TAGUM CITY COLLEGE OF SCIENCE AND TECHNOLOGY FOUNDATION INC.

Elpidio M. Gazmen Compound, Gazmen Road, Tagum City

SEC. Reg. No. 200630691 / Tel. No. 216-6824
E-mail Address: [email protected]

AIR,CONDITIONING

SYSTEM,SERVICING

Year Level: 2nd Year

Semester: 2nd Semester

COURSE CONTENT
AIRCONDITIONINGSYSTEMSERVICING

NELSON D. GIMANG = Contact # 09753167976

MAJOR TEACHER

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 Introduction

Addressing stress through AIRCONDITIONINGSYSTEMSERVICING College

Students. Studies show that students who engage in
AIRCONDITIONINGSYSTEMSERVICING.For many of them, common life
stressors include: bullying, peer influences, difficulty in time management and
perceived expectations of self and from others. However, within the school
context, physical activity classes provide students with opportunities to be
physically active and possibly mitigate daily stress.

This unit will introduce how Physical Activity helps handle one’s stress. It will
also benefit the Senior High School students in understanding how to utilize
AIRCONDITIONINGSYSTEMSERVICING

In this module you will learn about:

1. Define the car air condition
2. Service car air condition
OBJECTIVES

At the end of the module, you should be able to:

1. Define the car air condition

2. Service car air condition

PRE-TEST

MULTIPLE CHOICE

Direction: Read each item carefully and use your notebook to write your
answers.

1. Freon group of refrigerants are

(A) Inflammable
(B) Toxic
(C) Non-inflammable and toxic
(D) Nontoxic and non-inflammable

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2. The boiling point of ammonia is

(A) -10.5°C
(B) -30°C
(C) -33.3°C
(D) -77.7°C

3. For obtaining high COP, the pressure range of compressor should be

(A) High
(B) Low
(C) Optimum
(D) Any valu

4. A reversible engine has ideal thermal efficiency of 30%. When it is used

as a refrigerating machine with all other conditions unchanged, the
coefficient of performance will be

(A) 1.33
(B) 2.33
(C) 3.33
(D) 4.33

5. Cooling water is required for following equipment in ammonia

absorption plant
(A) Condenser
(B) Evaporator
(C) Absorber
(D) Condenser, absorber and separator (rectifier

6.
(B) -75.2°C
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 (C) -77.7°C
(D) -135.8°C

7. Mass flow ratio of NH₃ in comparison to Freon-12 for same refrigeration

load and same temperature limits is of the order of
(A) 1: 1
(B) 1: 9
(C) 9: 1
(D) 1:

8. In a refrigeration system, the expansion device is connected between

the

(A) Compressor and condenser

(B) Condenser and receiver
(C) Receiver and evaporator
(D) Evaporator and compressor

9. The vapour compression refrigerator employs the following cycle

(A) Rankine
(B) Carnot
(C) Reversed Rankine
(D) Reversed Carnot

10. In actual air-conditioning applications for R-12 and R-22, and

operating at a condenser temperature of 40° C and an evaporator
temperature of 5° C, the heat rejection factor is about
(A) 1
(B) 1.25
(C) 2.15
(D) 5.12

