2

REPAIR OF HERMETIC
REFRIGERATION SYSTEMS

REFRIGERATION AND
AIR CONDITIONING
 1.0 GENERAL
1.1 Fault location
1.2 Replacement of thermostat
1.3 Replacement of electrical equipment
1.4 Replacement of compressor
1.5 Replacement of refrigerant
2.0 RULES FOR REPAIR WORK
2.1 Opening the system
2.2 Brazing under an inert protective gas
2.3 Filter drier
2.4 Moisture penetration during repair
2.5 Preparation of compressor and
electrical equipment
2.6 Soldering
2.7 LokRing connections
2.8 Evacuation
2.9 Vacuum pump and vacuum gauge
3.0 HANDLING OF REFRIGERANTS
3.1 Charging with refrigerant
C O N T E N T S
3.2 Maximum refrigerant charge
3.3 Test
3.4 Leak test
R E P A I R O F H E R M E T I C 4.0 REPLACEMENT OF
R E F R I G E R A T I O N
DEFECTIVE COMPRESSOR
S Y S T E M S
4.1 Preparation of components
4.2 Removal of charge
4.3 Removal of defective compressor
4.4 Removal of refrigerant residues
4.5 Removal of filter drier
4.6 Cleaning of soldered joints and reassembly
5.0 FROM R12 TO OTHER REFRIGERANTS
5.1 From R12 to alternative refrigerant
5.2 From R12 to R134a
5.3 From R134a to R12
5.4 From R502 to R404A
6.0 SYSTEMS CONTAMINATED
WITH MOISTURE
6.1 Low degree of contamination
6.2 High degree of contamination
6.3 Drying of compressor
6.4 Oil charge
7.0 LOST REFRIGERANT CHARGE
8.0 BURNT COMPRESSOR MOTOR
8.1 Oil acidity
8.2 Burnt system

This leaflet is for service technicians installing compressors in hermetic

refrigerating systems using refrigerants R12, R134a, R290, R404A/R507,
Danfoss Compressors R407C and R600a.
1.0 Repairs of refrigerators and freezers demand skilled
GENERAL technicians who are to perform this service on a variety
of different refrigerator types.
Previously service and repair were not as heavily regu-
lated as now due to the new refrigerants, some of
which are flammable.

Fig. 2: Hermetic refrigeration system with expansion

valve

Repair and service is more difficult than new assembly,

since working conditions “in the field” are normally
worse than in a production site or in a workshop.
A precondition for satisfactory service work is that
Fig. 1: Hermetic refrigeration system with capillary tubes the technicians have the right qualifications, i.e. good
workmanship, thorough knowledge of the product,
Fig. 1 shows a hermetic refrigeration system with precision and intuition.
capillary tube as expansion device. This system type The purpose of this guide is to increase the knowledge
is used in most household refrigerators and in small of repair work by going through the basic rules. The
commercial refrigerators, ice cream freezers and bottle subject matter is primarily dealt with reference to repair
coolers. of refrigeration systems for household refrigerators
Fig. 2. shows a refrigeration system using a thermo- “in the field“ but many of the procedures may also be
static expansion valve. This system type is mainly used transferred to commercial hermetic refrigeration instal-
in commercial refrigeration systems. lations.

1.1 Before performing any operations on a refrigeration statements which faults could be possible, and for most
Fault location system the progress of the repair should be planned, i.e. faults a relatively accurate diagnosis can be made.
all necessary replacement components and all resources However, a precondition is that the service technician
must be available. To be able to make this planning the has the necessary knowledge of the functioning of the
fault in the system must first be known. product and that the right resources are available. An
For fault location tools must be available as shown in fig. elaborate fault location procedure will not be gone
3. Suction and discharge manometer, service valves, mul- through here, however, the most common faults where
timeter (voltage, current and resistance) and a leak tester. the compressor does not start or run are mentioned in
In many cases it can be concluded from the user’s the following.

