23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

Refrigeration cycle: HVAC system basics and refrigerant charging

Posted on May 5, 2018

The Refrigeration cycle (HVAC refrigeration system) and

its 5 essential parts:
1. Compressor.
2. Condenser.
3. Thermostatic expansion valve (TXV or TEV) or Metering Device.
4. Evaporator.
5. Piping

C → D: low-pressure vapor refrigerant ows into the compressor suction and discharges into compressed
high-pressure vapor.
D → A: pressurized refrigerant vapor condenses in the liquid state at constant pressure, rejection of heat to
the environment.
A → B: liquid refrigerant ows through the throttling expansion device at constant enthalpy, to a two-phase
state ashing as the pressure drops into 25% vapor and 75% liquid. Flashing lowers the coolant temperature
to a saturation temperature at the low-side pressure.
B→ C: Low-temperature refrigerant receives heat from the environment and continues to evaporate as it
ows at constant pressure through the evaporator

Refrigeration enthalpy vs. pressure relation

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 1/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

What is Heat?
Heat is a form of energy where every  object on earth contains heat energy in both quantity and intensity. Heat
intensity is measured by its temperature, commonly in either degree Fahrenheit (°F) or degrees Celsius (°C).

Removing all the heat from an object decreases its temperature to -459.6°F [-273.2°C].

This temperature is referred to as “absolute zero” and is the temperature at which all molecular activity stops. The
quantity of heat contained in an object or substance is not the same as its intensity of heat.

For example, the hot sands of the desert contain a large quantity of heat, but a single burning candle has a higher
intensity of heat.

Air-conditioning and refrigeration systems use the principles of heat transfer to produce cooling and heating. The
three principles discussed in this topic are:

Heat energy cannot be destroyed; it can only be transferred to another substance

Heat energy ows from a higher temperature substance to a lower temperature substance
Heat energy is transferred from one substance to another by one of three basic processes

To produce a cooling effect, remove heat from the substance by transferring it to another substance.

What is a ton of refrigeration?

It is the amount of heat in BTU (British thermal unit) required to melt one ton, i.e. 2000 lb (907.18 kg) of ice over a
period of 24 hours.

Therefore, one ton (2000lb) of ice melts to absorbs 288,000 Btu of heat. Similarly, a one-ton air conditioner absorbs
288,000 Btu of heat in 24 hours.

Compressors: Why is a compressor used in the

refrigeration cycle?
The purpose of the compressor in the Refrigeration cycle is to compress the low-pressure dry gas refrigerant from
the evaporator and raise its pressure and temperature to that of the condenser, to produce ow around the system.

The most easily recognizable compressor is a positive displacement type, which is the reciprocating or piston
compressor.

Let’s take an example of a refrigerator when the refrigerant passes from the evaporator, it changes its state from
liquid to vapor by taking away the heat from the refrigerator space.

Now to convert back the refrigerant from vapor to liquid state, the compressor comes into action.

The compressor increases the refrigerant temperature and pressure so that the refrigerant gets converted into a
liquid state by circulating hot surrounding air over the condenser coils.

In the absence of a compressor, the heat may start to ow from the condenser to the outside air.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 2/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

Like in hotter regions the outside air temperatures can go up to 42°C – 48 °C (107.6°F to 118.4°F) with this hot
outside air, the refrigerant gets cooled back from vapor to the liquid state.

This is possible due to the refrigerant property which is the “critical temperature of a refrigerant”.

The critical temperature of a refrigerant must be high

It is the temperature above which the vapor refrigerant remains in the vapor state and cannot be lique ed even
after passing through the condenser or any cooling medium at any given pressure.

This happens only when the refrigerant temperature reaches beyond its critical temperature, i.e. when a refrigerant
has a low critical temperature.

So, it’s better to select a refrigerant having a high critical temperature to be able to condense these gases into liquid
form at higher ambient temperatures.

Condenser

The condenser in a refrigeration cycle accepts hot, high-pressure gas from the compressor and cools it to remove
rst the superheat and then the latent heat so that refrigerant condenses back to a liquid state.

