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HI-E DRY 195
Installation, Operation and Maintenance Instructions
12
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10. Reconnect the wires to the compressor and capacitor; plug in and turn on the unit. If the compressor
fails to start, replace the run capacitor.
11. If the unit still does not start, adding a hard-start kit will provide greater starting torque. If this does not
work, the compressor has an internal mechanical defect and must be replaced.
5.6B Replacing a Burned Out Compressor
The refrigerant and oil mixture in a compressor is chemically very stable under normal operating conditions.
However, when an electrical short occurs in the compressor motor, the resulting high temperature arc causes
a portion of the refrigerant oil mixture to break down into carbonaceous sludge, a very corrosive acid, and
water. These contaminants must be carefully removed otherwise even small residues will attack replacement
compressor motors and cause failures.
The following procedure is effective only if the system is monitored after replacing the compressor to insure
that the clean up was complete.
1. This procedure assumes that the previously listed compressor motor circuit tests revealed a shorted or
open winding. If so, cautiously smell the refrigerant from the compressor service port for the acid odor of
a burn out.
WARNING: The gas could be toxic and highly acidic. If no acid odor is present, skip down to the
section on changing a non-burn out compressor.
2. Remove and properly dispose of the system charge. DO NOT vent the refrigerant or allow it to contact
your eyes or skin.
3. Remove the burned out compressor. Use rubber gloves if there is any possibility of coming in contact
with the oil or sludge.
4. To facilitate subsequent steps, determine the type of burn out that occurred. If the discharge line shows
no evidence of sludge and the suction line is also clean or perhaps has some light carbon deposits, the
burn out occurred while the compressor was not rotating. Contaminants are therefore largely confined to
the compressor housing. A single installation of liquid and suction line filter/driers will probably clean up
the system.
If sludge is evident in the discharge line, it will likely be found in the suction line; this indicates the
compressor burned out will running. Sludge and acid have been pumped throughout the system. Several
changes of the liquid and suction filter/driers will probably be necessary to cleanse the system.
5. Correct the system fault that caused the burn out. Consult the factory for advice.
6. Install the replacement compressor with a new capacitor and an oversized liquid line filter.
In a running burn out, install an oversized suction line filter/drier between the accumulator and
compressor. Thoroughly flush the accumulator with refrigerant to remove all trapped sludge and to
prevent the oil hole from becoming plugged. A standing burn out does not require a suction line filter/
drier.
7. Evacuate the system with a good vacuum pump and accurate vacuum gauge. Leave the pump on the
system for at least an hour.
8. Operate the system for a short period of time, monitoring the suction pressure to determine that the
suction filter is not becoming plugged. Replace the suction filter/drier if pressure drop occurs. If a severe
running burn out has occurred, several filter/driers may have to be replaced to remove all of the acid and
moisture.
