- . - - - -- - -- -. .

LACK OF COMPRESSOR CAPACITY:

ANALYSIS OF THE SYMPTOMS

We will refer to all the faults likely to cause a loss of refrigerating power in a
compressor as 'lack of compressor capacity' faults.
,
To help analyse the effects of a lack of compressor capacity on a refrigeration system,
we'll consider the example of a compressor which has two cylinder heads where one
of the suction (inlet) valves has just broken.

A) Effects on the compressor:

Since a suction valve has just broken in

. the cylinder head (point 1), when the
piston concerned rises in the cylinder,
there cannot be any increase of pressure
in the cylinder.

The associated discharge valve cannot

open, therefore, and the vapour returns
to the suction line.

Consequently, the movement of the

piston in the cylinder produces no
suction or discharge of the refrigerant. .

On the other hand, the other cylinder (point 2) draws in and discharges vapour quite
normally. '.

Everything happens as if the compressor only possesses one cylinder. This reduces
by a half the volume of vapour that it can handle. .

Sinc~ ,thE!,:cQmpre~SO(is drawing'in halfthe'n6hT1alamobrtt 'of'i"~frigercmt,

th,e,~a.~~'f,I()",,:ofr~frigerant .being. d rculated.is'also :apprd~irriCltel,Y'half,of
what
. itshoUld
. -, . beL'.:"".""""""":' , ,..:"<','.' ',"" ., ,. ., ..

Since the evaporator is now producing more vapour than the compressor can draw in,
the LP becomesexcessivelyhigh (point 3).

B) Effects on the expansion valve/evaporator assemblv.

Remember that every kilogram of liquid passing through the evaporator vaporises by
absorbing heat and thus produces a certain quantity of vapour.

LACK OF COMPRESSOR CAPACITY

- 139-

- - -
Since the mass flow of refrigerant in circulation has been halved, the amount of heat
absorbed by the evaporator (and therefore the refrigerant capacity) is also halved.

This decrease in the refrigeration capacity results in an increase in the temperature

inside the air-conditioned room, which in turn results in the client making a telephone
call to complain that "its too hor'.

Since the am-

bient tempe-
rature is much
too high, the
temperature at -+
the evaporator
inlet (point 4)
is also too
high.

In addition,
since the refri-
geration capa-
city is redu-
ced, the L'.8
for the air de-
creases.
CD
This results in
a noticeable
increase in the
temperature of the air outflow (point 5).

Another problem could arise since the expansion valve has been selected to provide a
refrigerant flow that corresponds to the nominal capacity of the evaporator and
compressor.

everything
Since the capacity provided by the evaporator decreases significantly,
appears as if the expansion valve had suddenly gained excess capacity.
This over-capacity in the expansion device can cause 'hunting', and result in liquid
hammer that is regular, but of smaU amplitude (see: remarks on expansion valve
oscillation, page 34).

The cyclicar liquid 'slugging' (point 6) and the high LP must not be allowed to confuse
the inexperienced engineer, who could wrongly conclude that there is excessive
expansion valve capacity.
A :ack of compiessoi capacity causes a ~aiga i6ductioil in the coolingcapacity. wvni:st
excessive expansion valve capacity results in an abnormally high cooling capacity.

TAKE CARE NOT TO CONFUSE LACK OFCOMPRESSOR CAPACITY WITH

PROBLEMS DUE To EXCESS'E'XPANSIb'N VALVE CAPACITY.,.,,;;.; '..'

LACK OF COMPRESSOR CAPACIIT

- 140-
.,
 C) Effects on the compressor I condenser assemblv.

The cooling of hermetic and semi-hermetic compressors relies principally on the

vapour that is being drawn in. Since the quantity of vapour is greatly reduced, the
cooling of the motor is less effectively carried out and the compressor body (point 7)
will be hot. .

In addition, we've seen that the cooling capacity is abnormally low. The condenser
was originally sized to cope with the normal cooling capacity of the installation.

Once again, everything appears as if the condenser has gained excess capacity.

If the HP regulation process used by the system doesn't vary the airflow over the
condenser, then the ~e for the air will be smaller than usual, and the temperature of
the air emerging from the condenser (point 8) will also be lower. In addition, since the
condenser has excess capacity, the HP (point 9) may tend to decrease, according to
the type of HP regulation system installed.

Again,. don't confuse a lack of compressor'capacity with an oversized

expaftsidn valve:" hi this last case: .the:HP.. w~uld be quite. normal or
perhaps high>. . ....

Since the mass flow of refrigerant circulating in the system is significantly reduced, the
"excess" fluid will be located in the liquid receiver and the condenser. Since there is
now more liquid in the condenser, the sub-cooling zone becomes larger and the
temperature of the liquid in the bottom of the condenser falls. Consequently, the sub-
cooling of the liquid measured at the condenser outlet (point 10) will be quite normal,
or even a little larger than normal.

Finally, since there is only one cylinder in operation, the mechanical energy that the
compressor is supplying to circulate the refrigerant also decreases. Therefore the
electrical energy being consumed by the compressor falls, and the current passing
through the motor decreases noticeably, especially if an LP valve is involved. A simple
measurement made using a clamp-on ammeter will quickly show whether the current
passing is much lower than the stated current.

