REFRIGERANT CIRCUIT EVACUATION AND PURGING METHODS

Abstract

A method of installing a split HVAC system includes purging and sealing new refrigerant lines using a pressurized, refrigerant-compatible fluid. A condenser having a service port and an evaporator are provided with at least two tubes configured to form a refrigerant circuit. A first tube is coupled between the condenser and the evaporator. A second tube is coupled to the evaporator while its condenser-side end remains unattached. A fluid container with a valve and a service-port fitting is connected to the condenser service port and opened to drive the pressurized fluid through the tubes. Purging is confirmed by fluid discharge from the unattached end of the second tube, after which that end is connected to the condenser, optionally while discharge continues to maintain positive pressure for leak checking. The container may be partially removed while leaving the fitting attached so residual fluid vents through the service port before final disconnection.

Claims

1. (canceled)

2. (canceled)

3. A method for installing a split HVAC system including a condenser and an evaporator and configured to circulate a refrigerant, the method comprising: providing at least two tubes, each tube being configured to connect the condenser to the evaporator, thereby forming a refrigerant circuit; providing a fluid container housing pressurized fluid that is different from the refrigerant but compatible with the refrigerant, the container comprising a container valve and a service port fitting; coupling a first tube of the at least two tubes to the condenser and evaporator, respectively; coupling a second tube of the at least two tubes to the evaporator, thereby leaving an unattached end of the second tube corresponding to the condenser; coupling the service port fitting of the fluid container to a service port of the condenser in fluid communication with the refrigerant circuit; opening the container valve such that the fluid container expels the pressurized fluid into the at least two tubes via the service port; determining that the pressurized fluid has purged the at least two tubes based on the pressurized fluid exiting from the unattached end of the second tube; and based on the determination, coupling the unattached end of the second tube to the condenser.

4. The method of claim 3, further comprising, after coupling the unattached end of the second tube to the condenser, leaving the container valve opened such that the fluid container continues to expel pressurized fluid into the refrigerant circuit.

5. The method of claim 4, further comprising performing a leak check while the fluid container continues to induce positive pressure into the refrigerant circuit.

6. The method of claim 3, further comprising decoupling the service port fitting of the fluid container from the service port of the condenser.

7. The method of claim 3, further comprising disconnecting a portion of the fluid container while leaving at least the service port fitting of the fluid container attached to the condenser.

8. The method of claim 7, further comprising operating the split HVAC system such that remaining pressurized fluid within the refrigerant circuit escapes through the service port fitting.

9. The method of claim 8, further comprising, in response to determining that the remaining pressurized fluid has escaped the refrigerant circuit, disconnecting the service port fitting from the service port.

10. The method of claim 3, wherein neither of the at least two tubes have been previously used for refrigeration.

11. The method of claim 3, wherein coupling the unattached end of the second tube to the condenser is performed while the pressurized fluid remains discharging.

12. A method for evacuating and flushing a refrigerant circuit of a split HVAC system without using a vacuum pump, comprising: coupling a service port fitting to a service port of a condenser of the split HVAC system; opening a valve of a container coupled to the service port fitting to introduce a pressurized fluid that is different from a refrigerant but compatible with the refrigerant into the refrigerant circuit; maintaining an open connection at a distal fitting corresponding to one of at least two tubes of the refrigerant circuit such that air and other non-condensable contents are expelled from the distal fitting; in response to observing discharge of the pressurized fluid from the distal fitting, sealing the distal fitting to close the refrigerant circuit while maintaining introduction of the pressurized fluid and thereby establishing a positive pressure in the sealed refrigerant circuit; and performing a leak check while the positive pressure is maintained.

13. The method of claim 12, wherein the pressurized fluid is introduced in an aerosolized form and is inert and non-reactive with components of the refrigerant circuit and the refrigerant.

14. The method of claim 12, wherein the service port comprises a Schrader valve and the service port fitting comprises a depressor configured to open the Schrader valve.

15. The method of claim 12, wherein the service port is located on a gas-side valve of the condenser, and the distal fitting corresponds to a liquid-side valve connection of the condenser.

16. The method of claim 12, wherein at least one of the at least two tubes has been previously used for refrigeration, and wherein the method is performed to repurpose the refrigerant circuit for use with a refrigerant that is different from a prior refrigerant.

