HVAC Troubleshooting

Commercial heating, venting, and cooling systems do more than simply regulating the temperatures in
the building. If there is a defect in a commercial HVAC system, it can affect the satisfaction and health of
the occupants, the productivity level, and the energy bills. That is why it is crucial to have HVAC systems
properly maintained. Regular checkups and maintenance of the HVAC systems help you to identify the
possible faults and solve them in advance.

Common HVAC Systems Along With Their Problems and

Solutions
Chillers
A chiller helps to condition the air and provide a perfect environment in a commercial building. The
chillers are linked to various problems, but here are the most common issues.
Oil failure
There will be an oil failure if there is a refrigerant leak that leads to low oil in the chiller, if the oil pump is
damaged, or if there is low superheat in the chiller.

Low/High-Pressure issue
Low pressure is normally caused by a broken power assembly capillary, insufficient water flow, mud
coating on the tubes, a blocked water filter, or low refrigerant.
The chiller can also encounter a high-pressure issue if the water-cooled condenser has a buildup of
minerals that affects the water quality, or if the condenser has little or no flow. On the other hand, the
temperature of the chilled water tank might be over 80 degrees Fahrenheit.

Starter trip or blown fuses

This can happen if the motor, wires, or compressor are over-amped or shortened. The best solution for
this is to check for shorts or grounds and fix them accordingly.

Freeze stat
This will occur if the water flow is poor or if the thermostat has been set lower than the required level.

Lack of flow
There might be a weak flow if pressure or flow switches in the water circuit are not getting the right
amount of flow. Also, the water valve might be off, or the water filter might be blocked. Though in most
cases, the flow switch paddle is broken.
The chiller is running but doesn’t reach the thermostat settings
Here, the evaporator might be iced up from the inside, or the antifreeze could be broken. Also, the
system load could be too heavy for the chiller to handle.
These are the common issues you would expect to experience with commercial chillers. Always
understand how the chiller works and how to identify each problem with ease.
Chillers maintenance tips
Proper maintenance of your chiller will help you to avoid problems with it. Here are some maintenance
tips.
Keep a daily report. A daily log of the chiller plant helps you to maintain its efficiency so that you will
know all the operating condition history such as the flow rates, pressures, temperature, and fluid level.
You can depend on remote monitor technology to inspect the unit.
Treat the condenser water often to avoid corrosion, scaling or biological growth.
Avoid changing the flow rate of the chilled water, which can affect the performance of the chiller.
Ideally, maintain a flow rate of between 3 FPS and 12 FPS.
Clean the tubes regularly to enhance the heat transfer efficiency.
Lower the temperature of the condenser water entering the chiller.
Evaluate the compressor lubrication oil annually. Preferably, send a sample to a lab for chemical
analysis. This will help you to decide if you need to change the oil or not.
Inspect the motors and start operation for any fault.
Install variable speed drives for energy saving benefits.
For complicated issues, always contact a professional HVAC contractor
.
Boilers
During cold seasons, boilers play a huge role in commercial buildings, so it is important to understand
the common problems that affect the boilers, and how to solve them.

System overheat

When there is a system overheat with the boiler, there could be an issue with the system controls. If
that is the case, check the temperature settings, safety switches, or the voltage. Also, the control
thermostat might have failed, or the high-limit thermostat could be ON. You can check the temperatures
in this case.

Failure to meet the system load

If the boiler fails to meet the system load, the potential problem could be that the aboiler thermostat
hasn’t been set correctly. Check the settings of the thermostat to fix this issue. There could also be an
issue with the combustion. Ideally, check the combustion quality, the flue, and the flame to ensure that
the combustion is perfect.

Ignition failure

If the boiler doesn’t ignite, it could be as a result of various defects. First off, the internal controls of the
boiler might have failed, which can be solved by resetting or replacing the controls. The boiler could also
be overheating, or maybe the cut-out has not been reset. Alternatively, the pilot flame might be missing,
or the supply fuse could be isolated or blown. In other cases, the main burner might not be igniting.

Fumes issues

If there are fumes in the boiler room, there could be issues with the combustion. Also, the combustion
might be experiencing poor airflow. To solve this, inspect the chimney and the boiler room to ensure
that the combustion is correct.
Overheating and noisy boiler

There could be a poor circulation in the main circuit. The solution is to vent the system accordingly. If
there is a low discharge pressure in the shunt-pump, check for any obstruction in the piping.

Continuous firing

If the boiler fires nonstop, the main issue might be a faulty thermostat. You can inspect the thermostat
and replace or repair it where necessary. If there is an issue with the wiring, inspect and repair as
required. The control valve could also be sticking or faulty. You can replace it to solve the problem.

Other possible problems with commercial boilers could be a fault in the flue gas system, or the boiler
might start but the flame goes out afterward, as well as high or low water temperatures. If you can’t fix
any of them, contact a qualified commercial HVAC contractor.

Cooling Towers
The cooling tower is basically a heat exchanger that utilizes air and water to shift the heat from the AC
units to the outdoor environment. Here are the common HVAC cooling tower problems.

Leaking issues
Leaks are commonly experienced with cooling towers, which end up damaging the building. Ideally, find
a professional contractor to inspect the cooling tower for any possible leakages.
Original coating delamination or breakdown
The original coating of the cooling tower could de-laminate or break down over time. In this case, water
will be trapped in the system, which then leads to erosion or corrosion of the unit’s parts.

