This video is brought to you by sportlin quality, integrity and tradition. Previously on hvacr videos, we've got a carrier package unit. This is a little guy. It's probably a five ton, i'm guessing i'll.

Look at the information right now complaining and it's not working pull out the filters and they are iced up. So i'm gon na get it defrosted real, quick, we're gon na shut down the unit and then uh we'll check it out and see. If we can figure out what's going on with this thing, so this is what we're looking at right now, it's approximately 88 degrees outside working on an r22 system. It's approximately 10 to 12 seer, it's probably a 2004 unit, so unit has fixed orifice metering devices.

You can see our sub cooling is really high. Our super heat's really high suction line. Temp is high. Liquid line, temp is low.

Our suction pressure is low. Our head pressure's a little bit high. I'm thinking that we've got a plugged up metering device. It's very common on these things, judging from the way that it was iced up.

So if we look back there, you can see that my metering devices are frosting up and that's because we have a plugged up fixed orifice metering devices very common on these carriers. So the clip that i just showed right now there is gon na be a card popping up right now on the top of the screen with the first video okay. And if you guys can't see that, because you're watching on a tv or something like that um, you can go into the show, notes and it'll be right in the top of the show notes, with the link to the first video, okay, the first video was actually Back in 2019, so this unit has been running for a very long time like that. All right - and you guys are gon na - see the repercussions of that when the video starts right now today we finally get to change this evaporator coil we've had a plugged up metering device on this for a long time and the unit is constantly iced up.

I don't know if it's going to be iced up today or not nope doesn't look like it today, but yeah it's. It's got a plugged up fixed orifice metering device. So we're gon na jump on this and uh. We got a whole new evaporator for it and we might have a problem compressor, contactors pulled in compressor's, not running, and it's red hot.

So it's probably off on internal overload. Let's hope the compressor is not bad all right. The system has refrigerant in it. We still have pressure controls, you know it's not bypassed as far as i know so we're trying to cool it off right now.

This is a newer compressor. It's like a year or two old sucks man. This is what happens when they take forever to approve, quotes. Um all right well, we're just cooling it off, well, keep holding it in it, pumps, okay, all right! Well compressor runs whether or not there's problems.

We don't know we're gon na go ahead and continue on with the repair. All right. We got the evaporator out, we're just looking to see if there's oil logged inside of it. Out of curiosity, oh yeah, look at that compressor's, not a happy camper.

We have to see if we can find some pv eve oil locally, because that's what this guy takes. All right: well, we know it's bad, so we got the old one out units in shambles. We're gon na put the new one in got the new evaporator and they didn't send a ding cap in this, or it came out that sucks. Oh well.

We already verified the sizes correct, so we're good on that now uh, the original installers ran the ding thermostat wires to the economizer damper, which is dumb so probably not gon na be able to take that out. We'll see we're gon na change the drain pan too. On this guy, why not you got it? Open, blower assembly looks nice and clean, i'm pretty sure i've cleaned this. Recently, it's not going to be too bad, we'll split this coil and clean the coil too, since we got the top off decided to make my life a little bit easier.

We decided to pull the condenser out of this guy so that way we can blow it out with nitrogen over here, and then it makes it easier to do some stuff. I need to do in here we're going to end up pulling this compressor. Pouring the oil out too, basically autopsy this whole unit. It's not the greatest thing in the world, but we're pouring all the oil out right now.

This thing is heavy man we're gon na start assembling the evaporator. While we have all this stuff out makes it a lot easier, they're gon na be extremely lucky if there's not permanent damage, because that compressor is nasty and it's the viscosity is kind of thick too kind of crazy all right. So we got to clean this up. Dry, it up, like i said, we're going to start assembling the evaporator, then we'll start putting the thing back together, all right so uh.

This takes pve oil uh, the viscosity is 32.. That's what danfoss wants in this guy. It takes. What is it 53 ounces? So there's 32 ounces in one and then we'll have to figure out the difference on the other, i'm just going to pour it in through the suction side.

Very slowly all right, we're gon na braise in this dryer, real, quick, we're doing it outside to try to make it go a little bit easier. We've got some heat blocking compound on there, so we should be good and we're purging with nitrogen, not gon na be the prettiest thing because there's existing braze joints on here but oh well. It should work so currently working on doing a pressure test. We got it all assembled back together, we've got uh, i changed both the pressure controls.

