2.2.1 Pressure and Leak Testing Tools
Accurate testing requires properly selected and maintained instruments. Using the wrong tool, or a poorly maintained one, can result in a missed leak, a false pass, or a dangerous over-pressurization event.
Electronic Detectors
Heated diode, infrared, or corona discharge sensors. Must be calibrated against a known reference leak. Scan after a pressure drop is confirmed.
Soap Solutions
Traditional and widely accepted. Applied to suspected sites — bubbles indicate escaping gas. Use specialized solutions, not dish soap.
Ultrasonic Detectors
Listen for high-frequency sound from escaping gas. Useful with nitrogen pressurization; less affected by airflow than other methods.
Pressure Gauges
Certified and calibrated gauges rated for the maximum test pressure. Select a range that gives good resolution near the test pressure.
Fluorescent Dyes
Added to the refrigerant circuit; leak sites glow under UV light with filter glasses. Follow manufacturer limits on dye quantity.
Regulators
Control test gas pressure from cylinders. Never connect a high-pressure cylinder to a system without a regulator. Match to gas type and cylinder.
Electronic Leak Detectors
Electronic leak detectors sense the presence of refrigerant in air and provide an audible or visual indication.
- Detector types include heated diode, infrared, and corona discharge technologies — each suited to different refrigerant families.
- Must be calibrated and checked regularly with a known reference leak to confirm sensitivity.
- Used to scan around joints, valves, coils, and other potential leak points after a preliminary pressure test has confirmed a loss of pressure.
Refrigerant and Soap Solutions
A traditional and widely accepted method of locating leaks — effective at pinpointing the exact leak site once a pressure loss has been identified.
- Refrigerant is introduced to provide test pressure within code limits; soap solution is then applied to suspected leak sites.
- Formation of bubbles indicates gas escaping through a leak.
- Use specialized leak-detection soaps or solutions — not dish soap. Specialized solutions are formulated not to damage metals or leave harmful residues.
Ultrasonic Leak Detection
Ultrasonic detectors listen for the high-frequency sound produced by gas escaping through a leak point.
- Useful when the system is pressurized with nitrogen or a nitrogen/refrigerant mixture.
- Less affected by airflow conditions than some other detection methods — an advantage in busy mechanical rooms.
Certified Pressure Gauges
Certified pressure gauges provide accurate measurement of test pressures during pressure and leak testing.
- Must be rated for the maximum test pressure and calibrated periodically to maintain accuracy.
- Select gauge ranges that provide good resolution near the test pressure — an oversized range reduces readability at lower pressures.
Leak Detection Solutions and Fluorescent Dyes
Commercial leak detection solutions and fluorescent dyes provide additional methods for identifying leaks, including those not visible by other means.
- Leak detection solutions are applied to joints and connections — visible bubbling indicates a leak site.
- Fluorescent dyes are added to the refrigerant circuit; leak sites are detected using ultraviolet (UV) light and filter glasses.
- Dye use must follow manufacturer guidelines — over-treating a system with dye can cause issues with oil compatibility and filter driers.
Regulators
Regulators control the delivery pressure of test gases such as nitrogen or CO₂ from high-pressure storage cylinders.
- High-pressure gas cylinders must never be connected directly to refrigeration systems without a properly adjusted regulator.
- Regulators are matched to the gas type and cylinder design — using a mismatched regulator is a safety hazard.
- Keep regulators clean, particularly of oil and grease when used with oxygen-compatible service equipment.