Compressor Service Procedure

1

CompressorServ i ce P rocedures

CompressorServ i ce P rocedures

All You Ever WantedTo Know AboutServicing Compressors,But Did Not KnowWhere To Find.

All You Ever WantedTo Know AboutServicing Compressors,But Did Not KnowWhere To Find.

© American Standard 1998© American Standard 1998

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Compressors

Subject Page

Compressor Fails to Start – Control Circuit – All ................................................................................................3Single Phase Compressors – Fails to Start – Motor Hums – All .......................................................................3

Single Phase Compressors – Fails to Start – Motor Doesn’t Hum – All ...........................................................3

3 Phase Compressor – Fails to Start – Motor Hums – All ............................................................................. ......4

3 Phase Compressor – Fails to Start – Motor Doesn’t Hum ...............................................................................4

Compressor Cycles on Internal Overload (I.O.L.) after Starting ...........................................................................5

Compressor Runs – Little or No Pumping ............................................................................................................6

Noisy compressor

Running .............................................................................................................................................................6

Starting And/Or Stopping .................................................................................................................................6

Scroll Functional Check ...........................................................................................................................................6

Compressor Power Supply – All ............................................................................................................................6

Scroll Power Interruptions ......................................................................................................................................7

Three Phase Power Supplies ..................................................................................................................................7

Run Capacitor(s)

Ohmmeter Test ..................................................................................................................................................7

Power Test .........................................................................................................................................................7

Metal-Cased Round Dual Capacitors ......................................................................................................................8

Start Capacitor – Checking a Start Capacitor Using the Ohmmeter .....................................................................8

Start Capacitor Relay ...............................................................................................................................................8

Motor Windings Continuity Test – Reciprocating

Ground Test .......................................................................................................................................................9

Single Phase with Internal Overload Protectors (I.O.L.) ........................................................................ .......10

3 Phase with Internal Overload Protectors (I.O.L.) ........................................................................................10

Single Phase with Internal Pilot Duty Thermostats (T.M.) ....................................................................... .....11

3 Phase with Internal Pilot Duty Thermostats (T.M.) .....................................................................................11

Hi Pot Testing (Scrolls) ...........................................................................................................................................12

Motor Windings Continuity Test – Reciprocating – 3 Phase Compressors withSolid State Motor Protection System (M.P.M.) ....................................................................................................12

Motor Protection Module Test – Robert Shaw – Reciprocating .......................................................................12

Motor Protection Module Test – Texas Instruments – Reciprocating ..............................................................13

Terminal Location – Protection Module ..............................................................................................................13

Checking Electrical Circuits – All .........................................................................................................................13

Important Start Up Procedure – Reciprocating ..................................................................................................14

Crankcase Heat – Reciprocating ..........................................................................................................................14

Crankcase Heat – Scroll ........................................................................................................................................14

Trickle Circuit Test – Used on Reciprocating Only ..............................................................................................14

Trickle Circuit Test ..................................................................................................................................................15

Compressor Replacement Procedure ...................................................................................................................15

Acid Formation in Compressors ...........................................................................................................................16

Acid Test Kits ..........................................................................................................................................................16

Liquid Line Driers ...................................................................................................................................................16

continued

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Compressors

Subject – continued Page

Suction Line Driers .................................................................................................................................................17

Discharging Refrigerant Systems .........................................................................................................................17

Recovering the Charge ..........................................................................................................................................17

Evacuation – Reason and Procedure ...................................................................................................................17

Refrigerant System Leaks

Equipment Necessary for Leak Testing .........................................................................................................18

To Check for Leaks ..........................................................................................................................................18

System Checkout After Leak Repair or Compressor Replacement .................................................................... 19

Notes of Interest .....................................................................................................................................................19

Compressor Servicing Notes to Remember ........................................................................................................19

Quick Troubleshooting List ....................................................................................................................................20

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Compressors

Compressor Fails to Start

Control Circuit – All

Check compressor contactor for energized position.

If compressor contactor is not energized, check voltageacross contactor coil.

If voltage is present, check contactor.

If no coil voltage is present, check control transformerand control fuse.

If transformer and fuse check good, jumper R to Y lowvoltage terminals or wires in the outdoor unit. If thecontactor energizes, the problem is in the room thermo-stat or connecting wiring.

If the contactor fails to energize when R to Y isjumpered, check all components connected in serieswith the compressor contactor coil. Identify compo-nents from the schematic diagram.

Single Phase Compressors

Fails to Start – Motor Hums – All

Turn room thermostat to off position.

Disconnect outdoor fan motor(s).

Measure supply voltage at the line side of the compres-sor contactor. Supply voltage should be within 10% ofequipment nameplate rating.

Connect a voltmeter to the load side of the contactor.

Observe the voltmeter. Manually engage the contactormomentarily. Voltage should not drop more than 10%below no-load voltage. If the voltage drops more than10%, check circuit wire size, length, and terminals forloose connections.

If the motor hums but fails to start, check run cap-acitor(s). Check start capacitor(s) if used.

Check start winding fuse if used.

Reciprocating

If the equipment does not use a start capacitor andrelay, be sure head and suction pressures are equalized.Equipment utilizing expansion valves may require along time period to equalize. Single-phase compres-sors without start capacitors will not start against apressure differential.

If the equipment does not use a start capacitor and re-lay, temporarily connect a start capacitor (CPT0091) inparallel with the run capacitor. Manually engage thecompressor contactor momentarily.

Scroll

Due to the inherent nature of the Alliance Scroll, theinternal pressures are always equalized even if systempressures are not. This allows excellent low voltagestartability.

Start component may be required for special situations.

CAUTION – Do not apply power for more than 5 sec-onds. Start capacitors are designed for intermittentduty only and could rupture if power is applied for ex-tended time periods.

If the compressor starts, remove power immediately.Disconnect the start capacitor. Try to restart the com-pressor. If the compressor starts, restore equipment tooperating condition. Operate the equipment until nor-mal operating pressures are reached. Measure thecompressor current draw in the compressor commonline. If the current draw is equal to or less than equip-ment nameplate amps, the servicer must use his expe-rience and judgment to determine whether theequipment will continue to start or a start kit is re-quired.