Issues with the water quality

The cooling tower could also experience poor water quality, which could be as a result of extreme
corrosion of the interiors. If this happens, you will need to hire a contractor to replace the unit or fix it
accordingly.

Maintenance tips for the cooling tower

Conduct a regular chemical or water treatment to eliminate the contaminants and other corrosive
elements in the unit.
Clean and prevent any blocked spray nozzles. Ideally, install clog-free nozzles to fix this problem.
Maintain an adequate airflow in the tower. Clear any debris that is at the outlet or inlet of the tower.
Also, inspect the fan blades, fan pitch, and gearbox for any faults.
Check that the pump performs perfectly. The best way to ensure this is by checking for clogged
strainers, loose bearings/connections, faulty vibrations, and any other fault that could affect the water
flow.
Conduct a preventive-maintenance program regularly.
Limit the temperature of the water leaving the tower.
Operate the cooling towers at the same time.
If the problem is overly complex, contact a professional for further assistance.
Cooling Tower Pumps
The pumps that serve the cooling towers might also be faulty, which will affect the entire cooling tower
unit. The most common issue with cooling tower pumps is loud noise, which sounds like pumping
marbles. The problem here could be an induced draft or a forced draft cooling tower. Also, negative
suction pressures can lead to pump noises.

If the component is imbalanced, the components are rubbing on each other, the coupler is misaligned,
or the base plate and motor are not installed properly, there can be a mechanical noise in the pump.

A liquid noise is caused by the movement of water in the pump. This can be caused by a flow separation,
water hammer, cavitation, or turbulence energy due to a high flow velocity.

Tips to eliminate the noise issue

Increase the liquid pressures to reduce flashing and decrease the suction lift. Here, you might have to
lower the pump and raise the tower, or simply straighten the suction piping so as to limit the friction
losses.

Decrease or increase the pump speed to limit the system resonance of the liquid or mechanical noises.

Inject a small amount of air into the centrifugal pump suction to provide a shock absorbing cushion and
limit the cavitation noises.

Adjust the pump to increase the clearance between the diffuser vanes/casing cutwater and the impeller
diameter.

Eliminate vortexing in the tower pan. You can add a baffle assembly to prevent vortexes forming. Always
contact a professional contractor if you fail to solve noises that come from the cooling tower pumps.

General HVAC Troubleshooting

Commercial HVAC systems can encounter the following problems:

Unpleasant odors or poor indoor air quality

If there is a bad smell or the air quality in the building is poor, there could be a problem with the filter or
there might be a gas leak. A bad smell will be emitted when the parts of the unit overheat, the air filters
are dirty, stagnant condensed water is in the unit, or melting debris gets into the ductwork from the
heat exchanger. Inspect the system and eliminate those common errors in the system as soon as
possible. You can call a professional if you can’t find the cause of the smell.

The IAQ can also be affected by a faulty damper, which should be checked several times throughout the
year. The damper stops the compressor when the air temperature outside is lower than a specified
point. When these dampers are not cleaned and perfectly lubricated, they tend to stick to each other.
This then overloads the cooling coils and prevents the unit from cooling itself.
Imbalanced Airflow

In most cases, holes or cracks in the ductwork can lead to inconsistent temperatures from one room to
another. When the temperatures are variable, the system uses more energy to replace the lost airflow,
leading to high energy bills.

Check for any cracks, sags, or separation in the ductwork to identify the cause of the leak. If the
ductwork is insulated, you can check for any dirty spots on the insulation. Ensure that any leaks are
corrected as soon as you identify them. Since it might be challenging and difficult to spot a leakage in
the ductwork, it is best to contact an HVAC expert.

Inefficient system

A lot of people end up replacing the commercial HVAC unit when they realize any sign of inefficiency.
Specialists point out that the efficiency of a commercial HVAC unit can be highly improved by cleaning
the condenser and the evaporator coils. Ideally, ensure that the coils in the system are cleaned twice
every year. This helps to eliminate any debris or dirty layer on the coils, which might reduce its
performance.

Loud noises

These systems will make loud noises, if there is an imbalanced system, or if some elements are blocking
the free flow of air and water inside the unit. A well-balanced pressure flow can help to get rid of any
strange noises produced by the system.

Conclusion
Most of the commercial HVAC units work differently from the regular units used in houses, because they
are designed to work for long hours and cover a bigger surface area or building. When the unit has
various faults, it will affect the air quality in the building and also lead to increased energy bills. If you do
not find the solution when carrying out the HVAC troubleshooting, always call a
HVAC Technical Support Component Analysis Chart

Compressors

Liquid Slugging Contamination of Mechanical Refrigeration System

Flooded Start

Loss of Lubricant Compressor Overheating

Condensers

High Head Pressure Refrigerant Charge Incorrect

Low Head Pressure

Evaporators

Low Airflow Excessive Airflow

Uneven Airflow over Coil Low Refrigerant Supply

Uneven Refrigerant dist. to coil Circuits or to Cooler Low Water Flow in Cooler (water-cooling evaporator for
Circuits Chillers)

Uneven Water Flow Through Cooler Low Refrigerant Supply to Cooler

Metering Devices

Evaporator Overfeed ("Flooding") Evaporator Underfeed ("Starvation")

