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COMPRESSORS &

S1<25·01 COPYRIGHT © CARRIER CORPORATION 1992 020·113

 INTRODUCTION compressor problems simply by using your natural
senses of sight, sound, touch and smell. You
might think of it as a quick check on what the
system is doing.

The second section describes what "Normal"

'l""\~
~ operating pressures and temperatures are for a
system. Think of these operating characteristics or
"conditions" as what the system should be doing.
These will be used as a benchmark for comparison
to the actual operating conditions of a system,
which will help detelllline if there's a problem.

The final section shows how abnormal pressures

1. These Carlyle compressors are among the most and temperatures are used to pinpoint the most
rugged compressors ever made. But, on air likely problems with a system or compressor.
conditioning or refrigeration duty, they don't stand
alone; they operate as part of a complete system. The three sections combined will show exactly
how the compressor is interacting and performing
A faulty system can damage or destroy even the with the system.
most rugged compressor. In fact, it's fair to say
that the system affects the compressor even more
than the compressor affects the system. PRELIMINARY INSPECTION
Conversely, a mechanical problem with the
compressor almost always causes the system to
malfunction.

This training program describes the interaction

between system and compressor; an interaction
you need to understand in order to provide longer
life and better operation for the compressors and
systems you service.

PROGRAM CONTENT
3. Before starting our preliminary inspection, let's
1. MAKING PRELIMINARY INSPECTION - talk about the most important part of your
USE YOUR NATURAL SENSES
job..... Safety.
2. UNDERSTANDING "NORMAL"
OPERATION Working on air conditioning, refrigeration or
heating systems means working on components
3. ANALYZING SYSTEM OPERATION that are pressurized, rotating, and either thellnally
or electrically hol So, be careful.

Before performing mechanical service, shut off all

2. The first part of this three-section program the power, then open, lock and tag all disconnects.
describes how to easily identify possible system or Use extreme caution when electrically trouble-

1
shooting live components. Utilize all safety
procedures shown in the printed instructions.
Don't take chances.
4. When starting the preliminary inspection,
always check the possibility that the owner or
operator of the equipment can supply infolIllation
on how the equipment is running.
The people in close contact with operating
machinery many times can describe an event or a
condition which will aid the technician in
troubleshooting.
5. Also, the Operating Log or Maintenance
records will often offer clues as to how the
equipment is operating. This can be very
important to a service technician.
2
The purpose of the Operating Log is of course to
maintain a running record of operation, main-
tenance, and service of the system. Items like the
addition of refrigerant or oil, replacement of parts,
and a check of operating data will assist the
technician in analyzing a system problem.
6. Now, let's review some initial inspection
techniques. To begin with, let's say that the
system is off.
To be sure it stays off during inspection, throw the
circuit breakers or pull the fuses at the main
electric panel and remember to lock and tag the
switches so that no one can start the equipment
while you're making the preliminary inspection.
BE SURE ALL ELECTRICAL POWER TO
THE EQUIPMENT IS DISCONNECTED.
7. Now, take a look around for the obvious. Is
there an evaporator or condenser above the
compressor which might dump liquid refrigerant
into the compressor?
9. Are there numerous system accessories such as
oil separators, liquid line solenoids, driers, sight-
glasses or accumulators? All of these serve a
purpose, and if there is a decided need for acces-
sories, they should be installed. Keep in mind,
however, that they increase system pressure drop
and can affect system operation by reducing
refrigerant flow, oil return, and capacity. So, if not
installed and operating conectly, they can cause
system problems and even a compressor failure.

Are there oil stains or other evidence of refrigerant

leaking at any joints, fittings, or piping
connections? Is the piping well designed?

8. Look for unsupported piping which might

vibrate and cause damage to the piping or noise
transmission through the building. Does the
system have a long or uninsulated suction line
which might develop excessive superheat? Are
any lines buried, which might cause refrigerant to
condense and cause slugging? Is there an
extremely long liquid line which might hold an
excessive amount of refrigerant? Excess
refrigerant is trouble. If extra refrigerant is
necessary, an accumulator should be used. 10. This diagram of a typical built-up system
provides some examples of a well-designed piping
Does the liquid line run through an unconditioned configuration.
(hot or cold) space which might affect sub-
cooling?

3
The compressor discharges into a muffler, at I,
which breaks up the gas pulses to protect the
piping and reduce operating sound.
A trap in the discharge line, at 2, helps prevent the
flow of liquid refrigerant back into the compressor
heads during shutdown. The check valve beyond
the trap, at 3, serves the same purpose.
11. Clamps at the ceiling support the discharge
line. The discharge line, however, is not rigidly
mounted. It has a chance to "flex," but it is sup-
ported by the clamps below and above the ceiling.
The liquid line is also supported by pipe clamps.
12. On some systems a liquid line solenoid valve
closes or "drops" on shutdown to prevent the wauu
high pressure liquid refrigerant from flowing, or
migrating, through the evaporator to the
compressor.
4
13. The suction line also has an inverted trap
which prevents liquid refrigerant from draining
back into the compressor at shutdown. The
suction line is clamped to the ceiling, but has
sufficient flexibility to allow for slight motion.
The refrigerant lines are relatively short in length,
are properly supported and insulated and are not
buried or run through rooms with excessively high
or low temperatures. Now that we've seen the
piping, let's continue our preliminary inspection by
looking closer at the system components.
PRELIMINARY INSPECTION
Check the Condition of:
• Fin Collars & Coils
• Supply Plenum
• Filters
• Fans, Belts, Motors
• Air Flow
14. Are the fm collars on the tubes of the
condenser and evaporator corroded from galvanic
action? Are the fins or coils dirty or damaged? Is
the supply plenum dirty? Are the fllters dirty or
missing? Are the fan belts at the proper tension?
Are the blowers and fans dirty? Are they rotating
in the right direction? Check their rotation when
you start the system. Does the evaporator show
 signs of freezing up, caused perhaps by insufficient UNDERSTANDING
air flow to the evaporator or is it being used for "NORMAL" OPERATION
low temperature work where some icing is
nOllual?
SYSTEM OPERATION

_ Handling the Load?

_ Condenser Rejecting Heat?
_ Evaporator Air Delivery
Sufficient?

17. Once we've completed this preliminary check,

15. And what about the compressor? Are the
service valves fully open? Do the installation
instructions say that the hold-down bolts should be
loosened? Is the crankcase heater working? Are
the cylinder heads scorched or blistered from
excessive heat? Do the compressors show rust
streaks indicating condensation from cold return
gas? This could indicate that the suction vapor is
returning too cold, with less than normal
superheat.
the next step will be to find out how the system is
operating. Does it appear to be handling the load?
Is the condenser rejecting heat? Is the air delivery
sufficient?
Remember, things happening in a problem system
can weaken or destroy a compressor, and a faulty
compressor is going to cause the system to
malfunction.
Before continuing with our diagnosis, let's review
some key points.
• ALWAYS WORK SAFELY
• USE YOUR NATURAL SENSES TO
CHECK THE SYSTEM
• LOOK FOR THE OBVIOUS PROBLEMS

16. Is the oil level at the proper height in the

sightglass? Giving the system a good once-over is
often all the troubleshooting you need to locate the
problem.

