Marine Refrigeration Series: Part 4

Troubleshooting Marine
Reefer System
About
Marine Insight©

Marine Refrigeration Series Part- 4

“Troubleshooting Marine Reefer System”
Publication date: December ’2015
Author: Marine Insight
Editor : Raunek Kantharia

Published by: Marine Insight

www.marineinsight.com

Graphic Design: Anish Wankhede

Copyright 2015 Marine Insight

NOTICE OF RIGHTS

All rights reserved. No part of this book may be rewritten, reproduced, stored in a retrieval system,
transmitted or distributed in any form or means, without prior written permission of the publisher.

NOTICE OF LIABILITY

The authors and editors have made every effort possible to ensure the accuracy of the information
provided in the book. Neither the authors and Marine Insight, nor editors or distributors, will be held
liable for any damages caused either directly or indirectly by the instructions contained in this book, or
the equipment, tools, or methods described herein.
Troubleshooting

COMPRESSOR

1. Compressor fails to start

• Current not passing due to open circuit
• Motor protection device active
• Defrost device active
• High or low pressure cutout active
• Oil pressure cutout active
 Check any open circuit
 Reset the motor protection device and rectify the cause
 Let the defrost cycle finish
 Check the cause and reset pressure cutout
 Check the oil level, filter etc. and reset oil pressure cutout

2. Compressor starts and stops often

• High pressure cutout active, malfunctioning or set at
wrong pressure
Troubleshooting

• Low pressure cutout cuts at too low pressure

• Low pressure cut out differential setting is too small
• Capacity of compressor is too high
• Suction line filter clogged
• Solenoid valve not correctly closed and malfunctioning
• Leaky compressor discharge valve
 Check and rectify the cause of high pressure in discharge
side
 Increase the differential pressure of low pressure cutout
switch
 Check the operating condition of compressor and reduce
the capacity if required
 Check and clean the suction line filter
 Overhaul/ Replace the defective solenoid valve
 Overhaul/ Replace defective discharge valve

3. Compressor starts but stops immediately

Troubleshooting

• Compressor motor protection active

• Low pressure cutout is active
• Oil pressure cutout malfunctioning
• Oil level is low
• Oil quality is very poor

 Check for overloading cause in the motor

 In case of star delta starter, set the starting time to
minimum
 Open any suction stop valve which is active
 Check and replace oil pressure switch
 Check and replenish the oil level if needed
 Check the condition of oil for foaming and water presence
 Renew the oil if required

4. Compressor runs continuously

• Low pressure cutout malfunctioning

Troubleshooting

• Low pressure cutout setting is wrong

• Restricted supply of refrigerant to compressor
• Refrigerant charge insufficient
• High load demand

 Check low pressure cutout and set it appropriately

 Clean the line filter and check proper functioning of
expansion valve
 Top up the refrigerant to normal required level
 Check and assess the load to modify the operational
setting of refrigeration devices accordingly

5. Abnormal noise from compressor

• Damaged compressor bearings

• Damaged motor bearings
• Problem in the alignment of compressor and motor
coupling
Troubleshooting

• Problem in the alignment of V-belt

• Compressor capacity too high during start
• Liquid refrigerant in the suction
• Loose foundation bolts
• Oil level is very low
• Too much oil circulating in the system
 Check and overhaul compressor bearings
 Check and overhaul motor side bearings
 Check trueness of motor compressor coupling
 Check all bolts of the coupling are properly tightened and
not damaged
 Check the tension of the V-belt and tighten/renew
 Adjust expansion valve and ensure no liquid comes in the
suction of compressor
 Tighten all the foundation bolt to their rated torque
 Check and refill the oil in crankcase
 Check and clean filters, solenoid valve, jet etc. in the oil
return system
Troubleshooting

7. Compressor capacity very less

• Icing on the evaporator
• Insufficient oil charge
• Less oil pressure due to defective oil pump
• Defective controlled capacity system

 Check the defrost system functioning and clean the ice

from evaporator
 Check and fill the oil till required level
 Check functioning of oil supply pump and overhaul if
needed
 Check and repair the defective capacity controller