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

Main switch released coking or copper platings due to moisture or non-con-

One potential fault may be a defective fuse, and the densable gases in the system.
reason may be a fault in the motor windings or in the Blown gaskets or broken valve plates are due to too high
motor protector, a short circuit or a burnt current lead-in peak pressures and short-time pressure peaks as a re-
on the compressor. These faults require the compres- sult of liquid hammering in the compressor, which may
sor to be replaced. be due to a too high refrigerant charge in the system or
a blocked capillary tube.
Compressor The voltage may be too low or the pressure too high for
Starting device and compressor motor may be a the compressor.
wrong choice. Compressor motor or winding protector Non equalized pressure causes the motor protector to
may be defective, and the compressor may be me- cut out after each start and will eventually result in a
chanically blocked. burnt motor winding.
Frequent reasons for reduced refrigeration capacity are A defective fan will also affect the compressor load and

D a n f o s s C o m p r e s s o r s 1
 may cause motor protector cut outs or blown gaskets. Thermostat
In case of unsuccessful start and cold compressor up A defective or incorrectly set thermostat may have cut
to 15 minutes may pass until the winding protector cuts out the compressor. If the thermostat loses sensor
the compressor out. If the winding protector cuts out charge or if the temperature setting is too high, the
when the compressor is hot up to 45 minutes may pass compressor will not start. The fault may also be caused
until the protector cuts the compressor in again. by a wrong electrical connection.
Before starting a systematic fault location it is a good Too low a differential (difference between cut in and
rule to cut off the voltage to the compressor for 5 min- cut out temperature) will cause too short compressor
utes. This ensures the PTC starting device, if any, to be standstill periods, and in connection with a LST com-
cooled sufficiently to be able to start the compressor. pressor (low starting torque) this might lead to starting
problems.
Should a brief power failure occur within the first See also point 1.2 “ Replacement of thermostat”.
minutes of a refrigeration process, a conflict situation
(interlocking) may arise between the protector and the For further details please refer to “Fault location and
PTC. A compressor with a PTC starting device cannot prevention in refrigeration circuits with hermetic com-
start in a system that is not pressure-equalized, and the pressors”.
PTC cannot cool so quickly. In some cases it will take
up to 1 hour until the refrigerator runs normally again. A careful fault determination is necessary before open-
ing the system, and especially before removing the
High and low pressure switches compressor from the system. Repairs requiring opera-
Cut out of the high pressure switch may be due to too tions in a refrigeration system are rather costly. Before
high condensing pressure, probably caused by lack of opening old refrigeration systems it may therefore be
fan cooling. appropriate to make sure that the compressor is not
A cut-out low pressure switch may be due to insufficient close to breaking down though it is still functional.
refrigerant charge, leakage, evaporator frost formation An estimation can be made by checking the compres-
or partial blockage of the expansion device. sor oil charge. A little oil is drained in to a clean test
The cut out may also be due to a mechanical failure, glass and is compared with a new oil sample. If the
wrong difference setting, wrong cut-out pressure set- drained oil is dark, opaque and containing impurities,
ting or irregularities in pressure. the compressor should be replaced.

1.2 Before replacing the compressor it is a good idea to In order to achieve the requested function the thermo-
Replacement of check the thermostat. stat sensor (the last 100 mm of the capillary tube) must
thermostat A simple test can be made by short-circuiting the ther- always be in close contact with the evaporator.
mostat so the compressor gets power directly. If the When replacing a thermostat it is important to check
compressor can operate like this the thermostat must whether the compressor operates satisfactorily both
be replaced. in warm and cold position, and whether the standstill
For replacement it is essential to find a suitable type, period is sufficient for the system pressure equalization
which may be difficult with so many thermostat types when using a LST compressor.
in the market. To make this choice as easy as possible With most thermostats it is possible to obtain a higher
several manufacturers, i.e. Danfoss, have designed so- temperature differential by adjusting the differential
called “service thermostats” supplied in packages with screw. Before doing this it is recommended to seek
all accessories necessary for thermostat service. advice in the thermostat data sheet which way the
With eight packages, each covering one type of refrig- screw must be turned.
erator and application, service can be made on almost Another way of obtaining a higher differential is to place
all common refrigerators. See fig. 4. a piece of plastic between the sensor and the evapora-
tor, since 1 mm plastic results in approx. 1°C higher

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 satisfactory pressure equalization
in the system standstill periods.

