Section 7: Air Conditioning (Cooling)

Unit 41: Troubleshooting

 Introduction

• Troubleshooting air-conditioning equipment involves

both the mechanical and electrical systems
• Symptoms may overlap
• Mechanical problems may appear to be electrical
and vice versa
• Technicians must diagnose problems correctly
 Mechanical Troubleshooting

• Gauges and temperature-testing equipment are

used when troubleshooting
• Always be aware of the system refrigerant
• Many newer gauges are more universal
• Gauges are most accurate in the middle of their
scale range
• Wireless, digital pressure/temperature gauges
• Smart devices offer new features, such as
Bluetooth technology and screenshots
 Temperature Difference, Temperature
Split, and Approach Temperature
• Approach temperature, temperature split, and
temperature difference
• Terms used to describe the difference in
temperature between heat exchange mediums
• Delta T (ΔT)
• Stands for change in temperature
• Applies to the inlet versus the outlet temperature of
the same medium
 Gauge Manifold Usage

• Displays the low- and high-side pressures while the

unit is operating
• Pressures can be converted to the saturation
temperatures for the evaporating and condensing
refrigerants
• Used whenever the pressures need to be known for
the system
• Two types of connections used:
• Schrader valve and service valve
 When to Connect the Gauges

• Gauge manifolds should not be connected every

time a system is serviced
• Small amounts of refrigerant escape each time the
gauges are connected
• Short gauge line connectors will limit the amount of
refrigerant lost
• Small core depressor can be used to keep
refrigerant in the system when disconnecting the
gauges
 Short Service Connection

Figure 41.8 This short service

connection is used on the high-
side gauge port to keep too much
refrigerant from condensing in the
gauge line.
Courtesy of Ferris State
University. Photo by John
Tomczyk
 Low-Side Gauge Readings

• Used to compare the actual evaporating pressure to

the normal evaporating pressure
• Verifies refrigerant is boiling at the correct
temperature for the low side of the system at some
load condition
• Hotter temperatures and higher humidity create an
oversized load on the evaporator
• Must wait for system to reduce the load to
determine whether the equipment is functioning
properly
 High-Side Gauge Readings

• Used to check the relationship of the condensing

refrigerant to the ambient air temperature
• Standard efficiency air-cooled condensers
condense the refrigerant at no more than 30°F
higher than the ambient temperature
• High-efficiency condensers normally condense the
refrigerant at a temperature as low as 20°F higher
than the ambient temperature
 Temperature Readings

• Temperature leads:
• Easily attached to refrigerant piping
• Insulated with foam line insulation
• Common temperatures used for evaluation:
• Inlet air wet-bulb and dry-bulb temperatures
• Outdoor air dry-bulb temperature
• Liquid- and suction-line temperatures
• Compressor discharge temperature
 Temperature Readings: Inlet Air
Temperatures
• May be necessary to know for a complete analysis
of a system
• A wet-bulb and a dry-bulb reading may be obtained
by placing a dry-bulb temperature lead next to a
wet-bulb temperature lead in the return airstream
• Velocity of the return air will be enough to
accomplish the evaporation for the wet-bulb reading
• Digital psychrometer could also be used
 Temperature Readings: Evaporator
Outlet Temperatures
• Seldom important
• Obtained in the same manner as the inlet air
temperature
• The temperature drop across an evaporator coil is
about 20°F when operating at typical operating
conditions
• If a wet-bulb reading is taken, there will be
approximately a 108°F wet-bulb drop from the inlet
to the outlet during standard operating conditions
Temperature Readings: Suction-Line
Temperatures (1 of 5)

Figure 41.17 An evaporator flooded with refrigerant.

 Temperature Readings: Suction-Line
Temperatures (2 of 5)

Figure 41.18 The evaporator is starved for refrigerant because of a low refrigerant
charge.
 Temperature Readings: Suction-Line
Temperatures (3 of 5)

Figure 41.19 If the suction pressure is too low, and the suction line is not as cool as
normal, the evaporator is starved for refrigerant. The unit refrigerant charge may be low.
 Temperature Readings: Suction-Line
Temperatures (4 of 5)

Figure 41.20 When the suction pressure is too low and the superheat is low, the unit is
not boiling the refrigerant in the evaporator. The coil is flooded with refrigerant.
Temperature Readings: Suction-Line
Temperatures (5 of 5)

Figure 41.21 The evaporator is full of refrigerant.

Temperature Readings: Discharge-Line
Temperatures

Figure 41.22 A thermometer is attached to the discharge line on this compressor. If the
compressor has an internal leak, the hot discharge gas will circulate back though the
compressor. The discharge gas will be abnormally hot. When a compressor is cooled by
suction gas, a high superheat will cause the compressor discharge gas to be extra hot.
 Temperature Readings: Liquid-Line
Temperatures

Figure 41.23 This

condenser is
operating at
normal conditions.
A technician can
use these readings
as points of
reference for a
condenser
operating at full-
load normal
conditions.
 Charging Procedures in the Field

• The charge is the correct amount of refrigerant in

the evaporator, liquid line, discharge line, and
suction line
• The amount of refrigerant:
• In the evaporator is measured by superheat
• In the condenser is measured by subcooling
• In the liquid line is determined by measuring the
length and calculating the refrigerant charge
 Charging Procedures in the Field:
Fixed-Bore Metering Devices
• Include the capillary tube and orifice type
• Allow refrigerant flow based on the difference in the
inlet and the outlet pressures
• When you need to check the system for correct
charge or to add refrigerant, the best method is to
follow the manufacturer’s instructions
• Orifice-type metering devices have a tendency to
hunt while reading steady-rate operation
 Charging Procedures in the Field: The
TXV System
• Restrict the airflow across the condenser to simulate
a 95°F ambient, 278 psig head pressure for R-22 or
445 psig for R-410A
• The superheat check will not work for TXV
• A subcooling check of the condenser can be used to
check the system charge
• Typical subcooling circuit subcools liquid refrigerant
from 10°F to 20°F cooler than condensing
temperature
• Excessive subcooling indicates overcharge
 Electrical Troubleshooting

• You need to know what the readings should be to

know whether the actual readings are correct or not
• Begin any electrical troubleshooting by verifying that
the power supply is energized and that the voltage
is correct
• If the power supply voltage is correct, move on to
the various components
 Compressor Overload Problems

• If you cannot hold your hand on the compressor

shell, the motor is too hot
• Ask these questions:
• Can the charge be low?
• Can the start-assist circuit not be working and the
compressor not starting?
• Allow compressor to cool before restarting it
• Have the gauges and a cylinder of refrigerant
connected when the compressor is started
 Compressor Electrical Checkup

• Technicians need to be careful when condemning a

compressor
• Many condemned compressors are not defective
• Unnecessary labor and material costs
• Compressor problems can be mechanical or
electrical
• Electrical portion easy to prove
• If problem is not electrical, it must be mechanical
 Troubleshooting The Circuit Electrical
Protectors—Fuses And Breakers
• Open circuit breakers or blown fuses should be
treated with caution
• Do not reset or replace a tripped breaker or fuse
without trying to determine what caused the fuse to
blow or the breaker to trip
• Be sure to isolate the compressor circuit before
condemning the compressor