LAB 2

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMH 2503 FUNDAMENTAL OF HVAC AND REFRIGERANT

LAB SHEET 2
INSTALLATION AND SERVICING OF WALL SPLIT AIR CONDITIONING (PUMP DOWN AND
FLUSHING)

Learning LO2 Perform experiment on vapour commpression cycle application

Outcome (LO):

Program PO4 Ability to plan and conduct experimental investigations of broadly-

Outcome: defined problems, using data from relevant sources

Synopsis: To apply basic idea regarding installation work of room air conditioner including
pump down, flushing, recharging and refrigerant recovery.

This lab activity will enrich students with knowledge on introduction for refrigeration
concepts with actual parts (components) observation in laboratory and identify
differences (principle, tools, components and refrigerant type) between 1hp
inverter and conventional (constant speed) split unit.
Related Lecture’s 1. Small HVAC Application (Chapter 6)
Topic:

Prepared by: Ts Muhammad Fairuz bin Abu Bakar Date: 9 November 2020

Approved by Dr Ilman Hakimi Date

LM/SLM/HOD

QMS : REVISION RECORDS

Revision Date Approved by

Description Prepared by :
No (DD/MM/YY) LM/SLM/HOD:
1.0 THEORY
PRINCIPLE OF REFRIGERATION

Understanding a word like heat is often difficult, and that may be because heat is extremely hard to
define. This is why a categorization of the actions of heat is in order. When an object is heated, that
object rises in temperature and change state. If you heat ice, it turns into water (change from solid to
liquid). If you heat it further and rise the temperature to 100°C, it begins to evaporate at the moment it
reaches 100°C (boils) and its temperature rises no further. The heat supplied until water reaches
100°C is used to raise the temperature of water and is called ‘sensible heat’ and can be measured by
using a thermometer. The heat occurring when the water changes from liquid to gas as it passes 100°
(change state) is called latent heat and cannot be measured by thermometer. The three physical states
of objects is:

1) Evaporation heat: Heat required for change from liquid to gas.

2) Condensation heat: Heat required for change from gas to liquid.
3) Fusion heat: Heat required for change from solid to liquid.
4) Solidification Heat: Heat required for change from liquid to solid.
5) Sublimation heat: Heat required for change from solid to gas.

Figure 1

Figure 1 picture illustrate of one (1) gram (1ml) of water (H2O) where the top arrow represent adding
heat and bottom arrow represent releasing heat.
Refrigeration is to cool an object below atmosphere temperature. The many different methods of
refrigeration may be categorized from the perspective of heat use where:

1) Ice method (use of fusion heat): When ice at 0°C is change into water at 0°C, about 80 kcal/kg
of heat is absorbed from surrounding environment.
2) Dry ice method (use of sublimation heat): When dry ice sublimates and turns into carbon
dioxide gas, it absorbs about 137 kcal/kg of heat from the surrounding environment.
3) Method of evaporation a liquid that easily evaporates (use of evaporation heat): When liquid
ammonia is evaporated into ammonia gas, it absorbs 327 kcal/kg of heat from the surrounding
environment.
 4) Peltier effect (electronic refrigeration): When two different kinds of metal are placed in contact
and a current is passed through them, either heat generation or absorption – depending on
the current’s direction – occurs at the point of contact. Using this effect to obtain low
temperature is electronic refrigeration. Two generally used materials are bismuth and telluriu

The kilocalorie (kcal) is the unit of heat required to raise the temperature of one kilogram
(1kg) of pure water (H2O) 1°C (14.5°C  15.5°C) at standard atmosphere pressure (1.033
kg/cm2abs).