D a n f o s s C o m p r e s s o r s 2
1.3 The cause for faults may also be found in the electrical many hermetic compressors the entire compressor
Replacement of equipment of the compressor, where it is possible to must be replaced.
electrical equipment replace starting relay/PTC starting device, motor pro-
tector, starting or run capacitor. When replacing a compressor the electrical equipment
A damaged starting capacitor may be caused by too must be replaced as well, since old electrical equip-
low thermostat differential setting, since the starting ment used with a new compressor may cause a com-
capacitor must maximum cut in 10 times/hour. pressor breakdown later.
If a fault is found on the winding protector built into

1.4 If the failure is a defective compressor, the technician The cooling capacity must correspond to the one of
Replacement of must take care to select a compressor with the correct the previous compressor, but if the capacity is un-
compressor characteristics for the appliance. known a comparison of the compressor displacements
If a compressor corresponding to the defective one is will be applicable. It would be appropriate to select a
available, and if it is intended for a non regulated refrige- compressor slightly larger than the defective one.
rant, no further problems will arise. However, in many For a capillary tube system with pressure equalization
cases it is impossible to provide the same compressor during the standstill periods a LST compressor (low
type as the defective one, and in this case the service starting torque) can be used, and for a system with
technician must be aware of some factors. expansion valve or no pressure equalization a HST
If it is a question of changing from one compressor compressor (high starting torque) is to be chosen.
manufactured to another it can be difficult to select the Of course a HST compressor may also be used in a
correct compressor, and therefore different parameters capillary tube system.
have to be considered. Finally the compressor cooling conditions must also
Compressor voltage and frequency must correspond be considered. If the system has an oil cooling ar-
to voltage and frequency on location. rangement, a compressor with an oil cooler must be
Then the application area must be considered (low, selected.
medium or high evaporating temperatures). In a service situation a compressor with an oil cooler
instead of a compressor without oil cooler can be used
without problems, since the spiral can be completely
ignored when it is not required.

1.5 The best solution for a repair is to select the same re- The flamable refrigerants must only be used in refrige-
Replacement of frigerant as used in the present system. ration systems meeting the requirements of EN/IEC
refrigerant Danfoss compressors are supplied or were supplied in 60335-2-24 or -2-89, including demands for flammable
versions for the refrigerants R12, R22, R502, R134a, refrigerants. and the service personnel must be spe-
R404A/R507/R407C and for the flammable refrigerants cially trained for the handling. This implies knowledge
R290 and R600a. of tools, transport of compressors and refrigerant as
The refrigerants R12 and R502, which are covered by well as all relevant rules and safety regulations.
the regulations in the Montreal Protocol, may be used in If open fire or electrical tools are used near the refrige-
very few countries only, and the refrigerants will eventu- rants R600a and R290, this must take place in con-
ally be phased out of production altogether. formity with current regulations.
For heat pump systems the refrigerant R407C is now The refrigeration systems must always be opened with
used instead of R22 and R502. a tube cutter.
The more environmentally acceptable refrigerant R134a
has replaced R12, and the refrigerants R404A and R507 Change from the refrigerants R12 or R134a to R600a
have replaced R22 and R502 in many applications. is not permitted, since the refrigerators are not approved
for use with flammable refrigerants, and the electrical
The flammable refrigerants R290 and R600a safety has not been tested according to current stand-
Maximum charge of these refrigerants in a system is ards. The same applies to change from the refrigerants
150 g according to today’s relevant appliance standards, R22, R502 or R134a to R290.
and they must be applied in small refrigerators only.

Blend refrigerants
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

Refrigerant blends mitted for a short period, which meant that they were
At the same time as the new environmentally acceptable not widely spread in connection with small hermetic
refrigerants (R134a and R404A) were introduced, some refrigeration systems.
refrigerant blends for service purposes were also intro- Use of these refrigerants cannot be recommended for
duced. They were better environmentally acceptable series production but they can be used for repair in
than the previously used CFC refrigerants (R12 and many cases, see the table above.
R502).
In many countries the refrigerant blends were only per-

