Compressor Failure Reasons There are a variety of reasons why a compressors usually fails and I felt it would be a good

idea to list and comment on the most common mechanical and electrical reasons for failure. Electrical Reasons. Start winding Burn

This is one of the principle reasons why a lot of compressors fail and can be caused by a technician not wiring up the compressor properly. Other reasons why this failure occurs include: - Wrongly sized or bad capacitor - Loose or badly corroded terminals - Compressor short-cycling - Motor overloaded due to pressures not equalised - Low voltage - Compressor not turning Run Winding Burn Out A run winding burn out often appears as a general burnout due to the start winding getting burnt out also. The reasons associated with start winding burn out are very similar to a run winding failure.. Spot Burn

Spot Burn is usually caused by a surge in electrical current or voltage to the compressor. This is usually out of the technicians hands due to an electrical supply problem. A spike in voltage or current can result in arcing through the winding points of weaker insulation. A spot burn is a localised burn which can be within a winding, between windings or from winding to ground. Mechanical Reasons Liquid Floodback / Flooding Liquid Floodback is when liquid refrigerant returns back to the compressor while running. As we already know liquid cannot be compressed. The liquid refrigerant floodback will also dilute the compressors oil which causes pistons, cylinders and ring wear. To prevent floodbacks happening an accumulator can be placed between the evaporator and the compressor which will catch any liquid refrigeration before accessing the compressor acting like a reservoir for any liquid. Liquid Slugging

Liquid slugging is a condition which occurs when liquid is allowed to enter one or more of the compressor cylinders. Slugging can occur when moisture has entered the sealed system of from floodback problems mentioned above. Because liquid is practically non-compressible, the compressor seals may be compromised when the pistons attempt to compress the liquid. Liquid slugging can lead to permanent valve damage and reduced compressor efficiency. Low Compressor Oil Compressors have moving parts and need oil to avoid seizure and overheating. The parts that compress the refrigerant vapour have to be lubricated and some oil always leaves the compressor with the refrigerant. There is a certain amount of oil pumped out of the compressor with each stroke of the piston (usually 3% of discharged volume). The same amount of oil must return to oil-sump if the compressor is to be sufficiently lubricated. In a properly designed refrigeration system the oil travels along with refrigerant, completing the full circle. The following can lead to lack of lubricant in the crankcase: - Gas velocity too small to pick-up the oil: - Due to lack of refrigerant in the system - Due to oversized suction line - Compressor short cycling - Blockage in the system High Discharge Temperatures Occasionally discharge temperatures in a compressor can become so high oil can lose its viscosity for proper lubrication. This results are similar to having low oil where the parts that need lubrication start to wear out and become damaged. Evidence that this problem has occurred can include: - Discoloured valve plate which cant be rubbed clean - Burned discharge valve reeds - Burned and worn pistons, rings and cylinders - Stator spot burn from metal debris.

In general, the biggest reasons for high discharge temperature are: - High condensing pressures - High system superheat - Low suction pressures - High compression ratios

Modern refrigerators & freezers compressors operate using the solid state relay alognside the run capacitor. Due to their reliability and better efficency manufacturers are now using the two components together. The PTC (Positive Temperature Coefficient) relay is a starting device. As typically, as current passes through PTC material it causes an increase in temperature which in turn results in increased resistance until it reaches an open circuit. The PTC is wired between Run and Start, when the compressor is powering up, the PTC is cold, which gives it a resistance of about 25 Ohms. So when starting, the compressor start winding gets current through it it needs to get up to speed. The same current heats the PTC (within less than a second), which causes its resistance to increase (to 10-30 kOhm), cutting the power from the start winding. The remaining current through the start winding keeps the PTC hot. The compressor now operates on the run winding only. However, this creates a new circuit through the run capacitor in series with the start winding, but not enough to either energize or burn the winding. This out-of-phase current (where the current leads the voltage a characteristic of capacitance) allows the motor to run more efficiently, consuming less power. This run capacitor is usually rated in the region of 8 15 microfarads.

Is it working correctly? Fist of all PTC Relays are reletively inexpensive so they are not problem to replace. For a time and money saving exercise most engineers will carry them on the van and just replace them if there is any doubt it may be stopping the compressor starting. A visual inspection along with smelling the part can give you an idea if the PTC is burnt out or not. A possible way of trying to identify if the part itself is faulty is to do the following test. Connect a household light bulb in series with the Mains voltage -> PTC -> light bulb -> mains return). The bulb should flash once when power is applied if it is working correctly.

Refrigeration Theory
Most people associate refrigeration with cold and cooling, yet the practice of refrigeration engineering deals almost entirely with the transfer of heat. A good definition of refrigeration is the removal of heat energy so that a space or material is colder than its surroundings. Heat is an energy which cannot be created, destroyed or seen however it can be moved. This is one of the most fundamental concepts that must be understood. Cold is really only the absence of heat, just as darkness is the absence of light, and dryness is the absence of moisture. Cold is just the absence of heat Below is a basic diagram of how heat is displaced in a household refrigerator. The heat energy is drawn via the evaporator, it is then displaced at the external part of the fridge via the condenser into the cooler air.

