Compressor Starting Problems

Nate Course #1063-0001

R50546-0920 © RectorSeal 2020
2019
Learning objectives

• Knowledge of the harmful effects of heat on

compressor motor windings.

• Understand benefits of a hard start device.

• Dangers of using the wrong start components.

• How to confirm Run Capacitor functionality.

© RectorSeal 2019
Agenda Overview

Review of conventional 3-wire hard start

devices and components

Review of 2-wire hard start technology

Comparing 3-wire versus 2-wire devices in real-

world testing

Competitor technologies

True Run Capacitor test

© RectorSeal 2019
What are hard start kits?

A mechanical Potential Relay connected to a Start Capacitor that is

wired into the compressor to aide in compressor starting.

© RectorSeal 2019
Why are hard starts needed?

Low supply Poor quality of Inadequate, or

voltage power supply undersized wiring

Pressure Multiple units

Times of Peak
differential running at once on
energy usage
at start the same grid

© RectorSeal 2019
Understanding counter EMF

Counter (back) EMF or

ElectroMotive Force is the voltage
generated from the motor field as
it operates.

The electric motor generates

voltage counter the applied
voltage.

An electric motor is
a generator.

Image Source: http://wagan.com/blog/back-emf/ “Extending Inverter life – Squashing Back-EMF (Counter EMF)”
© RectorSeal 2019
Agenda Overview

Review of conventional 3-wire hard start

devices and components

Review of 2-wire hard start technology

3-wire and 2-wire devices in

real-world testing

Competitor technologies

True Run Capacitor test

© RectorSeal 2019
Standard wiring

Traditional 3-wire hard start assemblies have been used since

the 1930’s.

Use a Potential Relay and Start Capacitor with dedicated

wires that can only attach at specific locations.

Every major compressor manufacturer utilizes the 3-wire

standard for their factory-installed hard start kits.

© RectorSeal 2019
3-wire design

The Potential Relay

is connected between
the Common and Start
in series with the Run
Capacitor.

The “entire series” is

in parallel with the
Run Capacitor, causing
the circuit to be in
series with the Start
winding.

© RectorSeal 2019
3-wire hard start schematic

Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

S C R
Start Common Run

© RectorSeal 2019
Traditional way to read counter EMF

Start Common Run

S C R

counter
EMF
±10’s Volts

© RectorSeal 2019
3-wire hard start schematic

Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

S C R
Start Common Run

© RectorSeal 2019
How it works

The speed of the Rotor is L1 L2

measured by the amplitude
of the voltage generated,
or “back EMF”.

This is how we determine the

correct time to take the start Run Start
capacitor out of the circuit.

This is how it is determined

which Potential Relay to use, 5 2
you simply match the relay
4 1
that takes the start circuit Start
out when the motor is at Capacitor
75% of its full speed.