D a n f o s s C o m p r e s s o r s 3
1.5 Add in Retrofit
Replacement of This designation is used when filling up an existing re- The term retrofit is used about service on refrigeration
refrigerant frigeration system with another refrigerant than the one systems replacing the CFC refrigerant by an environ-
originally charged. mentally acceptable HFC refrigerant.
This is especially the case when problems arise which The refrigeration system is flushed, and the compressor
must be solved with as small an operation as possible. is replaced by an HFC compressor. Alternatively the
Correspondingly, R22 systems were replenished with a compressor oil is replaced by a suitable Ester oil.
small amount of R12 in order to improve the flow of oil The oil must be changed several times after short op-
back to the compressor. erating periods, and the filter drier must be replaced.
In several countries it is not allowed to add in on CFC
systems (R12, R502, …...) In case of oilreplacement a statement from the com-
pressor manufactorer on material compatibility is nec-
Drop in essary.
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).

D a n f o s s C o m p r e s s o r s 4
2.0 To enable a hermetic refrigeration system to work as faults in a refrigeration system often start disadvanta-
RULES FOR intended and to achieve a reasonable service life the geous chemical processes, and that opening a refrige-
REPAIR WORK content of impurities, moisture and non condensable ration system creates possibilities for contamination.
gases must be kept on a low level. If a repair is to be carried out with a good result a se-
When assembling a new system these requirements ries of preventive measures is necessary. Before stating
are relatively easy to meet, but when repairing a defec- any details about the repair work, some general rules
tive refrigeration system the matter is more compli- and conditions have to be explained.
cated. Among other things, this is due to the fact that

2.1 Fig. 8 shows a recovery unit for refrigerants

Opening of the system

Fig. 5: Hermetic refrigeration system with capillary tube

If the refrigeration system contains a flammable refrige- Fig. 8: Recovery unit for refrigerants
rant like e.g. R600a or R290, this will appear from the
type label. A Danfoss compressor will be provided with Before starting to cut tubes in the refrigeration system
a label as shown in fig. 6. it is recommended to clean the tubes with emery cloth
in the places to be cut. Thus the tubes are prepared for
the subsequent soldering, and entry of dirt grains into
the system is avoided.
Only use tube cutter, never metal-cutting saw, for cut-
ting tubing in a refrigeration system.
Merely a small burr left in the system can cause a sub-
sequent compressor breakdown.
All refrigerants must be collected as per instructions.
When a capillary tube is cut it is essential not to admit
burrs or deformations to the tube. The capillary tube

R600a can be cut with special pliers (see fig. 9), or with a file a
8122-2

trace can be produced in the tube which can then be

broken.
Fig. 6: Label on compressor for R600a

Service and repair of such systems demand specially

trained personnel. This implies knowledge of tools,
transport of 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 pro-
cess tube, thus enabling an opening into the system
for draining off and collecting the refrigerant as per
instructions.

Fig. 9: Special pliers for capillary tubes

Fig. 7: Piercing valve

D a n f o s s C o m p r e s s o r s 5
2.2 A system charged with refrigerant must never be If the compressor is defective it would be appropriate
Brazing under an inert heated or soldered, especially not when the refrigerant to cut the suction and pressure tube outside the com-
protective gas is flammable. pressor connectors, not opening the process tube.
Soldering on a system containing refrigerant will cause If, however, the compressor is functional, it is recom-
formation of refrigerant decomposition products. mended to cut the process tube. Blow-through must
Once the refrigerant is drained off an inert protective be done first through evaporator and then through
gas must be filled into the system. This is done by a condenser. An inlet pressure of approx. 5 bar and a
thorough blow-through with dry nitrogen. Before the blow-through of approx. 1-2 minutes would be satis-
blow-through the system must be opened in one more factory on appliances.
place.

2.3 The filter drier is adsorbing the small water amounts Thus it is prevented that the Molecular Sieve (MS) balls
Filter drier released through the life of the system. Besides, it acts wear each other and produce dust, which may block
as a trap strainer and prevents blocking of the capil- the capillary tube inlet. This vertical position also en-
lary tube inlet and problems with dirt in the expansion sures a quicker pressure equalization in capillary tube
valve. systems. See fig. 10.

If a refrigeration system has been opened the filter drier

must always be replaced to ensure sufficient dryness in
the repaired system.

