WITH MORE THAN 60 YEARS OF APPLYING ADVANCED COMPRESSOR

EXPERIENCE IN COMPRESSOR TECHNOLOGIES TO ACHIEVE

TECHNOLOGY AND HIGHLY STANDARD SETTING PERFORMANCE
DEDICATED EMPLOYEES, OUR FOR LEADING PRODUCTS AND
FOCUS IS ON DEVELOPING AND BUSINESSES AROUND THE WORLD.

REPAIR OF HERMETIC
REFRIGERATION SYSTEMS

GUIDELINE

www.secop.com SETTING THE STANDARD

 TABLE
OF CONTENTS

1. General....................................................................................................... 3
1.1 Locating faults........................................................................................4
1.2 Replacing the thermostat.......................................................................5
1.3 Replacing electrical equipment.............................................................6
1.4 Replacing the compressor.....................................................................6
1.5 Replacing refrigerant.............................................................................6

2. Instructions for repair work....................................................................... 8

2.1 Opening the system ...............................................................................8
2.2 Brazing under an inert protective gas...................................................9
2.3 Filter drier.............................................................................................10
2.4 Moisture penetration during repair ....................................................11
2.5 Preparing the compressor and electrical equipment.........................11
2.6 Brazing..................................................................................................13
2.7 LOKRING® connections . ....................................................................15
2.8 Evacuation.............................................................................................16
2.9 Vacuum pump and vacuum gauge.......................................................18

3. Handling refrigerants .............................................................................. 19

3.1 Charging with refrigerant.....................................................................19
3.2 Maximum refrigerant charge ..............................................................20
3.3 Test........................................................................................................20
3.4 Leak test...............................................................................................20

4. Replacing a defective compressor...............................................................21

4.1 Preparing components ........................................................................21
4.2 Removing the charge............................................................................21
4.3 Removing the defective compressor....................................................21
4.4 Removing refrigerant residue..............................................................21
4.5 Removing the filter drier......................................................................21
4.6 Cleaning the brazing joints and reassembly.......................................21

5. Conversions ............................................................................................. 22
5.1 From R404A to R452A...........................................................................22
5.2 From R134a to R600a or R290.............................................................22
5.3 From R134a to R1234y..........................................................................22

6. Systems contaminated with moisture .....................................................23

6.1 Low level of contamination...................................................................23
6.2 High level of contamination . ...............................................................23
6.3 Evacuation.............................................................................................24
6.4 Drying the compressor.........................................................................24
6.5 Oil charge..............................................................................................25

7. Lost refrigerant charge ........................................................................... 26

8. Burnt compressor motor..........................................................................27

8.1 Oil acidity...............................................................................................27
8.2 Burnt system........................................................................................27

9. Locating faults on PL / DL / TL / NL / FR compressors............................ 28

9.1 Location of fault....................................................................................28
9.2 Electrical quick check..........................................................................28

10. Locating faults - detectable faults............................................................ 29

10.1 Checking the main and start winding..................................................29
10.2 Check protector....................................................................................29
10.3 Check relay...........................................................................................29
10.5 Check PTC.............................................................................................29

11. Locating faults – Table I............................................................................ 30

12. Locating faults – Table II........................................................................... 31

2
1.
GENERAL

Refrigerator and freezer repair work requires skilled technicians to perform this service on a variety of dif-
ferent refrigerator types. Previously service and repair was not as heavily regulated as now due to the new
refrigerants, some of which are flammable.

Fig. 1: Hermetic refrigeration system with capillary tubes

Fig. 1 shows a hermetic refrigeration system with a capillary tube as the expansion device. This system type
is used in most household refrigerators, small commercial refrigerators, ice cream freezers, and bottle
coolers.
Fig. 2 shows a refrigeration system using a thermostatic expansion valve. This type of system is mainly used
in commercial refrigeration systems.

Fig. 2: Hermetic refrigeration system with expansion valve

Repair and service is more difficult than with a new assembly, as conditions “in the field” are normally
more severe than on a production site or in a workshop. A requirement for satisfactory service work is that
the technicians have the right qualifications, i.e. good workmanship, thorough knowledge of the product,
precision, and intuition.

The purpose of this guide is to improve knowledge of repair work by going through the basic rules. The
subject matter primarily deals with reference to repair of refrigeration systems for household refrigerators
“in the field“ but many of the procedures can also be transferred to commercial hermetic refrigeration
installations.
3
 1.1 Before performing any work on a refrigeration system, the progress of the repair should be planned, i.e.
Locating faults all necessary replacement parts and all resources must be available. The fault in the system needs to be
detected to be able to plan any such work.

To locate the fault, tools such as a suction and discharge manometer, service valves, a multimeter (voltage,
current, and resistance), and a leak tester (see Fig. 3) must be available. In many cases, the potential faults
can be deduced from the user’s statements and for most faults a relatively accurate diagnosis can be made.
However, the service technician must have the necessary knowledge of the product's function and the right
resources must be available. An exhaustive procedure for locating faults will not be handled in this section,
instead, the most common faults that cause the compressor to not start or run are described below.

Fig. 3: Pressure gauges, service valve, multimeter, and leak tester

Main switch released

One potential fault could be a defective fuse, and the reason may be a fault in the motor windings/motor
protector, a short circuit, or a burnt current lead-in on the compressor. These faults require the compressor
to be replaced.

Compressor
The starting device and compressor motor may be a wrong choice. The compressor motor or winding
protector may be defective, and the compressor may be mechanically blocked.
Frequent reasons for reduced refrigeration capacity are coking or copper platings due to moisture or non-
condensable gases in the system.
Blown gaskets or broken valve plates are due to peak pressures being too high and short-time pressure
peaks as a result of liquid hammering in the compressor, which may be due to a high refrigerant charge in
the system or a blocked capillary tube.
The voltage may be too low or the pressure too high for the compressor.
Pressure that is not equalized causes the motor protector to cut out after each start and will eventually
result in a burnt motor winding.
A defective fan will also affect the compressor load and may cause the motor protector to cut out or a gasket
to blow. If the compressor will not start or is cold, up to 15 minutes may pass until the winding protector
cuts the compressor out. If the winding protector cuts out when the compressor is hot, up to 45 minutes may
pass until the protector switches the compressor on again.
Before starting to systematically locate the fault, it is a good rule to cut off the voltage to the compressor
for 5 minutes. This ensures the PTC starting device, if present, is cooled sufficiently to be able to start the
compressor.
Should a brief power failure occur within the first few minutes of the refrigeration process, a conflict situation
(interlocking) may arise between the protector and the PTC. A compressor with a PTC starting device cannot
start in a system whose pressure is not equalized, and the PTC cannot cool quickly enough. In some cases,
it could take up to 1 hour until the refrigerator runs normally again.

High and low pressure switches

The high pressure switch may cut out due to a condensing pressure that is too high, probably caused by lack
of cooling by the fan.
The low pressure switch may cut out due to insufficient refrigerant charge, leakage, evaporator frost
formation, or partial blockage of the expansion device.
The cut out may also be due to a mechanical failure, wrong difference setting, wrong cut-out pressure
setting, or irregularities in pressure.

4
 Thermostat
A defective or incorrectly set thermostat may have caused the compressor to cut out. If the thermostat loses
the sensor charge or if the temperature setting is too high, the compressor will not start. The fault may also
be caused by a wrong electrical connection.
A differential (difference between cut in and cut out temperature) that is too low will cause short compressor
idle periods, and in connection with a LST compressor (low starting torque) this might lead to starting
problems.
See also point 1.2 “Replacing the thermostat”.

Carefully determining the fault is necessary before opening the system, and especially before removing the
compressor from the system. Repairs requiring work on a refrigeration system are rather costly. Before
opening old refrigeration systems, it may therefore make sense to make sure that the compressor is not
close to breaking down although it is still functional.
An analysis can be made by checking the compressor oil charge. A little oil is drained into a clean test
glass and is compared with a new oil sample. If the drained oil is dark, opaque, and contains impurities, the
compressor should be replaced.