Run Capacitor

© RectorSeal 2019
Copeland handbook has 64 Potential
Relays!
COPELAND PICK UP DROP OUT CONT COPELAND PICK UP DROP OUT CONT
PART NO. VOLTS VOLTS VOLT PART NO. VOLTS VOLTS VOLT
040-000-1-00 320-340 60-140 395 040-000-1-55 190-200 60-121 375
040-000-1-01 150-160 15-55 130 040-000-1-56 200-220 40-90 332
040-000-1-03 340-360 45-155 156 040-000-1-58 260-280 60-140 395
040-000-1-04 340-360 55-125 336 040-000-1-59 210-230 60-150 420
040-000-1-05 280-300 50-125 336 040-000-1-60 190-200 55-115 332
040-000-1-08 320-340 60-160 420 040-000-1-61 320-340 60-120 420
040-000-1-09 300-320 45-115 256 040-000-1-62 150-160 35-77 253
040-000-1-11 170-180 35-90 253 040-000-1-63 300-320 50-140 375
040-000-1-12 260-280 60-150 420 040-000-1-64 260-280 60-150 420
040-000-1-17 260-280 50-140 375 040-000-1-66 300-320 45-115 332
040-000-1-18 300-320 50-140 375 040-000-1-68 240-260 60-121 420
040-000-1-19 240-260 60-140 375 040-000-1-69 320-340 60-160 502
040-000-1-20 190-200 40-130 375 040-000-1-71 280-300 50-110 375
040-000-1-22 120-130 15-50 130 040-000-1-75 120-130 15-40 130
040-000-1-24 240-260 35-95 253 040-000-1-77 240-260 35-77 253
040-000-1-25 150-160 35-95 253 040-000-1-79 170-180 40-96 332
040-000-1-34 240-260 60-150 420 040-000-1-80 140-150 20-65 168
040-000-1-35 210-230 60-150 420 040-000-1-82 220-240 40-90 332
040-000-1-36 200-220 40-115 332 040-000-1-83 260-280 60-140 395
040-000-1-37 170-180 40-115 332 040-000-1-84 280-300 75-150 420
040-000-1-38 190-200 55-115 332 040-000-1-85 280-300 75-170 495
040-000-1-41 140-150 20-65 168 040-000-1-86 220-280 60-135 495
040-000-1-42 260-280 60-140 395 040-000-1-87 260-280 60-140 395
040-000-1-43 280-300 75-150 420 040-000-7-00 150-160 15-45 130
040-000-1-45 280-300 75-150 495 040-000-7-04 340-360 55-125 336
040-000-1-46 220-240 40-115 332 040-004-6-00 340-360 55-125 336
040-000-1-47 220-280 60-135 495 040-004-6-01 320-340 60-140 395
040-000-1-48 150-160 15-40 130 040-004-6-02 320-340 75-160 420
040-000-1-49 340-360 50-100 332 040-004-6-05 300-320 45-115 256
040-000-1-50 340-360 55-125 336 040-004-6-08 170-180 45-90 256
040-000-1-51 170-180 35-77 253 040-004-6-09 150-160 20-55 130
040-000-1-53 260-280 50-110 375 040-004-6-10 340-360 45-115 256
040-000-1-54 240-260 60-121 375 040-004-6-16 280-300 55-125 336

© RectorSeal 2019
Capacitor and Potential Relay variations

With 100’s of variations of “back EMF”, there are 100’s of

Potential Relay and Start Capacitor combinations.
• Relays are calibrated to have different “Pick Up”, “Drop Out”, “Continuous”,
“Impulse”, and “Response Time” voltage.

© RectorSeal 2019
Copeland handbook has 64 Potential
Relays!
COPELAND PICK UP DROP OUT CONT COPELAND PICK UP DROP OUT CONT
PART NO. VOLTS VOLTS VOLT PART NO. VOLTS VOLTS VOLT
040-000-1-00 320-340 60-140 395 040-000-1-55 190-200 60-121 375
040-000-1-01 150-160 15-55 130 040-000-1-56 200-220 40-90 332
040-000-1-03 340-360 45-155 156 040-000-1-58 260-280 60-140 395
040-000-1-04 340-360 55-125 336 040-000-1-59 210-230 60-150 420
040-000-1-05 280-300 50-125 336 040-000-1-60 190-200 55-115 332
040-000-1-08 320-340 60-160 420 040-000-1-61 320-340 60-120 420
040-000-1-09 300-320 45-115 256 040-000-1-62 150-160 35-77 253
040-000-1-11 170-180 35-90 253 040-000-1-63 300-320 50-140 375
040-000-1-12 260-280 60-150 420 040-000-1-64 260-280 60-150 420
040-000-1-17 260-280 50-140 375 040-000-1-66 300-320 45-115 332
040-000-1-18 300-320 50-140 375 040-000-1-68 240-260 60-121 420
040-000-1-19 240-260 60-140 375 040-000-1-69 320-340 60-160 502
040-000-1-20 190-200 40-130 375 040-000-1-71 280-300 50-110 375
040-000-1-22 120-130 15-50 130 040-000-1-75 120-130 15-40 130
040-000-1-24 240-260 35-95 253 040-000-1-77 240-260 35-77 253
040-000-1-25 150-160 35-95 253 040-000-1-79 170-180 40-96 332
040-000-1-34 240-260 60-150 420 040-000-1-80 140-150 20-65 168
040-000-1-35 210-230 60-150 420 040-000-1-82 220-240 40-90 332
040-000-1-36 200-220 40-115 332 040-000-1-83 260-280 60-140 395
040-000-1-37 170-180 40-115 332 040-000-1-84 280-300 75-150 420
040-000-1-38 190-200 55-115 332 040-000-1-85 280-300 75-170 495
040-000-1-41 140-150 20-65 168 040-000-1-86 220-280 60-135 495
040-000-1-42 260-280 60-140 395 040-000-1-87 260-280 60-140 395
040-000-1-43 280-300 75-150 420 040-000-7-00 150-160 15-45 130
040-000-1-45 280-300 75-150 495 040-000-7-04 340-360 55-125 336
040-000-1-46 220-240 40-115 332 040-004-6-00 340-360 55-125 336
040-000-1-47 220-280 60-135 495 040-004-6-01 320-340 60-140 395
040-000-1-48 150-160 15-40 130 040-004-6-02 320-340 75-160 420
040-000-1-49 340-360 50-100 332 040-004-6-05 300-320 45-115 256
040-000-1-50 340-360 55-125 336 040-004-6-08 170-180 45-90 256
040-000-1-51 170-180 35-77 253 040-004-6-09 150-160 20-55 130
040-000-1-53 260-280 50-110 375 040-004-6-10 340-360 45-115 256
040-000-1-54 240-260 60-121 375 040-004-6-16 280-300 55-125 336

