1. Describe A/C troubleshooting?

What are the best practices for

troubleshooting a marine air
conditioning system?
1

Check the power supply

Inspect the filters and ducts

3

Test the refrigerant level and pressure

Examine the compressor and condenser

Check the evaporator and fan

Troubleshoot the control and sensor

1Check the power supply

The first step in troubleshooting a marine air conditioning system is to check the power
supply and make sure that the system is receiving enough voltage and current. You can use
a multimeter to measure the voltage and current at the main breaker, the control panel, and
the compressor. If the voltage or current is too low or too high, it could indicate a problem
with the wiring, the transformer, the fuses, or the circuit breakers. You should also check for
any loose or damaged connections, and replace or repair them as needed.

2Inspect the filters and ducts

The next step in troubleshooting a marine air conditioning system is to inspect the filters and
ducts and make sure that they are clean and clear of any debris, dust, or mold. Dirty or
clogged filters and ducts can reduce the airflow and efficiency of the system, and cause
overheating, icing, or poor cooling performance. You should clean or replace the filters
regularly, and use a vacuum cleaner or a brush to remove any dirt or obstructions from the
ducts. You should also check for any leaks or cracks in the ducts, and seal them with duct
tape or mastic.

3Test the refrigerant level and pressure

The third step in troubleshooting a marine air conditioning system is to test the refrigerant
level and pressure and make sure that they are within the specified range. The refrigerant is
the substance that circulates in the system and absorbs and releases heat. If the refrigerant
level is too low or too high, it could indicate a leak, a blockage, or a faulty expansion valve.
You can use a manifold gauge set to measure the refrigerant pressure and compare it with
the manufacturer's specifications. If the pressure is too low or too high, you should locate
and fix the leak, clear the blockage, or adjust or replace the expansion valve.

4Examine the compressor and condenser

The fourth step in troubleshooting a marine air conditioning system is to examine the
compressor and condenser and make sure that they are working properly. The compressor is
the device that compresses the refrigerant and increases its temperature and pressure. The
condenser is the device that cools the refrigerant and releases the heat to the outside air or
water. If the compressor or condenser is faulty, it could cause noise, vibration, overheating,
or poor cooling performance. You can use a clamp meter to measure the amperage draw of
the compressor and compare it with the manufacturer's specifications. If the amperage is
too high or too low, it could indicate a problem with the compressor motor, the capacitor,
the relay, or the wiring. You should also check for any signs of oil leaks, corrosion, or
damage on the compressor and condenser, and repair or replace them as needed.

5Check the evaporator and fan

The fifth step in troubleshooting a marine air conditioning system is to check the evaporator
and fan and make sure that they are working properly. The evaporator is the device that
evaporates the refrigerant and absorbs the heat from the inside air. The fan is the device
that blows the cooled air into the cabin or the space. If the evaporator or fan is faulty, it
could cause icing, dripping, or poor cooling performance. You can use a thermometer to
measure the temperature of the air entering and leaving the evaporator and compare it with
the manufacturer's specifications. If the temperature difference is too small or too large, it
could indicate a problem with the refrigerant flow, the expansion valve, the thermostat, or
the wiring. You should also check for any signs of frost, water, or dirt on the evaporator and
fan, and clean or replace them as needed.

Troubleshoot the controls and sensors

The sixth step in troubleshooting a marine air conditioning system is to troubleshoot the
controls and sensors and make sure that they are functioning correctly. The controls and
sensors are the devices that regulate the operation and performance of the system, such as
the thermostat, the pressure switch, the temperature sensor, and the timer. If the controls
or sensors are faulty, they could cause erratic, intermittent, or incorrect cooling
performance. You can use a multimeter to test the continuity and resistance of the controls
and sensors and compare them with the manufacturer's specifications. If the readings are
out of range, you should adjust or replace the controls or sensors as needed.

AC regulations with fire alarm can you please share answer for it?

Only 3 points

Damper close in auto

Accommodation door close in auto

Ac compressor trip.

