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3. Flush evaporator condenser and all connecting tubing with dry nitrogen or equivalent, to remove all contamination from system. Inspect suction and discharge line for carbon deposits. Remove and clean if necessary. 4. Reassemble the system, including new drier strainer and capillary tube. 5. Proceed with processing as outlined under hermetic component replacement. ROTARY COMPRESSOR SPECIAL TROUBLESHOOTING AND SERVICE Basically, troubleshooting and servicing rotary compressors is the same as on the reciprocating compressor with only one main exception: NEVER, under any circumstances, charge a rotary compressor through the LOW side. Doing so would cause permanent damage to the new compressor. Refrigerant Charging NOTE: BECAUSE THE RAC SYSTEM IS A SEALED SYSTEM, SERVICE PROCESS TUBES WILL HAVE TO BE INSTALLED. FIRST INSTALL A LINE TAP AND REMOVE REFRIGERANT FROM SYSTEM. MAKE NECESSARY SEALED SYSTEM REPAIRS AND VACUUM SYSTEM. CRIMP PROCESS TUBE LINE AND SOLDER END SHUT. DO NOT LEAVE A SERVICE VALVE IN THE SEALED SYSTEM. Proper refrigerant charge is essential to proper unit operation. Operating a unit with an improper refrigerant charge will result in reduced performance (capacity) and/or effi ciency. Accordingly, the use of proper charging methods during servicing 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 infl uenced 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. METHOD OF CHARGING The acceptable method for charging the RAC system is the Weighed in Charge Method. The weighed in charge method is applicable to all units. It is the preferred method to use, as it is the most accurate. The weighed in method should always be used whenever a charge is removed from a unit such as for a leak repair, compressor replacement, or when there is no refrigerant charge left in the unit. To charge by this method, requires the following steps: 1. Install a piercing valve to remove refrigerant from the sealed system. (Piercing valve must be removed from the system before recharging.) 2. Recover Refrigerant in accordance with EPA regulations. 3. Install a process tube to sealed system. 4. Make necessary repairs to system. 5. Evacuate system to 250 - 300 microns or less. 6. Weigh in refrigerant with the property quantity of R-22 refrigerant. 7. Start unit, and verify performance. 8. Crimp the process tube and solder the end shut. NOTE: In order to access the sealed system it will be necessary to install Schrader type fittings to the process tubes on the discharge and suction of the compressor. Proper refrigerant recovery procedures need to be adhered to as outlined in EPA Regulations. THIS SHOULD ONLY BE ATTEMPTED BY QUALIFIED SERVICE PERSONNEL. Refrigerant Charging UNDERCHARGED REFRIGERANT SYSTEMS An undercharged system will result in poor performance (low pressures, etc.) in both the heating and cooling cycle. Whenever you service a unit with an undercharge of refrigerant, always suspect a leak. The leak must be repaired before charging the unit. To check for an undercharged system, turn the unit on, allow the compressor to run long enough to establish working pressures in the system (15 to 20 minutes). During the cooling cycle you can listen carefully at the exit of the metering device into the evaporator; an intermittent hissing and gurgling sound indicates a low refrigerant charge. Intermittent frosting and thawing of the evaporator is another indication of a low charge, however, frosting and thawing can also be caused by insufficient air over the evaporator. Checks for an undercharged system can be made at the compressor . If the compressor seems quieter than normal, it is an indication of a lo...

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