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Tech Guide
Tech Guide
Technical
Help Guide
Thermal Expansion Valves
Solenoid Valves
System Protectors
Regulators
Basic Rules of Good Practice
Troubleshooting Guide
2006
Table of Contents
Thermal Expansion Valves . . . . . . . . . . . . . . 1
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . 30
System Protectors . . . . . . . . . . . . . . . . . . . . 42
Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Basic Rules of Good Practice . . . . . . . . . . . 56
Troubleshooting Guide . . . . . . . . . . . . . . . . 59
Thermal Expansion
Valves
2006
The amount of refrigerant gas leaving the evaporator can be regulated since the TXV responds to: (1)
the temperature of the refrigerant gas leaving the
evaporator and (2) the pressure in the evaporator.
Internal Equalizer
gas leaving the evaporator decreases, the pressure in the
remote bulb and power assembly also decreases and the
combined evaporator and spring pressure cause the valve
pin to move in a closing direction (P1 less than P2+P3).
For example, when the evaporator is operating with
134a at a temperature of 40F or a pressure of 35 psig
and the refrigerant gas leaving the evaporator at the
remote bulb location is 45F a condition of 10F superheat exists. Since the remote bulb and power assembly
are charged with the same refrigerant as that used in the
system R-134a, its pressure (P1) will follow its saturation
pressure-temperature characteristics. With the liquid in
the remote bulb at 45F, the pressure inside the remote
bulb and power assembly will be 40 psig acting in an
opening direction. Beneath the diaphragm and acting in a
closing direction are the evaporator pressure (P2) of 35
psig and the spring pressure (P3) for a 10F superheat
setting of 5 psig (35+5=40) making a total of 40 psig. The
valve is balanced, 40 psig above the diaphragm and 40
psig below the diagraph.
It also is obvious then that a minimum change of superheat to open the valve is of vital importance because it
provides saving in both initial evaporator cost and cost of
operation.
External Equalizer
psi is present (See fig. 3). The pressure at point C is 27
psig or 10 psi lower than at the valve outlet, point A,
however, the pressure of 37 psig at point A is the
pressure acting on the lower side of the diaphragm in a
closing direction. With the valve spring set at a compression equivalent to 10F superheat or a pressure of 9.7
psig, the required pressure above the diaphragm to
equalize the forces is (37 + 9.7) or 46.7 psig. This
pressure corresponds to a saturation temperature of 50F.
It is evident that the refrigerant temperature at point C
must be 50F if the valve is to be in equilibrium. Since the
pressure at this point is only 27 psig and the corresponding saturation temperature is 28F, a superheat of 50F
minus 28F or 22F is required to open the valve. This
increase in superheat, from 10F to 22F makes it
necessary to use more of the evaporator surface to
produce this higher superheated refrigerant gas. Therefore, the amount of evaporator surface available for
absorption of latent heat of vaporization of the refrigerants
is reduced, the evaporator is starved before the required
superheat is reached.
When in the same conditions of pressure drop exist in a system with a TXV,
which has the external equalizer feature (see fig. 4), the same pressure drop still
exists through the evaporator, however, the pressure under the diaphragm is now
the same as the pressure at the end of the evaporator, point C, or 27psig.
The required pressure above the diaphragm for equilibrium is 27 + 9.7 or 36.7
psig. This pressure, 36.7 psig, corresponds to a saturation temperature of 40F
and the superheat required is now (40F minus 28F) 12F.
The use of an external equalizer has reduced the superheat from 22F to 12F1
Thus the capacity of a system, having an evaporator with a sizable pressure
drop, will be increased by the use of a TXV with the external equalizer as
compared to the use of an internally equalized valve.
When the pressure drop through an evaporator is in excess of limits previously defined, or when a refrigerant distributor is used at the evaporator inlet,
the TXV must have the external equalizer feature for best performance.
The diagram used in this Section thus far has shown the single outlet type of
TXV. Although a multi-circuit evaporator in itself may not have an excessive
pressure drop, the device used to obtain liquid distribution will introduce a
pressure drop that will limit the action of the TXV without external equalizer,
because the distributor is installed between the valve outlet and the evaporator inlet (See fig. 5).
Do not under any circumstance cap or plug the external equalizer connection on a TXV, as it will not operate. If the TXV is furnished with an external
equalizer feature, the external equalizer line must be connected.
