Refrigerant leaks are one of the leading causes of reduced efficiency and failure in air conditioning systems. Even a small loss of refrigerant can lower capacity, overheat the compressor, and lead to oil contamination. Proper leak detection and pressure testing are essential to verify system integrity after repair or installation. Technicians use controlled pressure, calibrated instruments, and approved detection methods to ensure the system is sealed and safe for operation.
Purpose of Pressure Testing
Pressure testing confirms that all connections, coils, and brazed joints hold refrigerant without loss. The process is carried out before charging the system with refrigerant. It identifies leaks that cannot be seen under normal conditions. For accurate results, the system is pressurized with dry nitrogen or a nitrogen–hydrogen mixture to the rated design pressure.
Testing with air or oxygen is never allowed because these gases can react with oil and cause combustion.
Preparing the System
Before applying pressure, the system must be fully evacuated of refrigerant and moisture. The technician:
- Connects service gauges to both high- and low-pressure ports.
- Closes all service valves on the condenser and evaporator.
- Ensures isolation of the compressor to prevent damage from excessive pressure.
- Uses a regulated nitrogen cylinder with a calibrated pressure regulator and flexible charging hose.
Standard Pressure Test Procedure
- Pressurization: Nitrogen is introduced slowly through the service port until the system reaches the specified test pressure — typically between 200 and 350 psi (14–24 bar) depending on equipment rating. For high-pressure refrigerants such as R-410A, test pressure may reach 500 psi (34 bar).
- Stabilization: The system remains under pressure for a set period (usually 30–60 minutes). The technician monitors gauge readings for any drop. A stable reading indicates no leak.
- Soap-Bubble or Ultrasonic Check: A soap solution is brushed or sprayed on all brazed joints and fittings. The appearance of bubbles reveals the exact leak point. In noisy environments or when leaks are extremely small, ultrasonic detectors are used to pick up the high-frequency sound of escaping gas.
- Electronic Leak Detection: For pinpoint accuracy, an electronic leak detector is used after pressure release and partial refrigerant introduction. Detectors can sense halogen or hydrogen traces at concentrations as low as 3 g/year. The probe is moved slowly around fittings and coils until the alarm triggers.
- Hydrogen/Nitrogen Mixture Method: In advanced diagnostics, a 5% hydrogen and 95% nitrogen mixture (H₂/N₂) is used instead of pure nitrogen. Because hydrogen molecules are smaller, they pass through micro-leaks more easily and can be detected with highly sensitive sniffers. This method provides accurate results without contaminating the system.
Locating and Confirming Leaks
Common leak points include:
- Flare and compression fittings.
- Brazed joints on copper tubing.
- Schrader valve cores and service ports.
- Capillary tube connections.
- Evaporator and condenser coils.
Once a leak is detected, the surrounding area is cleaned, marked, and verified a second time to prevent false readings.
Repairing Detected Leaks
Small leaks in copper lines are repaired by brazing with silver-phosphorus alloy while maintaining nitrogen flow inside the tubing to prevent oxidation. Damaged Schrader valves are replaced with new cores. Coil leaks may require localized repair or coil replacement, depending on corrosion level. After repair, another pressure test is performed to confirm integrity before evacuation and charging.
Vacuum and Dehydration After Testing
After passing the pressure test, the system is evacuated with a two-stage vacuum pump to remove any residual nitrogen and moisture. The vacuum level is reduced to at least 500 microns and held for 15–30 minutes. A stable reading ensures no remaining leaks or trapped air.
Safety Considerations
- Always use nitrogen, never compressed air or oxygen.
- Monitor pressure constantly to avoid exceeding equipment limits.
- Wear eye and hand protection when working with pressurized systems.
- Release test gas through a regulator — never open the cylinder valve fully.
- Keep electronic detectors and leak sprays away from open flames.
Advantages of Proper Leak Detection
- Prevents refrigerant loss and associated environmental impact.
- Maintains correct operating pressures and efficiency.
- Protects compressor oil from air and moisture contamination.
- Reduces system downtime and long-term repair costs.
- Ensures compliance with EPA and F-gas regulations.
Common Errors to Avoid
- Skipping nitrogen flow during brazing leads to carbon buildup.
- Using a test pressure that is too high for the system rating.
- Assuming gauge stability without checking temperature changes that affect pressure.
- Failing to retest after repair or not performing a proper vacuum before charging.