LACK OF COMPRESSOR CAPACITY

- 141-

---
 LACK OF COMPRESSOR CAPACITY
A SUMMARY OF T~-iESYMPTOMS

e air outflow "

" Tends to
Increase
Tends to
~ Decrease

Superheat:
Possible
Oscillation

e ambient
I
"
Good
Sub-cooling

PERSONAL NOTES

LACK OF COMPRESSORCAPACITY

- ]42-
 LACK OF COMPRESSOR CAPACITY
METHOD OF DIAGNOSIS

Cooling capacity is low

{the compressor isn't "producing any cooling"}

Is the LP abnDrmally high? Different fault

YES

Is the HP abnormally high? Different /;iult

NO

LACK OF COMPRESSOR CAPACITY

THE ESSENTIAL FEATUR.EOFTHI5 FAMILYOF FAULT5 IS A HIGH LP

WITH A HP TH.ATtSNQR.MAL(OgEVEN5L1GHTLY LOW) AND A LACKOF
COOLING CAPACITY.... ... . . .

Do not confuse this problem with excess expansion valve capacity. The
latter would result in a normal cooling capacity and a rather high HP.
(Excess expansion valvecapacityfor liquidchillersis discussed on page 618).

If there is any dO'.Jbt,compare the current passing through the compressor with
the nominal value' (which is indicated on the identification plate of the
compressor).

LACK OF COMPRESSOR CAPACITY

- U3-

-- --
LACK OF COMPRESSOR CAPACITY SUMMARY

HP NORMAL

..,. '\ ?
I

?
II

.
?
0
Why isn't this compressor producing any cooling? let's fit the gauges...
Well, the LP's very high... Could the expansion valve be oversized?
But there's no cooling capacity, so that can't be right...
The HP appears to be nonnal, or perhaps a bit low...
So, this isn't a condenser problem...
It can only be...

A LACK OF COMPRESSOR CAPACITY!

LACK OF COMPRESSOR CAPACITY

- 144-
 LACK OF COMPRESSOR CAPACITY
SOME PRACTICAL ASPECTS

Let's now recap on some of the faults that give the symptoms of a lack of compressor
capacity.

'*' A valve isn't makinq a seal or is broken.

'*' The valve plate qasket is too thick.

'*' The cvlinders have been scored bv fraaments of broken valve.

These three faults have been analysed in detail in the last chapter (see: the problem
of broken valves, page 129).

'*'The c linder head asket does not form a seal between HP and
LP.

The cylinder head gasket, located between

the cylinder head and the valve plate, not
only provides a seal between the cylinder
head and the exterior, but also between
the HP and the LP in the central area of
the cylinder head.

During removal of a cylinder head for

repair or inspection, the gasket sometimes
"sticks" to the metal surfaces or is slightly
torn as the head is removed. If the
engineer then re-uses the split gasket (or
puts a new qasket on a metal surface
which hasn't been properly cleaned), he may be creating. a connection between HP
and LP inside the cylinderhead~

Note that the superheated vapour that is discharged

can then enter the suction side collector and can Leak

produce a significant increase in the temperature of

the compressor body, as well as the general symp-
toms associatedwith a lack of compressorcapacity.
L"Ihen cooling of the motor relies solely upo" t.'1e
vapour being drawn in, the temperature increase
could result in the compressor cutting out on its
internal thermal safety devices (e.g. klixon etc.).

So as well as checking and oiling them, ensure that all

surfaces (both sides) are perfectly clean when
replacing a gasket.

LACK OF COMPRESSOR CAPACITY

- 145-
* The compressor is operatinq Quite normallv. but its caoacitv is
less than that of the evaporator.

This problem generally occurs after a compressor has been replaced, and an error
has been made in the specification of the new compressor.

All that can be done here is to ensure that an engirleer exercises the
maximum possible care in obtaining the specifications of the equipment
that is being replaced.. . .

The engineer should always remember that consulting the catalogues and making the
telephone calls required to obtain the equipment is his personal responsibility, and his
alone! The author can recall one particular engineer who tried to order a replacement
compressor having recorded only the following information: "Hermetic compressor -
colour black - 718in.Inlet, 5lBin. outlet" !!

* Ca or is incorrectlv set.

If a compressor is equipped with a capacity regulation system, a lack of capacity could

be due to a malfunction in this system.

For example, if the capacity regulation is achieved using cylinder unloading, the lack
of capacity could be caused by' poor adjustment of the regulation system, a fault with
the cylinder charge solenoid, or a mechanical problem with the capacity control etc.

Inspection of the solenoids, touching the cylinder heads and measuring the current
through a motor provide precious information concerning the actual operation of a
compressor (see page 594).

If there is a capacity regulator device fitted, problems could be caused if unwanted or

unexpected injection of hot vapour somehow occurs. (see also: Capa9ity regulators,
principles of operation, page 220).

Let's .take the example of a system

whose capacity regulation is performed
by hot gas injection at the expansion
valve outlet..
HOT
If an engineer observes a lack of Ii1ir
cooling capacity (the ambient tempe-
HP normal
rature is too high), and all the symptoms
of a lack of compressor capacity (HP
appears normal and the LP is high), just
touching the gas injection tube enables
him to tell immediately whether the
capacity regulator is open, since with a
high ambient temperature it should be fully closed.