7469
Replacement of a filter drier must always be done with-
out use of a torch. When heating the filter drier there is
a risk of transferring the adsorbed moisture amount to
the system, and the possibility of a flammable refrige-
rant being present must also be considered.
In case of a non-flammable refrigerant, however, 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 Fig. 10: Correct location of filter drier
drier is detached.
Normally a filter drier can adsorb a water amount of Since water has a molecule size of 2.8 Ångstrøm, mo-
approx. 10% of the desiccant weight. In most systems lecular sieve filters with a pore size of 3 Ångstrøm are
the capacity is not utilized, but in cases of doubt about suitable for the normally used refrigerants, since the wa-
the filter size it is better to use an oversized filter than ter molecules are adsorbed in the pores of the desiccant,
one with too small a capacity. whereas the refrigerant can freely pass through the filter.
The new filter drier must be dry. Normally this is no
problem but it must always be ensured that the filter Compressor Filter drier
drier sealing is intact to prevent moisture collection dur- P and T 6 gram or more
ing storage and transport. F and N 10 gram or more
The filter drier must be mounted in a way that flow SC 15 gram or more
direction and gravitation have an effect in the same
direction.

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
HFC/HCFC blends x
R290, R600a x
Filter driers with a pore size of 3 Ångstrøm in relation to If a filter without aluminium oxide is required, Danfoss
refrigerant: type DCC or DAS burnout filters for the refrigerants
In connection with service on commercial refrigeration R134a and R404A are recommended. For R600a and
systems Danfoss DML filters are recommended. R290 type DCLE032 can be used.

D a n f o s s C o m p r e s s o r s 6
2.4 A repair must always be done quickly, and no refrigera- If it is impossible to complete the repair continuously,
Moisture penetration tion system must be open to the atmosphere for more the open system must be carefully sealed off and
during repair than 15 minutes to avoid moisture intake. Therefore charged with a slight overpressure of dry nitrogen to
it is a good rule to have all replacement components avoid moisture penetration.
made ready before the system is opened.

2.5 Rubber grommets are to be mounted in the compres-

Preparation of com- sor base plate while the compressor is standing on its
pressor and electrical base plate. If the compressor is placed upside down oil
equipment will gather in the connectors, which leads to soldering
problems.
Never use rubber grommets from a defective compres-
sor since they are often aged and harder than new
rubber grommets. 8223-3
Remove the cap (Capsolute) from the process connec-
tor of the new compressor and solder a process tube
into the connector. Leave the compressor closed until
it is to be soldered into the system.
Besides, it is recommended to plug all connectors on
compressor, filter drier and system if for some reason
the repair is delayed.
N S
The aluminium caps on the connectors must not be left
in the finished system.

The caps are only intended to protect the compressor

N L
during storage and transport and do not provide tight- C
ness in a system under pressure. The caps make sure
that the compressor has not been opened after it left
Danfoss. 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. Fig. 11: Wiring diagram with PTC and winding protector

It is recommended always to use new electrical equip-

ment with a new compressor, since use of old electrical Fig. 12 shows a wiring diagram with starting relay and
equipment with a new compressor may lead to the starting capacitor as well as a motor protector mount-
compressor soon developing defects. ed outside the compressor.
The compressor must not be started without a com-
plete starting device.
Since part of the starting circuit resistance lies in the
starting device, start without complete starting device
does not provide good starting torque and may result
in a very quick heating of the compressor start winding,
causing it to be damaged.
8226-2

The compressor must not be started in vacuum.

Start of compressor in vacuum may cause a break-

down 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 de-

vice and winding protector. A run capacitor connected
to the terminals N and S will reduce energy consump-
10 11
tion on compressors designed for this.
12 13

14

Fig. 12: Wiring diagram with starting relay and starting

capacitor

D a n f o s s C o m p r e s s o r s 7
2.5
Preparation of com- Fig. 13 shows a wiring diagram for large SC compres-
pressor and electrical sors with CSR motor.
equipment

