TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
Ayala Boulevard, Cor. San Marcelino St Ermita, Manila 1000

ACTIVITY NO. 4
CHARGING, CLEANING BY SELF-
VACUUMING, AND SYSTEM
DIAGNOSIS

MECHANICAL ENGINEERING LABORATORY III

PME8L-M

SUBMITTED BY:
Achavan, Lemuel T.
Atendido, Diony Jr. C.
Deroca, Mhark Deilan A.
Guevara, Llander O.
Nahibuan, Jhon Ashley N.
 ACTIVITY NO. 4
Charging, Cleaning by Self-vacuuming, and System Diagnosis

I. OBJECTIVE:

The activity aims to perform, identify, and address any potential problems with a domestic
refrigeration system in order to maintain its optimal functioning and energy efficiency.

Specific aims:

 To visually inspect the system for signs of damage or leaks.

 To check the temperature and humidity levels inside the refrigerator.
 To test the operation of the compressor and other components.
 To listen for unusual noises, and check the refrigerant level.
 To clean the coils, change the filters, and lubricate the moving parts.

II. INTENDED LEARNING OUTCOMES (ILO):

By the end of the lab experiment, students should be able to:

 Identify the components of a domestic refrigeration system.

 Describe the function of each component of a domestic refrigeration system.
 Explain the basic principles of operation of a domestic refrigeration system.
 Diagnose common problems with domestic refrigeration systems.
 Perform basic maintenance procedures on domestic refrigeration systems.

III. OVERVIEW

3.1 DOMESTIC REFRIGERATOR

A domestic refrigerator is a large household appliance that is used to store food and drinks
at a temperature below room temperature. It is a vital appliance in the modern kitchen, as it helps
to keep food fresh and prevent it from spoiling.

Domestic refrigerators work by using a refrigerant, which is a gas that absorbs heat from the
inside of the refrigerator and then releases it to the outside. The refrigerant is circulated through
the refrigerator by a compressor, which is an electric motor that pumps the refrigerant through a
series of coils. The coils are located in the back of the refrigerator, and they are surrounded by a
fan that helps to circulate the air around the coils.

The refrigerant absorbs heat from the air inside the refrigerator, and then it releases the heat
to the air outside the refrigerator. This process cools the air inside the refrigerator, and it helps to
keep food fresh.
 A domestic refrigerator works on the vapor compression refrigeration cycle. This cycle
consists of four main steps:

1. Evaporation. The refrigerant, which is a gas at room temperature, is pumped into the
evaporator coils inside the refrigerator. The evaporator coils are located in the back of the
refrigerator, where they are exposed to the air inside the refrigerator. As the refrigerant
evaporates, it absorbs heat from the air inside the refrigerator, which causes the air to cool
down.
2. Compression. The refrigerant vapor is then pumped into the compressor, where it is
compressed into a high-pressure gas. This increases the temperature of the refrigerant gas.
3. Condensation. The hot, high-pressure refrigerant gas is then passed through the condenser
coils, which are located outside the refrigerator. The condenser coils are exposed to the air
outside the refrigerator, which cools the refrigerant gas and causes it to condense into a
liquid.
4. Expansion. The liquid refrigerant is then passed through the expansion valve, which
reduces the pressure of the refrigerant. This causes the refrigerant to vaporize, which
absorbs heat from the surrounding air.

The refrigerant then returns to the evaporator, and the cycle repeats.

Fig. 1 Components of a Domestic Refrigerator

The vapor compression refrigeration cycle is a very efficient way to cool the air inside a
refrigerator. The refrigerant absorbs heat from the air inside the refrigerator and then releases it to
the air outside the refrigerator. This process helps to keep the air inside the refrigerator cool and
prevents food from spoiling.
3.2 MAIN OPERATIONAL SYSTEM

3.2.1 CHARGING

System charging is the process of supplying the proper quantity of refrigerant to a

refrigeration system in order for it to function properly. The mass of refrigerant that will
achieve the best efficiency and design cooling capacity (or heating capacity, in the case of
a heat pump) is known as the optimal charge. The optimal charge will vary based on the
system's design circumstances, such as the ambient temperature.

The system will not be able to cool or heat as efficiently if it is undercharged.

Overcharging the system might harm the compressor and other components. It is critical
to apply the stated charge to the system since it is what the system is built to manage.

 System charging ensures that the system operates as intended.

 System charging improves the efficiency of the system.
 System charging prevents damage to the system.
 System charging can improve the overall air quality in the system.

3.2.2 CLEANING

Cleaning is an important step in the process of repairing or replacing an air

conditioning system. It is necessary to remove all contamination from the system in order
to ensure that the new compressor will function properly. Even the smallest particle of
contamination can cause problems, and it takes very little debris to restrict the flow of
refrigerant and oil.