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 Information Sheet 1

Define the car air condition

Since the advent of the automotive air conditioning system in the 1940’s, many
things have undergone extensive change. Improvements, such as computerized
automatic temperature control (which allow you to set the desired temperature
and have the system adjust automatically) and improvements to overall
durability, have added complexity to today’s modern air conditioning system.
Unfortunately, the days of “do-it-yourself” repair to these systems, is almost a
thing of the past. To add to the complications, we now have tough
environmental regulations that govern the very simplest of tasks, such as
recharging the system with refrigerant R12 commonly referred to as Freon
(Freon is the trade name for the refrigerant R-12, that was manufactured by
DuPont). Extensive scientific studies have proven the damaging effects of this
refrigerant to our ozone layer, and its manufacture has been banned by the
U.S. and many other countries that have joined together to sign the Montreal
Protocol, a landmark agreement that was introduced in the 1980’s to limit the
production and use of chemicals known to deplete the ozone layer.
Now more than ever, your auto mechanic is at the mercy of this new
environmental legislation. Not only is he required to be certified to purchase
refrigerant and repair your air conditioner, his shop must also incur the cost of
purchasing expensive dedicated equipment that insures the capture of these
ozone depleting chemicals, should the system be opened up for repair. Simply
put, if your mechanic has to spend more to repair your vehicle – he will have to
charge you more. Basic knowledge of your air conditioning system is
important, as this will allow you to make a more informed decision on your
repair options.
Should a major problem arise from your air conditioner, you may encounter
new terminology. Words like “retrofit” and “alternative refrigerant” are now in
your mechanics glossary. You may be given an option of “retrofitting”, as
opposed to merely repairing and recharging with Freon. Retrofitting involves
making the necessary changes to your system, which will allow it to use the
new industry accepted, “environmentally friendly” refrigerant, R-134a. This
new refrigerant has a higher operating pressure, therefore, your system,
dependant on age, may require larger or more robust parts to counter its
inherent high pressure characteristics. This, in some cases, will add
significantly to the final cost of the repair. And if not performed properly, may
reduce cooling efficiency which equates to higher operating costs and reduced
comfort. Vehicles are found to have primarily three different types of air
conditioning systems. While each of the three types differ, the concept and
design are very similar to one another. The most common components which
make up these automotive systems are the following:
1. Compressor
2. Condenser
3. Evaporator
4. Orfice tube
5. Thermal expansion valve
6. Receiver-drier
7. Accumulator
Note: if your car has an Orifice tube, it will not have a Thermal Expansion
Valve as these two devices serve the same purpose. Also, you will either have a
Receiver-Dryer or an Accumulator, but not both.

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 Compressor

Commonly referred to as the heart of the system, the compressor is a belt

driven pump that is fastened to the engine. It is responsible for compressing
and transferring refrigerant gas.
The A/C system is split into two sides, a high pressure side and a low pressure
side; defined as discharge and suction. Since the compressor is basically a
pump, it must have an intake side and a discharge side. The intake, or suction
side, draws in refrigerant gas from the outlet of the evaporator. In some cases it
does this via the accumulator.
Once the refrigerant is drawn into the suction side, it is compressed and sent
to the condenser, where it can then transfer the heat that is absorbed from the
inside of the vehicle.

Condenser

This is the area in which heat dissipation occurs. The condenser, in many
cases, will have much the same appearance as the radiator in you car as the
two have very similar functions. The condenser is designed to radiate heat. Its
location is usually in front of the radiator, but in some cases, due to
aerodynamic improvements to the body of a vehicle, its location may differ.
Condensers must have good air flow anytime the system is in operation. On
rear wheel drive vehicles, this is usually accomplished by taking advantage of
your existing engine’s cooling fan. On front wheel drive vehicles, condenser air
flow is supplemented with one or more electric cooling fan(s).

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As hot compressed gasses are introduced into the top of the condenser, they
are cooled off. As the gas cools, it condenses and exits the bottom of the
condenser as a high pressure liquid.

Evaporator

Located inside the vehicle, the evaporator serves as the heat absorption

component. The evaporator provides several functions. Its primary duty is to
remove heat from the inside of your vehicle. A secondary benefit is
dehumidification. As warmer air travels through the aluminum fins of the
cooler evaporator coil, the moisture contained in the air condenses on its
surface. Dust and pollen passing through stick to its wet surfaces and drain off
to the outside. On humid days you may have seen this as water dripping from
the bottom of your vehicle. Rest assured this is perfectly normal.
The ideal temperature of the evaporator is 32 Fahrenheit or 0 Celsius.
Refrigerant enters the bottom of the evaporator as a low pressure liquid. The
warm air passing through the evaporator fins causes the refrigerant to boil
(refrigerants have very low boiling points). As the refrigerant begins to boil, it
can absorb large amounts of heat. This heat is then carried off with the
refrigerant to the outside of the vehicle. Several other components work in
conjunction with the evaporator. As mentioned above, the ideal temperature for
an evaporator coil is 32 F. Temperature and pressure regulating devices must
be used to control its temperature. While there are many variations of devices
used, their main functions are the same; keeping pressure in the evaporator
low and keeping the evaporator from freezing; A frozen evaporator coil will not
absorb as much heat.

Pressure Regulating Devices

Controlling the evaporator temperature can be accomplished by controlling

refrigerant pressure and flow into the evaporator. Many variations of pressure
regulators have been introduced since the 1940’s. Listed below, are the most
commonly found.

