Service Application Manual

SAM Chapter 620-87

Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
INTRODUCTION

Servicing heat pumps is no cinch. And the reversing valve is the part which is most difficult and time
consuming to replace. Yet experience shows that more than half of the reversing valves replaced in the
field are in perfectly good working order and needn't have been replaced at all.

This happens because all too often servicemen don't know enough about heat pumps and their operation
to do a proper job of troubleshooting. They tend to leap to seemingly obvious conclusions. If the reversing
valve doesn't reverse, they assume it is faulty. If the reversing valve is in the wrong position, they assume
it is faulty.

In reality, these judgments usually are the result of faulty diagnosis, not faulty valves. Nine times out of
ten, these conditions can be traced to electrical or low-on-charge problems.

Effective troubleshooting on heat pumps requires a thorough understanding of the heat pump system.
Let's begin by trying to gain an understanding of the reversing valve and its function.

HOW A REVERSING VALVE WORKS

Heat pumps operate in one of two modes: with reversing valve and unit operating in the cooling phase
when the solenoid coil is de-energized, or with valve and unit operating in the heating phase when the
solenoid is de-energized.

One is no more proper than the other. The choice depends upon the decision of the manufacturer's
design engineer as to which works best with his system.

For the purposes of this discussion, we'll assume that the system operates in the former mode: in the
cooling phase when the solenoid is de-energized (Figure 1); in the heating phase when the solenoid is
energized (Figure 2).

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 

The reversing valve is the same in either case. The mode in which the heat pump will operate is
determined by which reversing valve tubes are piped to the inside and outside heat exchangers.

In the cutaway view of the pilot valve in Figure 1, the valve is shown in the de-energized position. The
solenoid plunger is seated in the right port, sealing of the right capillary tube from leaking into the center
portion, where suction gas is present. The solenoid plunger has pushed the back-seat valve open, so that
the left capillary tube has suction pressure down to the piston seat.

When the coil is energized, the solenoid plunger is pulled to the right, opening the seat to the right pilot
tube. This enables the right pilot tube to evacuate the high-pressure gas from the right piston seat to
effect a reversal of valve operation.

As the solenoid plunger is pulled to the right, the spring forces the left plunger to the right also, sealing the
left pilot tube from the suction pressure of the system.

In the cutaway view of the reversing valve in Figure 1, you can see the position of the slide and pilot valve
in the cooling phase. Note that the slide now is as far to the left as it can possibly go.

Hot gas from the compressor enters the reversing valve through tube No. 1 and flows to the main cavity
of the valve. Because the slide is covering the left tube opening (No. 3) and the suction tube opening (No.
2), the hot gas passes around the slide and on to the outside heat exchanger through tube No. 4.

Cool gas from the inside heat exchanger enters the valve through tube No. 3. flows under the slide, and
exits through the suction tube (No. 2) on its way to the compressor. Hot gas passes through the bleed
hole in the right end of the piston to the valve cavity beyond the piston, enters the end port, then passes
up through tube No. 6 to the right port of the pilot valve, which is closed.

The hot gas also can pass through the left piston into the valve cavity, but cannot enter the left pilot tube,
because the end port is sealed by the piston needle assembly. However, tracing tube No. 5 up to the pilot
valve, you can see that the valve is open to the center pilot tube, which is connected to the suction tube.
This provides suction pressure from the compressor on the back of the piston seat.

With high pressure on both ends of the piston and in the valve cavity, suction pressure under the slide
holds the valve in this position until the solenoid is energized.

To start the reversal of the cycle from cooling to heating, the solenoid is energized. Figure 2 shows what
the system looks like after that happens.

In the pilot valve, the plunger on the right has been pulled off its seat and has opened the port, allowing
the high-pressure gas that was in the right capillary tube to escape into the suction tube.

The left port in the pilot valve is closed as its needle moves to the right, blocking the left capillary tube.

The open port on the pilot valve, due to its size, can reduce pressure faster than gas can bleed through
the piston port, so the pressure in the cavity approaches compressor suction pressure. This reduction of
pressure on the right side of the right end of the piston, combined with the high pressure already present
on the left side of the piston, makes the slide start to move.

As the slide starts to move to the right, the left piston needle leaves its seat, allowing high-pressure gas to
enter the left pilot tube, which is now blocked at the pilot valve. The high-pressure gas fills the left bleed
tube, so that no pressure can exist on this side of the piston to impede the transfer.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
The lower pressure on the right side of the piston assembly combined with the high pressure on the left
end of the piston forces the slide to the right. As it moves, it starts to cover the right tube and uncover the
left tube.

When it reaches the midpoint of its travel (Figure 3), a dramatic transition takes place. The high pressure
gas now can enter both the right and left tubes, while the dome of the slide has all three lower tubes
common. This is an instantaneous happening which allows for rapid pressure equalization, preventing
hammering.

