Student CD for

Commercial Refrigeration for A/C Technicians

Chapter 8
Compressor Motor Controls
 Learning Objectives

• Three-phase motors
• Contactors and starters
• Single-phase motors
• Start relays and capacitors
• Motor overloads
• Troubleshooting motors

Copyright 2006 Thomson Delmar Learning 2

 Three-Phase Motors
• In comparison to single phase motors, 3Ø
motors have the following advantages:
– Low operating costs
– Lower amperage circuit
– High starting torque
– No start components needed
• However, they are subject to phase loss
and voltage unbalance

Copyright 2006 Thomson Delmar Learning 3

 Calculating Voltage Unbalance
• Vu = Vd  Va
Voltage unbalance = Voltage deviation  Voltage average
• Example: L1- L2 = 230v, L2 - L3 = 240v, and
L1 - L3 = 245v.
– Va = (230 + 240 + 245)  3 = 238v average
– Vd = 238 - 230 = 8v; 240 - 238 = 2v; 245 - 238 =7v
– Use the highest deviation which is 8v
– Vu = Vd  Va = 8v  238 = .034 or 3.4%
A voltage unbalance of over 2% can damage a 3Ø
motor.

Copyright 2006 Thomson Delmar Learning 4

 Contactor Cut-away view

• The side view of a contactor shows how

the coil pulls in the armature and closes
the contacts

Copyright 2006 Thomson Delmar Learning 5

 Contactor Side View
LINE
L1 L2
CONTROL
CIRCUIT

T1 T2

LOAD
Copyright 2006 Thomson Delmar Learning 6
 Contactor Side View
LINE
Power to
L1 L2 Contactor
CONTROL
CIRCUIT

Magnetic Coil Contacts

energized pulled in

Power to
T1 T2 Load

LOAD
Copyright 2006 Thomson Delmar Learning 7
 Contactor Troubleshooting

• 1st Test: Check the mechanical linkage

– Armature must move freely
– Burned coils can restrict movement

Copyright 2006 Thomson Delmar Learning 8

 Contactor Troubleshooting
• 2nd Test: Ohm the contactor coil
– 0 ohms means it’s shorted
– Infinite ohms (OL) means coil is open
– Measurable resistance, coil is good

• Note: If the coil is shorted or open, correct

the problem before replacing contactor

Copyright 2006 Thomson Delmar Learning 9

 Contactor Troubleshooting

• 3rd Test: Check voltage across contacts

(voltage must be applied):
– 0 volts means contacts are good
– Line voltage means contacts are open
– Any voltage reading means contacts are
burned

Copyright 2006 Thomson Delmar Learning 10

 Check Voltage Across Contacts
LINE Example:
230 Volt Line
L1 L2 10 Volts across contacts
CONTROL Replace
CIRCUIT Contactor
NOTE: Any
voltage reading
across contacts
0
10
can mean
contacts are BAD.
Zero is
good
T1 T2

LOAD
Copyright 2006 Thomson Delmar Learning 11
 Motor Starter

• Basically a contactor with overloads

Copyright 2006 Thomson Delmar Learning 12

 Motor Starter Diagram

Coil and contacts:

Magnetic overloads:

Overloads open switches

on high current draw.
Switches are wired in series.
Any switch that opens will
interrupt power to the coil.
Copyright 2006 Thomson Delmar Learning 13
 Motor Starter
Power In

Coil

Contacts
(inside)
Overloads

Manual
Reset Power Out

Copyright 2006 Thomson Delmar Learning 14

 Split Phase Motor

This motor needs power to

the start winding to start

S C R

START RUN
WINDING WINDING
This motor
This motor needs needs power to
a start winding for the run winding
a phase shift to run
LINE

Copyright 2006 Thomson Delmar Learning 15

Starting a Split Phase Compressor

• Power must first go to both the

run winding and the start winding

Copyright 2006 Thomson Delmar Learning 16

Split-Phase Compressor Motor Starting

Power is also
needed to start
S C R

START RUN
WINDING WINDING
Once started, the start Power is needed for
windings are removed the motor to run
from the circuit
LINE

