Air-Conditioning Principle &

Troubleshooting
Purpose

To maintain Temperature & Humidity of the Air

inside Accommodation for Human Comfort. (By
Cooling, Heating, Humidifying, depending on
outside temperature)
The desired & Most Comfortable range for
Humans is: Temperature: 22-24 Deg. C & Relative
Humidity: 40-60%.
Comfort Zone
Comfort Zone
 How Its Done
Air-con System is like a Heat Pump: I.E. Transferring
Heat from inside accommodation to Outside.
(Same principle applies to Refrigeration System as
well)
How Air Conditioners Work
 Principle of Refrigeration Cycle:
Saturation temperature (Boiling Point) of a liquid
varies with change in pressure) . At Sat. Point is like
Transition phase. An addition of heat will boil
(evaporate) the liquid into vapour and an removal of
heat will condense it to liquid. Temp. remains same
during phase change & the heat added/removed is
called latent heat(Panas Laten).
At Higher Pressure Boiling Point (Temp.) is higher &
at Lower Pressure Boiling Point is lower.
E.G. Water boils at 100 deg C at Atm. Pressure. If We
reduce pressure (as in FWG), water boils at abt 500 C.
Same way in Boiler water boils at 1200 & above (when
pressure is higher)
Boiling Point Variation with Pressure
 Principle of Refrigeration Cycle:

When a liquid boils or evaporates it absorbs heat

(from hot surroundings) and when it condenses it is
releases heat (to a cooling medium).
So we want a Refrigerant material which:
Absorbs heat from accommodation while
evaporating (for example at 18 Deg C) [ At Low
Pressure] and
Releases heat to outside atmosphere (Air or Water
e.g. at 40 Deg C) while condensing, [at High
Pressure].
Boiling Point Variation with Pressure
Principle of Refrigeration Cycle:
Principle of Refrigeration Cycle:
 Main Components
Compressor: Reciprocating single or two stage 
compressor is commonly used for compressing and
supplying the refrigerant to the system.
Condenser: Shell and tube type condenser is used to
cool down the refrigerant in the system.
Receiver: The cooled refrigerant is supplied to the
receiver, which is also used to drain out the
refrigerant from the system for maintenance purpose.
Drier: The drier connected in the system consists of
silica gel to remove any moisture from the refrigerant
 Main Components
Solenoids: Solenoid valves are used to control the flow
of refrigerant into the hold or room.
Expansion valve: Reduces the pressure & regulates the
refrigerant to maintain the correct hold or room temp.
Evaporator unit: The evaporator unit act as a 
heat exchanger to cool down the hold or room area by
transferring heat to the refrigerant.
Control unit: The control unit consist of different
safety and operating circuits for safe operation of the
refer plant.
 Main Components
Capacity Controller: Controls the output of the
plant depending on the load demand. (e.g. Change in
Atmosphere Temperature, Frequent Opening of
Doors, More people or fresh food stored in the fridge
rooms). By unloading the Suction Valves.
Safety Devices:
a)Low Pressure or LP cut off.
b)High pressure or HP cut out
c)Oil differential cut out
d)Relief valves
e)Solenoid valves
f)Oil heater
 Common Troubles
We shall discuss following common troubles in
next session. Please send me the specific
problems you are facing on your ships:
a)No or reduced cooling Effect
b)Compressor Not Working
c)Reducing oil level in compressor
d)Unusual Sound from Compressor
e)High Compressor Discharge Temperature
f)Compressor Starts But Stops immediately
g)Compressor Start and Stops Frequently
h)Compressor is Running Continuously (fridge)
i)Discharge Pressure Too Low
j)Discharge Pressure Too High
 Common Troubles
k) High Pressure Switch Cuts-Off
l) Suction Pressure Too High
m) Suction Pressure Too Low
n) Low Pressure Switch Cuts-Off
o) Evaporator Coil Icing
p) Evaporator Not Cooling
q) Reduced Cooling Capacity
r) Icing on Suction Pipe
 No or Reduced Cooling Effect
Less Refrigerant quantity (undercharged)
Too much leakage from the Accommodation (Doors &
portholes always kept open)
Air conditioner unit is under capacity
Compressor valve damage or ineffective compression due to
Piston/Liner/Piston ring issues.
Expansion valve not effective or incorrect size
Filter drier or strainer is clogged (Refrigerant)
Air filter is clogged
Evaporator is dirty/clogged
Fan motor belt loose or slip
Temp. setting of thermostat too high or sensor placed at wrong
place
Duct damper is closed, Duct trunking corroded (leaking),
 Compressor Not Working
A) Check the Power supply, Motor, Belts or any
Trip/Alarm on panel.

