COMERCIAL AIR CONDITIONIG

TECHNICAL TRAINING GUIDEBOOK

Teacher: Luis Valera

2013

Manual Pump down on an A/C system.

What is the MANUAL PUMP DOWN?
This method is applied to store the refrigerant in a system of air conditioning using the
compressor. The refrigerant charge is stored between the compressor, condenser and the
liquid line service valve. (King valve)
When is needed MANUAL PUMP DOWN?
The main reason is to avoid a system from lost the refrigerant charge when perform repairing
job services or to relocated the unit. These are all repairment jobs between the liquid line and
suction service valve in the compressor only:
a) Change the filter dryer and/or flare nuts.
b) Change TXV.
c) Change sight glass moisture indicator.
d) Change evaporator coil.
e) Change the suction service valve.

MANUAL PUMP DOWN ADVANTAGES.

We can save the cost for refill a refrigerant stored charge and help to reduce the air
pollution. Why we must throw out the refrigerant if we can stored it and save money?
Imagine if the system used a lot of amount of refrigerant but we do not store it to recycle
later? We waste the gas and cost for refill it back and deplete the ozone layer.
Why pump down method is important when we perform a task that require open or dismantle a
pipe line or a/c system.
a)
b)
c)
d)

It helps to save refrigerant.

Technicians save money, refrigerant and time.
Helps to save the ozone layer.
Improve the following 608 section of the Clean Air Act and technicians avoid fines of
US$27,500.00 per violation.
e) Helps to keep clean the environment and free of pollution.

When MANUAL PUMP DOWN cant be performed?

Technicians cant perform MANUAL PUMP DOWN if the repairment jobs are located between
the compressor, condenser and the liquid line service valve. The best way to handle the
refrigerant charge is installing the recovering machine, recover the refrigerant and store it in
the recycle EPA tank.
Jobs in this area:
a)
b)
c)
d)
e)

Change the compressor discharge service valve.

Change condenser coil.
Change the liquid line service valve.
Change compressor.
Change compressor oil change.

All maintenance hvac technicians must know how to perform pump down on an air
conditioning system.

We must setup for the tool and equipment needed.

Tools and Equipment

A.
B.
C.
A.
B.
C.
D.
E.

Manifold gauge.
Ratchet Offset Wrench.
Two jaws jumper cable.
Adjustable wrench.
Safety glass.
Gloves.
Digital Multimeter.
Workshop Cleaning wipe.
.

Manual Pump down method step by step

A.
B.
C.
D.
E.

F.

G.
H.
I.
J.

K.

L.
M.

Check the disconnecting switch to ensure the air conditioning unit is shut down by the
main switch. Check the thermostat and switch it to fan and cool modes.
Be sure the king and suction valves are back seated.
Remove the service port cap and valve stem cap. Open the end cap of the service valves
for suction and king valve using an adjustable wrench.
Verify the closed position in the manifold gauge valves.
Install the manifold gauge. Use the blue hose (Low pressure meter in the left side) and
connect it to the suction service valve on the compressor (This is the big tubing coming
from the evaporator) do not tight the blue hose. Use the red hose (high pressure meter
in the right side and connect it to the king valve in the liquid line. (This is the small
tubing coming from the condenser).
Mid seat the king service valve (located downstream from the condenser in the liquid
line. The small tubing) using a Ratchet Offset Wrench. Turn it around four times with
clockwise rotation, to ensure we have refrigerant in the hoses. Open the high side gauge
manifold with two turns counterclockwise (the red in the right side).
Open the low side gauge manifold with two turns clockwise. (the blue in the left side)
and purge the suction line hose to evacuate the air in the gauge hoses.
Front seat the king valve. Using a Ratchet Offset Wrench. Turn it around with clockwise
rotation until it reaches the end. (by turning the stem valve outwards as far as it will go.
Mid seat the suction service valve in the compressor.
Jump the low pressure control automatic reset switch that open on Pressure Fall to
prevent compressor shut down at 30 psi when is in operation. Remove the wire nuts to
the low pressure control automatic reset switch. Use an alligator clips wire to jump it.
Turn on the unit by the main switch and check the process until the low side gauge
reading should drop to a lower suction pressure on the gauge. This indicates the low
pressure gauge readings reaches between 0 psi to -10 inches of Hg vacuum. All of
refrigerant in the system goes through the compressor and we have stored it
temporarily between the compressor, the condenser and the king valve.
Back seat the suction service valve, turn it around with counterclockwise rotation until
it reaches the end. (by turning the valve stem inwards as far as it will go)
Turn off main switch of the unit. Close both (the low and high side gauge manifold);
check your gauges readings to ensure you have MANUAL PUMP DOWN in the system.
The low pressure gauge readings should be between 0 psi to -10 inches of Hg vacuum.