8. Slugging in the compressor during start up

• Absorption of refrigerant in oil

• Foaming of crankcase oil leading to reduction in pressure
• Condensed refrigeration in suction line or in crankcase
Troubleshooting

• Problematic oil supply pump

 Reduce compressor capacity

 Start throttling compressor suction valve
 Heating arrangement to be provided in the crankcase
 Check the correct operation of oil supply pump
 Liquid separator to be mounted in suction pipe

9. Slugging in the compressor during operation

• Refrigeration gas in the liquid line

• Wrong setting of thermostatic expansion valve
• Malfunctioning/ oscillating expansion valve

 Ensure proper working of condenser

 Check the superheat setting of expansion valve normally
set between 5 to 8 °C
 Replace faulty expansion valve
Troubleshooting

10. Compressor cuts off on oil pressure control

• Insufficient oil in the system

• Lack of oil separator on freezer systems
• Defective oil pump or the oil pump inlet screen is restricted
• Crankcase heater not installed or defective
• Oil pressure control defective or improperly wired
• Oil trapped in the system, probably in the evaporator

 Recharge oil to correct level

 Install an oil separator
 Check and overhaul defective oil supply pump
 Check the working of crankcase heater
 Check the correct functioning of oil pressure controller
 Check for oil traces within the evaporator. Clean and rule
out cause for oil contamination

11. Compressor motor pulling high ampere

Troubleshooting

• Excessive suction pressure beyond the limits of the compressor’s

ability to run
• Excessive system load
• Improperly wired (very common mistake)
• Defective run or start capacitor
• Defective start capacitor
• High or low voltage
• Excessive discharge pressure

 Check the performance charts of the compressor for the

maximum suction pressure
 The use of a Crankcase Pressure Regulator (CPR) may be
required
 Check the load on the system and set the operating
condition according to the load
 Check the wiring to all electrical connection of the motor
 Check and replace defective starter or capacitor
 Check and rectify the cause of high discharge pressure
Troubleshooting

12. Compressor crankcase sweating or frosting

• Liquid in suction line

• Expansion valve sensor misplaced
• Liquid regulating valve or float valve producing too much
liquid
 Check for liquid in suction line and rectify cause
 Check positioning of expansion valve sensor
 Increase superheating on thermostatic expansion valve

13. Compressor too hot

• Compressor and possibly motor overloaded because of

evaporator load and thereby suction pressure too high
• Poor motor and cylinder cooling because of insufficient
liquid in evaporator
• Suction and discharge valves not tight
• Condensing pressure too high
Troubleshooting

 Reduce evaporator load or replace compressor with larger

size
 Locate fault on the line between condenser and
thermostatic expansion valve
 Replace valve plates
 Reduce the condensing pressure

14. Compressor too cold

• Flow of liquid refrigerant from evaporator to suction line

• Incorrectly set thermostatic expansion valve

 Check for liquid in suction line and rectify cause

 Set thermostatic expansion valve for lower superheat

15. Compressor Oil level too high

• Oil quantity too large

Troubleshooting

• Refrigerant absorption in crankcase oil because of too low

ambient temperature

 Drain oil to correct level, but first ensure that the large
quantity is not due to refrigerant absorption in the oil
 Install heating element in or under compressor crankcase

16. Compressor Oil level too low

• Oil quantity too small

• Poor oil return from evaporator
• Diameter of vertical suction lines too large
• No oil separator
• Insufficient fall of oil in horizontal suction line
• Wear on piston/piston rings and cylinder
• Equalizing pipe too small
• Oil return from oil separator partly or fully blocked, or float
valve sticking
Troubleshooting

 Fill oil to correct level, but first be sure that the oil quantity
in the crankcase is not a result of oil collection in the
evaporator
 Install oil lock at 1.2 m to 1.5 m from vertical suction lines
 If liquid supply is at the bottom of the evaporator, it can be
necessary to swap inlet and outlet tubes (liquid supply
uppermost)
 In all circumstances the compressor started last is most
subject to oil starvation
 Line up compressors so that they are in same horizontal
plane. Install larger equalizing pipe
 Fit vapor equalizing pipe if necessary
 Clean or replace level container with float valve
 Clean or replace oil return pipe or replace float valve or
whole oil separator