Superheat
A vapor is said to be superheated whenever its temperature is
higher than the saturation temperature corresponding to its pressure. The amount of the superheat equals the amount of the
temperature increase above the saturation temperature at the
existing pressure. For example, a refrigeration evaporator is
operating with Refrigerant 134a at 35 psig suction pressure (See
fig. 6). The Refrigerant 134a saturation temperature at 35 psig is
40F. As long as any liquid exist at this pressure, the refrigerant
temperature will remain 40F as it evaporates or boils off in the
evaporator.
As the refrigerant moves along in the coil, the liquid boils off into a
vapor, causing the amount of liquid present to decrease. All of the
liquids are finally evaporated at point B because it has absorbed
sufficient heat from the surrounding atmosphere to change the
refrigerant liquid to a vapor. The refrigerant gas continues along the
coil and remains at the same pressure (35 psig); however, its
temperature increases due to continued absorption of heat from
the surrounding atmosphere. When the refrigerant gas reaches
the end of the evaporator, (See point C) its temperature is 50F.
This refrigerant gas is now superheated and the amount of superheat is 10F. (50F minus 10F).
Adjustment of Superheat
superheat, the recommended practice is to install a
calibrated pressure gauge in a gauge connection at
the evaporator outlet. In the absence of a gauge
connection, a tee installed in the TXV external
equalizer line can be used just as effectively.
A refrigeration type pocket thermometer with appropriate bulb clamp may be used or more effective is
the use of a service type potentiometer (electric
thermometer) with thermocouples (leads &
probes).
Application
In general, for best evaporator performance, the TXV should be
applied as close to the evaporator as possible and in such location
as to make it easily accessible for adjustment and servicing. On
pressure drop and centrifugal type distributors, apply the valves as
close to the distributor as possible. (See fig.7)
The T Series valves [with the exception of the W-(MOP), G(MOP) or GS-(MOP) gas charged types] may be installed in any
location in the system. The gas charged type must always be
installed in such a manner that the power assembly will be
warmer than the remote bulb. The remote bulb tubing must not be
allowed to touch a surface colder than the remote bulb location. If
the power assembly or remote bulb tubing becomes colder than
remote bulb, the vapor charge will condense at the coldest point
and remote bulb will lose control.
When it becomes desirable to increase the sensitivity of the remote bulb, it may be necessary to use
a remote bulb well. This is a particularly true for
short coupled installations and installations with
large suction lines (2 1/8 OD or larger). Remote
bulb wells should be used (1) when very low
superheats are desired and (2) where converted
heat from warm room can influence the remote
bulb. (See fig. 9).
Hunting
Hunting of TXVs can be defined as the alternate overfeeding and starving of the refrigerant flow to the evaporator.
It is recognized by extreme cyclic changes in both, the
superheat or the refrigerant gas leaving the evaporator and
the evaporator or suction pressure.
Hunting is a function of the evaporator design, length and
diameter of tubing in each circuit, load per circuit, refrigerant
velocity in each circuit, temperature difference (TD) under
which the evaporator is operated, arrangements of suction
piping and application of the Thermal Expansion Valve
remote bulb. Hunting can be minimized or eliminated by
the correct rearrangement of the suction piping, relocation of
the bulb and use of the recommended remote bulb and
power assembly charge for the TXV.
10
the seat. When the valve again opens, the same type of
action occurs and the pin bounces off the seat with a
rapid frequency. This type of phenomenon is more
frequently encountered with the larger single ported TXVs
as the force due to the pressure differential is magnified
by the larger port area.
We have seen that a TXV may Hunt due the lack of
anticipating and compensating features and an unbalance
in the equilibrium forces at lower end of its stroke.
We know from some experience that a TXV, when
intelligently selected and applied, will overcome these
factors and operate with virtual no Hunt over a fairly wide
load range.
Single ported TXVs will generally operate satisfactory to
somewhat below 50% of nominal capacity but its again
dependant on evaporator design, refrigerant piping, size
and length of evaporator, and rapid changes in loading.
Nothing will cause a TXV to hunt quicker than unequal
feeding of the parallel circuits by a distributor or unequal
air loading across the evaporator circuits.
11
TXV Charges
Over the years or more precisely, since Emerson
Climate Technologies produced the first valve for
ammonia in 1925, the matter of a proper power
charge in the thermal sensing element has been a
major concern. Liquid charges, gas charges, cross
liquid charges, cross vapor charges, high temperature charges, ultra-low temperature charges,
commercial charges, etc. all have been tried with
The C Charge
the refrigeration unit pulled down in temperature
resulting in the necessity to make readjustment
at times.