© RectorSeal 2019
Voltage variance specification

Voltage is specified between the Start and Run terminals when a

motor is designed, in order to match the Run Capacitor
requirements.

Voltage between Start and Common varies by 100’s of volts

• whereas voltage between the Start and Run terminals is
“consistent”, varyies by only 10’s of volts.
• Why, because Start and Run terminal voltage variation is “specified”
by the Engineers in the design process.

www.rectorseal.com © RectorSeal 2019

Agenda Overview

Review of conventional 3-wire hard start

devices and components

Review of 2-wire hard start technology

3-wire and 2-wire devices in

real-world testing

Competitor technologies

True Run Capacitor test

© RectorSeal 2019
How the 2 Wire System Was Found

We now know that voltage between Start and Common terminals

varies and voltage between Start and Run terminals is relatively
constant, so what does that mean?

All PSC (Permanent Split Capacitor) motors have essentially the

same back EMF between Start and Run terminals.

www.rectorseal.com © RectorSeal 2019

The First Move

On this diagram we will be taking the wire from the

Common terminal and move it over to the Run terminal. Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

S C R
Start Common Run

© RectorSeal 2019
Updated 3-wire hard start schematic

Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

S C R
Start Common Run

© RectorSeal 2019
2-wire hard start

We can redraw the wiring without changing it electronically.

• Move the Start lead to the left side of the Run Capacitor.
• Connect the Potential Relay to the Run Capacitor.
• Connect the Run winding wire to the Run Capacitor.

Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

S C R
Start Common Run

© RectorSeal 2019
2-wire diagram

The diagram is unchanged electronically, but we have moved the

wiring into a new schematic.
• The Potential Relay and Start Capacitor are inside one box with 2 wires coming out.
• Reversing the 2-wire configuration across the Run Capacitor will not change the function
in any way.

Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

S C R
Start Common Run

© RectorSeal 2019
The Kickstart® Way to Read Counter EMF

• Read the Counter EMF between Start and Run terminals,

• use only ONE relay instead of having to pick from 100’s of relays.
• Hard start kit with a single Potential Relay that can be used on all 2-
pole PSC motors with two wires that are not dedicated!

Run Capacitor

Potential Start Capacitor

Relay

Start winding Run Winding

Counter
S EMF C R
Start ±10’s Volts Common Run

© RectorSeal 2019
Locked Rotor Amps

Locked Rotor Amps (LRA), or Locked Rotor Current, is the

amount of energy needed to begin the motion of the rotor
within an electric motor.