17. Compressor oil boiling off during operation

Troubleshooting

• Flow of liquid refrigerant from evaporator to suction line

• Incorrectly set thermostatic expansion valve

 Check for liquid in suction line and rectify cause

 Set thermostatic expansion valve for lower superheat

18. Compressor short cycles on high pressure control switch

• Water flow very less

• Water inlet valve stuck or malfunctioning
• Dirty or scaled condenser
• Defective high pressure control switch
• Wrong high pressure switch setting

 Check the flow of water

 Check and overhaul inlet valve
 Clean the condenser
 Check the settings of the high pressure switch and make it
to normal
Troubleshooting

 Renew defective high pressure cut off switch

19. Compressor oil discolored

• Cleanliness not observed during installation

• Oil breakdown because of moisture in system
• Oil breakdown because of high discharge pipe temperature
• Worn out particles from moving parts
• Inadequate cleaning after motor burn-out
 Change oil and filter drier
 Clean out refrigerant system if necessary
 Locate and remedy cause of excessive discharge pipe
temperature
 Replace worn out parts
 Check the compatibility of oil in the system with the
manufacturer
 Replenish the crankcase only with approved oil as per the
compressor manufacturer
Troubleshooting

20. Compressor oil black in color

• Carbonization resulting from air in the system

 Remove air from system

21. Compressor oil gray or metallic in color

• Compressor bearing wear down

• Compressor piston ring wear down
 Check and replace bearings
 Check and replace piston rings

22. Compressor oil brown in color

• Copper plating caused by moisture in the system

 Change filter drier or dehydrator, if installed
Troubleshooting

23. Compressor discharge pressure high

• Air in the system

• Dirty condenser
• Refrigerant overcharge
• Liquid refrigerant backed up in the receiver
• Restriction in the discharge line due to physical damage or
internal restriction
• Receiver too small for summer application
• Pressure drop through the condenser exceeds rated
pressure, forcing the bypass port to open partially
• Restricted water flow, water too warm
• Defective water regulating valve for condenser
 Check for low pressure side for leakage
 Clean the condenser
 Check and ensure refrigerant inside the system is not
overcharged
Troubleshooting

 Check for any physical or internal damages in the

discharge line of compressor
 Assess the size of the receiver as per the system’s
requirement
 Check the functioning of bypass valve and ensure the
setting is right
 Check the functioning of water supply valve of condenser
 Check the temperature of cooling water for condenser is
not too high

24. Liquid hammer in the compressor

• Expansion valve capacity too large

• Superheat on expansion valve set too low
 Replace expansion valve or the orifice with a smaller one
 Reset or increase the superheat on thermostatic
expansion valve to a higher value
Troubleshooting

25. Motor hums but does not start

• Seized compressor
• Hydro lock inside the compressor
• Failed capacitor in the control panel
• Failed start relay in the control panel
• Stuck centrifugal disconnect switch
• Seized motor or compressor bearings

 Check and overhaul piston and liner assembly

 Ensure no liquid goes inside the compressor
 Replace the capacitor
 Replace/ renew the relay
 Starter routine to be carried out in the switch
 Renew switch if faulty
 Overhaul motor to renew bearings
 Overhaul and renew compressor bearings
Troubleshooting

26. No indication of compressor motor starting

• Open circuit of electric motor

• Burned motor winding
• Internal connection wire may be fatigued and cracked
• Worn out brushes
• Very dirty commutator

 Check continuity of wires in the circuit

 Check and renew burned winding
 Check all the internal wirings for continuity
 Renew worn out brushes
 Clean the commutator

27. Overload tripping of compressor motor

• The start relay not opening

• The breaker itself is failing
• Poor feed wire condition
Troubleshooting

• Short circuit in motor winding

• A seized compressor

 Check the functioning of start relay

 Do starter routines on relay
 Renew the breakers
 Replace the wirings
 Renew the burnt motor winding
 Ensure compressor bearings, piston and piston rings are
not seized and there is no liquid lock