1.2 Before replacing the compressor it is a good idea to check the thermostat. A simple test can be made by
Replacing the short-circuiting the thermostat so the compressor gets power directly. If the compressor can operate like
thermostat this then the thermostat must be replaced.
During replacement, it is essential to find a suitable type, which may be bit of a challenge with so many
thermostat types on the market. To make this choice as easy as possible several manufacturers, i.e. Danfoss,
have designed so-called “service thermostats” supplied in packages with all accessories necessary for
thermostat service.
With eight packages, each covering one type of refrigerator and application, service can be performed on
almost all common refrigerators. See Fig. 4.

Fig. 4: Service thermostat package

The application area of each thermostat covers a wide range of thermostat types. Moreover, the thermostats
have a temperature differential between cut in and cut out sufficient to ensure sufficient pressure equalization
during system idle periods.

In order to achieve the desired function the thermostat sensor (the last 100 mm of the capillary tube)
must always be in close contact with the evaporator. When replacing a thermostat it is important to check
whether the compressor operates satisfactorily both in warm and cold position, and whether the idle period
is sufficient for system pressure equalization when using a LST compressor.
With most thermostats it is possible to obtain a higher temperature differential by adjusting the differential
screw. Before doing this, it is recommended to consult the thermostat data sheet to learn which way the
screw must be turned.
Another way of obtaining a higher differential is to place a piece of plastic between the sensor and the
evaporator, since 1 mm plastic results in approx. 1 °C higher.

5
 1.3 The cause of faults may also be found in the electrical equipment of the compressor, where it is possible to
Replacing replace the starting relay/PTC starting device, motor protector, or starting or run capacitor.
electrical equipment A damaged starting capacitor may be caused by the thermostat differential setting being too low, since the
starting capacitor must be maximum cut in 10 times/hour. If a fault is found on the winding protector built
into many hermetic compressors, the entire compressor must be replaced.

When replacing a compressor, the electrical equipment must be replaced as well, since old electrical
equipment used with a new compressor may cause a compressor to breakdown later.

1.4 If the failure is a defective compressor, the technician must pay attention to selecting a compressor with the
Replacing the correct characteristics for the appliance.
compressor If a compressor corresponding to the defective one is available, and if it is intended for a non-regulated
refrigerant, no further problems will arise. However, in many cases it is impossible to provide the same
compressor type as the defective one, and in this case the service technician must be aware of some factors.
If it is a question of changing from one compressor to another, it can be difficult to select the correct
compressor, and therefore different parameters have to be considered. Compressor voltage and frequency
must correspond to voltage and frequency on location. Then the application area must be considered (low,
medium, or high evaporating temperatures).

The cooling capacity must correspond to the one of the previous compressor, but if the capacity is unknown,
a comparison of the compressor displacements will be applicable. It would be appropriate to select a
compressor slightly larger than the defective one.
For a capillary tube system with pressure equalization during idle periods, a LST compressor (low starting
torque) can be used, and for a system with expansion valve or no pressure equalization a HST ­compressor
(high starting torque) is to be chosen. Of course a HST compressor may also be used in a capillary tube
system.
Finally the compressor cooling conditions must also be considered. If the system has an oil cooling setup, a
compressor with an oil cooler must be selected.
When performing service work, a compressor with an oil cooler instead of a compressor without oil cooler
can be used without any problems, since the spiral can be completely ignored when it is not required.

1.5 The best solution for performing repairs is to select the same refrigerant as used in the present system.
Replacing Secop compressors are supplied or were supplied in versions for the refrigerants R12, R22, R502, R134a,
refrigerant R404A/R507/R407C and for the flammable refrigerants R290 and R600a.
The refrigerants R12 and R502, which are covered by the regulations in the Montreal Protocol, may only be
used in a very few countries, and the refrigerants will eventually be phased out of production altogether.
For heat pump systems, the refrigerant R407C is now used instead of R22 and R502.
The more environmentally acceptable refrigerant R134a has replaced R12, and the refrigerants R404A and
R507 have replaced R22 and R502 in many applications.

The flammable refrigerants R290 and R600a

Maximum charge of these refrigerants in a system is 150 g according to today’s relevant appliance standards,
and they may only be used in small refrigerators.
The flammable refrigerants may only be used in refrigeration systems meeting the requirements of EN/IEC
60335-2-24 or -2-89, including demands for flammable refrigerants. Service personnel must be specially
trained to handle them. This implies knowledge of tools, transporting compressors, and refrigerants as well
as all relevant rules and safety regulations.
If open fire or electrical tools are used near the refrige­rants R600a and R290, this may only take place in
conformity with current regulations.
The refrigeration systems must always be opened with a tube cutter.

Changing from the refrigerants R12 or R134a to R600a is not permitted, since the refrigerators are not
approved for use with flammable refrigerants, and the electrical safety has not been tested according to
current standards. The same applies to change from the refrigerants R22, R502 or R134a to R290.

6
Refrigerant blends
Some refrigerant blends for service purposes were also introduced at the same time as the new
environmentally acceptable refrigerants (R134a and R404A) were introduced. They are more environmentally
acceptable than the previously used CFC refrigerants (R12 and R502).
In many countries, the refrigerant blends were only permitted for a short period, which meant that they were
not widely used in connection with small hermetic refrigeration systems.
Use of these refrigerants cannot be recommended for series production but they can be used for repair in
many cases (see the table below).

Refrigerant Trade name Composition Replacing Application area Applicable oils

R401A Suva MP39 R22, R152a, R124 R12 L-M Alkylbenzene

R401B Suva MP66 R22, R152a, R124 R12 L Alkylbenzene

Polyolester
R402A Suva HP80 R22, R125, R290 R502 L Alkylbenzene

Polyolester
R402B Suva HP81 R22, R125, R290 R502 L-M Alkylbenzene

Add in
This designation is used when filling up an existing refrigeration system with another refrigerant than the
one originally charged. This is especially the case when problems arise which must be solved with as little
work as possible.
Correspondingly, R22 systems were replenished with a small amount of R12 in order to improve the flow
of oil back to the compressor. In several countries, it is not allowed to add in to CFC systems (R12, R502,...)

Drop in
This term means that during service on an existing refrigeration system i.e. > 90 % of the original mineral
oil is poured out and replaced by synthetic oil, and a new suitable filter drier is mounted. Furthermore, the
system is charged with another compatible refrigerant (i.e. blend).

Retrofit
The term retrofit is used with service on refrigeration systems, replacing the CFC refrigerant by an
environmentally acceptable HFC refrigerant. The refrigeration system is flushed, and the compressor is
replaced by an HFC compressor. Alternatively the compressor oil is replaced by a suitable ester oil. The oil
must be changed several times after short operating periods, and the filter drier must be replaced.

When replacing the oil, a statement from the compressor manufacturer on material compatibility is
necessary.

7
 2.
INSTRUCTIONS FOR REPAIR WORK

To enable a hermetic refrigeration system to work as intended and to achieve a reasonable service
life, the content of impurities, moisture and non-condensable gases must be kept at a low level. When
assembling a new system, these requirements are relatively easy to meet, but when repairing a defective
refrigeration system, the matter is more complicated. Among other things, this is due to the fact that faults
in a refrigeration system often start adverse chemical processes, and that opening a refrige­ration system
creates possibilities for contamination.
A series of preventive measures is necessary if repair work is to be successful. Before stating any details
about the repair work, some general rules and conditions have to be explained.
2.1
Opening the system

Fig. 5: Hermetic refrigeration system with capillary tube

If the refrigeration system contains a flammable refrige­rant such as R600a or R290, for example, this will
appear on the type label. A Secop compressor will be provided with a label as shown in Fig. 6.

Fig. 6: Label on compressor for R600a & R290

Servicing and repairing such systems demand specially trained personnel. This implies knowledge of tools,
transporting a compressor, and refrigerants as well as the relevant guidelines and safety rules.
When working with the refrigerants R600a and R290, open fire may only occur as described in existing
guidelines.

Fig. 7 shows a piercing valve for mounting on the pro­cess tube, thus creating an opening in the system for
draining off and collecting the refrigerant as per instructions.

8
 Fig. 7: Piercing valve

Fig. 8: Recovery unit for refrigerants

Before starting to cut tubes in the refrigeration system it is recommended to clean the tubes with an emery
cloth in the places to be cut. This prepares the tubes for subsequent brazing and prevents grains of dirt from
entering the system.
Only use tube cutter, never metal-cutting saw, for cutting tubing in a refrigeration system. Merely a small
burr left in the system can cause a subsequent breakdown of the compressor. All refrigerants must be
collected as per instructions.
When a capillary tube is cut, it is essential to avoid burrs or deformations to the tube. The capillary tube can
be cut with special pliers (see Fig. 9), or with a file a trace can be produced in the tube which can then be
broken.