17. The method of claim 12, wherein the leak check and evacuating are performed without manifold gauges and without a vacuum pump.

18. A method for removing flushing fluid from a sealed refrigerant circuit of a split HVAC system, comprising: after sealing the refrigerant circuit and introducing a flushing fluid therein, coupling a service port connector hose to a service port of a condenser of the split HVAC system to depress a check valve of the service port; allowing internal pressure of the sealed refrigerant circuit to drive expulsion of the flushing fluid through the service port connector hose to atmosphere; and disconnecting the service port connector hose from the service port in response to determining that expulsion of the flushing fluid has ceased.

19. The method of claim 18, wherein the service port connector hose is the same fitting previously used to introduce the flushing fluid, with a fluid container removed.

20. The method of claim 18, wherein determining that expulsion of the flushing fluid has ceased comprises detecting cessation of audible discharge from the service port connector hose.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings are illustrated as example embodiments of the present invention and are not intended to be limited by the depicted figures, in which similar references may contain elements that bear resemblance and in which:

[0010] FIG. 1 illustrates an embodiment of the present invention intended to demonstrate the application and methodology without exclusion of any other possible embodiments.

[0011] FIG. 1Element 11 illustrates the container of the pressurized fluid consumed during the usage of the present invention for its intended purpose in flushing the circuit, and possess a check valve or other means of allowing the retrieval of the fluid.

[0012] FIG. 1Element 12 depicts the connector of the valve hose to the container, which can be threaded or attach through other means of fastening and houses a depressor pin, or other mechanism for manipulating and controlling the flow rate.

[0013] FIG. 1Element 13 shows the depressor pin and flow-rate control mechanism, which can manifest as a rotation or twisting handle, push plunger, or other undepicted embodiments.

[0014] FIG. 1Element 14 shows the fluid transfer hose through which the fluid in the container will flow out of the container and enter the refrigeration circuit.

[0015] FIG. 1Element 15 depicts the service port fitting through which the present invention can securely access the refrigeration circuit of the system and transfer its contents without compromising the sealed nature of the circuit.

[0016] FIG. 2 illustrates the primary embodiment of the present invention in usage for its intended purpose during the installation of a split system with refrigeration circuit.

[0017] FIG. 2Element 16 shows the present invention connected to the refrigeration circuit as will be needed during usage for its intended purpose.

[0018] FIG. 2Element 17 depicts the connected portion of the refrigeration circuit, which will be on the same valve that contains the service port whereby the circuit can be accessed.

[0019] FIG. 2Element 18 shows the thicker tube of the refrigeration circuit, which is fully connected at both points of the outside condenser system and indoor evaporator system.

[0020] FIG. 2Element 19 depicts a simplified X-ray view of what is known by those well-versed in the art as the evaporator unit coil, which will be on the other end of the condensing unit in a typical refrigeration circuit for a split system air conditioner.

[0021] FIG. 2Element 20 shows the thinner tube of the refrigeration circuit, which at the beginning is only connected at the indoor evaporator system side and unconnected at the condenser side.

[0022] FIG. 2Element 21 illustrates the unconnected portion of the refrigeration circuit, which will be the final connection point and furthest away from the servicing port.

[0023] FIG. 2Element 22 illustrates what is known by those well-versed in the art as the condensing unit, which will be on the other end of the evaporator unit in a typical refrigeration circuit for a split system air conditioner.

[0024] FIG. 3 depicts the primary embodiment of the auxiliary process of the present invention, whereby the main process has been completed and the supplementary process is occurring.

[0025] FIG. 3Element 23 shows the now-connected portion of the thinner tube of the refrigerant circuit, being connected at the liquid-side valve of the condenser unit.

[0026] FIG. 3Element 24 depicts a non-X-rayed view of the evaporator unit portion of the split-system air conditioner to provide an understanding of the post-process appearance.

[0027] FIG. 3Element 25 depicts the elements of FIG. 1 excluding Element 11, whereby being used to facilitate the fluid that had entered previously to now exit back out of the circuit.