We put a high pressure right there auto reset, and then we got rid of the stupid loss of charge switch and we went with a low pressure control because, with the loss of charge switch, it will not shut the unit off if it has a restricted metering Device which might i'm thinking be why this compressor was off on thermal overload this morning and hoping there's no permanent damage. We've still got a lot of work to do. We got to secure that liquid line, so it's not rubbing out tie in the pressure controls, but we're just working on the pressure test and then once we get that done, then we'll get the evacuation running and just keep assembling this unit pressure test looks fine. 0.3.

Over 21 minutes at 0.4, i'm not worried about that at all. So we just got all the pressure controls wired in we're just trying to clean up some of the wiring and stuff um. We're gon na go ahead and get the vacuum pump running on this guy right now, so we ended up redoing the drain too, because it was all wonky looking. We had plenty of room and i had all the pipe fittings and everything literally so so all right.

We got a new trap installed uh. We did, let's see plenty of tees unions to take it apart. We got ta clean out here. We always make sure that the top of this tee is lower than the drain.

So that way, if the main line plugs up, it'll overflow out this and won't back up into the main - and then we don't braise this on so that way we can do a clean out, but of course, because of the negative airflow you've got to have it There so we just leave that there and this guy's good to go. We're currently uh doing our evacuation, we're about 870 microns and it's kind of stalling out. So i think i'm gon na go into an oil change and see if that'll help us out. So the liquid line just sits there and dangles on the bottom of the unit, so we put two big globs of silicone and it'll dry and then that'll hold it nice and good in place.

No more rubbing. You know on the bottom of the unit or anything like that. That'll be really cool, so we're about to turn this on. We we put in the initial uh refrigerant charge on this and uh it wouldn't take.

I i ran out of my cylinder, so we got to add some extra but um. We need to put one pound three ounces in it. We added a couple extra pound and some ounces pound one pound four ounces uh, because my recovery machine or my recovery tank was a little bit short um we're looking pretty darn good we're on the tail end. You know of high head pressure.

We do have a very damaged condenser, so that's to be expected. Um super heat's a little bit high, but i really don't want to put any more refrigerant in this guy. I will say i'm going to investigate uh some airflow temperature, splits, decent air flow seems decent on there. Um i mean guys.

I don't know if it's gon na get much better than this. It's pretty darn good, especially for just being turned on it's under a heavy load. Let's see what my return air temperature is on this guy, it's 108 degrees outside right, now, 80 degree return, dry, bulb, 63 wet bulb yeah. This thing is uh, pretty much doing everything that it can.

I don't know if it's going to get too much better than this uh one last thing you know the sub coin does seem a little bit high, but we're using discharge pressure. So we're going to go ahead and check the uh liquid line pressure and see what the sub coin is so 25 degrees, sub coin discharge and 339 psi, we'll put it onto the liquid line port all right. So this is liquid line pressure. So i think it's like a 36 psi pressure drop or something like that.

We're about 20 degrees, sub cooling, which is a little bit better, i'd still like to see a little lower. But you know it's not gon na get much better than this, so this unit's done. This is all they're going to get out of it. I tried to get them to replace it, but they didn't want to so.

Instead they got a new evaporator new drain line. New compressor oil, new dryer added a suction line dryer. Now we added a spoiling catch-all for the suction line dryer and for the liquid line dryer to protect the compressor and protect the system because uh we don't know if the new oil is going to scrub the walls like poe. I don't know how that pve oil works or pev or whatever you want to call it.

I don't know how, if it works like poe oil, where it scrubs the walls, and i know that the old oil was really contaminated, so i wanted to put that suction line, filter, dryer and the liquid line filter dryer. Now we use sporlan's hh cores on both of them, because i don't know if there's like a wax, buildup or anything inside here. I know that they had a grounded compressor on this system way in the past um and so before me - and i don't know if we're going to start scrubbing all that crap out of the system. So i'll note this down before i was done, i checked the suction line, filter, dryer and there's about a 3 psi pressure drop across the suction line, filter dryer.