Fig. 9: Special pliers for capillary tubes

2.2 A system charged with refrigerant must never be heated or brazed, especially not when the refrigerant is
Brazing under an inert flammable. Brazing on a system containing refrigerant will cause the formation of refrigerant decomposition
protective gas products.
Once the refrigerant is drained off, an inert protective gas must be filled into the system. This is done by a
thorough blow-through with dry nitrogen. Before the blow-through, the system must be opened in one more
place.

If the compressor is defective, it would be advisable to cut the suction and pressure tube outside the
compressor connectors, not opening the process tube. However, if the compressor is working properly, it is
recommended to cut the process tube. Blow-through must be done first through the evaporator and then
through condenser. An inlet pressure of approx. 5 bar and a blow-through of approx. 1–2 minutes would be
sufficient for appliances.

9
 2.3 The filter drier absorbs the small water amounts released through the life of the system. It acts as a trap
Filter drier strainer and prevents the capillary tube inlet from blockage and problems with dirt in the expansion valve.

If a refrigeration system has been opened, the filter drier must always be replaced to ensure sufficient
dryness in the repaired system.

The filter drier must always be replaced without the use of a torch. When heating the filter drier, there is a
risk of transferring the absorbed moisture amount to the system. The possibility of a flammable refrige­rant
being present must also be considered.
In case of a non-flammable refrigerant, a blowpipe flame may be used, but the capillary tube must be
broken, and then dry nitrogen must be blown through the filter towards the open air while the filter drier is
detached.
Normally, a filter drier can absorb a water amount of approx. 10% of the desiccant weight. In most systems,
the capacity is not utilized, but in cases of doubt about the filter size, it is better to use an oversized filter
than one with a small capacity.
The new filter drier must be dry. Normally this is no problem, but it must always be ensured that the filter
drier sealing is intact to prevent moisture collection during storage and transport. The filter drier must be
mounted in a way so that the flow direction and gravitation have an effect in the same direction.

This prevents the Molecular Sieve (MS) balls from wearing against each other and producing dust, which
could block the capillary tube inlet. This vertical position also ensures quicker pressure equalization in
capillary tube systems. See Fig. 10.

7469

Fig. 10: Correct location of filter drier

As water has a molecule size of 2.8 Ångstrøm, molecular sieve filters with a pore size of 3 Ångstrøm are
suitable for commonly used refrigerants. The water molecules are absorbed in the pores of the desiccant,
whereas the refrigerant can freely pass through the filter.

Compressor Filter drier

P and T 6 gram or more

F and N 10 gram or more

SC 15 gram or more

UOP Molecular Sieve Division, USA

4A-XH6 4A-XH7 4A-XH9
(earlier Union Carbide)
R12 x x x
R22, R502 x x
R134a, R404A x x
HFC/HCFC blends x
R290, R600a x x
Grace Davision Chemical, USA 574 594
R12, R22, R502 x x
R134a x
HFC/HCFC blends x
R290, R600a x
CECA S.A., France NL30R Siliporite H3R
R12, R22, R502 x x
R134a x x
HFC/HCFC blends x
R290, R600a x
10
2.4 A repair must always be done quickly, and no refrigeration system must be open to the atmosphere for more
Moisture penetration than 15 minutes, to avoid moisture intake. Therefore, it is a good rule to have all replacement parts ready
during repair before the system is opened.

If it is not possible to complete the repair continuously, the open system must be carefully sealed off and
charged with a slight overpressure of dry nitrogen to avoid moisture penetration.

2.5 Rubber grommets should be mounted in the compressor base plate while the compressor is standing on
Preparing the its base plate. If the compressor is placed upside down, oil will gather in the connectors, which leads to
compressor and brazing problems. Never use rubber grommets from a defective compressor because they are often aged
electrical equipment and harder than new rubber grommets.
Remove the cap (capsolute) from the process connector of the new compressor and braze a process tube
into the connector. Leave the compressor closed until it is to be brazed into the system.
It is recommended to plug all connectors on compressor, filter drier, and system if for some reason the
repair is delayed.

The aluminum caps on the connectors must not be left in the finished system.

The caps are only intended to protect the compressor during storage and transport and do not provide
tightness in a system under pressure. The caps make sure that the compressor has not been opened after it
has left Secop. If the caps are missing or are damaged, the compressor should not be used until it has been
dried and the oil has been replaced.

Never reuse old electrical equipment.

It is always recommended to use new electrical equipment with a new compressor, since the use of old
electrical equipment with a new compressor may lead to the compressor developing defects.
The compressor must not be started without a complete starting device. Since part of the starting circuit
resistance lies in the starting device, starting without the complete starting device does not provide good
starting torque and may result in the compressor's start winding to heat very quickly, causing it to be
damaged.

The compressor must not be started in a vacuum.

Starting the compressor in vacuum may cause a breakdown inside between the pins of the current lead-in,
since the insulation property of the air is reduced at falling pressure.

Fig. 11 shows a wiring diagram with PTC starting device and winding protector. A run capacitor connected to
the terminals N and S will reduce energy consumption on compressors designed for this purpose.

Fig. 11: Wiring diagram with PTC and winding protector

11
 Fig. 12 shows a wiring diagram with starting relay and starting capacitor as well as a motor protector
mounted outside the compressor.
Fig. 13 shows a wiring diagram for large SC compressors with CSR motor.

Fig. 12: Wiring diagram with starting relay and starting capacitor

Fig. 13: Wiring diagram for CSR motor

12
2.6 Creation of the correct brazing fit is important. Recommended brazing gaps for brazing joints.
Brazing
If the connection tube is made of steel a solder without phosphor and with a melting point below 740 °C
must be used.

Material Material
Silver brazing solder Copper tubes Steel tubes
Easy-flo 0.05 - 0.15 mm 0.04 - 0.15 mm
Argo-flo 0.05 - 0.25 mm 0.04 - 0.2 mm
Sil-fos 0.04 - 0.2 mm Not suitable

The connectors of most Secop compressors are copper plated steel tubes welded into the compressor
housing. The welded connections cannot be damaged by overheating during brazing.
It is possible to drift the 6.2 mm connectors to 6.5 mm, which fits a ¼” (6.35 mm) tube, but it is not
recommended to drift the connectors more than 0.3 mm. During drifting a backstop is necessary to prevent
the connector from breaking off. See Fig. 14.

Fig. 14: Drifting of connector

Instead of drifting the connectors a reducing pipe as shown in Fig. 15 can be used.

Fig. 15: Reducing pipe

Brazing connectors to a copper tube may be done with a solder containing 2% silver. Phosphorus solder may
also be used provided that the connected tube is made of copper.

It may also be sufficient to use just one solder for all joints, and in this case it is recommended to use
a solder with a silver content of at least 30% to keep the melting temperature in the solder as low as
possible. This prevents the brazing joints from overheating. A flux must be used with the solder, and it is
recommended to stir this into alcohol instead of water (approx. 1/3 flux in 2/3 alcohol). In this way the risk of
water entering the system is reduced.
After brazing the flux residues must be removed by brushing the joint.
13
 To achieve a sufficiently high torch flame temperature, it is recommended to use both acetylene and oxygen
or propane and oxygen since bottled gas, for example, provides a temperature that is too low.

Brazing steel connectors is slightly different from brazing of copper connectors.

Below you will find guidelines for brazing steel connectors:

During heating, the temperature must be kept as close to the solder melting point as possible. Overheating
will cause damage to the tube surface, which reduces the chances for a good joint.

Use the soft heat in the torch flame when the joint is heated.
Distribute the flame in a way that at least 90% of the heat is concentrated around the connector and approx.
10% around the connection tube. See Fig. 16.

Fig. 16: Brazing process for steel connector

When the connector is cherry red (approx. 750 °C), the flame must be moved to the connection tube for a
few seconds. See Fig. 17.

Fig. 17: Brazing process for steel connector

Continue heating the joint with a soft flame and add solder. See Fig. 18.

Fig. 18: Brazing process for steel connector

Draw the solder into the brazing gap by slowly moving the flame towards the compressor and then removing
the flame. See Fig. 19.