TXV Hunting Distributor Nozzles (TXV Applications)

Refrigeration Cycle Accessories

Plugged Filter-Drier (Liquid Line) Wet Filter-Drier

Undersized Filter-Drier Crankcase Heater Inoperative

Oil Separator Float Valve Stuck Open 4-Way (reversing) Valve Damaged or Stuck-Cooling
 Refrigerant Piping

Suction Line Sizing and Design Hot Gas Line Sizing and Design

Liquid Line Sizing and Design Refrigerant Condensate Line Sizing and Design

Flash Gas at Metering Device Inlet

Component System Analysis

Troubleshooting Chart

General
Problem Symptoms Possible Causes
Category

Compressors
-Inadequate Airflow
-Noisy Operation
Over Evaporator
-Excessive Charge
-Excessive Vibration (with Fixed Metering
Device)
-Overheating -Oversized TXV
Liquid
Slugging -High Compressor Power Draw (kW) -Frosted Evaporator
-Crankcase Heater
-Compressor Failure
(Refrigerant or Inoperative
Oil) -Pumpout Control
-Reduced Capacity
Faulty
-High Saturated Suction Temperature -Flooded Start

-Compressor Does Not Pump Properly

-Zero Suction Gas Superheat

-Liquid Line Solenoid

Valve Stuck On
-Crankcase Heater Off
or Faulty
-Improper Piping
Flooded Start -See “Liquid Slugging” Symptoms
System Design
-Pumpout Control
Faulty
-Leaky Liquid Solenoid
Valve

-Overheating -Flooded Start

Loss Of
Lubricant -Floodback of Liquid
-Mechanical Seizure
Refrigerant
 -High Compressor Power Draw (kW) -Oil Trapped in System

-Failure to Start

-Noisy Operation

-Compressor Winding Thermostat Trips

-Compressor Intermittently Trips Off on Internal Motor Protection

-Improper
-System Valve(s) Stick
Evacuation/Dehydration
-Compressor Does Not Pump Properly -System Leak

-Compressor Failure -Strainer-Drier Loaded

Contamination -High Temperature
of Mechanical Break Down Oil,
Refrigeration -Overheating of Compressor Refrigerant And System
System Materials
-High Compressor Power Draw (kW) -Carbonized Valves

-Discoloration of moisture Indicator in Liquid Line Sight Glass -Sludged System

-Sealed-Tube Refrigerant Test Shows High Acid and/or Moisture Content

-Compressor Failure -Condenser Dirty

-Inadequate Condenser
-High Compressor Power Draw (kW)
Airflow or Water Flow
-Excessive Evaporator
-High Compressor Casing Temperature
Superheat
Compressor -Electrical Line Current
Overheating -Compressor Safety Winding Thermostat Trips and/or Voltage
abnormal or unstable
-Failure to Pump Properly -Loss of Lubrication
-Undercharged or
Overcharged System
-Liquid Slugging

Condensers
-Compressor Cycles off Intermittently on High Pressure Switch while System -Faulty Head Pressure
Calls for Cooling Control Device
High Head -Compressor Cycles Intermittently on Compressor Motor Protection Switch -Dirty Condenser Coil
Pressure
(Saturated -Faulty Condenser Fan
-High Saturated Condensing Temperature
Condensing Motor
Temperature
or Saturated -High Discharge Gas Superheat -Extensive Fin Damage
Discharge -Condenser Air Re-
Temperature) -Compressor Overheats
circulation
-Compressor Seizure -Dirty Condenser Fan
 -Condenser Airflow
-Compressor Motor Burnout
Blocked
-Prevailing Winds
-High Compressor Power Draw (kW) Prohibit Proper Airflow
Across Coil
-Backward Condenser
-Low System Capacity
Fan Rotation
-Slipping Condenser
-Saturated Suction Temperature Normal to High
Fan Belt
-Bent or Broken
-Excessive Condenser Water Flow Rate Condenser Fan
Blade(s)
-Scaled Water-Cooled
Condenser Tubes
-Faulty Condenser
Water Pump
-Damaged Water Pump
Impeller
-Plugged Condenser
Water Lines or Screens
-Condenser Water
Valve Stuck Closed
-Cooling Tower
Problems
-Condenser Vapor
Locked by Undersized
or Poorly Laid Out
Refrigerant Condensate
Line which Prevents
Refrigerant from freely
Draining to Receiver

-System Overcharged

-Noncondensible Gas
Present

-High Head Pressure

-High Liquid Subcooling

-Low System Capacity -System Overcharged

-High Saturated Suction Temperature

-High Compressor Power Draw

Refrigerant
Charge
Incorrect
-Low Head Pressure

-Low Saturated Suction Temperature

-Low System Capacity

-System Undercharged
-Low or Nonexistent Liquid Subcooling

-Flash Gas at Metering Device Inlet

 -Faulty Head Pressure
-Low Saturated Condensing Temperature
Control Device
-Refrigerant System
-Low System Capacity
Low Head Leak
Pressure
-Low Saturated Suction Temperature -Undercharged System
-Condenser Water
-Low Compressor Power Draw
Valve

Evaporators
-Dirty Evaporator Coils
-Low Saturated Suction Temperature
(no Filters?)
-Badly Bent Evaporator
-Low Suction Gas Superheat
Fins
-Low Saturated Condensing Temperature -Dirty Filters
-See 'Airside-Low
-Low Compressor Power Draw (kW) Airflow Over
Evaporator"

