ACC System Performance Testing & Troubleshooting Information A. Performance Testing the system: Performance testing is to assure that the air conditioner system is operating efficiently and satisfactorily. Before testing, it should be determined that the conditioned air is being distributed Properly from the evaporators to the air outlets in the aircraft. ‘The following testing procedures require the use of a manifold gauge set and thermometer: NOTE Testing & servicing of the air conditioner system should be preformed by qualified personnel only! a. Connect the high and low side pressure hoses of the manifold gauge set to their respective service ports, and insure the manifold valves are closed. b. Set the air conditioner controls for maximum cooling, and place a thermometer at the evaporator air outlet ©. Operate the air conditioning system for ten minutes. d. Check the thermometer at the evaporator air outlet. Depending on the outside air temperature and humidity conditions - generally the following temperatures will give you an idea of how well the system is performing, ©. Check the manifold low pressure gauge reading to determine that it is with in the range of 30 to 40 Psi Outlet Air Temperature _ ‘System Performance : 25° - 30° F below that of the outside air Excellent 7 temperature e _ 25° - 20° F below that of the outside air Fair LL temperature _ z 20° - Or less than that of the outside air Poor temperature _ : f. To determine which of the conditions apply from the trouble shooting charts on the following pages: Connect a manifold gauge set to the system. 2. Allow the system to stabilize (approximately 10 minutes) 3. Compare actual gauge readings with those given for each condition. NOTE All gauge readings illustrated are for an outside air temperature of 95° F, with 40% humidity. If the temperature and humidity of your testing area is not the same the pressures shown will be slightly higher or lower. 4, After making sure that the conditions apply, perform specified corrective procedures on following pages. Page 1 of 11Complaint Little or no cooling tow sipe Low Lowsis HAND VALVE Low sine Hose coMNEeTED TO Lowsine service CONNECTOR Conditions 1. Low side pressure too low. Gauge should read 30-35 psi. 2. High side pressure too low. Gauge should read 210-225 psi 3. Evaporator air not cold. c= Ny Test Procedure #1 HGH 10 Low 3 ec SOS CONNECTOR Diagnosis Refrigerant is low in system, Page 2 of 11 HIGH sI08 Hose CONNECTED To NIGH SIDE SERVICE Cause Refrigerant slightly low hice sine HAND VALVE close Corrective Procedures 1. Leak test the system 2, Repair leaks (discharge the system, replace lines or components.) 3. Assure that there has been on loss of refrigerant oi 4. Evacuate the system 5. Charge the system. 6. Performance test the system,Test Procedure #2 Complaint Cause Insufficient cooling Refrigerant excessively low LowsineLow micu S108 Low somsios eee She sscnsice eae SOS eee S oer sous ea susstise aoe gua aie of gor Conditions Corrective Procedures 1, Low side pressure very low. 1. Leak test the system. Gauge should read 30-35 psi. 2. High side pressure too low. 2. Discharge the system. Gauge should read 210-225 oa 3. Evaporator air warm, 3, Repair leaks. 4, Assure that there has been no loss of refrigerant oil, 5. Evacuate the system. 6. Charge the system. 7. Performance test the system. [ ~ Diagnosis 7 System refrigerant is extremely low. A serious leak is indicated, Page 3 of 11Complaint Insufficient cooling LowSIDE NORMAL one oS Beton mt Lowsine Hose CONNECTED TO Gwasreance [] (CONNECTOR. 1. Low side pressure reading does not change, With thermostatic control, pressure should drop until compressor eycles; with suction control, pressure should modulate. 2. High side pressure reading slightly high or low (with auxiliary fan) should read 210- 225 psi 3. Evaporator air not cold. SSS NY ey Test Procedure #3 Cause Air in System MIGH SIDE NORMAL, MiGH SIDE HAND VALVE ctasen Migs 108 Hose ConwecreD ro NIGH SIDE SERVICE CONNESTOR Corrective Procedures Leak test system, Discharge system Repair leaks. Replace receiver drier bottle Evacuate the system. Charge system. Performance test system Bene Noo Diagnosis Non-condensable (air or moisture) present. / system not fully charged. Page 4 of 11Complaint Insufficient cooling See BS Lowsine Hose CONNECTED TO tonsioesenvice [] ‘CONNECTOR Conditions 1, Low pressure side reading too high. Should be 30-35 psi 2. High side pressure reading too low, Should be 210-225 psi 3, Evaporator air not cool Comm Sst Test Procedure #4 Cause Compressor Malfunction HoH SIDE Low . Might si0e NAN vaLvs cose i] YS N wah SIDE Hose CONNECTED TO NIGH SIDE SERVICE CONNECTOR Corrective Procedures 1. Repair or Replace Compressor Assy. Diagnosis Internal leak in compressor caused by wom / scored piston rings, or oylinders. Page 5 of 11Test Procedure #5 Complaint Cause Insufficient or no cooling Condenser not functioning Properly Lowsip nick MiGH si9€ Hic Low sine wan size ano VaLve ano valve Sloe Stas ow sibe Hose NIGH sie Hose connecrep To Connecrea ro tBweior senvice flaw sibe senvice eonwecron nor usen ‘¢ Sonnecron u Conditions Corrective Procedures 1. Low side pressure reading 1, Check belt tension, Loose too high. Should read 30-35 or wor drive belt can cause psi excessive pressures. 