Fig. 19: Brazing process for steel connector

Brazing capillary tubes requires quite some precision, partly because overheating will quickly occur, and
partly because the capillary tube is easily blocked.

14
 When the capillary tube is inserted into the filter drier, it can be put so far in that it pushes against the filter
mesh. On the one hand, this may cause blockages, as the refrigerant can only pass a limited part of the
filter mesh. On the other hand, the capillary tube may not be put far enough into the filter drier, thus risking
it to be closed by solder. These problems can be avoided by using capillary tube pliers as shown in Fig. 20.

Fig. 20: Capillary tube correctly located in the filter drier

Depending on the routine a large or small torch size must be used. In some cases it may be necessary to use
a double torch as shown in Fig. 21, as both sides of the joint can then be heated at the same time.

Fig. 21: Double blowpipe

Refrigeration systems containing the flammable refrigerants R600a and R290 must not be brazed. In these
cases a LOKRING® connection can be used.

2.7 When servicing systems with flammable refrigerants, LOKRING® connections may be used for tube joints,
LOKRING® connections especially for closing the process tube. With a LOKRING® connection as shown in Fig. 22 tight tube joints can
(VULKAN Lokring be established in aluminum, copper, and steel. Before assembly, the tube ends must be carefully cleaned
Rohrverbindungen GmbH with steel wool or an emery cloth, and cleaning must be using rotating movements to avoid scratches along
& Co. KG) the tubes, which may complicate sealing. Make sure that no dirt enters the system.

Fig. 22: LOKRING® connection

To ensure a tight seal, the tube ends must be moistened with LOKPREP®, since this material fills any
irregularities present in the tube surface. Once the tube ends have been inserted in the LOKRING®
connection until they reach their final position, the tubes must be turned to obtain a good distribution of
LOKPREP® ® on the tube surfaces. The joint must then be pressed together with a special tool as shown
in Fig. 23.
15
 Fig. 23: Tool for LOKRING®

After 2–3 minutes, the LOKPREP® will harden, and the joint will be stable.

2.8 When a refrigeration system is assembled it must be carefully evacuated, i.e. the air is removed from the
Evacuation system, before it is charged with refrigerant. This is necessary to achieve a good repair result. The primary
purpose of the evacuation is to reduce the amount of non-condensable gasses (NCG) in the system, and
secondly, limited drying will take place. Moisture in the system may cause ice blocking, a reaction with the
refrigerant, aging of the oil, acceleration of oxidation processes, and hydrolysis with insulation materials.

Evacuation of refrigerating system.

Non-condensable gasses (NCG) in a refrigeration system may mean increased condensing pressure and
thus greater risk of coking processes and a higher energy consumption.
The content of NCG must be kept below 1 vol. %.

Evacuation may be done in different ways depending on the volume conditions on the suction and discharge
side of the system. If the evaporator and compressor have a large volume, one-sided evacuation may be
used, otherwise double-sided evacuation is recommended.

One-sided evacuation is done through the compressor process tube, however this method means slightly
worse vacuum and a slightly higher content of NCG. The air must be removed through the capillary tube
From the discharge side of the refrigeration system, thus resulting in substantial restriction. The result will
be higher pressure on the discharge side than on the suction side.
The main factor for the NCG content after evacuation is the equalized pressure in the system, which is
determined by the distribution of volumes. Typically, the volume on the discharge side will constitute 10-20 %
of the total volume, and therefore the high end pressure has less influence on the equalized pressure here
than the large volume and low pressure on the suction side.

Fig. 24: Evacuation process

16
Sample calculation concerning the amount of NCG after evacuation in a system with:
• Discharge side: pD = 50 mbar volume VD = 15 %
• Suction side: ps = 0.3 mbar volume Vs = 85 %

Example:
After evacuation
• Total volume V = 2.25 l
• Discharge side p1 = 50 mbar
V1 = 15% = 0.3375 l
• Suction side p2 = 0.3 mbar
V2 = 85% = 1.9125 l

p1 · V1 + p2 · V2
Pequilized =
Vtotal

50 · 0.3375 + 0.3 · 1.9125

Pequilized = = 7.755 mbar
2.25

Typical operating point of example appliance with R134a.

Evaporating temperature -30 ˚C suction pressure 0.844 bar.

Condensing temperature +44 ˚C discharge pressure 11.30 bar.
Pressure ratio 13.39.

NCG will be pumped with the refrigerant and be compressed with the same pressure ratio.

(p · V)NCG = 7.755 · 2.25 = 17.45 mbar I

(p · V)R134a = p1 · V1 + p2 · V2 =
0.844 · 1.9125 + 11.30 · 0.3375 = 5.4279 bar I

(p · V)NCG 17.45
NCGvol = = · 0.0032 = 0.32 %
(p · V)R134a 5.4279 · 100

This calculation does not take into account the quantity of air absorbed in the compressor's oil filling, which
can vary from 0 to 10 vol.%. This means that the NCG content will be slightly higher in practice.

One-sided evacuation must be done until a sufficiently low pressure is obtained in the condenser. Here it
might be necessary to do one or more short evacuations with intervening pressure equalizations.

Double-sided evacuation must be done until a sufficiently low pressure is obtained.

These procedures require the parts to have a low moisture content when being mounted.
It is possible to obtain a low pressure in the system within a reasonable time by doing a double-sided
evacuation. This means that a leak test is possible before charging the refrigerant.

Fig. 24 shows a typical course of a one-sided evacuation from the compressor process tube. It also shows
a pressure difference in the condenser, which may be remedied by increasing the number of pressure
equalizations.
The broken line shows a procedure in which the two sides are evacuated at the same time. When time is
limited, the final vacuum depends only on the vacuum pump capacity and the content of volatile components
or non-condensable gasses in the oil charge.

Fig. 25 shows an example of an evacuation process with a built-in leak test. The vacuum obtained depends
on the process chosen.

Double-sided evacuation gives the best result and must be recommended.

Once a vacuum below 1 mbar is obtained, the system must be pressure equalized before the final evacuation
and charge of refrigerant.
Normally mbar is used as an expression of a vacuum but other entities are also used, e.g.:
1 mbar = 0.75 torr = 0.75 mmHg
1 mbar = 100 Pascal = 7.5E2 micron

There will always be a certain increase in pressure in a tight system when the connection to the vacuum
pump is closed due to desorption of moisture from inner surfaces in the system and evaporation of volatile
components from the compressor oil charge. In practice, a pressure rise of approx. 0.1 mbar is anticipated.
This pressure rise is often used as an indication of the degree of dryness and tightness in the system and is
very much used during service.

17
 Fig. 25: Evacuation process with leak test

2.9 A good vacuum pump must be available to perform sufficient evacuation. See Fig. 26.
Vacuum pump and
vacuum gauge

Fig. 26: Vacuum pump

For stationary use, a two-stage 20 m3/h vacuum pump can be recommended but for service, a smaller two-
stage 10 m3/h vacuum pump is better suited due to its lower weight.
A hermetic refrigeration compressor is not suitable for the purpose since it is not able to produce a sufficiently
low pressure. Also, a compressor used as a vacuum pump would become overheated and damaged.
The insulation resistance of the air is reduced at falling pressure, and therefore an electrical breakdown at
the current lead-in or in the motor of the hermetic compressor will quickly occur.
The same vacuum pump may be used for all types of refrigerants provided that it is charged with ester oil.
A flameproof vacuum pump must be used for refrige­ration systems containing the flammable refrigerants
R600a and R290.

There is no point in having a suitable vacuum pump available if the vacuum obtained cannot be measured.
Therefore, it is strongly recommended to use an appropriate robust vacuum gauge (Fig. 27) able to measure
pressure below 1 mbar.

Fig. 27: Vacuum gauge

18
3.
HANDLING REFRIGERANTS

To ensure a reasonable refrigeration system life the refrigerant must have a maximum moisture content of
max 20 ppm (20 mg/kg).
Do not fill refrigerant from a large container into a filling bottle through several container sizes, since the
water content in the refrigerant is increased considerably with every drawing-off.

Flammable refrigerants R290 and R600a

R600a must be stored and transported in approved containers only and must be handled according to
existing guidelines.

Do not use open fire near the refrigerants R600a and R290.
The refrigeration systems must be opened with a tube cutter.