The cross charges (C & Z) usually would create
conditions of high superheat upon start up and
reduce the superheat as the unit pulled down
thus again the need to adjust as the unit got
colder. Between the operating conditions of
20F to +50F the straight C charge rarely if ever
needs to be re-set after a satisfactory superheat
has been established. In fact, the straight C
charge as received from the factory will not have
to be re-set at all in the majority of cases.
M.O.P.
Once below the MOP, the TXV will re-open and feed
in a standard manner or until such time as there is
an overload again.
12
Solder Bodies
Direction of Flow
13
Servicing
To inspect, clean, or replace parts on all take-apart types
remove the two cap screws, lift off the power assembly, and
remove cage assembly. Be sure gaskets are replaced in
proper places when reassembling valve (See Figure 12).
When assembling External Adjustment valves (TCL,
TJL, TER, TIR or THR) be sure the two lugs on the cage
assembly fit into the grooves provided for them in the power
assembly (See ,Figure 13). Dont force valve together. Make
the cage fit properly before tightening body flange. See
EMERSONs Service Hints for detailed procedure recommended for trouble shooting a refrigeration or air conditioning
system.
14
Fig. 15
Yellow
Green
Orchid
Light Blue
Rose
Orange
15
Bath
Temperature
Code
Letter
+32F
+10F
0F
-10F
-20F
A
B
C
D
E
TXVREPLACEMENTCHARGESYMBOLSCROSSREFERENCE
OLD BULB CHARGES VS. NEW REPLACEMENT BULB CHARGE
AIR CONDITIONING
OLD CHARGE
REPLACEMENT
FW
FG55
FW55
FQ55
FGA
FLA
FGS
FWS
FC
FWS
HC
HW
HG100
HW100
HQ100
HGA
HLA
HW85
HGS
HWS
HCA
HC
HW85
HWS
COMMERCIAL REFRIGERATION
OLD CHARGE
REPLACEMENT
REFRIGERANTR12/R134a
F OR FL
FC
FC
FW
FG35
FW35
FW35
FQ35
FGS35
FGS35
FWS
FWS
REFRIGERANT R22
H OR HL
HC
HW
HG65
HW65
HQ65
HC
HW65
HGS65
HGS65
HWS
HWS
REFRIGERANTR502/R404A/R507
RL
RC/SC/PC
RW
RW65
RW65
RWS
RWS
LOWTEMPERATURE
OLD CHARGE
REPLACEMENT
FWZ
FW15
FW15
FZ
FW15/MW15
FWS
FZ/MZ
FX
FWS
FZ/MZ
FX
HWZ
HW35
HQ35
HZ
HW35
HWS
HZ
HX
HWS
HZ
HX
RWZ
RZ
RW35
RW45/SW45
RWS
RWS
RWS
RZ
RZ/SZ/PZ
NOTE
NOTE: ALL OTHER CHARGE SYMBOLS MUST BE REPLACED WITH AN IDENTICAL MODEL OR AT THE OPTION OF THE ALCO TECHNICAL SERVICE DEPARTMENT WHO MAY MAKE ENGINEERING AUTHORIZED
SUBSTITUTION OF EQUIVALENT TYPE TO PROVIDE EQUIVALENT OPERATION AND PERFORMANCE.
NOTE
NOTE: FOR FIELD REPLACEMENT PURPOSES, HC CAN BE USED TO REPLACE HCA
HCA.
RW
RW110
RWS
RC/SC/PC
16
Figure 1 explains how it works. At A, hot, highpressure liquid refrigerant enters the TXV. At B,
cold, low-pressure liquid, plus flash gas, enters the
evaporator. At C, the entire liquid refrigerant has
been boiled off, or vaporized by the heat load (latent
heat). Between C and D, the vapor temperature
increases dramatically as further heat load is
applied (sensible heat). At this point, the gas is
superheated above its saturation temperature. At D,
suction line temperature of the superheated gas is
monitored by the sensing bulb, which signals the
TXV to open or close accordingly.
17
If the test indicates that a valve adjustment is required, remove the seal cap covering the adjusting stem.
Rotate the stem clockwise to decrease refrigerant flow through the valve and increase superheat; counter
clockwise increases flow and decreases superheat.