2. High side pressure reading 2. Look for clogged passages too high. Should read 210-225 between the fins and coils psi 3. Evaporator air warm 3, Replace receiver drier 4, Evacuate and recharge system. 5. Performance test the system, ~ Diagnosis ~ 1 Lack of cooling caused by too high pressure on the high side, resulting from improper operation | of condenser. (May also be a result of system over charging). | Page 6 of 11Test Procedure #6 Complaint Insufficient cooling during hottest part of hot days Cause Moisture in the system LowsiDE NonmaL, Mich SIDE NORMAL, Lowsine HaND VALVE Hertel HAND VAL Man VALVE close: Low sing Hose vsi0e» gs soe wos fonsioceemce acne oe ‘CONNECTOR NOT USED CONNECTOR u Conditions Corrective Procedures 1. Low side pressure reading 1. Discharge the system is normal (30-35 psi), but 2. Replace receiver drier drops to a vacuum reading 3. Evacuate the system during testing 4. Charge the system 2. High side reading is normal 5. Performance test the (210-225 psi) but drops when system. low side reading shows a vacuum | 7 ~~ Diagnosis ~ Excessive moisture in the system, Drying agent in the receiver drier bottle is saturated. This moisture collects and freezes in the expansion valve preventing the flow of refrigerant through the evaporator. Page 7 of 11Test Procedure #7 Complaint Cause Insufficient or no cooling Large amount of air in system Low sipe nici Wich siDE Has uso br nano va.ve [it — mi yo Ea ae ee WS Cc) ory coe nea aon eee tite poet Sher Corrective Procedures Discharge the system Replace the receiver drier Evacuate the system Charge the system Performance test the system 1. Low side pressure to high Should read 30-35 psi 2, High side pressure too high. Should read 210-225 psi 3. Evaporator air not coo! grona Diagnosis Air in system. This and the moisture in the air is contamination the refrigerant, causing the __system to operate improperly. Page 8 of 11Test Procedure #8 Complaint Cause Insufficient or no cooling Improper operation of thermostatic expansion valve (stuck open) wow sive Hiait HGH siDE HGH Lowsioe HAND VALVE. choses wax siDe MAND vaLvE choseD. owNSd ai, — i SY SWS Co) Cais LowsiDE Hose CONNECTED TO Lowsibe seRvice HIGH s10€ Hose CONNECTED To WiGH sibe SERVICE conneeroR aes CONNECTOR Conditions Corrective Procedures 1. Low side pressure too high. Contact ACC Service Should read 30-36 psi Department for additional corrective procedures 2. High side pressure too high. Should read 210-225 psi 3. Evaporator air warm 4, Evaporator and suction hose to compressor shows considerable moisture. Diagnosis ‘Thermostatic expansion valve is allowing to much refrigerant ot flow through the evaporator coils. The valve maybe stuck open or the temperature sensing bulb may be mounted incorrect! Page 9 of 11Test Procedure #9 Complaint Insufficient cooling HIGH SIDE HIGH Cause Improper operation of thermostatic expansion valve (stuck closed) Lowsipe HoH SIDE HAND VALVE. HAN vaive ctoseo ctoseo, Lowsibe Hose Had sive Hose CONNECTED TO. ConnecreD To tow sibg senvice High sibe senvice CONNECTOR wor yeep CONNECTOR u Conditions Corrective Procedures 1, Low side gauge reading too Contact ACC Service low (0 psi or vacuum). Should Department for further read 30-35 psi corrective procedures 2. High side pressure too high. Should read 210-225 psi 3. Evaporator air moderately cool - ~ Diagnosis 7 Expansion valve is not permitting a sufficient flow of refrigerant. Causes include: Valve stuck in_| restricted or closed position, Valve screen clogged (R 12 syst of refrigerant in the temperature sensi Page 10 of 11 lems only), or insufficient amount | ing bulb,Test Procedure #10 Complaint Cause Insufficient cooling Restriction in high side of system Low sie Low wich SIDE Low Low sine aH S106 HAND VALVE HAND VALVE closes — he SS cLoseD iwatbe senvice WiGH ibe seRVIcs sCTOR coe CONNECTOR Conditions Corrective Procedures 1, Low side pressure too low. 1, Discharge the system Should read 30-35 psi 2. Replace lines, receiver 2. High side pressure too drier, and other suspected low. Should read 210-225 components psi 3. Evacuate system 3. Evaporator air only slightly - 4. Charge the system cool 5. Performance test the 4. Receiver drier cool to the system touch: 7 Diagnosis There is a restriction in the lines or receiver drier bottle “starving” the evaporator (The compressor is removing refrigerant from the evaporator faster than it can enter) Page 11 of 11