BASIC COMPONENTS FOR REFRIGERATING CYCLE

The refrigerating cycle consists of compressor, condenser, capillary tubes and evaporator as shown
in Figure 2. Fixed amount of refrigerant is charged inside and refrigerant circulates while changing
from gas to liquid to gas repeatedly.
1) Compressor (Absorbs and compresses refrigerant gas state and places it in an easily
liquefiable state): The compressor sucks in the refrigerant gas which has been evaporates by
the evaporator. This refrigerant is then compressed to the high temperature gas refrigerant
state in which it can be easily liquefied by the use of coolant water and air at room temperature.
2) Condenser (Change the refrigerant from liquid to gas): The gaseous refrigerant which comes
out of the compressor at high temperature and high pressure now enters the condenser where
it is heat exchanged by coolant water or air at room temperature. The heat removed here is
called ‘condensed latent heat’.
3) Capillary tube (Placed the liquid refrigerant in an easily evaporable state in a low temperature):
The capillary tube action decreases the pressure of the liquid refrigerant which was changed
to room temperature and high pressure state in the condenser, and places it in a state of easy
evaporation before it enters the evaporator. At the same time that it acts to reducing pressure
it also controls the amount of liquid refrigerant flow.
4) Evaporator (Change the refrigerant from liquid to gas): The liquid refrigerant in the evaporator
removes the heat required for evaporation (evaporation latent heat) from the air surrounding
the evaporator and turns into a gas.
 Figure 2

INVERTER AND CONVENTIONAL (CONSTANT SPEED) AIR CONDITIONER

With an inverter room air conditioner, the rotation speed of the compressor is freely changed using
an inverter. In this way, the capacity is changed over a wide range corresponding to requirements or
cooling loads.
There are two methods to change rotation speed of the compressor.
DC system:

AC voltage DC voltage
DC motor with inverter
(50 / 60 Hz) (75 ~ 220 V)
The efficiency of a DC motor is about 10% higher than a conventional AC motor.
AC system:

SAFETY PRECAUTION
 Read all the safety precaution carefully before start experiment (operating the unit).
 Be sure the unit operates in proper condition after dismantle and installation.
 Since the working pressure R410A is 1.6 times higher than R22, some of the piping and
installation and service tools are special.
 Please request assistant engineer or teaching engineer or qualified persons for guidance.
Improper procedure or steps may cause electric shock and fire.
 Make sure the units ae mounted at locations which are able to provide full support to the
weight of the units. If not, the unit may collapse and impose danger.
 Observe rules and regulations of the electrical installation when dealing with electrical work.
Use power cable approved by SIRIM only.
  When installing or removing an air conditioner, only specified refrigerant (R410A and R22)
shall be allowed, do not allow air or moisture to remain in the refrigeration cycle. Otherwise,
pressure in the refrigeration cycle may become abnormally high that may cause rupture to
the refrigeration cycle.
 After completion if installation work, check to make sure that there is no refrigeration gas
leakage. If the refrigerant gas leaks into laboratory, coming into contact with fire in fan-driven
heater, space heater, a poisonous gas may occur.
 Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs
please inform assistant engineer and teaching engineer.
2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

1) Indoor and outdoor 1hp inverter split wall air conditioner unit.
2) Indoor and outdoor 1hp conventional (constant speed) split wall air conditioner unit.
3) Connecting pipe for R22 refrigerant type outer diameter size 6.35 mm for high pressure side
and 9.52 mm for low pressure side.
4) Connecting pipe for R410A refrigerant type outer diameter size 6.35 mm for high pressure
side and 9.52 mm for low pressure side.
5) Screwdriver.
6) Measuring tape.
7) Pliers or wrench.
8) Manifold valve.
9) Charge hose.
10) Vacuum pump.
11) Gas leakage detector.
3.0 PROCEDURES/ METHODOLOGY

PUMP DOWN
1. Make sure unit in operate condition.
2. Connect manifold gauge to service valve or known as low side pipe. Make sure manifold gauge
in fully close condition.
3. Open manifold gauge to check pressure in unit. Normal condition for R22 is 70 psi and R410A
is 110 psi.
4. Open cap at high and low side valve.
5. Using Allen key to fully close valve at high side valve.
6. Wait until pressure gauge at low side until 0, immediately close low side valve.
7. Switch off unit after fully close low side valve, make sure no delay to immediate close or it
cause damage to compressor.
 8. Open high side connecting pipe to check fully pump down complete or not, if yes, dismantle
connecting pipe or copper pipe.
9. Dismantle between indoor and outdoor for servicing.
10. Using copper fitting experienced on previous laboratory session to replace / using new
connecting pipe.