Orifice Tube

The orifice tube, probably the most commonly used, can be found in most GM
and Ford models. It is located in the inlet tube of the evaporator, or in the
liquid line, somewhere between the outlet of the condenser and the inlet of the
evaporator. This point can be found in a properly functioning system by
locating the area between the outlet of the condenser and the inlet of the
evaporator that suddenly makes the change from hot to cold. You should then
see small dimples placed in the line that keep the orifice tube from moving.
Most of the orifice tubes in use today measure approximately three inches in
length and consist of a small brass tube, surrounded by plastic, and covered
with a filter screen at each end. It is not uncommon for these tubes to become
clogged with small debris. While inexpensive, usually between three to five
dollars, the labor to replace one involves recovering the refrigerant, opening the
system up, replacing the orifice tube, evacuating and then recharging. With
this in mind, it might make sense to install a larger pre filter in front of the
orifice tube to minimize the risk of of this problem reoccurring. Some Ford
models have a permanently affixed orifice tube in the liquid line. These can be
cut out and replaced with a combination filter/orifice assemb

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 Thermal Expansion Valve

Another common refrigerant regulator is the thermal expansion valve, or TXV.

Commonly used on import and aftermarket systems. This type of valve can
sense both temperature and pressure, and is very efficient at regulating
refrigerant flow to the evaporator. Several variations of this valve are commonly
found. Another example of a thermal expansion valve is Chrysler’s “H block”
type. This type of valve is usually located at the firewall, between the
evaporator inlet and outlet tubes and the liquid and suction lines. These types
of valves, although efficient, have some disadvantages over orifice tube
systems. Like orifice tubes these valves can become clogged with debris, but
also have small moving parts that may stick and malfunction due to corrosion.

Receiver Drier

The receiver-drier is used on the high side of systems that use a thermal

expansion valve. This type of metering valve requires liquid refrigerant. To
ensure that the valve gets liquid refrigerant, a receiver is used. The primary
function of the receiver-drier is to separate gas and liquid. The secondary
purpose is to remove moisture and filter out dirt. The receiver-drier usually has
a sight glass in the top. This sight glass is often used to charge the system.
Under normal operating conditions, vapor bubbles should not be visible in the
sight glass. The use of the sight glass to charge the system is not recommended
in R-134a systems as cloudiness and oil that has separated from the
refrigerant can be mistaken for bubbles. This type of mistake can lead to a
dangerous overcharged condition. There are variations of receiver-driers and
several different desiccant materials are in use. Some of the moisture removing
desiccants found within are not compatible with R-134a. The desiccant type is
usually identified on a sticker that is affixed to the receiver-drier. Newer
receiver-driers use desiccant type XH-7 and are compatible with both R-12 and
R-134a refrigerants.

Accumulator

Accumulators are used on systems that accommodate an orifice tube to meter

refrigerants into the evaporator. It is connected directly to the evaporator outlet
and stores excess liquid refrigerant. Introduction of liquid refrigerant into a
compressor can do serious damage. Compressors are designed to compress gas
not liquid. The chief role of the accumulator is to isolate the compressor from
any damaging liquid refrigerant. Accumulators, like receiver-driers, also remove
debris and moisture from a system. It is a good idea to replace the accumulator
each time the system is opened up for major repair and anytime moisture
and/or debris is of concern. Moisture is enemy number one for your A/C
system. Moisture in a system mixes with refrigerant and forms a corrosive acid.
When in doubt, it may be to your advantage to change the Accumulator or
receiver in your system. While this may be a temporary discomfort for your
wallet, it is of long term benefit to your air conditioning system.

