NUST COLLEGE OF ELECTRICAL & MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Experiment no.1 Charging of a Refrigeration System

Objective:

1. To evacuate a refrigeration system.

2. To charge a refrigeration system.

Apparatus:

Portable charging station, Refrigerant cylinder, System to be charged, Gauge manifold set,
Spanner set, Leak detector / Soapy Water

Introduction:
This system can be used to fully service any short / leak of refrigeration system. Firstly the
refrigeration system is evacuated in order to get rid of air or any short of fluid in the system. Then
refrigerant is transferred from the cylinder to the refrigerant tube in the charging station and
finally the refrigerant is charged in the required system.

Procedure:

First of all connect one line of gauge manifold with the charging port of refrigeration system and
other line to the cylinder. Open the gauge valve and pressurize the system for leak testing. Test the
system for all joints with leak detector or soapy water. Keep the pressure between 50 psi to 100 psi
for one or two hours to ensure no leakage in the system. Disconnect the line from the cylinder and
open the gauge valve to release the pressure from the system. Connect one side of the gauge with
the system and the other line to the vacuum pump. Use the lower side of the gauge for vacuum.
Start the vacuum pump. When the compound gauge reading is 29.92 Hg the vacuum is complete.
Turn the vacuum pump "Off" and disconnect the line. Connect the line with refrigerant cylinder for
charging of refrigerant. Open the cylinder valve and purge down the line with gas pressure. Open
the gauge valve slowly and enter the refrigerant into the system. When the pressure is about to 0
psi to 25 psi start charging the refrigeration system. Check the full load ampere of the system,
cooling temperature and site glass. Ensure that the site glass has shown completely liquid form
refrigerant in the system, required cooling temperature is achieved and rating current of system is
normal. When the charging is complete and system is in working condition, turn "Off" the system
and disconnect the gauge manifold with the system. Close the charging port with service valve or
punching tools.

Precautions
1. Before starting ensures all service valves of compressor are open.
2. During evacuation and filling process disconnect the electrical supply to the system to be
charged.

General Questions
1. What are the indications of the full charged system.
2. What will happen if some atmospheric air is left in the system.
3. What will be position of the sustain service valve after charging is complete.
4. Why the system is drawing more current then its rated value.
5. Explain the different positions of suction service valve.