LRA is much greater that the Full Load Amps (FLA) or Running
Load Amps (RLA) because of the power required to operate the
equipment attached to the electric motor during start-up as well.
- LRA can be as much as 600 to 800% the normal FLA
(depending on the motor)

www.rectorseal.com © RectorSeal 2019

Compressor with no hard start

3 ton recip. compressor

230v @ LRA NO HARD START pressure equalized @ 140 psig

Volts (Amps)
500

400

300

Run Capacitor Voltage – RMS

200 Run Winding Amps

100

-100

-200
0 100 200 300 400 500 600
Time (ms)
© RectorSeal 2019
As the motor begins to turn, the rotor
struggles to get to operating speed
3 ton recip. compressor rotor motion Rotor
NO Hard Start Run Winding Current

Number of turns Run Capacitor Voltage

6
Rotation
5 (no. of turns)

2 Counter EMF

-1

-2 LRA
-3

-4

-5
0 50 100 150 200 250

Note: IL and Vc NOT TO SCALE Time (ms)

© RectorSeal 2019
As the motor begins to turn, the rotor
struggles to get to operating speed
3 ton recip. compressor rotor motion Rotor
NO Hard Start Run Winding Current

Number of turns Run Capacitor Voltage

6

5 75% of full
speed after
4
2.5 - 3 turns of
3 compressor
motor
2

-1

-2

-3

-4

-5
0 50 100 150 200 250

Note: IL and Vc NOT TO SCALE Time (ms)

© RectorSeal 2019
As the motor begins to turn, the rotor
struggles to get to operating speed
3 ton recip. compressor rotor motion Rotor
NO Hard Start Run Winding Current

Number of turns Run Capacitor Voltage

6

5 75% of full
speed after
4
2.5 - 3 turns of
3 compressor
motor
2

-1

-2

-3

-4

-5
0 50 100 150 200 250

Note: IL and Vc NOT TO SCALE Time (ms)

© RectorSeal 2019
Agenda Overview

Review of conventional 3-wire hard start

devices and components

Review of 2-wire hard start technology

3-wire and 2-wire devices in

real-world testing

Competitor technologies

True Run Capacitor test

© RectorSeal 2019
Compressor with factory hard start

3 ton recip. compressor

187v FACTORY HARD START (145 MFD) 90 # S - 280 # D

Amps
Run Winding Current
150
Start winding Current

100

50

-50

-100

-150
0 100 200 300 400 500 600 700 800
Time (ms)
© RectorSeal 2019
Compressor with KickStart TO-5

3 ton recip. compressor

187v KICKSTART TO-5 (189 MFD) 90 # S - 280 # D

Amps
Run Winding Current
150
Start winding Current

100

50

-50

-100

-150
0 100 200 300 400 500 600 700 800
Time (ms)
© RectorSeal 2019
Factory hard start vs KickStart TO-5

3 ton recip. Compressor 187v FACTORY HARD START (145 MFD) 90 # S - 280 # D
Amps
150
100
50
0
-50
-100
-150
0 100 200 300 400 500 600 700 800
Time (ms)
Run Winding Current
WITH KICKSTART TO-5 (189 MFD) Start winding Current
Amps
150
100
50
0
-50
-100
-150
0 100 200 300 400 500 600 700 800
Time (ms)

© RectorSeal 2019
Copeland Scroll hard start comparison

Copeland Scroll ZR57K3-PFV 197 V NO HARD START DEVICE

Amps
300
200
100
0
-100
-200
-300
0 100 200 300 400 500 600
Time (ms)
Run Winding Current
WITH KICKSTART KS-1 Start winding Current
Amps
300
200
100
0
-100
-200
-300
0 100 200 300 400 500 600
Time (ms)

© RectorSeal 2019
Compressor warranty claims

Typical warranty compressor returns

(out of 100 units) ILLUSTRATIVE
100%
Carbon
90% No Defect Build-up
80%
Moisture
70%

60%
Liquid Heat kills
50% Related compressors!
40% Defective
30%
Start
20% Winding
Burn Out
10%

0%
Compressor Returns Defect Breakdown

© RectorSeal 2019
Agenda Overview

Review of conventional 3-wire hard start

devices and components

Review of 2-wire hard start technology

3-wire and 2-wire devices in

real-world testing

Competitor technologies

True Run Capacitor test

© RectorSeal 2019
PTCR
Positive Temperature Coefficient Resistor

(I) R PTCR discs

CP (Curie Point):
Current Temp where material
resistant
Current

can no longer conduct

electricity

Resistant

20° 248° Temp t°

0.8 sec Time T

PTCR discs are appealing because they are a cheap

technology compared to OEM-approved Potential Relays

© RectorSeal 2019
Timing Device

Set duration could

cause start to happen
too early or too late.

