Finding problems in

HVAC/R refrigeration cycle

By D Opperman, Comtest

Valuable advice on troubleshooting a compressor, associated problems that can cause a system to fail
prematurely, proper methods of diagnosing and repairing system problems, rather than just their symp-
toms.

T
he core of a refrigeration system is the compressor, which is To measure the pressures on a DMM in conjunction with the standard
designed to pump cool refrigerant gas from the evaporator into manifold gauges, take the following steps:
the condenser. To accomplish this task the compressor raises Attach the pressure/ vacuum module hose fitting to the refrigerant
the temperature and pressure of the low superheated gas, forcing it service hose on the manifold gauge set, usually the yellow hose
into the condenser. The compressor should never pump liquid. This Attach the pressure/ vacuum module to a DMM and set the mod-
will not only damage the compressor, but could create a potential ule function to cm/in Hg
safety hazard. Install the blue and red hoses to the suction side and high side
If the refrigeration compressor is not properly maintained, it of the system as during any normal service process
malfunctions or stops running - at which time it gets replaced and the
system is back and running - temporarily. Often the culprit is not the To read the suction pressure on the DMM, open the blue handle on
compressor, but a system failure or design problem with accessory the manifold gauges. This puts the system suction pressure into the
equipment which kills the compressor prematurely. pressure/ vacuum module. Read the pressure on the digital readout
and compare it to the gauge pressures. Do not be alarmed if the
pressures do not match exactly. Certain modules are typically much
Measuring compressor suction and discharge pressure more accurate than a standard set of refrigeration gauges. To read the
Both the suction and discharge pressures at the compressor are nor- discharge pressure on the DMM, close the blue valve on the gauges
mally measured with a standard set of refrigeration gauges. However, and open the red handle on the manifold gauges. This puts the system
this article will explain how to measure both pressures on the suction discharge pressure into the module. To remove the module, simply
and high side of the system with the digital multimeter (DMM) and a reverse the process followed when installing the unit.
pressure/vacuum module, with or without the standard gauges. If the
gauges are left on the system and used in conjunction with this test, Be sure to close the high side port of the gauges first, and
the module will verify the accuracy of the standard manifold gauges. remember to remove the refrigerant from the high side gauge by
allowing the compressor to run and pull excess refrigerant into the
low side of the system.

To measure the pressures on the DMM and pressure/ vacuum mod-

ule without installing the manifold gauges, take the following steps:
Attach the module hose fitting to any standard refrigerant service
hose
Connect the refrigeration hose to the service port on the compres-
sor
Open up the service port and read the refrigerant pressure directly
on the pressure/ vacuum module.

Read one pressure at a time using a single pressure vacuum module,

and record the suction or discharge pressure one at a time. If using a
DMM meter with a minimum/ maximum (min /max) feature, record
the suction pressure as the minimum value and then the discharge
pressure as the maximum value.
To remove the pressure/ vacuum module, simply reverse the
process followed when installing the unit. Take care when removing
Figure 1: Infrared thermometer. the high side port of the gauges as it can be under very high pres-

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 Abbreviations
DMM Digital Multi-Meter
HVAC/R Heating, Ventilating, and Air Conditioning/ Refrigeration
PT Pressure Test