18
19
Emersons TXV
Here, the power element contains the same refrigerant as the system in which the valve is used. In
manufacturing, it is put into the remote bulb in a
liquid state. Volume is controlled so that within the
design temperature range of the power element,
some liquid always remains in the bulb.
So power element pressure is always
the saturation pressure corresponding to
the temperature of the remote bulb.
Liquid charges have both advantages
and disadvantages. They include: not
subject to cross-ambient control loss;
little or no superheat at start-up; superheat increases at lower evaporator
temperatures, and slow suction pressure
pull down after start-up.
Any MOP point temperature depends on how that bulb was initially charged and where it will be used. All
gas charges are susceptible to cross-ambient control loss when the power element is colder than the
remote bulb. They are inherently faster to respond, but tend to hunt for the proper operating level, so a
ballast is often added to the remote bulb to minimize that tendency.
As in liquid charges, the remote bulb can be filled with the same refrigerant as the system refrigerant. Or,
it can be filled with a different refrigerant, producing a gas cross-charge.
20
Adsorption Charges
The final type of charge is adsorption.
In adsorption, solids hold large quantities of gas, not by
taking them into the body of the solid, as in absorption,
but by gathering them and holding them on the surface
of the solid without chemical reaction.
The vapor penetrates into the cracks and furrows of the
solid, allowing considerably greater capacity than
possible with absorption.
21
22
23
There are additional possibilities, but these are the most common.
25
26
Heres An Example
In Figure 2, we selected a nominal 2-ton Emerson TCL (E)
2FC TXV operating at +20F. evaporator pressure, with a 175lb. Pressure drop - giving a capacity of 3.4 tons. Operating at
liquid temperature of 110F, the 3.4-ton capacity becomes 3.2
tons when multiplied by the .94 correction factor. In this case,
a nominally-rated 2-ton valve has plenty of capacity for a 3-ton
system. In the same situation, a nominally-rated 3-ton valve
would actually be too big, delivering 4.7 tons and possibly
flooding the evaporator.
Fig 2. Typical Extended Capacity Chart TCL(E) 2FC shown in the shaded bar
10
1.54
1.63
1.51
1.90
20
1.48
1.56
1.45
1.80
30
1.42
1.49
1.40
1.70
40
1.36
1.42
1.34
1.60
50
1.30
1.36
1.29
1.50
60
1.24
1.29
1.23
1.40
70
1.18
1.21
1.17
1.30
80
1.12
1.14
1.12
1.20
90
1.06
1.07
1.06
1.10
27
100
1.00
1.00
1.00
1.00
Cancelled Forces
28
Emersons HF Line
At that time, see your Emerson Wholesaler about the Emerson
HF line of balanced port valves. He can give you full specs and fit
your needs perfectly with Emerson quality.
HF Series Features
Capacities 1/8 thru 13 tons for R-404A/R502
Bar-stock brass body
Replaceable power assembly
Internal/external equalizer
Field-proven internal seal construction
Tailored bulb charges for specific temperature ranges
Interchangeable with other commercial refrigeration TXVs
Advantages/Benefits
HF-series TXVs improve valve operation and stability
under varying system conditions such as: high and low
head pressures; high and low degrees of sub-cooling;
wide range of pressure drops across the valve; and
varying evaporator loads.
Wider load range characteristics of HF valves can result
in fewer models required to cover the normal range of
commercial refrigeration requirements.
Larger H-size removable power element provides
smoother and consistent valve control.
Replaceable power element offers flexibility in matching
charge requirements with system refrigerant.
29
Solenoid Valves
30
2006
Solenoid Valves
Introduction
In most refrigeration applications, it is necessary to start or stop the flow in a refrigerant
circuit in order to automatically control the flow of fluids in the system. An electrically
operated solenoid valve is usually used for this purpose. Its basic function is the same as a
manually operated shut off valve, but by being solenoid actuated, it can be positioned in
remote locations and may be conveniently controlled by simple electrical switches.
Solenoid valves can be operated by a thermostatic switch, float switches, low pressure
switches, high pressure switches or any other device for making or breaking an electric
circuit, with the thermostatic switch being the most common device used in refrigeration
systems.