As the slide approaches the end of its travel to the right, the port to the inside heat exchanger becomes
clear, and high-pressure gas now enters tube No. 3.

The high-pressure gas now occupies all of the valve cavity except for the diminishing space to the right of
the piston. The compressor common suction is now connected to the outside heat exchanger through
tube No. 4. Suction pressure is still present at the right end of the piston through the open right needle
port of the pilot valve.

Figure 4 shows the reversal complete. The slide has reached the end of its travel to the right, and the
piston needle has sealed the right pilot tube. With high pressure to both ends of the piston and in the
valve cavity, suction pressure within the slide holds the valve in this position until the solenoid is de-
energized.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 

All of the reversal action detailed here takes place in a matter of 2 or 3 seconds in a normally operating
system. The reversal is usually accompanied by an audible sw-o-o-sh, which is readily recognizable.

REVERSING VALVE PROBLEMS

Problems experienced with reversing valves fall into four general categories:

1. Valve will not shift from cooling to heating.

2. Valve will not shift from heating to cooling.

3. Valve starts to shift but does not complete reversal action.

4. Valve suffers apparent leak when shifting.

Failure of a valve to reverse properly does not necessarily mean that the valve is faulty. Often this failure
may be caused by some other problem. So do not remove the valve from the system until you have
checked the system thoroughly and are sure you have diagnosed the problem correctly. Be sure to find
out what is making the valve malfunction before you consider replacing it. You'll save time and money.

Here are the necessary steps to follow in diagnosing the cause of a reversing valve malfunction. Perform
each step systematically. Do not skip any of these steps because you think you know what the problem
is. The true cause of the trouble isn't always apparent.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
INSPECT FOR PHYSICAL DAMAGE

This point is often overlooked on the assumption that since the valve had been functioning properly,
damage could not be the cause of the failure. The truth is that a physically damaged valve, in conjunction
with some other problem, can result in a malfunction.

Look closely for any dents or scratches on the valve. Inspect the capillaries for damage. A partially closed
or blocked capillary tube and a dirty system can combine to cause a malfunction.

Inspect the valve to see if there is any evidence of overheating when the valve was installed. Torch flare
marks, wide areas of burned paint, and heavy oxide scaling can give you a clue. These valves can
withstand heat of 250°F during installation, but overheating can cause distortion of plastic parts within the
valve which may result in a malfunction when certain other conditions exist.

CHECK ELECTRICAL SYSTEM

Make sure you have voltage to the solenoid coil at the proper time. This coil is only energized during
certain modes of operation. We know of one case in which a service mechanic replaced a valve, only to
find later that the real cause of the trouble was that the coil wire had been left disconnected inadvertently
when a previous cooling problem was corrected.

With the coil in the energized mode, remove the nut holding the solenoid coil on the pilot valve. Slide the
coil partly off the stem. If the coil and valve are operating, you'll hear a clicking or snapping sound when
the plunger moves.

Another check to determine it the solenoid coil is energized is to remove it from the stem and insert the
blade of a small screwdriver in the hole. The magnetic field created will exert a pull on the screwdriver.
One caution, however: Do not leave the coil off the stem while energized; without the plunger in the
magnetic field, the coil will overheat.

CHECK REFRIGERATION SYSTEM

If you have determined that the electrical system is operating correctly, check the refrigeration system
carefully. This step is extremely important. Make certain that the refrigeration system is operating
correctly and has the proper charge.

Check against the manufacturer's recommendations for the particular equipment involved, with pressure
gauges connected and thermometers in place as necessary. An undercharge or overcharge of refrigerant
can cause the reversing valve to malfunction. Undercharge is a frequent cause of valves failing to
reverse. Adjust the charge as necessary, following the manufacturer's instructions.

If you have followed all of these procedures and everything checks out okay, then make the Touch Test
on the reversing valve, following the chart in Figure 4A. This is a simple test made by feeling temperature
relationships at certain recommended locations on the valve. Once you have determined the comparative
temperatures, you can determine the possible cause of the malfunction and take corrective action.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
Touch Test Chart (Figure 4A)

DISCHAR SUCTION Tube Tube to LEFT RIGHT NOTES: *Temperature

GE TUBE TUBE to to OUTSID Pilot Pilot of Valve Body.
VALVE from Compress INSID E COIL Capilla Capilla **Warmer than Valve
OPERATI Compress or E ry Tube ry Tube Body.
NG or COIL
CONDITIO 1 2 3 4 5 6 Possible Correction
N Causes s
NORMAL OPERATION OF VALVE
Normal Cool Hot as
COOLING Hot Cool as (2) (1) *TVB *TVB
Normal Hot Cool as
HEATING Hot Cool as(1) (2) *TVB *TVB
MALFUNCTION OF VALVE
Repair
No voltage electrical
Check electrical circuit and coil to coil. circuit.
Defective Replace
coil. coil.
Repair
leak,
Low recharge
Check refrigeration charge charge. system.
Pressure
differential Recheck
too high. system.
De
energize
solenoid,
raise head
pressure,
reenergize
solenoid to
break dirt
loose. If
unsuccessf
Cool Hot as
Hot Cool *TVB Hot ul, remove
as (2) (1)
valve, wash
out. Check
on air
before
installing. If
no
Valve will Pilot valve movement,
not shift okay. Dirt in replace
from cool one bleeder valve, add
to heat hole. strainer to

