Refrigeration Systems | Common Issues And Solutions

Posted by Craft Group on September 5th, 2022

Your refrigeration system must work well. A malfunctioning system can  cause a catastrophe for your company. System failures can be prevented  with regular maintenance.
Things like Refrigeration Couplings can be found in fluid transfer applications to facilitate the maintenance of air conditioning systems.
The ideal applications include air conditioning and refrigeration  systems, as well as split refrigeration and split beverage systems.
In the event of equipment failures, they are inevitable, and we must  adapt accordingly. It is crucial to be aware of what to do in the event  of an emergency. 
Here are some typical issues with their solution that can arise with commercial refrigeration equipment.

Undercharging Refrigeration System Indication

You can detect that a refrigeration system is undercharging when:  It  is because the compressor has been heating up, and performance  decreases. Also, there is the possibility of a decrease in suction as  well as the pressures of discharge.


  1. There are also bubbles of vapor in the liquid view glass.
  2. The condenser shows an unusually low number of readings.
  3. The compressor analyzes the low-ammeter reads.
  4. The cold rooms are hotter than normal.
  5. The compressor runs longer than normal.


The leakage of refrigerant can lead to undercharging. Leakage of  refrigerant may occur on the shaft, the flange couplings, and the gaskets of  valves. The cause of undercharging could be obstructions at an  expansion valve or the evaporator.


Look for leaks in refrigerant around the shaft seal, the flange  couplings, as well as valve gaskets. Clean the driers and filters.  Replace the lost refrigerant using a new refrigerant. Be sure to follow  and adhere to the instructions of the manufacturer.

Overcharge of the Refrigeration System

A refrigeration system that is overcharged is one that is running  with more refrigerant than it is able to handle. These are signs that a  system is overcharged.


  • High condenser gauge readings.
  • Abnormal stop and start sequences for the compressor.
  • High suction and discharge pressures.


Overcharges in refrigeration systems can be caused by excessive refrigerant levels. Air in the system could cause an overcharge.


Remove the refrigerant that is too high out of the system. As a  result, this can be accomplished by connecting a cylinder with a  charging valve (liquid line). 
The compressor should be started and operated on the charge valve.
If you believe that air is the reason for the overcharge, rectify it by cleaning the air.

Moisture within the System

The starving of refrigerant in the evaporator and rapid increase in  pressure of the condenser causes the compressor to run shorter. So,  clogging at the expansion valve filter.


The issue is caused by the infiltration of air into the system. The  air’s humidity can make the expansion valve freeze. In turn, the  refrigeration system could show indicators of overcharging. In addition,  moisture may cause corrosion in the system.


If there is a small amount of moisture in the system, replace the gel  with silica. It is also possible to remove the refrigerant and then  pump out all air from the system.

Air in the System


  • Compressor overheating due to excessive discharge pressures.
  • Air bubbles are present in the sight glass of liquid inside the condenser.
  • The compressor is running for long periods.
  • Air could cause the gauge’s pointer to leap.


Air could be introduced into the system during the charging process.  Freon-12 has low working pressure. When you use freon-12, air leaks  could occur on your suction lines.


It is possible to remove air from the system by using the condenser.  Keep the condenser’s cooling water on. Let the air out at the very top  of the condenser. Connect a collecting cylinder with the purging line.  The line can be opened to let the air out.
After purging the air, make sure to close the purge valve securely.  Verify your refrigerant level. Make sure that the refrigeration system  is charged by using fresh refrigerant. Be sure to take all security  precautions when you start the compressor.

Oil in the Refrigeration System


  • You might be noticing that the temperature isn’t dropping in the cold space as it usually does.
  • Overly frosty at the suction lines
  • The compressor is running for long periods of time
  • A drop in lubrication levels
  • A drop in refrigerant levels


  • An oil separator that is not working properly can cause a leakage of oil into the system.
  • Compressor linings that are worn out and pistons that are defective.
  • Current with high capacity at the beginning of the cycle of refrigeration.


  • Replace and check the oil separator if it’s damaged.
  • Clean the dryer if needed
  • Clean the evaporator coil to get rid of any oil residues
  • Enhance the evaporator as well as condenser temperature differences to allow the suction pipe to defrost.
  • Heat the pipes using an electric blow torch.

Refrigerant Flooding

The term “flooding” refers to the process of letting liquid back into  the suction line of the compressor that cools refrigerant. So, the  cause of this issue could be inadequately adjusted or damaged expansion  valves. 


It could also cause by leakage from the solenoid valve. The  overcharging of the refrigerant system could also result in refrigerant  flooding.
If the problem is not addressed If not addressed, flooding could cause ice to the evaporator or even damage the compressor.


The refrigerant is excessively leaking out of the system. It is  possible to do this by connecting a cylinder with a charging valve  (liquid line). The compressor should start and operate to charge the  valve.

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Craft Group
Joined: February 24th, 2021
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