Conversion from refrigerants R12 or R134a to R600a is not permitted, since the refrigerators are not
approved for operation with flammable refrigerants, and the electrical safety has not been tested according
to existing standards either. The same applies to conversion from refrigerants R22, R502 or R134a to R290.

3.1 Normally, charging with refrigerant is no problem with a suitable charging equipment which displays the
Charging with current charging amount. The current refrigeration charge of the system has to be known. See Fig. 28.
refrigerant

Fig. 28: Charging board for refrigerant

Always charge the refrigerant amount and type stated by the refrigerator manufacturer. In most cases, this
information is stated on the refrigerator type label.
The different compressor brands contain different amounts of oil, so when converting to another brand it
may be advisable to adapt the amount of refrigerant.
Refrigerant can be charged by weight or by volume. Flammable refrigerants such as R600a and R290 must
always be charged by weight. Charging by volume must be done with a refrigerant charging cylinder.
The refrigerant R404A and all other refrigerants in the 400 series must always be charged as liquid.

If the charging amount is not known, charging must be done gradually until the temperature distribution
above the evaporator is correct. However, it will be often times more appropriate to overcharge the system
and then gradually draw off refrigerant until the correct charge has been obtained. The refrigerant charge
must be made with a running compressor, refrigerator without load, and with the door closed.

The correct charge is characterized by the temperature being the same from inlet to outlet of the evaporator.
At the compressor suction connector the temperature must be approx. ambient temperature. This prevents
moisture from being transferred to the refrigerator insulation. See Fig. 29.

19
 Fig. 29: Evaporator temperatures

Systems with an expansion valve must be charged with refrigerant until there are no bubbles in the sight
glass, which should be placed as close to the expansion valve as possible.

3.2 If the permissible limit of refrigerant charge stated in the compressor data sheet is exceeded, the oil will
Maximum refrigerant foam in the compressor after a cold start and may result in a damaged valve system in the compressor.
charge The refrigerant charge must never exceed the amount that can be contained in the condenser side of the
system.
Compressor Max. refrigerant charge
type R134a R600a R290 R404A
P 300 g. 120 g - -
T 400 g* 150 g 150 g 600 g
DELTA - 150 g - -
X - 150 g - -
D, DLV - 150 g 150 g -
TL ... G 600 g 150 g 150 g -
KAPPA - 150 g - -
N, NLV 400 g* 150 g 150 g -
F 900 g. 150 g - 850 g
S, SLV 1300 g - 150 g 300 g * Single types with
G 2000 g - - 2000 g higher limits available,
SC Twin 2200 g - - 2200 g see data sheets.
3.3 Please also refer to the compressor data sheets, since the present maximum refrigerant charge may deviate
Test on single types from the information in the form. The maximum charge of 150 g for R600a and R290 is an
upper safety limit of the appliance standards, whereas the other weights are stated to avoid liquid hammer.
Before completing repair work, the entire refrigerator must be tested to make sure that the expected
result has been achieved. It must be ensured that the evaporator can be cooled down and thus enable the
requested temperatures to be obtained.
For systems with a capillary tube as the throttling device it is important to check if the compressor runs
satisfactorily on the thermostat. In addition, it must be checked if the thermostat differential allows for
sufficient idle periods for pressure equalization so an LST compressor (low starting torque), if any, can start
and operate without tripping on the motor protector.
In areas where undervoltage may occur, it is important to test operating conditions at 85% of the nominal
voltage, since both starting and stall torque of the motor will decline when the voltage is falling.

3.4 A hermetic refrigeration system must be tight, and if a refrigerator is to have a reasonable lifetime it is
Leak test necessary to keep any leaks below 1 gram refrigerant annually.
Many refrigeration systems with the flammable refrigerants R600a and R290 have charging amounts below
50 g, in these cases the leaks should be below 0.5 g refrigerant annually. This requires high-quality electronic
testing equipment that can measure these small leak rates.
It is relevant to test all brazed joints of the system, also in places where no repair has been made. The joints
on the discharge side of the system (from the compressor discharge connector until condenser and filter
drier) must be examined during operation of the compressor, which results in the highest pressures.
Evaporator, suction tube, and compressor must be examined while the compressor is not operating and the
pressure in the system is equalized, as this results in the highest pressures here (see Fig. 30).
If no electronic detector (Fig. 30) is available, the joints may be examined using soapy water or with spray,
but of course small leaks cannot be found with these methods.

Fig. 30: Leak detector

20
4.
REPLACING A DEFECTIVE
COMPRESSOR

A procedure for replacing a defective compressor in a hermetic refrigeration system is outlined below
according to the basic guidelines. A precondition is that there is a refrigerant overpressure in the system
and that the system is not contaminated with moisture. The refrigerant must correspond to the original
refrigerant.
During fault finding the compressor is found to be defective. If it turns out that the motor has burnt resulting
in strong contamination of the system then another procedure is required.

4.1 By starting with preparing the replacement parts later, prevents delays with opened systems, and thus also
Preparing poses increased risk for admission of moisture and impurities.
components A process tube with process valve must be mounted into the process connector of the new compressor.
In some cases, it may be an advantage to insert a piece of connecting tube into the compressor suction
connector.
By doing so, the later connection of the suction tube to the compressor can take place further away from the
compressor if mounting conditions in the machine compartment are narrow.
When the compressor is ready, process valve and connectors must be closed. Further, the correct filter drier
type must be ready but the cover must remain intact.

4.2 Place a piercing valve connection to a recovery unit on the compressor process tube. Puncture the tube and
Removing the charge collect the refrigerant according to the guidelines. Follow the rules described earlier.

4.3 Cut the compressor suction and discharge tube with a tube cutter approx. 25-30 mm from the connectors in
Removing the defective question. Beforehand, the places to be cut must be trimmed with emery cloth preparing the brazing.
compressor If the compressor is to be tested later, the tube ends must be closed with rubber plugs.
To facilitate any analysis or guarantee repair later the compressor must be provided with the cause for the
fault and the refrigerator production date. Compressors for R600a and R290 must always be evacuated and
sealed before they are returned to refrigerator manufacturer or dealer.

4.4 To avoid decomposition of any refrigerant residues in the system during the subsequent brazing operations
Removing refrigerant the system must be thoroughly blown through with dry nitrogen. This is done by connecting the connection
residue tube from the bottle with dry nitrogen first to the cut suction tube and afterwards to the cut discharge tube.

4.5 The filter drier at the condenser outlet should be cut with a tube cutter but another method may also be
Removing the filter used. Produce a slight flow of dry nitrogen through the discharge tube to the condenser and maintain this
drier flow while the filter is carefully removed with a torch. Avoid heating the filter enclosure itself.

Soldering silver must be removed from the condenser outlet. This is best done by brushing it off while the
4.6 soldering silver is still liquid. The other tube ends are to be prepared for brazing in case this has not yet been
Cleaning the braze done. Take care that grains of dirt or metal do not enter the system when trimming brazed joints.
joints and reassembly If necessary, blow through with dry nitrogen while trimming.
The new filter drier must be mounted at the condenser outlet, and the filter must be kept covered until
assembly can take place. Avoid heating the filter enclosure itself with the flame.
Before brazing the capillary tube into the filter a slight stop must be produced on the tube as described
earlier to ensure the tube end is in the right place in the filter to avoid blockage. Be careful when brazing
the capillary tube to avoid any burning.
Mount the compressor, which should be fitted with rubber grommets during preparation. Mount the
electrical equipment and connect the wires. Evacuation and charge are to be done as described in chapters
2.8 and 3.1. Test to be made as described in chapters 3.3 and 3.4. The process valve must be removed when
the process tube is squeezed and brazed.