B) Check if broken: Reasons:

a) No correct assembly.
b) Not genuine spare parts
c) Alarms & Trip malfunction.
d) Suction & Discharge valves problem
e) Oil pressure not enough
f) Under capacity compressor (Over load)
g) System malfunction (Liquid carry over, over
charge, air or moisture in the system)
 Reducing oil level in compressor
Due to leakage or increase in consumption of lube oil due to
following reasons:
Nozzle or filter clogged (Ensure that the nozzle in oil return line
or filter in solenoid valve is cleaned and not choked)
Foaming of oil due to liquid in suction line (Foaming of oil may
arise due to liquid refrigerant entering the crankcase. Replenish
oil and troubleshoot cause of liquid in suction of compressor)
Drive side seal leaking (The compressor is provided with oil seal
at the drive side. Ensure it is not leaking and renew it if required)
Worn out piston rings/ liner leading to oil carryover in the
system (Renew the compressor piston rings or liner)
Oil separator not working properly
 Unusual Sound from Compressor
This may be due to trouble with mechanical components
inside the compressor:
Incorrect alignment of compressor and motor (Check the
alignment and set motor and compressor in one line)
Loose foundation (Ensure that the compressor foundation is
secured and all foundation bolts are checked for tightness)
Loosening of driving belt (Ensure to check the elasticity of
the belt and renew if the belt is slack)
The capacity control setting is too high, leading to knocking
sound during starting (Reduce the capacity control setting)
The oil pressure is low (Ensure that the oil level is
maintained and no foaming of oil is developed. Replenish or
refill the lube oil if required)
High Compressor Discharge Temperature
Excessive suction temperature due to less refrigerant in the
circuit (Recharge the circuit to maintain refrigerant
quantity in the circuit. Ensure Expansion valve is of correct
type and is set properly and supplying enough to the
evaporator.
Leak in the discharge valve leads to generation of heat
(renew the leaky valve)
Leak in the safety valve (Renew safety valve)
Compressor Starts But Stops immediately
Low pressure cut out gets activated (Ensure that all the suction
line valves are in open condition, the refrigeration is properly
charged and the low pressure cut out is not defective)
Defective oil pressure cut out (Check for proper functioning of oil
pressure cut out and replace the defective cutout)
Defrosting timer is getting activated frequently (If the defrost
timer is getting activated frequently, leading to cutout of
compressor, check and repair defrost timer) (Fridge)
The lube oil level is below required level (This can be because of
leakage of lube oil from seal or carry over of oil. Rectify the
leakage and refill the oil level)
Foaming of oil leading to reduced oil pressure (Ensure no foaming
takes place, renew the oil if required)
Motor overload cut outs are activating (Ensure that electrical
motor trips are working properly.)
 Compressor Start and Stops Frequently
Applicable mainly for Fridge:
Wrong Setting of Cutouts: It may be because the high pressure (HP)
cutout is set too low or LP cutout is set too high (Check and change
the setting to limit as per makers)
Differential Setting Gap is Small: The low pressure (LP) cut out is
provided with starting and stopping pressure setting. If the setting gap
is too small, it will lead to frequent cut-in and cut-out of the
compressor (Change the setting and increase the span between
starting and stopping compressor pressures.)
Defective Valves: If the compressor discharge valve is leaky or the
line solenoid valve is not closing properly, this will lead to variation in
sensor pressure and result in frequent cut-in and cut-out of
compressor (Replace all the defective valves)
Clogged Suction Filters: Compressor is provided with a filter in the
suction line. If that is clogged, it will lead to frequent LP cut out (clean
the filter)
Compressor is Running Continuously (fridge)
Not sufficient Refrigerant for cooling evaporator
(Ensure thermostatic expansion valve is working
properly and clean the filters inside TEV)
Thermostat low pressure cut-out not activated at
low temperature/ pressure (Correctly set the LP
cut-out to correct setting)
Refrigerant charge is low in the circuit (Check for
leakage of refrigerant and charge with required
refrigerant)
 Discharge Pressure Too High (High
Pressure Switch Cuts-Off)
Overcharge of refrigerant
Air inside refrigerant circuit
Condenser is dirty, water flow too little, inlet
water temperature too high, flow direction wrong,
cooling water short circuit (broken division plate)
Refrigerant discharge valve blocked or closed
Air conditioner system is under capacity
 Discharge Pressure Too Low
Refrigerant is undercharged
Excessive condenser water flow
Condenser outlet water temperature too low
Air conditioner unit is over capacity
Ineffective compression of compresor or valve is
damaged
Ambient temperature too low
 Suction Pressure Too High
Refrigerant is overcharged
Expansion valve is oversized
Air conditioner unit is under capacity
Excessive opening of Thermo valve
Ineffective compression of compressor or valve is
damaged
Ineffective contact of sensor bulb of Thermo valve
Suction Pressure Too Low / Low Pressure
Switch Cuts-Off
Refrigerant is undercharged
Evaporator coil is dirty
Temperature setting of thermostat too low
Duct damper is closed
Duct resistance too high
Supply air short-circuit
Expansion valve undersized
Air conditioner unit is over capacity
Not enough opening of thermo valve
Expansion valve clogged
Ineffective expansion valve
Air filter is clogged
Room temperature is too low
Both Low Pressure and High Pressure Too High
Condenser dirty, not enough water flow, inlet
water temperature too high
Overcharge of refrigerant
Air inside refrigerant circuit
Excessive opening of thermo valve
Ineffective contact of sensor bulb of thermo valve
Condenser water is circulating in the reverse
direction
Air conditioner unit is under capacity
Both Low Pressure and High Pressure Too Low
Expansion valve undersized or clogged
Refrigerant is undercharged
Filter drier or strainer is clogged
Evaporator coil is dirty
Excessive condenser water flow, cooling water temperature
too low
Air conditioner unit is over capacity,
Not enough opening of thermo valve
Temperature setting of thermostat too low
Duct damper is closed, Duct resistance too high
Air filter is clogged, Supply air short-circuit
Room temperature is too low, Ambient temperature too low
High Pressure Too Low and Low Pressure Too High 