sure. To minimise refrigerant loss, learn to practise safe refrigerant Recording a temperature overnight
handling habits when removing the module from the high side of
To check refrigeration system performance, it is often useful to record
the system. This includes shutting off the compressor prior to gauge
temperatures in the refrigerated space. This makes it possible to
removal and allowing the pressure to equalise. When removing the
detect problems that may go unnoticed with a single system check.
gauge from the low side of the system it is not necessary to first shut
For instance, in a refrigerated space it is important to ensure that
down the compressor.
temperature variations are minimised. Temperature variations may
result from changes in load or ambient conditions that occur over
Troubleshooting the compressor periods of time, so constant monitoring is called for. By recording min/
discharge line temperatures max temperatures in key locations over a period of time, air circulation
and refrigeration capacity will meet the application requirements.
Pressure and temperature are fundamental tests that must be per-
Digital recording thermometers record min/ max temperatures
formed to determine what is happening inside the compressor. It is
over extended periods of time. Temperature values can be viewed
important to know the correct methods for checking the refrigerant
at anytime by pressing the view button (recording still continues). If
superheat and sub-cooling at the compressor [1]. To measure the
the hold button is pushed, the recorded min/ max values are saved
temperature of the compressor, take the following steps:
and recording stops. The data is saved until the user selects a differ-
Use a pipe clamp accessory with a DMM to measure the discharge
ent input or turns off the instrument. Some DMM scan also measure
line temperature at the discharge of the compressor. High tem-
min/ max of a single temperature, plus they offer the benefit of a
peratures above 275 - 300F (135 - 148C) will slowly destroy the
100-hour relative time stamp to record when the min/ max occurred.
lubricant qualities as well as the performance of the compressor.
When selecting a digital recording thermometer look for a model
These high temperature conditions can be caused by high con-
that can record hundreds of temperature samples for precise meas-
densing temperatures/ pressures, insufficient refrigerant charge,
urement. Additional features that are helpful include a time stamp
non-condensables within the system, high superheat from the
feature, operator interval settings and dual channels to record two
evaporator, restricted suction line filters, or low suction pressure.
temperatures at the same time. With this type of device temperature
These conditions cause the compressor to have a higher than
difference across a coil can be recorded for extended periods of time.
normal compression ratio, work harder, generate hotter internal This feature is especially handy for troubleshooting erratic problem
hermetic motor windings, and as a result, cause compressor wear, areas of the HVAC equipment where time limitations do not allow
fatigue and failure. the technician to wait until the problem occurs.

A temperature survey is a critical part of the service technicians job.

A quick check of a systems components not only helps to diagnose Compressor valve performance test
troubles but also allows failures to bed anticipated by regular moni- To test small hermetic and semi-hermetic compressors used for me-
toring of critical temperatures. Use an infrared thermometer to do a dium and low temperature applications, the following method can be
quick survey of: used to test for internal valve leakage (see Figure 2):

Compressor head temperatures

Compressor oil sump temperatures
Evaporator coil and suction line temperatures
Discharge line temperatures
Condenser coil and liquid line temperatures
Fan motor temperatures.

With an infrared thermometer a refrigeration system can be surveyed

quickly by scanning the temperatures of various components. While
touching each of the components often does this, a non-contact in-
frared tool is faster. By keeping careful records it is possible to detect
trends that indicate impending failure. This allows for keeping the
system in top condition - avoiding costly failures. Figure 2: Use a multimeter and a pressure module to quickly and accurately
determine suction pressure.
IR instruments read best when measuring an object with a dull
(not shiny) surface. If the surface is shiny, dull it with black markers, Attach a pressure/ vacuum module to a DMM and set the module
non-gloss paint, masking tape or electrical tape. to cm/in Hg
Connect the module at the suction line service port

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 Close the compressor off from the low side of the system by front These problems include:
seating the suction service valve Poor piping practices resulting in oil not adequately returning to
Run the compressor for two minutes the compressor during the run cycle
Turn off the compressor and observe the reading High discharge temperatures creating acids in the oil
Insufficient air flows across the evaporator and condenser coils.
The compressor should have pulled down to at least 16 (410 mm) of Extremely low suction pressures
Hg. If the vacuum reading starts weakening toward 10 (254 mm) of Hg Liquid refrigerant flooding back into the compressor
vacuum, the discharge valves of the compressor may be leaking and
will probably need to be replaced. If the compressor does not pull a Diagnosing these refrigeration system problems and avoiding com-
vacuum below 16 Hg, the suction valves are weakening and may need pressor failure can be done effectively using DMMs, clamp meters,
to be replaced. If the compressor is welded or hermetically sealed and digital thermometers, pipe clamps, infrared thermometer and pres-
these conditions exist, a new compressor is the only possible remedy. sure/ vacuum modules.