28. Compressor motor is noisy or erratic

• Motor bearing failure or winding failure

• Wrong calibration on control elements

 Renew faulty bearing and motor winding

 Calibrate the control elements
Troubleshooting

29. Run capacitor burned out

• Excessively high supply voltage

• High supply voltage, light compressor load
• Incorrect capacitor, capacitor voltage rating too low
 Check and regulate the supply voltage
 Ensure compressor is evenly loaded
 Renew with correct rating capacitor

30. Start capacitor burned out

• Compressor short cycling

• Relay contacts sticking
• Incorrect capacitor
• Start winding staying in the circuit for too long

 Troubleshoot short cycling of compressor

 Do the relay contactor routine
Troubleshooting

 Replace with correct rating capacitor

 Check the functioning of start winding

31. Start relay burned out

• Compressor short cycling

• Low or high supply voltage
• Improper mounting of the relay
• Incorrect start or run capacitor
• Incorrect starting relay
 Troubleshoot short cycling of compressor
 Supply correct voltage
 Check the arrow on the side of the relay, it should be
pointing up
 Use appropriate run capacitor
 Check the specifications of relay with the compressor
manufacturer
Troubleshooting

CONDENSER

32. Excessive condenser pressure

• Overfilling of refrigerant inside the condenser

• Insufficient condenser cooling
• Cooling water valve malfunctioning
• Water supply pump damaged/ leaking
• Fouling of heat transfer surface
• Presence of non-condensable gases (air)

 Draw refrigerant if in excess

 Check supply of condenser cooling water
 Overhaul condenser cooling water valve
 Check and rectify/ overhaul water supply pump
 Clean the condenser if fouling is present
 Remove air from the refrigeration system
Troubleshooting

33. Condensing pressure too low

• Water quantity too large

• Water temperature too low

 Install automatic water valve or set existing valve

 Reduce water quantity by using automatic water valve

34. Condensing pressure hunts

• Vapor formation in liquid line because improper cooling
• Refrigerant collection in condenser
• Thermostatic expansion valve hunting
• Fault in condensing pressure regulating valves (orifice too
large)
• Cooling water valve malfunctioning or choked

 Set differential on lower value or use valve regulation

 Set thermostatic expansion valve for higher superheat
Troubleshooting

 Replace orifice with smaller size

 Replace valves with smaller size
 Check and rectify the cause of "Suction pressure hunting”

Evaporator

35. High superheat at evaporator outlet

• Unbalanced system, load in excess of the design conditions
• Compressor discharge valve leaking
• Leaking hot gas defrost solenoid or hot gas bypass valve
• Hot gas bypass regulator pipe connected directly to the
suction line without a liquid injection valve
• Incorrect expansion valve installed
• Starving evaporator

 Check and reduce the load on the system if possible

 Overhaul the leaky compressor valves
Troubleshooting

 Check and rectify leakages and if needed overhaul or

replace solenoid and bypass valves
 Check the capacity of expansion valve
 Use the correct size of thermostatic expansion valve for
the system
 Ensure evaporator has enough refrigerant for cooling and
it is free from moisture and debris

36. Low superheat at evaporator outlet

• Oversized expansion valve
• External equalizer on the expansion valve plugged or capped
• Expansion valve defective or held open by a foreign material
causing liquid flood back
• Moisture in the system causing the expansion valve to freeze
in the open position
• Expansion valve superheat set too low
• Ruptured suction line of liquid line heat exchanger
Troubleshooting

• Unit coming out of defrost (normal)

• Uneven or inadequate evaporator loading due to poor air
distribution
 Assess the expansion valve and use correct size
 Check and remove any obstruction from external equalizer
line
 Check and overhaul expansion valves and seat to remove
foreign material causing liquid flood back
 Remove moisture from the system
 Correctly set the expansion valve superheat using setting
screw
 Check and rectify any leakages on suction line of liquid line
heat exchanger
 Ensure air flow over the evaporator is good and avoid
fluctuation of load

37. Too high superheat in evaporator

Troubleshooting

• Flash gas in the liquid line

• Insufficient refrigerant charge
• Excessive pressure drop in the liquid line due to an
undersized liquid line or excessive vertical lift
• Liquid line restrictions
• Improper piping design
• Inadequate sub-cooling
• Low head pressure
• Expansion valve distributor or cap tube restricted
• Excessive load on the evaporator above the design
conditions
• System contamination, probably moisture or wax
• Undersize expansion valve
• Internally equalized expansion valve used on a system with
too much pressure drop through the evaporator or used with
a refrigerant distributor
• Expansion valve power element has failed or lost its charge
• Incorrect expansion valve power head charge
Troubleshooting