If the compressor draws excessive current at operatingconditions, condemn the compressor.

If the compressor failed to start with the start capacitorconnected, condemn the compressor.

Single Phase Compressors

Fails to Start – Motor Doesn’t Hum – All



Connect a voltmeter to the load side of the compressorcontactor.

Manually engage the contactor momentarily.

If adequate supply voltage is present and the compres-sor motor does not hum when power is applied, dis-connect all power.

Determine from the wiring diagram what type of over-load protection system is used.

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Compressors

If the compressor utilizes an internal line break protec-tor, it will be identified on the wiring diagram as I.O.L.Check I.O.L.

If the compressor utilizes and internal pilot duty protec-tor, it will be identified on the wiring diagram as T.M.Check T.M.

If the compressor utilizes external line breakprotector(s), they will be identified on the wiring dia-gram as XOL and XOLS. Check XOL and XOLS.

Compressors utilizing T.M. also utilize XOL and XOLS.

If protectors check good, measure compressor resis-tance at the compressor terminals.

Reciprocating

If compressor has 5 terminals, check for continuitybetween the 3 top terminals. An open reading betweenany of these terminals indicates an open winding. Con-demn the compressor. The 2 lower terminals are con-nected to the internal pilot duty overload (TM) and willnot measure continuity to the top 3 terminals.

Check all top 3 terminals to the suction line or dischargeline for grounds. If the ohmmeter indicates less than50,000 ohms, condemn the compressor.

Reciprocating and Scroll

If compressor has 3 terminals, check for continuitybetween the 2 bottom terminals (start to run). If anopen circuit is measured, an open winding is indicated.Condemn the compressor. If continuity is measuredbetween the start and run terminals, check from thestart terminal to the top terminal (common), and fromthe run terminal to common. If both start and run ter-minals are open to the common terminal, the internaloverload (I.O.L.) is open. Allow adequate time for theI.O.L. to reset before condemning the compressor.

If either run to common or start to common measuresan open circuit and the other winding measures conti-nuity, condemn the compressor for open winding.

Check all 3 terminals to the suction line or dischargeline for grounds. If the ohmmeter indicates less than50,000 ohms, condemn the compressor.

3 Phase Compressors

Fails to Start – Motor Hums – All



Measure phase to phase voltage at the line side of thecompressor contactor. Supply voltage should be within10% of equipment nameplate rating.

Connect a voltmeter across 1 phase on the load side ofthe contactor.

Observe the voltmeter. Manually engage the contactormomentarily. Voltage should not drop more than 10%below no-load voltage. If the voltage drops more than10% below no-load voltage, check circuit wire size andlength and check terminals for loose connections.

Check each phase.

Determine from the wiring diagram what type overloadprotection system is used.

If the compressor utilizes external protectors, they willbe identified on the wiring diagram as XOL. CheckXOL.

If the compressor motor hums when power is applied,line voltage on all 3 phases check good, all XOL protec-tors check good and voltage is present at all 3 compres-sor winding terminals, then condemn the compressor.

3 Phase Compressors

Fails to Start – Motor Doesn’t Hum


Disconnect outdoor fan(s).

Manually engage the compressor contactor and mea-sure phase to phase voltage at the load side of the com-pressor contactor. Phase to phase voltage should bewithin 10% of equipment nameplate rating.

If the supply voltage checks good and the compressordoes not hum when power is applied, determine fromthe wiring diagram what type overload protection sys-tem is used.

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Compressors

Reciprocating

If the compressor has 5 terminals and the protec-tors are identified as XOL, check the XOL protectors.

If the XOL protectors check good, phase to phase volt-age checks good, supply voltage is present at the top 3compressor terminals and the compressor fails to hum,an open winding is indicated.

Disconnect power and remove wiring from compressorterminals. Verify open winding by measuring continu-ity between the top 3 compressor terminals. If an opencircuit is measured between any of the top 3 compres-sor terminals, condemn the compressor. The lower 2terminals are connected to the internal pilot duty pro-tector and will not measure continuity to the top 3 ter-minals.

Reciprocating and Scroll

If the compressor has 3 terminals and the overloadprotector is identified as I.O.L. on the wiring diagram,the protection system is an internal line break system.

If the compressor fails to hum when power is applied toan I.O.L. protected compressor, the I.O.L. is open. Al-low adequate time for the I.O.L. to reset before con-demning the compressor.

To verify an open winding or defective I.O.L., permit atleast one hour for the compressor to cool. If the I.O.L. isopen, an open circuit between all three compressor ter-minals will be measured with an ohmmeter. An opencircuit measurement with an ohmmeter between any 2or the 3 compressor terminals indicates an open wind-ing. Condemn the compressor.

Reciprocating

If the compressor has 3 power terminals and 3protector terminals, the compressor is protected by asolid state protection system.

When power is applied by manually engaging thecontactor, and the compressor fails to hum, an openwinding is indicated.

Remove the leads from the upper 3 compressor termi-nals and verify open windings. An open circuit mea-sured with an ohmmeter between any 2 of the 3 upperterminals verifies an open winding. Condemn the com-pressor.

Compressor Cycles on InternalOverload (I.O.L.) After Starting

Listed below are various conditions or problems whichmay cause a compressor to cycle on the internal over-load.

1. HIGH HEAD AND HIGH SUCTION PRESSURE

(a) Dirty Condensor Coils

(b) Overcharge

(c) Restricted Air to Condenser

(d) Filter Dirty (Heating Mode)

(e) Lack of ID Airflow (Heating Mode)

(f) Defective Condenser Fan Motor/Capacitor

1. Outdoor (Cooling Mode)

2. Indoor (Heating Mode)

(g) Recirculation of Condenser Air

(h) Excessive Airflow through Evaporator(Cooling Mode)

(i) Heating Operation Above 65°F OD Ambient.

