Common faults in a Refrigeration system.

1. Low refrigeration effect.

2. Air in refrigeration system.

3. Water vapor in the refrigeration system

4. Insufficient refrigerant.

5. Faulty Compressor.

6. Faulty expansion valve.

7. Oil in the system

8. Water vapor in the cool room

9. Insufficient condenser coolent.

The inability of commercial refrigeration systems to provide enough cooling may

be due to: dirty condenser and evaporator coils, a malfunctioning compressor or
thermostat, incorrect temperature settings, dirty fans, inadequate air flow inside
the refrigerator, door gaskets that aren’t sealing properly, or refrigerant leaks.  

An important, yet often overlooked, aspect is that a malfunctioning compressor

can cause significant temperature fluctuations inside a refrigerator and affect its
efficiency. While there are many different potential causes of compressor failure,
high compressor discharge temperatures represent one of the most common
problems when it comes to commercial refrigeration.

Because a malfunctioning compressor needs to work harder and longer in order

to maintain the temperature levels desired in refrigerated compartments, the
discharge temperature is often going above the limit recommended by the
manufacturer. Eventually, this will lead to compressor overheating. Some of the
potential causes of this problem include:

 dirty condenser and/or evaporator coils;

 an under-charge of refrigerant or an incorrect oil-refrigerant ratio that can
lead to increased suction temperatures;
 a leak in the discharge or relief valve, which will ultimately result in
excessive heat generation.

Another common problem in commercial refrigerator compressors is ice

accumulation on evaporator coils. Because this issue can negatively affect the
cooling capacity of the system—which will eventually lead to inefficient and
inadequate refrigeration—it is imperative to address and solve the root causes of
ice accumulation on evaporator coils in a timely manner. Some factors that could
cause ice to form on evaporator coils are:

 excessively low temperature settings;

 dirty fans and filters, followed by inconsistent and improper airflow;
 reduced cooling capacity of the coil, which can be due to dirt and debris
accumulation;
 failure of the evaporator fan motor;
 a malfunctioning defrost system.

Liquid slugging and lack of lubrication are two other factors that can cause a
commercial refrigeration compressor to fail. Excess friction due to lack of
lubrication can also lead to compressor overheating. If you suspect any problem
with your compressor, you should have it checked by a professional right away,
regardless of whether or not it’s still under warranty.  

1. Compressor Starts But Stops immediately

When the compressor in the reefer circuit starts and suddenly stops, it can be
because of the following reasons:

Reasons Solutions
  Ensure that all the suction line valves are

 Low pressure cut out gets in open condition, the refrigeration is

activated properly charged and the low pressure cut

out is not defective

 Check for the proper functioning of oil

 Defective oil pressure cut out pressure cutout and replace the defective

cutout

 If the defrost timer is getting activated

frequently,

 Defrosting timer is getting

activated frequently leading to a cutout of the

compressor, check and repair

defrost timer
  This can be because of leakage of lube oil
 The lube oil level is below
from seal or carryover of oil. Rectify the
the required level
leakage and refill the oil level

 Foaming of oil leading to the  Ensure no foaming takes place, renew the

reduced oil pressure oil if required

 Motor overload cutouts are  Ensure that electrical motor trips are

activating working properly

seconds of 30 secondsVolume 0%
2. Compressor Start and Stops Frequently

If while maintaining the correct temperature of the ship’s provision room or

reefer cargo, the reefer compressor is frequently cutting-in and out, then such
problem needs to be sorted out immediately. The most normal causes for such
operation are:

Reasons Solutions

Wrong Setting of Cutouts: It Check and change the setting to advisable

may be because the high

pressure (HP) cutout is set too

high or LP cutout is set too limit

low

Differential Setting Span is

Small: The low pressure (LP)

cut out is provided with

Change the setting and increase the span
starting and stopping pressure
between starting and stopping
setting. If the setting span is
compressor pressures.
too small, it will lead to

frequent cut-in and cut-out of

the compressor

Defective Valves: If the Replace all the defective valves

compressor discharge valve is

leaky or the line solenoid

valve is not closing properly,

this will lead to variation in

 sensor pressure and result in

frequent cut-in and cut-out of

the compressor.