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
discharge
tube,
mount
valve
horizontally
.
Stop unit.
After
pressures
equalize,
restart with
solenoid
energized.
If valve
shifts,
reattempt
with
compressor
running. If
still no shift,
Piston cup replace
leak. valve.
Raise head
pressure,
operate
Cool Hot as solenoid to
Hot Cool *TVB *TVB
as (2) (1) free. If still
no shift,
Clogged replace
pilot tubes. valve.
Raise head
pressure,
operate
solenoid to
free
Cool Hot as
Hot Cool Hot Hot Both ports partially
as (2) (1)
of pilot clogged
open (Back port. If still
seat port no shift,
did not replace
close.) valve.
Defective
Cool Warm
Warm Cool *TVB Warm Compress
as (2) as (1)
or.
Not enough Check unit
Start to pressure for correct
shift but differential operating
Hot Warm Warm Hot *TVB Hot
does not at start of pressures
complete stroke or and
reversal not enough charge.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
flow to Raise head
maintain pressure. If
pressure no shift,
differential. use valve
with
smaller
ports.
Body Replace
damage. Valve.
VALVE OPERATED SATISFACTORILY PRIOR TO COMPRESSOR MOTOR BURN OUT—caused by
dirt and small greasy particles inside the valve. To Correct: Remove valve, thoroughly wash it out.
Check on air before reinstalling or replace valve. Add strainer and filter dryer to discharge tube between
valve and compressor.
Raise head
pressure,
operate
Hot Warm Warm Hot Hot Hot solenoid. If
Both parts no shift,
of Pilot replace
open. valve.
Body Replace
damage. Valve.
Valve hang
up at mid- Raise head
stroke. pressure,
Hot Hot Hot Hot *TVB Hot Pumping operate
volume of solenoid. If
compressor no shift,
not use valve
sufficient towith
maintain smaller
reversal. parts
Raise head
pressure,
Start to operate
shift but Hot Hot Hot Hot Hot Hot solenoid. If
does not Both parts no shift,
complete of Pilot replace
reversal open. valve.
Operate
valve
several
times than
Hot Cool as
Hot Cool *TVB **WVB recheck. If
as (1) (2)
Piston excessive
needle on leak,
Apparent end of slide replace
leak in leaking. valve.
heating Hot Cool Hot Cool as **WVB **WVB Pilot needle Operate

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
as (1) (2) and piston valve
needle several
leaking. times then
recheck. If
excessive
leak,
replace
valve.
Stop unit.
Will reverse
during
equalizatio
Pressure n period.
differential Recheck
too high. system.
Hot Cool as
Hot Cool *TVB *TVB Raise head
as (1) (2)
pressure
operate
solenoid to
free dirt. If
still no shift,
Clogged replace
Pilot tube. valve.
Raise head
pressure,
operate
solenoid.
Remove
valve and
wash out.
Check on
air before
re-
Hot Cool as installing. If
Hot Cool Hot *TVB
as (1) (2) no
movement,
replace
valve. Add
strainer to
discharge
tube.
Mount
Dirt in valve
bleeder horizontally
hole. .
Stop until,
Will not after
Hot Cool as
shift from Hot Cool Hot *TVB pressures
as (1) (2)
heat to Piston cup equalize,
cool leak. restart with

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
solenoid
de-
energized
with
compressor
running. If it
still will not
reverse
while
running,
replace
valve.
Hot Cool as Defective Replace
Hot Cool Hot Hot
as (1) (2) Pilot. Valve.
Defective
Warm Cool as
Warm Cool Warm *TVB compressor
as (1) (2)
.

Before you can effectively use this method of troubleshooting, you need to be familiar with the
temperatures around the reversing valve on a normally operating heat pump in both the cooling and
heating phase.

With the heat pump operating in the cooling phase (Figure 1), you will find that the discharge tube (1)
from the compressor is hot and the suction tube (2) to the compressor is cool. (It is important to
understand that these two tubes will have the same comparative temperatures in both the cooling and
heating phase.)

You'll also find that the tube (3) connected to the inside heat exchanger is cool, while the tube (4)
connected to the outside heat exchanger is hot.