LACK OF COMPRESSOR C.'\PACITY

- 146-
 - - - -

All that remains for the engineer is to determine why the capacity regulator is open
when the LP is high (is it due to poor adjustment, a mechanical blockage etc.) and
then to remedy this.

* The internal safe valve of the comoressor isn't sealin

properlv.

Some manufacturers equip their compressors with an internal safety valve between
the discharge collection chamber and the crankcase.
This valve .limits the
GITl pressure increase that
llliJJ. HP occurs if there is an
Internal Safety Valve
... .. -.. excessively high HP
... .:.:.:.:.:-:
......
..........
.....
......
.....
......
.....
......
.:.:.:-:.:. (after a discharge line
valve has been closed

....
<>
(l)(/)
.<%+{
... .
.
HP normal
.
. >v!;fe
.....
.....

Excess
Pressure
accidentally for exam-
ple). It. does this by
releasing the excess
pressure into the crank-
case through a by-pass
between the HP and LP
sides.

The valve spring is set by the manufacturer to ensure that it keeps the valve closed
under normal operating conditions. However, as soon as the HP level becomes
dangerous, the force being exerted by the HP vapour causes the spring to be
compressed and the valve to open. The HP vapour is then released into the
crankcase, and the valve then closes again. If the HP rises again, the same process' is
repeated.

Sometimes the valve fails to close properly or jams open. This results ir:)vapour being
continually released into the crankcase.

If this 'leak' were large enough, this fault would result in exactly the same symptoms
as those of a damaged head gasket. In particular there would be an abnormally hot
compressor body (which might result in the internal thermal safety device cutting out
the compressor), or, say, an abnormally long pump-down time, with a rapid rise in the
LP after the compressor has stopped. An effective pump-down may actually be
impossible If there is a large amount of vapour being released into the crankcase.

* Althou~h desi~ned for a 60 Hz su the comoressor is

connected to a 50 Hz supplv.

Remember that the speed of rotation of an AC motor depends on the frequency of the
supply.

Hence a motor of US origin designed to rotate at 1720 rpm at a frequency of 60 Hz

will only have a rotation speed of about 1440 rpm if it is connected to a 50 Hz supply.

LACK OF COMPRESSOR CAPACITY

- 147-
This problem usually occurs with equipment that is manufactured in the US, although
it can occur if European equipment is for export and designed for use with a 60 Hz
supply.

If connected to a 50 Hz supply, these compressors will have a rotation speed which is

reduced by about 17%. The cooling capacity will therefore be similarly reduced.

In order to maintain an acceptable cooling capacity, some manufacturers use a

different refrigerant according to whether the supply is 50 Hz or 60 Hz.

For example, Carrier have used R500 instead of R12 in certain heat pumps
manufactured in the US and fitted with a 60 Hz compressor. This type of machine,
then, (the identification plate will clearly indicate whether the equipment is charged
with R500) will have a reduced cooling capacity if it is re-charged with R12 after
repair.

Note that like R12, R500 is a CFC blend, and is destined to disappear in the same
way as R12.

* The oil separator float is iammed open.

Although rarely found in air conditioning plant, oil separators are widespread in
industrial and commercial refrigeration (see a/so: A specific problem associated with
oil separators, page 201).

Since this book doesn't aim to deal with all the technologies that will be encounterE!d,
we can simply say the main function of an oil separator is too minimise the amount of
oil circulating in the system as much as possible. It does this by separating oil from the
refrigerant after the compressor discharge, and then directing it back into the
compressor crankcase.

This oil for return slowly

accumulates in the bottom of Float Jammed Open
the separator.
-t..
As the oil level rises, it lifts a
float, and the valve needle
then rises to open the orifice.
This allows oil to be forced by
Tubing
the HP back into the compres- is hot
sor crankcase.
HP gets into
crankcase
The presence of contaminants
or other mechanical problems
can cause the f~oatto j3m in the open position. \,\'hen th~s occurs, the HP is direct!y
connected to the crankcase. This produces exactly the same symptoms as a
damaged head gasket.

T111~Hfaulti~easilyHdiagnosed.. because~()YCl1irg.theoil "r~t~r~ , tube

betWeen the separator and the. ctankcaseWili show:<whether 'it is
permimently hot.H , . . . ..>,H .. H ... .H. ..,:.", :. .,

LACK OF CO:MPRESSOR CAPACITY

- 148 - .
----
 * The speed of rotation of the compressor is too low.

This problem can occur when the compressor used is of the open type (with an
external motor).

Too low a rotation speed can then be due to wear or poor tensioning in the
transmission belts. Changing or adjusting the drive belts readily cures this problem.

Low speeds of rotation can also originate from too small a diameter on the motor
pulley. In this instance, before changing the pulley, the engineer should confirm that
the compressor is capable of operating at higher speeds, and that the electric motor
has enough power to provide the increase in speed that is required.

The electrical power that is used by a motor increases with the speed of the
compressor, and the compressor manufacturers graphs must be consulted to
establish the electrical power needed at the new speed.

If it appears necessary to replace the motor with a more powerful model, certain
precautions must be taken.

The replacement motor will have a significantly higher current passing through it, and
modification to electrical equipment will be required. This could include using larger
diameter cable (for the supply and other wiring) and fuses, contactors or thermal
relays of a larg"errange etc.

In addition, the new motor may not have the same dimensions (for the mounting base,
location holes etc.) or shaft diameter (to order new pulleys). Usually drive belts will
also need to be changed, as they may need to be of a different length and section.