2. DEFECTIVE RUN/START CAPACITORS

3. IMPROPER OR DEFECTIVE START RELAY (CSR)

4. HIGH LINE VOLTAGE (TOLERANCE IS VOLTAGERATING PLUS OR MINUS 10%)

5. HIGH SUPERHEAT

(a) Low Refrigerant Charge

(b) Liquid Side Restriction – Drier, TXV, QuickAttach Fittings

(c) Leaking Switch-Over Valve

(d) Leaking Internal Pressure Relief Valve (IPR)

(e) Low Side Restriction - Metering Device,Distributor Tubes, Coils, Quick Attach Fittings

(f) Excessive Airflow through Evaporator(Cooling Mode)

(g) High Superheat During Defrost

6. TIGHT BEARINGS (I.O.L. WILL TRIP AFTERCOMPRESSOR STARTS)

7. LOW LINE VOLTAGE (TOLERANCE IS VOLTAGERATING PLUS OR MINUS 10%)

8. OPEN START WINDINGS

9. SHORTED WINDINGS

10. Defective internal overload (I.O.L.)

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Compressors

Scrolls

All of the above conditions apply in addition to:

High Discharge temperatures

(a) Loss of charge

(b) Extremely high compression ratio caused byan evap fan failure.

CAUTION – During these conditions, compressor dometemperatures can exceed 400°F.

Compressor Runs

Little Or No Pumping

High suction pressure and low head pressure are symp-toms of a poor pumping compressor, but can also besymptoms of other system component failure.

Heat Pump – Check Check Valves

Heat Pump – Check Reversing Valve

Check Expansion Valve(s)

Check Internal Pressure Relief Valve (IPR)

If equipment has service valves, perform pumpdown test.

If system components check good and compressor willnot pull suction pressure down, condemn the compres-sor.

Scroll

All Symptoms above plus: 3 phase compressors, whenwired incorrectly, will run in reverse. Due to the inher-ent nature of the Scroll, no pumping will occur. Com-pressor damage will occur if operation is continued inreverse rotation.

Noisy Compressor – Running

Check equipment for level installation. Disable outdoorfan(s); observe compressor noise without fan(s) to besure noise is in the compressor.

Check operating pressures per charts attached to theequipment - (fans operating). Excessive pressures willincrease running noise.

If noise is isolated to the compressor, change the com-pressor.

Scroll

All symptoms above plus 3 phase compressor, whenwired incorrectly, will run in reverse. Due to the inher-

ent nature of the scroll, excessive noise indicates re-verse operation. Compressor damage will occur if op-eration is continued in reverse rotation.

Noisy Compressor

Starting And/Or Stopping – All

Check equipment for level installation.

Check compressor for level installation in equipmentbase pan.

Check compressor mounting grommets and bolts.

Check refrigerant tubing clearance to equipment cabi-net, to adjacent tubing, fan motor(s).

Check operating pressures per charts attached tothe equipment. Excessive head pressure can causestopping noise.

Be sure the noise is in the compressor. Noise causedby reversing valve operation or rapid pressure balanc-ing expansion valve can appear as compressor noise.

If noise level is unacceptable, change the compressor.

Scroll Functional Check

Alliance Scrolls do not have internal suction valves ordischarge valves that can be damaged. Do not close offthe suction service valve to check how low the suctionpressure will drop. This type of testing could damagethe compressor.

To troubleshoot the compressor:

1. Check for proper voltage to the unit.

2. If compressor will not run, check for an opensafety device and allow time to reset if open.

3. Remove terminal wire plug for compressor andmeasure winding resistance. If open, allow upto 24 hours to reset, with power removed.

4. Check for proper refrigerant charge.

5. Check for system restriction.

Compressor Power Supply – All

Supply voltage to air conditioning and heating equip-ment should be measured at the load side of thecontactor, relay or switch that supplies power to theequipment – not at a main or auxiliary disconnect.

Equipment should be operating at normal load condi-tions, or attempting to start, when making voltage mea-surements.

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Compressors

Supply voltage should be within 10% of the equipmentnameplate rating. Equipment is not generally limited to10% of nameplate rating, but may require special con-sideration or application limitations. Consult your localField Service Representative for limits.

Scroll Power Interruptions

Brief power interruption (less than 1⁄2 second) can resultin powered reverse rotation of single phase AllianceScroll compressors. This occurs as a result of highpressure discharge gas expanding backward throughthe scrolls at power interruption. This causes the scrollto orbit in reverse rotation. If power is reapplied whilethe reverse rotation is occurring, the compressor maycontinue to run in reverse rotation until the internal pro-tector trips.

The symptoms of reverse rotation are lack of pressuredifferential and the compressor will be unusually noisy.Once the internal protector trips and resets, the com-pressor will start and run normally.

Three Phase Power Supplies

Phase to phase voltages should be within 2.5% of theaverage phase to phase voltage.

Example: Phase 1 = 485 Volts

Phase 2 = 477 Volts

Phase 3 = 487 Volts

Total = 1449 Volts

Average = 1449/3 = 483 Volts

Run Capacitor(s)

Ohmmeter Test – Continuous Duty OilFilled Capacitors

1. Connect capacitor to A.C. supply that does not ex-ceed the capacitor voltage rating.

2. Measure and record the applied A.C. voltage.

3. Measure and record amp. Draw of the capacitor.

4. On 60 HZ MFD. =

On 50 HZ MFD. =

5. Example: Capacitor draws 3 amps at 230 volts.(60HZ) Indicated capacitor value is 33 MFD.

Calculated value should be within10% of value stamped on capacitor.

2. If capacitor has a discharge resistor connectedbetween terminals, disconnect resistor from oneterminal.

3. Set ohmmeter to RX1000 or high scale.

4. Short meter leads and adjust ohmmeter to Zero.

5. Observe meter scale and touch meter leads tocapacitor terminals.

6. Good Capacitor – Meter pointer will deflect upscaletoward zero ohms reading and slowly return down-scale to infinity ohms reading.

7. Open Capacitor – Meter pointer does not movefrom infinity ohms reading.

8. Shorted Capacitor – Meter pointer will indicate adefinite ohm reading less than infinity.

Run Capacitor(s)

Power Test – Continuous Duty Oil FilledCapacitors

CAUTION – DO NOT PERFORM THIS TEST ON START

CAPACITORS

Amp. Draw X 2650Applied A.C. Volts

Amp. Draw X 3185Applied voltage

1. Disconnect capacitor from power circuits.

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Compressors

Metal-Cased Round Dual Capacitors

The round metal-cased dual capacitors with stampedmarking of “C”, “HERM” and “FAN” on the top surfaceare generally used in an air conditioner in a conven-tional circuit using “C” to “HERM” in the compressorcircuit with “C” to “FAN” in the fan motor circuit. Thefan portion of the capacitor is usually not larger than 15MFD in capacity.

