How to Fill AC Gas: A Step-by-Step Guide

If you are looking for a new AC, know how to get it on Easy EMIs with Bajaj Finserv.
Air Conditioners on Easy EMIs
3 min
17-July-2025

Regular AC gas refilling is essential to maintain cooling efficiency and prevent performance issues. Low refrigerant levels can lead to insufficient cooling, increased energy consumption, and potential compressor damage. Ensuring the correct gas pressure in your air conditioner helps maintain its longevity and keeps your home comfortable during peak summer months.

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Introduction to the importance of AC gas filling

Proper AC gas filling is crucial for maintaining efficient cooling performance and extending the lifespan of your air conditioner. Refrigerant gas plays a vital role in absorbing heat and cooling the air inside your home. Over time, leaks or low gas levels can reduce cooling efficiency, leading to increased energy consumption and strain on the compressor. Regular maintenance and timely refilling prevent costly repairs and ensure optimal performance.

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Safety precautions before filling AC gas

  • Wear protective gear: Use gloves and safety goggles to avoid direct contact with refrigerant gas.
  • Check for leaks: Inspect the AC system for leaks before refilling gas to prevent wastage and inefficiency.
  • Ensure proper ventilation: Conduct the gas filling process in an open or well-ventilated area.
  • Use the correct refrigerant: Always refill with the manufacturer-recommended refrigerant type to avoid system damage.
  • Turn off power supply: Ensure that the AC unit is switched off and disconnected from power before starting.
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Comprehensive steps to check for leaks in the AC system

  • Inspect AC pipes: Look for oil stains or frost buildup, which indicate possible refrigerant leaks.
  • Use a leak detector: A gas leak detector helps identify even the smallest leaks in the system.
  • Perform a soap bubble test: Apply a soap-water solution to suspected areas; bubbles indicate a leakage.
  • Check pressure levels: Low pressure on the manifold gauge can be a sign of refrigerant loss.
  • Repair leaks before refilling: Seal any detected leaks using a professional-grade sealing compound before proceeding with gas filling.
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Detailed instructions on connecting the manifold gauge

  • Turn off the AC unit: Ensure that the system is completely powered off before attaching the gauge.
  • Locate service ports: Find the low-pressure and high-pressure ports on the AC unit.
  • Connect the hoses: Attach the blue hose to the low-pressure port and the red hose to the high-pressure port.
  • Secure the gauge: Tighten all connections properly to avoid gas leaks during the process.
  • Check pressure readings: Ensure that the gauge displays the correct pressure levels before proceeding with gas filling.
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How to refill refrigerant correctly

  • Check refrigerant type: Use only the recommended gas type specified by the manufacturer.
  • Weigh the refrigerant: Measure the required amount to avoid overfilling or underfilling.
  • Slowly release gas: Open the valve gradually to prevent sudden pressure buildup.
  • Monitor pressure levels: Use the manifold gauge to track the refrigerant flow.
  • Seal and test: Once refilled, seal the valves and run the AC to check cooling performance.

Common mistakes to avoid during AC gas filling

  • Skipping leak detection: Refilling gas without fixing leaks leads to frequent refrigerant loss.
  • Using the wrong refrigerant: Incompatible gas types can damage the compressor and reduce efficiency.
  • Overfilling the system: Excess refrigerant can cause pressure imbalances and reduce cooling performance.
  • Not checking pressure levels: Incorrect pressure settings may lead to ineffective cooling.
  • Ignoring safety precautions: Handling refrigerant without protective gear can lead to health risks.

Understanding different types of refrigerants

  • R-22 (Freon): Older refrigerants are being phased out due to environmental concerns.
  • R-410A (Puron): Eco-friendly and widely used in modern ACs for efficient cooling.
  • R-32: Energy-efficient and has a lower global warming impact.
  • R-134a: Common in car air conditioning systems and some household units.
  • R-290 (Propane): A natural refrigerant with high energy efficiency but flammable properties.

Signs your AC needs a gas refill

  • Reduced cooling efficiency: The AC struggles to maintain desired temperatures.
  • Increased energy bills: Low refrigerant levels make the unit work harder, consuming more power.
  • Ice formation on coils: Low gas levels can cause the evaporator coil to freeze.
  • Hissing or bubbling sounds: Indicates possible gas leaks within the system.
  • Short cycling: The AC turns on and off frequently due to improper refrigerant levels.

Cost overview of AC gas filling

  • Standard refill cost: Prices vary depending on the AC type, typically ranging from Rs. 1,500 to Rs. 3,500.
  • Leak detection charges: Additional costs may apply if a technician checks for and repairs leaks.
  • Service charges: Professional AC gas refilling services may include a labour fee.
  • Refrigerant type impact: R-410A and R-32 gases may be more expensive than older refrigerants.
  • DIY vs professional refill: While DIY kits are available, professional servicing ensures correct refilling and leak checks.
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Frequently asked questions

What types of refrigerants are used in AC units?
Air conditioners use different types of refrigerants, including R-22, R-410A, R-32, and R-134a. R-22 is being phased out due to environmental concerns, while R-410A and R-32 are more energy-efficient and eco-friendly. R-290 and R-600a are newer, natural refrigerants with low environmental impact but require careful handling.

How much does it cost to refill gas in an AC?
The cost of refilling AC gas varies based on the refrigerant type and AC capacity. On average, refilling can cost between Rs. 1,500 to Rs. 4,500. R-410A and R-32 gases are generally more expensive than older refrigerants like R-22. Additional charges may apply for leak repairs and service fees.

How often should I refill the gas in my AC?
AC gas does not need frequent refilling unless there is a leak. Ideally, refrigerant levels should last for years. If cooling efficiency drops, check for leaks and get a professional inspection. Routine maintenance helps ensure optimal performance and prevents unnecessary gas refills.

How long does a refrigerant refill last?
A properly sealed AC system does not require frequent refills. If there are no leaks, the refrigerant can last the lifetime of the unit, typically 10–15 years. However, if gas levels drop, it indicates a leak that should be repaired before refilling to avoid repeated loss.

What types of refrigerants are used in AC units?
Air conditioners use different types of refrigerants, including R-22, R-410A, R-32, and R-134a. R-22 is being phased out due to environmental concerns, while R-410A and R-32 are more energy-efficient and eco-friendly. R-290 and R-600a are newer, natural refrigerants with low environmental impact but require careful handling.

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