Compressor valve damaged or ineffective

compression
 Evaporator Coil Icing
 Too low temperature setting ( Increase the coil
temperature by adjusting TEV or it’s sensor)
The coil capacity is less (Install large capacity
evaporator coils)
Defrost is not operational (Check if the defrost
system is functioning at regular intervals)
 
 Icing on Suction Pipe
Air conditioner unit is over capacity
Air filter is clogged
Ambient/ accomodation temperature is too low
Evaporator is dirty,
Fan motor belt loose or slip
Fan motor in rotating in the reverse direction
Temperature setting of thermostat too low
Duct damper is closed, Duct resistance too high
Supply air short-circuit
 Routine Maintenance
1) Leak test by flame or electronic meter.
2) Defrosting evaporator coil.
3) Compressor oil level check and top up as
required by Oil Charging pump.
4) Check refrigerant level in compressor
5) Clean condenser routinely.
6) Clean air filter from time to time.
7) Charging the Refrigerant (Gas or Liquid
charging)
8) After Compressor maintenance or opening the
system (Use Vacuum pump & N2 purging)
9) Replace oil separator cartridge or Silica Gel (as
par maker’s recommendation)
 Symptoms of Good Working System
1) Good cooling with normal parameters
2) No Loss of Refrigerant. (Normal Refrigerant
level in condenser is seen)
3) No loss of compressor oil (Normal oil level
maintained)
4) No frosting on suction pipe (Should be slight
cold).
5) Suction pressure and discharge pressure in
normal range.
6) Oil pressure 2-3 bars more than suction
pressure.
7) Normal sound and vibrations.
 To be continued

