SECTION 7

AIR CONDITIONING (COOLING)

UNIT 41
TROUBLESHOOTING
 UNIT OBJECTIVES
After studying this unit, the reader should be able to

• Select the correct instruments for checking an air conditioning unit with a mechanical
problem.
• Calculate the correct operating suction pressures for both standard- and high-efficiency air-
conditioning equipment under various conditions.
• Calculate the standard operating discharge pressures at various ambient conditions.
• Select the correct instruments to troubleshoot electrical problems in an air-conditioning
system.
• Check the line- and low-voltage power supplies.
• Troubleshoot basic electrical problems in an air conditioning system.
• Use an ohmmeter to check the various components of the electrical system.
 INTRODUCTION
• Troubleshooting air-conditioning equipment involves both the mechanical
and electrical systems
• Symptoms may overlap
• Mechanical problems may appear to be electrical and vice versa
• Technicians must diagnose problems correctly
MECHANICAL TROUBLESHOOTING
• Gages and temperature-testing equipment are used when performing
mechanical troubleshooting
• Always be aware of the system refrigerant
• R-410a pressures are much higher than R-22
• R-22 gages on R-410a systems will be over pressurized and can
become damaged
• Not all refrigerant oils are compatible, so gages should be used on only
one type of refrigerant
LOW PRESSURE GAGE

Pressure scale

Gage needle
Temperature scales for
various refrigerants

Vacuum range
Gages provide temperatures and pressures for saturated refrigerants
 GAGE MANIFOLD USAGE
• Displays the low- and high-side pressures while the unit is operating
• These pressures can be converted to the saturation temperatures
• Gage manifolds are used whenever the pressures need to be known
for the system
• Gages are connected to service ports
• Used to calculate superheat and subcooling
LOW PRESSURE GAGE
68.5 psig

40°F

This low side gage indicates a suction pressure of 68.5 psig, which means that the
refrigerant is boiling at 40°F in the evaporator
Schrader valves to access refrigeration circuit

When pin in the valve is

pushed in, the valve is open
and the refrigerant circuit
can be accessed

When pressure on the pin is

removed, the valve seals itself
closed and the refrigerant circuit
is once again sealed closed
 SERVICE VALVES

Service port
Line port Valve stem

Packing gland
Device port
 SERVICE VALVES

Backseated Position
• Service port is sealed, line port is open to the device port
• Normal operating position
 SERVICE VALVES

Cracked off the Backseat Position

• Service port is open to the line port and device port

• Position used for taking system pressure readings
• Position used for adding or removing system refrigerant
 SERVICE VALVES

Midseated Position

• Service port is open to the line port and device port

• Position used for system evacuation and leak checking
 SERVICE VALVES

Frontseated Position

• Service port is open to the device port

• Line port is sealed off
• Position used for pumping the system down
 WHEN TO CONNECT THE
GAGES
• Gage manifolds should not be connected every time a system is
serviced
• Small amounts of refrigerant escape each time the gages are
connected and removed from a sealed system
• Short gage hoses will limit the amount of refrigerant lost
• Low-loss fittings should be used
 LOW-SIDE GAGE
READINGS
• Used to compare the actual evaporating pressure to the normal
evaporating pressure
• Standard-efficiency systems usually have a refrigerant boiling
temperature of about 35°F cooler than the entering air temperature
• Under increased loads, the evaporator is absorbing extra sensible
and latent heat from the air
• Gage readings when the system is operating in or close to design
range will verify system’s true performance
 HIGH-SIDE GAGE
READINGS
• Used to check the relationship of the condensing refrigerant to the
ambient air temperature
• Standard efficiency air-cooled condensers condense the refrigerant at
no more than 30°F higher than the ambient temperature
• High-efficiency condensers normally condense the refrigerant at a
temperature as low as 20°F higher than the ambient temperature
 TEMPERATURE READINGS
• For determination of the system’s superheat and subcooling
temperatures
• Common temperatures used for evaluation are:
– Indoor air wet-bulb and dry-bulb temperatures
– Outdoor air dry-bulb temperature
– Suction-line temperature
– Condenser outlet temperature
– Compressor discharge line temperature
 CHARGING SYSTEMS IN THE
FIELD
• When the system is operating correctly under design conditions, there
should be a prescribed amount of refrigerant in the condenser, the
evaporator, and the liquid line
• The amount of refrigerant in the evaporator can be measured by
superheat
• The amount of refrigerant in the condenser can be measured by
subcooling
 FIELD CHARGING THE TXV SYSTEM
• Reduce the airflow across the condenser to simulate a 95°F outside air
temperature
• The superheat check will not work for the TXV because it is designed to
maintain a constant superheat of 8° to 12° under any load condition
• A subcooling check of the condenser can be used to check the system
charge
• Typical subcooling circuit will subcool the liquid refrigerant from 10° to
20° cooler than the condensing temperature
• Excessive subcooling indicates an overcharge
 ELECTRICAL TROUBLESHOOTING
• You need to know what the readings should be to know whether the
actual readings are correct or not
• Begin any electrical troubleshooting by verifying that the power supply
is energized and that the voltage is correct
• If the power supply voltage is correct, move on to the various
components
 L1 L2
RELAY OR
CONTACTOR CONTROL
CIRCUIT

