Title : Perform leak detection test of A.C.
system
Leak Test :
Leaks in the refrigeration system are the major cause of most refrigeration failure. Any leak
regardless of its size, if on high pressure side of system will result in the loss of quite good amount of
refrigerant. This loss of refrigerant will result in failure of refrigeration system. If the leak is on low
pressure side of the system, the effects are even greater.
When the compressor operates at pressure lower than atmospheric, air will be drawn into the
refrigeration system. Air could be removed from the system but after the effect of having moisture in
system may result in the permanent damage to the compressor. Thus leak testing is most important step
in the installation of refrigeration system.
General Procedure of leak test:
1. Install the gauges and gauge manifold. Note the pressure and temperature in the beginning.
2. Close the manifold valves A and B.
3. Now attach the refrigerant cylinder at the centre of the gauge manifold. Do not open the refrigerant
cylinder valves. Do not operate compressor.
4. Start halide/freon leak detector.
5. Now open the refrigerant cylinder valve.
6. Open gauge manifold valves A and B slowly raising the pressure to about 1.75kgf/cm2.
7. Check the leaks with torch. Any leak detected should be repaired properly.
8. Raise the system pressure to about 3.75kgf/cm2 and check leaks at every joint and surface. If any
leak is found place should be repaired immediately.
9. Now, raise the pressure to about 5.0kgf/cm2 in the gauges and check the leaks in the system at
various joints, surfaces and repair the leaks.
10. If the flame colour is blue, there is no leak, if the flame colour is yellow-green the leak is small, if
the flame colour is bright blue purple the leak is large. If the leakage is severe, the flame is put out. 11.
Close refrigerant cylinder valve after completing the job, close gauge manifold valves A and B.
Different leak detection methods are :
a) Halide leak detection method
b) Fluroscent leak detection method
c) Nitrogen leak detection method
a)Halide Leak Detector
Halide Torch Function: To find out the type of
refrigerant leakage in air-conditioning
system.
1. Halide leak detector as shown in figure
can detect a leak as slight as 0.4536kg in
ten years.
2. This instrument is popular because of its
low initial cost, ease of handling and
simplicity in construction and operation.
3. It consists of two major parts; the detector
unit and the gas cylinder.
4. The gas cylinder is a non refillable
pressure tank containing a gas such as
propane or butane
5. . The detector unit consists of valve, the
burner and the search hose.
6. After igniting the gas and air mixture, the
flow of gas is regulated until the flame burns about 6mm above the opening in the reactor plate.
7. The plate is heated by flame to red hot temperature.
8. When search hose comes into contact with leaking refrigerant, the refrigerant is drawn into the
search tube and is brought to the receiver plate, where different colour flames are produced. in
the burner.
9. If the flame colour is blue, there is no leak, if the flame colour is yellow-green the leak is small,
if the flame colour is bright blue purple the leak is large.
10. If the leakage is severe, the flame is put out
b)Fluorescent leak detector:
1. The user adds a small amount of fluorescent dye into the air conditioning system, and then
allows the dye to circulate throughout the system.
2. Wherever the refrigerant escapes, so does the dye.
3. Although the refrigerant evaporates, the dye remains at the sites of all leaks.
4. When the system is scanned with a high-intensity ultraviolet or UV/blue light lamp, the dye
glows bright yellow to pinpoint the precise location of every leak.
5. This method cuts refrigerant expenses because we find leaks while they are very small.
6. And since we find the leaks so quickly, our labor costs have been reduced considerably.”
7. This method reduces inspection time by 75 percent or more.
8. This leak detection method is so accurate that it locates the smallest, most elusive leaks in
tubing, soldered joints, fittings, coils, valves, compressors, and more.
c) Nitrogen Detection Method:
Nitrogen Leak Tester :It is used to find out the leakage,If any,of the refrigerant in air conditioning
system.-
Nitrogen Leak test – Regulator Operations:
1. Turn valve A on regulator counter clockwise until loose.
2. Open valve B on nitrogen cylinder, supply gauge will read 2000/2200lb when full
3. Turn valve B on regulator r clockwise until gauge reads 175lbs
4. Close valve B on nitrogen cylinder.
5. Turn valve A on regulator clockwise until pressure reading on use gauge stops rising. This will
usually be between 200- 250lbs. this will also cause the reading on supply gauge to drop to 200-250lbs.
6. The system is now in test mode and any leak will cause the use gauge to drop.