The AC compressor is the only moving part in the entire system, and it is the only
reason for oil in the system. The oil is circulated throughout the system, which means that
all of the components (condenser, hoses, tubes, evaporator, drier, and accumulator) have
some coating of oil internally. If any dirt, debris, or contamination enters the system, all of
the components will be affected.

The only way to remove all of the contamination from the system is to remove the
oil. The oil is what attracts and holds contaminants within the system. Once the old oil is
removed, the new oil can be added, and the system will be properly flushed and ready to
operate.

 Cleaning can help to extend the life of the compressor.

 Cleaning can improve the efficiency of the air conditioning system.
 Cleaning can help to prevent the spread of contaminants to other parts of the
vehicle.
 Cleaning can help to improve the overall air quality in the vehicle.
 3.2.3 SYSTEM DIAGNOSIS
The process of discovering and repairing refrigeration system faults in a household
refrigerator is known as system diagnosis. The initial stage in system diagnosis is to
identify the problem's symptoms. The following are common signs of a refrigeration
system problem:

 The refrigerator is not cooling properly.

 The refrigerator is not defrosting properly.
 The refrigerator is making noises.
 The refrigerator is leaking water.
 The refrigerator is not turning on.

Once the symptoms of the problem have been identified, the system must be
troubleshooted. Troubleshooting is the process of determining the root cause of a
problem. The following are some of the most common reasons of refrigeration system
problems:

 A refrigerant leak.
 A faulty compressor, condenser, evaporator, thermostat, defrost timer, and door
switch.

Once the cause of the problem has been identified, the next step is to repair the
system. Repairing the system may involve replacing a component, adjusting a setting, or
cleaning a part.

IV. MATERIALS/ EQUIPMENT

Here is the list of materials and equipment needed for the laboratory experiment:
 Refrigerant 413A
 Refrigerator Starter Relay
 Refrigeration High and low-Pressure Gauge
 Refrigerator Overload Protector
 Flashlight
 Soap
 Gloves
 Sponge
 Napkins/ Rag
 Clamp Ammeter
 Spanner
 Mirror
V. PROCEDURE

5.1 SYSTEM DIAGNOSIS

5.1.1 Compressor Start Relay (CSR) Testing

Procedure:

1. First and foremost, safety. To avoid electrical shock, make sure the power source is
switched off and removed before working on any electrical component.
2. Remove the back panel of the refrigerator.
3. Find the compressor's pins, which are typically found on the lower side of the
compressor.
4. Look at the resistance values:
a. To determine the resistance value of each pair of terminals, connect the tester's pins
to the terminals.
b. Collect the resistance readings and note which pairs of components provided each
reading.
c. Draw a clear and organized diagram that shows the readings of pairs.
5. Identify Each Terminal.
6. Test for a ground fault in the compressor.

5.1.2 Leak Testing

Procedure:

1. The auxiliary port of the manifold gauge has three color-coded hoses. The yellow hose
should be connected to the middle auxiliary port, the red hose to the red gauge, and the
blue hose to the blue gauge.
2. Attach the yellow hose to the refrigerant canister, the blue hose to the suction line, and
the red hose to the discharge line.

NOTE: Do not start a leak test on the low side of the system. If there is a leak on that side,
the soap suds used to detect the leak will be sucked into the system. This can damage the
system and make it difficult to repair. Always start the leak test on the high side of the
system, using the red hose and yellow hose.

a. The low side of a system is under lower pressure than the high side. This means
that if there is a leak on the low side, the soap suds used to detect the leak will be
sucked into the system more easily.

b. The soap suds can damage the air conditioning system in a number of ways. They
can clog the filters, corrode the metal parts, and damage the electrical components.

c. It can be difficult to repair an air conditioning system that has been damaged by
soap suds. In some cases, the entire system may need to be replaced.
 To avoid these problems, it is always best to start a leak test on the high side of a system.
The high side is under higher pressure, which makes it less likely that the soap suds will
be sucked into the system. The red hose and yellow hose are the high side hoses on an air
conditioning system.

3. To perform a leak test on an air conditioning system, follow these steps:

a. Start by locating the yellow hose. This is the high side hose on the system.

b. Open the refrigerant tank to allow vapor to flow.

c. Apply soap suds to the auxiliary port and fittings on the yellow hose.

d. Observe for the movement of soap suds. If you see any bubbles forming, this is
an indication of a leak.

