Motor Compressor and its Accessories I.

Terms and Definitions

Calibrate to adjust a meter so that the needle is properly aligned to the proper set point on the scale. Contactor magnetic relay switch which usually opens and closes a line voltage circuit actuated by a control circuit magnetic coil. Continuity complete circuit in which current can flow. Control relay electromagnetic switch that controls a line voltage load by means of control voltage. Current relay (Coil type) motor starting relay that disengages the start winding after the compressor reaches 75% of its rated speed; used on fractional horsepower motor. Current relay (Hot wire type ) motor starting relay that disengages the start winding by the movement of a thermal wire; used on small fractional horsepower motor. Full Load Amperage (FLA) total current the device draws when it is running fully loaded. Infinity (Infinite Resistance) the extreme end of the ohmmeter designated by .

RAC ELECTRICAL COMPONENTS:

Line Voltage main power supply

Locked Rotor Amperage (LRA) the current drawn by a motor when not running but supplied with power. Potential relay motor starting relay that operates off of the back EMF generated in the start winding; used primarily on hp or larger motor compressors.
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Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D
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Probes insulated ends on test instruments leads that are held while checking the circuit. Relay an electromagnetic switch. Solid state relay a thermal- sensitive motor starting switch constructed from a ceramic material encased in a nonflammable covering.

Time delay relay provides a predetermined interval between operations of a device. Range limits of a particular portion of a meter. Example: 230 VAC (volts alternating current)- this range would be alright to use for any AC voltage 1 to 230; anything over would damage the meter. Zeroing the ohmmeter to align the meter needle over zero on the ohm scale.

II. Safety Rules in Testing Electrical Circuit 1. 2. Stand on dry, non-conductive surfaces when testing live circuits. Be sure the power is off when checking a circuit with an ohmmeter. (Note: an ohmmeter could explode if it came in contact with line voltage.) 3. 4. Do not use meter leads with defective probes. Do not have both hands in a high voltage cabinet. (Note: Clip one voltmeter lead on and then take the other lead and check the circuit.) 5. 6. 7. 8. 9. 10. Do not touch metal cabinet or other grounded material. Wear eye protection. Use fuse pullers (if needed on the trainer). Do not work on live circuits alone. Do not assume that the power is OFF. Discharge capacitors with a bleed resistor before removing or testing.

III. General Rules for Protection of the Tester 1. Keep clean and dry. 2. Avoid exposure to high temperature.
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Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D
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3. Use only for intended purpose. 4. Use within meter range limits. 5. Set meter in highest range prior to taking readings. 6. Follow directions on specific operating instructions.

IV. Meter Applications 1. Voltmeter Me asure s l i ne vol tage

Me asure s vol tage drop at the l oad Me asure s l ow vol tage I ndi cate s ope n compone n ts

2.

Ohmmeter (Caution: Be sure all power is off before checking an electrical circuit with an ohmmeter.)
C he cks for a path for curre nt fl ow

(conti nui ty) C he cks for re si stance to curre nt fl ow De te rmi ne motor w i ndi ngs and te rmi nal s C he cks for shorts and grounds C he cks capaci tor (C auti on: Be sure that the charge i s bl e d off be fore che cki ng. )

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Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D

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3. 3. 3. 3. 3. Ammet er Checks locked rotor amperage Checks starting amperage Checks running amperage

4. Circuit Conditions 4.1. Open Circuit Most frequent circuit problem No path of current Voltmeter will indicate voltage across open Caused by Pitted Contacts Defective relay coil Broken wire Blown fuse Tripped circuit breaker Open switch 4.2. Short Circuit Second most frequent circuit problem

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Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D

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Electrical circuit that has a lower resistance than intended

Indications Blown fuse Tripped circuit breakers Melted wires Swollen run capacitors Blackened terminals Burnt case (Example: Touching a screw driver to a current carrying conductor and at the same time against the side of appliance cabinet would result in a blown fuse, a badly burnt screwdriver, a burnt spot on the cabinet and possible personal injury)

4.3. Grounded Circuit A high resistance path that current may take to a common ground May be caused by a blown fuse or tripped circuit breaker May be determined with an ohmmeter