Copyright 2006 Thomson Delmar Learning 17

 Motor Speeds

• The synchronous, or “nominal” speed of a

motor can be determined by the number of
its poles
• The more poles, the lower the speed

Copyright 2006 Thomson Delmar Learning 18

Two Pole Motor Windings

Courtesy of
7200  2 = 3600 Copeland

RPM
Copyright 2006 Thomson Delmar Learning 19
 Calculating Motor Speeds

• One cycle has two current flow reversals

• 60 cycles has 120 flow reversals
• Speed = (60 Hz x 120 reversals) ÷ Poles
– Example: 7200 ÷ 2 Motor poles = 3600 RPM

Copyright 2006 Thomson Delmar Learning 20

 1 2
Four Pole Motor 1

4 2
7200  4 = 1800 RPM

4 3 3
Courtesy of
Copeland

Copyright 2006 Thomson Delmar Learning 21

 Start Relays

• A relay is used to energize the start

winding
• The same relay is also used to take the
start winding out of the circuit
• The next slide is a diagram of where
start components are located in a
compressor motor circuit

Copyright 2006 Thomson Delmar Learning 22

Diagram of Compressor Start Components
For the motor to run, N L1

power is needed to
Common and Run

S R
For the motor to start,
power is needed to the
Add torque with a
Start terminal.
Start Capacitor
START After start up, A Start
RELAY Relay opens the circuit
Copyright 2006 Thomson Delmar Learning 23
 Types of Compressor Starting

• RSIR: Resistance start, induction run

– Uses a start relay only
• CSIR: Capacitor start, induction run
– Uses a start relay and start capacitor
• CSCR: Capacitor start, capacitor run
– Uses a start relay and both start and run
capacitors

Copyright 2006 Thomson Delmar Learning 24

Two Types of Starting Relays

• Current Relays
• Potential Relays

Copyright 2006 Thomson Delmar Learning 25

Current and Potential Relay

Copyright 2006 Thomson Delmar Learning 26

 Current Relays

• Used on compressors under one

horsepower
• Switch contacts are normally open (NO)
• Relay coil energized by high starting
current

Copyright 2006 Thomson Delmar Learning 27

 Current Relay

Copyright 2006 Thomson Delmar Learning 28

 Motor Amp Draw on Start up
1. Current relays respond to amp draw
2. Relay contacts close on high starting current
3. Relay contacts open as amperage drops

Motors draw high amps (LRA) on start up.

LRA
60A
Amperage Draw

Amperage drops as
40A
speed increases.
20A
Start Up RLA
0A
20% 40% 60% 80% 100%
Motor Speed

Copyright 2006 Thomson Delmar Learning 29

 Starting with a Current Relay

• Current relays are used on refrigeration

systems with fixed metering devices
• When system pressures are equalized only
a relay is needed to start the compressor

Copyright 2006 Thomson Delmar Learning 30

 Split Phase Motor with Current Relay
1- High starting amps energize relay coil, close contacts

2- Line voltage goes to start windings

3- Motor speed increases, amperage decreases,
relay coil allows contacts to open
S C R

START WINDING RUN WINDING M S

4- Start Winding drops out CURREN

T RELAY
5- Motor continues to run,
L
drawing normal current
POWER ON
Original Diagram from
Copeland Handbook
LINE

Copyright 2006 Thomson Delmar Learning 31

 How a Current Relay Works

• The drawing on the next slide shows how

the start winding is energized, then how it
is taken out of the circuit

Copyright 2006 Thomson Delmar Learning 32

 Current Relay
Jumper wire

nect
t o con citor
s ed capa
Power In u rt
Also nal sta
opti
o 1
2
S
M To Start
Terminal
Relay Coil
To Main (Run)
Terminal

Copyright 2006 Thomson Delmar Learning 33

 Energize Start and Run Windings
Voltage ready for
Start Winding
Contacts close

Voltage through coil

Power to
Start Winding
High starting current
increases coil magnetism Power to Main
(RUN) Winding

