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Classroom Manual/Shop Manual: Diagnosis of The Refrigeration System

This document discusses diagnosing air conditioning systems. It identifies the low and high sides of the system and discusses using gauge readings to diagnose six common system malfunctions. Temperature-pressure relationships are examined and differences between R-134a and R-12 systems outlined. Procedures for determining electrical or mechanical failures, system charge state, and functionally testing components are provided.

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77 views

Classroom Manual/Shop Manual: Diagnosis of The Refrigeration System

This document discusses diagnosing air conditioning systems. It identifies the low and high sides of the system and discusses using gauge readings to diagnose six common system malfunctions. Temperature-pressure relationships are examined and differences between R-134a and R-12 systems outlined. Procedures for determining electrical or mechanical failures, system charge state, and functionally testing components are provided.

Uploaded by

liviugrasu_scribd
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Chapter 7

Classroom Manual/Shop Manual

Diagnosis of the
Refrigeration System
Objectives
• Identify the low and high side of the air
conditioning system.
• Diagnose six system malfunctions by gauge
readings.
• Read and understand temperature-pressure
charts.
• Discuss temperature-pressure relationships.
• Identify the differences between R-134a and R-
12 systems.
Objectives
• Determine if the air conditioning malfunction is due
to an electrical or mechanical failure.
• Determine the “state-of-charge” of refrigerant in the
air conditioning system.
• Perform functional testing of the electrical and
mechanical systems.
• Understand general troubleshooting procedures and
practices.
Start the Diagnostic Process by
Following a Logical Systematic Approach
Identify System
Pressure Review
• Low to high pressure at
compressor
• High-pressure side
– Compressor output
– Condenser
– Receiver dryer (if equipped)
– High-side gauge
• High to low at metering device
• Low-pressure side
– Metering device output
– Evaporator
– Accumulator (if equipped)
– Low-side gauge
Temperature Versus Pressure
• For a given temperature, there is a given pressure.
• For a given pressure, there is a given temperature.
• If ambient temperature is known, then the refrigerant
pressure and temperature can be charted.
Performance Table
System Condition Status
• There are generally 7 basic system conditions. Normal
operation and Six basic malfunctions identified by gauge.
1. Normal Operation
2. Insufficient cooling: low side low, high side normal
3. Insufficient cooling: low side low to very low, high side low
4. Insufficient cooling: low side low, high side high to
extremely high
5. Insufficient cooling: low side high, high side low
6. Insufficient cooling: low side high, high side normal
7. Insufficient cooling: low side high, high side high to
extremely high
Normal Operation Condition 1
• Normal conditions
– Both high- and low-
side gauges showing
normal pressures
System Malfunctions Condition 2
• Insufficient cooling
– Gauge readings
• Low-side low
• High-side normal
– Possible causes
• Restriction on Low side
of system
• Moisture in system
• TXV malfunction-which
limits refrigerant flow will
cause evaporator
refrigerant starvation
resulting in insufficient
cooling.
• Restricted orifice tube
causing evaporator
starvation.
System Malfunctions Condition 3
• Insufficient cooling
– Gauge readings
• Low-side low to very low
• High-side low
– Possible causes
• Clogged inlet screen or
FOT restricted
• Defective TXV
• Low refrigerant charge
level (inspect for leak)
• High side restriction
System Malfunctions Condition 4
• Insufficient cooling
– Gauge readings
• Low-side low
• High-side High to
extremely high
– Possible causes
• Restriction high side of system
– The higher the high-side
pressure the closer the
restriction is to the
compressor
– Moderately high, high-side
pressure may be
restricted receiver dryer or
liquid line
• Look for temperature change at
restriction point
• A system that has too much
refrigerant oil may also exhibit
these symptoms. Lines may
also be vibrating or pulsating.
System Malfunctions Condition 5
• Insufficient cooling
– Gauge readings
• Low-side high
• High-side low
– Possible causes
• Low refrigerant charge level
• Electrical malfunction
– Pressure switch
– Ambient air temperature switch
(will not allow AC to operate below
a predetermined temperature)
– Fin sensor (evaporator
temperature sensor)
– Inspect – is compressor turning?
• Mechanical
– Defective compressor clutch or
coil
– Defective compressor (valve
plate, piston rings, etc.)
Evaporator outlet and all lines
warm to the touch. Both low-and
high-side pressures equalize
quickly after turning compressor
off.
– Inspect – listen for noises from
compressor, erratic engagement
indicates a compressor clutch or
circuit problem.
System Malfunctions Condition 6
• Insufficient cooling
– Gauge readings
• Low-side high
• High-side normal
– Possible causes
• This condition is
generally only found on
TXV systems
• TXV not closing or
remote bulb is not
contacting evaporator
outlet tube
• Also if a blend door is
open on an upstream
heater core hot air could
be flowing across
evaporator core.
System Malfunctions Condition 7

• Insufficient cooling
– Gauge readings
• Low-side high
• High-side high to extremely
high
– Possible causes
• Air contaminated system
(non-condensable gas)
• Over charge of refrigerant
• Incorrect refrigerant
(contaminated)
• Condenser fan not turning
on
• Condenser air flow
restricted
• Defective high pressure
switch
• Overheating engine
Malfunctions:
Mechanical Versus Electrical
• Three electrical possibilities
– Only clutch works
• Fuse or controls for other components bad (blower?)
– Only blower works
• Fuse or controls for other components bad (compressor
clutch?)
– Nothing works
• Main fuse or control for entire system (other systems not
working?)
Malfunctions

To play, click the video screen.


Malfunctions:
Mechanical Versus Electrical

• Mechanical
– Evaporator or connection leaks or is plugged
– Compressor - noisy, seizure, belt slipping
– Orifice tube plugged - poor cooling
– Expansion valve failure - poor cooling
– Line restrictions - poor cooling; one or both
pressures will not be normal
Poor Cooling
with Abnormal Pressures

• Check condenser fins.


• Check between condenser and radiator.
• Check lines for bend or kinks causing
restriction.
• Check for refrigerant leaks.
Poor Cooling
with Abnormal Pressures

• Check air distribution system (case and


ducts).
• Check for air blockage into and out of
evaporator.
• Check for clutch operation.
• Check for drive belt operation and tension.
Locate and Test
Electrical Components
• Use service manual.
• Understand function of each device within system.
• Use wiring diagrams and component locator.
• Isolate fault as common to system or one device.
• Test as any other electrical devices.
• Use caution on electronic devices and circuits.
Functional Check
• Operate in all modes and temperatures.
• Do not turn A/C on first to allow engine coolant to
warm.
• Start with MAX cool and work through each mode in
cold.
• Set to hot and check heater operation.
• Check DEFROST in hot and cold.
Orifice Tube Testing
• Is compressor operating?
– Test electrical first.
• Are pressures normal?
– Use pressures to locate probable failure.
• Isolate to compressor and compressor
control(s), power.

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