* Thermal loads are exceptionallv hiqh.

Although this may not be strictly called a refrigeration fault, since the installation may
be working quite normally despite being under-sized, an engineer must be able to
recognise the problem posed by thermal loads which are too great for the capacity of
the installation.

For examples of exceptional thermal loads, consider the very high ambient
temperature in an air-conditioned room when the windows arc le't open in the middle
of summer, or if the blinds are not lowered over large glass windows.

The same problem occurs in a badly insulated cold store whose doors are opened too
often, or where there is hot produce or large volumes of produce continually being
brought in.

The ambient temperature is then only reduced with difficulty, and the LP is abnormally
high (since the llO total is effectively constant). This may wrongly lead us to conclude
that there is a lack of compressor capacity.

LACK OF COMPRESSOR CAPACITY

- 149-

-- -
 With the slide Jammed in an intermediate The slide of a cycle inversion valve can
position then there is a direct connection become jammed in an intermediate
between HPand LP
position for a number of reasons.

When this occurs, there is in effect a

direct connection between the LP and HP
sides. This can produce the same
symptoms as a lack of compressor
capacity.

for additional information see: The four-way cycle inversion valve, page 325, and
defrost by cycle inversion, page 433.

PERSONAL NOTES

LACK OF COMPRESSOR CAPACITY

- 150-
 EXCESS REFRIGERANT:
ANALYSIS OF THE SYMp.TOMS

We'll consider that a refrigeration system has 'excess refrigerant' when the cause of
any fault is too much refrigerant in the system. Let's analyse the symptoms produced
by this fault

A) Effects on the compressor/condenser assemblv:

Since the thermostatic expansion valve controls the amount of refrigerant contained in
the evaporator, it prevents any excess refrigerant building up in the evaporator.

The only locations in a systel11where there !s "space available" are the condenser and
the liquid receiver. Therefore it's in these two components that excess refrigerant will
be found.

CD

The level of liquid first rises in the receiver, whose function is precisely that of dealing
with fluctuations in the liquid If::!vel.Following this, the condenser gradually fills.

The I:nuid level in the condenser therefore rises abnormally. The heat exchange area
c:i".:=iIab!efor de-superheating and then condensing the vapour that is continually
arriving from the compressor discharge is accordingly reduced.

This reduction in surface area results in less effective cooling of the vapour that is
entering the condenser. This causes an increase in the temperature of the saturated
vapour and the HP pressure (point 2) increases. (see: control of air-cooled
condensers, page 239).

On the other hand, because the condenser is flooded, the liquid it contains is in
contact with the external air passing over it for much longer (point 3). This,
paradoxically. produces good sub-cooling.

EXCESSREFRIGERANT

- 151 -

----
In summary, then, an excess of refrigerant simultaneously causes a reduction in the
size of the condensation zone and an increase in the sub-cooling zone.

Since the HP rises and the liquid leaving the condenser is cooled more effectively, the
sub-cooling measured at the liquid exit of the receiver (point 4) is acceptable or
perhaps even slightly large.

B) Effects on the evaporator/compressor assembly:

Since the HP is increased, the vapour tr.apped in the clearance volume at top dead
centre is at a higher pressure. This means that there is a reduction in the mass flow
of gas being drawn in by the compressor, which in turn results in a reduction in the
cooling capacity (see: effect of pressures on mass flow and cooling capacity, page
39).

II

CD

Because the cooling capacity is low, an air-conditioned room w:ould be less well
cooled. In an extreme case, if the excess of refrigerant is too large, the system could
cut out on HP.

Since the temperature inside the room increases, the temperature of the air at the
inlet to the evaporator also increases (point 5).

If the ambient temperature increases and the refrigeration capacity decreases, the air
outflow temperature (point 6) also increases.

In addition, since the HP is high, the expansion valve capacity increases (see:
thermostatic expansion valve capacity, page 32), although the evaporator capacity is
reduced.

When an expansion valve with excess capacity supplies an evaporator that has
reduced capacity, there is a risk of expansion valve 'hunting' being produced,
although there is a perfectly normal (or perhaps even slightly small) superheat being
measured at the bulb.

EXCESSRERUGERANT

- 152-
 C) Effects on the compressor:

Point 1: Whatever the reason may be,

when one of the two operating pressures IfHP then LP
(LP or HP) varies in one direction, the other Increases... Increases...
pressure always tends to vary in the same ~
direction except in the particular case of a
lack of compressor capacity, where the HP
falls as the LP increases.

We've just seen, then, that excess

refrigerant causes an increase in HP.
This in turn results in a reduced mass
flow of refrigerant vapour being drawn
in by the compressor. f t
HP LP
We can conclude that since the HP has
I and VICEVERSA I
increased, and the compressor is
drawing in less refrigerant than normal, EXCEPTwhere' there is a
then the LP (point 8) tends to increase. "lack of compressor capacity"

Point 2: The energy that the compressor motor must supply (and which is drawn
from the electrical supply) depends largely on the value of the HP it must work against
when it makes the pistons rise to compress the vapour in the cylinders. (see: Effect
of HP on the current consumed, page 43).

Since an excess of refrigerant causes. an

increase in HP, the compressor will draw an
increased amount of energy from the
supply (point 9).