21
 5.
CONVERSIONS

5.1 At Secop, product development is focused on high efficiency and eco-friendly products. We believe, like all
From R404A to R452A the major market stakeholders, that hydrocarbon refrigerants (isobutane R600a and propane R290) are the
best solution for DC-powered applications.
The use of R404A is under pressure due to global regulations, however, special attention is given to F-gas
regulation in Europe. Secop recommends the move to hydrocarbon refrigerant solutions (R600a and R290)
which perfectly meet the increasing market demand for high efficiency while utilizing natural refrigerants
with very low GWPs.
We understand that there is a transition period, where specific applications will use different refrigerants
while application redesign to hydrocarbons is not possible within a short period of time. Tests have so far
shown good results with refrigerant R452A as a drop-in replacement for R404A.
Based on this information, Secop allows the use of R452A on all its R404A released compressors. It is the
customer’s responsibility to validate the application and they should carefully consider the requirements
and constrains when changing the R404A to R452A in their application.
(Please refer to Product Bulletin "Refrigerant R452A in Secop Compressors")

5.2 Conversions from refrigerants R134a to R600a are not permitted as 1:1 replacements, as the refrigerator
From R134a to R600a must be approved for operation with flammable refrigerants, and the electrical safety has to be tested
or R290 according to existing standards. The same applies to conversions from refrigerants R502 or R134a to R290.
In many cases of transition from non-flammable to flammable refrigerants the appliance cabinet must be
modified for safety or other reasons.
Refrigerant containing system parts according to IEC / EN 60335 must withstand a specified pressure
without leaking. The high pressure side must withstand saturation overpressure of 70 °C times 3.5, and the
low pressure side must withstand saturation overpressure of 20 °C times 5.
Secop has been a pioneer and early adopter of hydrocarbons as refrigerants and offers a variety of suitable
compressors for R600a and R290.
(Please refer to Application Guideline "Practical Application of Refrigerants R600a and R290 in Small
Hermetic Systems").

5.3 R1234yf is a future refrigerant candidate in auto air conditioning replacing R134a. Likewise it might be used
From R134a to R1234y in DC-powered applications where a redesign of the system to propane is not possible.
R1234yf is classified as flammable in the relevant safety standards. It is more expensive than R134a, yet
holds remarkably less greenhouse potential than R134a.
Our R134a compressors can be used for testing with this refrigerant and we are ready to support you in your
investigation and approval procedure.
Investigations on material compatibility have so far shown good results with refrigerant R1234yf in Secop
R134a compressors. These results must be confirmed in ongoing long term tests.
At present, testing system performance can be carried out with the compressors originally designed for
R134a. The same application limits as described on the R134a data sheet may be used.
The compressors designed for R134a do currently (07/2017) not have a safety approval for flammable
refrigerants like R1234yf, but might be available in approved variants within the near future.
(Please refer to Product Bulletin "Refrigerant R1234yf in Secop Compressors")

22
6.
SYSTEMS CONTAMINATED WITH
MOISTURE

Systems contaminated with moisture can vary in the degree of contamination, and the scope of repair work
will vary accordingly. Systems containing moisture can be divided into two categories: namely the ones with
a low degree of contamination and the ones with a high degree of contamination.
Systems with a low degree of contamination are intact and maintain refrigerant overpressure. Systems with
a high degree of contamination, have been in contact with the atmosphere or moisture has been added
directly. The two types of defect will be treated independently.

6.1 This defect is usually characterized by cooling often interrupted due to ice blockage in the capillary tube
Low level of or in the expansion valve. With heat supply the ice blocking is gradually removed, but if the refrigerant
contamination circulates the blockage will quickly build up again.
This defect may be due to the following reasons:

The system has not been assembled carefully enough.

The components used may have been moist.
A refrigerant with a moisture content that is too high may have been used.
The system will often be new or it has just been repaired. Usually the moisture amounts are small, and
therefore the defect can normally be remedied by replacing refrigerant and the filter drier. The procedure
is as follows:

a) Open the system at the process tube and collect the refrigerant.
It is beneficial to first let the compressor run until it is hot. In this way the moisture and refrigerant amount
left in the motor or in the oil is reduced.
If ice is blocking capillary tube or expansion valve, it is possible to run the compressor hot, however, the
system will not run.
If the capillary tube or expansion valve are accessible, the blockage may be kept hot with a heating lamp or
a cloth with hot water to cause the refrigerant to circulate.
The evaporating temperature in the system may also be increased by heating the evaporator. Do not use an
open flame for heating.

b) After collecting the refrigerant, the system must be blown through with dry nitrogen. Nitrogen injection
must take place through the compressor process tube, and first the suction side and then the discharge side
must be blown through, first directing the nitrogen flow from the compressor through the suction tube and
evaporator and out through the capillary tube, then through compressor and condenser and out through the
filter drier at the condenser outlet. It is beneficial to blow through with so much pressure that any oil in the
components is removed.

c) Replace the filter drier and process tube as described above. It pays to use an oversized filter drier.

d) When the system is reassembled, evacuation must be carried out very carefully. Charge and test according
to earlier mentioned guidelines.

6.2 If there is a rupture in a refrigeration system and the refrigerant overpressure escapes, moisture contamination
High degree of will take place. The longer the system is exposed to the atmosphere, the higher the degree of contamination.
contamination If the compressor is operating at the same time, conditions will worsen further. The moisture amount
admitted will distribute in the compressor, filter drier, and other system components depending on their
ability to hold the moisture.
The oil charge, in particular, in the compressor will absorb the water. Contamination in the evaporator,
condenser, and tubes will primarily be determined by the oil amounts present there. Of course the largest
water amounts will be present in compressor and filter drier. There is also a high risk that valve coking
has begun damaging the compressor. Therefore, compressor and filter drier must be replaced during the
normal repair procedure.

23
 a) Remove the compressor from the system with a tube cutter.
b) Break the capillary tube at the condenser outlet, and blow through the condenser with dry nitrogen as
protective gas.
Remove the filter drier.
Repeat the blow-through with increased pressure to remove oil from the condenser, if any.
Cover condenser inlet and outlet.

c) Treat suction line heat exchanger and evaporator in the same way. The opportunity of an efficient blow-
through is improved if the capillary tube is broken off at the evaporator inlet. Blow-through with
nitrogen will then take place in two paces; first suction tube and evaporator, then capillary tubes.
If the reason for the repair is a broken capillary tube, the operations must be changed to replace the
entire heat exchanger.

d) Reassemble the system with a new compressor and a new filter drier in the right size.

6.3 Evacuation must be done with special care, and subsequently charged and tested according to the general
Evacuation guidelines. The outlined procedure is best suited for simple refrigeration systems.
If the system has difficult access and the design is complex the following procedure may be better suited.

e) Remove the compressor from the system and treat it according to point a.

f) Break the capillary tube at the condenser outlet. Blow through with nitrogen through suction and
discharge tube.

g) Mount a new oversized filter drier at the condenser outlet. Connect the capillary tube to the filter drier.

h) When the system, excl. compressor, is intact again carry out a drying. This is done at the same time by
connecting suction and discharge tube to a vacuum pump and evacuating to a pressure lower than 10 mbar.
Equalize pressure with dry nitrogen. Repeat evacuation and equalization of pressure.

i) Mount the new compressor. Then evacuate, charge, and test.

In some markets, it may be necessary to repair a moist compressor in a workshop, and one is then obliged
to manage somehow. The drying process described here can offer the desired result, provided that the
process is closely complied with.

6.4 Draw off the compressor oil charge.

Drying the compressor Then flush the compressor inside with ½-1 liters of a non-flammable low pressure refrigerant or solvent.
Plug the compressor with the solvent inside and shake it thoroughly in all directions so that the refrigerant
coats all inside surfaces.
Collect the solvent as explained.
Repeat the operation once or twice to ensure that no substantial oil residues are left in the compressor.
Blow through the compressor with dry nitrogen.
Connect the compressor to an arrangement as shown in Fig. 31.

Plug the discharge connector.

The connections to the compressor suction connector must be vacuum tight. This can be achieved by using
brazed joints or a suitable vacuum hose.
Bring the compressor up to a temperature between 115 °C and 130 °C before starting evacuation. Then start
the evacuation that must bring the pressure in the compressor down to 0.2 mbar or lower.
The joints in the vacuum system must be tight in order to achieve the required vacuum. The moisture
content in the compressor will also influence the time for reaching the vacuum.
If the compressor is highly contaminated a few pressure equalizations with dry nitrogen to atmospheric
pressure will enhance the process.
Shut off the connection to the vacuum instrument during the pressure equalization.
Temperature and vacuum must be maintained for approx. 4 hours.
Upon finishing the drying process, the pressure in the compressor must be equalized to atmospheric
pressure with dry nitrogen and the connectors must be sealed.
Charge the compressor with the specified oil type and amount and mount it into the refrigeration system.