© RectorSeal 2019
Technology comparison

Copeland CRA1 0150-PFV 197 V PTCR WITH CAPACITOR

Amps
80
40
0
-40
-80
0 100 200 300 400 500 600 700 800
Time (ms)

Copeland CRA1 0150-PFV 197 V ELECTRONIC TIMING DEVICE W/ 88-106 START CAPACITOR
Amps
80
40
0
-40
-80
0 100 200 300 400 500 600 700 800
Time (ms)

Copeland CRA1 0150-PFV 197 V KICKSTART TO-5 OR MATCHED FACTORY 3-WIRE KIT
Amps
80
40
0
-40
-80
0 100 200 300 400 500 600 700 800
Time (ms)

Run Winding Current Start winding Current © RectorSeal 2019

The so-called “universal” 3-wire kits

It IS impossible to
make a universal
hard start kit using
the standard 3-wire
connections.

But some still

sell them.

© RectorSeal 2019
Copeland handbook has 64 Potential
Relays
COPELAND PICK UP DROP OUT CONT COPELAND PICK UP DROP OUT CONT
PART NO. VOLTS VOLTS VOLT PART NO. VOLTS VOLTS VOLT
040-000-1-00 320-340 60-140 395 040-000-1-55 190-200 60-121 375
040-000-1-01 150-160 15-55 130 040-000-1-56 200-220 40-90 332
040-000-1-03 340-360 45-155 156 040-000-1-58 260-280 60-140 395
040-000-1-04 340-360 55-125 336 040-000-1-59 210-230 60-150 420
040-000-1-05 280-300 50-125 336 040-000-1-60 190-200 55-115 332
040-000-1-08 320-340 60-160 420 040-000-1-61 320-340 60-120 420
040-000-1-09 300-320 45-115 256 040-000-1-62 150-160 35-77 253
040-000-1-11 170-180 35-90 253 040-000-1-63 300-320 50-140 375
040-000-1-12 260-280 60-150 420 040-000-1-64 260-280 60-150 420

One Potential Relay cannot replace all 64 relays in a 3-wire configuration!

040-000-1-17
040-000-1-18
260-280
300-320
50-140
50-140
375
375
040-000-1-66
040-000-1-68
300-320
240-260
45-115
60-121
332
420
040-000-1-19 240-260 60-140 375 040-000-1-69 320-340 60-160 502
040-000-1-20 190-200 40-130 375 040-000-1-71 280-300 50-110 375
040-000-1-22 120-130 15-50 130 040-000-1-75 120-130 15-40 130
040-000-1-24 240-260 35-95 253 040-000-1-77 240-260 35-77 253
040-000-1-25 150-160 35-95 253 040-000-1-79 170-180 40-96 332
040-000-1-34 240-260 60-150 420 040-000-1-80 140-150 20-65 168
040-000-1-35 210-230 60-150 420 040-000-1-82 220-240 40-90 332
040-000-1-36 200-220 40-115 332 040-000-1-83 260-280 60-140 395
040-000-1-37 170-180 40-115 332 040-000-1-84 280-300 75-150 420
040-000-1-38 190-200 55-115 332 040-000-1-85 280-300 75-170 495
040-000-1-41 140-150 20-65 168 040-000-1-86 220-280 60-135 495
040-000-1-42 260-280 60-140 395 040-000-1-87 260-280 60-140 395
040-000-1-43 280-300 75-150 420 040-000-7-00 150-160 15-45 130
040-000-1-45 280-300 75-150 495 040-000-7-04 340-360 55-125 336
040-000-1-46 220-240 40-115 332 040-004-6-00 340-360 55-125 336
040-000-1-47 220-280 60-135 495 040-004-6-01 320-340 60-140 395
040-000-1-48 150-160 15-40 130 040-004-6-02 320-340 75-160 420
040-000-1-49 340-360 50-100 332 040-004-6-05 300-320 45-115 256
040-000-1-50 340-360 55-125 336 040-004-6-08 170-180 45-90 256
040-000-1-51 170-180 35-77 253 040-004-6-09 150-160 20-55 130
040-000-1-53 260-280 50-110 375 040-004-6-10 340-360 45-115 256
040-000-1-54 240-260 60-121 375 040-004-6-16 280-300 55-125 336

© RectorSeal 2019
The so-called “universal” 3-wire kits

Peel back
the sticker to
see the specs.