Now, the cooling of hermetic and semi-

hermetic compressor motors is performed
by the vapour being drawn in.

Since excess refrigerant causes a reduction

in the mass floN of the vapour being drawn
in, the compressor motor will be less
effectively cooled (except where the over-capacity of the expansion valve causes
periodic liquid 'slugging').

Furthermore, since the current passing through the motor i5 larger than usual, it will
tend to become warmer.

If the motor is getting warmer and being less effectively cooled, then the temperature
of the compressor crankcase (point 10) will increase, as will the temperature of the
gas being discharged (point 11).

EXCESSREAUGERANT

- 153-

---
Finally, note that the .6.0 total at the condenser will be abnormally large, since the
condensation temperature read on the HP gauge will be very high in relation to the
temperature of the air at the condenser inlet.

Note 1: It often proves necessary to perform a test for non-condensables (see page
159) to differentiate excess refrigerant from the presence of non-condensables. This
will be examined later.

A system that is stopped should therefore never be run (especially if there is a fault)
without fitting a gauge set and checking that the temperature shown on the HP gauge
is co.nsistent with the ambient temperature of the condenser.

TAKE CARE NOT TO CONFUSE AN

EXCESS OF REFRIGERANT
WITH, ' "
THE PRESENCE OF NON-CONDENSABLES

Note: 2 If there is excess refrigerant in a system, it means that the engineer has to
remove some of it.
. .
Release of refrigerant from refrigeration systems to the' atmosphere was a common
procedure until the start of the '90s. However, CFCs cause environmental problems,
particularly in their effect on the ozone layer that protects the Earth from certain ultra-
violet radiation. To prevent s~ch damage, regulations covering this sort of activity
have been extended, and above all will be more and more strictly enforced in the
future.

It will therefore be essential tohpr~parf)..totthe"iffiinychanges in

working practices that willberequlreQ../n.paiti6.fJl;if,'kndWI..edge. qf
thf}.. '..teqh.hiq4~*Hal1d ~qufpmei1tjqvptY~q''jir.;m~''f~C;dvery:of
refrigera hts hff.i5.ifisy~teij1s ...'.wittJ0l1.temJ~~i9t1S,...:p'~i,iigiJ1acfe .'to
atmosphefe,wilrbe,required~ (Thes(rwill/:)ep()11sidiff.~C1Jjifpage'391).

EXCESSREFRIGERANT

- 154-

-
 EXCESS REFRIGERANT
SUMMARY OF THE SYMPTOMS

e airoutfloW' "
" Tends to
Increase

Tends to
Decrease

..- ....-...............................

e ambient
I
"
HP"

Very good
Sub-cooling

.:~::::;~..~rankcase ... "..

~ ...
.
::":":!,:,:::.
..
,:,...'
:a,
,..,~
.

PERSONAL NOTES

EXCESS REFRIGERANT

- 155 -

----
 EXCESS REFRIGERANT
METHODS OF DIAGNOSIS

Cooling capacity is low

(the compressor isn't "producing any cooling")

Is the LP rather high? Different fault

YES
Lack of
Is the HP rather high ? compressor
C47pacily
YES
Lack of
Is there good sub-cooling? condenser
c.?pacify
YES

Are there non-condensables present?

(the test must be performed)

NO YES

EXCESS NON-CON DENS ABLES

REFRIGERANT PRESENT

Faults caused by high HP are relatively simple to diagnose.

P "'''' .. b .,.."',.,li" '" 1",,..1,,Of ,..c nrfonco r ,..a n",,..in, nf te n
, r s "" v e cfc;
C>li hO"''''''ce:>
~ WY::::I::::f
-~- ."""'-II.
" . - .,' _ "'--'''''''J ( _. II _______
the condenser is simply "dirty").

Acceptable sub-cooling suggests that there is either excess refrigerant or

a significant presence of non-condensables in the system.

Excess refrigerant with water-coofed condensers: see page 481.

EXCESS REFRIGERANT
eo
- lSG-

---
 EXCESS REFRIGERANT SUMMARY II

LOW COOLING
CAPACITY

, P
.11'

?1:1

?.
0
Why isn't this compressor pr,jducing any cooling? let's see...
Well, the LP is pretty high... Perhaps there's a broken valve?
No, the HP is high too... Could there be a lack of condenser capacity?
No, there's good sub-cooling, so that's not it...
What's the result of the non-condensables test ?..
No non-condensables... It can only be...
EXCESS REFRIGERANT!

EXCESS REFRIGERANT

- 157-

--
 ~-----------

EXCESS REFRIGERANT
SOME PRACTICAL ASPECTS

Excess refrigerant problems tend to appear after the first hot weather of the year,
especially in installations that operate 'between seasons' with low outside
temperatures, and whose air-cooled condensers are either poorly controlled or have
no control system.

If we consider an exaggerated case, imagine a system like this, with the correct
refrigerant charge that has operated quite satisfactorily throughout the summer. Once
the cold weather arrives, the drop in the external temperature causes a large
decrease in the HP because of the lack of any effective control of the condenser.

This decrease in the HP results in turn in a 'poor supply of liquid to the expansion
valve, and thence the evaporator. This results in an excessively low LP, and even
causes the compressor to cut out on low pressure.