2. Draw TEV & explain?

 Thermostatic expansion valve

Thermostatic expansion valve maintains a constant superheat of the vapour refrigerant at the end
of the evaporator coil, by controlling the flow of liquid refrigerant through the evaporator. Thus, its
operation is based on the principle of constant degree of superheat at the evaporator outlet by
controlling the flow of liquid refrigerant through the evaporator.
Thermostatic expansion valve consists of a needle valve and a seat, a metallic diaphragm, a spring
and an adjusting screw.

In addition to this, it has a feeler or thermal bulb, which is mounted on the suction line near the
outlet of the evaporator coil. The feeler bulb is partly filled with the same liquid refrigerant as used
in the refrigeration system. The opening and closing of the valve depends upon the forces acting on
the diaphragm.

When refrigeration load on the evaporator increases

If refrigeration load on the evaporator increases, it causes the liquid refrigerant to boil faster in the
evaporator coil. The temperature of feeler bulb increases due to early vaporization of liquid
refrigerant. Thus, the feeler bulb pressure increases and this pressure is transmitted through a
small diameter tube (also known as capillary tube) to the diaphragm. The diaphragm moves
downwards and opens the valve to admit more quantity of liquid refrigerant to the evaporator.
This continues till the pressure equilibrium on the diaphragm is reached.

When refrigeration load on the evaporator decreases

On the other hand, when refrigeration load on the evaporator decreases, less amount of liquid
refrigerant evaporates in the evaporator coil. The excess liquid refrigerant flows towards the
evaporator outlet, which cools the feeler bulb. Due to this, the feeler bulb pressure decreases due
to decrease in its temperature. The low feeler bulb pressure is transmitted through the capillary
tube to the diaphragm and moves the diaphragm in upward direction. This reduces the opening of
valve and thus, reduces the flow of liquid refrigerant to the evaporator. The evaporator pressure
decreases due to reduced quantity of liquid refrigerant flowing to the evaporator. This continues till
the evaporator pressure and the spring pressure maintains equilibrium with the feeler bulb
pressure.

Faults:
High suction temperature (superheat) caused by the lack of insulation on the suction, or by too
small opening of expansion valve and hence the admission of too little liquid to the evaporating
coils.

 Accommodation AC common problems:

Types of fault
1. Loss of oil from crankcase
2. Excessive amount of oil in the crankcase
3. Refrigerant leakages
4. Refrigerant undercharged
5. Refrigerant overcharged
6. Fall off in refrigerating effect
 7. Short cycling on HP cut out
8. Short cycling on LP cut out
9. Moisture in the system
10. Air in the system
11. Frost on evaporator coils
12. Compressor drawing in refrigerant liquid
13. Noisy compressor
14. Poor cooling in condenser

Loss of oil” from the crankcase:

1.1) Low crankcase oil level – operational leakages.
1.2) Foaming – sudden “disappearance” of oil.

Operational Leakages due to malfunction of the mechanical seals resulting :

a) Loss of oil.
b) Loss of refrigerant – the end clearance of the piston/scraper rings allows a small amount
of refrigerant gas to reach the crankcase

1.2) Foaming can happen when –

a) Pressure drops rapidly in the evaporator.
b) Compressor high capacity to pull down pressure rapidly.
c) Crankcase space developing a low pressure condition.
With the formation of Low Pressure within the crankcase space :
- lubricating oil is unable to hold the small bubbles in the oil.
- small bubbles enlarge , attain buoyancy
- bubbles raise to the oil surface

Excessive amount of oil in the crankcase

Do not top up the oil level in the crankcase to excessive high level. It may cause :
 Overloading of the OIL SEPARATOR.
 Oil passing to the condenser and the rest of system - hampering optimum heat transfer.
 Always maintain the oil level at the recommended level as indicated on the sight glass.