Low Airflow -Low Supply Air Temperature

-Low System Capacity

-High Space Air Temperature

-Iced or Frosted Evaporator

-Compressor Slugging

-See 'Airside' for others

-Fan Motor Speed Set

-High Supply Air Temperature
Too High
-Wrong Fan Drive
-High Saturated Suction Temperature
Package and/or Setting
Excessive -Undersized Coil
Airflow -High Compressor Power Draw (kW)
(Applied Air Handler)
-Noisy Air System Condensate Carriers
Over Air Handler Drain
Pan into Fan and
-Water Dripping from Fan and Supply Ductwork Near Air Handler
Supply Ductwork

-Bad Duct Design near

-Low System Capacity
evaporator Coil
-Coil placement
-Low Saturated Suction Temperature
improper
Uneven
Airflow Over -Uneven Condensate Coverage over Coil Surface -Air Turbulence at Coil
Coil
-Lack of Necessary Air
-Uneven Coil Surface Temperature
Baffling near Coil
-Obstruction Within Air
-Refrigerant Floodback to Compressor
Handler
 -Obstruction in
Ductwork Near Air
-Compressor Slugging Handler
-Mismatched Coil and
Air Handler

-Low System Capacity -System Undercharged

-Liquid Line Kinked or
-Low Saturated Suction Temperature
Crushed
-Evaporator Tube
-High Suction Gas Superheat Crushed (especially
return bends)
-System Refrigerant
-Low Compressor Power Draw (kW)
Leak
-Malfunctioning
-Low Saturated Condensing Temperature
Metering Device
Low -TXV Power Element
Refrigerant -Measurable Temperature Drop in Liquid Line
Low on Charge
Supply
-Undersized Metering
-Visible Bubbles in Liquid Line Sight Glass
Device
-Undersized Distributor
-High Supply Air Temperature
Nozzle
-Head Pressure Control
-Frosted or Iced Evaporator Faulty at Low Outdoor
Ambient Temperatures
-TXV Plugged
Distributor Oil Nozzle
-High Discharge Gas Superheat
-Free Water in System
Forms Ice

-Plugged Evaporator
-Low system capacity
feeder tube(s)
-Kinked or crushed
-Low Saturated Suction Temperature
feeder tube(s)
-Partially blocked
-Little or No Suction Gas Superheat
distributor
-TXV hunts -Oversized distributor
Uneven
Refrigerant -Oversized distributor
Distribution to -Compressor Floodback nozzle (applied air
Coil Circuits handlers)
or to Cooler -Improperly installed
Circuits -Compressor Slugging distributor (applied air
handlers)
-Crushed evaporator
-Uneven Coil Surface Temperature tube (especially return
bends)
-Uneven Condensate formation on Evaporator
-Plugged evaporator (or
cooler) circuit
-Frost on Some areas of Evaporator but not on others

-Low Saturated Suction Temperature -Chilled Water Pump

 -Low Suction Gas Superheat -Faulty Pump Motor
-Damaged or Blocked
-Low Saturated Condensing Temperature
Pump Impeller
-Blocked Chilled Water
-Low Compressor Power Draw (kW)
Line or Valve
-Water Baffle(s) in D-X
-Low Leaving Chilled Water Temperature Cooler misplaced
Low Water blocking flow
Flow in Cooler
-Excessive water
-Low System Capacity
scaling (flooded cooler)
-Reverse Chilled Water
-High Space Temperature
Pump Rotation
-Blockage in Chilled
-High Temperature Drop Between Entering and Leaving Chilled Water
Water piping
-Chiller shuts down Intermittently (even though thermostat calls for cooling) on -Water flow control
low Leaving Water Safety Thermostat valve restricting Flow

-Low System Capacity -(D-X) Cooler:

-Low Saturated Suction Temperature -misplaced or broken

baffle(s)
-Compressor Floodback
-excess air in water
system
-Compressor Slugging
-debris inside shell of
Uneven Water cooler
Flow Through
Cooler -High Leaving Chilled water Temperature -(Flooded Cooler):

-badly scaled water

tube(s)

-Low Temperature drop between Entering and Leaving Chilled Water -kinked or crushed
water tube(s)

-plugged water tube(s)

or water box

-Low System Capacity -System undercharged

-Head Pressure Control
not working at Low
-High Leaving Chilled Water Temperature
Outdoor Ambient
Temperatures
-Refrigerant System
Low -Low Saturated Suction Temperature
Leak
Refrigerant
-Flooded Cooler
Supply to
Cooler
-refrigerant flow from
-High Suction Gas Superheat condenser blocked

-cooler refrigerant
supply valve stuck
-Low Compressor Power Draw (kw) -D-X Cooler:
 -Low Saturated Condensing Temperature
-liquid line or
-Space Temperature Too Warm accessories plugged

-liquid line kinked or

crushed

-TXV power element

low on charge

-TXV plugged or stuck

-Chiller Compressor Cycles on and off Intermittently on Low Pressure Switch -refrigerant distributor
or nozzle plugged