The maintenance engineer may notice that there is excessive condenser capacity,
and may be tempted "as a temporary measure" to add refrigerant to the system. This
reduces the heat exchange surface, reduces the condenser capacity and enables the
system to operate as well as can be expected taking into account the relatively low
external temperatures. (Naturally, a competent and conscientious engineer would
suggest that the client install a suitable HP regulation system).

Winter then passes, and once the warm weather returns, the lack of he.at exchange
surface in the condenser soon results in a large increase in HP or even causes the
system to cut out on HP. The engineer called to investigate the problem (perhaps
even the same engineer!) decides that there is excess refrigerant present and
removes some of the charge... and so on...

Excess refrigerant in a system is unfortunately frequently due to the incompetence of

some engineers, ranging from those who charge the' system "withe clamp-on
ammeter" to those "add a bit of extra gas, in case there's a leak"!

Remember that an undersized receiver can cause exactly the same symptoms as an
excess of refrigerant charge.

* The liquid receiver is too small.

To facilitate maintenance operations, the liquid receiver is often designed so that it

can hold all the refrigerant in a system (see: Problems associated with the refrigerant
charge, page 72), which deals in detail with the problems due to incorractly sized
receivers).

We'll also see later that installing a HP regulator valve requires that a liquid receiver of
maximum capacity be fitted. If this is not done, the symptoms of excess refrigerant
charge can be produced as soon as the weather starts to get warmer (see:
Regulation using a HP valve: Analysis of faults, page 241).

EXCESS REFRIGERA~T

"'::('
 INTERPRETATION OF
THE TEST FOR NON-
CONDENSABLES

A) The effect that non-condensables have on a system:

First of all, we should recall that Dalton's Law states that the total pressure of a
mixture of gases is equal to the sum of the partial pressures that each individual gas
wo.uld exert if they alone occupied the total volume of the mixture.

. . . . . <0. 6 . 6 .

-
o .. ..
. . . ~ ~ 6 6 6. 6. 6. 0
. . . . .6.6.0..
+
o .. ..
. . .. 6 <0 6 0- 6. 6. 0. 0
. . . . o .. .. .0.0....
. . . 0- 0 6 0- 6.6.6.0
. . . . o .. .. .6. 6. 6.
.. . . 0- 6 6 6 6.6.6.6

Therefore if a non-condensable gas (usually air or nitrogen) is present inside a

refrigeration system, the partial pressure of this gas ad9s to the normal pressure that
is exerted by the refrigerant to give a total pressure in excess of the usual pressure.

This1s why .anabnormal/y high HP isthe'firstindicationof the presence of a

large amount of non-condensable gas..n. n'.. .., n

B) How can non-condensable et into a refriaeration

System?

The presence of non-condensables in a system is often

the result of a mistake, e.g.

An inefficient evacuation operation, or one where

parts of the system are isolated (by manual valves
inadvertently left closed, or by closed solenoid
valves).

Air introduced during service or inspection of an

"open system".

Warning: When fitting gauges, unless an engineer

evacuates his hoses, there will always be air left in the
manifold chambers.

NON-CONDENSABLES

- 159 -
 If he then has to use the service valves of the gauge set, for example if he is adding
refrigerant to the system, the air contained in the hoses will be introduced into the
system.

This error causes two distinct types of problem, which can both prevent correct
operation:

Firstly moisture introduced with the air can result in acid formation, and secondly the
partial pressure of air introduced will add to the normal pressure of the system.

Note: There are significant amounts of water vapour contained in atmospheric air. For
example, air at 21C and 40% relative humidity contains more than 6 grams of water
per kg of air. At 29C and 60% humidity, air contains more than 159 of water per kg of
air! (see: some psychrometric concepts, page 499)

C) Where do we find non-condensables in a system?

Non-condensables won't remain in

the liquid line or in the evaporator, Non-condensables
because they will be forced from
these areas by the. liquid
refrigerant.

Since the non-condensables are

lighter than the refrigerant vapour,
a small proportion will be found in
the discharge line. The majority of
any non-condensables, however,
will be trapped in the upper part of the liquid receiver.

Since ne?lrly all the non-condensables will accumulate in the top of the receiver, their
pressure 'will add to the condensation pressure. This results in a HP (and therefore a
~e total for the condenser) that is abnormally high.

D)How is the test for non-condensables carried out? .

First of all, there must be no doubt that there is liquid refrigerant in the condenser. To
check this, it is recommended that all the refrigerant be returned to the liquid receiver,
the receiver .liquid outlet valve closed and the compressor run until it is cut out under
low pressure by the pressure switch.

The compressor must then rema.ininoperative in ()rder to ens.ure t~afnomore

'heat'is'sehttothecondenser.. ... ..

At this point, the condenser fan (or fans) must be made to run in order to equilibrate
the temperature of the refrigerant in the condenser with that of the surrounding air.

At first, the HP falls rapidly, and then the drop in pressure slows down until the
pressure is at a constant value (the condenser fans must usually run for at least a
quarter of an hour before this occurs).

NON-CmmENSABLES

- 160-

---
 The temperature of the air passing over the condenser should now be measured
using a thermometer, and this temperature compared with that shown by the HP
gauge on the scale corresponding to the refrigerant used in the system.

.. ..~,. . .-".'--'-,..
.....

