Indoor EEV failure in VRF System

Introduction
The EEV (Electronic Expansion Valve) and VRF (Variable Refrigerant Flow) system are interrelated
components of an HVAC system. The EEV controls the flow of refrigerant from the condenser to the
evaporator, ensuring that the correct amount of refrigerant is delivered for cooling or heating. This precise
control leads to improved energy efficiency and reliability of the VRF system, as well as maintaining indoor
comfort levels by quickly responding to changing demands. The EEV is a critical component in optimizing
the performance of a VRF system.

Site Selection
The location of the issue was in room 603 on the 6th floor of the Vivanta Hotel in Jhamsikhel, Kathmandu.

Problems Occurred
During heating operation, the discharge component in the indoor unit was not functioning correctly. The
airflow rate was too low and the air temperature from the evaporator did not meet the desired set point
temperature to meet the comfort level.

Troubleshooting and Diagnosis

1. Check the air filter for clogs or blockages, and clean or replace as needed.
2. Verify the correct operation of the indoor and outdoor units, including their control panels, fans,
and refrigerant lines.
3. Check the refrigerant pressure, level, and temperature to ensure it meets the manufacturer's
specifications.
4. Inspect the electrical connections and wiring for any loose, damaged, or corroded components.
5. Utilize diagnostic software and tools to access the system's control board for any error codes or
fault codes

LG provides the LGMV software which allows users to monitor, diagnose, and control their VRF systems
remotely. The software provides real-time information on the operating status of the VRF system. Mobile
LGMV hardware consists of a Wi-Fi module and a two-piece cable. The Wi-Fi module sends and receives
Wi-Fi signals to/from the smartphone. The cable connects the Wi-Fi module to the outdoor unit
connector.
Using LGMV software the issue was found to be with the indoor expansion valve having a higher pulse
rate.

Figure 1 LGMV device connected to outdoor connector

In case of other brands, technicians use a diagnostic approach to identify problems in VRF systems by
employing various techniques and experience. The common step they follow are as follows:

1. Isolate the problem: By monitoring the system's performance, error codes, and other symptoms,
technicians can isolate the problem to a specific component or system.
2. Conduct tests: Technicians use various diagnostic tools and techniques, such as pressure testing,
electrical testing, thermal imaging, leak detection, and performance testing, to gather data and
identify the problem.
3. Analyze data: Technicians analyze the data gathered from the tests to determine which
component is causing the problem. For example, if the pressure test shows low refrigerant
pressure, the technician may conclude that there is a leak in the refrigerant piping.
4. Confirm the diagnosis: Technicians may conduct additional tests or inspections to confirm the
diagnosis, such as checking the refrigerant levels or inspecting the refrigerant piping for leaks.
5. Repair or replace the component: Once the technician has confirmed the diagnosis, they can
repair or replace the faulty component, making sure to follow the manufacturer's instructions and
safety procedures.

For instance, in our site case the suction pipe is overheated but the evaporator is cool, it could indicate
a problem with the expansion valve. The expansion valve regulates the flow of refrigerant from the
high-pressure side of the system to the low-pressure side, and responsible for maintaining the correct
pressure balance in the system. If the expansion valve is not working properly, it can result in an
 overpressure on the suction side, causing the suction pipe to overheat. Meanwhile, the refrigerant
flow to the evaporator will be restricted, causing it to remain cool. To confirm this diagnosis, it is
necessary to perform a pressure test to measure the refrigerant pressure on both the suction and
discharge sides of the system. They would also inspect the expansion valve to see if it is clogged,
damaged, or otherwise not working properly.

Maintenance Procedures

1. A pressure test using pressure gauge manifold is done to ensure that the system is sealed and that
all the refrigerant is contained within the system. This allows to evacuate the refrigerant safely
without the risk of refrigerant escaping into the environment. For this the two red pipes are
connected to the suction and discharge pipe.

Figure 2 Pressure gauge connected to suction and discharge pipes

2. Pump Down Process: Pump down is a process in a refrigeration or air-conditioning system where
the refrigerant is removed from the system and accumulated in a designated container, such as
an accumulator.
The pump down process is accomplished by controlling the flow of refrigerant in the system,
typically through manual means such as using a valve or tool. This is typically done when
maintenance or repair work is being performed on the system and requires control of the flow of
refrigerant. The process is carried out by using a manual tool such as an Allen key to shut the
discharge and open the suction line. Pump down reduces pressure in a refrigeration system by
controlling the flow of refrigerant, which is safely accumulated in an accumulator. This provides
safe access to system components and helps prevent refrigerant release into the environment.
Similarly, the same accumulated refrigerant could be used to circulate after fixing the system.
 3. Replacing the EEV:
• After the pump down process, the indoor unit can be safely opened or dismantled, and
the process of replacing the EEV can continue. At first, we turned off the power supply to
ensure safety and disconnected the refrigerant lines.
• We used the tools like pliers, wrenches, other fitting tools etc. to remove the mounting
bolts and screws.
• Along with the evaporator the EEV was demounted and started replacing the new EEV via
brazing process as shown in figure:

Figure 3 Detaching EEV from Evaporator Figure 4 Reattaching EEV from Evaporator

Brazing is a metal joining process that uses a filler metal in the form of a rod or wire, which is melted and
flowed between two parts to create a permanent bond. The filler metal is heated to a temperature above
its melting point and is then applied to the parts being joined. The parts are then heated, causing the filler
metal to melt and flow into the joint, creating a strong and permanent bond. Brazing is used in a variety
of applications, including the manufacture of refrigeration and air conditioning systems, where it is
commonly used to join copper pipes and fittings. In these systems, brazing is used to replace the expansion
valve (EEV) by creating a strong and leak-proof connection between the copper pipes and the EEV.

• Now we reconnect the refrigerant lines to the new EEV. Retighten the mounting bolts or screws
to secure the EEV in place. Incase we may need to use flaring tools to connect the refrigerant lines
again.

4. Perform a leak test on the system: We apply the soapy solution to the joints and connections in
the system using a brush or spray bottle. Observe the joints and connections for any bubbles,
which indicate the presence of a refrigerant leak. If a leak is detected, mark the leak site and repair
or replace the affected component as needed. As we found no any leaks.
 5. Evacuate/Vacuuming and recharge the system with refrigerant: This process involves removing
any residual refrigerant and contaminants from the system through vaccum pump and then
adding the correct amount of fresh refrigerant. This process can be done using a refrigerant
recovery machine to evacuate the system, and then using a refrigerant charging station to add
the correct amount of refrigerant.
This process should be done until a deep vacuum is achieved and the system is free of any residual
refrigerant or contaminants ass shown in figure below indicated by yellow pipe:

Figure 5 Evacuating residuals using Pump

Next, the refrigerant charging station is connected to the system and the correct amount of refrigerant is
added if required. This is typically done by following the manufacturer's specifications for the system,
which may involve using a refrigerant charge chart or using superheat and subcooling measurements to
determine the correct amount of refrigerant.

Throughout the process, the system should be monitored using gauges to ensure the proper refrigerant
pressure levels are maintained. Once the correct amount of refrigerant has been added, the system is
turned on and the performance is checked to ensure that it is operating properly.

In our site as we’ve already stored the refrigerant in accumulator through pump down process so, small
amount of refrigerant was added to the to reach the required pressure, and the results were monitored.

Results
The problem during the operation was solved. The discharge component in the indoor unit was
functioning correctly. The airflow rate was optimum and the air temperature from the evaporator meet
the desired set point temperature to meet the comfort level.