• Superheat setting on expansion valve too high

 Charge the refrigerant in the system and remove the air
 Ensure the size of liquid line is as per the load and
components
 Replace sharp bends and piping with proper pipes
 Check and ensure TEV line is free from any hindrance
 Maintain required design load at all times
 Clean the system off wax and remove moisture if any
 Check and assess the size of TEV. Replace if the size is small
 Check the pressure drop in expansion valve and maintain it
under required limit
 Renew defective TEV power element
 Check and adjust the superheat setting of TEV

38. Too low superheat in evaporator

• Overcharge of refrigerant or oil

• Excessive accumulation of oil in the evaporator
Troubleshooting

• Malfunctioning defrost control or defrost cycle setting is

wrong
• Expansion valve bulb and/or equalizer tube located
improperly on the system
• External equalizer line plugged or capped
• Oversized expansion valve
• Expansion valve defective or held open by a foreign material
causing liquid flood back
• Moisture in the system causing the expansion valve to freeze
in the open position
• Expansion valve defective or has incorrect power element
charge
• Expansion valve, solenoid valve or the compressor discharge
valve leaks. This will leave the refrigerant in the low side
which creates the possibility of flooding on start up
• Excessive icing on evaporator coil
• Superheat setting on expansion valve too low
Troubleshooting

 Remove excess refrigerant from the system

 Check oil accumulation and clean the same
 Rectify damaged defrost control & enhance defrost timings
 Place the sensor bulb in correct position
 Check and ensure TEV equalizing line is free from any
hindrance
 Assess and replace to correct size TEV
 Overhaul expansion valve for dust, damage and leakages
 Remove moisture from the system
 Rectify leakages in solenoid valve, compressor valve etc
 Clean the excessive icing from the evaporator and check
proper working of defrost system
 Check and adjust the superheat setting of TEV

39. Oil inside evaporator coil

• Flooded compressor circulating oil at start-up

• Too much oil in the system
Troubleshooting

• System not piped correctly (no oil traps or piping too large)
• Liquid migration during off cycle, causing crankcase oil
foaming on start-ups
• TEV out of adjustment (too little superheat causing a
refrigerant-flooded compressor)
• Not enough defrost periods for low-temperature application
machines
• Wrong type or viscosity of oil

 Ensure compressor is not flooded and works as per the

load
 Check the oil level and remove the excess oil
 Install oil trap in the system
 Check the proper functioning of TEV and adjust the
superheat by setting screw if needed
 Check and adjust defrost timing
 Use correct viscosity oil suggested by maker
Troubleshooting

40. Icing over evaporator coil

• Ripped or broken door gasket

• Door left open for long
• System is low on refrigerant
• Improper adjustment of TEV
• Condenser is dirty
• Improper defrost timer
• Evaporator drain is choked or improper vent
• Heater not functioning
• Faulty evaporator fan
 Ensure room door is properly sealed and not open for long
time
 Top-up the system with required amount of refrigerant
 Adjust the superheat of TEV using setting screw
 Clean the condenser
 Check and adjust the timings of defrost system
Troubleshooting

 Clean the evaporator drain and vent

 Repair the heater
 Repair the evaporator fan

41. Evaporator room temperature too high

• Pressure drop across expansion valve is less than designed

limit
• Lack of sub-cooling ahead of expansion valve
• Sensing bulb located in the wrong area
• Expansion valve blocked with ice, wax and other impurities
• Size of expansion valve is inappropriate
• Loss of charge from expansion valve
• Evaporator completely or partly covered with ice

 Replace expansion valve with external pressure equalizer

or reset superheat of expansion valve
 Try replacing the nozzle or adjust superheat
Troubleshooting