© RectorSeal 2019
The so-called “universal” 3-wire kits

It is not possible for only 2 Potential Relays to cover the

entire range of equipment with a 3-wire device.

© RectorSeal 2019
The so-called “universal” 3-wire kit’s
compatibility with Copeland
COPELAND PICK UP DROP OUT CONT COPELAND PICK UP DROP OUT CONT
PART NO. VOLTS VOLTS VOLT PART NO. VOLTS VOLTS VOLT
040-000-1-00 320-340 60-140 395 040-000-1-55 190-200 60-121 375
040-000-1-01 150-160 15-55 130 040-000-1-56 200-220 40-90 332
040-000-1-03 340-360 45-155 156 040-000-1-58 260-280 60-140 395
040-000-1-04 340-360 55-125 336 040-000-1-59 210-230 60-150 420
040-000-1-05 280-300 50-125 336 040-000-1-60 190-200 55-115 332
040-000-1-08 320-340 60-160 420 040-000-1-61 320-340 60-120 420
040-000-1-09 300-320 45-115 256 040-000-1-62 150-160 35-77 253
040-000-1-11 170-180 35-90 253 040-000-1-63 300-320 50-140 375
040-000-1-12 260-280 60-150 420 040-000-1-64 260-280 60-150 420

Works for less than 10% of relays on all Copeland compressors!

040-000-1-17
040-000-1-18
260-280
300-320
50-140
50-140
375
375
040-000-1-66
040-000-1-68
300-320
240-260
45-115
60-121
332
420
040-000-1-19 240-260 60-140 375 040-000-1-69 320-340 60-160 502
040-000-1-20 190-200 40-130 375 040-000-1-71 280-300 50-110 375
040-000-1-22 120-130 15-50 130 040-000-1-75 120-130 15-40 130
040-000-1-24 240-260 35-95 253 040-000-1-77 240-260 35-77 253
040-000-1-25 150-160 35-95 253 040-000-1-79 170-180 40-96 332
040-000-1-34 240-260 60-150 420 040-000-1-80 140-150 20-65 168
040-000-1-35 210-230 60-150 420 040-000-1-82 220-240 40-90 332
040-000-1-36 200-220 40-115 332 040-000-1-83 260-280 60-140 395
040-000-1-37 170-180 40-115 332 040-000-1-84 280-300 75-150 420
040-000-1-38 190-200 55-115 332 040-000-1-85 280-300 75-170 495
040-000-1-41 140-150 20-65 168 040-000-1-86 220-280 60-135 495
040-000-1-42 260-280 60-140 395 040-000-1-87 260-280 60-140 395
040-000-1-43 280-300 75-150 420 040-000-7-00 150-160 15-45 130
040-000-1-45 280-300 75-150 495 040-000-7-04 340-360 55-125 336
040-000-1-46 220-240 40-115 332 040-004-6-00 340-360 55-125 336
040-000-1-47 220-280 60-135 495 040-004-6-01 320-340 60-140 395
040-000-1-48 150-160 15-40 130 040-004-6-02 320-340 75-160 420
040-000-1-49 340-360 50-100 332 040-004-6-05 300-320 45-115 256
040-000-1-50 340-360 55-125 336 040-004-6-08 170-180 45-90 256
040-000-1-51 170-180 35-77 253 040-004-6-09 150-160 20-55 130
040-000-1-53 260-280 50-110 375 040-004-6-10 340-360 45-115 256
040-000-1-54 240-260 60-121 375 040-004-6-16 280-300 55-125 336