4. To observe your blind spots, you can use a mirror and a flashlight.

5. Follow the same steps for the red hose.

5.2 SYSTEM MAINTENANCE

5.2.1 Charging Refrigerant

Procedure:

1. Gather your tools and materials. You will need a compound pressure gauge, a
refrigerant tank, a soap and sponge, and a set of wrenches.
2. Isolate the compressor. This can be done by turning off the power to the system and
disconnecting the refrigerant lines from the compressor.
3. Connect the pressure gauge to the suction and discharge lines. The blue connector
should be connected to the suction line and the red connector should be connected
to the discharge line.
4. Open the refrigerant tank and allow a small amount of refrigerant to flow into the
system.
5. Close the refrigerant tank and turn on the power to the system.
6. Use the leak detector to check for leaks by the means of soap and sponge. If you
find any leaks, repair them before continuing.
7. Once the system is running, check the pressure readings. The normal range of
pressures will vary depending on the type of refrigerant and the size of the system.
8. If the pressure readings are outside of the normal range, there may be a problem
with the system.

NOTE: Make sure that the refrigerant tank is in the correct position. The tank should be in
a right position where the pin is on the top in order to make sure that the gas part of the
refrigerant will be the only one flowing to the compressor suction line.
 Do not supply refrigerant while the tank is upside down. This will let the liquid part
of the refrigerant to flow to the compressor resulting for the compressor to wet compression
and rust.

Before you supply a refrigerant from the tank, do a leak test to the pins of the tank
first to check if it has any leaks.

In doing leak test, do not start the test in the suction line. The starting flow of the
supplied refrigerant is the suction line and also since its suction line it is intended to suck
in the refrigerant and if it has a leak it will suck also the soap foam bubbles and go towards
the compressor and since soap foam bubble has a liquid part it can cause compressor's
inside to rust and have wet compression. So in order to prevent that we must start the leak
test once the refrigerant is supplied and the system turns on, in the discharge side or high
pressure line.

5.2.2 Cleaning by Self-vacuuming

1. Gather your tools. You will need two wrenches that have the same size as the nuts
of the filter drier. You will also need an attachment to block the end of the filter
drier, a refrigerant source, and a leak detector which is a soap and sponge.
2. Locate the filter drier. The filter drier is usually located in the condenser.
3. Open the end of the filter drier. Use the two wrenches to loosen the nuts on the end
of the filter drier. Be careful not to overtighten the nuts.
4. Release the refrigerant and air. Once the nuts are loose, the refrigerant and air will
be released from the filter drier. Allow the refrigerant to escape until the pressure
drops.
5. Block the end of the filter drier. Use the attachment to block the end of the filter
drier. This will prevent air from entering the filter drier.
6. Flash the refrigerant. Use the refrigerant source to flash the refrigerant. This will
remove any remaining air from the filter drier.
7. Purge the air. Plug the open part of the liquid line (line from condenser to capillary
tube) with your thumb. After some time, the pressure will build up in the liquid line
and your thumb will be forced to move. This means that the air has been purged
from the system.
8. Repeat steps 6 and 7 as needed. If the air is not completely purged from the system,
repeat steps 6 and 7 until the air is gone.
9. Close the open connections. Once the air is purged from the system, you can close
the open connections.
10. Apply a leak test. Use the leak detector to check for any leaks. If you find a leak,
repair it before proceeding.

NOTE: Be careful not to overtighten the nuts on the end of the filter drier. This can damage
the filter drier. Make sure to use the correct type of refrigerant for your system. Using the
wrong type of refrigerant can damage your system.
 .

VI. RESULTS AND DISCUSSION

6.1 SYSTEM DIAGNOSIS

6.1.1 COMPRESSOR START RELAY

COMPRESSOR START RELAY

TRIAL/S AMPERE BLUE SIDE (LOW RED SIDE (HIGH

PRESSURE) PRESSURE)

1 0.887 A 7.37 psi 100 psi

2 0.825 A 7.37 psi 115 psi

DISCUSSION: The overload protector is a safety device that is used to protect the compressor
from overcharging or high current. When the overload protector detects an excessive current, it
will open the circuit and stop the flow of current to the compressor. This prevents the compressor
from overheating and being damaged.

The compressor is a vital part of the air conditioning system. It is responsible for pumping
the refrigerant through the system and removing heat from the air. If the compressor is not working
properly, the air conditioning system will not be able to cool the air.

There are a few things that can cause the overload protector to trip. One common cause is
overcharging. This can happen if too much refrigerant is added to the system. The excess
refrigerant can cause the pressure in the compressor to increase, which can lead to overheating.

Another cause of overload protector tripping is high current. This can happen if the
compressor is not properly matched to the refrigerant. If the compressor is not designed to use the
specific refrigerant that is in the system, it can draw too much current and trip the overload
protector.

If the overload protector trips, it is important to check the system for the cause of the
problem. If the system is overcharged, the excess refrigerant must be removed. If the compressor
is not properly matched to the refrigerant, it may need to be replaced.

It is also important to keep the filter drier clean and free of debris. A blocked filter drier can
restrict the flow of refrigerant, which can lead to overheating and overload protector tripping.