DETAILED DESCRIPTION

[0028] The terms and descriptions herein are used for the sole purpose of describing a particular embodiment only and are in no way intended to limit the scope of the invention. Any usage of the singular forms of articles such as a or an are intended to encompass both plural and singular forms, unless directly stated otherwise. Any terms such as comprises, comprising, contain, or composed of when used in this specification, refer to and specify the presence of declared instructional steps, processes, components, and features, but do not exclude or preclude the presence or addition of one or more instructional steps, processes, components, features, or other associated elements thereof. Any usage of and and or includes any and all associated listed combinations.

[0029] Unless directly or explicitly stated otherwise, all technical and scientific terms possess the same meaning as what is commonly understood by those skilled in the art for which the category of this invention belongs to. Furthermore, any language or verbiage used herein should be interpreted according to their definitions in commonplace dictionaries and should not be interpreted in an overly radical or formal sense.

[0030] By describing this invention, various technical steps and procedures are in included for the sake of explanation. Each listed step has a specific purpose in achieving the intended effect. In some instances, the language may be intentionally repetitive to avoid misinterpretation. It will be evident to those skilled in the art that the present invention requires the practicing of the steps, however not necessarily in the given order or with the knowledge of all specific details, as there may exist some variations in other embodiments. Therefore, the disclosed invention is to be considered as an exemplary and primary embodiment, and is not intended to limit the scope of the invention to that of what is illustrated by the figures and descriptions enclosed below.

[0031] The present invention will now be detailed through reference of the attached figures representing preferred embodiments. FIG. 1 depicts an overall view of the elements that may comprise the refrigerant circuit evacuation apparatus (the apparatus), according to various embodiments of the present invention. In preferred embodiments, each of the elements of the apparatus are configured with at least one fluid container 11. which is configured to accept one valve hose connector 12. Fluid container 11 contains a pressurized fluid that is environmentally friendly, completely harmless and/or compatible with the refrigerant to be used in the circuit, and will exit the container in either a liquid or aerosolized form, and contains a check valve or other means of retrieval of the fluid.

[0032] Valve hose connector 12 may fasten to fluid container 11 by threaded or unthreaded means. The means of fastening valve hose connector 12 to fluid container 11 includes any embodiments whereby the fluid contents of fluid container 11 can be securely and directly accessed upon this connection. Valve hose connector 12 will possess a mechanism of access, in the preferred embodiment being a depressor pin, whereby the mechanism of access can be controlled directly or indirectly by flow-rate control mechanism 13. The flow-rate control mechanism 13, in the preferred embodiment manifesting as a rotating handle, also includes any embodiments whereby the depressor pin or other method of access is controlled by the mechanism, which can also manifest as a push plunger or any other mechanism that is intended to be used to control the flow rate of fluid out of fluid container 11. By the nature of the pressurized contents of fluid container 11, and the elimination of restriction by opening of the valve using flow-rate control mechanism 13, it will permit the fluid to begin to transfer out of the container.

[0033] The fluid transferring out of fluid container 11 at the rate controlled by flow-rate control mechanism 13, will be contained and transfer through fluid transfer hose 14. This element is not directly required in the apparatus, however, is included in the preferred embodiment to allow for comfort and flexibility of usage. The endpoint of fluid transfer hose 14 is at service port fitting 15, whereby this acts as both the point of connection between the present invention and the refrigerant circuit and facilitates access of the refrigerant circuit through the depression of a Schrader valve, check valve, or other means. Service port fitting 15 acts as the final point of contact before fluid from the apparatus begins entering the refrigerant circuit.

[0034] FIG. 2 illustrates steps 1-6 in FIG. 4 as a wide perspective of all elements involved in the system and implementation of the apparatus. The entire apparatus 16 is connected to the condenser unit 22 via the fluid transfer hose 14 and service port fitting 15 at the servicing port. The apparatus itself remains the only item connected to the circuit and bypasses the need for any other tools or procedures. The setup and procedure up until this point is given by steps 1-4 in FIG. 4. Gas-side valve connection 17 depicts the point where the thicker of the two refrigerant tubes is connected at the gas-side valve. When fluid leaves apparatus 16, it will then be allowed to successfully enter the circuit via the fixed connection 17 at this location. The liquid-side fitting 21 belongs to the thinner of the two refrigerant tubes 20 and is to remain unconnected for most of when the apparatus is being utilized. Step 5 and 6 from FIG. 4 are described for the remainder of FIG. 2. The fluid leaving apparatus 16 to transfer into the circuit via gas-side valve connection 17 will first pass through the circuit via the thicker refrigerant tubing 18. It is reminded that at this point of the procedure, the circuit is incomplete since liquid-side fitting 21 remains unconnected.