V. Servicing and External Testing of Hermetic Motor Compressor Using Continuity Tester 1. Servicing Electric Motors
The mai nte nance , troubl e shooti n g, re moval , re pai r and i nstal l ati on of e le ctri c motors as we l l as thei r acce ssori e s is a maj or porti on of a se rvi ce te chni ci an s j ob. Such pe rson must know how to use i nstrume nts and be know l e dge abl e about e le ctri ci ty to accurate l y de te rmi ne the troubl e . I t i s i mporta nt that a sol i d base be provi de d for the i nstal l ati on of any motor and that i t be bol te d dow n se curel y. The armature shaft shoul d be le vel e d for a hori zon tal motor and e xactl y ve rti cal for a ve rti cal motor. RE F and AIRC ON F UN DAME NT AL S
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I f the motor i s se ve re l y damage d and must be re pl ace d, the fol l ow i ng i nformati o n must be take n: a) b) c) d) e) type of motor ope rati ng l i ne vol tage maxi mu m curre nt draw di re cti on of rotati on and spee d mounti ng hardw are

Use the manufact ure r s name pl ate to ge t al l the re qui re d motor spe ci fi cati on as the ori gi nal motor. The re pl ace me nt motor may have a maxi mu m curre nt draw of 10 % l arge r, but ne ve r l e ss than the motor be i ng re pl ace d.

Approximate amperage rating for small hermetic motors @ 220 240 VAC HP Full Load Locked Rotor Rating 1/6 2.2 13.2 1/4 2.9 17.4 1/3 3.6 21.6 1/2 4.9 29.4 3/4 6.9 41.4 1 8.0 48.0 1 1/2 10.0 60.0 2 12.0 72.0 3 17.0 102.0 2. Motor Lubrication
O pe n motors may be l ubri cate d i n vari ous w ays. It de pe nds on the type of be ari ng use d and the posi ti on of the motor. O pe n motors usi ng bronze bushi n gs, pl ai n or sl ee ve may be l ubri cate d i n tw o di ffe re nt w ays: a) W i ck syste m b) Sl i p ri ng syste m The w i ck syste m use s a w el l or re se rvoi r i n the e nd be ll . A w i ck ( co t t o n o r wo o l yarn ) carri e s oi l from thi s we l l to the shaft and bushi n g. Thi s syste m all ow s l ong i nte rval be twe e n se rvi ci ng be ari ngs and pre ve nt the be ari ng from ge tti ng too much oi l. I f the be ari ng i s to be re move d from the shaft, the yarn shoul d be l i fte d cle ar of the be ari ng to pre ve nt i t from bei ng force d be tw ee n the shaft and the be ari ng upon re pl ace me nt.

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Wick lub ricat e d be aring s ho uld b e o ile d o ne o r t wo d ro p s e ve ry s ix mo nt hs us ing me d ium vis co s it y (2 0 0 3 00 vi scosi ty) , no de t e rg e nt o il such as SAE 20 o r 30 .

3. Cleaning Motors
a) Dust and li nt i n the motor w i ll pre ve nt prope r ai r ci rcul ati on. b) C ompre sse d ai r or hand be ll ow s shoul d be use d to bl ow the di rt out. c) Any oi l w hi ch may ove rfl ow from the be ari ng shoul d be wi pe d off. d) I f the motor must be di smantl e d, al l parts shoul d be care ful l y cl e ane d be fore bei ng w orke d on or re asse mbl e d.

4. Servicing Fan Motors

The common fan motor troubl e s are : a) b) c) d) e) f) g) l oose conne cti on dry be ari ng w orn be ari ng burn out motor l oose fan out- of- bal ance fan fan bl ade s touchi n g the housi ng

L oo s e o r d irt y co nne ct io ns will caus e t oo much vo lt ag e d rop at the motor and the fan motor wi l l l ose spee d, hum l oudl y and ove rhe at . To che ck, use se nsi ti ve ohmme te r and don t re l y on vi sual i nspe cti on. A d ry b e aring w il l cause the same symptoms but w i ll l ast for a short pe ri od of ti me be fore the be ari ng w i ll sei ze ( bi nd ) or be come badl y w orn. A rattl e i n the fan motor may some ti me s be nothi ng more than a l oose fan on the motor shaft. Thi s noi se can be re me di e d by ti ghte ni ng the se t scre w that faste ns the fan hub to the shaft. I f the fan bl ade touche s the fan housi ng, the motor may be out of l i ne or the shrou d or housi ng may be be nt. I t can be re me di e d by movi ng the fan on the shaft or movi ng the shroud or housi ng. Do no t be nd t he f an b lad e s . It will caus e t he unit t o vib rat e . RE F and AIRC ON F UN DAME NT AL S
Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D
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5. External Testing of Hermetic Motors