If a normal system is transferred to the heating phase, (Figure 2), the discharge tube (1) will still be hot
and the suction tube (2) will still be cool. However, the tube (3) connected to the inside heat exchanger
will now be hot, and the tube (4) connected to the outside heat exchanger will now be cool, just the
reverse of the situation in the cooling phase. Rerouting of the gas flow causes the reversal of functions of
the inside and outside heat exchangers.

The capillary tubes connecting the pilot valve to the main valve eventually will become the same
temperature as the main valve body. Be sure to allow enough time for this to occur.

Inside the reversing valve, the compressor discharge gas, hot from compression, heats the discharge
tube, the valve, and the tube to the inside heat exchanger. As the cool suction gas returns to the
compressor, it cools the outside heat exchanger, the suction tube to the outside heat exchanger, and the
suction tube leading back to the compressor.

Since the valve is in a static condition, the valve body and pilot valve capillary tube will approach the
same temperature they had in the cooling phase.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
VALVE CHANGE-OUT

After completing the Touch Test you should know if the valve needs to be replaced. Before tackling the
job, you should be aware that a reversing valve change-out is probably the toughest part of servicing a
heat pump.

Here are some tips on proper procedures for removing the faulty valve.

Use an oxy-acetylene torch for unsoldering the connections. Other torches may not have the heat
capacity to do the job with minimum time and temperature.

Removing the valve by using a tube cutter instead of unsoldering the joints usually means that you will
have to fabricate new sections of refrigerant line. Never use a hacksaw under any conditions to cut
tubing.

Be careful to protect the valve from excessive heat. Temperatures above 250°F are apt to damage
internal parts. Wrapping a wet rag around the valve body while using the torch should do the trick.

Applying too little heat is also a problem. Not only will the soldered joints be difficult to separate, but also
the buildup of heat over the longer period of time required will transfer to the valve body and possibly
damage internal parts.

The joint should be separated in seconds, not minutes. Use enough heat to accomplish this, while relying
on the wet rag to protect the valve body. And remember that the remelt temperature of any solder alloy is
much higher than the initial soldering temperature.

Some old timers in the business like to apply silver solder flux to the outside of the joint to make the
unsoldering easier. They claim it lowers the remelt temperature and helps prevent heat oxidation. It
seems to work.

After removing the valve, inspect the lines to make sure they are round and do not have any large solder
blobs, which would interfere with the mechanical fit of the new joints.

And, above all, keep dirt and moisture from entering the tubes.

Installing the new valve also requires certain precautions.

Be sure you have a replacement reversing valve with correct capacity for the heat pump system. Check it
for shipping damage: dents, cracks, deep scratches, flattened tubing, poorly aligned solenoid coil.

Make sure the system is completely clean. If you have a choice of locations, choose one where the valve
will be subjected to minimum vibration.

When changing the valve be sure to protect all tubes from entry of foreign matter, such as moisture, metal
filings, dust or dirt. It takes only a tiny bit of scale, flux, lint, or the like to clog a pilot valve.

Use wet rags around the valve body and adjoining tubing to prevent overheating. Direct the flame of the
torch away from the valve body.

Use low-temperature brazing rod as local code will permit, and use an inert gas to prevent oxide scale on
the inside of the tubing.

Preferably use a phosphorus-bearing silver solder, which requires no external flux. The entrance of even
a tiny bit of flux may be enough to damage the new valve.

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 Service Application Manual
SAM Chapter 620-87
Section 18

HOW TO DIAGNOSE AND CORRECT REVERSING VALVE PROBLEMS

Ranco Controls
 
If you must use silver solder with externally applied flux, be sure the sections to be joined are bright and
clean, and that you use the flux sparingly. This will do the job, but because this type of solder requires
exceptional skill, most valve manufacturers are reluctant to recommend it.

The need for care in replacing reversing valves can't be stressed too strongly.

Connecting tubes, and often the valve body, are made of copper. Copper is an excellent conductor of
heat, so you must take precautions to keep the valve body temperature from rising above 250°F;
otherwise, the needle valves, piston seats, piston seals, and slide seat may be damaged from
overheating.

Avoid rough handling of the valve during installation. This especially includes the use of vise-type pliers to
manipulate the valve body while inserting the piping into the connection tubes. If the valve body or the
capillaries are dented or flattened, the reversing action may be impaired or stopped completely.

After soldering is completed, inspect the joints, with a mirror if necessary, to make sure you have not left
any voids or created any potential leaks. If the joints look good, pressurize the system with refrigerant to
at least 100 psi and check for leaks.

If you find any leaks, dump the leak check charge, repair the leaks, pressurize the system again, and
retest.

When all leaks have been repaired, triple evacuate the system with a good vacuum pump, charge the
system fully, start it up, and check it out. Cycle the reversing valve a dozen times or so to make sure it is
operating properly.

Copyright © 1980, 2001, By Refrigeration Service Engineers Society.

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