Clogged Suction Filters:

Compressor is provided with a

filter in the suction line. If that Clean the filter

is clogged, it will lead to

frequent LP cut out

3. The compressor is Running Continuously

The function of the compressor in a refrigeration system is to act as a pump to

circulate the refrigerant in the cooling circuit. It can happen that to maintain the
cooling temperature in the rooms, the compressor is running continuously. If this
happens following can be the causes for the same:

Reasons Solutions

Ensure thermostatic expansion valve

Refrigerant not sufficient
is working properly and clean the
for cooling evaporator
filters inside TEV

Thermostat low-pressure
Correctly set the LP cut-out to correct
cut-out not activated at low
setting
temperature/ pressure

Refrigerant charge is low in Check for leakage of refrigerant and

the circuit charge with required refrigerant

4. Unusual Sound from Compressor

One of the most common problems in any machinery is abnormal sound coming
from some of its parts. This may be due to trouble with mechanical components
inside the compressor or due to the reasons stated below:
Reasons Solutions

The capacity control setting

is too high, leading to

Reduce the capacity control setting
knocking sound during

starting

Ensure that the oil level is maintained and

The oil pressure is low no foaming of oil is developed. Replenish or

refill the lube oil if required

Incorrect alignment of Check the alignment and set motor and

compressor and motor compressor in one line

Ensure that the compressor foundation is

Loose foundation secured and all foundation bolts are checked

for tightness
 Ensure to check the elasticity of the belt and
Loosening of the driving belt
renew if the belt is slack

5. High Compressor Discharge Temperature

It may happen that all the provision rooms or cargo holds are maintained at the
correct temperature, but in doing so the discharge temperature of the
compressor is going above the limit. This problem may arise due to the following
reasons:

Reasons Solutions

Excessive suction temperature Recharge the circuit to maintain

due to less refrigerant in the refrigerant quantity in the circuit.

circuit Ensure TEV is set properly and supplying

enough to the evaporator, else degree

of superheating will result in an

increase of suction and discharge

 temperatures of the compressor

The leak in the discharge valve

Renew the leaky valve
leads to the generation of heat

Leak in the safety valve Renew safety valve

Open bypass between suction

Control the bypass to avoid this
and discharge

6.  Evaporator Coil Icing

Another common problem in reefer system is the icing of the evaporation coils
which may happen due to:

Reasons Solutions

Increase the coil temperature by adjusting

Too low-temperature setting
TEV or it’s the sensor
 The coil capacity is less Install large capacity evaporator coils

Check if the defrost system is functioning

Defrost is not operational
at regular intervals

7. Reduced Cooling Capacity

If the cooling capacity of the plant has reduced and it is not being able to maintain
the provision room or cargo hold temperature, the following may be the causes:

Reasons Solutions

Inadequate refrigeration Charge refrigerant in the circuit

Insufficient or damaged
Check and renew the insulation
insulation in the room
 Room or hold is over Ensure that the room is not filled above its

packed capacity

Malfunctioning solenoid Check the functioning of these valves and

or TEV renew if not functioning properly

Poor thermostat location

Place the sensor of the TEV in proper location
that senses cold
i.e discharge of the evaporator
temperatures

Ensure to close the door while exiting the

 Room door is kept open
provision room

 8. Reducing oil level in the compressor

If the oil level in the compressor crankcase of the refrigeration system is reducing
within short intervals, this indicates leakage or increase in consumption of lube oil
due to the following reasons:
Reasons Solutions

Ensure that the nozzle in oil return line or

Nozzle or filter
filter in solenoid valve is cleaned and not
clogged
choked

Foaming of oil may arise due to liquid

Foaming of oil due to
refrigerant entering the crankcase. Replenish
liquid in the suction
oil and troubleshoot the cause of liquid in the
line
suction of the compressor

The compressor is provided with oil seal at the

Drive side seal leaking drive side. Ensure it is not leaking and renew it

if required

Worn out piston rings/ Renew the compressor piston rings or liner

liner leading to oil

carryover in the
 system