So we'll make sure we note that and we'll follow up with the system in a couple weeks to see if that pressure drop increases, that suction line dryer might be cleaning the system up and we may have to you know, change it or take it out. Who knows so um yeah we'll definitely note that down i'm pulling this evaporator apart and i tried to drain out as much oil, but obviously there's still a bunch left in there, because it just keeps igniting it's kind of a pain in the butt all right. I have two identical evaporators here. This one right here is a fixed is the one that we just did the video on.

This is another one. So this is our acurator liquid header right here. So liquid line comes in goes through tiny, little pistons and then comes out the other side of the evaporator. Now this one i autopsied completely, and we can actually look right here.

If you look very closely, you guys can see that we have a large pinhole on the left and a very small pinhole on the right. Now i've got the flashlight shining through the liquid header and that's just showing how they're restricted inside now. I've also got one right here. This is just a cutaway and there's actually a piston right inside of there and that one, you can kind of see a little bit of light too, but we just have some that are restricted, some that aren't here's another one too.

This one you're probably not going to see light through because i think oh yeah, this one has some good openings. Actually so these little pistons get plugged up now, what's interesting to know, a lot of people say that you can clear them and while i don't doubt that you can get some success, i personally have not had very good success, but i want to point something out: This is a double piston or it's a double orifice so see. I cut it right in the middle right, the fixed, orifice metering device. You can see the the pinch point right here and i cut it right in the middle and you still have an orifice on that side and you have an orifice on this side.

So there's a double piston there. So if something makes its way through there, which is what's happening, it's gon na get stuck in between and you're, not truly gon na be able to clear these things. Okay, so this is why now you can also change just the metering device, but even that is gon na be a pain in the butt. It's just so much easier just to change the whole evaporator.

Okay, that um didn't start out quite the way that i wanted. It to you know, uh having that compressor being off on thermal overlap like that. That's a bit, you know, don't know exactly what was going on. Don't know if there's permanent compressor damage, but that is why i change the oil and it's i don't know why they use that pve oil.

It's interesting because if you read up on the pve oil, it's actually more hydroscopic than uh polyester oil, so meaning it can absorb more moisture potentially than polyester oil faster. I shouldn't say: i don't know why they don't use it because reading up on it too uh, it actually works better with the alternative refrigerants than polyester oil, essentially so the 407cs and the different things like that. That was the article that i had read on it, but anyways. So you know i did my best to cool down the compressor.

It was kind of frustrating, because this was a quoted job to change that evaporator and then we get there and the compressor's not running. But i did my best cooled it down real quick, made, sure the compressor restarted and then went ahead and went with the repair. Okay, like i showed in the teardown, you can certainly try to clear those fixed or face metering devices. I have personally not had any luck and if you look at the way that i tore them down and shown them, it's not very practical that you're actually going to clear them.

To be honest with you, because you know the best way that it would make logical sense is that you, you push the nitrogen in from the suction side and you're gon na push it backwards through the liquid header and you're gon na push whatever was stuck because The theory would be that it would be stuck on the first side of that orifice right, so you're gon na push it back backwards, but that stuff is actually making it through the orifice into the second. So there's actually two orifices right there, so you're going to have a pressure drop and then you're not going to have a lot coming out now, when you do try to clear them, what you can do is you put the you you put high pressure, nitrogen flowing Through there and then you take a a torch and you heat up the the piston or the metering device or the fixed orifice metering device, whatever you want to call it and you'll start seeing oil coming out and stuff and smoke and all that. But i don't know i just haven't - had very good luck that and the amount of time it takes to recover the charge put nitrogen in there by the time it's all said and done you're there for minimum four hours with the recovery, a dryer change and all That it just seems like a waste of the customer's time, because i have not had very good success and it's hard to go through all that effort. You know when you could just change the evaporator and be done with it.

Okay, now, why are these getting plugged up? Okay? Now it's frustrating that that carrier and even train uses these too the multiple pistons, the accurate or metering devices, the short orifice headers, whatever you want to call them right. Trane does the same thing on some of their older units. Um, i'm sure it's a cost thing, i'm sure it's all about saving money. If you get into the more high efficient units these days, they all have txvs or for the most part they have txvs.