Some of these capacitors may have much larger ratingson the terminal labeled “FAN” and are applied in theTrickle circuit of the compressor to warm the compres-sor windings during the off cycle. The diagram illus-trates this use. The capacitors may be rated 20/20 MFDor 30/30 MFD instead of the more common 20/4 MFD,for example. The presence of a bleed resistor, whenused, is an indication of the “HERM” portion of the ca-pacitor. This resistor is there for your protection. Donot remove it!

Start Capacitor

Checking a Start Capacitor Usingthe Ohmmeter

1. Disconnect capacitor from power circuits.

2. Set ohmmeter to RX10 or RX 100 scale.


4. Observe meter scale and touch meter leads tocapacitor terminals

5. Good Capacitor – Meter pointer will deflect upscaletoward zero ohms reading. Pointer will indicateohm value of the discharge resistor.

6. Open Capacitor – Meter pointer will not swing up-scale near zero ohms reading. Pointer will indicateohm value of the discharge resistor.

7. Shorted Capacitor – Pointer will indicate a definiteohm reading between zero ohms and less than theohm value of the discharge resistor.

CAUTION – DO NOT PERFORM POWER TEST ON

START CAPACITORS.

Start Capacitor Relay

This relay may be mounted in any position. However,the relay is calibrated in the position shown. The pickup and drop out voltage will be slightly different whenmounted in other positions.

Start relay (RLY 1097) should be used as a replacementfor all American Standard single-phase reciprocatingcompressors that require start components. Relayswith a different pick up voltage rating should notbe used.

Start relay (RLY 02227) must be used as a replacementfor the Alliance Scroll Compressor.

HE

RM

FAN

C

SECTIONCOPPER TAB

PANEL

DFC

CAPACITOR

CPR

S

R

FANMOTOR

S

C

R

C

IOLMS-2

MS-1

F

C

H

OR

BR

/RD

BR/RD

YL/BR

RD

BROWN

PURPLE

BLA

CK

BL/WH

OR BK/BL

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Compressors

Relay Coil Checkout

Disconnect power to unit.

Remove wires from terminals #2 and #5.

Check for continuity between terminals #2 and #5.If open circuit, replace relay. If closed circuit, checkcontacts.

Relay Contacts Checkout

Disconnect power to unit.

Remove wires from terminals #1 and #2.

Check for continuity between terminals #1 and #2. Ifopen circuit, replace relay. If closed circuit, check relayvisually.

Visual Checkout

If coil and contacts check out OK, remove relay coverand visually inspect contacts and coil for signs of pittedor burned contacts and for burned or charred wiring. Ifany of these are found, replace relay.

Motor Winding Ground Test

MAX. ST HOT (40°C) COLD DROP CONTINOUSWINDING AMPS. VOLTAGE PICK UP PICK UP OUT COIL

@ 230 V RATING VOLTS VOLTS VOLTS RATING (40 °C)

50 A 230 V 190 – 200 150 – 175 60 – 110 42060

1 0



50 A 230 V 260 – 280 239 – 268 60 – 135 50260

1 0



35 A 230 V 260 – 280 239 – 268 60 – 135 50260

1 0

Reciprocating (Part No. RLY 1097)

Reciprocating – Dual Compressor Model Units(Part No. RLY 1869)

1. Disconnect all electrical leads from compressor ter-minals.

2. Set an ohmmeter to the highest scale (R X 10,000or R X 100,000).


4. Check from each compressor terminal to the com-pressor case or equipment ground. Be sure theohmmeter probe is touching a bare metal ground.

5. Any definite resistance measurement of less than50,000 ohms between any compressor terminaland ground indicates a grounded motor.

6. A grounded motor normally has operated at ex-tremely high temperatures prior to failure. It is ab-solutely necessary to conduct an acid test on thefailed compressor oil before the replacement com-pressor is installed.

Scroll Compressor (Part No. RLY 0227)

Mounting shown above.

Mounting shown below.

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Compressors

Motor Windings Continuity Test

Single Phase Compressors with InternalOverload Protectors (I.O.L.)

Motor Windings Continuity Test – All

3 Phase Compressors with InternalOverload Protectors (I.O.L.)

1. Disconnect all electrical leads from the compressorterminals.

2. Set an ohmmeter to the RX1 scale. Short meterleads and adjust ohmmeter to Zero.

3. Measure for continuity between the start and runterminals.

(a) A continuity reading indicates that the motorwindings are intact. Proceed to step 4.

(b) An infinite reading indicates an open winding.The compressor must be replaced.

4. If continuity is measured between start and run ter-minals, then measure between start and common,then measure between run and common. An infi-nite resistance (open) measurement between com-mon and both start and run terminals indicates atripped or open I.O.L. Allow adequate time forI.O.L. to reset before condemning the compressor.Up to two hours may be required if the compressoris extremely hot.

5. Internal overload protectors are identified by I.O.L.designation on the equipment wiring diagram.


2. Set an ohmmeter to the RX1 Scale. Short meterleads and adjust ohmmeter to Zero.

3. Measure for continuity between compressor termi-nals. Resistance should be the same ohm valuebetween all terminals.

4. If continuity is measured between any two termi-nals and an infinite resistance (open) to the remain-ing terminal, the motor is open and the compressormust be replaced.

5. If an open circuit is measured between all termi-nals, the I.O.L. is tripped or open. Allow adequatetime for the I.O.L. to reset before condemning thecompressor. Up to two hours may be required ifthe compressor is extremely hot.

6. Internal overload protectors are identified by I.O.L.designation on the equipment wiring diagram.

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Compressors

Motor Windings Continuity Test –Reciprocating

3 Phase Compressors With Internal Pilot DutyThermostats (T.M.)


Single Phase Compressors with InternalPilot Duty Thermostats (T.M.)



3. Measure for continuity between the common andstart terminals. Measure for continuity between thecommon and run terminals. An infinite reading(open) between either common and start or com-mon and run indicates an open winding. The com-pressor must be replaced.