-electronic expansion
valve faulty or
microprocessor
problem

-frost-pinched cooler
tubes

Metering Devices
-System Overcharge
-High Saturated Capacity
(fixed metering device)
-Oversized Metering
-Low Suction Gas Superheat
Device
-Liquid Floodback -TXV Stuck Open
-TXV Superheat setting
-Compressor Slugging
too Low
-TXV type wrong for
-Compressor Overheats
Refrigerant in system
Evaporator -Uninsulated TXV
OverFeed -High Compressor Power Draw (kW) sensing bulb in warm
("Flooding") area
-Loose TXV sensing
-Compressor Failure
bulb
-Incorrectly located
-Compressor Pumps improperly
TXV sensing bulb
-Partial load too low for
Metering Device
-Excessive Oil
-TXV Hunts
Circulating in System
-High Head Pressure
(fixed metering device)

-Low System Capacity -System undercharged

Evaporator -Undersized metering
Underfeed -Low Saturated Suction Temperature
device
("Starvation")
-Plugged metering
-High Suction Gas Superheat
device
 -Plugged distributor or
-Low Compressor Power Draw (kW)
nozzle
-Undersized distributor
-Low Saturated Condensing Temperature
or nozzle (TXV jobs)
-Kinked or crushed
-High Discharge Gas Superheat
capillary tube
-TXV stuck in closed
-High Supply Air Temperature
position
-TXV power element
low on charge
-Wrong TXV for
refrigerant in system
-Plugged or crushed
TXV external equalizer
line
-TXV superheat setting
too high
-Iced or Frosted Evaporator
-Incorrect TXV sensing
bulb location
-Free water in system
forms ice and blocks
refrigerant flow
-Low head pressure
(fixed metering device)
-Faulty head pressure
control device

-Saturated suction temperature oscilates High then Low, in a cyclical fashion -Oversized TXV
-Improper part-load
TXV Hunting -Suction gas superheat oscilates high and low in a cyclical fashion control operation loads
TXV too lightly
-Very light cooling load

-Undersized distributor
-Evaporator Underfeed (see symptoms above) Nozzle (quite unlikely
on comfort work)

Distributor -Evaporator unevenly fed by refrigerant (see symptoms on evaporator sheet) -Oversized Nozzle
Nozzles (TXV
Applications) -Nozzle not sized for
load stability

-Faulty Part-Load
control sequence for
evaporator sections

Refrigeration Accessories
Plugged Filter-
-Dirty refrigeration
Drier (Liquid -Starved evaporator symptoms (see evaporator sheet)
system
Line)
-Improper
-Compressor cycles on low pressure switch
evacuation/dehydration
 -Metal chips, scale,
etc., in system from
installation

Wet Filter- -System Refrigerant

-Moisture indication sight glass shows wet
Drier leak
-Improper
-Valves stick intermittently and system cycles off from internal blockage
evacuation/dehydration
-Leaking water-cooled
-Sealed Tube test of refrigerant shows wet
condenser tubes
-Filter-Drier exposed to
air before installation

-Low system capacity

-Low compressor power draw (kW)

-Bad design on field
-Low saturated suction temperature
piping system
Undersized
Filter-Drier -Low saturated Condensing Temperature

-High discharge gas superheat

-Flash gas in liquid line sight glass

-High liquid refrigerant subcooling

-Flooded Start:

-High Compressor power draw (kW)

-Noisy operation -Never switched on

Crankcase -Excessive compressor vibration

Heater
Inoperative -Overheating of compressor
-Violent oil foaming (visible in compressor sight glass) -Heater element broken

-Control Circuit problem

-Electrical power or
control connection
loose or corroded

-Sludge blocking oil

-Oil level low on compressor sight glass separator float valve
orifice

Oil Separator -Oil separator float

-High compressor power draw (kW)
Trapping Oil assemble faulty
-Compressor overheating

-Compressor noisy
 -Debris at oil separator
-High saturated suction temperature orifice keeps float valve
from seating properly
-High saturated condensing temperature -Faulty Float assembly
Oil Separator
Float Valve -Liquid refrigerant
Stuck Open migrates through
-High compressor power draw (kW) separator to
compressor oil sump at
shutdown
-Flooded Start

-Sludge in refrigeration
-Low or no heating capacity
system
4-Way -Acids in refrigeration
(reversing) -Compressor cycles intermittently on internal overload
system
Valve
Damaged or -Improper
-Compressor runs but low on heating capacity
Stuck-Heating evacuation/dehydration
-4-way valve leaks
internally

-Undersized suction
-Low system capacity
line
-Low saturated suction temperature -Pinched suction line

-High compression ratio -Obstructed suction line

-Compressor overheats -Oversized suction line

-Suction line layout
-Compressor noisy
creates oil entrapment
-Suction riser oversized
-High compressor power draw (kW)
or improperly laid out
-Mechanical seizure of compressor
Suction Line
Sizing and -Compressor won't start
Design
-Compressor trips off on motor protection

-Contaminated system

-Compressor pumps inadequately

-Lack of insulation on
-Suction line sweating
suction line
-Excessive suction gas superheat

-High discharge gas superheat

 --Improperly laid out
-Broken Suction line and/or supported near
compressor
-Noisy line vibration

-Undersized hot gas

-Low system capacity
line
-High saturated condensing temperature -Pinched hot gas line