Plunger is pulled up

Copyright 2006 Thomson Delmar Learning 34

 Start winding de-energized

No voltage to
Plate falls, Start Winding
contacts open

As motor speed increases, Power to Main

amperage falls (RUN) Winding

Plunger falls Compressor continues running

Copyright 2006 Thomson Delmar Learning 35

 Adding a Start Capacitor

• A refrigeration system with a TEV requires

more starting torque
• Adding a start capacitor in series with the
start winding is all that is needed

Copyright 2006 Thomson Delmar Learning 36

Capacitor Start Induction Run Motor (CSIR)

START
CAPACITOR
High current draw on start-up
closes contacts between L and S.
S C R

START RUN WINDING M S

WINDING
CURRENT
RELAY
As motor speed increases
L
contacts open, dropping
out start windings.
LINE

Copyright 2006 Thomson Delmar Learning 37

 Start Capacitors
• They provide more phase shift to the start
winding
• Start capacitors are designed to be in the circuit
for only a few seconds
• A resistor quickly bleeds off capacitor charge to
prevent excessive arcing across the relay
contacts
• Note: Always replace capacitors with the same
microfarad rating (MFD or µF) and equal (or
greater) volt amp capacity (VAC)

Copyright 2006 Thomson Delmar Learning 38

 Start Capacitor

Bleed Resistor
15,000 Ohms

Copyright 2006 Thomson Delmar Learning 39

 Terminal box on a small compressor

• A current relay plugs into the start and run

terminals
• The external overload is mounted inside
the terminal box

Copyright 2006 Thomson Delmar Learning 40

 Current
Overload Relay
C

S R

Copyright 2006 Thomson Delmar Learning 41

 Current Relay and Overload
mounted on hermetic compressor

S R

Copyright 2006 Thomson Delmar Learning 42

Terminals - Current Relays - Overloads

C
Jumper
Wire

 
S R
L1

Remove jumper wire when installing start capacitor

Copyright 2006 Thomson Delmar Learning 43
 Two-wire Overload

• Single phase overloads are usually in the

common wire
• Its bimetal disk warps when heated
• It responds to motor heat and amperage

Copyright 2006 Thomson Delmar Learning 44

 2-wire bimetal overload

L1
3
Power on
Load 1 2

Normal operating condition: 1-2 closed

If the load draws high current,
the heater from 2-3 becomes hot.
This warps bimetal 1-2, and
opens the circuit between 2 and the Load.

Copyright 2006 Thomson Delmar Learning 45

 Potential Relays

• Used for starting single phase

compressors up to five horsepower
• Contacts are normally closed (NC)
• The relay coil is energized by Back EMF
(electromotive force) generated in the
start winding

Copyright 2006 Thomson Delmar Learning 46

 Potential Relay – Top View
S “Dummy” terminal

To start 2
terminal
From common
Contacts
terminal
Solenoid Coil
“Dummy” terminal
1 C
5

From run terminal

Copyright 2006 Thomson Delmar Learning 47

 Potential Relays in Operation

• The normally closed contacts allow full

voltage to the start winding
• The relay coil is energized
• The contacts open
• Back EMF keeps the coil energized, which
keeps the contacts open

Copyright 2006 Thomson Delmar Learning 48

 Potential Relay
Capacitor Start Induction Run (CSIR) Motor

2 1

POTENTIAL START
Back EMF RELAY CAPACITOR
keeps the coil
5
energized
S C R

START RUN WINDING

WINDING

LINE
Copyright 2006 Thomson Delmar Learning 49
 Adding a Run Capacitor

• A run capacitor is added to the starting

circuit
• When the potential relay opens the run
cap stays in the circuit

Copyright 2006 Thomson Delmar Learning 50

 Potential Relay
Capacitor Start-Capacitor Run (CSCR) Motor

RUN
2 1 CAPACITOR

POTENTIAL START
Back EMF RELAY CAPACITOR
keeps the coil
5
energized
S C
R

START RUN WINDING

WINDING

The run capacitor stays

in the circuit for greater
motor efficiency LINE

Copyright 2006 Thomson Delmar Learning 51

 Run Capacitors

• When the compressor is running, a run

capacitor provides partial voltage to the
start winding
• This lowers compressor amperage,
increasing motor efficiency

