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
• R-410a pressures are much higher than R-22;
gauges have to be built to handle the higher
pressure
• R-22 gauges on R-410a systems will be over
pressurized and can become damaged
– Many newer gauges are more universal
 Approach Temperature and
Temperature Difference
• Approach temperature or temperature
split is the difference in temperature
between heat exchange mediums
• Temperature difference (TD) 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
– Used whenever the pressures need to be
known for the system
– Gauges are connected to service ports
– Used to calculate superheat and subcooling
 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 and removed
from a sealed system
– Short gauge hoses will limit the amount of
refrigerant lost
– Low-loss fittings should be used
Gauges
 Low-Side Gauge Readings
• Compares the actual evaporating pressure
to the normal evaporating pressure
– Standard-efficiency systems usually have a
refrigerant boiling temperature of about 35°F
cooler than the entering air temperature
 Low-Side Gauge Readings
(cont’d.)
• Under increased loads, the evaporator is
absorbing extra sensible and latent heat
from the air
• Gauge readings when the system is
operating in or close to design range will
verify system’s true performance
 High-Side Gauge Readings
• 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
• For determining the system’s superheat
and subcooling temperatures
– Common temperatures used for evaluation:
• Indoor air wet-bulb and dry-bulb temperatures
• Outdoor air dry-bulb temperature
• Suction-line temperature
• Condenser outlet temperature
• Compressor discharge line temperature
 Temperature Readings
(cont’d.)
• 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
 Temperature Readings
(cont’d.)
• 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
 Temperature Readings
(cont’d.)
• Suction-line temperatures

Figure 41–17 An evaporator flooded with refrigerant

Figure 41–18 The evaporator is starved for refrigerant because of a low

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
(cont’d.)
• Suction-line temperatures (cont’d.)

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
(cont’d.)
• Suction-line temperatures (cont’d.)

Figure 41–21 The evaporator is full of refrigerant

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
(cont’d.)
• 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 (cont’d.)
• Fixed-Bore Metering Devices—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
instruction
 Charging Procedures in the
Field (cont’d.)
• Field Charging the TXV System
– Reduce the airflow across the condenser
to simulate a 95°F outside air
temperature
– The superheat check will not work for TXV
– A subcooling check of the condenser can
be used to check the system charge
Charging Procedures in the
Field (cont’d.)
– Typical subcooling circuit will subcool the
liquid refrigerant from 10° to 20° cooler
than the condensing temperature
– Excessive subcooling indicates an
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
– If suction gas cooled, is the charge low?
– Is the start-assist circuit not working?
• Allow the compressor to cool before
restarting it
 Compressor Electrical
Checkup
• Technicians need to be careful when
condemning a compressor
– Many condemned compressors are not bad
– Unnecessary labor and material costs
• Compressor problems can be
mechanical or electrical
 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
 Summary
• Troubleshooting air-conditioning
equipment involves both the mechanical
and electrical systems
• Mechanical problems may appear to be
electrical and vice versa
• Gauges and temperature-testing
equipment are used when performing
mechanical troubleshooting
 Summary (cont’d.)
• Gauge manifolds are used whenever
the pressures need to be known for the
system
• Gauges are used to calculate superheat
and subcooling
• Gauge manifolds should not be
connected every time a system is
serviced
 Summary (cont’d.)
• Standard-efficiency systems usually
have a refrigerant boiling temperature of
about 35°F cooler than the entering air
temperature
• Standard efficiency air-cooled
condensers condense the refrigerant at
no more than 30°F higher than the
ambient temperature
 Summary (cont’d.)
• Temperature readings are needed to
calculate evaporator superheat and
condenser subcooling
• The amount of refrigerant in the evaporator
can be measured by superheat
• The amount of refrigerant in the condenser
can be measured by subcooling
 Summary (cont’d.)
• Typical subcooling circuit will subcool
the liquid refrigerant from 10° to 20°
cooler than the condensing temperature
• Begin any electrical troubleshooting by
verifying that the power supply is
energized and that the voltage is correct
 Summary (cont’d.)
• Use an ohmmeter to check compressor
windings for grounds, shorts and open
circuits
• Compressor voltage readings should be
within 10% of the rated voltage
• If the supply voltage to the compressor
is correct, the compressor should start