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18. In order to recognize when the system or
compressor has a problem, you must fITSt know
what the operating conditions should be when the
system and compressor are functioning normally.
Then, by comparing these values to actual system
and compressor operating conditions, you can
detelluine if there is a problem and where it is.
19. So just like a doctor, in order to make a
reasonable diagnosis of the system and the
compressor's state of health, we have to measure
vital signs by observing fluid levels, reading
pressures, and taking temperatures. To do this
we're going to need pressure gauges and electronic
temperature measuring devices. We're also going
6
to need a multimeter and an ammeter to measure
the voltage at the compressor and to measure the
current which the compressor is drawing. All will
be used to provide a more complete system
analysis.
To start with, let's say we have an R-22 air con-
ditioning system with an 06E compressor and an
air cooled condenser. The outdoor ambient air
temperature is 90°F.
20. Before we turn this system on, we'll follow
safe practice and connect the measuring devices
needed to measure actual operating conditions.
These gauges and meters should, by the way, be
calibrated on a regular basis to insure accuracy.
Install the charging hoses on the service valves.
At this time, crack the valves to purge the hoses
and check the refrigerant pressures on the gauges.
Positive pressure indicates there is a charge in the
system.
IMPORTANT: Purging service hoses is subject to
Environmental Protection Agency regulations.
21. Now let's take a look at how this system
operates and compare its readings to those of a
normal air conditioning system. While this
system has an air-cooled condenser. we should
mention here that we will occasionally discuss
water-cooled systems. since many of the same
troubleshooting techniques apply to both.
22. Start the system by first turning off the
thellllostat or control and closing the disconnects.
then turning on the system at the theIIllostat or
control.
Listen to the compressor sound at start-up. A
knocking. rattling. or "heavy buzzing" sound
indicates liquid refrigerant is being drawn into the
cylinders. If it continues for more than a few
seconds. shut down the system and look for the
cause of excess liquid return. This can damage the
compressor.
7
23. Watch the gauges and the oil sightglass.
Heavy foaming at the sightglass should not
continue more than 5 to 10 minutes after start-up.
If it does. there may be excessive oil or refrigerant
in the system. Continue to check for abnoIIllai
sounds. vibration. and even odors that may
indicate a problem. Listen and be sure the
unloaders "snap" in when they activate. .
OVERHEATING
COULD BE
CAUSED BY
VOLTAGE OR
CURRENT IMBALANCE
24. Check the voltage and CWlent at the
compressor contactor a minute or two after start-
up. If there have been reports of overheating of
the compressor motor or evidence of it. a voltage
and/or CWlent imbalance could be the cause.
Current imbalance increases rapidly with a small
voltage imbalance. so any voltage imbalance over
2% must be COllected.
 L1- L2 220V- 215 V = 5V 2.27 % Imbalance
L2- L3 221 V - 220V = 1V is excessive
L3 - L1 224V - 220V = 4V and must be
% Imbalance = 5 / 220 x 100 reduced to
% Imbalance = 2.27 % 2% or below.

25. Measure the voltage on the load side of the 3 26. The maximum acceptable imbalance is 2%, so
phases at the disconnect or contactor with the the voltage supplied to this compressor must be
compressor operating. Let's say you've got these balanced in the distribution system of the building
readings: or the power company's incoming power.

L1 - L2 215V
L2· L3 221V
L3 - L1 224V
660V
L 1 - L2 218V
660V divided by 3 = 220V; the average voltage.
L2 - L3 219V
Now check the differential between the average
and the actual readings. L3 - L1 221V
Then use this formula: 658/ 3 = 219.3V average voltage

% Imbalance = 5{220 x 100

% Imbalance = 2.27%
27. By balancing some electrical loads in the
The % imbalance equals the maximum building, the new voltage measurements are:
imbalance divided by the average
voltage times 100.
L1 - L2 218V
L2 - L3 219V
L3 - L1 221V
658V

658 divided by 3 equals 219.3V; the average

voltage.

8
 Any cwtent imbalance over 10% must be
corrected. The imbalance is figured in the same
Find difference manner as the voltage imbalance. which is the
between each leg differential between the actual reading and the
average amperage.
and average vo~age

1.7 / 219.3 = 0.8 %

New imbalance is acceptable.
Compare actual conditions
28. The difference between the average and the
maximum imbalance readings is: to "normal" conditions
L1 - L2 2l9.3V - 2l8V -- l.3V
L2 - L3 2l9.3V - 2l9V -- 0.3V
L3 - L1 22lV - 2l9.3V - 1.7V
% Imbalance = 1.7/219.3 x lOO = 0.8% 30. Our next step is to measure the "actual"
operating pressures and temperatures of the system
So now we know that we have a well balanced and compare them to "nollnal" readings for the
electrical input. system. A table of typical system pressures and
temperatures for an R-22 system on air
conditioning duty at 90°F ambient is provided in
Appendix A.

A large imbalance causes Comparing actual system readings to what they

should be can provide a quick clue to what is
an increase in current wrong with the system. For instance. if the
suction pressure is running high. say at 76 psig.
of other 2 legs. instead of the typical 68 psig. the system may be
overcharged or excessively loaded. A discharge
Current imbalance over pressure well over 260 psig indicates the
condenser may be at fault.
10 % must be corrected.

29. A current imbalance can be caused by a

defect in a wire or terminal connection causing a
high resistance. which decreases the current flow
in that leg. This increases the current in the other
two legs and overheats them.

9
 , '. '- ... , ..... -.