4. Measure for internal thermostat (T.M.) continuitybetween the two lower compressor terminals. T.M.should read continuity (zero ohms). An infinitereading (open) is measured across T.M.; the ther-mostat is tripped or open. Allow adequate time forT.M. to reset before condemning the compressor.Up to two hours may be required if the compressoris extremely hot.

5. Internal thermostats are identified by T.M. designa-tion on the equipment wiring diagram.



3. Measure for continuity between the upper threecompressor terminals.

(a) An infinite (open) reading between any twoterminals or all terminals indicated an openwinding. Replace the compressor.

(b) 3 phase compressors with good windingsshould measure the same resistance betweenterminals.

4. Measure for internal thermostat (T.M.) continuitybetween the two lower compressor terminals. T.M.should measure continuity (zero ohms). An infinite(open) reading across T.M. indicates that T.M. istripped or open. Allow adequate time for T.M. toreset. Up to two hours may be required to T.M. toreset if the compressor is extremely hot.

5. Internal thermostats are identified by T.M. designa-tion on the equipment wiring diagram.

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Compressors

Hi Pot Testing

Scrolls

Alliance Scrolls are configured with the motor downand the pumping components at the top of the shell.As a result, the motor can be immersed in refrigerantto a greater extent than the reciprocating compressorwhen liquid refrigerant is in the shell. When theAlliance Scroll compressors are hi pot tested withliquid refrigerant in the shell, higher levels of leakscould be observed. The level of current leakage doesnot represent any safety issues. Brief operation ofthe compressor will redistribute the refrigerant andshould give normal hi pot readings.


3 Phase Compressors with Solid State MotorProtection System (M.P.M.)

1. Disconnect electrical leads from compressor motoronly (upper 3 terminals).


3. Check for continuity between the compressor ter-minals.

(a) An infinite (open) reading between any two orall compressor motor terminals indicates anopen winding. Replace the compressor.

(b) 3 phase compressor motors should read thesame resistance between all terminals.

4. If motor windings check good, proceed with motorprotection module system checkout describedbelow.

Motor Protection Module Test –Robert Shaw Type – Reciprocating

If compressor does not operate, proceed as follows:

1. Jumper control circuit contacts and energize unitfor a maximum of five seconds.

(b) If (MS) picks up but compressor does not run,de-energize immediately.

1. Check all terminals in power and control cir-cuits. Repair loose connections and re-en-ergize (5 sec. Max.). If compressor fails torun, de-energize.

2. Remove and isolate power leads at com-pressor. Energize and check 3 phase volt-age. If voltage is correct on all phases,compressor has internal problem and mustbe replaced.

2. If compressor operates with jumper, check eachcomponent of solid state protection system for pos-sible malfunction as follows:

Transformer (MPT)

(a) Primary side must be connected to line side ofcontactor.

(b) Remove secondary leads (S, CT, S) from mod-ule and measure voltage between each X andCT. The two voltages should be the same, ap-proximately 12 volts. If not, MT is defectiveand must be replaced.

(a) If contactor (MS) does not pick up, problem isin the controls external to compressor terminalbox.

MPMSEN 2

SEN 1

CS

CTSC

ON

TRO

L

CIR

CU

IT

Sensors – Remove sensor leads (C, Sensor 1, Sensor 2)from module. Measure resistance between C and eachsensor using a battery powered volt-ohm meter.*

*WARNING: DO NOT USE A VOLT-OHM METER

WHICH APPLIES MORE THAN 3 V DC TO CHECK SEN-

SORS OR SENSOR FUSES. BOTH ARE EASILY DAM-

AGED AND NO ATTEMPT SHOULD BE MADE TO

CHECK CONTINUITY BY ANY OTHER MEANS.

(a) Resistance should measure between 60 and150 ohms. If resistance is greater than 90ohms, motor is too hot to permit operation. Al-low to cool until sensor resistance is less than90 ohms.

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(b) If sensor resistance is greater than 150 ohms:

1. Check sensor fuses. Spare fuses are tapedin terminal box. Use only MKB 1/16 ampfuses.

2. If fuses are okay, remove terminal blockfrom small terminal and check sensors ac-cording to diagram below. If either sensorhas a resistance greater than 150 ohms,compressor must be replaced.

Module (MPM) – If sensor fuses, sensors and trans-former are not defective, module must be replaced.

Motor Protection Module Test –Texas Instrument Type – Reciprocating

This compressor overload system consists of a solidstate module located in the compressor terminal boxand solid state sensors buried in the compressor motorwindings.

The sensors are connected to the two small terminalslocated at the lower part of the compressor terminalbox.

If the sensors in the motor windings sense a motortemperature that is too high for safe motor operation,they will cause the electronic protection module toopen a normally closed switch circuit between terminalM1 and M2 of the module. When this switch circuitopens, power to the compressor motor starter coil isinterrupted, de-energizing the motor starter.

Terminal Location –Protection Module

If the compressor contactor fails to energize, jumperterminals M1 and M2 of the module. Do not jumper formore than 5 seconds. If compressor contactor still failsto energize, the problem is in the controls external tothe compressor terminal box. If the compressorcontactor energizes when module terminals M1 and M2are jumpered, check voltage at terminals T1 and T2 onthe module. Voltage should be between 21 and 30 voltsA.C.

If T1 and T2 voltage is present, disconnect the motorsensor leads from module terminals S and S1. Mea-sure resistance of the motor sensors with a batterypowered ohmmeter. Sensors will be damaged if ex-posed to high voltage. Resistance should be between2,000 and 45,000 ohms. If resistance is above 10,000ohms the motor is too hot to permit operation. Allowmotor to cool until sensor resistance is below 10,500ohms before operating the compressor.

If sensor resistance is above 45,000 ohms sensors aredamaged and the compressor must be replaced.

If sensor resistance and supply voltage are correct andthe motor contactor will not energize, the module is de-fective.

Compressor motor overheating can be caused by:

(a) Shorted or grounded motor windings

(b) Defective run capacitors

(c) Defective start capacitors or start relay

(d) Low line voltage

(e) Low refrigerant charge

(f) Dirty condenser or excessive head pressuredue to refrigerant overcharge.