REMOVING THE GAUGES

A.
B.
C.
D.
E.

F.
G.
H.
I.
J.

Be sure that you have closed both (the low and high side gauge manifold)
Back seat the king service valve.
Mid seat the suction service valve.
Start the unit by the main switch.
Open the high side gauge manifold and slowly open the low side to ensure we are
equalizing the pressure between the two hose and the system. When done back seat the
suction service valve in the compressor and close both valves on the manifold gauge .
Remove the manifold gauge and attach the hoses in the dummy ports on back side.
Replace the service port cap and the valve stem caps.
Turn off the unit by the main switch.
Clean the manifold gauge, the hoses and the service port valves with workshop cleaning
wipe.
Remove the jumper from the low pressure control automatic reset switch. Replace the
wire nuts to the low pressure control automatic reset switch.

What is a king valve in an air conditioning system?

When referring to the "king" valve, most air conditioning technicians are referring to the valve
which is found downstream from a liquid line receiver. It is also commonly referred to as a
liquid line service valve or an isolation valve. This valve is not as common as other valve types in
residential units. It is called a "king" valve perhaps because it can be closed to permit the
pump down of an air conditioning system in order to trap the refrigerant in the receiver and
condenser; in that sense, it rules the system.

Working With Compressor Service Valves

Many refrigeration compressors incorporate a suction service valve and a discharge service
valve. These are used to allow refrigeration gauges to be attached to the system; and, if
needed, they are used to isolate the compressor from the rest of the system.
Working with these valves is not difficult, but there are some finer points to remember.

Service Valve Parts

A typical compressor service valve is composed of four essential parts:
1. Line connection.
2. Compressor connection.
3. Valve stem.
4. Gauge port.
There are three positions in which the valve can be oriented. If the valve stem is all the way
out, the valve is considered to be in the back seated position. The gauge port is closed and the
valve is open, allowing refrigerant to flow through the system.
If the valve stem is all the way in, the valve is considered to be in the front-seated position.
The gauge port is open to the compressor connection and the refrigerant line (suction or
discharge) connection is closed.
If the valve stem is between the front-seated and back seated position, it is considered to be
in the mid-seated position. In this position all three connections the gauge port, line, and
compressor are open. This allows the refrigerant to flow through the system and the
system pressure to be read through the gauge port.
When placing the valve in its mid-seated position, be sure to turn the valve in its back seated
position first and then turn the valve stem only one or two complete turns into the mid-seated
position.
Points of use
When opening a service valve, make sure it is secured by placing it in a vise or attaching it to
the compressor.
Also, look to see if the service valve has a packing gland nut. Many service valves will have this.
The packing gland nut helps to ensure a leak-free seal. It is typically made of brass and is
found at the base of the valve stem. It must be loosened by a quarter turn to a full turn
before opening the valve stem.
Not loosening the gland packing prior to turning the valve stem may cause the valve to leak. In
addition, make sure you tighten the nut when you are finished manipulating the valve stem.

When opening and closing compressor service valves, make sure to use the right tools, such as
an appropriately sized service wrench. Do not attempt to open a service valve with an
adjustable wrench. You can easily round the valve stem edges, rendering the valve useless.
If the valve stem is difficult to open and appears to be stuck, lightly tap the end of the valve
stem with a hammer. This should open the valve. (Remember to loosen that packing gland nut
before attempting to open the valve stem!)

Remember to replace the service port cap and valve stem cap after closing the valve port and
removing your refrigeration gauges. These caps serve two purposes:
1. They help prevent a refrigerant leak; and
2. They prevent the threads on the service valve from being rusted over or otherwise
damaged.

When brazing either a suction or discharge service valve, make sure the valve is mid-seated
before brazing. If left in either the front-seated or back seated position, heat from brazing
can cause the inside plunger to weld to the seating area on the inside of the valve body.
When brazing, its best to wrap the service valve in a wet rag. This prevents the valve from
being overheated and damaged. Be sure not to allow water to enter the system.
Working with these valves is very simple. Just remember some basic rules for trouble-free
operation.