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Refrigerant Charging
 
Proper refrigerant charge is essential to proper unit opera-
tion. Operating a unit with an improper refrigerant charge will 
result in reduced performance (capacity) and/or efficiency. 
Accordingly, the use of proper charging methods during ser-
vicing will insure that the unit is functioning as designed and 
that its compressor will not be damaged. 
Too much refrigerant (overcharge) in the system is just as bad 
(if not worse) than not enough refrigerant (undercharge). They 
both can be the source of certain compressor failures if they 
remain uncorrected for any period of time. Quite often, other 
problems  (such  as  low  air  flow  across  evaporator,  etc.)  are 
misdiagnosed as refrigerant charge problems. The refrigerant 
circuit  diagnosis  chart  will  assist  you  in  properly  diagnosing 
these systems. 
An  overcharged  unit  will  at  times  return  liquid  refrigerant 
(slugging) back to the suction side of the compressor eventually 
causing  a  mechanical  failure  within  the  compressor.  This 
mechanical failure can manifest itself as valve failure, bearing 
failure,  and/or  other  mechanical  failure.  The  specific  type  of 
failure will be influenced by the amount of liquid being returned, 
and the length of time the slugging continues. 
Not enough refrigerant (undercharge) on the other hand,  will 
cause the temperature of the suction gas to increase  to the point 
where it does not provide sufficient cooling for  the compressor 
motor. When this occurs, the motor winding temperature will 
increase causing the motor to overheat  and possibly cycle open 
the compressor overload protector.  Continued overheating of 
the motor windings and/or cycling of the overload will eventually 
lead to compressor motor or overload failure. 
Unplug and/or disconnect all electrical power 
to the unit before performing inspections, 
maintenances or service.  
 
Failure to do so could result in electric shock, 
serious injury or death.
Sealed Refrigeration System contains refrigerant 
and oil under high pressure.
Proper safety procedures must be followed, 
and proper protective clothing must be worn 
when working with refrigerants.
Failure to follow these procedures could 
result in serious injury or death. 
WARNING
WARNING
RISK OF ELECTRIC SHOCK 
HIGH PRESSURE HAZARD 
seALeD ReFRIgeRATION sYsTeM RePAIRs
ANY SEALED SYSTEM REPAIRS TO COOL-ONLY MODELS REQUIRE THE INSTALLATION OF A LIQUID LINE DRIER. 
ALSO, ANY SEALED SYSTEM REPAIRS TO HEAT PUMP MODELS REQUIRE THE INSTALLATION OF A SUCTION LINE DRIER.
IMPORTANT
EQUIPMENT REQUIRED:
  1.  Voltmeter
  2.  Ammeter
  3.  Ohmmeter
  4.   E.P.A. Approved Refrigerant Recovery System
  5.  Vacuum  Pump  (capable  of  200  microns  or  less 
vacuum.)
  6.  Acetylene Welder
  7.  Electronic Halogen Leak Detector capable of detect-
ing HFC (Hydrofluorocarbon) refrigerants.
  8.  Accurate refrigerant charge measuring device such 
as:
    a.  Balance Scales - 1/2 oz. accuracy
    b.  Charging Board - 1/2 oz. accuracy
9.      High Pressure Gauge - (0 - 750 lbs.)
10.  Low Pressure Gauge - (30 - 200 lbs.)
 11.  Vacuum Gauge - (0 - 1000 microns)
 12.  Facilities for flowing nitrogen through refrigeration tubing 
during all brazing processes.
EQUIPMENT MUST BE CAPABLE OF:
  1.  Recovering refrigerant to EPA required levels.
  2.   Evacuation from both the high side and low side of the 
system simultaneously.
  3.  Introducing  refrigerant  charge  into  high  side  of  the 
system.
  4.  Accurately  weighing  the  refrigerant  charge  actually 
introduced into the system. 
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