[0035] Once flow through thicker tube 18 is established, the fluid must then flow through the portion of the refrigeration circuit located within evaporator unit 19. This portion of the pipeline, while typically having numerous bends and twists, is still mainly considered as one contiguous tube that runs throughout the interior of evaporator unit 19 as depicted, and is only subject to a single modification of decreasing in thickness as it exits evaporator unit 19. The evaporator unit is shown in FIG. 2 as a simplified X-ray depiction of the interior (known by those well-versed in the art as the evaporator coil) for illustrative purposes, and without X-ray depiction in FIG. 3. As the fluid travels into and back out of the evaporator unit 19, the remainder portion of the circuit is illustrated in the figure as the thinner refrigerant tubing 20.

[0036] Upon completion of installation, the thinner tube 20 will finally be connected to condenser unit 22 via the liquid-side fitting 21, but during the utilization of apparatus 16, remains unconnected. The fluid is now being transmitted, as an aerosolized form in the preferred embodiment, throughout the entire circuit, and in doing so, flushes air and all non-condensable contents out of the circuit and back into the atmosphere at its exit point at unconnected liquid-side fitting 21. In the preferred embodiment of the apparatus, the flushed contents exiting from liquid-side fitting 21 will initially be pure air and other impurities, and as the process ensues, will eventually be solely comprised of the fluid from the apparatus, either in liquid or aerosolized form, as depicted in FIG. 2.

[0037] During this ongoing process, the liquid-side fitting 21 will then be connected to its final intended connection point located on the liquid side valve of condenser unit 22, in the equivalent fashion as gas-side valve connection 17 is currently made, as depicted in FIG. 3. The flowing process of the fluid out of the apparatus and into the circuit shall continue even after the circuit is sealed, until the remainder contents of the apparatus are completely used up. This will permit a leakage check as indicated in step 7 of FIG. 4, whereby it can be verified whether the refrigeration circuit is truly sealed or not. It is through this process, as indicated in step 8 of FIG. 4, where it is determined whether the previous process was sufficient, or if it needs to be repeated upon repair of the point of leakage. Those well-versed in the art will know the importance of verifying the sealed nature of the system and will appreciate the opportunity to do so. The apparatus 16 can then be disconnected from the refrigeration circuit at this point.

[0038] FIG. 3 illustrates steps 9-10 in FIG. 4, whereby the main process of the apparatus is completed, and the auxiliary process can begin. It is at this stage that the previously unconnected liquid-side fitting is now fixed in its final intended place as a connection point at liquid-side valve connection 23. The refrigerant circuit is now a sealed system circuit, completely closed off from the atmosphere and free of air and non-condensable elements. The evaporator unit 24 is shown in the non-X-ray view as would appear after the system is successfully installed. The manipulated remainder component of the apparatus is the service port connector hose 25, hereby defined as all elements of FIG. 1 minus the fluid container 11. Upon the sealing of the refrigerant circuit, it may be desired to remove any leftover fluids or aerosolized fluids back out of the sealed circuit.

[0039] At this point, the internal pressure of the refrigeration circuit is greater than that of atmospheric pressure. Therefore, upon connection of the service port connector hose 25 to the service port located on the same valve as gas-side connection 17, the check valve is once again depressed, and secure access to the refrigeration circuit is once again facilitated. The natural state of a greater internal pressure within the circuit than that of atmospheric pressure allows for the newly deposited flushing fluid to be retrieved back out into the atmosphere, as depicted in FIG. 3. This one-way flowing process is the reverse of the previous, whereby it flows out of the refrigeration circuit as opposed to in. The process should continue until all contents have exited the refrigeration circuit, in this embodiment indicated by the cessation of any hissing noises and measured differently in other embodiments. At this point of the process, the service port connector hose 25 is then disconnected, re-engaging the check valve and resealing the refrigeration circuit, which has now been fully flushed, evacuated, and ready to accept refrigerant.