 Check for lack of sub-cooling and establish better sub-

cooling ahead of TEV
 Locate the sensing bulb in correct position
 Clean/ overhaul the expansion valve
 Assess the refrigeration system capacity and replace the size
of TEV as per the same
 Clean the icing over the evaporator and check the proper
functioning of defrost system
 Check the valve for loss of charge. Replace the valve or
adjust the superheat if required

42. Evaporator room humidity too high

• Evaporator surface too large causing operation at excessive
evaporating temperature during short running periods
• Load on room too low, e.g. during winter
• Insufficient dehumidification because of short total running
time per 24 hours
Troubleshooting

 Replace evaporator with smaller size

 Establish humidity regulation with hygrometer and heating
elements

43. Evaporator room humidity too low

• Cold room poorly insulated
• High internal energy consumption, e.g. lights and fans
• Evaporator surface too small, causes long running times at
mainly low evaporating temperatures
 Recommend improved insulation
 Recommend less internal energy consumption
 Replace evaporator with larger size
Troubleshooting

Thermostatic Expansion Valve

44. Valve not feeding enough refrigerant

• TEV superheat adjustment wrong
• Sensor bulb position is wrong
• Wax, moisture or dust inside the valve
• TEV filter is choked
• Flashing of gas before or inside the TEV
• The drop across TEV is not correct
 Adjust the superheat after assessing the systems
requirement
 Correctly place the sensing bulb and ensure no external
heat is affecting its operation
 Check for moisture or air in the refrigerant and clean the
valve seat off wax and dust
 Clean the TEV inlet filter at regular intervals
Troubleshooting

 Correct the pressure drop. Remove the source of

additional pressure loss at inlet or additional pressure
increase at the outlet of TEV

45. TEV continuously flooding evaporator

• TEV superheat adjustment wrong
• TEV is hunting
• Uneven load inside the evaporator room or fan not working
• Wrong placement of sensing bulb
• Back pressure valve of vegetable room not working

 Adjust the superheat after assessing the system

requirement
 Eliminate the cause of hunting
 Ensure room door is closed and load is kept even. Check if
fan is properly working
 Correctly position the sensing bulb
Troubleshooting

 Check the opening and closing of back pressure valve and

overhaul if needed

46. Thermostatic expansion valve is hunting

• Oversized thermostatic expansion valve
• Incorrect superheat setting
• Undercharged system
• Poor bulb contact
• Imbalanced heat exchanger
• Uneven airflow
 Assess the system and use correct size of TEV
 Adjust the setting screw to alter superheat setting
 Intermittent loss of sub-cooling is causing loss of
expansion valve capacity and resulting intermittent high
superheat. Charge the system as per the requirement
 Ensure bulb is at correct position and pipe contact of the
bulb is clear of corrosion, wax and dust
Troubleshooting

 With multi room evaporator, ensure the load is balanced

 Clean dirty coils or damaged coil fins as they can affect the
airflow

47. Icing on TEV and/or low pressure pipeline or equalizing line

• Insufficient refrigerant charge
• Failed TEV power head
• Leakage in the capillary tube
• Faulty sensing bulb
• Plugged TEV strainer

 Locate and repair leak and charge the system

 Overhaul TEV and check for its functioning
 Repair leakage in the capillary tube
 Check and correct location and fluid of sensing bulb
 Clean the TEV strainer
Troubleshooting

Defrost System

48. Defrost terminates prematurely

• Wrongly set thermostat
• Wrongly positioned thermostat

 Check and reset the thermostat

 Check and relocate the thermostat position

49. Iced up drip tray

• Drain line blocked
• Drip tray heaters faulty
• Drip tray heaters not on during drain down period
 Clear drain line
 Replace heaters
 Change faulty wiring so drain tray heaters are on for
complete defrost cycle
Troubleshooting

50. Drip tray frozen up

• Faulty drip tray heaters

 Replace faulty heaters

51. Coil block not fully clearing at top

• Faulty heaters
• Defrost termination too quick
 Check heaters and replace faulty ones
 Adjust termination thermostat

Other Line Equipment

52. Liquid level in receiver too high – refrigeration output too low
• Partial blockage of a component in liquid line
• Thermostatic expansion valve faulty
 • Superheat setting of TEV too high or orifice too small
• Blockage of wax or dust in TEV valve seat