Condenser cooling mediums are usually fan or water

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 3/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

The small condensing surface required by a domestic appliance such as a fridge/freezer uses outside metal skin of
the body itself as a surface heat exchanger.

In such a construction, the condenser tubes are mechanically xed in close contact with the skin, so that heat gets
conducted through to the outside air by natural convection.

This system depends on the appliance watt rating. Condensers can be of 3 types:

1. AIR-COOLED CONDENSERS
2. WATER-COOLED CONDENSERS
3. EVAPORATIVE CONDENSERS

Thermostatic expansion valve (TXV or TEV) or Metering

Device
The function of the expansion valve is to control the refrigerant ow from the high-pressure condensing side of the
system into the low-pressure evaporator side.

The unit also controls the ow through the evaporator so that the condition of the refrigerant leaving the
evaporator is a slightly superheated gas.

T.E.V ensures that the full latent heat has been absorbed by the refrigerant which in turn reduces the mass ow rate
required by the system.

A sensing bulb with a good thermal contact is fastened at the evaporator outlet to make sure the refrigerant gas
leaving the evaporator outlet is superheated.

As the bulb temperature increases, the refrigerant within the bulb expands thereby opening the expansion valve
allowing more gas to ow through the evaporator.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 4/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

When the refrigerant ow becomes excessive, then the temperature will fall reducing the pressure within the bulb,
hence closing the expansion valve.

The capillary tube is used almost exclusively in small refrigeration and air conditioning systems.

Another factor takes place across the Thermostatic expansion valve(TEV), ie. ashing effect. We know (Gay-
Lussac’s Law) Pressure Temperature Law that pressure is directly proportional to temperature for a given amount
of gas at constant volume.

Therefore as the pressure drops due to the throttling effect of the expansion valve, the liquid refrigerant
temperature goes down by extracting heat from the remaining refrigerant at the condenser side.

Due to the loss of heat in the remaining refrigerant, it starts to evaporate or ash to vapor state. This process is
called “ ashing”.

Also, when the evaporator and TEV valve is located vertically above the receiver, vapor or ash gas forms in the
liquid line as the liquid refrigerant has to overcome the vertical head.

The expansion valve is designed to handle liquid and not a mixture of vapor and liquid to avoid TEV malfunction.

Here, the thermostatic expansion valve (TEV) plays a vital role in controlling and metering the ow of liquid in the
system, by connecting a sensing bulb via a capillary tube to the evaporator outlet lled with the same system
refrigerant.

Avoid a ash gas problem by providing enough subcooling to the liquid refrigerant in the condenser. Liquid lled
inside the sensing bulb is the same as that of the system (R134a), and the reason is:

1. To get the same expansion as that of the system refrigerant, ie. R134a.
2. To avoid contamination if the diaphragm ruptures or leaks.
    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 5/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

TEV operation determines the following three fundamental pressures:

1. Bulb pressure on one side of the diaphragm tends to open the valve.
2. Evaporator pressure on the opposite side of the diaphragm tends to close the valve.
3. Spring pressure applied to the pin carrier gets transmitted through the pushrods to the evaporator side of
the diaphragm. This assists in closing the valve.

What is the difference between subcooling and

superheating?
Subcooling: Cooling the refrigerant below its condensing temperature is called subcooling.

Condensing temperature means all  vapor  fractions turned to zero ie. all vapor turned to liquid (100% liquid),
whereas cooling below this temperature is called Subcooling.

The advantage of subcooling is

To reduce Flash gas formation during the process of expansion in the thermostatic expansion valve.
To reduce the speci c volume occupied by the vapor refrigerant and thereby increasing the evaporator
cooling capacity.

Also, an increased evaporator ef ciency extracts more heat from the load.

Why does refrigerant gas need to be superheated before

entering into the compressor suction?
Superheat means adding more heat to vapor refrigerant after it gets converted from its liquid state to a vapor state
inside the evaporator coil, as the refrigerant absorbs heat from the load.

Cooling is achieved by the recirculation of the room air over the evaporator coils.