NORMAL CONDITIONS
(AIR
,
CONDITIONING
I,.~M:(~~:-:""""'.. ':'_'" ~
DUTY)
,..:x?<.*--,'
~,
~
'--
. ,

• SUCT. p .< ", 'J~ 88 PSIG

• sueT. T @ COMP. r (52 FJ
0

. DISOH. P " - p$IG 2eo

• LlQ. t @ TXV 11O°F1,
.. . .. ," ';" '. ·r_~-.'-"""_,~.r.,,.~/

31. The point here is that in order to detelJuine
whether the system has a problem, you must first
know what the operating conditions are when the
system and compressor are operating nOlJllally.
These pressures and temperatures do vary with
equipment application and refrigerant. It's
therefore important to check the manufacturer's
service literature for "normal" system readings
before troubleshooting a system.
The number of actual readings taken during a
system troubleshooting procedure is dependent of
course on how quickly you fInd the problem.
Also, if the load is high and the system has not
been running, it may take several hours for actual
system pressures and temperatures to stabilize.
For the purposes of this section of the program,
we'll assume this R-22 system has stabilized and
we've taken some essential measurements.
32. With these measurements, we'll continue
checking the system by calculating the superheat.
Superheat is necessary to ensure that the
refrigerant being returned to the compressor is in
the form of vapor and not liquid. Liquid
refrigerant cannot be compressed, so the superheat
provides a safety factor that prevents pumping of
liquid and its potential for breaking up valves,
pistons, and rods in the compressor. A W&.1J1l
vapor also provides capacity improvement over a
cold vapor.
To calculate superheat, use a Temperature-Pressure
Chart to convert suction pressure to saturated
evaporator suction temperature. Obtain superheat
by subtracting this fIgure from the actual
temperature of the suction line at the suction
service valve.

33. As an example, our R-22 system on air

conditioning duty is running at 68 psig suction
pressure. This means the evaporator saturated

10
 suction temperature is about 40°F. If the actual
suction line temperature measures about 52°F,
there is about 12 degIees of superheat being added
to the refrigerant at the leaving end of the
• evaporator and in the suction line.
Typical Ale duty superheat
0 liquid will fmally subcool as heat continues to be
is 10 -12 F
Normal EXV superheat
0
is 3 -10 F
34. A typical air conditioning duty superheat with
a TXV would be 10 to 12°F above the saturated
evaporator temperature.
A nOHnal superheat with an electronic expansion
valve might be 3 to IOoF, because of the added
control available with electronics.
35. In order to achieve the proper capacity, we
must also feed the metering device a constant
supply of subcooled liquid refrigerant. This
prevents "flash gas" or bubbles of refrigerant vapor
from entering the metering device, which will
cause erratic operation and loss of capacity.
11
To protect against flash gas in the liquid line, the
charge must be sufficient and the liquid line must
be cool enough to maintain 10 to 20°F of
subcooling.
Here's how liquid subcooling is obtained. The
high pressure, high temperature hot gas leaving the
discharge line rejects superheat in the first portion
of the condenser. As the refrigerant continues
through the condenser, it condenses first to a
mixture of gas and liquid, then to a liquid. The
rejected to the air or water flowing through or over
the condenser.
RED F1GUAES • YACY'JM a' *CM' FIGURE. . . . . . . . . .
"F R-12 R-13 R-22 1I-4lOO R-5O
--
-
36. Measuring the amount of subcooling is similar
to measuring the superheat.
First, read the discharge pressure, which in this
case is 260 psig. At this pressure the
Temperature-Pressure Chart shows the saturated
discharge or condensing temperature of the liquid
is 120°F. Then, by measuring the actual
temperature of the liquid entering the TXV at
110°F and subtracting, we see that the liquid is
subcooled 10°F. If the system is rated with IO
degrees of subcooling, this provides approximately
5% improvement in system capacity.

0
2 Subcooling Loss =
1 % Capacity Loss
37. So if you don't have enough subcooling, you
will be shon of capacity by about 1% for every 2
degrees of subcooling.
38. Next, measure the hot gas discharge line
temperature, which is usually 60° to lOO°F above
the sarurated condensing temperarure, which in this
case is 120°F. We have 190°F measured on our
system, which is good.
12
IF HOT GAS TEMPERATURE
EXCEEDS 275°F, CHECK:
• High Superheat
• Lubrication
• Electrical Problem
• High Compression Ratio
• Refrigerant Flow Restriction
39. If the hot gas line temperature approaches
275°F, the system must be shut down and the
cause of the high gas temperarure analyzed. The
actual temperarure of the hot gas at compressor
discharge valves is 25 to 50°F higher than the line
temperarure and the refrigerant and oil can begin
to carbonire at these elevated temperarures. High
superheat, a lubrication problem, an electrical
problem, high compression ratio, or a refrigerant
flow restriction can cause overheating of the
compressor.
40. After the system has been running for 20 to
30 minutes, the temperature should be checked
using a thelillometer on the side of the compressor
head, crankcase, and motor barrel. Be careful
not to touch the top of the compressor head. It
can be well over 180°F.
The bottom of the head is usually at a temperature
of 80 to 120°F. The crankcase will be slightly
wallu as the oil temperature goes from 90 to
135°F depending on loading of the system. The
motor barrel runs cooler because of the refrigerant
being drawn through it and so it will range from
60 to 105°F, depending on location. If the load is
high, it may take time to reach the lower
temperature.
When these operating temperatures are too cool or
too hot it means something is wrong with the
compressor or system. Check the typical operating
temperatures in the back of the workbook to
detennine the possible cause of these temperature
• •
vanatlons.
41. If there are any suspicions of lubrication
problems or overheating, the oil pressure must be
checked. It should run about 14 to 20 psig above
the suction pressure on R-22 air conditioning
systems. All 06E and later model 06D compres-
sors have oil pressure taps.
13
DISCHARGE 260 PSI+14.7 PSI 274.7
SUCTION 68 PSI+14.7 PSI
-
- -
82.7
3.32
=--- COMPRESSION
RATIO
1
42. The last item to check is the compression
ratio. Calculate this ratio by dividing total
absolute discharge pressure by the total absolute
suction pressure. The resulting figure or ratio is
an indication of the work being perfOIllled by the
system.
For example: rust add an atmospheric pressure of
14.7 psi to typical suction and discharge gauge
pressures of 68 psig and 260 psig. Then divide
these absolute pressures, which gives a 3.32 to 1
compression ratio.
Compression ratios above 4: 1 on air conditioning
systems may indicate abnormal conditions causing
low suction pressures or high discharge pressures.
Higher compression ratios with the same model
compressor are common on low temperature duty
or with heat pumps running in reverse cycle
heating in low ambient conditions.
In fact, compression ratios of 8, 9 or 10 to 1 are
common on heat pump systems operating in low
ambient conditions.
 R- 22 Air R 12 Med R 502 Low
Condo Temp, Ref, Temp, Ref,
Ambient Air T 9O "F go F 90F

SUCTION P 68 PSIG 21 PSIG 23 PSIG

SATSUCT T 40 "F 20 F 10 F
SUCT LINE T 52 " F 45 F 40'F
SUPERHEAT 12 ' F 25 F SO'F

DISCH P 260 PSIG 157 PSIG 283 PSIG

SAT DISCH T 12O"F 120 F 120F
DISCHLINE T 19O' F 200 F 240'F
SUBCOOLING 10' F 10 F S'F
LIQ T ENTTXV 11O' F 110 F 115 F

43. Now we've covered "Making a Preliminary
Inspection" and "Understanding Normal
Operation." As you've seen, the system has great
influence on how efficiently and how reliably the
compressor operates. We've also discussed the
readings and observations that might be made on
a normal R-22 ali conrutioning system.
44. Remember, these readings do vary based on
equipment application and operating conrutions.
For instance, an R-12 system on meruum temp-
erature refrigeration duty, or an R-502 system on
low temperature refrigeration duty will have
different readings. Always refer to the man-
ufacturer's service literature to find typical
rearungs for your unit or system. A typical
temperature/pressure comparison chart for different
refrigerants is provided in Appenrux B.