Solenoid Anatomy
31
Solenoid Valves
32
Solenoid Valves
33
Solenoid Valves
Installation
Solenoid Valves having a spring loaded plunger or
diaphragm may be installed and operated in any
position, however, the older style conventional
solenoid valve with a plunger, which depends on
gravity to close, must always be installed with the
plunger in an upright vertical position with the pipe
horizontal. An adequate strainer or filter drier should
be installed ahead of each solenoid valve to keep
scale, pipe dope, solder, and other foreign matter
out of the valve.
When installing a solenoid valve, be sure the arrow
Application Overview
Application
Product Family
50RB
100RB
200RB/500RB
240RA/540RA
50RB
100RB
200RB/500RB
240RA/540RA
34
710RA
713RA
Solenoid Valves
Cause
Effect
2- Improper wiring.
5- Oversized Valve
5- Install correct size valve see solenoid catalog and extended capacity
table.
35
Solenoid Valves
Cause
Effect
7- Coil Burnout
a) Locate cause of low voltage and
correct (check transformer, wire
size, and control rating).
Improper wiring:
f)
Inrush voltage drop causing the
plunger to fail to pull into magnetic
field due to:
Wiring the valve to the load side
of motor starter.
Wiring the valve in parallel with
another appliance with high
inrush current draw.
Poor connections, especially on
low voltage, where connec
tions should be soldered.
Wire size of electrical supply too
small.
36
Solenoid Valves
Valve Closes,
But Flow Continues
(Seat Leakage)
Cause
Effect
37
Solenoid Valves
Cause
Effect
External leakage
(high temperature steam up to 400)
External leakage
(high temperature steam up to 250 or
water up to 210)
38
Solenoid Valves
Basics of Solenoids
The solenoids main function is to start or stop the
refrigerant flow in the circuit automatically controlling the fluid flow to match requirements. When and
how they act depends on the type of valve, capacity, the fluid charge and the valves characteristics.
Simply stated, the solenoid valve consists of two
parts: an electrical solenoid coil and a valve. When
electricity passes through the windings of the
solenoid, magnetism draws the valve plunger into
the middle of the coil opening an orifice in the valve
body and allowing fluid movement.
When the current stops, the plunger returns to its
normal position, closing the orifice.
Pilot-Operated Valves
Direct-Acting Valves
In this type valve, the plunger is mechanically
connected to the needle valve and directly raises
the needle from its seat when the coil is energized.
It will operate from zero pressure differential to
maximum rated pressure differential regardless of
line pressure.
39
Solenoid Valves
1. Fluid to be controlled. Each valve is rated by its manufacturer for a specific refrigerant
fluid. Dont overlook that rating.
When the wrong valve-fluid combination occurs, the valves capacity changes. Over-sized
pilot-operated valves refuse to open; undersized valves cause excessive line drops.
In addition, different types of materials are used in valve seats depending on the service.
Special seat materials used for high temperatures may deteriorate rapidly in the wrong
fluid.
2. Capacity vs. MOPD. Some servicemen select for line size rather than system capacity.
For safetys sake they pick the next size larger than needed. With too large or too small a
differential, the valve just wont work as it should, if it works at all. MOPD takes into consideration both the inlet and outlet valve pressures. If a valve has 500psi inlet and 250psi outlet
pressure, and an MOPD of 300psi, it will operate because the difference (500-250) is less
than the 300 MOPD rating. If it is greater than the MOPD, the valve wont open.
3. Electrical ratings. Both voltage and Hertz ratings of the coil must match the system
ratings. Yet some servicemen neglect these considerations - as they do the type of current
involved. DC-rated valves frequently have different internal construction than do AC-rated
valves.
4. Maximum working pressures (MWP). A solenoid valve must never be used for an
application when the pressure is higher than the maximum working pressure.
40
Solenoid Valves
41
System Protectors
42
2006
System Protectors
Types of Filter-Driers
Commonly, there are two types of filter-driers; each
type has multitudes of versions, but they operate
essentially the same.
43
System Protectors
Most manufacturers rate their filters to ARI Standard 710. But even though
two clean filter-driers may be rated the same, there can be a vast difference
in flow as the quantity of solids picked UP increases.
Moisture Capacities
44
System Protectors
Such protection is generally encouraged by compressor manufacturers in any case, but there are
two sets of circumstances that make suction line
filters or filter-driers particularly advisable
45
System Protectors
Compressor Burnout
A compressor burnout can be expected to release
a variety of pollutants into the system, including
acids. Standard procedures following any compressor burnout should include replacing the liquid line
filter-drier with an over-size unit, in addition to
installing a new suction line filter-drier. Then all
control components and strainers should be thoroughly cleaned and the system triple evacuated to
at least 50 microns before recharging.