24
 Fig. 31: Drying of compressor

6.5 In some cases it can be necessary to replenish a compressor with oil if it has lost some of the charge.
Oil charge On some older Secop compressors, the amount of oil is indicated on the type label, however, not on all, so
the present oil type and amount must be found in the compressor data sheet.

It is absolutely essential to use the oil approved for the compressor in question. If a lost oil charge in a
compressor must be replaced, it must generally be assumed that approx. 50 ccm of the oil charge will be
left in the compressor when it is emptied completely by draining oil off from a connector.

25
 7.
LOST REFRIGERANT CHARGE

The term “lost charge” covers cases in which the desired cooling function is not achieved because there is
no sufficient amount of refrigerant in the system.

The repair procedure implies a refrigerant overpressure in the system so that the contamination problems
that may be caused by penetrating moisture can be disregarded. “Lost charge” is characterized by the
fact that the intended cooling is not achieved. The running time is long, and the compressor may run
continuously. The build-up of rime on the evaporator is only partly and perhaps only around the injection
area. The compressor will operate at low evaporating pressures, and this means low power and current
consumption. The compressor will have a higher temperature than normal due to the reduced refrigerant
transport.

The difference between “lost charge” and “blocked capillary tube” consists in the prevailing condenser
pressure, however, after some time, the pressure will be the same in both cases.

“Blocked capillary tube” results in the refrigerant being pumped into the condenser, and the pressure
reaches a high level. As the evaporator is pumped empty, however, the condenser will become cold.
If the blockage is complete pressure will not be equalized when the compressor is in an idle state. With “lost
charge”, however, the pressure in the condenser will be lower than normal.
A considerable part of the repair procedure consists of finding the cause of the defect. If this is not done, it
will only be a question of time until the defect occurs again.
If the capillary tube in small systems is blocked, they will normally be scrapped, but if large expensive
systems are concerned, it may be necessary to replace the suction line heat exchanger.
The main steps for conducting repairs may be as ­follows (for non-flammable refrigerants only).

a) Mount a service valve on the compressor process tube.

Mount a pressure gauge and use this for fault determination.

b) Increase the refrigerant pressure in the system to 5 bar.

c) Examine all joints to see if there is any oil oozing out.

Perform a thorough search with leak test equipment until the leak is found.

d) Release the overpressure from the system.

Break the capillary tube at the condenser outlet.
Blow through the system with dry nitrogen.

e) Replace filter drier as described earlier.

Replace the process tube and repair the leak.

f) Evacuate the system and charge it with refrigerant.

Subsequently make a new leak test and test out the system.
After a pressure test of the system with high pressure perform a slowly starting evacuation with a large
vacuum pump since otherwise the oil can be pumped out of the system.

26
8.
BURNT COMPRESSOR MOTOR

A burnt motor has destroyed the wire insulation. Burning means motors where the wire insulation has
eroded. A real burning is characterized by the wire insulation in the motor having been exposed to critical
temperatures for a long time. If the temperature conditions in a compressor are changed in a way that the
insulation material is exposed to a critical temperature for a long time, then burning will occur.
Such critical conditions may arise when the ventilation conditions are reduced (e.g. due to a defective fan),
when the condenser is dirty or under abnormal voltage conditions.

8.1 The fault “lost charge” may have a corresponding effect. A part of motor cooling is done by causing the
Oil acidity refrigerant to circulate. When the refrigeration system loses charge, the evaporating pressure becomes
abnormally low, less refrigerant is circulated per time unit, and cooling is reduced. In many cases a motor
protector mounted in the electrical equipment cannot protect against such conditions. The motor protector
is activated both by current and by temperature. If the current consumption is low, a high temperature
is required around the protector to cause cut-out. However, at falling evaporating temperatures, the
temperature difference between motor and compressor housing will increase due to the poorer heat
transmission. Winding protectors placed directly in most motors provide a better protection in this situation,
since they are primarily activated by the motor winding temperature.

8.2 If the wire insulation has eroded, very high temperatures will arise at the short-circuited wires. This may
Burnt system cause further decomposition of refrigerant and oil. As long as the compressor is functional, the entire
process may cause circulation of breakdown products and thus contaminate the system.
The break down of certain refrigerants may produce acid. If no cleaning is done when replacing a compressor,
the start of the next breakdown is sure to occur.
Motor defects in hermetic compressors in household refrigerators are relatively rare.
Normally, failures in the start winding do not cause contamination to the system but a short-circuit in the
main winding may very well result in contamination.

As a burnt motor may result in contamination to the system by acid products, the acidity can be taken as a
criterion whether the system requires a thorough cleaning. The compressor itself and the discharge side
of the system up to the filter drier will be the most contaminated part of the system. Once the refrigerant is
removed from the system the compressor oil will show contamination or acidity. A simple assessment can
be made with an oil sample in a clean test glass. If the oil is dark, sludgy, and perhaps contaminated with
decomposed particles from the motor insulation and there is an acidic smell, there is something wrong.

Repairing a burnt system with products of decomposition is not recommended, and if a repair has to be
performed nevertheless, it is absolutely essential to remove the decomposed products from the system
to avoid contamination and thus breakdown of the new compressor. The following procedure can be used.
a) Remove the defective compressor.
Blow through the tubes to remove old oil.
b) Mount a new compressor and a Danfoss DAS suction line burnout filter in the suction tube in front of
the compressor to protect it against contamination products.
Replace the filter drier at the condenser with a DAS filter.
c) Evacuate and charge the system.
Then let the system operate continuously for at least 6 hours.
d) Check the oil for acidity.
If the oil is ok no further cleaning is required.
Remove the filter in the suction line.
Blow through the capillary tube thoroughly.
Mount a new filter drier at the condenser outlet, e.g. Danfoss DML.
Evacuate the system and charge it with refrigerant.
e) If the oil is acid under item d, replace the suction line filter and let the system operate for another 48
hours and then check the oil. If the oil is ok, follow the instructions in d).

27
 9.
LOCATING FAULTS ON
PL / DL / TL / NL / FR COMPRESSORS

This chapter is directed especially to the service network, for household appliances and similar. For detailed
information on compressors see the specific data sheets.
Compressors type PL, DL, TL, NL, FR, and partly SC are equipped with a PTC starting device (Fig. 32) or a
relay and start capacitor (Fig. 33). The motor protector is built into the windings.

In the event of a start failure with a cold compressor, up to 15 minutes can elapse before the protector cuts
out the compressor.

When the protector cuts out and the compressor is warm, it can take up to 1 hour before the protector cuts
in the compressor again.

The compressor must not be started without the electrical equipment.

Fig. 32: PTC starting device Fig 33.: Starting relay

9.1 Before beginning systematic fault location, a good rule is to cut the supply voltage for at least 5 minutes. This
Location of fault ensures that the PTC starting device has cooled off and is ready for start.
A voltage drop or blackout within the first minutes of a pull down of the appliance with cold compressor, can
lead to an interlocking situation. A compressor with PTC cannot start at non-equalized pressure and the PTC
does not cool down so fast. It can take more than 1 hour until the appliance then operates normally again.

9.2 To avoid unnecessary protector operation and consequent waiting time, it is important to carry out fault
Electrical quick check location in the sequence given below. Tests are made according to descriptions on following page.
• Remove electrical equipment
• Check electrical connection between main and start pins of compressor terminal
• Check electrical connection between main and common pins of compressor terminal
• Replace compressor, if above connection checks failed
• Else, replace electrical equipment

If the compressor still will not operate, most probably there is no electrical compressor failure. For more
detailed information on locating faults, please see the tables in chapter 11 and 12.

28
10.
LOCATING FAULTS –
DETECTABLE FAULTS

10.1
Check main and start
winding

Fig. 34: Compressor terminals Fig 35: Windings and protector

Resistance between pins M (main) and S (start) on compressor terminals is measured with an ohm-meter
(see Figure 34)
• Connection: Main and start
windings normally OK
• No connection: Main or start winding
defective: Replace compressor

At cold compressor (ca. 25 °C) the values are ca. 10 to 100 Ohm for 220-240 V compressors. For partial short
circuit detection, exact values are needed from data sheets of the specific compressor, which can be found
on our website.