Moisture in the system

Moisture Contamination occurs when moisture enters the refrigeration system. Moisture can exist in three forms water, solid and gas and this article applies to all three. A compressor is designed to perform efficiently under specific controlled conditions. if contaminants are introduced into the system they act to reduce compressor efficiency, effectiveness and durability. If moisture enters in to a refrigeration system, it combines with the refrigerant to form an acidic solution which may erode internal compressor components. Moisture doesnt actually cause direct compressor failure; the failure results from the failure of a part which has been weakened as a result of the effects of rust and/or corrosion. Copper plating is a condition in which metal parts in the compressor become coated / plated with copper. This condition is often observed in compressors which have a high moisture content in the system. Although copper plating alone does not cause a specific failure of the compressor, the conditions under which it is likely to occur are very detrimental to compressor durability. Moisture Contamination occurs as a result of moisture being allowed to enter and remain in the System. This condition can be caused by the following: A) System leaks. B) Improper Vacuuming of system. C) Contaminated system components. D) Contaminated refrigerant and / or oil. E) Saturated or malfunctioning drier. There are 4 primary identifiers of moisture: 1) Copper Plating 2) Slugged Valves 3) Rust 4) Contaminated compressor Oil

Capacitor testing
Capacitors are used in most refrigeration systems and are regularly seen next to, or attached to the compressor or large motors. Start Capacitor Start capacitors are usually housed in a black plastic housing and have a mfd range. Start capacitors increase motor starting torque and allow a motor to be cycled on and off rapidly. Start capacitors are designed for momentary use. They stay energized long enough to rapidly bring the motor to 3/4 of full speed and are then taken out of the circuit Run Capacitor Run capacitors are rated in a range of 3-70 microfarad (mfd). They are also rated by voltage classification. The voltage classifications are 370V and 440V. Run capacitors are designed for continuous duty, and are energized the entire time the motor is running. Single phase electric motors need a capacitor to energize a second phase winding. If the wrong run capacitor is installed, the motor will not have an even magnetic field. This will cause the the motor to become noisy, increase energy consumption, cause performance to drop, and cause the motor to overheat Capacitor Discharge If you suspect that the motor is not at fault by checking the windings and resistance levels it may be a defective capacitor that may be problematic. For your safety and to avoid damaging the component or test equipment capacitors must be fully discharged before tests are made. This also applies to soldering or before any of the motor circuitry is touched in any way. Some of the capacitors commonly found in refrigeration system store a potentially lethal charge therefore full discharge is a real necessety.

To discharge a capacitor this procedure is often followed. - Do this by touching the blade of an insulated-handled screw driver to one terminal, then slide it toward the other terminal until it makes contact and hold it there for a few seconds. You may get a flash or pop which shouldnt be a problem. - Repeat this procedure to get a short between each capacitor terminal and chassis ground. - If the capacitor has three terminals, use the same method to create a short circuit between each terminal and then from each terminal to ground.

To test to find out if the capacitor is faulty do the following - Disconnect the power supply by unplugging. - Dishcharge the capacitor (as above). - Carefully record which wires connect to the terminals and carefully remove all leads from the capacitor. - Set you multimeter / ohmmeter (I prefer to use an anlogue rather than digital for this test) to its highest resistance zero or infinity. - Measure from one terminal to the other for a normal reading of infinity. - Place one probe of your multimeter on one terminal, then place the other probe on the other terminal. The meter should deflect quickly and then gradually move back to infinity. - Reverse the leads placing the probes in the opposite direction. This should produce the same meter deflection and act in the same way. - If the test does the above, the compressor is usueable. If nothing happens, or the reading is different to above its a faulty capacitor - Visual inspection will also reveal certain defects, such as: - Evidence of arcing or burning at the insulators. - Evidence of an oil or smell suggests a leak - A bulging case indicates dielectric breakdow

Capacitor testing
Capacitors are used in most refrigeration systems and are regularly seen next to, or attached to the compressor or large motors. Start Capacitor Start capacitors are usually housed in a black plastic housing and have a mfd range. Start capacitors increase motor starting torque and allow a motor to be cycled on and off rapidly. Start capacitors are designed for momentary use. They stay energized long enough to rapidly bring the motor to 3/4 of full speed and are then taken out of the circuit Run Capacitor Run capacitors are rated in a range of 3-70 microfarad (mfd). They are also rated by voltage classification. The voltage classifications are 370V and 440V. Run capacitors are designed for continuous duty, and are energized the entire time the motor is running. Single phase electric motors need a capacitor to energize a second phase winding. If the wrong run capacitor is installed, the motor will not have an even magnetic field. This will cause the the motor to become noisy, increase energy consumption, cause performance to drop, and cause the motor to overheat Capacitor Discharge If you suspect that the motor is not at fault by checking the windings and resistance levels it may be a defective capacitor that may be problematic. For your safety and to avoid damaging the component or test equipment capacitors must be fully discharged before tests are made. This also applies to soldering or before any of the motor circuitry is touched in any way. Some of the capacitors commonly found in refrigeration system store a potentially lethal charge therefore full discharge is a real necessety.

To discharge a capacitor this procedure is often followed.

- Do this by touching the blade of an insulated-handled screw driver to one terminal, then slide it toward the other terminal until it makes contact and hold it there for a few seconds. You may get a flash or pop which shouldnt be a problem. - Repeat this procedure to get a short between each capacitor terminal and chassis ground. - If the capacitor has three terminals, use the same method to create a short circuit between each terminal and then from each terminal to ground.

To test to find out if the capacitor is faulty do the following - Disconnect the power supply by unplugging. - Dishcharge the capacitor (as above). - Carefully record which wires connect to the terminals and carefully remove all leads from the capacitor. - Set you multimeter / ohmmeter (I prefer to use an anlogue rather than digital for this test) to its highest resistance zero or infinity. - Measure from one terminal to the other for a normal reading of infinity. - Place one probe of your multimeter on one terminal, then place the other probe on the other terminal. The meter should deflect quickly and then gradually move back to infinity. - Reverse the leads placing the probes in the opposite direction. This should produce the same meter deflection and act in the same way. - If the test does the above, the compressor is usueable. If nothing happens, or the reading is different to above its a faulty capacitor - Visual inspection will also reveal certain defects, such as: - Evidence of arcing or burning at the insulators. - Evidence of an oil or smell suggests a leak - A bulging case indicates dielectric breakdow