MAKING MODERN LIVING POSSIBLE

Why Compressors Fail

Part 9 Electrical Testing of Compressor Motors
Electrically testing Compressor motors and keeping

Klixon device at the common point to the Start winding,

records of the motors winding resistances can some-

so if the klixon /overload device trips, the Start windings

times help in preventing the early death of a compressor.

will be open circuited to try to prevent a burnout.

Prior to installing a new compressor the motor windings

The compressor motor pins are

resistance and their insulation value should be checked

Termed as C= Common, S = Start , and

to make sure the motor has suffered no damage during

R = Run. The resistance of the Start

its transportation to site.

winding is normally of a higher ohmic

Compressor manufacturers often list the motor resist-

value than the Run Winding. This is

ance data for their various compressor types and this

due to the Start winding being

information is invaluable in testing if a machine is good

wound in a lighter gauge wire than

or damaged.

the Run winding.

Measuring the Winding resistance is simply done using
an Ohmeter . The meter probes are connected to two
of the three motor pins in turn. And the measurements
noted.

Single Phase Motors

Single phase motors have two windings, called the
START and RUN windings which are commoned through
a third pin. This connection sometimes has a Thermal

Measuring the Start & Run winding resistance of a MTZ18-5

Field Service Note 018

Using a Maneurop Compressor type MTZ28JE-5 (230v

Single phase compressor electrical components com-

1ph 50 Hz) as a reference, the design resistances for the

prise of Potential Relays and Start and sometimes Run

Run and Start windings are 1.16 Ohm (RUN) & 3.24 Ohm

capacitors.

(Start). When measuring the resistance between the Run

& Common Pins the resistance should read 1.16 Ohms
and between the Start & Common pins the resistance
should be 3.24 Ohms. When measuring between the
Run & Start pins the sum of the Run and Start winding
resistances should be measured ie 1.16 + 3.24 =4.4
Ohms.
These readings confirm that the motor windings are
good to run.

here we have both PSC and CSR starting kits for single phase
compressors.

A further test of the compressor motor is the insulation

test . This test is to make sure that there is no earth leak-

If there is any doubt as to the electrical components

age through the motor insulation.

integrity then they should be changed immediately.

This test is carried out using a Megger insulation tester,

Capacitors in general give good life time operation, but

a 500 volt dc megger is ideal. This involves simply put-

capacitors are designed to store electricity and the Start

ting one of the meter probes onto the compressors earth

Capacitor is there to enhance the compressors starting

terminal or other part of its metallic shell, and the other

ability when pressure differences across the compressor,

meter probe onto the motor pins, one at a time. The test

during start up or quick re starts to the motor are

on all three pins should all show an insulation value of

required. Pressure differences between the suction and

at least 1 Meg ohm or higher, values showing infinity

discharge of the compressor above 7 Bar should be

are the desired value. Values lower than 1 Meg are a

avoided, as even single phase machines designated as

cause for concern and usually mean the motor windings

an HST ( HIGH START TORQUE) motor will only cleanly

are damaged and need further investigation.

start a machine where the pressure difference is less

than 7 Bar. Failing to ensure that the starting PD is less
than 7 Bar can cause the compressor to struggle to start,
and as such the potential relay will hold the START winding in circuit longer than desired and will eventually
cause the START winding to overheat and quickly burn.
( For every second that the START winding is in circuit
its winding temperature will rise approx. 10C).

Insulation test of a MTZ18-5 indicates there is no problem

with the motor windings.
NOTE :Care should be taken when carrying out Insulation testing as the meter will generate 500 volts dc into the windings and compressor earth/shell . By touching the compressor shell whilst under this test can cause the person
to receive a nasty electric shock.
2

Start winding burnout

A weak Capacitor or a leaky capacitor will often com-

the three phase windings is a KLIXON device which

promise the compressors motor.

is both current and temperature sensitive. If this trips

there will be no resistance measured between the

Capacitors can be checked with various CAPACITOR test-

compressor motor terminal pins as the klixon breaks

ers on the market.

the power circuit between the three phases creating

A quick test will tell if the capacitor is OK to be used or

an open circuit.

thrown away and replaced. Capacitors have a lifetime

Note:- On Maneurop Compressors if the Klixon open

and deteriorate if not used for some time.

circuits during an overload or temperature problem ,

it may take up to 8 hours to reset, depending on the
motors temperature.

Capacitor tester, this model indicates the capacitors size

in f
Ohmeters and Meggers can be used for checking
capacitors,

but it must be remembered that

Capacitors store electricity and after testing with a

Here we have a Klixon fitted to a 3-phase motor.

The Klixon is the compressors last line of defence and
should not be used to cycle the compressor.

Designated Capacitor checking device, the device will

automatically drain the charge making it safe to touch,

These machines are connected to the three phase

whereas if using a Megger, the charge that the Megger

supply via a three phase contactor and sometimes a

puts into the capacitor will be stored in the capacitor if

close coupled overload is also fitted.

its a good one. To remove the charge, simply touch the

Testing a three phase machine is similar to the single

two capacitor wires together being careful not to touch

phase machine, only this time when resistance

the wires with your fingers as you will receive a nasty

measurements are taken across the 3 motor terminals

electrical shock that is not at all pleasant. Capacitor

, two at a time, the results should be the same for

testers can be just simple indicator testers with a LED

the three measurements. The three terminals are

indicator or a more sophisticated type that actually

designated T1, T2, T3.

tests the capacitor and can also measure the capacitors

If the measurements vary from winding to winding

size in f or microfarads. Capacitors can weaken over

then the motor has been damaged or burnt due to

time and should be checked during service visits.

over current/temperature, or has been running with a

loss of a phase voltage possibly a blown line fuse. This

Three Phase Motors

causes only two phases to run the compressor motor,

Three phase motors are wound

but these two phases will draw extra current and run

differently where all the three

in an overloaded condition. This situation often causes

windings have an equal resistance

the machine to cycle on the machines internal klixon

value unlike their single phase

leading to eventual klixon failure or the motor burns

alternative. At the Star point of

out.

Using the same size compressor but a three phase

At this stage fitting a new drier and /or changing the

version, the resistance across the three windings is 7.11

compressors oil charge, could potentially save the

ohms.

compressor motor. As moisture, and weak acids plus

Resistance from T1-T2 =7.11ohm, T2-T3 = 7.11ohm, T3-

heat increase in the system due to age and poor

T1= 7.11 ohm. This motor is OK.

maintenance such as leaky systems, these acids will

Insulation testing is the same as for the single phase

start to attack the motors insulation. If left, further

version.

deterioration to the insulation will occur and eventually

the insulation will break down at its weakest point,

If electrical Test records are kept as to the resistance of

causing a spot burn in the windings and then complete

the windings and also its Insulation value, then every

failure of the motor will occur soon after.

6 or 12 months the condition of the motor can be

checked against its previous condition. If for instance
the resistance values and especially the insulation
value, starts to drop, in a compressor motor this could
be a sign of moisture or oil degradation in the system.
A visual Indication of this can be seen in liquid
line moisture indicating sight glasses, and also
discolouration of the oil in the compressors oil sight
glass are easy visual checks to make during a service or
maintenance visit.

Moisture along with week acids and heat can cause a

spot burn in the windings.

Sight glasses are quipped with sensitive indicators that reflects a color, which depends on the moisture content of
the refrigerant.

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already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.
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Field Service Note 018

Field Service Notes are produced by Glenn K Moore

Field Support Manager, Danfoss Ltd.
E-mail glenn.moore@danfoss.com

Danfoss Ltd 9-2013