Checking Electrical Circuits – All

Checking compressor electrical circuits requires the useof the equipment wiring diagram to locate and trouble-shoot components in the circuits.

Wiring diagrams are attached to control box covers orpower panel covers on all equipment.

The wiring diagram shows physical location of compo-nents, terminal connections, and physical wiring layout.

The schematic portion of the diagram shows electricalconnections to components necessary to operate eachelectrical circuit in the system.

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When a component fails to operate, the schematicshould be used to identify all other components thatcomplete the circuit. The wiring diagram should beused to physically locate the components.

Wire color codes are shown on wiring diagrams andschematics to assist in circuit tracing.

The wiring diagram identifies compressor terminalsand internal overload protector terminals.

Before condemning a compressor for internal electricalfailure, measure resistance between all terminals andmeasure each terminal to ground.

Important Start Up Procedure –Reciprocating

The procedure listed below should be followed at initialstart-up and at any time the power has been removedfor 12 hours or more.

To prevent compressor damage which may result fromthe presence of liquid refrigerant in the crankcase:

1. Make certain the room thermostat is on “off” posi-tion. (The compressor is not to operate.)

2. Apply power by closing the system disconnectswitch. This energizes the compressor heaterwhich evaporates the liquid refrigerant in the crank-case. Allow 30 minutes for each pound of refriger-ant in the system as noted on the unit nameplate.

3. After proper elapsed time, the thermostat may beset to operate the compressor.

4. Except as required for safety while servicing – DONOT OPEN SYSTEM DISCONNECT SWITCH.

Crankcase Heat – Reciprocating

A major cause for stuck bearings is failure of the com-pressor crankcase heater. Without a crankcase heaterin operation, liquid refrigerant will accumulate in thecrankcase, reducing the lubricating qualities of the oilby dilution and cause the oil to foam and leave thecompressor at start-up. The crankcase heater shouldalways be checked when replacing a compressor.

Compressor mechanical failures are caused by brokenvalves, stuck bearings, broken springs or broken inter-nal tubing. Each type of failure can usually be attrib-uted to specific system faults that caused the failure.When a compressor fails, the system should be exam-

ined to determine whether a system fault contributed tothe compressor failure, and may cause the replacementcompressor to fail.

Crankcase Heat – Scroll

Due to the Alliance Scroll’s inherent ability to handleliquid refrigerant in flooded conditions, crankcase heatis only used in high system charge and other uniquesituations.

Trickle Circuits – Used onReciprocating Only

The trickle circuit serves the same purpose as a crank-case heater, preventing accumulation of refrigerant inthe compressor crankcase during the compressor offcycle.

The trickle circuit permits a small amount of current toflow through the compressor run capacitor and thecompressor start winding when the compressorcontactor is de-energized. The contactor interruptspower to the compressor run winding.

The capacitor used in the trickle circuit has a resistorconnected across its terminals. The only purpose of theresistor is to serve as a capacitor discharge path whenpower to the unit is turned off.

Replacement capacitors in units utilizing trickle circuitsmust be the same microfarad rating or circuit malfunc-tion may occur. Nuisance tripping of compressor over-load protectors is likely.

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Only factory supplied start kits should be used with

trickle circuit units. Field wired start kits might causestart circuit malfunctions.

Compressor Replacement Procedure

If the following replacement procedure is performed,step by step, minimum time will be required forchange-out:

1. Recover Refrigerant charge using an approved re-covery system.

NOTE: SCROLL ONLY

If the refrigerant charge is removed from the highside only, it is possible for the scrolls to seal pre-venting pressure equalization through the com-pressor. This may leave the low side shell andsuction line tubing pressurized. To prevent this oc-currence, remove refrigerant from both high andlow sides of the unit.

2. While charge is being recovered, remove panelsand components necessary for compressor access.Remove compressor cover (if used) and compres-sor hold down bolts. Remove wiring from com-pressor terminals. Uncrate replacementcompressor. Set up and start vacuum pump on selfpull down. Check indoor unit air filters.

3. When high and low side pressures reach 0 psig,loosen compressor rotolock fittings. Remove thefailed compressor from the equipment. Take oilsample from failed compressor and perform acidtest. Install rotolock caps from replacement com-pressor on failed compressor. Remove existingliquid line drier(s). Replace with new drier(s). Setreplacement compressor in place. Tighten roto-locks. Install permanent suction line drier if acidtest indicates acid system. Connect vacuum pumpto equipment and begin evacuation.

4. While evacuating system, install compressor holddown bolts. Connect wiring to compressor termi-nals. Replace compressor cover (if used). Replacecomponents and panels removed for compressoraccess. Pack failed compressor in replacementcompressor shipping box. Locate charging chartattached to equipment.

5. When acceptable vacuum is reached, shut offcharging manifold valves. Do not apply power to

compressor under vacuum. Damage could occur.

Remove vacuum pump. Connect the center mani-fold hose to a charging cylinder. Purge the hosewith refrigerant. Open the high side manifold valveand charge liquid refrigerant into the high side. Donot charge liquid into the low side. Leave low side

Trickle Circuit Test

Turn the unit off at the room thermostat. Leave powersupply to outdoor unit energized.

Connect a clamp on ammeter to one of the lines sup-plying the outdoor unit. The ammeter should indicate 2to 4 amps with the outdoor unit off.

The current draw of the trickle circuit is not indicative ofpower consumed or dissipated by the circuit. Actualpower consumed by the circuit is 45 to 65 watts.

CAUTION – Always disconnect power to the unit beforeremoving unit power panel covers. The compressorcontactor on trickle circuit units interrupts only one linefrom the power supply.

If trickle circuit units nuisance-trip compressor internalmotor protector during the off cycle, check the micro-farad rating of the trickle capacitor against proper ratingshown on the unit wiring diagram. The microfarad rat-ing shown on the wiring diagram must be used. Checkfor mis-wiring if field wired start kit has been installed.