270C 10 bar (27C)

'\
Valve
closed
.---
Compressor
not running

R22 Liquid

For example, if the temperature of the air passing over the condenser is 27"C (with
the compressor not in operation) and with R22 in the system, then .after being allowed
to equilibrate, the HP gauge should show the pressure of R22 at 27"C. According to
the pressure-temperature relationship for R22 this should be 10 bar (we could expect
about 6 bar with R12 and 6.1 bar with R134a).

If the readings 'on the HP gaugepandthe thermometer are within 2C of each

other, then We can conc;/tide that there are nonon-condensables in the system.

We can conclude then that there must be at least one drop of liquid in the condenser,
since it only needs one drop or liquid for the pressure-temperatiJre relationship of
refrigerants to be valid (see: The pressure-temperature relationship, Page 13).
Therefore, this test cannot indicate whether or not there is sufficient refrigerant in the
system.

Note: HP gauges for use in the plant room are generally not laboratory quality
instruments. The lack of precision that is inevitable in reading the pressures they
indicate means that in practical terms there must be a tolerance of 2C.

Note: see also the test for non-condensables for water-cooled condensers, page 483.

NON-CONDENSABLES

- 161-

---
 roduce different
E) What if the thermometer and HP
temperature values?
So that there is no possible confusion (not all systems operate on R22 or R12), the
identity of the refrigerant in use in the system must be known with certainty. This can
be obtained (for example) from the information on the thermostatic assembly of the
expansion valve.

If the temperature indicated by the

HP gauge is greater than the
~estOK
Y\
measured temperature by more
than 2C, then there are non-
Lack of R22 27C

!
condensables present (and the
larger the temperature difference, }9C
Non-
the larger the proportion of non-
condensables in the system).

If the temperature shown on the

\
J
ondensab\es

gauge is less than tlie measured

temperature by more than 2C,
)
then there is not a single drop of
liquid refrigerant in the system
(the system is completely empty
of liquid).

It is essential that a sufficiently precise and accurate thermometer is used, and that
.the pressure gauge calibration has been checked before it is connected for this test.

. F) How can the non-condensables be removed?

Since the non-condensables are less dense than the refrigerant'vapollr, they can be
found at the top of the liquid receiver.

The presence of the dip-tube that draws liquid R22

Non Conden t Purge Valve from the bottom of the receiver means that the
-sables
non-condensables cannot leave _ the receiver.
R22 "'- Similarly the non-condensables c'annot be removed
Vapour
from the receiver (or water-cooled condenser),
unless a purge valve has been fitted at its highest
point. The receiver can be partly purged by
loosening the thread of the connecting nut at the
receiver inlet (unless, of course, this is a brazed
joint).

4= ;If this is not feasible, an engineer must completely

evacuate the system (in accordance with all
regulations), pull an effective vacuum on the system to remove all non-condensables,
and then recharge it (all of which is a real nuisance!).

Note: If there are non-condensables present, they may be due to the presence
of atmospheric air. Therefore, there may be water in the system. It is essential,
therefore, to check the colour of the moisture indicator in the liquid sight-glass,
perform an acidity test on the compressor oil and take any necessary actions.

NON-CONDENSABLES

- 162-
 NON-CONDENSABLES
ANALYSIS OF THE SYMPTOMS

In the previous chapter, the problems associated with non-condensables were

discussed in general terms.

Now the effects of this fault on all the operating parameters of a standard refrigeration
system will be considered. ..

A) Effects on the compressor/condenser assemblv:

Regardless of the way in which non-condensables (air, nitrogen etc.) were .introduced
into a system, they will not remain in the liquid line or in the evaporator. They will
eventually be forced out of these areas by the liquid refrigerant before being drawn
into the compressor. They will then be discharged towards the condenser and liquid
receiver.

Since non-condensables are less dense than refrigerant, most of the non-
condensables will become trapped at the top of the liquid receiver (point. 1). They
cannot escape from this area because of the presence of the dip-tube used to draw
liquid from the bottom of the receiver.

If we apply Dalton's law for gas mixtures, the partial pressure of the non-
condensables will be added to the partial pressure of the refrigerant (which is at the
actual condensation pressure) to produce the total pressure reading on the gauge
(point 2). This will be abnormally high.

The presence of non-condensables causes the HP gauge to give an artificially high

temperature reading (for example 55C), in relation to the true condensation
temperature (for example 40C). The larger the proportion of non-condensables
present, then, the larger that the apparent sub-cooling of the liquid will be (in this
example at least 15C) (point 3) .

NON-CONDENSABLES

- 163-

- --- --
A) Effects on the expansion valve levaporator assembly:

As the HP increases, the vapour trapped in the dead space (or clearance volume) at
top dead centre will be at a higher pressure. This means that there will be a reduction
in the mass flow of refrigerant drawn in by the compressor, and consequently a
reduction in refrigerating capacity (see: effect of pressures on the mass flow and
cooling capacity, page 39).

Since the cooling capacity is reduced, the ambient temperature of the air-conditioned
room will be higher (especially in the middle of summer). In extreme instances, the
system may even cut out under HP. This will r.esult in a service call from the client
saying "it's too hot"!

Since the ambient

./..-----..............
/ . temperature rises,
/ the temperature of
/ the air arriving at the
-+~ \
inlet of the evapo-
rator (point 4) also
increases.