The compressor used in many refrigeration system designs are positive displacement type, and if by any chance
refrigerant enters in the liquid form in large quantity, then it can cause severe damage to the compressor parts.

As liquid is incompressible, refrigerant needs to enter in gas form; this is the reason why refrigerants must to be
superheated before it enters into the compressor suction. 

Evaporator
The purpose of the evaporator is to receive low-pressure, low-temperature uid from the expansion valve and to
bring it in close thermal contact with the load.

The refrigerant takes up its latent heat from the load and leaves the evaporator as a dry gas.

This unit is tted in the space which is to be cooled and absorbs the heat by being at a cooler temperature than
space. To ensure that there is a high heat transfer from the space (load) to the evaporator, the Convection heat
transfer needs to be improved.

Convection heat transfer is achieved by extending the surface area using ns and fans, to increase airspeed across
the cold evaporator surface.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 6/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

As evaporator is in an area of high humidity (the ability of air to absorb water reduces as the temperature
decreases), the surface of the evaporator coil may form an ice coating, which reduces heat transfer rates.

Defrosting elements remove the ice by increasing the local temperature of the evaporator, and hence causing the
ice to melt and drain away.

Control the room temperature by either compressor capacity control or by closing the refrigerant inlet solenoid
valve.

Types of evaporators:

1. AIR COOLING EVAPORATORS

2. LIQUID COOLING EVAPORATORS 

Refrigerant charging
 Liquid refrigerant charging
Liquid refrigerants are normally added in the liquid line following proper conditions. If any heating method is used
to ash liquid refrigerant into the suction line, 100% vapor must enter the compressor.

Liquid refrigerants are incompressible and can cause severe damage to any compressor.

Vapor refrigerant charging

Always charge the vapor refrigerant from the point where the system pressure is lower than the pressure in the
charging cylinder.

If we try to charge from the discharge side of the compressor then instead of refrigerant going from the charging
cylinder to the system it may start reversing, lling the charging cylinder itself.

Remember that high pressure ows towards the lower side.

Only during system evacuation or when the system is out of refrigerant, The refrigerant can be inserted to both the
high and low-pressure side of the HVAC unit.

Mostly large charging cylinder has two valves. The red one is connected to the dip tube and is for the liquid
charging. Blue one is connected from the top with no dip tube and is for gas charging. In both, the conditions
cylinder is kept in an upright position while charging.

If the refrigerant charging cylinder has only one valve, then we don’t have a dip tube and in this case, It’s necessary
to invert the cylinder for liquid charging.

Why do we need to evacuate an (HVAC unit) air

conditioning system using a vacuum pump?
The refrigeration system is designed to run without moisture and non-condensable gases else it may not work as
designed and is likely to fail prematurely.
    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 7/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

Presence of moisture may lead to the formation of acidic sludge in the oil and may cause restrictions on various
places like expansion valve and evaporator coils thereby reducing the overall cooling effect.

In case of a hermetic compressor, it may cause deterioration of the insulation winding which may lead to short
circuit and compressor motor burn out.

Non-condensable gases are just air which can enter during refrigerant charging, repair or maintenance. These
gases take up space in the condenser and limit the amount of condensate refrigerant leading to reduced cooling
ef ciency.

Evacuation is carried out by using a vacuum pump and a recovery bottle, ones the system evacuates we need to
wait for about 20-25 min to check the pressure gauge is holding the negative pressure as shown in the image.

This process may ensure that there are no leakages in the system as chances are air or moisture could enter via pipe
cracks or leaky gasket or joints while performing evacuation procedure.

In the above image, we can see there are two devices tted one is an analog pressure gauge showing the nal
negative reading and another one is a digital vacuum gauge showing 500 microns as nal reading, connected to the
same line to ensure the system is 100% evacuated.

What is Copper Plating in a refrigerating system?

When moisture is present in the system, it combines with the refrigerant to form an acidic solution.

This acidic solution dissolves copper tubings and extracts copper from copper-based alloys like brass or bronze
present in different parts of an air conditioning system.

This copper gets deposited into the compressor bearings and suction/discharge valves as a copper plating which
may lead to system leaks, improper evacuation or vacuuming of the system, malfunction of lter/drier,
contamination of refrigerant and oil.