-High Compressor power draw (kW) -Obstructed hot gas line

-High compressor ratio

-Oversized hot gas line

-Compressor overheats
(especially risers)
-Hot gas line layout
-Compressor noisy
causes oil entrapment
-High compressor power draw (kW) -Hot gas riser oversized
Hot Gas Line
Sizing and -Hot gas riser laid out
Design -Mechanical seizure of compressor
wrong
-Oil or liquid refrigerant
backflow to compressor
-Compressor won't start
at shutdown or at low
capacity
-Compressor trips off motor protection

-Compressor pumps inadequately

-Ruptured (Failed)
-Broken hot gas line
Vibrasorber
-Improperly laid out
-Noisy line vibration and/or supported piping
near compressor
-Lacking hot gas line
check valve near
-Compressor noisy at startup after shutdown period condenser inlet. Liquid
refrigerant lays on
compressor heads
-Valves damaged or
broken from hydraulic
-Flooded start after shutdown
forces caused by liquid
on heads
Liquid Line -Compressor vibrates excessively at startup after shutdown period -
sizing and
Design High compressor power draw (kW) after shutdown period

-Compressor pumps inadequately

-Flash gas at liquid line sight glass -Undersized liquid line

-Pinched liquid line

-Low saturated suction temperature
 -Low compressor power draw (kW) -Obstructed liquid line
-Low system capacity -

-High suction gas superheat

-Condenser vapor lock

-Low system capacity
from undersized line
-Line layout prevents
-High saturated condensing temperature condenser from freely
draining to receiver
-High discharge gas superheat
Refrigerant
Condensate -High compressor power draw (kW)
Line Sizing and
Design

Flash Gas at
Metering
Device Inlet

To use the HVAC Technical Support AC Pressure Temperature Chart,

1. Turn unit on; monitor system running approximately 15 to 30 minutes.

Take a reading of your refrigerant system pressure (PSIG).
2. Find the corresponding saturated pressure for your refrigerant.

Superheat (for units with fixed metering device): Compute the superheat by
determining saturated suction temperature from Temperature Pressure Chart.
Subtract from actual suction line temperature before compressor. The
manufacturers recommended superheat is usually listed in the installation
instructions on on the units rating plate. If it is not listed use 15 degrees of
superheat as a default.

Subcooling (for units with Thermostatic Expansion Valve or TXV): Compute

subcooling by determining saturated condensing temperature from Temperature
Pressure Chart. Subtract from liquid temperature entering TXV. The manufactures
recommended subcooling is usually listed on units rating plate. If it is not listed use
15 degrees of subcooling as a default.

PSIG R-22 R-134A R-410A PSIG R-22 R-134A R-410A

0 -41 -15 -60 78 46 75 20

2 -37 -10 -58 80 48 76 21

4 -32 -5 -54 85 51 79 24
6 -28 -1 -50 90 54 82 26

8 -24 3 -46 95 56 85 29

10 -20 7 -42 100 59 88 32

12 -17 10 -39 105 62 90 34

14 -14 13 -36 110 64 93 36

16 -11 16 -33 115 67 96 39

18 -8 19 -30 120 69 98 41

20 -5 22 -28 125 72 100 43

22 -3 25 -26 130 74 103 45

24 0 27 -24 135 76 105 47

26 2 30 -20 140 78 107 49

28 5 32 -18 145 81 109 51

30 7 35 -16 150 83 112 53

32 9 37 -14 160 87 116 57

34 11 39 -12 170 91 120 60

36 13 41 -10 180 94 123 64

38 15 43 -8 190 98 127 67

40 17 45 -6 200 101 131 70

42 19 47 -4 210 105 134 73

44 21 49 -3 220 108 137 76

46 23 51 -2 225 110 139 78

48 24 52 0 235 113 142 80

50 26 54 1 245 116 145 83

52 28 56 3 255 119 148 85

54 29 57 4 265 121 151 88

56 31 59 6 275 124 153 90

58 32 60 7 285 127 155 92

60 34 62 8 295 130 158 95

62 35 64 10 305 133 161 97

64 37 65 11 325 137 167 101

66 38 66 13 355 144 173 108

68 40 68 14 375 148 177 112

70 41 69 15 405 155 182 118

 72 42 71 16 500 173 202 134

74 44 72 17 600 N/A N/A 149

76 45 73 19 700 N/A N/A 159

I have no cooling
POSSIBLE CAUSE The circut breaker might have been tripped.

RECOMMENDED ACTION Try resetting your home's circut breaker.

POSSIBLE CAUSE Your thermostat controls may be set incorrectly.
RECOMMENDED ACTION Try turning the thermostat off and then on again. Reset on the desired
temperature and see if that helps.
POSSIBLE CAUSE The indoor unit is running, but the outdoor unit is not.
RECOMMENDED ACTION Try turning off your thermostat controls for 1 to 3 hours to see if the system
resets itself. If there is no change and the air coming through the vents is
warm,

I have no heating
POSSIBLE CAUSE If it’s a gas furnace, the gas might be shut off.
RECOMMENDED ACTION Check the furnace shut-off valve located on the supply gas piping coming
into the furnace. Make sure it wasn’t accidentally switched off.
POSSIBLE CAUSE The circuit breaker might have been tripped.
RECOMMENDED ACTION Try resetting your home's circut breaker.

POSSIBLE CAUSE Your thermostat controls may be set incorrectly.