Indication of refrigerant leakages:

 Low refrigerant level in sight glass
 Large bubbles in sight glass
 Oil weeping at joint and connection
 Relative lower pressure readings across the system (LP,OP & HP)
 High superheat at compressor suction
 Compressor running continuously - room temperature not reducing

Fall off in refrigerating effect (over a short period)

• Refrigerant loss through valve stem gland packing, pipes, fittings compressor etc
• Broken suction, discharge valves of compressor
 • Belt slipping – motor to compressor
• Icing of expansion valve

HP cut out
• Insufficient or intermittent water flow for condenser cooling
• Relatively higher temperature of cooling water
• Scaled or fouled condenser
• Overcharging of refrigerant
• Air in the system

Short cycling on LP cut out

• Malfunction LP pressure switch
• Evaporator coils heavily frosted
• Strainer for TEV chocked
• Leaky discharge valves
• Deflective expansion valve
• Refrigerant undercharge

Refrigerant undercharged
• Large bubbles noted in sight glass
• Lower LP , OP , HP pressure
• Continuous running of compressor- room temperature not reducing
• Relative less frosting on compressor suction line/valve
• System performance drops

Refrigerant overcharged
• Sight glass refrigerant level higher than normal
• Higher LP/OP/HP pressure
• Compressor stopping on HP cutout
• Severe frosting on compressor suction line/valve – Malfunction of TEV

Moisture in the system

• Frosting on inlet side of expansion valve
• Low LP pressure
• Corrective Actions: Renew the filter/drier.
 Water (not removed by the filter/Drier) if present with the refrigerant at the
• TEV will become ice – restricting proper refrigerant flow.
 In a good working order refrigeration system, a thin layer of ice of about 2-4mm will be
formed on the TEV (external body). The ice formation is due to the unavoidable “flash
off” of liquid refrigeration when it passes through the orifice. The presence of an extra
volume of ice formation on the TEV indicates that Excessive flash off is taking place.
Frost on evaporator coils
• Compressor runs longer
• Short cycling on LP switch
• Performance drops
• Low suction pressure – Refrigerant temperature drops to 0 degree celsius or lower
 Frost coming back in evaporator coil continuously because of relative lower pressure
existing in the coils. The low pressure could be due to refrigerant leakages, dirty
filter/drier, dirty strainer of the TEV – any reasons that results in a lower than normal
pressure within the coils.The pressure of the refrigerant directly affects the temperature
of the refrigerant in the coil. The lower the pressure – the lower will be the temperature
of the refrigerant. If the temperature of the refrigerant is near to or lower than or at the
freezing point of water, high relative humidity air flowing pass the evaporator coil will
cause ice to be built up persistently.
 Remedy : Restore the working pressure of the LP side to the marker’s recommended
value – bring the operating temperature of the refrigerant away from the freezing point
of water.

Compressor drawing in refrigerant liquid

Usually is due to malfunction of TEV resulting :
• Excessive frosting at inlet valve body of the compressor and/or icing on the cylinder
head.
• Oil level at compressor sump reduced
• High suction pressure
• Noisy compressor operation

Noisy compressor
• Liquid knock / hammering
• Lack of lubrication
• Internal components damaged

Air in the system

• High condenser pressure (HP pressure)
• Jumping of pressure gauges pointer
• Compressor noisy
• Small bubbles at sight glass
• Relative small difference in cooling water in & out temperature – Less heat transfer

 Air (or moisture) can be accidentally introduced into the refrigeration system during
topping up of refrigerant into system or during topping up of lubrication oil for the
compressor.
 Air will finally be accumulated in the condenser.
o Mainly nitrogen(78%) and oxygen(21%) - it is not possible to condense air with
the cooling water.
o The volume of air will occupy the space at the top of the condenser –
 o prevents refrigerant gas entering the condenser.
o reduces the total cooling surface area for the refrigerant.
o Result in
o higher pressure reading in the HP side of the system and
o reduction in temperature differential of the cooling
water.Cooling water inlet temperature minus outlet
temperature.

 Removal of Air :
o Connect a refrigerant recovery bottle to the purging cock (of
the condenser) via a flexible hose.
o Remove the air until the flexible hose is cold or/and the
cooling water difference temperature of about 8-10 degree
Celsius is achieved.

Note: The refrigerant used although do not contribute to ozone depletion , it is

still a greenhouse gas Therefore , it should not be released directly into the
atmosphere