Imdaad

LEADS
by Example
 Technical
Refresher Training
Technical Trainer :- Sony Thomas

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 Air Conditioning
Troubleshooting

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 Air Conditioning System

An air conditioning system can be divided into 2 main functioning groups

• Electrical circuit
• Refrigerant circuit

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 Air Conditioning System

To troubleshoot a system, one must have to adopt “divide and

conquer” technique

• Divide the “Big” problem into multiple smaller

problems.
• Solve each of the problem individually.
• Put electrical problem in first priority.
• A main point to take note is that if a system do
not start, the faulty must be from electrical fault.

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 Troubleshooting electrical faults
Always ask a lot of questions and do not make assumption
before we check.

• Is the power supply being switch on / being

connected ?
• Is the wiring being done properly?
• Is the wire loose ?
• Is there any signal coming from controller or
thermostat ?

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 Troubleshooting electrical faults
1) Unit will not start

• Main power supply fail ? Voltage fluctuation ?

• Blown fuse or varistor ?
• Faulty transformer ?
• Loose connections ?
• Shorted or broken wires ?
• Safety device opens ?
• No signal from thermostat/controller ?
• Faulty thermostat ?

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 Troubleshooting electrical faults

2) Some components do not start

• Loose connections ?
• Shorted or broken wires ?
• No signal from thermostat/controller ?
• Faulty magnetic contactor ?

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 Troubleshooting electrical faults

3) Controller/thermostat

• A clear understanding of the functional

specification of the controller/thermostat is
crucial.
• Setting of the controller/thermostat must be
obtained.
• Operating temperatures must be obtained (exp:
room, return air, ambient, water, etc.)

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 Troubleshooting refrigerant faults
Some of the major problems found in a air conditioning system

• The air conditioner runs but shortly stops.

• The air conditioner short cycles with insufficient cooling.
• The air conditioner runs continuously with insufficient
cooling.

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 Troubleshooting refrigerant faults

Three main conditions in the air conditioners that are operating but not
cooling satisfactorily are

• High discharge pressure

• Low suction pressure
• High suction pressure

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 Troubleshooting refrigerant faults
1) High discharge pressure

• Dirty or partially blocked condenser.

• Air or other non-condensable gases in
refrigeration cycle.
• Overcharge of refrigerant.
• Insufficient condensing medium.
• High temperature condensing medium.
• Short cycling of condensing air.

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 Troubleshooting refrigerant faults

2) Low suction pressure

• Insufficient air or heat load on evaporator coil.

• Resistance against refrigerant flow.
• Shortage of refrigerant.
• Faulty capillary tube or expansion valve.

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 Troubleshooting refrigerant faults
3) High suction pressure

• Heavy load conditions.

• Unit undersized for application.
• Low superheat adjustment.
• Improper expansion valve adjustment.
• Poor installation of feeler bulb.
• inefficient compressor.

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 Troubleshooting refrigerant faults
Some of the problems of refrigerant system can be diagnose
through the use of pressure gauge and also an ammeter

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 Troubleshooting electrical faults
H.P Pressure and running current reading
L.P • Both high and low pressure are very high
• Running current increase extremely
AMP

Main causes of
troubles

• Refrigerant overcharged >> Wet operation.

• In case refrigerant overcharged excessively, high pressure
switch or overcurrent relay functions.

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 Troubleshooting electrical faults
Pressure and running current reading
H.P
• Discharge pressure is very high
L.P • Suction pressure is a little higher than normal
AMP • Running current increases

Main causes of troubles

• Insufficient condensing medium.

• Dirty condenser.
• Partially blocked condenser.
• Malfunction of condenser fan or fan motor.
• Reverse revolution of condenser fan.
• Short cycling of condensing air.
• High temperature condensing air.

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 Troubleshooting electrical faults
H.P Pressure and running current reading
L.P • Discharge pressure is a little higher than normal
• Suction pressure is very high
AMP
• Running current increases

Main causes of troubles

• Unit undersized for application.

• Heavy load condition.
• High suction air temperature >> superheated operation.
• Excessive air flow rate.
• Excessively opened expansion valve >> wet operation.

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 Troubleshooting electrical faults
H.P Pressure and running current reading
L.P • Discharge pressure is a little lower than normal
• Suction pressure is very low
AMP
• Running current decreases
* Frost grows on evaporator coil

Main causes of troubles

• superheated operation.
• Shortage of refrigerant.
• Restricted refrigerant flow.
• Expansion valve or capillary tube obstructed.
• Dryer or filter clogged with dirt.
• Valve in liquid line partially closed.
• Obstruction in liquid line.
• Leaking power element on expansion Valve.

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 Troubleshooting electrical faults
H.P Pressure and running current reading
L.P • Discharge pressure is a little lower than normal
• Suction pressure is very low
AMP
• Running current decreases

causes of troubles

• Insufficient heating medium >> wet operation.

• Poor evaporating air flow rate.
• Dirty air filter.
• Slippage of fan belt.
• Reverse revolution of evaporator fan.
• Short cycling of cooling air.
• Light load condition.
• Low suction air temperature.

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 Troubleshooting electrical faults
Pressure and running current reading
H.P
• Discharge pressure is a little lower than normal
L.P
• Suction pressure is very high
AMP • Running current decreases

Main causes of troubles

• Malfunction of compressor >> super heated operation.

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 Troubleshooting electrical faults

H.P Pressure and running current reading

L.P • Both high and low pressures are very low
AMP • Running current decreases extremely

Main causes of troubles

• Extreme refrigerant shortage >> super heated operation.

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 Wet operation
Liquid refrigerant comes back to the compressor

Liquid Insufficient Refrigerant is Motor coil

compression lubrication dissolved in oil insulation is
(washed out) being eroded
Oil foaming
Vane or valve
failure Motor coil failure
Bearing failure

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 Super heated operation
Suction and discharge gas temperature is higher than the normal

Oil temperature
becomes higher

Carbonization of oil Oil viscosity Insufficient cooling

drops for motor coil

Incomplete seat Insufficient Motor coil failure

action lubrication

Bearing failure

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 Question &
Answer

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