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HERMETIC COMPONENT REPLACEMENT
The following procedure applies when replacing components in the sealed refrigeration circuit
or repairing refrigerant leaks. (Compressor, condenser, evaporator, capillary tube, refrigerant
leaks, etc.)
1. Recover the refrigerant from the system at the process tube located on the high side of the
system by installing a line tap on the process tube. Apply gauge from process tube to EPA
approved gauges from process tube to EPA approved recovery system. Recover CFCs in
system to at least 5%.
2. Cut the process tube below pinch off on the suction side of the compressor.
3. Connect the line from the nitrogen tank to the suction process tube.
4. Drift dry nitrogen through the system and unsolder the more distant connection first. (Filter
drier, high side process tube, etc.)
5. Replace inoperative component, and always install a new filter drier. Drift dry nitrogen
through the system when making these connections.
6. Pressurize system to 30 PSIG with proper refrigerant and boost refrigerant pressure to 150
PSIG with dry nitrogen.
7. Leak test complete system with electric halogen leak detector, correcting any leaks found.
8. Reduce the system to zero gauge pressure.
9. Connect vacuum pump to high side and low side of system with deep vacuum hoses, or
copper tubing. (Do not use regular hoses.)
10. Evacuate system to maximum absolute holding pressure of 200 microns or less.
NOTE: This process can be sped up by use of heat lamps, or by breaking the vacuum with
refrigerant or dry nitrogen at 5,000 microns. Pressurize system to 5 PSIG and
leave a minimum of 10 minutes. Recover refrigerant, and proceed with evacuation
of a pressure of 200 microns or a minimum of 10%.
11. Break vacuum by charging system from the high side with the correct amount of refrigerant
specified. This will prevent boiling the oil out of the crankcase.
NOTE: If the entire charge will not enter the high side, allow the remainder to enter the low
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
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