Air Conditioning System Troubleshooting

Air Conditioning System Troubleshooting
August 4, 2008
John Tomczyk
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In reciprocating compressors, leaky valves or worn piston rings are two of the major
problems that lead to inefficiencies associated with compressors.
This is the final article in a series covering inefficient compressors, non-condensibles in the
system, low and high condenser entering air temperatures, and different metering devices as
they apply to troubleshooting air conditioning systems.
Inefficient compressors certainly decrease the heat transfer ability of the air conditioning
system since they are responsible for circulating the refrigerant through the system while it
absorbs heat and then rejects it. In reciprocating compressors, leaky valves or worn piston
rings are two of the major problems that lead to inefficiencies associated with compressors.
Symptoms for an inefficient compressor are high suction pressures and low discharge (head)
pressures. If the compressor is inefficient, the evaporator cannot handle the high heat load
due to a decreased refrigerant flow rate and the conditioned space temperature will start to
rise. This rise in return air temperature will overload the evaporator with heat causing high
suction pressures and higher-than-normal superheats.
Piston ring blow-by and reed valve leakage can also cause high suction pressures from recirculation of refrigerant. This is also a cause of low refrigerant flow rate. The condenser will
also see a reduced heat load to reject from the decreased mass flow rate of refrigerant being
circulated through it. The reduced condenser load will cause a low condensing temperature
High suction pressures;
Low head pressures;
High superheat (capillary tube and orifice);
Condenser sub-cooling.
High return air temperature;
Low compressor amp draw;
and pressure.
The compressor amp draw will be lowered from less work having to be expended with the
low mass flow rate of refrigerant from re-circulated refrigerant. Subcooling in the condenser
should be a bit low from the reduced heat load on the condenser.
Symptoms for an inefficient reciprocating compressor with bad valves and leaky rings could
include:
NONCONDENSIBLES
Air and water vapor are probably the best known non-condensible in a refrigeration or air
conditioning system. Non-condensibles usually enter a system through poor service practices
and/or leaks.
A technician forgetting to purge hoses can let air and water vapours into a system. The air and
water vapor will pass through the evaporator and compressor because the compressor is a
vapor pump. Once the air gets to the condenser, it will remain at its top and not condense.
The sub-cooled liquid seal at the condensers bottom will prevent the air from passing out of
the condenser. This air and water vapor will take up valuable condenser surface area and
cause high-head pressures. Subcooling will be high because of the high-head pressures
causing a greater temperature difference between the liquid temperature in the condenser and
the ambient.
Non-condensibles in a system and an overcharge of refrigerant have very similar symptoms
when a TXV metering device is used.
Symptoms of non-condensibles in a system could be:
High head (condensing) pressures;
High sub-cooling;
High compression ratios;
High discharge temperatures.
LOW CONDENSER ENTERING AIR TEMPERATURE
Low condenser entering air temperature will cause a low-head pressure from the excessive
heat transfer between this cool ambient and the condenser coil. Low-head pressure may
reduce flow through metering devices that have capacity ratings dependant on the pressure
differences across them. This reduced refrigerant flow causes a starved evaporator that will
cause low suction pressures and high superheats. However this could be offset by increased
sub-cooling at these lower ambients.
This entire drop in capacity may decrease the air conditioners heat removal abilities if it is
not designed for it. If not designed properly, liquid will start to back up in the condenser. But,
because of a low heat transfer rate caused from the lower condenser temperature, the liquid
temperature in the bottom of the condenser will be low, causing liquid subcooling in the
condenser to be increased.
Also, less refrigerant circulated means less work for the entire system to perform, so the
ampere draw of the compressor will be lowered.
However, if the system is set up for this reduced condenser air entering temperature, the head
pressure can be designed to float or change with the changing ambient temperature. This
will give lower head pressures and increased efficiencies. A properly matched TXV to handle
reduced pressure drops across its orifice may have to be incorporated into the design.
Symptoms of low condenser entering temperature could be:
Low entering air temperature;
Low suction pressure if not designed for low-head pressure at the TXV;
Low discharge (condensing) pressure;
High superheat if not designed for low-head pressure at TXV;
Low amp draw;
High subcooling.
HIGH CONDENSER ENTERING AIR TEMPERATURE
High ambients will have much different effects on an air conditioning system. The higher
outdoor ambients will cause head pressure to elevate in order to complete the heat rejection
task. The temperature difference (TD) between the condensing temperature and the ambient
will go down and the refrigerant gas will not condense until the head pressure rises. The
condenser cannot reject as much heat at this lower TD, and thus will accumulate the heat.
The accumulated heat forces the condensing temperature to elevate to a TD where the heat
can be rejected. Remember, the temperature difference is the driving potential for heat
transfer. However, this heat rejection happens at a higher condensing temperature forcing the
system to have higher compression ratios and lower efficiencies.
High-head pressures cause the compression ratio to increase causing low volumetric
efficiencies from higher-pressure vapors re-expanding in the clearance volume of the piston
cylinder on each down stroke.
As volumetric efficiencies decrease, mass flow rates decrease and the compressor is less
efficient. High-head pressures also elevate liquid temperatures entering the metering device,
which will increase evaporator flash gas and thus decrease the net refrigeration effect.
Because of these inefficiencies, the suction pressure may be a bit higher. The system will
have a hard time maintaining temperature and humidity of the conditioned space.
METERING DEVICES
Evaporator superheats will vary depending on the type of metering device.
Flow rates through a capillary tube-metering device or any fixed orifice-metering device
depend on the pressure difference across the metering device. Higher head pressures will
increase the flow rate through this metering device pushing the subcooled liquid at the
condensers bottom through the metering device at a faster rate. Because of this, condensing
subcooling will decrease. Evaporator superheat will also decrease because of a flooded
evaporator coil with a lot of flash gas at its entrance.
TXV systems will try to maintain evaporator superheat even though the pressure drop across
the valve may be out of its control range at the highest-ambient temperatures. Here, the
condenser subcooling may be normal.
FINAL THOUGHT
As one can see, air conditioning system diagnosis isnt easy. A service technician must be a
trained professional to diagnose a system efficiently and correctly. No longer can we rely on
rules of thumb for coil temperatures or pressures.

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What are some common problems that can cause an inefficient compressor?

What are some symptoms of an inefficient compressor?

Air Conditioning System Troubleshooting

LOW CONDENSER ENTERING AIR TEMPERATURE

HIGH CONDENSER ENTERING AIR TEMPERATURE

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