10.2 Resistance between pins M (main) and C (common) on compressor terminals is measured with an ohm-
Check protector meter (see figure 34 and 35.)
• Connection: Protector OK
• No connection: Compressor cold: Protector defective: Replace compressor
Compressor hot: Protector could be
OK, but cut out: Wait for reset

10.3 Remove relay from compressor. Measure connection between connectors 10 and 12 (see figure 36):
Check relay • No connection: Relay defective: Replace relay

Measure connection between connectors 10 and 11:

In normal vertical position (like mounted, solenoid upward):
• Connection: Relay defective: Replace relay
• No connection: OK

In top-down position (solenoid downward):

• Connection: OK
• No connection: Relay defective: Replace relay

10.4 Remove PTC from compressor. Shake by hand. Pin C can slightly rattle.
Check PTC • Internal rattle noise
(except pin C): PTC defective: Replace PTC

Measure resistance between pins M and S (see figure 37). Resistance value between 10 and 100 Ohm at
room temperature for 220 V PTC.
• Connection: PTC working: OK
• No connection: PTC defective: Replace PTC

Fig. 36: Relay connections Fig 37: PTC connections (backside)

29
 11.
LOCATING FAULTS
TABLE I

Customer First analysis Possible cause Check Activity

claim (depends on result)

No/reduced Compressor Compressor gets no Voltage at plug and fuse

cooling does not run or bad power supply Appliance energized
Thermostat function
Cables and connections in appliance
Voltage at compressor terminals
Defective starting Relay function by shaking to hear if Replace relay
equipment armature is working
Start capacitor function Replace start capacitor
PTC by shaking Replace if noise appears
PTC resistance 10 to 100 Ohm Replace PTC
between M and S pin
Compressor with PTC Stop time long enough for pressure Adjust thermostat
can not start at equalization difference
pressure difference
PTC defective PTC resistance 10 to 100 Ohm Replace PTC
between M and S pin
Relay defective Relay function by shaking, to hear Replace relay and
moving of armature capacitor
Compressor Condenser pressure and ventilation Ensure proper ventilation
overloaded Ambient temperature too high
according to type label of appliance
Defective motor Check winding resistances Replace compressor
windings
Defective protector Check protector with ohmmeter Replace compressor
Mechanically blocked Start with proper starting equip- Replace compressor
compressor ment, voltage and conditions,
windings and protector OK
Compressor No or low refrigerant Recharge and search for leaks Ensure leakfree system
runs 100% charge and proper charge,
replace drier
Too high ambient Ambient temperature according to
temperature type label of appliance
Too high condensing Condenser and compressor Ensure proper ventilation
temperature ventilation and wall distance
Capillary partly Recharge and search for leaks,
blocked measure suction pressure. Capillary
blocked, if pressure very low
Valves coked or Recharge and search for leaks Replace compressor, if
damaged still not cooling properly
Compressor Thermostat not OK Thermostat type and function Replace thermostat
runs on/off Wrong refrigerant Recharge and search for leaks Ensure leakfree system
charge and proper charge,
replace drier
Ice block built up on Check for ice on evaporator Defrost properly
evaporator Thermostat function and settings Replace thermostat
Internal no-frost fan function
Compressors trips on Compressor load, compressor and Ensure proper ventilation
motor protector condenser ventilation and wall distance
Compressor voltage supply for Ensure proper power
minimum 187 V supply
Compressor voltage supply for drop Fix all connections
outs. Check thermostat and appli-
ance cables for loose connections
Motor windings resistance for partly Replace compressor
short circuit or earth connection

30
12.
LOCATING FAULTS
TABLE II

Customer First analysis Possible cause Check Activity

claim (depends on result)

Noise Rattle or Tube touching cabinet Tube placing Bend tube to their right
humming place, carefully
Compressor touching Compressor mounting and rubber Place rubber feet and
cabinet feet mounting accessories
correctly
Broken internal Listen to compressor with screw- Replace compressor, if
suspension spring or driver against compressor with edge abnormal sounds
discharge tube and to your ear with grip
Resonance Find vibrating mounting parts Place or fix correctly
Fan noise Vibration of fan or fan mounting Fix fan and blade, replace,
if defective
Banging at Compressor block hit- Compressor overload by pressure Clean condenser if dusty.
start or stop of ting housing internally Make sure, that ventilation
compressor gaps for air circulation are
satisfactory
Fan function
Refrigerant charge Recharge, if too high
Pressure equalization before start Adjust thermostat, if stop
and number of on/off cycles time less than 5 min
Ambient temperature according to Take appliance out of
type label function, if ambient too
hot
Relay clicking Compressor over- Ventilation to compressor and con- Clean condenser if dusty.
frequently after loaded denser. Check fan function Make sure, that ventilation
start gaps for air circulation are
satisfactory
Relay defective Right relay type for compressor Replace relay, if wrong
Fuses are Short circuit in Defective cabling in All connecting cables and power Fix connections properly
blown by appliance appliance supply cord for loose connections,
appliance short circuits
Defective thermostat Thermostat connections Fix connections properly
Ground connection Resistance from line/neutral to earth
Short circuit in Defective terminals For burns on the terminal pins Replace electrical
compressor accessories
Short circuit between Connectors and cables at com- Insulate cables and
cables at terminals pressor connectors
Short circuit in Resistance values in windings Replace compressor, if
compressor motor Resistance between terminals and short circuited
earth
Fuse blows at Supply voltage too Supply voltage at compressor start
compressor low >187 V
start Fuse loaded by too Total fuse load Connect appliance to
many appliances different fuse
Resettable fuse too Fuse load and type If possible replace by
quick acting slightly slower type
Partly short circuit to Resistance between terminals and Replace compressor, if
earth earth short circuited
Starting capa- Defective relay Relay function by shaking, to hear Replace relay and
citor exploded moving of armature capacitor
Wrong relay type Relay type Replace relay and cap
Extremely many starts Relay type Replace relay and cap
and stops of com- Thermostat defect or differences too Adjust or replace
pressor small thermostat
Starting relay Short circuit in com- Compressor motor resistances Replace compressor
cap blown off pressor motor

31
www.secop.com
OUR IDENTITY
At Secop we are committed to our industry and are genuinely passionate about the difference we are able to
make for our customers. We understand their business and objectives and the challenges of today's world of
refrigeration and cooling systems.
We work in a straightforward way, being open, direct and honest because we want to make things clear and easy.
Our people are committed to increasing value for our customers and constantly strive for better performance,
knowing that our own progression and success is dependent on theirs.

A NEWCOMER WITH 60 YEARS OF EXPERIENCE

Formerly known as Danfoss Compressors, Secop is one of the founding fathers of modern compressor
technology with an experience that goes back to the beginning of the 1950s.
For more than 25 years, Secop has been setting the standard in compressor technology by developing highly
efficient variable speed compressors and by compressors working with hydrocarbons.

OUR JOURNEY SO FAR

1970 2013
1956 Introduction of SC
1992 1999 2005 2008 Introduction of the XV compressor

Production facility and

compressors.
The birth of a standard- 1990 Start of production with Production facility
- opening a new chapter in
refrigeration history.
headquarters in Flensburg, setting platform in the light Introduction of NL Introduction of PL natural refrigerant Introduction of GS in Wuqing, China Secop acquires ACC Fürstenfeld,
Germany founded. commercial market. compressors. compressors. R290 (propane). compressors. founded. Austria.

1958 1972 1977 1993 2002 2010 2015

Start of production for Introduction of FR Introduction TL and BD Start of production with Production facility in Zlate Introduction SLV-CNK.2 New generation of
PW compressors. compressors. compressors. natural refrigerant R600a (isobutane). Moravce, Slovakia founded. and SLV-CLK.2 variable energy-efficient propane
Production facility in Crnomelj, speed compressors. compressors.
Slovenia founded. Introduction BD1.4F New variable speed platforms
Micro DC compressor. for household and light
Introduction of DLX and commercial applications.
NLU compressors.

Low Cooling Capacity High

HOUSEHOLD

LIGHT COMMERCIAL

AC

P-Series T-Series DELTA X-Series KAPPA D-Series N-Series F-Series S-Series G-Series

DC

BD Micro BD BD
P-Housing T-Housing

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on order provided that such alterations can be made without subsequential changes being necessary to specifications already agreed. All trademarks in this material are the property of the respective
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Produced by Secop | May 2018 DES.G.620.A2.02