Not all of them, but essentially yeah, it's frustrating that they have those, but it's really all about not maintaining the equipment. Okay, so it really comes back on the customer not doing proper preventative maintenance. Even if a customer has a pm program majority of the time, they don't want to go all the way in they don't want to spend the time that they truly need to spend on these units, because in all practicality, if you have a roof that has five Or six air conditioners on it realistically to properly pm one unit and to go through all the electrical, the air flow cleaning and all that stuff you're going to spend four to five hours per unit like doing a proper, thorough job and most customers. They only want you spending six hours at the most on the roof for the entire pm program that includes doing downstairs, work, ice machines, air conditioners, so really you're.

Just there to change filters, rinse off the condensers customers in my area, they never pay to clean the the the split condenser, the inside condensers. They never pay to do that. That's always just a reactive thing when they when they go down you clean them. So when you have equipment that runs dirty and runs in high ambience, what's going to happen, is you're going to lead to what you saw in here, higher superheat situations, okay, and it's going to be inadequate, cooling coming back to the compressor, because our compressors are refrigerant.

Cooled compressors, typically, okay, especially these scroll ones. So you need a cold enough: suction gas, coming back to cool off the compressor and when you don't have that cold suction gas coming back, because you have restricted condensers higher head pressure, higher condensing temp, it starts to break down the oil and you start to have Repercussions within the system, okay, so the reason why these are being plugged up is because they're not being maintained properly majority of the time, uh, not majority of the time, but a a large portion of the time. A lot of people don't even know, and i can see it in the comments in my videos - don't even know that there's a split condenser on these - and you know i don't know - i didn't know for the longest time - either. Okay, but when you have that split condenser people are always trying to clean it and they've got they're running high head pressure and they just kind of give up and leave it be when you really got to pull the top or it may not even be that They don't know you get on some of these bigger units and you need two people to pull the top off the unit and again nobody's doing that on a pm.

You know majority of the time, so it's just kind of a um. You know just a huge issue, and i mean it has to do with the design it has to do with the lack of maintenance, and you know the equipment just goes downhill fast, okay, which leads to more compressor failures and issues like that and every time. This compressor fails. It pushes deposits into the system um, you know, and it can be hard to clean all that stuff up, and that is especially why i went back with the spoiling catch-alls, the suction dryer and the liquid dryer, and i went with the hh cores.

Okay, so that's a solid desiccant core, but it has the high wax removal content inside of it to help remove any wax particles and different things like that. As far as the wax goes, if you have acidic systems it can start to break down the wax that protects the compressor windings that keeps the windings separated right. The electrical system inside that compressor is encapsulated and the oil is all around it, but it has like a wax coating on the windings and when the gas becomes acidic and the oil becomes acidic, it starts breaking down that wax and it leaves it in the system. So that's why i went with those hh cores, because i want to try to catch as much of that as possible and there's always a possibility.

We'll have to come back and do another dryer change too. That's that's perfectly normal on a system. That's this contaminated! Okay! So we'll watch the system over the next couple weeks and see how it performs the next time we're out there doing a pm, we'll check for a pressure drop across that dryer again check the temperature drop across the liquid dryer and just kind of see. What's going on, okay, you know, and at the same time you have to understand that when you get these old systems with the beat up, condensers and stuff, they're, never gon na be a hundred percent perfect.

I wasn't like ecstatic with the pressures in the operation of the system, but it was much better than it was and it was doing everything it could. So i suspect that we're gon na have to do some dryer changes on this to try to clean it up again. Um, keep in mind too that in a situation like this, you know uh, i i had a hunch and i poured that oil out of that compressor and that oil was severely contaminated. So there's a very good possibility.

There is internal compressor damage, too, of which you know there's only so much. We can do with that. So i poured out the oil poured in new oil, you know and everything was operating properly. So let's see how this one goes.

I really appreciate you guys making it to the end of the video it's so amazing and so humbling to get the support from you guys, uh the encouragement, the comments, the criticism, i'm okay, with the criticism too, because it helps me to grow as a service technician. Okay, um and i appreciate it right as long as it's you know, constructive criticism and not just being a jerk, but i really don't get too many people like that. I get a lot of constructive criticism and i do appreciate it. Okay, so keep it coming.

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