TECH @ Bung PREVENTING COMPRESSOR FAILURES DIAGNOSING AND CORRECTING SYSTEM/COMPRESSOR PROBLEMS GTc4-101 COPYRIGHT® CARRIER CORPORATION 1990 020-490 CA Sale age es eee ae Oe Ee pe a NO Se om See CRETE. esPREVENTING COMPRESSOR FAILURES WORKBOOK ‘The contents of this Service Training Program, (Catalog no. 020-491) are: one 25 minute 1/2" VHS video tape, (55) 35mm slides and this workbook, TABLE OF CONTENTS Section Title Slide No. Page No. Introduction 1-4 1 Refrigeration Cycle 5-9 2 Refrigerant Problems 10 - 18 4 Refrigerant and Oil 19 - 29 6 Contamination 30 - 36 9 Electrical Problems 37-43 u Overheating 44 - 46 13 Prevention 47 - 55 14 Appendix 18 Test 19 Test Key 4 icine e Upon completion of this training program, you will be familiar with the common problems of semi-hermetic ‘compressors, how they relate to system operation, and how to diagnose and correct them. Obtain necessary audio visual equipment, handout materials and program workbooks for each participant. Present the video tape. Review, discuss and ask questions atthe end of each segment. Show slides to highlight topics of importance. Distribute and review handout materials (see suggested list of handout materials below). Give test, then review using page references in the test key. Certificates of achievement are available through Literature Distribution. ‘Handout Materials/ Additional Training Materials- (Available through Literature Distribution) 1. 06D, 06E Installation and service instructions. 2, Visual aids such as compressor components and appropriate tools to support discussion. 3. See Appendix for listing of additional training materials. Self Instruction ‘When using this program for self instruction, review the video tape, read the workbook in its entirety, and complete the test, Test answers with page references are located in the Test Key. [sXD SERVICE LITEKATUME SHOULD Be CONSULTED BEFORE ATTEMPTING TE PROCEDURES, PROCESSES, OR TECHNIQUES DESCRIED HERE Copyright © Carrier Corporation 1990INTRODUCTION cae! eee ALG PREVENTING COMPRESSOR FAILURES 1. This training program has been developed to provide service personnel with information helpful in the detection and correction of compressor problems, before failure occurs. Special emphasis is placed on the positive effect that a correctly designed, installed and maintained system has on compressor life. ‘As with any equipment, be sure to use proper safety procedures and equipment as well as proper refrigerant handling and disposal techniques. Current product literature such as Installation, Start-up and Service Instructions, Wiring Dia- grams, and Troubleshooting Manuals should be referenced. (Refer to the Appendix for additional training materials.) rr eat Cod Sue Ey Cereal ry Cereal ar) Lbsepaleg et Cereal Poor 2. This program is divided into 8 sections; Intro- duction, Refrigeration Cycle, Refrigeration Prob- lems, Refrigerant and Oil, Contaminates, Elec trical Problems, Overheating, and Prevention. Much of the important information will be found in this program, but you should also refer to the detailed information on these subjects found in the literature available from your distributor. tell ee SICH) bMS ie alee Lire) bol MoS Re) AUT eel lied) es) ume Wiel) © Electrical problems 3. These are casualties, unfortunately cut down in their prime, before they finished the work they were designed to do. They were done in by: 1. Incorrect installation 2. Refrigerant flooding 3. Loss of lubrication 4. System contamination 5. Electrical problems ‘And like casualties in other conflicts, many of them were sacrificed needlessly.4. Many things can attribute to the death of a compressor, and deciding just what caused a failure can be confusing. By going back to basics, troubleshooting becomes a bit easier. For in- stance; understanding the refrigeration cycle; the interaction of the refrigerant and the oil; and the lubrication of the compressor; the problem of analyzing becomes easier. REFRIGERATION CYCLE ae elle Pe og 10 You measure voltage at the disconnect with the compressor running. Your readings a LI to L2 215V 12 TO L3 220V L3 TO LI 225v You decide these readings are: A. normal B. out of tolerance 21Prevention. ‘When checking a compressor at tear-down, look for: electrical problems loss of lubrication carbon, discoloration, sludge, acid ‘overheated motor windings, burned windings broken parts or lubrication failure A. contamination wiped or overheated bearings, broken rods B. over heating bearing failure, winding deterioration or dirt C. flooded starts D. E. IL ‘The best way to prevent compressor failures is to do a good installation and keep-up maintenance, The aim is to prevent the first compressor failure. The is included with every replacement compressor and must be filled out and sent back with your claims. A good technician does not just replace a compressor and go. He takes the time to really inside the compressor to find the problem, and he the owner of the system for any information on abnormal or changing operation If a compressor fails and the cause has not been determined and eliminated, the replacement compressor will 210. PREVENTING COMPRESSOR FAILURE TEST KEY Refrigeration Cycle/Problems/Oil == =————‘Reeferences Slide No. Page No. Answers include, but not limited to: I * Incorrect installation * Refrigerant flooding, slugging * Loss of lubrication * System contamination * Electrical problems * Leaving the valves closed condenser s metering devise evaporator compressor refrigerant 6 oil * oversized, misplaced or damaged TXV 10-18 * loose sensing bulb * overcharge of refrigerant * cold ambient conditions * badly designed piping * reduction of airflow over the evaporator Flooding 14 * defective motor 16 * broken belts * dirty or broken filters * dirty or broken fanwheels * dirty air bypass * frosting of the coil c. 1000 u migration 19 stratify 20 crankcase heater C. poor oil return 28 24i. 12. refrigerant 20-21 yes short cycling 24 ‘Contamination/Electrical/Overheating 1. dirt 30-31 2. moisture 3. acid 4, air refrigerant 30 - 31 clean 30 evacuated B. 2 38 B. out of tolerance 39 Prevention C. flooded starts 49 E. loss of lubrication A. contamination B. overheating D. electrical problems routine 48 semi-hermetic compressor check sheet 51 look 49 asks fail 50 25 7 9-10 9-10 10 12 12 15 15 16 15 16