CHAPTER 6
Maintenance, repairs
and paRTS/Refrigerant
REPLACEMENT OF vcrs
Defrosting
Defrosting is the melting away of ice from the evaporator cooling surfaces. The source of ice is the humidity of air. As
the ice layer forms, it forms a barrier between the refrigerated space and the evaporator surface, impeding the heat
transfer from the evaporator to the refrigerated space. Defrosting can be made in a number of ways:
Electric Defrost: This is the most common form of automatic defrosting used in most commercially available
refrigerators today. The appliance uses electricity to power a heating element which will melt away any frost or ice
build-ups regularly, several times throughout the day.
Hot Gas Defrost: Another form of auto-defrost relies on the hot gases from the compressor. These hot gases are
channelled to areas where frost accumulates to melt the ice off efficiently. A form of this defrosting is interchanging the
evaporator and condenser for a short time, letting the hot gas melt the ice away (reverse cycle defrosting).
Water Defrost: Some industrial refrigerators use hot water to melt away the frost instead of a heating element or hot
gases. These are rarely seen in refrigerators for household use.
Off-Cycle Defrost: This form of defrosting is very straightforward, as it involves turning off the refrigeration process
entirely for a short period. Again, this type of defrosting is used in industrial applications. It can also be made
automatically, either by compressor suction pressure control or by evaporator temperature control.
Manual defrost : Used in some home refrigerators. The user shuts the refrigerator for some time and lets the frost to
melt away.
Electric Defrosting
Manual defrosting
Cross-section of an evaporator tube with
electric defrosting – inner part is an
electrical heating element.
The compressor is stopped for some time and electric current is passed through the heating
elements until the ice is removed.
Hot gas defrosting (Through manual valve)
Defrost mode operation
Normal operation
Hot gas defrosting (Through a four-way valve valve)
Hot gas defrosting (Through a thermostatically controlled solenoid valve)
Compressor suction pressure control
When there is ice accumulation on evaporator surfaces, there shall be less heat transfer and hence
less evaporation inside the evaporator. In this case, compressor suction pressure shall drop. A
pressure switch shall automatically stop the system for some time until the ice melts away.
Temperature control defrosting
The principle is similar to compressor suction pressure control- when the temperature in the refrigerated
space increases, as sensed by a thermostat, the system is automatically shut down for a while, until the ice
melts away.
Evacuating a System
A refrigeration system should only contain its refrigerant in a liquid or vapour state and a compatible
lubricant. However, moisture and other substances often enter a refrigeration system during service.
This happens after refrigerant has been recovered and the system is opened to the atmosphere. To
remove this unwanted moisture, a technician must evacuate the system.
Evacuation is the removal of all vapours, gases, and fluids from a system. Evacuation occurs after the
refrigerant has been recovered from the system and before the system is recharged.
Any liquid that is left in the system shall evaporate and be cleared off the system after a vacuum is
maintained. A vacuum pump is used for this purpose.
Air Purging
Air that leaks into the system should be expelled out of the system for the refrigerant to be totally filled in. This is
made by a purging system (basically a vacuum compressor).
Filling of Refrigerant into the Vapour Compression
Refrigeration System
Both charging and evacuation of refrigerant to and from a
refrigeration unit is made by special ‘’manifolds’’.
The following procedure is used to add refrigerant:
1. Evacuate the system.
2. Connect the refrigerant cylinder to the charging manifold.
3. Charge only with correct refrigerant vapour.
The refrigerant cylinder may be heated with warm water or an electric heater insert. Temperature must not
exceed 49 oC. Never use an open flame for heating.
An electronic manifold
Both high and low pressure sides closed
Both high and low pressure sides open
Only low pressure side open
Only high pressure side open
Recovering the
refrigerant in the
compressor by
isolating the
compressor. The
compressor can be
removed for
repairs.
REFRIGERANT LEAK DETECTION
Refrigerant system leaks are usually very tiny and require sensitive detecting devices. Commonly used
devices include bubble solutions, flourescent dyes, refrigerant dyes, halide torch, and electronic detection.