Now again continuing with our vapor charging process, the charging cylinder must be weighed before charging by
using a weighing scale.

Case 1: Full HVAC system refrigerant gas charge

Considering that we have are very low in refrigerant and need to replenish whole of the system with a fresh charge.

1. Connect hose 2 and 3 to connection C and D respectively.

2. Both the gauges must be zeroed.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 8/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

1. Attach the temperature probe at the correct location near the sensing bulb to sense the degree of superheat.
2. Evacuate the system into a recovery bottle by connecting the vacuum pump to the charging hose 1, open
both the valves A and valve B with HVAC system(air conditioner or split ac) in stop condition.
3. Stop the vacuum pump after the system has evacuated at the desired negative pressure, close the valve A
and B, check the pressure drop for around 20 min to know if there has been any leakage in the system.
4. Disconnect the charging hose 1 from the vacuum pump and connect it to the blue connection of the charging
cylinder for a gas charge.
5. Open the valve A, slightly open the connection at C and purge the whole line by from 1 to 2 by crack opening
the gas valve of the refrigerant cylinder, try not to avoid any excess leak directly into the environment.
6. Same way purge the high-pressure liquid side from 1 to 3 to remove any air inside the hose.
7. Now tight both the low and high-pressure side hose at position C & D respectively as shown in the image.

1. Start charging the gas refrigerant to the low-pressure side of the HVAC system at connection C by opening
the valve A and the refrigerant valve until the vacuum comes to zero.
2. Now start the compressor as the suction pressure goes above zero.
3. After about 30 – 40 seconds of charging close the valve A and check the suction gauge pressure for a rise in
pressure.
4. Keep monitoring the degree of superheat by the temperature calibrator to ensure liquid is not entering into
compressor suction also we can calculate how much charge present in the system by the pressure chart.
    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 9/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

5. If the superheat temperature is high, then it means the system is running low in refrigerant whereas lower
superheat temperature than the desired value means the system has overcharged.
6. Repeat the procedure 10 to 11 until the suction pressure reaches to 60 psi (as per maker) this avoids the risk
of overcharging of the system also keep measuring the refrigerant by the weighing scale.
7. Once the refrigerant has charged, disconnect all the hoses and secure everything.

CASE 2: Topping up refrigerant for an HVAC system (small

quantity recharge)
Topping up of refrigerant is harmful to the environment, if we have not checked or repaired the leak then we may
release the refrigerant again into the atmosphere.

So it’s better to nd out the cause as many refrigerants are falling into the category of ozone layer depletion and
global warming potential.

HFC refrigerant contains chlorine which reacts with ozone (O3) to convert it into oxygen (O2) hence depleting the
ozone layer.

The ozone layer protects the life on earth by absorbing U.V rays from the sun, U.V rays are responsible for skin
cancer, genetic damage and immune suppression in humans.

HFC refrigerants have a high global warming potential which can lead to global warming causing increased sea
level, rising temperature and damage to habitats. Now, coming back to topping up an HVAC system running short of
refrigerant.

1. Connect all the hose 1, 2 and 3 with the HVAC kit.

2. Purge the hose from 2 to 1 by tightening it at point C, valve A open, valve B closed and connection to the
charging cylinder slightly open later close after purging.
3. Likewise, purge the high-pressure side hose 3.
4. Keeping the HVAC system running we will open the charging cylinder gas valve, valve B closed and open the
valve A, allowing the charge into the system
5. Rest we need to follow the procedure from 10 to 14.

Liquid refrigerant charging on HVAC refrigeration

system
Liquid charging on large ships and commercial plants:
Liquid charging is on a liquid line, and it must get vaporized before it reaches to the compressor suction.

There is always a risk of liquid refrigerant entering compressor suction which can cause a severe damage to the
compressor as liquid is compressible.

To avoid liquid going into the compressor we usually charge before the thermostatic expansion valve (TXV) or
metering device which ensure the degree of superheat gets achieved (i.e., liquid converted to 100% vapor) before
reaching to compressor suction.