When a severe burnout occurs, characterized by
discoloration of the oil, a strong acid odor, and the
A Look Inside
Internally, suction line filter-driers
employ the same types of elements
as liquid line units. One is the core
type, in which the filter-drier element
consists of a rigid, cylindrical, porous
block that may perform both the filter
and drier functions, or be used in
combination with a separate accordion-type filter element.
The core type filter-drier is available
either in a hermetically sealed configuration or in take-apart designs with a
replaceable element.
46
System Protectors
Removing Contaminants
Just like any other refrigeration system, heat
pump system components should have the
benefit of filter-drier protection to remove
solid and soluble contaminants. This may be
handled several ways.
47
System Protectors
48
Regulators
49
2006
Regulators
How it Works
50
Regulators
A Few Cautions
In systems that utilize a Venturi type distributor, the bypass gas should be fed into the
system between the outlet of the expansion valve and the inlet to the distributor. In
the case of pressure drop distributors that utilize an orifice, the inlet must be between the orifice and the inlet to the distributor.
The hot gas bypass line should be insulated to minimize system heat loss.
In systems with sequential compressor unloading, the valve should be set to begin
opening at two to three pounds below the last stage of unloading, because compressor unloading is considerably more efficient and should be utilized before resorting to
bypassing.
For oil return considerations. The bypass line must feed in ahead of the evaporator
when the evaporator is physically located below the compressor.
The hot gas bypass valve should be located as close as practical to the condensing
unit, to minimize condensing ahead of it.
In systems that operate on a pump down cycle, there must be a solenoid valve or
some other means of shutoff in the bypass line.
51
Regulators
52
Regulators
Crankcase Regulators
Normally open, the CPR (Fig. 4),
closes when compressor pressure
rises above the pre-set maximum,
forcing the valve back onto its seat.
As suction pressure drops, the valve
begins reopening, maintaining the
balance.
53
Regulators
Controlling the volume of airflow through the condenser coils can be done by cycling cooling fans on
and off, or by a damper system that proportions
airflow passing through, or through bypassing the
condenser. Controlling the flow of refrigerant
through the condenser is by valving, and, because
this offers some distinct advantages over controlling the air- flow, we will concentrate here on valvetype head pressure controls.
Among its major advantages, a head pressure
control valve is capable of precision in maintaining
optimum pressure, typically within a 5-10 psi range,
while airflow control systems might vary as much
as 50psi. In addition, airflow control systems are
effective only down to a certain temperature, while
the refrigerant valving system continues to maintain
head pressure at much lower ambients. Finally, a
valve system is simpler to install and maintain.
54
Regulators
How it Works
Inside of a typical head pressure control is a valve which, when
closed, routes the refrigerant through the condenser to the
receiver, and when open, allows refrigerant gas to by-pass the
condenser. The valve is operated by a pressure charge in the
head of the valve acting on a diaphragm.
When ambient is warm enough, normal head pressure on the
opposite side of the diaphragm counteracts the pressure
charge, keeping the valve closed and routing the refrigerant
through the condenser. As the ambient temperature falls, the
pressure charge overcomes the resulting lower head pressure,
opening the valve and allowing bypass gas to enter the receiver.
This creates back pressure at the condenser outlet, causing a
buildup of condensed liquid in the condenser, popularly referred
to as flooding the condenser, which effectively reduces its
working surface and its cooling capacity.
55
Basic Rules of
Good Practice
56
2006
DOs
57
DONT be a parts-changer.
DONTs
Analyze problems based on the symptoms, and determine the specific cause
before making any changes or repairs. Emersons Troubleshooting Expansion
Valves, Parts I and II, describe a wide variety of problems that may be encountered, and their probable causes.
DONT think of a thermal expansion valve as a temperature or pressure
control.
Thinking of it as a superheat control is basic to achieving optimum system
performance.
DONT attempt to use any control for any application other than the one it
was designed for.
Using a pressure regulator for a pressure relief valve-or any similar substitution - is
not good practice and almost certainly wont deliver proper performance. Misapplications can lead to equipment damage and even injury. When doubt exists, check
with the manufacturer.
DONT energize a solenoid coil while it is removed from the valve.