RECOMMENDED ACTION Try turning the thermostat off and then on again. Reset to the desired
temperature and

My utility bill is higher than expected

POSSIBLE CAUSE If you have your thermostat set to a temperature drastically warmer or
cooler than the outside temperature, your system has to work harder to
maintain the temperature. This can result in a higher than usual utility bill.

RECOMMENDED ACTION Try adjusting your thermostat to a more moderate temperature.

POSSIBLE CAUSE Your utilities company might have raised their rates.
RECOMMENDED ACTION Contact your utility company and compare the rates on your current bill
with those from previous months.

I have no airflow
POSSIBLE CAUSE The filters for your system may need to be changed.

RECOMMENDED ACTION Consult the owner’s guide for your system to find out how to replace the
filters and what type of filters you will need.
POSSIBLE CAUSE A dirty coil may be stopping up your system.
RECOMMENDED ACTION If it’s a problem with the coil, you’ll need the assistance of your local
Trane Comfort Specialist™.

My system is constantly running

POSSIBLE CAUSE The thermostat temperature might be set too low (in summer months) or too
high (in winter months).
RECOMMENDED ACTION Try adjusting your thermostat. If this does not solve the problem,

The drain pan is overflowing

POSSIBLE CAUSE The drain pan below your interior AC unit might not be moving
condensation to the nearby drainage pipe.
RECOMMENDED ACTION Your electric pump, which moves the water to the nearby drainage pipe,
might have come unplugged. Check to be sure. Also check to see if there are
any observable kinks or blocks in the drainage line. If you have any
questions,

FLOODING&SLUGGING

Flooding is liquid refrigerant entering the compressor’s crankcase while the compressor is running.
Flooding occurs to a compressor only during the on cycle.

Causes could be:

• Wrong TXV setting (no compressor superheat);

• Overcharge;

• Evaporator fan out;

• Low load on evaporator;

• End of cycle (lowest load);

• Defrost clock or heater out (iced coil);

• Dirty or blocked evaporator coil;

• Capillary tube overfeeding;

• Capillary tube system overcharged;

• Expansion bulb loose on evaporator outlet;

• Oversized expansion valve;

• Flooding after hot gas termination;

• Heat pump changeover; and

• Defrost termination.

Since liquid refrigerants are heavier than refrigeration oils, liquid refrigerant returning to the
compressor will settle under the oil in the bottom of the compressor’s crankcase. This liquid refrigerant
will gradually be boiled off from the low pressures in the crankcase. However, since the liquid
refrigerant being boiled off is under the oil in the crankcase, very small oil particles will be entrained in
this vaporization process. The oil level in the crankcase will now drop and rob mechanical parts of vital
lubrication.

Often, refrigerant-cooled semihermetic compressors have check valves located on a partition between
the crankcase and motor barrel to prevent oil and liquid refrigerant from mixing. Air-cooled semi-
hermetic compressors and hermetic compressors are often more prone to flooding. Suction
accumulators can help a flooding condition, but if the situation is severe, accumulators can also flood.

Crankcase pressures can become excessively high from liquid refrigerant boiling in the crankcase. These
high crankcase pressures can cause refrigerant and entrained oil particles to escape around the rings of
the pistons during its down stroke. Once in the compressor’s cylinders, the refrigerant and oil will be
pumped by the compressor into the discharge line. The compressor is now pumping oil and refrigerant
and robbing the crankcase of lubrication.

Oil in the system and not in the crankcase will coat the inner walls of the tubing and valves and cause
unwanted inefficiencies. Higher than normal crankcase pressures caused from the higher density
refrigerant and oil mixture being pumped through the compressor’s cylinders will cause high
compressor current draw. This may overheat and even trip the compressor. Broken valves can also
occur from this phenomenon. A telltale sign that a compressor’s crankcase is being flooded with
refrigerant will be a cold, frosted, or sweaty crankcase. A foaming compressor’s oil sight glass with a low
oil level are also signs of flooding. Higher than normal current draws will also be present.

SLUGGING

Slugging is liquid refrigerant, or liquid refrigerant and oil, entering the compressor’s cylinder during an
on cycle. Causes could be:

• No compressor superheat;

• Migration (off cycle);

• Bad TXV;
• TXV hunting;

• Low load;

• End of cycle (lowest load);

• Evaporator fan out;

• Iced evaporator coil;

• Defrost timer or heater out;

• Dirty evaporator;

• Capillary tube overfeeding; and

• Overcharge.

Air-cooled semi-hermetic compressors are more prone to slugging liquid than refrigerant-cooled semi-
hermetic compressors. This is because refrigerant is often drawn directly into an air-cooled semi-
hermetic compressor’s cylinder without passing through the motor barrel. Slugging can result in broken
valves, broken head gaskets, broken rods,

Most hermetic compressor’s suction lines end at the shell of the compressor.

ICE ON THE COILS AND WHY IT NEEDS REPAIR

There are a number of causes for the development of ice and frost along the coils. These are the most
common:

Clogged air filter

Dirty evaporator coil
Lowered refrigerant charge

In each case, the evaporator coil loses its ability to effectively absorb heat. This prevents the cold
refrigerant moving through the coil from warming up, and subsequently the moisture that condenses
along the coil will freeze.