FLUSHING
1. Assemble copper pipe high and low side properly.
2. Open valve high side for few second then close it back.
3. Open cap on low side for flushing and immediately close it back.
4. Open valve high and low side.
5. Run unit for 15 – 20 minute then check pressure using manifold gauge.
 Please refer to operation manual / service manual / installation manual for details screw
location or refer to assistant engineer and teaching engineer for details works and procedures.
 Please do 5s activities after test run the unit and return all tools to original place.

4.0 RESULTS

1. Kindly please state 5 cautions on split-type room air conditioner installation work.
(Example answer: Carefully examine the strength of the wall and ceiling where the room air
conditioner will be installed)

2. By referring to technical specification, what are the relationship between gas amount and
condenser size?

3. How to identify gas amount in the refrigeration cycle is under charge or over charge?
5.0 DISCUSSION

1. How inverter unit and conventional (constant speed) works? Please generally compare the
efficiency between inverter and conventional (constant speed) type.

2. Once inverter unit, should use electronic expansion valve instead of capillary. This laboratory
activities found the outdoor inverter unit use capillary. As competent persons in HVAC fields,
please comment on this issue.

6.0 CONCLUSION
Please state your conclusion regarding laboratory session and findings. Also please evaluate yourself.

7.0 OTHERS

The report must be prepared as APPENDIX.

ASSESSMENT CRITERIA:

Your response to each task will be graded separately based on the checklist attached. To obtain
maximum marks, ensure that your response addresses each of the tasks in the question accordingly.

Assessment checklist for Lab Activity 1

Assessment tasks Mark LO PO C/P/A level

allocation

Outcome (Result- Ability to identify 35 LO2 PO4 P2 - Set

work process)

Outcome (Discussion- Ability to 25 LO2 PO4 P6 – Adaptaion

describe inverter and conventional
unit)

Outcome (Discussion- Explanation 25 LO2 PO4 P6 – Adaptaion

of the capalary tube)

Outcome (Conclusion) 15 LO2 PO4 P5 - Complex

Overt Response

TOTAL 100
APPENDIX 1
 LAB 2
FAKULTI TEKNOLOGI KEJURUTERAAN
MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMM 2333 PNEUMATIC AND HYDRAULIC TECHNOLOGY

LAB REPORT 2
INSTALLATION AND SERVICING OF WALL SPLIT AIR CONDITIONING (PUMP DOWN AND
FLUSHING)

INSTRUCTOR’S NAME TS. Muhammad Fairuz bin Abu Bakar

STUDENT’S NAME MATRIX NO:

S1.
S2.
S3.
S4.
S5.

ASSESSEMENT RUBRICS
MARK GIVEN MARKS
ASSESSMENT TASK/ITEMS
ALLOCATION
1. Outcome (Result- Ability to identify work 35
process)
2. Outcome (Discussion- Ability to 25
describe inverter and conventional unit)
3. Outcome (Discussion- Explanation of 25
the capalary tube)
4. Outcome (Conclusion) 15

TOTAL MARKS 100

Approved By: ………………………………………………..…..

(Instructor’s Signature & Stamp)

Date: …………………………………………….........
OUTCOME (RESULT- IDENTIFY WORK PROCESS)

1. Kindly please state 5 cautions on split-type room air conditioner installation work.
(Example answer: Carefully examine the strength of the wall and ceiling where the room air
conditioner will be installed)

2. By referring to technical specification, what are the relationship between gas amount and
condenser size?

3. How to identify gas amount in the refrigeration cycle is under charge or over charge?
OUTCOME (DISCUSSION - DESCRIBE WORK PROCESS)
1. How inverter unit and conventional (constant speed) works? Please generally compare the
efficiency between inverter and conventional (constant speed) type.

2. Once inverter unit, should use electronic expansion valve instead of capillary. This laboratory
activities found the outdoor inverter unit use capillary. As competent persons in HVAC fields,
please comment on this issue.

CONCLUSION
Please state your conclusion regarding laboratory session and findings. Also please evaluate
yourself.