Since the air at the

evaporator inlet is
warmer, . and the
cooling capacity is
reduced, the air will
be less' effectively
::~... cooled, and the air
outflow temperature
(point 5) will also
increase.

As the HP rises, the thermostatic expansion valve capacity also increases (see:
thermostatic expansion valve capacity, page 32), although the refrigeration.capacity of
the evaporator is reduced.

Since the evaporator of reduced capacity is now being supplied by an expansion

valve with increased capacity, the expansion valve could 'hunting' in conj~nction with
an acceptable (or even rather small).superheat measured at the bulb (point 6).

C) Effects on the compressor:

The energy that the compressor motor must furnish (and which is drawn from the
electricity supply) depends to a large extent on the value of the HP that it must work
against as the pistons rise to compress the vapour in the cylinders (see: Effect of HP
on the current consumed, page 43).

NON-CONDENSABLES

- 164-
 Since the presence of non-condensables causes an increase in HP, the motor must
provide more energy to the compressor, and so will take more current from the supply
(point 7).

The cooling of a motor in hermetic and semi-

hermetic compressors is performed by the
vapour that is being drawn into the com-
pressor.

Since the mass flow is reduced because of

the increase in HP, there is less vapour
arriving at the suction side of the coropressor,
and cooling of the motor is less effectively
performed, except where there is periodic
liquid "slugging" reaching the compressor
caused by the excess of expansion valve
capacity.
i

Furthermore, since there is a larger current passing through the motor, the
i
compressor tends to get warmer. I

Since the motor is getting warmer, and is not being as effectively cooled, the
temperature of the compressor crankcase (point 8) will be higher than normal and the \

temperature of the gas being discharged (point 9) will also tend to increase.
l
Note also that the ll8 total at the condenser will be abnormally large, since the !,
condensation temperature obtained from the HP gauge reading will be higher in
relation to the temperature of the external air. .

Finally, since the mass flow is smaller, the compressor is drawing in less vapour than
normal and the LP (point 10) will tend to increase.

Be Warned: The general symptoms of non-condensables are exactly the same as

those of excess refrigerantin the system.

Therefore, in order to differentiate between these two problems with any degree of
c~rtainty, the test for non-condensables must be performed.

'TAKECARENOT.Tq<;9~f..t.J~ETHE
. PRE5ENCEOFN()N;G,Q~DENSABLES
... .
... . . WITH
. . ,.. .. .
'
.. .. ...
'"
..
.. . .. '. .

EXCESS REFRIGERANT CHARGE

NON-CONDENSABLES

- 165-

-----
 NON-CONDENSABLES
SUMMARY OF SYMPTOMS

e air outflow "

" Tends to
Increase

~ Tends to
Decrease

e ambient
I
"
llG Total
condenser" HP"
Very Good
Sub-cooling
(at first sight)

PERSONAL NOTES

NO~ -CONDENSABLES

- 166-

- --
 NON-CONDENSABLES
METHODS FOF DIAGNOSIS

Cooling capacity Is low

(thecompressorisn't"producinganycooling")

Is the LP rather high ? Different fault

YES
NO u&k. of
Is the HP rather high ? compressor
capacity
YES
NO Lack of
Is there good sub-cooling? condenser
capacily
YES

Are there non.condensables present?

(the test must be performedf

YES NO

NON-CONDENSABLES EXCESS
PRESENT REFRIGERANT

Warning: REMEMBER THAT IF THE LIQUID LINE TEMPERATURE IS AT

say 45C:
o sub-cooling is adequate if condensation is occurring at 55C

. sub-cooling is TOO SMALL if condensation is occurring at 46C

For water-cooled condensers: see page 482.

NON-CONDENSABLES

- 167-
 ON-CONDENSABLES SUMMARY

GOOD
SUB.COOLING

NON-CONDENSABLES
TEST POSITIVE
I

- ,?
?Ii

o 0 ?
Why isn't this compressor producing any cooling? let's see...
. Well,the LP is very high... Perhaps there's a broken valve?
No, the HP also is very high... Could there be a lack of condenser capacity?
No, the sub-cooling is very good...
What was the result of the non-condensables test ?..
Wow!Over 3 bar difference! That can mean that...
THERE ARE NON-CONDENSABLES PRESENT!
L

NON-CONDENSABLES

- 168-

---
 NON-CONDENSABLES
SOME PRACTICAL ASPECTS

The answers to most of the questions concerning non-condensables have already

been considered in the last chapter (see page 159).

However, we'll examine here a practical "trick" which will save a lot of time during a
repair.
.
A rapid test for non-condensables:

When arriving to repair a system that has stopped running, the refrigerant
temperature has generally had plenty of time to equilibrate with that of the air around
the condenser. .

The first thing that should always be done is to fit a gauge manifold set.

?. /0
o
The system has been stopped for a good
while and the HP gauge reads 10 bar.
Now that's. about 27 degrees C for R22...
What's the actual condenser temperature
though?...

Then, before trying to start the compressor always compare the

temperature indicated by the HP gauge with the ambient temperature of the
condenser.

In this way, you will immediately be able to tell if there are any non-condensables
present in the system, without having to carry out the full test.

A: fewseconds:to.thinka breakdown through wi/lsave you a

great deal of time/a lot of trouble and help prevent you taking
anynutriber of wrol1gturnings~ ..' . , H

NON-CONDENSABLES

- 169-