Once ice begins to form along the coil, it further blocks heat absorption and initiates a downward cycle
where even more ice forms. Without remedy, the entire coil will eventually have a block of ice covering
it, completely halting heat exchange and preventing the air conditioner from providing any cooling. (The
mass of ice can also permanently damage the coil.)
A clogged air filter

is the most frequent cause of icing, but also one that is easily preventable. Make sure you change the
filter once a month while the air conditioner runs regularly (i.e. most of the summer) and you shouldn’t
encounter a problem from the evaporator coil receiving insufficient warm air. If ice starts to form,
change the filter first, but still call for repairs to help defrost the coil and check that another malfunction
isn’t creating the situation.

A grime-covered evaporator coil

will also require professional repairs; in order to properly clean the coil, it must first be removed from
the unit, and this calls for the work of a trained technician. Keep in mind that simply scraping off the ice
will not solve the problem.

Loss of refrigerant charge

is the most serious cause of icing. Not only will it start the ice development across the coil, it will change
the pressure inside the system and damage other components. The compressor—the heart of the AC—
is at particular risk, since the refrigerant will no longer cool it down adequately and the component may
overheat and burn out. You must call for repairs if you suspect a refrigerant leak is lowering its charge (a
hissing sound is one of the warning signs). Professionals will locate the leaks, seal them, check for
compressor damage, and then recharge the refrigerant to its correct level.

The compressor's discharge temperature is often an overlooked temperature when

troubleshooting a refrigeration or air conditioning system. However, it is very important because
it's an indication of the amount of heat absorbed in the evaporator and suction line, and any heat
of compression generated by the compression process.

Because the compressor's discharge temperature is superheated, a pressure-temperature

relationship does not exist and it must be read directly on the discharge line by some sort of
temperature-measuring device.

The compressor's discharge temperature should be measured about 1 to 2 inches away from the
compressor on the discharge line. This discharge temperature should never exceed 225°F. Carbonization
and oil breakdown can occur if compressor discharge temperatures exceed 225°.

The three causes for high discharge temperatures are:

High condensing temperature.

Low evaporator pressures and temperatures.

High compression ratios.

HIGH CONDENSING TEMPERATUREThere are many potential causes of high compressor discharge
temperatures. A high condensing temperature is one of them.

When the condensing temperature is high, the compressor must compress the refrigerant from the low-
side (evaporating) pressure to an elevated high-side (condensing) pressure. This added work done by
the compressor would raise the heat of compression. Thus, the compressor's discharge
temperature will be higher.

Remember, condensing temperature is the temperature the refrigerant is as it changes from a vapor to
a liquid in the condenser. There is a pressure-temperature relationship with the condensing
temperature because of the phase change. A gauge reading on the high side of the system is all that is
needed to find the condensing temperature. Convert this pressure to a temperature using a pressure-
temperature chart. This is the condensing temperature.

However, there are many causes for high condensing temperatures, which will also cause high discharge
temperatures; high condensing temperatures cause high compressor discharge temperatures. Listed
below are causes for high condensing temperatures:

Dirty condenser.

High ambient temperature.

Noncondensable (air) in the system.

Condenser fan out.

Restricted airflow over condenser.

Refrigerant overcharge.

Wrong refrigerant.

High heat load on evaporator.

LOW EVAPORATOR PRESSURES AND TEMPSLow evaporator pressures also may cause a high compressor
discharge temperature. When evaporator pressures are low, the compressor must compress refrigerant
from this lower evaporator pressure to the condensing temperature. This added work of compression
would make the heat of compression higher. Thus, the compressor's discharge temperature will
be higher.

Remember, evaporator temperatures are the temperature of the refrigerant as it changes from a liquid
to a vapor in the evaporator. There is a pressure-temperature relationship with the evaporating
temperature because of the phase change.
A gauge reading on the low side of the refrigeration system is all that is needed to find the evaporating
temperature. Convert this pressure to a temperature using a pressure-temperature chart. This will be
the evaporating temperature.

However, there are many causes for low evaporating pressures and temperatures, which will also cause
high compressor discharge temperatures, since low evaporating pressures cause high compressor
discharge temperatures. Listed below are causes of low evaporator pressures:

Dirty evaporator coil.

Iced up evaporator coil.

Evaporator fan motor out.

Shortage of airflow over the evaporator.

Frosted evaporator coil from high humidity.

Frosted evaporator coil from a bad defrost heater or other defrost component malfunction.

Low heat load on the evaporator coil.

Defrost intervals set too far apart on the time clock.

Undercharge of refrigerant.

End of the running cycle.

Partially plugged filter-drier.

Compressor inlet screen partially plugged.

Restricted liquid line.

Wrong refrigerant.

Metering device starving.

compressor oil

The two categories of oils commonly used in the compressors are mineral or synthetic oils.

One type of mineral oil (MO) called Naphthenic is commonly used.

Synthetic oils such as glycols, esters and alkylbenzenes (AB) have been used in the refrigeration
applications for some time without any problem.

Caution

When servicing the compressor, always consult the manufacturers of the compressor to find out the
type and amount of oil that can be used for that particular refrigerant.

Os&y valve

is the sectional valve and it consist of

- Os&y gate valve for maintenance(normally open).

-Tamper switch to sure os&y is open.

-PRV (pressure reduce valve).

-Check valve (non return valve).

-Flow switch.

-Pressure gauge.

-Test drain.