![]() The returning gas (suction) cools the compressor, which helps to remove some amount of heat from the compressor’s motor. This causes a loss in its electrical resistance, a short to the ground, as well as an open winding.Īlso, high temperatures can cause the oil to break down, and as such, the lubrication provided will be insufficient, which increases friction within internal components. Here’s why: A high temperature removes the motor windings’ insulation. Increase in the Compressor Motor Windings’ Temperature:Īn increment in the temperature of the compressor’s motor windings or discharge area can lead to burnout. ![]() Some of these issues result from:Ĭompressor burnout can be attributed to the following: 1. Now work with us, and we’ll show you how to replace a compressor or clean a unit after experiencing a compressor burnout. In the same vein, a step by step guide to compressor replacement can help you remedy these problems – It will ensure that the replacement you’ve installed does not break down when you least expect. However, the repaired or replaced compressor could also fail after a few months if the source of the problem was not corrected properly.įor this reason, it is essential to know what can lead to compressor failure to ensure such problems are averted in the near future. With this guide, compressor replacement doesn’t have to ruin your businesses productivity. Refrigeration and Air-conditioning Technology, 3 rd Edition By: William C Whitman & William M.Your Step By Step Guide to Compressor ReplacementĪ failed compressor needs to be repaired or replaced to get things running smoothly. Prepare report and list all details and equipment parameters after work done. Start the system and keep it running as long as practical to circulate the refrigerant through the filter drier.Ĭonduct current reading on the compressor and on the fan motor.Ĭheck the discharge air temperature of the evaporator if cooling is evident. Make sure that suction and discharge pressure will be 60 to 69 psig and 250 to 275 psig. Let the system stand for a while and check the pressure gauge, if the reading falls, there is a leak.Ĭonduct system evacuation using a vacuum pump.Ĭharge the system with refrigerant as per refrigerant charging procedure. Do not pressurize any system above its working pressure as written on the label of the equipment. Isolate the compressor by front seating the suction and discharge valve of the compressor.Ĭharge the system with dry nitrogen until pressure reaches 150 psig. Conduct leak testing using standing pressure test procedure If you are installing old compressor, change the oil first with specified grade (either 3GS or 4GS). Install the new refrigerant compressor by either brazing the suction and discharge line to their corresponding connections or by using flare joint connection. Install the liquid line filter just before the metering device (expansion valve) to prevent contamination from restricting the refrigerant flow. This line may be purged toward the compressor suction line. ![]() Purge the Nitrogen through the liquid line toward the compressor.ĭisconnect the nitrogen after pushing off all contaminants on this point.Ĭonnect the nitrogen to the expansion device side of the liquid line. Without compressor in the system, you can safely use 250 psig for high pressure refrigerant systems.ĭisconnect the pipeline before the expansion valve device where a liquid line filter can be installed later. Do not exceed the system working pressure with nitrogen. Use dry nitrogen to push some of the contaminants out of the system by simply attaching the nitrogen regulator to one of the lines and allowing it to blow out the other. ![]() Remove the refrigerant gas from the system.ĭismantle the old compressor unit either by cutting the suction and discharge pipe or removing the flare connection. Make sure the availability of all tools and equipment’s necessary for replacing the refrigerant compressor like gas cylinder, gauge manifold, brazing set, brazing rod, flaring tool, spanner, adjustable wrench, vacuum pump, clamp ammeter, screw driver, etc. It is also important to place a fire extinguisher near the working area during brazing works. Prior to the start of work, wear safety shoes, goggles and gloves. The Supervisor and the maintenance engineer shall assure the implementation of this maintenance procedure during the maintenance works. Refrigerant compressor is considered as the heart of the air-conditioning system therefore care should be taken during replacement works. Technician must be competent enough and has a complete background in Air-conditioning system maintenance to avoid any further damage on the equipment. It is the responsibility of the maintenance technician to replace the damage compressor either with a new one or a used but working compressor unit.
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