MOTOR
RUN
START
RELAY
START
 L1 L2
Fuses

Contactor contacts

Contactor coil

3A 25A
L1 Contactor coil
L2

Disconnect CC 24V from inside

house
CC1 CC2

C Low pressure
control
R
Compressor

Condenser fan motor

Wiring diagram of basic components in a control and compressor circuit

 COMPRESSOR ELECTRICAL
CHECKUP
• Technicians need to be careful when condemning a compressor
– Many condemned compressors are not bad
– Unnecessary labor and material costs
• Compressor problems can be mechanical or electrical
 ELECTRICALLY CHECK A
SINGLE-PHASE COMPRESSOR
• Make certain wires are disconnected from the compressor
• Make certain all compressor terminals are clean
• Check resistance from windings to ground (ohmmeter or megohmmeter)
• Check resistance of the start and run windings
 ELECTRICALLY CHECK A SINGLE-
PHASE COMPRESSOR (cont’d.)
• Check continuity between run and start terminals
• Check voltage between common and run terminals and between
common and start terminals
• Voltage readings should be within 10% of the rated voltage
 ELECTRICALLY CHECK A
THREE-PHASE COMPRESSOR
• Check resistance from windings to ground
• Make certain wires are disconnected from the compressor
• Make certain all compressor terminals are clean
• Check each winding from terminal to terminal
• The resistance readings should be the same in all windings
 MECHANICALLY CHECKING A
COMPRESSOR
• If the supply voltage is correct, the compressor should start
• If the compressor does not start, the compressor may be stuck
• Reversing the direction of the motor may free the motor
 COMPRESSOR CAPACITY
• One or more cylinders may not be functioning properly
• Simulate design conditions as closely as possible
• If voltage is correct and amperage is very low, the compressor is
not pumping to capacity
• Indicated by a high suction pressure and a low head pressure
 TROUBLESHOOTING THE CIRCUIT
ELECTRICAL PROTECTORS –
FUSES AND BREAKERS
• Open circuit breakers or blown fuses should be treated with
caution
• Do not reset or replace a tripped breaker or fuse without trying to
determine what caused the fuse to blow or the breaker to trip
 SUMMARY - 1
• Troubleshooting air-conditioning equipment involves both the mechanical
and electrical systems
• Mechanical problems may appear to be electrical and vice versa
• Gages and temperature-testing equipment are used when performing
mechanical troubleshooting
• Gage manifolds are used whenever the pressures need to be known for
the system
• Gages are used to calculate superheat and subcooling
 SUMMARY - 2
• Gage manifolds should not be connected every time a system is
serviced
• Short gage hoses will limit refrigerant loss
• Standard-efficiency systems usually have a refrigerant boiling
temperature of about 35°F cooler than the entering air temperature
• Standard efficiency air-cooled condensers condense the refrigerant at
no more than 30°F higher than the ambient temperature
 SUMMARY - 3
• Temperature readings are needed to calculate evaporator superheat
and condenser subcooling
• The amount of refrigerant in the evaporator can be measured by
superheat
• The amount of refrigerant in the condenser can be measured by
subcooling
• Typical subcooling circuit will subcool the liquid refrigerant from 10° to
20° cooler than the condensing temperature
 SUMMARY - 4
• Begin any electrical troubleshooting by verifying that the power supply
is energized and that the voltage is correct
• Use an ohmmeter to check compressor windings for grounds, shorts
and open circuits
• Compressor voltage readings should be within 10% of the rated
voltage
• If the supply voltage to the compressor is correct, the compressor
should start