Copyright 2006 Thomson Delmar Learning 52

 Run Capacitors

Old style New Style

Copyright 2006 Thomson Delmar Learning 53

 Checking a Run Capacitor

• Use a capacitor tester

• Capacitance should be within at least ± 10% of
the motor manufacturer’s recommendation

Note: A capacitor’s actual output may vary from its

rating. See the following slide:

Copyright 2006 Thomson Delmar Learning 54

Checking a Run Capacitor

Capacitor Measured 25µF ±10% = 2.5

rating capacitance
Acceptable range:
25 + 2.5 = 27.5
25 – 2.5 = 22.5

25µF ±6% = 1.5

Acceptable range:
25 + 1.5 = 26.5
25 – 1.5 = 23.5

Copyright 2006 Thomson Delmar Learning 55

 Run Capacitors in Parallel & Series

• Sometimes the capacitor you have is not

the one you need
• In an emergency, wiring two capacitors
together may give you the capacitance
you need

Copyright 2006 Thomson Delmar Learning 56

 Run Capacitors in Parallel
Total capacitance = Cap1 + Cap2
= 10 µF + 10 µF
= 20 µF
10 µF

From run terminal To start terminal

R S
10 µF

This meter can µF Note:

check  V Does this look familiar?
AC
capacitance
DC 2 Resistances in parallel:
µF RTOTAL = R1 + R2
COM V/

Copyright 2006 Thomson Delmar Learning 57

 Run Capacitors in Series (Cap1 x Cap2)
Total capacitance =
Cap1 + Cap2
10 x 10
=
10 + 10
10 µF 100
=
20
= 5 µF
R S
10 µF

µF
Note:
 Does this look familiar?
V
AC
2 Resistances in series:
DC
(R1 x R2)
µF RTOTAL =
(R1 + R2)
COM V/

Copyright 2006 Thomson Delmar Learning 58

 PTC Relays

• Positive Temperature Coefficient (PTC)

solid state relays
• The resistance of the ceramic disc
increases with temperature

Copyright 2006 Thomson Delmar Learning 59

P.T.C. Relay Cutaway Wire spring holds disk and
serves as a conductor

Run Start

Power from Power to

Run terminal Start terminal
Ceramic Disk

Copyright 2006 Thomson Delmar Learning 60

 Location of the PTC Relay

• The relay is wired in parallel to the run

capacitor
• It allows full voltage starting, then drops
out of the circuit

Copyright 2006 Thomson Delmar Learning 61

PTC Relay and Run Capacitor
PTC Relay

Relay is wired in
parallel with the
run capacitor

Copyright 2006 Thomson Delmar Learning 62

 Common Electrical Problems

• Open windings
– There MUST be measurable resistance
• Shorted winding to winding
• Shorted winding to ground

Copyright 2006 Thomson Delmar Learning 63

 Checking Motors with an Ohmmeter

No Resistance
Shorted winding or closed
relay contacts
OHMS VOLTS

AC

DC

COM V/

Copyright 2006 Thomson Delmar Learning 64

 Checking Motors with an Ohmmeter

Infinite Resistance
Open winding or contacts

OHMS VOLTS

AC

DC
Measurable resistance
Motor winding or coil is good
COM V/

Copyright 2006 Thomson Delmar Learning 65

 Checking Motors with an Ohmmeter

Measurable resistance
Motor winding or coil is good

OHMS VOLTS

AC

DC

COM V/

Copyright 2006 Thomson Delmar Learning 66

 1Ø Compressor with Open
Internal Overload
1

OHMS VOLTS
2 3 AC

DC

If both Run & Start are open to Common COM V/

the Internal Overload is open
Copyright 2006 Thomson Delmar Learning 67
 3Ø Compressor with Open
Internal Overload
1