CPR

S

R

FANMOTOR

S

C R

C

IOLMS-2

MS-1

F

BR

/RD

BR/RD

PURPLE BLACK

OR BK/BLCH

CR-A

CR-BRD

BROWN

CF

RD

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manifold valve closed. Permit liquid refrigerant tocharge into the high side for 2 to 3 minutes. Closethe high side manifold valve. Allow time for highand low side gauges to indicate equalized pressure.Start the equipment and observe pressure readingsfor proper system operation; balance the refriger-ant charge by charging refrigerant vapor into thesystem low side. Do not charge liquid into the lowside – compressor damage will result.

6. Use the correct charge balancing method for thetype flow control used in the system.

Acid Formation in Compressors

Acids in hermetic refrigera-tion systems are formedwhen refrigerant is exposedto high temperature andmoisture.

All refrigerant systems con-tain small amounts of mois-ture, since refrigerant cannotbe manufactured totallymoisture-free.

The purpose of refrigerantdriers is to trap and holdnormal amounts of moisturein the system.

The most common cause ofexcessive acid build-up isthe introduction of moisturein the system when the sys-tem is opened for serviceand proper evacuation is notdone.

A shorted or grounded hermetic compressor motor thatresults in a motor burnout causes the most severe acidcondition. Extremely high motor temperature duringthe burnout results in excessive acid build-up in thesystem. The severity of the acid build-up dependsupon the length of time that refrigerant is exposed tothe high temperature conditions before motor failureoccurs.

Excessive acids must be detected and removed fromthe system when compressor is replaced or the re-placement compressor will fail prematurely when ex-posed to the acid system.

Oil Samples

Oil is a scavenger for acids. If acids are present in thesystem, they can be detected by testing the compressoroil.

CAUTION – Highly acid oil can cause chemical burns toeyes and skin.

Obtain an oil sample from the suction port of the failedcompressor.

Use a clean glass or plastic container for the oil sample.

If the oil sample is badly discolored or contains solidparticles, clean up the system without further tests.

Conduct acid test on oil immediately upon removalfrom the compressor. Acids may be neutralized bychemical reaction with the container (including glasscontainers).

Acid Test Kits

Acid Test Kit (KIT 1021) is a one-time-use kit for con-ducting a single test.

The kit contains explicit instructions and precautions forconducting the acid test.

If the test indicates excessive acid, a permanent suctionline drier must be installed.

Reciprocating Also add Acid Away (CHM0077) perthe package instructions.

If the test indicated a safe acid level, it is not necessaryor recommended to install a permanent suction linedrier.

A new liquid line drier should always be installed when

replacing a compressor or refrigerant system compo-

nent.

Liquid Line Driers

Liquid line driers are vitally important to the life expect-ancy of air conditioning equipment. Their purpose is toremove moisture and neutralize acid build-up in the re-frigerant system.

Liquid line driers should be replaced if the refrigerantcharge is lost due to leaks, when a compressor is re-placed, or when the refrigerant must be recovered forrepairs.

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Liquid line driers should never be oversized, since sys-tem refrigerant charge will be increased to accommo-date the drier. Excessive refrigerant charge can causecompressor liquid slugging at start-up.

Heat pump equipment may contain one or two liquidline driers. A check valve arrangement ensures that liq-uid flow through the driers is in the same direction re-gardless of flow direction in the liquid line.

Replacement driers in heat pump equipment must belocated in the same physical location as the originalequipment drier.

Do not use commercially available 2-way driers adver-

tised for use in the liquid line outside the heat pump

equipment cabinet.

Replacement driers in straight cooling equipment maybe installed in the liquid line outside the equipmentcabinet only if the existing defective drier is removed

from the refrigerant circuit and replaced by refrigerant

pipe.

Note the flow direction arrow or “in” — “out” markingon the original equipment driers. Replacement drier(s)must be installed in the same flow direction.

Suction Line Driers

The suction line drier must be installed in any systemthat has been established as a “burn-out.”

The suction line drier must be permanently installed inthe suction line as near to the compressor as is pos-sible.

On heat pump units, the suction line drier must be in-stalled between the switchover valve and compressor.

Discharging Refrigerant Systems

Refrigerant should never be discharged into the atmo-sphere. Proper recovery techniques must be followedin all service procedures.

Refrigerant may contain acids harmful to eyes, skin,clothing, pets, shrubs, and flowers and has beenproven harmful to the ozone layer.

Always wear protective clothing, glasses or face maskwhen recovering refrigerant.

Recovering the Charge

Connect the charging manifold center fitting to a hoseor pipe that is attached to a certified recovery device.Follow the instructions for the device you are using torecover and store the refrigerant.

Evacuation

1. Proper evacuation of a refrigerant system aftercompressor replacement, leak repair or any otherreason for recovering the refrigerant is absolutelynecessary if the system is expected to maintain along life expectancy with good reliability.

2. Purging a system with refrigerant is not adequateto maintain good reliability and not permitted.

3. Replacement of liquid line driers after compressorreplacement or leak repair is imperative for goodreliability.

4. The presence of air, moisture or other foreign mate-rials in a refrigerant system will result in poor sys-tem performance and reduced life expectancy.

5. High vacuum measurements require the use of avacuum micron gauge. Manifold pressure gaugesare not capable of measuring high vacuum.

Evacuation Procedure

The purpose of evacuating a refrigerant system is to re-move moisture and foreign gases from the system.

Moisture in an operating refrigerant system chemicallycombines with refrigerants, forming acids that damageor destroy refrigerant system components, particularlyhermetic compressor motors.

Foreign gases such as air, hydrogen or nitrogen in therefrigerant system are non-condensable at operatingpressures and will cause elevated head pressures anderratic operation of flow controls.

To adequately evacuate a system, a high vacuum pumpcapable of 50 micron pull down is required. (RobinairNo. 15001, 15021 or equiv.). To properly measure ahigh vacuum, a thermocouple vacuum gauge is re-quired. (Robinair No. 14010 or equiv.). Manifoldgauges are not adequate for high vacuum measure-ments.

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Charging manifold used for evacuation must be ingood condition. Hoses must be leak-proof and nolonger than 48 inches. Long hoses with small internaldiameter will not permit adequate vacuum pull down.

CAUTION – Close vacuum pump shut-off valve andmanifold valves before stopping the vacuum pump, oroil from the pump may flow back into the refrigerantsystem, unless an oil trap is used.

Remove the manifold center hose from the vacuumpump and connect the hose to a refrigerant cylinder.