Bubble Solutions
The bubble method of leak detection, employing a water-soap solution, is commonly used. This solution
is brushed over an area of suspected leaking. The gas coming through the solution will cause bubbles to
form.
In addition to common soaps, patented solutions provide a stronger, longer lasting bubble film than the
soap solution.
Refrigerant Dye and Fluorescent Leak Detecting
Refrigerant dye is another tool used for locating leakage problems. Refrigerant dye in a system produces a
bright red spot in the leakage area.
The ultraviolet fluorescent leak detection procedure is another similar method used. A fluorescent additive
is circulated through the system. The leakage shall become visible by an ultraviolet light.
Halide Torch Leak Detector
Alcohol, propane, acetylene, and most other torches burn with an almost colourless flame. A flame will
continue to be almost colourless if a copper strip is placed in it. However, the tiniest quantity of halogen-
containing refrigerant, brought into contact with the heated copper, will cause the flame to change to a
bright green colour (Halogen refrigerants include R-12, R-22, R-11, R-500, R 502, etc.). This principle is
used in halide torches to check leaks in refrigeration systems.
Halogenic elements: Flourine (F), Chlorine (Cl), Bromine (Br), Iodine (I), Astatine (At)
Electronic Leak Detectors
Three commonly used types of electronic leak detectors are electrochemical sensor, ultrasonic, and
dielectric.
The electrochemical sensor consists of a ceramic layer covered by a reactive element maintained at high
temperature by a built-in heating element. Contact with a halogen-bearing gas causes an electrical
current to flow to a collection electrode. This electrical current is used to produce a warning signal for the
refrigerant leak.
Ultrasonic leak detectors have also become widely used in the industry. These units use headphones and
a portable detector that can receive sounds that are beyond the range of human hearing. Ultrasonic
detectors detect the sound that a vapour makes as it is excaping from a pressurized system.
The dielectric leak detector operating principle is based on the difference between the dielectric property
differences of different gases. The gases are run between the plates of a capacitor. The gases act as a
dielectric (insulator) for each capacitor. Different dielectric properties cause a difference in the
capacitance of the condenser, which cause a change in the frequency of an oscillator. This change of
𝜀𝐴
frequency indicates a leak. ( 𝐶 = , ε changes with the existence of refrigerant)
𝑑
REFRIGERATION SYSTEM PIPING
Most tubing used in refrigeration and air conditioning is made of copper. However, some aluminum,
steel, stainless steel, and plastic and flexible plastic tubings is also used. Ammonia, a common
refrigerant, is highly corrosive for copper. For ammonia, preferred piping material is steel.
Refrigerant line velocities
Economics, pressure drop, noise, and oil entrapment establish feasible design velocities in refrigerant
lines. These are:
Suction line - 200 – 1200 m/s
Discharge line - 150 to 1100 m/s
Condenser drain line – 30 m/s or less
Liquid line - 40 to 140 m/s
The length of the tubing between the evaporator exit to
compressor inlet is insulated to avoid extra superheating,
thus helping to reduce the compressor work.
Soldering and brazing
For the repair of refrigeration piping, both soldering and brazing are used. Refrigerant carrying tubes are
repaired by brazing and water pipes and drains are repaired by soldering.
The difference between soldering and brazing is the lower temperature at which solder flows. If the
temperature required to melt the alloy used to join copper tubing is below 450oC, it is considered
soldering. lf the temperature required to flow the alloy is above 450oC, it is referred to as brazing.
Brazing produces stronger bonds compared to soldering. Brazing filler materials can join both similar and
dissimilar materials at brazing temperature. Brazing filler materials can be classified into two:
1. Alloys containing 30% to 60% silver,
2. Copper-phosphorus alloys
Brazing is usually made with oxy-acetylene torch.
An alternative to soldered/brazed connections is the use of
flaring the ends of copper tubes and using flared joints.
Flared joints
Flaring tool to flare the ends of copper tubes
Pipe cutter for cutting the tubes
Connections, elbows and T- joints used in refrigeration piping
Thermoplastic tubing used in refrigeration