14
 QUIZ #1
INITIAL INSPECTION AND "NORMAL" OPERATION

•
1. A long or uninsuIated suction line can cause:
a. excessive superheat. c. high subcooling.
b. low superheat. d. low subcooling.

2. (True or False?) A buried suction line can cause liquid slugging.

3. A liquid line passing through an unconditioned space will affect:

a. superheat. c. none of the above.
b. subcooling. d both a and b.

4. A good indication of a source of a refrigerant leak is:

a. rust stain at the compressor suction valve. c. oil stain on a mechanical connection.
b. coil fin corrosion. d. a hissing sound.

5. (True or False?) A discharge line muffler breaks up gas pulses to protect the piping and reduces
• •
operating nOise.

6. A device in the liquid line that prevents liquid from migrating to the compressor at shutdown is a:
a. TXV. c. liquid line solenoid valve.
b. discharge line muffler. d. all of the above.

7. An invened suction line trap prevents:

a. liquid from draining back to the c. flash-gas in the liquid line.
compressor at shutdown d. none of the above.
b. too much oil from returning to the compressor.

8. (True or False?) Rust streaks on the compressor are an indication of not enough superheat.

9. (True or False?) Whenever possible, test equipment and gauges should be connected to a system
when the system is turned ON.

10. (True or False?) When powering up a system, the thelJllostat should first be in the OFF position
before closing the disconnect.

11. Knocking, rattling, or heavy buzzing in the compressor at start-up is an indication of:
a. undercharge. c. overcharge.
b. liquid refrigerant in the compressor. d. high superheat.

12. On a 3-phase system, the voltage imbalance should not be above or below the average voltage by
more than %.

15
 13. To properly diagnose a system problem you must fIrst:
a. measure the system operating conditions. c. know the system normal operating
b. check the system with your sense of smell conditions.
hearing. sight and touch. d. check the voltage imbalance.

14. Superheat is calculated by:

a. subtracting liquid temperature entering the b. subtracting the saturated evaporator
TXV from the saturated suction temperature. temperature from the actual temperature
at the suction valve.

15. (True or False?) Superheat ensures that only liquid returns to the compressor.

16. The metering device must be fed a constant supply of liquid refrigerant to prevent:
a. flooding the compressor with liquid. c. low superheat
b. flash gas. d. all of the above.

17. (True or False?) Subcooling of 2 or 3°F ensures suffIcient liquid to prevent "Flash Gas" at the
metering device.

18. Saturated suction and discharge temperatures are obtained from:

a. a psychrometric chart. c.temperature measured at suction and
b. the unit nameplate. discharge valve of the compressor.
d. refrigerant temperature-pressure chart.

19. Every 2°F of subcooling equals how much change in system capacity:
a. 0.5% c. 2.0%
b. 1.0% d. 5.0%

20. Compressor oil pressure should run 14 to 20 psig above:

•
a. discharge pressure. c. suction pressure.
b. saturated discharge pressure. d. atmospheric pressure.

21. Compressor compression ratio is calculated by dividing the:

a. discharge pressure by the suction pressure. c. saturated discharge temperature by the
b. absolute discharge pressure by the absolute discharge pressure.
suction pressure.

16

L
t _ _ _ _ _ __ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ______. . . . . . . . . . . . . . .
 •

ANALYZING SYSTEM OPERATION conditioning duty at 901'" ambient temperature we

had the following conditions:
ANAL YZING SYSTEM OPERATION
(COMMON SYMPTOMS) 68 psig suction pressure
260 psig discharge pressure
- Low capacity
12 of superheat
- Low or high pressures 10 degrees of subcooling
- Low or high temperatures
- Low or high superheat And, both current and voltage were balanced
- Low or high subcooling within acceptable parameters.
_ Low or high current draw
_ Low or high compression ratio Now let's go over the symptoms related to some
of the more common problems. We'll start with
an electrical malfunction.
45. The final section of the program will deal
with recognizing and analyzing the symptoms of a
compressor or system that is operating incorrectly.

We'll discuss common complaints, the symptoms

observed, and then some possible causes.

A system and/or compressor problem will

generally make itself known by:

Low capacity
Low or high pressures
Low or high temperatures
Low or high superheat
Low or high subcooling
Low or high compressor current draw 47. If the system doesn't start or run, first check
Low or high compression ratio the temperarure control to be sure it is set
properly, and that the setting is below the space
temperarure. Check the power circuit to be sure
there is line power. Check the control circuit
voltage to be sure it is correct. Also check the
safety switches.

46. Just as a reference point or benchmark: when

we examined the R-22 system on nOllnal air

17
 and nonnal operating temperatures have been
exceeded. power should be shut off and the
compressor allowed to cool.
When the compressor is overheated. the cause
must be determined. High superheat, electrical
problems. lubrication problems. or condenser
problems are possible causes.

48. If there is power and control voltage. check

out the pressure and temperature controls. which
are electrically ahead of the relays or contactors
activating the fans. pumps. or compressor. Also.
be sure to check contactors and other electrical
devices which close to provide power.
If the compressor attempts to start but immediately
cuts out. it may be on locked rotor. or an overload
may be defective and the cause must be
50. Now let's talk about some capacity problems
determined.
which refer to the ability of the evaporator to
Is the compressor out because of TimeGuard? absorb heat
Allow time for it to reset or replace the
Heat from the product or space to be cooled must
TimeGuard if it is faulty.
be transferred to the evaporator and into the
More on electrical troubleshooting can be found in refrigerant in order for cooling to occur.
the programs on "Advanced Troubleshooting."
If some condition prevents this heat transfer. the
"Electrical Test Instruments." and "Understanding
compressor will not be loaded and will not
Wiring Diagrams."
establish a high enough pressure in the condenser.
This low pressure will not feed refrigerant to the
metering device properly and the evaporator
IF THE COMPRESSOR capacity. pressures. and temperatures will remain
low.
IS OVERHEATED
LOOK FOR:
• High Superheat
• Electrical Problems
• Lubrication Problems
• Condenser Problems

49. A compressor may also be out because of the

compressor protection. If the compressor is hot

18

•
 As discussed earlier in the program, perhaps the
air flow is restricted by dirty filters, a dirty coil or
closed dampers. Maybe corroded fin collars and
tubes are also reducing capacity. Or maybe the
problem is in the air-moving equipment such as
motors, belts and blowers or fans. An evaporator
fan running backwards, or a loose set screw on a
sheave or pulley can also affect capacity.