Loosen the center hose fitting at the manifold end andpurge the hose with refrigerant. Release only theamount of charge necessary to purge the hose. Chargesystem with refrigerant.

Refrigerant System Leaks

Equipment Necessary for Leak Testing

Electronic type leak detectors

Halide torch leak detector

Soap solution

NOTE: Since both florescent leak detectors and dyesare considered additives to the refrigerant and oils, theyare not recommended for use.

To Check for Leaks

Connect a pressure gauge to the low side Schradervalve on unit cabinet, or pressure taps on refrigerantlines.

If the gauge registers a positive pressure, proceed withthe test.

If the gauge indicates the system is out of refrigerant,add sufficient charge to pressurize the system, thenproceed with the test.

Using an electronic leak detector (follow the directionsfurnished with the detector), check all joints, pressureswitch capillaries, etc., for leaks, or:

Using soap solution, dab solution on joints, etc., – tell-tale bubbles pinpoint the leak.

When using Refrigerant 22, you may also use a halidetorch. Check all joints, etc. A leak will show up as achange in the torch flame – a green flame indicates asmall leak – a rising brilliant blue flame indicates largerleak. Remember the alternative refrigerants, such asR410A, will not cause an indication with a halide torch,as they do not contain chlorine.

Connect a charging manifold to the pressure taps lo-cated on the equipment cabinet, refrigerant lines or ser-vice valve ports.

Install a shut-off valve at the vacuum pump inlet.

Connect a thermocouple vacuum gauge at the shut-offvalve outlet side with a tee that permits the gauge tomeasure system pressure with the shut-off valveclosed.

Connect the manifold center hose to the tee.

Close the vacuum pump shut-off valve.

Fully open the manifold valves.

Start the vacuum pump. Permit pump to pull down fora few minutes before opening the shut-off valve.

Slowly open the shut-off valve. Rapid evacuation startsmay foam the compressor oil or vacuum pump oil.

Evacuate until the vacuum gauge indicates 350 micronsor less.

Close the shut-off valve for one minute. If system pres-sure does not increase to more than 500 microns in oneminute, evacuation is adequate.

If system pressure increases to 500 microns in less thanone minute, continue evacuation.

Continue evacuation until system pressure rise from350 to 500 microns takes one minute or longer.

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Compressor Servicing Notes to Remember:

Dry nitrogen may be used to pressurize the system inlocating small leaks. Do not pressurize the systemabove 300 psig. Rupture of system components can re-sult.

Never pressurize a refrigerant system with compressed

oxygen. Oil and oxygen under pressure will explode.

System Checkout After Leak Repair orCompressor Replacement

1. Evacuate the system to the pressure outlined underevacuation procedures.

2. Pressurize the system with Refrigerant vapor.

3. Leak check repaired joints, rotolock couplings,quick attach couplings, etc.

4. Check air filters, fans, blower wheels, and coil sur-faces for cleanliness prior to system charging.

5. Check air registers and grilles to be sure that theyare open and unobstructed.

6. Start the equipment and charge with refrigerant perthe charging instructions attached to the equip-ment. An accurate refrigerant charge is an absolutemust for good system reliability and efficient opera-tion.

7. After system charging has been completed, checkhead and suction pressures. Compare pressures to“normal operating characteristics” charts attachedto the equipment.

8. COOLING EQUIPMENT – Check thermostat for:

(a) Fan only operation

(b) Cooling operation

9. HEAT PUMP EQUIPMENT – Check thermostat for:

(a) Fan only operation

(b) Cooling operation

(c) Heating first stage (heat pump only)

(d) Heating second stage (heat pump plus resis-tance heat)

(e) Emergency Heat – Resistance heaters only

Notes of Interest

1. Bleed Resistor is always across CR-A.

2. Normally the “Fan” Terminal (if it is actually for fan)will not exceed 15 MFD.

3. Normally the “Fan” Rating will be lowest MFD.

4. There are capacitors rated at 20/20 and 30/30 MFD.

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Quick Troubleshooting List(DETAILS IN PROCEDURE)

COMPRESSOR WON’T RUN — CONTACTOR CLOSED

Possible Causes: Confirmation Of Cause:

1. Open I.O.L. ............................................................................ Check resistance C to S and C to RAllow compr. to cool and re-test

2. Open Windings .................................................................... Check resistance Start to Run

3. Grounded Compressor ........................................................ Check resistance of terminals to ground

4. Locked Rotor (stuck) ............................................................ Voltage Present @ C to S and C to R LockedRotor Amps on C(Start capacitor may be required for starting)

5. Defective Run Capacitor/St. Cap. ........................................ Check with Ohmmeter

6. Open Start Leg Fuse ............................................................ Check for continuity

7. Shorted Windings ................................................................ Compare winding resistance to valves fromService Manual

COMPRESSOR RUNS BUT TRIPS I.O.L.


1. Insufficient Refrigerant ........................................................ Compare System press to Performance Charge/Restriction Charts

2. Defective Run Cap./St. Cap.................................................. Check with Ohmmeter

3. Defective Start Relay ........................................................... Current on St. Cap should drop off within 5 sec.

COMPRESSOR RUNS BUT DOESN’T PUMP


1. Compr. Valves Defective ...................................................... Little or no difference between head and suction

2. Internal Mechanical Failure ................................................. Suction press rises sharply during off cycle

3. SOV not seated .................................................................... Check temp rise of suction line across SOV

2Pub. No. 34-4012-02 P.I. (L)

Note: This publication is general in nature and is intended forINSTRUCTIONAL PURPOSES ONLY. It is not to be used forequipment selection, application, installation, or specific serviceprocedures.

Section 608, paragraph C of the Clean Air Act of 1990 states:

Effective July 1, 1992, it shall be unlawful for any person, in the course of maintaining,servicing, repairing, or disposing of an air conditioning system, to knowingly vent orrelease any CFC or HCFC refrigerant. Minimal releases (air purges or refrigerant hoses)associated with good faith attempts to recapture or recycle are exempt from the ban onventing.

The Clean Air Act has provisions for significant fines and/or imprisonment for non-compli-ance. These fines could range from $5,000 to $25,000 per day.

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Compressor Service Procedure

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