6.1.2 LEAK TESTING

LEAK TESTING

TRIAL/S AMPERE BLUE SIDE (LOW RED SIDE (HIGH

PRESSURE) PRESSURE)

3 0.898 A 0 psi 150 psi

 6.2 SYSTEM MAINTENANCE

6.2.1 CHARGING REFRIGERANT

CHARGING REFRIGERANT
TRIAL/S AMPERE BLUE SIDE (LOW RED SIDE (HIGH
PRESSURE) PRESSURE)
4 0.938 A 8 psi 160 psi

DISCUSSION: To repair a refrigeration system, first isolate the compressor and connect the
suction line (evaporator to compressor) and discharge line (compressor to condenser). The blue
pressure gauge will have a negative reading since it is connected to the low side line or suction
line, and the red pressure gauge will have a positive reading since it is connected to the high side
or discharge line. If the pressure goes up to 1 in the blue pressure gauge, then you can do a leak
test in the suction line. You can also check for leaks by observing the red pressure gauge connected
to the discharge line. If the pressure is still the same and doesn't lower, then there are no further
leaks.

You will need two refrigerant supply tanks, one for the supply of the refrigerant and one for
the cleaning process of the tubes of the refrigeration system. The compressor is the most likely
part to be damaged, and it is very difficult and expensive to replace. Evaporators and condensers
can also be damaged, but they are not as expensive to replace. If the evaporators or condensers
have leaks, it is not advisable to plug them with tape.

To compute the total mass of the refrigerant, weigh the refrigerant supply tank before and
after supplying refrigerant. The accumulator is a device that separates the liquid refrigerant from
the vapor refrigerant. The capillary tube is coiled in the suction line to apply heat transfer. The
Refrigerant Filter Drier has an arrow indicated in order to position it correctly.

6.2.2 CLEANING BY SELF-VACUUMING

CLEANING BY SELF-VACUUMING
TRIAL/S AMPERE BLUE SIDE (LOW RED SIDE (HIGH
PRESSURE) PRESSURE)
5 0.985 A 10 psi 180 psi

DISCUSSION: To vacuum a refrigeration system, first open the high side or discharge line. If
you have a vacuum pump, connect it to the line and start suctioning the excess air. In this activity
we don't have a vacuum pump, which is why we use the flashing and purging method. To do this,
open the low side or suction line and allow the refrigerant to flash into a vapor. Then, close the
line and purge the vapor from the system. It is important to note that flashing and purging is a more
dangerous method than using a vacuum pump. If you are not careful, you can damage the
compressor. When working with refrigerants, it is important to take safety precautions.
VII. CONCLUSION

A domestic refrigerator is a large household appliance that uses a refrigerant to cool the air inside.
The refrigerant is a gas that absorbs heat from the air inside the refrigerator and then releases it to the
outside. The refrigerant is circulated through the refrigerator by a compressor, which is an electric motor
that pumps the refrigerant through a series of coils. The coils are located in the back of the refrigerator,
and they are surrounded by a fan that helps to circulate the air around the coils.

The compressor is the most important part of the refrigerator. It is responsible for pumping the
refrigerant through the system and removing heat from the air. If the compressor is not working properly,
the refrigerator will not be able to cool the air.

The other important parts of the refrigerator are the evaporator and the condenser. The evaporator
is located inside the refrigerator and it is where the refrigerant absorbs heat from the air. The condenser is
located outside the refrigerator and it is where the refrigerant releases heat to the air.

Charging is the process of replenishing the refrigerant in a refrigerator. Refrigerant is a gas that
circulates through the refrigerator and absorbs heat, helping to keep food cold. Over time, refrigerant can
leak out, which can cause the refrigerator to not work properly. Charging the refrigerator can help to
restore its cooling capacity.

Cleaning by self-vacuuming is the process of removing dust and dirt from the interior of a
refrigerator. Dust and dirt can build up on the coils of the refrigerator, which can reduce its efficiency.
Self-vacuuming systems use a fan to remove dust and dirt from the coils, without the need for manual
cleaning.

System diagnosis is the process of identifying and repairing problems with a refrigerator. A
refrigerator may have problems with its compressor, condenser, evaporator, or other components. System
diagnosis can help to identify the problem and determine the best course of action for repair.

REFERENCES:
Domestic Refrigerator Working Principle & Construction - Your Electrical Guide. (2022, December
12). Your Electrical Guide. https://www.yourelectricalguide.com/2019/07/domestic-refrigerator-
working-principle.html
Magnaparthi. (2022, September 2). Domestic Refrigerator | 5 Ultimate Ways The Biggest Contribution
Of A Typical Domestic Refrigerator To Humanity Will Ever Rule The World. | BlogMech.
BlogMech | A Complete Online Guide For Every Mechanical Engineers.
https://blogmech.com/domestic-refrigerator-layout-of-a-typical-domestic-refrigerator/