© RectorSeal 2019
Kickstart’s compatibility with Copeland

COPELAND PICK UP DROP OUT CONT COPELAND PICK UP DROP OUT CONT
PART NO. VOLTS VOLTS VOLT PART NO. VOLTS VOLTS VOLT
040-000-1-00 320-340 60-140 395 040-000-1-55 190-200 60-121 375
040-000-1-01 150-160 15-55 130 040-000-1-56 200-220 40-90 332
040-000-1-03 340-360 45-155 156 040-000-1-58 260-280 60-140 395
040-000-1-04 340-360 55-125 336 040-000-1-59 210-230 60-150 420
040-000-1-05 280-300 50-125 336 040-000-1-60 190-200 55-115 332
040-000-1-08 320-340 60-160 420 040-000-1-61 320-340 60-120 420
040-000-1-09 300-320 45-115 256 040-000-1-62 150-160 35-77 253
040-000-1-11 170-180 35-90 253 040-000-1-63 300-320 50-140 375
040-000-1-12 260-280 60-150 420 040-000-1-64 260-280 60-150 420

Tested to perform with each PSC single-phase compressor.

040-000-1-17
040-000-1-18
260-280
300-320
50-140
50-140
375
375
040-000-1-66
040-000-1-68
300-320
240-260
45-115
60-121
332
420
040-000-1-19 240-260 60-140 375 040-000-1-69 320-340 60-160 502
040-000-1-20 190-200 40-130 375 040-000-1-71 280-300 50-110 375
040-000-1-22 120-130 15-50 130 040-000-1-75 120-130 15-40 130
040-000-1-24 240-260 35-95 253 040-000-1-77 240-260 35-77 253
040-000-1-25 150-160 35-95 253 040-000-1-79 170-180 40-96 332
040-000-1-34 240-260 60-150 420 040-000-1-80 140-150 20-65 168
040-000-1-35 210-230 60-150 420 040-000-1-82 220-240 40-90 332
040-000-1-36 200-220 40-115 332 040-000-1-83 260-280 60-140 395
040-000-1-37 170-180 40-115 332 040-000-1-84 280-300 75-150 420
040-000-1-38 190-200 55-115 332 040-000-1-85 280-300 75-170 495
040-000-1-41 140-150 20-65 168 040-000-1-86 220-280 60-135 495
040-000-1-42 260-280 60-140 395 040-000-1-87 260-280 60-140 395
040-000-1-43 280-300 75-150 420 040-000-7-00 150-160 15-45 130
040-000-1-45 280-300 75-150 495 040-000-7-04 340-360 55-125 336
040-000-1-46 220-240 40-115 332 040-004-6-00 340-360 55-125 336
040-000-1-47 220-280 60-135 495 040-004-6-01 320-340 60-140 395
040-000-1-48 150-160 15-40 130 040-004-6-02 320-340 75-160 420
040-000-1-49 340-360 50-100 332 040-004-6-05 300-320 45-115 256
040-000-1-50 340-360 55-125 336 040-004-6-08 170-180 45-90 256
040-000-1-51 170-180 35-77 253 040-004-6-09 150-160 20-55 130
040-000-1-53 260-280 50-110 375 040-004-6-10 340-360 45-115 256
040-000-1-54 240-260 60-121 375 040-004-6-16 280-300 55-125 336

© RectorSeal 2019
Copeland scroll using wrong relay

Copeland scroll ZR42K3 – PFV

WRONG RELAY

Amps
Run Winding Amps
350
Start winding Amps
300
250
200
Potential Relay
150 picks up too soon
100
50
0
-50
-100
-150
-200
-250
-300
0 100 200 300 400 500 600
Time (ms)
© RectorSeal 2019
Copeland scroll using wrong relay

Copeland scroll ZR42K3 – PFV

WRONG RELAY

Amps
Run Winding Amps
200
Start winding Amps
150
Pick up voltage too
high
100

50

-50

-100

-150

-200
0 100 200 300 400 500 600 700
Time (ms)
© RectorSeal 2019
Correct Potential Relay pick-up