Whenever replacing a compressor with faulty valves, be sure

Like the human heart, the refrigeration compressor
to diagnose the complete refrigeration system before and after a
new compressor is installed to avoid repeated compressor failures. needs to be properly maintained and requires periodic in-
spection and testing. Unfortunately, the compressor is often
Troubleshooting compressor electrical motor faults
ignored until it malfunctions or simply stops running.
A clamp meter is a great tool for troubleshooting electrical motor
faults, especially meters designed to accurately measure both ac These are simple procedures to diagnose refrigeration
voltage and ac current. These meters allow current to be measured problems:
without breaking into the electrical circuit. A compressor failure is Compressor bearings can fail or lock up due to poor piping prac-
often caused by an electrical fault. To check the compressor for elec- tices, which causes oil clogging in the system and results in insuf-
trical problems, remove the electrical terminal cover and check the ficient oil return to the compressor. If the bearings dont lock-up
following external connections. and continue to wear during these conditions, the rotor will lower
Check line voltage at the load centre with the compressor off. Low into the stator housing, shorting out the windings. To diagnose this
line voltage causes the motor to draw more current than normal problem, measure the compressor amps. They should not exceed
and may result in overheating and premature failure. Line voltage the manufacturers full load ratings. Worn bearings will cause
that is too high will cause excessive inrush current at motor start, higher than normal amps. Inspect the oil level via the compressor
again leading to premature failure sight glass. If there is no sight glass, use the infrared thermometer
Check line voltage at the motor terminals with the compressor to measure the sump of the compressor housing. The oil level can
running. The voltage should be within 10% of the motor rating be detected with the temperature probe. The sump temperature
Check running current. The readings should not exceed manufac- will be different on the compressor housing at the oil level.
turers full load rated amps during heavy load periods. Low amps
are normal during low load conditions. Excessive high current Whenever an oil problem exists due to poor piping practices,
maybe due to shorted or grounded windings, a bad capacitor, a the correct remedy is to fix the piping, not to continue to add more
faulty start relay, or an indication of excessive bearing fatigue oil to the system.

When performing electrical measurements on compressors High discharge temperatures are caused by high head pressures or
with internal thermal motor protection devices that have been run- high superheat. The compressor discharge line can be measured
ning extremely hot, be sure to give the compressor time to cool quickly using the infrared thermometer on a dull section of pipe.
down prior to the electrical test. This will allow the device to reset to Measure the discharge pressure using a pressure/vacuum module.
its normal position. Convert the refrigerant pressure to temperature and compare it to
the ambient air temperature. If there is a temperature difference
greater than 20 - 30F (11-17C), there are either non-condensable
Troubleshooting compressor electrical motor failures
gases in the system or restricted airflow across the condenser.
caused by refrigeration system problems
Occasionally defective compressors with electrical winding failures are Temperature differences will vary due to original manufacturers
diagnosed by a service technician as caused by an electrical system design and efficiencies.
problem. However, mechanical system failure or inferior installation
and service practices often cause compressor electrical problems.

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 is imperative that the service technician understands the principles
and the tools needed to perform proper troubleshooting efficiently.

Reference
[1] Troubleshooting HVAC/R systems using refrigerant superheat and
sub-cooling. Fluke Application Note.

Darius Opperman has several years experience in Mechanical

and Electrical fields with emphasis on technical maintenance,
technical troubleshooting and repairs, and technical sales. His
focus is on electrical motors, gearboxes and pumps and all
common types of rotary machinery. Darius is a Fluke Level 1
Figure 3: Record evaporator temperature differences as well as min/ max
vibration analyst, determining specific faults on rotary machinery to due fail-
temperatures with a digital thermometer.
ing components and incorrect commissioning. Enquiries: Tel: 011 608 8520 or
email dopperman@comtest.co.za.
Check for insufficient airflows across the evaporator using a digital
thermometer (see Figure 2). Place a bead thermocouple on the
discharge side of the coil and on the return side of the coil. Record
the temperature difference on the air conditioning unit - expect
about 18 - 22F (10 - 12C) temperature difference; on refrigeration
units expect about 10 -15F (5 8,5C) temperature difference.

Temperature differences may vary depending upon initial design

and humidity requirements.

Extremely low suction pressures can be checked using the pres-

sure/ vacuum module and the DMM. Install it at the compressor
and record the suction pressure. Convert the refrigerant pressure
to temperature using a pressure temperature (PT) chart. Meas-
ure the return air temperature before the evaporator. Compare
the refrigerant temperature to the desired evaporator return air
temperature. On air conditioning units, expect about 35 - 40F
(19 - 22C) temperature difference and refrigeration units expect
about 10 - 20F (5 - 11C)
Check for liquid refrigerant flooding back to the compressor by
determining the superheat using the pressure/ vacuum module
and pipe clamp, along with the DMM. Check suction pressure
and convert the refrigerant pressure to temperature, using the
PT chart. Measure the suction line pipe temperature. Compare
the difference of the two temperatures. If there is no temperature
difference, then the back liquid is being brought back into the
compressor. If there is a temperature difference between 10 - 20F
(5 -11C), the superheat is normal and the compressor is not being
slugged with unwanted liquid.

Conclusion
Troubleshooting and servicing refrigeration air conditioning and
heat pump systems are challenges for any technician, entry level
or experienced. Regardless of the size or location of the system, it

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