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 Self-check Questions

Direction: Read each item carefully and use your notebook to write your
answers.
1. Technician A says some vehicles have VARIABLE DISPLACEMENT A/C
compressors that operate continuously when the engine is running.
Technician B says all A/C compressors use PISTONS to pump refrigerant
through the A/C system.
Who is right?
a. Technician A only
b. Technician B only
c. Both Technician A and B
d. Neither Technician A nor B

2. All of the following statements about A/C CONDENSERS are TRUE EXCEPT:
a. It is usually located in front of the radiator
b. It receives high pressure refrigerant gas from the compressor
c. It cools the air entering the passenger compartment
d. It cools the refrigerant so the gas will condense into a liquid

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3. The MAGNETIC CLUTCH on an A/C compressor:
a. Traps magnetic particles that might damage the system
b. Cycles on and off to drive the compressor as needed
c. Cannot be replaced separately from the compressor
d. Contains lubricant for the compressor

4. An ORIFICE TUBE does what in an A/C system?

a. Regulates the flow of refrigerant into the evaporator
b. Regulates the flow of refrigerant into the compressor
c. Regulates the flow of refrigerant into the condenser
d. Regulates the flow of coolant into the heater core

5. Technician A says the ACCUMULATOR should always be replaced if an A/C

system has been opened up for repairs. Technician B says a plugged ORIFICE
TUBE is a common cause of compressor failure. Who is right?
a. Technician A only
b. Technician B only
c. Both Technician A and B
d. Neither Technician A nor B

6. The ORIFICE TUBE is located where in an A/C system?

a. At the compressor inlet
b. At the compressor outlet
c. At the condenser inlet
d. Between the condenser outlet and evaporator inlet

7. Which of the following is a possible reason for FLUSHING an A/C

condenser?
a. To replace the old refrigerant with new refrigerant
b. To remove sludge and debris
c. To remove moisture
d. To improve cooling efficiency

8. Technician A says most PARALLEL style A/C condensers cannot be flushed

adequately because of their design, and should be replaced if the A/C system is
contaminated. Technician B says most R-134a A/C compressors require PAG
oil for lubrication. Who is right?
a. Technician A only
b. Technician B only
c. Both Technician A and B
d. Neither Technician A nor B

9. A VARIABLE orifice tube does what?

a. Improves low speed cooling
b. Improves high speed cooling
c. Has no effect on cooling performance
d. Filters out contaminants

10. Which of the following is NOT a common viscosity for R-134a PAG oils?
a. 46
b. 100
c. 150
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d. 200

11. Technician A says using the WRONG type of compressor oil in an A/C
system may cause the compressor to fail. Technician B says putting too much
compressor oil in an A/C system may LOWER cooling performance. Who is
right?
a. Technician A only
b. Technician B only
c. BOTH Technician A and B
d. Neither Technician A nor B

12. To minimize the risk of a repeat failure after replacing a compressor, which
of the following should also be replaced at the same time?
a. Suction hose filter
b. In-line filter
c. New accumulator or receiver/drier
d. All of the above

13. If compressor discharge pressures are unusually HIGH, it may indicate:

a. Too much refrigerant in the system
b. Cross-contamination of refrigerants (Mixing R-134a with R-1234yf)
c. A blockage in the condenser
d. All of the above

14. LOWER than normal HIGH SIDE readings in an A/C system may be caused
by any of the following, EXCEPT:
a. A plugged condenser
b. A leaky compressor discharge valve
c. A restricted suction hose or compressor inlet
d. Low refrigerant

15. Which of the following can cause intermittent EVAPORATOR freeze-up?

a. Too much refrigerant in the system
b. Wrong refrigerant in the system
c. Too much oil in the system
d. Air in the system

16. The EVAPORATOR is usually located where?

a. In front of the radiator
b. Behind the radiator
c. Inside the passenger compartment
d. Outside the passenger compartment

17. If an A/C system is cooling poorly, any of the following could be the cause
EXCEPT: a. Air in the system
b. A refrigerant leak
c. Insufficient compressor oil in the system
d. Low refrigerant

18. Where is the HIGH SIDE (high pressure) of an A/C system?

a. Between the compressor outlet and condenser inlet
b. Between the compressor outlet and evaporator inlet
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c. Between the evaporator inlet and compressor inlet
d. Between the evaporator outlet and compressor inlet

19. Where is the LOW SIDE (low pressure) of an A/C system?

a. Between the compressor outlet and condenser inlet
b. Between the compressor outlet and evaporator inlet
c. Between the evaporator inlet and compressor inlet
d. Between the evaporator outlet and compressor inlet

20. Where is the refrigerant in a liquid state inside an A/C system?

a. Between the compressor outlet and condenser inlet
b. Between the condenser outlet and evaporator inlet
c. Between the evaporator inlet and compressor inlet
d. Between the evaporator outlet and compressor inlet

Prepared by:

NELSON D. GIMANG
Faculty

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