51. The problem here can exist with either the

load entering the evaporator or with the condition
of the refrigerant in the evaporator. Or, is the
evaporator or cooler load so low that the system
capacity should be low? If the normal temperature
of the return air is 80 0 DB and noWB, and a
check of the return air shows 75°DB and 65°WB,
the cooling load is obviously reduced. The system
will not operate as if it were fully loaded. It will
operate at reduced capacity, pressures, and
53. Should a sheave need to be adjusted, be
temperatures, and compressor current will be low.
careful not to overload the motor by increasing the
Perhaps the majority of the load is being handled speed of the blower too much. Check the
by the economizer, if the system is so equipped. equipment manufacturer's instructions for the rated
This obviously will reduce the load on the system. amperage draw of the motor.

52. If the evaporator entering air (return air)
temperatures are high enough to call for operation,
then something is preventing the evaporator from
picking up the load. This may be caused by an air
flow problem preventing heat transfer from the air
to the refrigerant
54. In liquid-chilled systems, anything which
lowers liquid flow through the cooler can prevent
the system from picking up the load.
The flow of the liquid through the cooler must be
great enough to load the refrigerant with heat.

19
Restricted flow caused by scaling or other factors
could cause refrigerant temperatures low enough to
freeze the water or other liquid in the cooler. This
poses a serious threat to the system and to the
compressor in addition to capacity problems.
55. Lack of refrigerant flow through the system
and through the evaporator can also cause low
capacity indicated by low suction and discharge
pressures. Things that influence refrigerant flow,
such as low charge, a restriction in the TXV or
liquid line, or a leaking TXV sensor bulb will also
cause high superheat
56. High superheat means the normal cooling of
the compressor motor is reduced, since cool return
vapor is the key item in keeping the motor and
compressor at the proper temperature. Any
indication of high temperatures in the compressor
means the superheat must be checked and a cause
established.
20
A restriction in the suction line screen, a partially
closed service valve or a restricted back pressure
regulator, accumulator or suction line would
probably also restrict refrigerant flow and result in
low capacity and related symptoms such as high
superheat
57. The reduced flow of refrigerant such as that
caused by an undercharge, piping restriction, or
metering problem could also result in oil logging,
since refrigerant velocity is a key item in oil
return.
58. This is serious, since compressor lubrication
problems could result if the oil is not returned to
the crankcJlse as rapidly as it leaves it If extra oil
is added to an undercharged or restricted system
and then the malfunction is COllected, excessive oil
will be returned to the compressor and oil slugging
will occur.
 With any of these symptoms we could have the
potential for compressor damage. The fault causing
these conditions must be COllected.
For instance, insufficient air flow or water flow
through or over the condenser will reduce heat
removal from the refrigerant and the condenser
will act like it is too small to do the job. 1b.is will
cause inefficient condensing, elevated pressures
and power draw, and reduced system capacity.

SYSTEM OPERATING AT
•

REDUCED CAPACITY
REDUCTION OF
• Check Load HEAT TRANSFER
• Check Evaporator Flow
• Check Refrigerant Flow _ Dirty or Blocked Coils
• Check Refrigerant Charge _ Damaged Fins or Fin
Collars
_ Abnormal Motor Rotation
59. To sum up the points made: if the system
appears to be performing at a reduced capacity, the
evaporator load, evaporator air or liquid flow,
refrigerant flow path, and refrigerant charge must 61. In air-cooled systems, coils that are dirty, too
be checked. close to a wall, or too close to each other, will
cause a reduction in heat transfer. Coils may
become blocked by vegetation. As with the
evaporator, damaged or bent fins and eroded fin
CONDENSER PROBLEMS collars are also a possible cause of trouble. A
motor running slowly or backward will produce
- Load Too High? high saturated discharge and low subcooling.
_ Water or Air Flow
Problem?
WATER COOLED SYSTEMS
- Restricted Refrigerant
• Insufficient Flow
Flow?
• Defective Pump
• Dirt
• Scaled Piping
60. On the high side of the system, the purpose of • Defective Pressure
the condenser is to receive high pressure, high Controls
temperature gas from the compressor and to de- • Blocked Cooling
superheat it, condensing the gas to liquid and Tower
subcooling the liquid. The heat from the
evaporator load, the superheat, and the heat of
compression must be transferred to the condenser 62. In water-cooled systems, insufficient flow of
cooling medium. If this heat transfer process is water, air in the water supply, defective pumps,
not completed, system operation or capacity will restricted water line strainers, scaled water piping,
be affected. defective head pressure controls, or dirty or
blocked cooling towers, will also cause high

21
 saturated discharge temperature and low sub-
cooling. Sometimes a combination of several
factors may be involved.
EXCESSIVE LOAD
collars. Or there may be a problem with the
condenser or flow of refrigerant.
To quickly check the effectiveness of the
condenser, measure the temperature of the air or
water as it enters the condenser and as it leaves
the condenser. An appreciable rise in temperature
of the air or water must be measured in order to
achieve cooling of the refrigerant and its change of
state from hot gas to WaIlII liquid. Check product
literature for recommended air or water flow and
temperature rise. If air and water flow are okay
and the temperature rise is lower than it should be,
the condenser may be undersized or contain non-
condensibles.

63. Excessive loading of the evaporator can result

in increased pressures and temperatures in the
system, including the condenser. If the system
cooling design temperature is 90°F but the outdoor
temperature is 100°F, the system will be operating
at high pressures, use exira power, and may not be
able to carry the cooling load as efficiently.
This has to be considered "nOIl11al" under the
conditions of the outdoor temperature.

65. The condenser is 25 to 33% larger than the

evaporator because the condenser has to reject the
heat taken on by the evaporator, superheat and
heat of compression developed in the compressor.
If it is too small, it will not be able to cool the
refrigerant sufficiently and bubbles of vapor may
be mixed with the liquid entering the metering
device, causing reduced liquid flow to the TXV
and elevated pressures.

