed for use with that
refrigerant

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Thinking Green: Refrigerant
Conservation
• An environmentally conscious technician not only minimizes and
repairs all refrigerant leaks, but also takes steps to ensure that
refrigerants remain pure, clean, and dry.
• For example, if a compressor motor burns out because of improper
service, the technician has not only cost the customer money, but
has also wasted the energy and materials that will be required to
evacuate and flush the system and recycle the refrigerant.

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.
Digital Charging Scales
• Electronic refrigerant scale
• Monitors weight of cylinder
• While refrigerant is being charged into a system
• While refrigerant is being recovered from a system

Ritchie Engineering Co., Inc. – YELLOW JACKET Products Division

Copyright © 2025 Goodheart-Willcox Co., Inc. All Rights Reserved. You may not reproduce or allow unauthorized access to any G-W course or other materials, except as permitted by U.S. copyright law.
Such materials may be used for your own educational purposes only, in a location not accessible by the general public.