Without the magnetic effect of the solenoid core, the coil will burn out in a matter
of minutes.
DONT install a previously used filter-drier or replaceable cartridge.
It could introduce contaminants that it has picked up since its removal from a
system
DONT select solenoid valves by line size or port size, but by valve capacity.
They must also be compatible with the intended application with regard to the
specific refrigerant used, the maximum opening pressure differential (MOPD), the
maximum working pressure (MWP), and the electrical characteristics. Never apply
a valve outside of its design limits or for uses not specifically catalogued.
DONT rely on sight or touch for temperature measurements.
Use an accurate thermometer. Once again, you cant get accurate diagnoses with
faulty inputs.
58
Troubleshooting
Guide
59
2006
Symptoms
1) Liquid Slugging
Valve Feeds
2) Low Superheat
Too Much
3) Suction Pressure Normal or High
Causes
Corrective Action
Oversized Valve
Moisture
Valve
Doesn't
Feed or
Doesn't
Feed
Enough
Symptoms
Causes
Corrective Action
Short of Refrigerant
High Superheat
Moisture
Wax
Replace valve
Symptoms
Causes
Corrective Action
Refrigerant Drainage
Remove restriction
Symptoms
1) Suction Pressure Hunts
2) Superheat Hunts
3) Erratic Valve Feeding
Causes
Corrective Action
Reposition Bulb
System Design
Redesign system
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Symptoms
Causes
Corrective Action
Correct piping
Low Load
Mismatched Coil/Compressor
Correct match
Incorrect Distributor
Evaporator Oil-Logged
Causes
Corrective Action
Improper wiring
Oversized Valve
Coil Burnout
a) Supply voltage at coil too low (below 85% of
rated coil voltage)
b) Supply voltage at valve too high (more than
10% above coil voltage rating)
c) Valve located at high ambient
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Problem
Causes
Corrective Action
Problem
Causes
Corrective Action
Causes
Corrective Action
Causes
Doesn't Flow
Corrective Action
Turn Stem
Leak at Stem
Replace Valve
20F
0F
-20F
-40F
R12, R134a
2.0
1.5
1.0
0.5
R22, R410A
3.0
2.0
1.5
1.0
0.5
R502, R404A/507
3.0
2.0
1.5
1.0
0.5
Causes
Bleed Hole in U-Tube Plugged
Corrective Action
Replace Accumulator; Install Filter Ahead of
Accumulator
Replace Accumulator
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Causes
Corrective Action
Replace Receiver
Causes
OMB out of calibration
Replace OMB
Problem
Problem
Causes
Corrective Action
Replace filter
Replace coil
Corrective Action
Flood back through suction; Increase superheat
on expansion valve; Refrigerant condensing in oil
separator - add heater to oil separator and/or
adjust system setting to eliminate flood back
Problem
Corrective Action
Causes
Corrective Action
Replace OMB
Causes
Oil outlet valve closed or partially closed
Corrective Action
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TROUBLESHOOTING REGULATORS
Problem
Causes
Pilot inlet filter screen obstructed
Corrective Action
Clean or replace.
Excessive Pressure Drop Across the Regulator Pilot or solenoid leaking internally
Regulator undersized
Piston bleed port obstructed
Clean or replace.
Pilot inlet filter screen obstructed
Regulator Hunting-side Fluctuations in Controlled
Pressure
Regulator oversized
Clean or replace.
Clean or replace.
Causes
Corrective Action
Valve undersized
Oversized valve
Bad pilot
Replace pilot
Causes
Corrective Action
With system running, open the valve adjustment
to open the valve and flush away the contaminant.
If this fails, replace valve.
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Problem
Causes
Corrective Action
Replace valve
Causes
Corrective Action
Change valve
Fan cycling
Check solenoid
3/8"
40
1/2"
-20
-40
5/8"
40
-20
-40
40
-20
-40
R134a
.051
.054
.055
.057
.095
.099
.102
.105
.150
.157
.164
.167
R22
.051
.054
.055
.056
.094
.099
.102
.104
.150
.159
.163
.167
R404A/R507
.053
.056
.058
.059
.098
.104
.107
.109
.157
.166
.171
.175
* Return bends: 3/8 O.D. - 20 ft; 1/2 O.D. - 25 ft.; 5/8 O.D. - 30 ft.
** Wall thickness: 3/8 O.D. - .016; 1/2 O.D. - .017; 5/8 O.D. - .018
65