CompressorDiagnosis

Compressor Diagnosis
byMr.
by Mr.J.J.M.
M.Diaz-Sastre
Diaz-Sastre
Copyright©©Sanden
Sanden2006
2006
Copyright

A Global First Class Supplier of Automotive Air Conditioning Technology

Copyright © Sanden 2006

Compressor diagnosis:
Root failure causes and
solutions
Identify the
problem
Monitor the Define the
system problem

Corrective Understand the

action problem

Identify the
root cause

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 Compressor inspection
results

No fault
Compressor replaced
Faulty no liable to
in new cars
compressor during warranty period
Liable to compressor

30% of compressors are OK

< 5% Warranty

Consequences:

-Cost to Sanden
Why?
-Cost to vehicle manufacturer Wrong diagnosis
-Cost to dealer
-Cost to final customer Wrong repair
-Bad image

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 Compressor enemies

• Hits

• Dirtiness

• Refrigerant/oil
wrong circulation

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 Hits

Leak

Lock

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 Dirtiness

• System not cleaned

in previous repair

• Small particle under

discharge valve

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Refrigerant/oil wrong circulation

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 Consequences of
Refrigerant/oil wrong circulation

Circulation

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 Cause of
Refrigerant/oil wrong circulation
• Wrong amount

•Lock

Receiver Drier

Expansion device

•Small leak

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Why pressure switch does not
protect from small leaks
A.C. Off.
Pressure depends on
temperature

R134a saturation pressure

15
GAS
P. Bars (Abs)

10 LIQUID

5
GAS
0
LIQUID
0
4.5
9
13.5
18
22.5
27
31.5
36
40.5
45
T (ºC)

Ambient Vehicle charge spec. R134a charge to reach

temperature grs - R134 2 bar grs. %
19ºC 650 50 7.70%
25ºC 740 38 5.10%

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Important!!
• It is impossible to
replace only the
compressor!
• Refrigerant is
always replaced!
• Check leaks
carefully!

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 Diagnosis by oil color

Clear yellow color. Light grey color Green color. Clear oil
•OK. New oil, used oil •OK. Common in •OK. Leak detector
compressors with additive
few running hours

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 Symptom: Orange oil
Diagnosis: System contaminated by humidity

Possible root causes:

•Poor vacuum.
•Components contaminated by water.

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 Symptom: Dark grey oil
Diagnosis: Balance ring wear, compressor seized

Root cause:
• Poor oil/refrigerant circulation
(See related material)

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 Symptom: Silver color oil
Diagnosis: Damaged compressor.
Medium/big particles in suspension

Root causes:
•Compressor defect
•Abnormal running conditions

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 Symptom: “Label blistering”
Diagnosis: Seized compressor.

Root causes:
Poor oil/refrigerant circulation
(See related material)

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 Symptom: Burned clutch
Diagnosis: Internal damage or
oil in clutch friction area.

Root causes:
-Poor oil/refrigerant circulation
-Particle under discharge valve
-Oil leak by shaft seal
-Oil on friction surface from external source
-Low voltage supply

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 Symptom: Open coil
Diagnosis: Internal damage or
clutch slippage.

Root causes:
-Poor oil/refrigerant circulation
-Particle under discharge valve
-Oil leak by shaft seal
-Oil on friction surface from external source
-Low voltage supply

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 Symptom: Short circuit coil
Diagnosis: Short circuit diode

Root cause:
- Wrong polarity applied to compressor

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 Symptom: Dark discharge area
Diagnosis: High discharge pressure/temperature

Possible root causes:

•Dirty condenser
•Fan electric problem
•Refrigerant overcharge
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 A.C.
Noise
Sanden’s NVH chamber

• The compressor (like any other

machine) creates noise. Noise level
inside the vehicle depends on many
factors rather than compressor’s NVH
level itself.
• A proper design of the A. C system
(compressor bracket, hoses, pipes,
HVAC insulation, etc.) is key to avoid
noise.
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 Abnormal Identify the
problem

A.C. Noise Monitor the

system
Define the
problem

Corrective Understand the

action problem
When the noise appears:
Identify the
- Idling/specific rpm range root cause

- Ambient temperature cold/hot days

- Continuously/sporadically
- Pressure values
Kind of noise:
- Metallic
- Contacts
- Whistle
- Etc.
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 Abnormal
A.C. Noise
WITH CLUTCH UN-ENGAGED.
1. Armature contact with pulley. -> Replace clutch
2. Pulley oscillation due to external hit.-> Replace clutch
3. Pulley contact with foreign element -> Remove contact

WITH ENGAGED CLUTCH

1. Incorrect refrigerant amount -> Verify charge
4. Liquid refrigerant arriving to compressor -> Check expansion valve
5. Pipes/hoses contacts with vehicle body-> Remove contact
6. Clutch slippage due to oil -> Remove compressor
7. Particle under discharge valve -> Pressures are quickly balanced when AC
stops
8. Internal compressor damages -> Replace compressor

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Second compressor fails.
Why?

• Leaks?
• Clean
system?
• New filter?
• TXV ok?

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