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One of the best-known ways for a service technician to organize his or her thoughts is through the use
of a service checklist like the one shown here.
SERVICE CHECKLIST
Measured values:
Compressor discharge temperature*
Condenser outlet temperature*
Evaporator outlet temperature*
Compressor in temperature*
Ambient temperature*
Box temperature*
Compressor volts
Compressor amps
Low-side (evaporating) pressure (psig)
High-side (condensing) pressure (psig)
By simply measuring and recording the above six temperatures (noted above with *) with thermistors or
thermocouples, getting the low- and high-side pressure readings from a gauge manifold set, and
determining the compressor’s voltage and amperage, a technician will be able to thoroughly
troubleshoot any refrigeration system quickly. These six temperatures and two pressures give the
technician evaporator superheat, compressor superheat, condenser subcooling, and condenser split for
the system.
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TROUBLESHOOTING
08/10/2018 Troubleshooting An Undercharge of Refrigerant
Referring to the checklist, a technician can analyze a system for faster systematic troubleshooting. Let’s
take the categories of the service checklist one by one for an undercharged system, as detailed in the
next checklist. Temperatures are in degrees Fahrenheit (degrees F). The system is a low-temperature
refrigeration system with R-134a as the refrigerant. The system incorporates a liquid receiver and a
TXV for a metering device. In all cases, let’s assume that this system has components that were
originally sized properly and are still on the system.
REFRIGERANT UNDERCHARGE
Measured values:
Compressor discharge temperature…...220
Condenser outlet temperature………….78
Evaporator outlet temperature…………10
Compressor in temperature……………50
Ambient temperature………………….70
Box temperature…………………….…20
Compressor volts …………………….230
Compressor amps ……………………Low
Low-side (evaporating)
pressure (psig)…3.94 in. Hg (-20 degrees)
High-side (condensing)
pressure (psig)…....86.4 psig (80 degrees)
SYMPTOMS
Medium to high compressor discharge temperature;
High evaporator superheat;
High compressor superheat;
Low condenser subcooling;
Low compressor amps;
Low evaporator pressure; and
Low condensing temperature.
COMPRESSOR DISCHARGE
This temperature is very high compared to normal system operations. The 220 degree discharge
temperature is caused from the evaporator and compressor running high superheat along with high
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08/10/2018
compression ratios. When undercharged, Troubleshooting
do not expect An Undercharge of Refrigerant
the TXV to control superheat. The TXV may be
seeing vapor and liquid at its entrance. The evaporator will be starved of refrigerant and running high
superheat. The compressor now sees high superheat coming to it, and with the compression stroke will
superheat the vapors even more.
COMPRESSION RATIOS
Compression ratios will also be elevated, giving the system a higher than normal heat of compression.
Compression ratios will be high from low evaporator pressures. This will give the system very low
volumetric ef ciencies and cause unwanted inef ciencies with low refrigerant ow rates. The
compressor will now have to compress much lower pressure vapors coming from the suction line to the
condensing pressure. This requires a greater compression range and a higher compression ratio. This
greater compression range from the lower evaporator pressure to the condensing pressure is what
causes more compression work and generates more heat of compression. This increased heat may be
seen by the high compressor discharge temperature.
Higher compression ratios and higher superheats are what cause the discharge temperature to be high.
Remember that the discharge line sees all of the superheat coming to the compressor, the electric
motor heat generated, and the heat of compression.
The absolute limit that any discharge temperature should be when measured at a distance of about 3
inches from the compressor on the discharge line is 225 degrees. The back of the discharge valve is
usually about 50 to 75 degrees hotter than this point on the discharge line. This would make the back of
the discharge valve about 275 to 300 degrees. This could vaporize oil around the cylinders and cause
excessive wear. At 350 degrees, oil will break down. Overheating of the compressor will soon occur.
Compressor overheating is one of today’s most serious eld problems. Try to keep your discharge
temperatures below 225 degrees for longer compressor life. (Note: For more information on compressor
discharge temperatures, refer to “A Look At Compressor Discharge Temperatures” in the March 4, 2002
issue of The News.)
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08/10/2018 Troubleshooting An Undercharge of Refrigerant
Again, since the liquid line, TXV, and evaporator are being starved of refrigerant from the undercharge,
so too will be the compressor. This can be seen in the high compressor superheat reading.
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08/10/2018 Troubleshooting An Undercharge of Refrigerant
The temperature difference between the condensing temperature and the ambient is called the
condenser’s delta T or split. (See Equation 1.) The service industry often refers to this as the condenser
split. The term condenser split will be used from here on in this article in place of delta T.
Equation 1:
Condensing temperature - Ambient temperature = Condenser split
As the condenser sees less and less heat from the evaporator and compressor because both of them are
starved of refrigerant from the undercharge, the condenser split will decrease. No matter what the
ambient temperature is, the condenser split (or, in other words, the difference between the condensing
temperature and the ambient) will remain the same if the load remains the same on the evaporator.
Condenser split will change if the load on the evaporator changes. Some common condenser splits for
refrigeration applications are listed below in Table 1. Box temperatures will tell the technician what
evaporator load the system is under. A low box temperature means a low load and a high box
temperature means a high load.
CONCLUSION
As one can see, systematic troubleshooting entitles a thorough knowledge of the refrigeration system
and its components. How and why temperatures and pressures respond the way they do when
something goes wrong with the system can only be understood through a thorough analysis of a system
checklist. System checklists let service technicians organize their thoughts and help them nd the
answers to tough problems faster.
Tomczyk is a professor of hvac at Ferris State University, Big Rapids, MI, and author of the book
Troubleshooting and Servicing Modern Air Conditioning & Refrigeration Systems, published by ESCO
Press. To order, call 800-726-9696. Tomczyk can be reached at tomczykj@tucker-usa.com.
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