64. If, however, the outdoor ambient temperature

is 84°F and capacity problems, high pressures and
high CWlent draw are noted, a problem may exist
with the transfer of heat from the refrigerant to the
water or air flowing through the condenser. This
could be caused by damaged fins or corroded fin

22

t

66. If there is air, nitrogen or any other
noncondensible gas in the system, it will occupy
space in the top of the condenser and reduce the
space needed by the refrigerant. This, in effect,
creates a condenser that is too small to do the job.
This can be checked by shutting the system off,
allowing the condenser to settle out to ambient
temperature, and checking the pressure of the
refrigerant at the discharge service valve. Pressure
should be within 5 psig of the pressure called for
at room temperature. Higher pressures indicate the
presence of noncondensibles.
Noncondensibles must be removed from the
system by complete evacuation and recharging of
the system. Air must be purged from the water
supply of water-cooled condensers.
67. Pumping against this excessive pressure can
cause higher current draw, resulting in the
compressor overheating.
23
Any condition which dettacts from the heat
transfer between the air or water and the
refrigerant in the condenser will have symptoms
similar to those mentioned above.
TVX PASSING LIQUID
.L o. 'b. re • 'OJ TO
, ~ • ~ . EVAPORATOR
. .""
••••
TVX PASSING LIQUID AND VAPOR
~ .L ~ .o . re. 'OJ TO
COO '8" • •• EVAPORATOR
Q)~O. oa ~"o "
• • • •
68. The capacity of the metering device is
reduced greatly if it is fed vapor; so an adequately
sized condenser that is operating correctly without
the presence of non-condensibles must supply
subcooled liquid to the metering device.
Remember that the latent heat of vaporization (the
changing of a liquid to a vapor) is where the
refrigerant really picks up the load. If it's a vapor
as it enters the evaporator, it can't do an adequate
job.
Some vapor is formed at the needle valve of the
TXV even when it is fed subcooled liquid, but the
TXV should not be fed vapor or a vapor-liquid
mixture, since the metering device is sized for
regulating the flow of liquid Ten to 20°F of
subcooling is recommended for good perfollllance
and higher system efficiency.
 69. This also assures that a liquid seal is present
at the TXV, especially in the case of long liquid
lines, where there is the danger of "flash gas."
Flash gas is formed from pressure drop caused by
the friction of the tube walls to the flow of
refrigerant. It can drop the pressure to the point
that the liquid reverts back to a vapor.
70. An oversized and open TXV tends to flood
the evaporator and possibly the compressor. The
sensing bulb then quickly chills down and signals
the valve to close. This cycle constantly repeats,
resulting in extremely unstable operation.
24
71. The frequency of the valve operation will
show sharp peaks and valleys rather than the
slower, flatter cycle of a nOIlllal valve. This is
called "hunting".
72. An undersized TXV will act like a restriction
in the liquid line, causing pressure reduction on the
low side of the system and high superheat which
can result in compressor damage.
A loose or uuinsulated TXV sensing bulb could
flood the evaporator, causing compressor flooding.
A defective TXV could cause starving of the
evaporator.
Replacement of the defective, undersized or
oversized TXV is essential and it may be
necessary to check the compressor in case the
liquid refrigerant has caused damage to the
•
runmng gear.
I
73. An excessive charge of refrigerant will raise
the pressure in the system. This affects the ability
of the TXV to control refrigerant flow, causing
low superheat and possible compressor floodback.
The superheat will be low and the subcooling high.
Any of these problems, if allowed to continue, will
take their toll with regard to compressor reliability.
74. The low pressure side of the system and the
high pressure side of the system are divided in the
head of the compressor, in the metering device,
and at the hot gas bypass valve, if the system is so
equipped.
25
75. If this separation is opened, such as at a tear
in the valve plate gasket or if the cast iron "web"
between the suction and discharge sections of the
compressor head is broken or leaking, high
pressure, high temperature gas will flow into the
suction side of the compressor.
76. Broken or bent valves can also affect the seal
between high and low sides.
If this happens, the suction pressure will rise and
the discharge pressure will be reduced because of
the "shon-circuited" flow to the suction side. The
compressor may also overheat.
If the separation is small, the pressure differences
from nonna! operation will also be small. This
would also be the case with a slightly bent or
cracked valve.

77. This can be a very frustrating condition, since
the customer and the technician may feel that there
is a problem, but it will be very difficult to
pinpoint the exact cause without disassembly.
As a separation opens wider or if the valve breaks,
the problem becomes more apparent by a decrease
in high-low side pressure differential. The smaller
differential in pressures, with the suction pressure
going higher and the discharge pressure lower also
decreases the compression ratio.
78. If disassembly is necessary, fITSt be sure the
system and/or compressor pressure is at zero psig
and then remove the head and valve plate to check
the gaskets, valve and web condition. This type of
damage may have been caused by refrigerant or oil
floodback or slugging, so these possibilities must
be checked and cOllected before more serious
compressor damage occurs.
26
,
REVIEW
• Work Safely
• Don't Check Moving Parts
While System is Operating
• Use Your Natural Senses
• Compare Actual Temperatures
and Pressures to Normal Operating
Data For Your System
79. In this section, we've covered the more
common causes of operating problems. Now,let's
review some of the major points that were covered
in this program.
• The most important aspect of your job is to
work safely.
• DO NOT CHECK MOVING PARTS, such as
pulleys, sheaves, wheels, fans, or other moving
parts WHILE OPERATING. Disconnects
must be opened, locked and tagged before
checking these moving components.
• System problems can damage a good
compressor.
• Look around, use your natural senses, then use
test instruments to determine system problems
or identify performance.
• If the problem is not readily identifiable,
compare actual operating temperatures and
pressures to normal operating conditions for
your system
If there is a significant difference berween a
"normal" system and the one we're inspecting, the
symptoms will help us to pinpoint the system area
or condition to check.
• Among the more important items to check are
superheat of the return vapor and subcooling at
the TXV.
 - a

• The hot gas discharge line should not exceed

."ZZL__
100°F above the saturated condensing
temperature.
---
,
--
• If there is any evidence of overheating, the
:1:-_
•

= ='
-
- ::.
':::::..
~-
refrigerant charge, lubrication system and
electrical power must be checked.

• The system capacity, pressures, temperatures,

current draw and compression ratio give us an
idea of where to look for possible trouble.

• Generally, low capacity, low pressures, and low

current draw mean evaporator problems, low
charge or TXV problems.
• Low capacity with high pressure current draw
means condenser problems, excessive charge or
TXV problems.
• A problem with air or water flow over the
condenser, or non-condensibles in the system
will cause inefficient condensing and high head
pressures.
• An undersized condenser will cause reduced
capacity or enatic operation. Non-condensibles
in the system could have the equivalent effect.
• Lower capacity, high suction pressure, lower
discharge pressure and reduced current draw
could mean a leak between the high and low
sides.
80. Additional information on semi-heliuetic
compressors can be found in the programs listed in
Appendix C. Also, review the System Analyzer in
this booklet It provides a basic procedure for
identifying compressor or system problems.
What it all boils down to is that a system problem
is a compressor problem, and a compressor
problem is a system problem.
It is rare to have one without the other. The
compressor is the most complex and most costly
component in the system.
Understanding the interaction of the compressor
and the system is your best insurance against
inefficient operation, downtime and extensive
•
reparrs.