OHMS VOLTS
2 3 AC

DC

Overload opens all three legs COM V/

at the same time
Copyright 2006 Thomson Delmar Learning 68
 Checking for open windings

• If only one winding shows no resistance,

the compressor has an open or broken
winding

Copyright 2006 Thomson Delmar Learning 69

 1Ø Compressor with Open Run Winding
1

OHMS VOLTS
2 3 AC

DC

Open Run Winding (Infinite) Resistance

COM V/
Start Winding Shows Measurable Resistance
Copyright 2006 Thomson Delmar Learning 70
 Shorted Winding to Winding

• Acid and debris can cause shorts

• If windings are not at their rated ohms they
could be burned or shorted

Copyright 2006 Thomson Delmar Learning 71

 1Ø Compressor with Shorted Windings
1

OHMS VOLTS
2 3 AC

DC

Note: If not “0”, Resistance will be close to it

COM V/

C-S and C-R: Higher than rating in manual

Copyright 2006 Thomson Delmar Learning 72
 Shorted Winding to Ground

• No circuit should be detected

– From any terminal to ground
• Use copper suction line to check ground
– Painted compressor body is no good

Copyright 2006 Thomson Delmar Learning 73

1Ø Compressor Winding Shorted to Ground
1

OHMS VOLTS
2 3 AC

DC

COM V/
Check for ground by placing lead on suction line

Copyright 2006 Thomson Delmar Learning 74

 Motor Power Problems

• Motor does not even try to start

– Check voltage to the motor
– If no voltage check fuses, circuit breakers, etc.

Copyright 2006 Thomson Delmar Learning 75

 Checking Fuses with Power ON
• If checking with power on - be careful!!
– Put voltmeter where you can easily see it
• What to look for:
– No voltage: Good
– Full voltage: Bad
– Partial voltage: Bad

Copyright 2006 Thomson Delmar Learning 76

 Using a Voltmeter to Check Fuses
0 Volts (no potential difference)
 VAC
All power through fuse DC

Fuse is GOOD COM V/

Full Voltage 120 V

 VAC
Leads have become jumper wires DC

Fuse is open (BAD) COM V/

Measurable Voltage
 VAC
But not full voltage DC

Fuse is BAD COM V/

Copyright 2006 Thomson Delmar Learning 77

 Motor Tries to Start

• Motor hums, but goes off on overload

– Check for low voltage
– Check capacitor
– If it is a fan motor, try to rotate motor shaft

Copyright 2006 Thomson Delmar Learning 78

 Motor Runs with High Amps

• Motor runs but draws high amperage

– Check the run capacitor
– If it is a fan motor, is the load too much for it?

Copyright 2006 Thomson Delmar Learning 79

 Common Compressor Problems

• Compressor does not even try to start

– Check voltage to compressor
• Hums but won’t start:
– Check voltage
– Check starting components
• Starts, runs, then goes off on overload
– Start relay stuck closed

Copyright 2006 Thomson Delmar Learning 80

 Potential Relay Troubleshooting

 Œ
• Ohm contacts (#1 to #2): POTENTIAL
– Closed (0 resistance) = Good RELAY
• Ohm coil (#2 to #5): 
– Measurable resistance = Good
• Compressor draws high amps, trips overload:
– Contacts may be stuck closed
• Use the correct replacement relay

Copyright 2006 Thomson Delmar Learning 81

 Current Relay Troubleshooting

1
2
• Ohm contacts (#1 to S): S
M
– Open when relay upright
– Closed when turned upside down
• Ohm coil (#2 to M):
– Measurable resistance = good
1
– 0 ohms = shorted 2
S
–  ohms = open M

Copyright 2006 Thomson Delmar Learning 82

 PTC Relay Troubleshooting

• A hot PTC relay is normal

– They get up to 210° F while in the circuit
• They will not recycle in less than 3 minutes
• The relay must be at room temperature
before checking with an ohmmeter
– Normal reading is 20 to 40 ohms

Copyright 2006 Thomson Delmar Learning 83

Copyright 2006 Thomson Delmar Learning 84