 Find the component and clean or replace it

 Check the functioning of thermostatic expansion
valve
 Adjust (lower) the superheat setting
 Clean or overhaul the thermostatic expansion valve

53. Solenoid valve chatter

• Defective solenoid valve control

 Replace the defective solenoid valve
 Check and clean the solenoid valve and valve seat

54. Liquid level in receiver too high – Refrigeration output normal

• Refrigerant charge in system too large

Troubleshooting

 Recover a suitable quantity of refrigerant, but condensing

pressure must remain normal and the sight glass free of
vapor

55. Liquid level in receiver too low

• Insufficient refrigerant in system
• Evaporator overcharged
• Low load, leading to refrigerant collection in evaporator
• Thermostatic expansion valve faulty (e.g. superheat setting
too low, bulb location wrong)
• Refrigerant collection in condenser because condensing
pressure lower than receiver pressure (receiver placed
warmer than condenser)
 Investigate cause (leakage, overcharge in evaporator),
repair fault and charge system if necessary
 Rectify faulty TEV
 Place receiver together with condenser
Troubleshooting

 Ensure superheat is adjusted as per the system requirement

and load

56. Filter drier is frosting

• Partial blocking of dirt strainer in filter drier
• Filter drier completely or partly saturated with water
• Filter drier completely or partly saturated with acid
 Check whether there are impurities in the system, clean out
where necessary, replace filter drier
 Check whether there is moisture or acid in the system
 Clean out where necessary and replace filter drier
 If acid contamination is severe, replace refrigerant and oil
charge. Replace filter drier

57. Moisture indicator discolored- Yellow.

• Moisture in system
Troubleshooting

 Check system for leakage and do the repairs

 Check system for acid. Replace filter drier, several times if
necessary
 In severe cases it can be necessary to change refrigerant
and oil

58. Moisture indicator discolored- Brown or black

• Impurities, i.e. small particles in system

 Clean out system if necessary
 Replace sight glass if necessary
 Replace or clean filter drier

59. Vapor bubbles in sight glass

• Impurities, i.e. small particles in system

• Insufficient liquid sub-cooling from large pressure drop in
liquid line
Troubleshooting

• Insufficient liquid sub-cooling because of heat penetration of

liquid line, possibly from high temperature around liquid line
• Insufficient sub-cooling because of wrong cooling water flow
direction
• Condensing pressure too low
• Hydrostatic pressure drop in liquid line too high (height
difference between thermostatic expansion valve and
receiver too large)
• Insufficient refrigerant in system

 Replace liquid line with tube of suitable diameter

 Replace sharp bends and components causing too large a
pressure drop
 Check for impurities, clean out if necessary, replace filter
drier
 Reduce ambient temperature or insulate liquid line
 Swap over cooling water inlet and outlet (Water and
refrigerant flow must be opposite)
Troubleshooting

 Recharge system if necessary

60. Damaged filter in hermetic or semi-hermetic compressor

• Moisture, dirt or air
• Defective starter
• Too small refrigerant charge
• Hot gas temperature higher than 175°C

 Remove moisture and air from the system

 Replace the defective starter
 Charge the system with appropriate quantity
 Maintain compressor parameters to maintain hot gas
temperature within limit

61. Loss of thermostat charge

• Damage due to vibration

Troubleshooting

• Capillary tube not secured properly

• Surplus capillary tube not intact
• Wrong setting
 Secure the thermostat body firmly
 Secure the capillary tube firmly
 Loop the surplus capillary tube and secure it
 Correctly set the thermostat

62. Capacity regulation oscillating

• Oil foaming in crankcase

 Replenish new oil and remove cause of foaming

63. Impossible to bleed plant

• Solenoid valve leaky

• Defective piston rings
Troubleshooting

• Defective discharge valves

• Defective suction valves

 Pinpoint and seal leak

 Change leaky component
 Check and replace defective piston ring
 Overhaul and replace defective discharge valve
 Overhaul and replace defective suction valve

These are some of the major problems which a ship engineer encounters
in marine refrigeration system. If you have any other questions or
suggestion, please ask them in our forums:
Additional eBooks For Marine Engineers

Other Premium eBooks for Maritime Professionals