For a large commercial refrigeration HVAC plant or refrigeration plant of large ships are provided with a large
receiver to collect liquid refrigerant.

The receiver has a gauge glass where we can see the amount of refrigerant during operation and stop condition.
Gauge glass helps to calculate the amount of refrigerant required prior charging.

Procedure for a smaller quantity refrigerant charge in large refrigerating plants are performed by pump down
method.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 10/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

Pump down means collecting refrigerant temporarily inside receiver

1. Start the cooling medium to the condenser (fan or water).

2. Close the receiver liquid outlet valve
3. Start the compressor to suck the lower pressure side of the refrigerant into the condenser.
4. The compressor stops automatically as the low pressure cut out switch gets activate (the set point at around
0.02Mpa).
5. Connect the liquid line charging hose at the liquid side charging point usually at the lter/drier and purge it.
6. Attach the temperature probe to measure the degree of superheat.
7. Open the liquid charging valve of the charging cylinder and start the compressor.
8. Keep measuring the degree of superheat, if the degree of superheat temperature is going down; start
throttling the liquid refrigerant from the charging bottle.
9. Keep an eye on the receiver gauge glass for an increase in level.
10. Check the suction gauge and ones the desired pressure has reached as per maker, stop the compressor.
11. Remove the charging connection, open the condenser outlet valve and run the system normally.
12. It’s very important to weigh the charging bottle before charging and log down the amount of refrigerant
charged.

For small HVAC systems like split air conditioner, window a.c we do not have a refrigerant gauge glass for a small
sized receiver to check the refrigerant level.

Liquid refrigerant charging for an air conditioner,

window a.c (HVAC system)
1. Evacuate the system by pumping down the refrigerant into a recovery bottle using a vacuum pump.
2. Connect the liquid and gas line hose and purge it.
3. Connect the charging hose to the red connection of the charging cylinder for a liquid charge, and if only one
connection provided, then we need to invert the cylinder.
4. Attach the temperature probe at the correct location near the sensing bulb to sense the degree of superheat
and subcooling at the condenser outlet.
5. Allow the liquid refrigerant to ow by opening the valve A and keeping the valve B closed.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 11/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

6. Since the system has a vacuum, the liquid refrigerant enters the system and move towards the evaporator
and condenser, therefore admitting the refrigerant up to the cylinder pressure.
7. Start the system, the liquid refrigerant gets equally divided between the evaporator and the condenser, and
no danger of liquid ooding exists in the compressor.
8. As the refrigerant leaves the charging cylinder, the charging cylinder pressure decreases, so to maintain the
ow create a negative pressure by partially closing the receiver outlet throttle valve and allow the
refrigerant to ow from the cylinder.
9. In an HVAC system receiver outlet are provided with a “king valve” used for liquid charging, it can work as a
throttle valve and can trap entire system refrigerant inside receiver.
10. This way liquid refrigerant gets admitted safely, but since the throttle valve reduces the pressure across the
expansion valve, the system doesn’t run normally.
11. In between close the refrigerant charging valve A and open the throttle valve fully and check the
temperature and pressure readings.
12. When fully charged the sight glass get’s clear also weigh the charging cylinder to know how much charge
required as per maker.

This entry was posted in Refrigeration cycle: Basic refrigeration system. Bookmark the permalink.

Working of commercial refrigeration system and safeties

→

Got something to share? Let's hear it.

Your email address will not be published.

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 12/13
23/08/2018 Refrigeration cycle: HVAC system basics and refrigerant charging

Comment

ADD COMMENT

Search …

RECENT POSTS

Commercial ducted air conditioning system and its working

Components and safety devices on HVAC refrigeration system

Refrigeration problems, causes and solution

Refrigerant R22, R134a, R410a, properties and applications

Working of commercial refrigeration system and safeties

Refrigeration cycle: HVAC system basics and refrigerant charging

Contact Us

Copyright © 2005 - 2018 refconhvac.com, Inc.

Terms and Conditions - Privacy Policy

    
http://refconhvac.com/refrigeration-cycle-hvac-refrigeration-charging-liquid/ 13/13