In d iag ram A , The starti ng w i ndi ng i s be i ng che cke d for conti nui t y. I f the bul b l i ghts on, i t me ans that the curre nt i s fl ow i ng throu gh the starti ng w i ndi ng from S to C . I n thi s case, the re i s no ope n spot i n the w i ndi ngs. In d iag ram B ,

The windings are being checked for grounds. Grounding means the same part of the internal wiring or the terminals are touching or making electrical contact with the metal parts of the unit. If the bulb lights on when one of the electrical lead is touched to any of the terminals and the other lead is touched to the clean or bare metal body of the dome, it means that the current is flowing along the internal wires and through a grounded wire into the metal. Be sure that the terminals are clean and dry during the test; it might be temporarily grounded by dirt .
In d iag ram C ,

The continuity of both the running and starting windings are being checked.
In d iag ram D ,

The running winding only is being checked for continuity. Any shorting of the motor winding will increase the current draw, decrease power and overheat the unit. (a shorted circuit sometimes be detected by an interruption in the steady hum of the motor when it is running).

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Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D

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VI. Identifying the Run (R), Start (S), and Common (C) Terminals of Single - Phase (1PH) Hermetic Compressor
Terminals of Hermetic Compressors can be: Screw Type Screw and Lock Quick Connector Type Usually, a single phase electric motor have two main windings for starting and operation. The terminals are connected as follows: One end is connected to run windings One end is connected to start windings The third terminal is common lead to both windings STEPS 1. Draw the picture of the terminal on a piece of paper (which may be in these forms).

2. Take the readings by pairing the two leads. Result: The pair with the highest resistance reading is the start and run. The pair with the higher resistance reading is the start and common.( this identifies the lighter gage higher resistance wire of start winding ) The pair with the lowest resistance reading is run and common.

3. Example

F ro m th e p ai re d t e rmi nal r e ad ing s: ... t he p ai r wi th t he h i ghe st re sis tance i s a-c, so b i s the co mmo n t er mina l (l ab el i t C).

. . . the p ai r w it h the lo we st res ist ance is b -c, t he refor e c i s the run t e rmi nal (l ab el i t R). RE F and AIRC ON F UN DAME NT AL S Page 4 of 12 Academic Year 2004 2005, Sem e s the e r 1re ma inin g t e rmin al i s ( a) ...t Prepared By: Nolasco K. Malabago, w Ph .D hi ch i s th e s ta rt t e rmin al (l ab el i t S ).

a -b = 8W a -c = 1 2W b -c =4 W

VII. Electrical Symbols

VIII. Wiring Diagrams Why Use a Diagram? Most electrical problems can be diagnosed with the aid of a wiring or schematic diagram. The diagram serves as a road map to the electrical connections of the appliance and, like any map, must be studied before the best route to proceed can be determined. Like a conventional road map, the appliance diagram will help identify the different routes that current can take, identify points of interest (circuit components), and provide important information such as resistance values and the colors of different wires. It's impossible to describe and list every new component and illustrate every method of depicting it. One reason for this is that,
RE F and AIRC ON F UN DAME NT AL S
Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D
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 appliance technology is changing rapidly; there are far too many manufacturers to fully represent
them all in the manual. Wiring versus Schematic Diagrams

Schematic diagram. The more commonly used are ladder schematic because The components are laid out in a stacked, straight line manner, much like the rungs of a ladder. Of all the types of diagrams available, this type is probably the easiest to read and understand. The ladder diagram is preferred over the wiring diagram for troubleshooting purposes.

Schematic Diagram of a Refrigerator

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Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D

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W i ri ng Di ag ram o f a

Wiring diagram. This type has distinct advantages of over a schematic.

Each separate wire is shown along with its color. Multiple connection points, such as the terminal block on the defrost timer (circled above) are readily apparent. This feature makes replacing the timer much easier since the wires can be reconnected by wire color and terminal number. Termination point for each wire is shown thus, tracing a particular wire is also simplified.

As a general rule, each type of diagram has its purpose.

For component works best.

troubleshooting

purposes,

the

schematic

The wiring diagram simplifies locating and replacing parts or locating breaks in wires.

In most cases, only one type of diagram is supplied by the manufacturer so, regardless of which is available, the technician must be able to use either with some degree of competency.

RE F and AIRC ON F UN DAME NT AL S

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RE F and AIRC ON F UN DAME NT AL S

Academic Year 2004 2005, Semester 1 Prepared By: Nolasco K. Malabago, Ph.D

Page 4 of 12