27
 SYSTEM ANALYZER

The System Analyzer, attached to this page, provides a basic, sequential procedure for identifying a
compressor or system problem. Once you're familiar with this procedure, it will become routine on every
service call. More sophisticated analysis and testing may be required to determine what's wrong with
a system. To use the analyzer, follow this step-by-step procedure.

I. Check off reasons for the service call. Talk to the owner or tenant. Request an equipment log.
All can provide important clues.

2. OBSERVE ALL SAFETY PRECAUTIONS!

3. Record system nameplate data. It's the easiest way to get acquainted with a system. Besides, you'll
need this infoullation to troubleshoot and identify equipment in service literature.

4. Look around. A simple inspection may quicldy reveal the problem. Use your natural senses.

5. Start the system. Make sure all components are operational. Check for obvious defects.

Before going to Step 6, review the "typical" system operating pressures and temperatures shown in
Table 3.

CAUTION: The "typical" operating pressures and temperatures shown in Table 3 are provided
solely to demonstrate this method of analyzing systems. Since actual readings will vary with the
items that affect systems operation such as system components, application, load, outdoor
temperature, etc., the Table 3 readings should not be used as the basis for troubleshooting systems.
Check manufacturer's installation and service literature for this type of operational data.

6. Record actual temperature and pressure measurements in Table 3 on lines A through U. Compare
them to typical readings taken from manufacturer's literature. Use them to calculate superheat,
subcooling, compression ratio and capacity. Analyze this infoullation to determine the system
problem.

7. Go to the "Quick System Analysis" chart on page 4 of the System Analyzer to verify the problem.

8. Use the System Analyzer to perfOl'1ll exercises 1 through 5 on the following pages; then complete
Quiz 2 on page 36

29

•
 SYSTEM ANALYZER

The System Analyzer, attached to this page, provides a basic, sequential procedure for identifying a
compressor or system problem. Once you're familiar with this procedure, it will become routine on every
service call. More sophisticated analysis and testing may be required to determine what's wrong with
a system. To use the analyzer, follow this step-by-step procedure.

1. Check off reasons for the service calL Talk to the owner or tenant Request an equipment log.
All can provide important clues.

2. OBSERVE ALL SAFETY PRECAUTIONS!

3. Record system nameplate data. It's the easiest way to get acquainted with a system. Besides, you'll
need this information to troubleshoot and identify equipment in service literature.

4. Look around_ A simple inspection may quickly reveal the problem. Use your natural senses.

5. Start the system. Make sure all components are operational. Check for obvious defects.

Before going to Step 6, review the "typical" system operating pressures and temperatures shown in
Table 3.

CAUTION: The "typical" operating pressures and temperatures shown in Table 3 are provided
solely to demonstrate this method of analyzing systems. Since actual readings will vary with the
items that affect systems operation such as system components, application, load, outdoor
temperature, etc., the Table 3 readings should not be used as the basis for troubleshooting systems.
Check manufacturer's installation and service literature for this type of operational data.

6. Record actual temperature and pressure measurements in Table 3 on lines A through U. Compare
them to typical readings taken from manufacturer's literature. Use them to calculate superheat,
subcooling, compression ratio and capacity. Analyze this information to determine the system
problem.

7. Go to the "Quick System Analysis" chart on page 4 of the System Analyzer to verify the problem.

8. Use the System Analyzer to perform exercises 1 through 5 on the following pages; then complete
Quiz 2 on page 36

29
 EXERCISE 2

TYPE OF EQUIPMENT: Air Conditioning System

- Cooling System
- Water Cooled Condenser
- Refrigerant - R-22
- Metering Device. - TXV

REPORTED OPERATING CONDmONS:

- Insufficient cooling
- Compressor cycling

SYMPTOMS:
- Compressor starts and runs for short periods then shuts down
- Discharge pressure rises to 320 psig at time of compressor shut down
- Suction pressure higher than nOllllal
- Amps increase with compressor run time to 15-20% above nameplate rating
- Superheat is low
- Subcooling is high
- System pressure at shutdown equalizes at 182 psig at 95°F ambient

What is the most likely system defect?

A. Overcharge
B. Undercharge
C. Restricted liquid line
D. Partial loss of condenser air/water

31
 TROUBLESHOOTING EXERCISES
(System Analyzer)

These exercises will help you apply the knowledge you've gained from this program. Use the Quick
System Analysis chart on page 4 of the System Analyzer to help you complete exercises I through 5.

EXERCISE 1

TYPE OF EQUIPMENT: Air Conditioning System

- Cooling System
- Air Cooled Condenser
- Refrigerant - R-22
- Metering Device - TXV

REPORTED OPERATING CONDmONS:

- Loss of evaporator air
- Compressor cycling

SYMPTOMS:
- Compressor starts and runs for short periods then shuts down
- Suction pressure drops to 35 psig during during short run periods
- Discharge pressure is 200 psig
- Low superheat, high subcooling
- Low amperage
- Low evaporator air

What is the most likely system defect?

A. Condenser fan motor not running
B. Inconect evaporator fan motor speed
C. Restricted (dirty) evaporator air filters
D. Overcharge
E. Dirty condenser

30
 EXERCISE 3

TYPE OF EQUIPMENT: Air Conditioning System

- Cooling System
- Water Cooled Condenser
- Refrigerant - R-22
- Metering Device. - TXV

REPORTED OPERATING CONDmONS:

- Insufficient cooling

SYMPTOMS:
- Evaporator air adequate
- Suction pressure: 78 psig
- Discharge pressure: 280 psig
- Superheat: 2-3°F
- Air entering evaporator: 85°F
- Air leaving evaporator: 75°F
- Subcooling: 0-2°F
- Amps: 5% above nameplate rating
- Water temperature rise across condenser: 18°F
- System pressure at shutdown equalizes at 168 psig at 90°F ambient

What is the most likely defect?

A. Overcharge
B. Undercharge
C. Condenser water shortage
D. Ambient at 112° Centigrade

Hint: Use the "Quick System Analysis" chart to solve this problem.

32
 -- - -.

EXERCISE 4

TYPE OF EQUIPMENT: Air Conditioning System

- Cooling system
- Water or air cooled condenser
- Refrigerant - R-22
- Metering device - TXV

REPORTED OPERATING CONDmONS:

- Insufficient cooling

SYMPTOMS:
- Suction pressure: 76 psig
- Adequate evaporator air
- Discharge pressure: 275 psig
- Superheat: 3°F
- Air entering evaporator: 83 OF
- Air leaving evaporator: 73°F
- Subcooling: 4°F
- Amps: 5% above nameplate rating
System pressure equalizes at 179 psig at 90°F ambient
- Sightglass clear

What is the most system defect?

