I'm working on a walk-in freezer running on R404A that's taking way too long to reach its target temperature of −18°C (0°F).
At first, I noticed an uneven frost pattern on the evaporator. Some circuits were frosting up while others weren't. I suspected oil might be trapped in the evaporator, so I added some refrigerant hoping to improve circulation, but it didn't help. The freezer actually started losing temperature.
When I inspected the evaporator more closely, I found traces of oil and discovered a refrigerant leak at the service valve. I replaced the Schrader valve core and added refrigerant and oil, but the system was still cooling very slowly.
Since the evaporator seemed to be underfed, I started opening up the TXV in ¼-turn increments, eventually reaching ¾ of a turn from its original setting. I noticed the suction pressure increased and the frost pattern across the evaporator became more even. The suction line running back to the compressor also started frosting up, so I had to readjust the valve to avoid possible liquid floodback.
I also checked the superheat with my temperature probe placed next to the TXV sensing bulb. With 35 psi measured at the evaporator outlet, I calculated around 6.7 K of superheat. However, using the 25 psi reading taken at the condensing unit, the calculated superheat was around 12.8 K.
Eventually, I replaced the Danfoss TXV and installed a No. 06 orifice, which was sized and recommended by a Danfoss distributor based on the system specifications.
My latest readings are 26 psi on the low side and 197 psi on the high side, with an evaporating temperature of −21.8°C (−7.2°F). The freezer was at −6.4°C (20.5°F) when I took those readings.
Despite everything I've done, the freezer is still taking too long to pull down to temperature.
What else would you guys recommend checking to figure out what's causing this?