Copeland scroll ZR57K3-PFV

197 V KICKSTART KS1 - GE-3ARR3CT3P5/kit

Amps
Run Winding Current
300
Start winding Current

200

100

-100

-200

-300
0 100 200 300 400 500 600
Time (ms)
© RectorSeal 2019
Wrong Components

Using the wrong combination of start capacitor and Potential

Relay causes heat to build in the Start winding of the compressor
motor.
Remember: Heat Kills Start windings!
Typical warranty compressor returns
(out of 100 units) ILLUSTRATIVE

100%
Carbon
90% No Defect Build-up
80%
Moisture
70%
60% Burnt out Start
Liquid
50% windings were the
Related
largest warranty
40% Defective return from
30% compressor
Start
20% Winding manufactures.
10% Burn Out
0%
Compressor Returns Defect Breakdown

© RectorSeal 2019
Tested quality and reliability
with OEM approval.

© RectorSeal 2019
Agenda Overview

Review of conventional 3-wire hard start

devices and components

Review of 2-wire hard start technology

3-wire and 2-wire devices in

real-world testing

Competitor technologies

True Run Capacitor test

© RectorSeal 2019
True Run Capacitor test

Run Cap Test: Process of testing the Run Capacitor

while the system is running, providing an accurate reading.
• Start compressor with Run Capacitor connected.
• Measure and record the Amp Draw of the capacitor (multiply 2654).
• Measure and record the Applied Voltage.

AMP DRAW X 2654 Calculated value should

MFD = = 50.2
APPLIED VOLTAGE be within 10% of value
stamped capacitor.

Example:
Capacitor draws 7 amps at 370 volts

7X 2654
MFD = = 50.2
370

© RectorSeal 2019
True Run Capacitor test values

Capacitor Amps
2 3 4 5 6 7 8 9 10 11 12 13
315 17 25 34 42 51 59 67 76 84 93 101 109
320 17 25 33 41 50 58 66 75 83 91 99 108
325 16 24 33 41 49 57 65 73 82 90 98 106
330 16 24 32 40 48 56 64 72 80 88 96 104
335 16 24 32 40 48 55 63 71 79 87 95 103
340 16 23 31 39 47 55 62 70 78 86 94 101
345 15 23 31 38 46 54 62 69 77 85 92 100
350 15 23 30 38 45 53 61 68 76 83 91 99
355 15 22 30 37 45 52 60 67 75 82 90 97
360 15 22 29 37 44 52 59 66 74 81 88 96
Capacitor Volts

365 15 22 29 36 44 51 58 65 73 80 87 94
370 14 22 29 36 43 50 57 65 72 79 86 93
375 14 21 28 35 42 50 57 64 71 78 85 92
380 14 21 28 35 42 49 56 63 70 77 84 91
385 14 21 28 34 41 48 55 62 69 76 83 90
390 14 20 27 34 41 48 54 61 68 75 82 88
395 13 20 27 34 40 47 54 60 67 74 81 87
400 13 20 27 33 40 46 53 60 66 73 80 86
405 13 20 26 33 39 46 52 59 65 72 79 85
410 13 19 26 32 39 45 52 58 65 71 78 84
415 13 19 26 32 38 45 51 58 64 70 77 83
420 13 19 25 32 38 44 51 57 63 69 76 82
425 12 19 25 31 37 44 50 56 62 69 75 81
430 12 19 25 31 37 43 49 56 62 68 74 80
435 12 18 24 30 37 43 49 55 61 67 73 79
440 12 18 24 30 36 42 48 54 60 66 72 78
445 12 18 24 30 36 42 48 54 60 66 72 77

© RectorSeal 2019
Kickstart® models

TO-5 KS-1
• Maximum Torque. • Maximum Torque.
• For all reciprocating, scroll and • For all reciprocating, scroll and
rotary compressors 1 to 3 tons. rotary compressors 3.5 to 5 tons.

© RectorSeal 2019
Summary

• Heat Kills Start windings!

• KickStart does not generate heat build up.
• PTCR and Timer devices do not work consistently.
• A "universal" 3-wire only meets a subset of applications.

• Correct Potential Relay and Start Capacitors reduces damage

to compressors.

• Always test your Run Capacitor.

www.rectorseal.com © RectorSeal 2019

© RectorSeal 2019