A. Overcharge
•
B. Non-condensibles in system
C. Loose or uninsulated TXV bulb
D. Loss of charge in TXV bulb

Hint: Use the "Quick System Analysis" chart to solve this problem.

33
--

EXERCISE 5

TYPE OF EOUIPMENT: Air Conditioning System

- Cooling system
- Air or water cooled condenser
- Refrigerant - R-22
- Metering device - TXV

REPORTED OPERATING CONDmONS:

- Insufficient cooling

SYMPTOMS:
- Evaporator air adequate
- Suction pressure: 55 psig
- Discharge pressure: 210 psi g
- Superheat: 30°F
- Air entering evaporator: 85°F
- Air leaving evaporator: 78°F
- Subcooling: 0 to 3°F
- Amps: 20% below nameplate rating
- Cloudy or flashing in sightglass
- System pressures equalize at 156 psig at 85°F ambient

What is the most likely system defect?

A. Overcharge
B. Undercharge
C. Loose or uninsulated TXV bulb
D. Loss of charge in TXV bulb

Hint: Use the "Quick System Analysis" chart to solve this problem.

34
 EXERCISE SOLUTIONS
(System Analyzer)

1. Most likely cause is "s" - incorrect evaporator fan motor specxl. However "C," restricted evaporator
air filters, will give the sallie conditions.

2. Most likely cause is "A" - overcharge indicated by rapid cycle rate.

3. Most likely cause is "c" - Condenser water shortage. Probably due to either a partially plugged water
filter/strainer or defective water control valve. Check filter/strainer fIrst to be assured there is an
adequate supply of condensing water.

4. Most likely cause is "s" - Non-condensibles in the condenser will cause these conditions.

5. Most likely cause is "s" - Undercharge. Probably due to system leak. Determine source of leak and
repair before adding charge. Check for leaks at mechanical and exposed joints flfSt

35
 QUIZ #2
ANALYZING SYSTEM AND COMPRESSOR PROBLEMS

1. (True or False?) If a system won't start, check the thelJllostat, power, and control components in
that order.

2. When the cooling load is reduced below its normal operating condition; the system will operate at
_ _ _ _ _ _ _(increased/decreased) capacity, pressures, temperatures, and compressor CWlent
draw.

3. Increasing fan speed by adjusting the sheave on the drive pulley is limited by:
a. rated amps of the drive motor. c. type of fan.
b. fan speed. d. number of fan blades.

4. (True or False?) Reduced refrigerant flow through the evaporator will cause the superheat to
•
mcrease.

5. The device that desuperheats, condenses and subcools the hot gas is the:
a. evaporator. c. condenser.
b. TXV. d. compressor.

6. A lack of cooling agent (air or water) in the condenser will _ _ _ _ _ (increase/decrease)

discharge pressure.

7. Condenser fan rwming backwards will cause the discharge pressure and temperature to
_ _ _ _ _ _ (increase/decrease).

8. On a water-cooled system; a defective pump, dirty cooling tower, scale in the piping or defective
head pressure control will cause (Iow/high) subcooling.

9. (True or False?) The evaporator coil is 25 to 33% larger than the condenser coil because it must
pick up heat from the area being conditioned.

10. (True or False?) Non-condensible gas ends up in the top of the condenser.

11. A system pressure reading a few minutes after shutdown exceeding 5 psig of the figure obtained
from the refrigerant Temperature-Pressure Chart is an indication of:
a. defective TXV. c. non-condensibles in the system.
b. overcharge. d undercharge.

12. "Flash Gas" entering the metering device _ _ _ _ _ _ _ (increases/decreases) pressure.

13. An oversized TXV will cause what condition to occur?

a. Hunting c. Slugging
b. Increased subcooling d. Flooding

36

,
 14. (True or False?) An overcharge will increase system pressures beyond the control of the TXV and
result in low superheat, floodback:. and high subcooJing.

15. (True or False?) The high and low sides of a refrigeration system are divided in the compressor
•
heads and in the metering device.

37

I
 QUIZ KEY
QUIZ#!

Page No.

I. a 8 3
2. T 8 3
3. b 8 3
4.c 9 3
5.T 10 4
6.c 12 4
7.a 13 4
8.T 15 5
9.F 20 6
10. T 22 7
II. b 22 7
12. 2% 24 7
13. c 31 10
14. b 32 10
15. F 32 10
16. b 35 II
17. F 35 II
18. d 32 & 36 10 & II
19. b 37 12
20. c 41 13
21. b 42 13

QUIZ #2
I. T 47 17
2. decreased 51 19
3. a 53 19
4. T 55 20
5. c 60 21
•
6. Increase 60 21
•
7. Increase 61 21
8. low 62 21, 22
9. F 65 22
10. T 66 23
II. c 66 23
12. decreases 69 24
13. a 71 24
14. T 73 25
15. T 74 25

38
 APPENDIX A

Typical Readings on Normal R-22 Air Conditioning

Systems at 90°F Ambient.

Suction Pressure 68 PSIG

Saturated Suction Temperature 40°F

Suction Line Temperature 52°F

Superheat 12°F

Discharge Pressure 260 PSIG

Saturated Condensing Temperature 120°F

Discharge Line Temperature 190°F

Subcooling lOOF

Liquid Temperature Entering TXV llO°F

Oil Pressure 86 PSIG

Suction Area of Head Temperature 70°F Loaded

100 - 120°F Unloaded
Crankcase Temperature 100°F
Motor Barrel Temperature 90°F
Compression Ratio 3.32 : 1

39
 APPENDIX B
Typical Temperature-PrfAAure Comparison
for Common Refrigerants

R-22 R-ll R-S02

Air Medium Temp. Low Temp.
Conditioning Refrigeration Refrigeration
Ambient Air Temp 90°F 90°F 90°F

Suction Pressure 68 PSIG 21 PSIG 23 PSIG

Sat. Suction Temp. 20°F - 10°F
Suction Line Temp. 45°F 40°F
Superheat 25°F 50°F

Discharge Pressure 260 PSIG 157 PSIG 283 PSIG

Sat. Discharge Temp. 120°F 120°F 120°F
Discharge Line Temp. 190°F 200°F 240°F
Subcooling 10°F 10°F 5°F
Liq. Temp. Entering TXV 110°F 110°F 115°F

Oil Pressure 86 PSIG 41 PSIG 43 PSIG

Heat Temperature 50°F
Crankcase Temperature 120°F
Motor Barrel Temp. 55°F
Compression Ratio 3.32 : 1 4.8 : 1 7.9 : 1

40