8227-2

5 2

4 1

1 1
2 2
N N
L L

Fig. 13: Wiring diagram for CSR motor

D a n f o s s C o m p r e s s o r s 8
2.6 Creation of the correct soldering fit is important. If the connection tube is made of steel a solder without
Soldering phosphor and with a melting point below 740°C must
Recommended soldering gaps for brazing joints 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 Danfoss compressors are It can also be appropriate to use just one solder for
copperplated steel tubes welded into the compressor all joints, and in this case it is recommended to use a
housing, and the welded connections cannot be dam- solder with a silver content of at least 30% to keep the
aged by overheating during soldering. melting temperature in the solder as low as possible.
It is possible to drift the 6.2 mm connectors to 6.5 mm, Thus overheating of the brazing joints is avoided. A flux
which fits a ¼” (6.35 mm) tube, but it is not recom- must be used with the solder, and it is recommended
mended to drift the connectors more than 0.3 mm. to stir this into alcohol instead of water (approx. 1/3
During drifting a backstop is necessary to prevent the flux in 2/3 alcohol). In this way the risk of water entering
connector from breaking off. See fig. 14. to the system is reduced.
After soldering the flux residues must be removed by
brushing the joint.

To achieve a sufficiently high torch flame temperature it

is recommended to use both acetylene and oxygen or
propane and oxygene since e.g. bottled gas provides
too low a temperature.

Brazing of steel connectors is slightly different from

brazing of copper connectors.

In the following you will find guidelines for brazing of

Fig. 14: Drifting of connector steel connectors:
During heating the temperature must be kept as close
Instead of drifting the connectors a reducing pipe as to the solder melting point as possible. Overheating will
shown in fig. 15 can be used. cause damage of the tube surface, which reduces the
chances for a good joint.

Use the soft heat in the torch flame when the joint is
heated.
ø 6.5± 0.09

Distribute the flame in a way that at least 90% of the

heat is concentrated around the connector and ap-
ø 5± 0.1

ø 3± 0.1

prox. 10% around the connection tube. See fig. 16.

1385

19

Fig. 16: Soldering 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. 15: Reducing pipe

Soldering of connectors to a copper tube may be

done with a solder containing 2% silver. The so-called
phosphorus solder may also be used provided that the
connected tube is made of copper. Fig. 17: Soldering process for steel connector

D a n f o s s C o m p r e s s o r s 9
2.6 Continue heating the joint with the soft flame and add
Soldering (continued) solder. See fig. 18.

Fig. 18: Soldering process for steel connector Fig. 20: Capillary tube correctly located in the filter drier

Draw the solder into the soldering gap by slowly mov- Depending on the routine a large or small torch size
ing the flame towards the compressor and then remov- must be used. In some cases it may be appropriate to
ing the flame. See fig. 19. use a double torch as shown in fig. 21, as both sides
of the joint can then be heated at the same time.

Fig. 19: Soldering process for steel connector

Fig. 21: Double blowpipe
Soldering of capillary tubes requires quite some preci-
sion, partly because overheating will quickly occur, and Refrigeration systems containing the flammable refrig-
partly because the capillary tube is easily blocked. erants R600a and R290 must not be soldered. In these
When the capillary tube is mounted into the filter drier cases a LokRing connection can be used.
it can be put so far in that it pushes against the filter
mesh. This may cause blockage, since the refriger-
ant 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.

D a n f o s s C o m p r e s s o r s 10
2.7 During service on systems with flammable refrigerants To ensure a tight sealing the tube ends must be mois-
LokRing connections LokRing connections may be used for tube joints, es- tened with Lokprep, since this material fills irregularities
pecially for closing the process tube. in the tube surface, if any. Once the tube ends have
With a LokRing connection as shown in fig. 22 tight been inserted in the LokRing connection until stop the
tube joints can be established, in aluminium, copper tubes must be turned to obtain a good distribution of
and steel. Before assembly the tube ends must be Lokprep on the tube surfaces. Subsequently the joint
carefully cleaned with steel wool or emery cloth, and must be pressed together with a special tool as shown
the cleaning must be done with rotating movements in fig. 23.
to avoid scratches along the tubes, which may com-
plicate sealing. Make sure that no dirt is entering the Assembly jaws
system.

Tube LokRing LokRing Joint Bolt

Before the After the

assembly assembly

Tool
Tube LokRing Joint LokRing Tube

Fig. 23: Tool for LokRing

LokRing union joint
After 2-3 minutes Lokprep has hardened, and the joint
Fig. 22: LokRing connection in stable.

2.8 When a refrigeration system is assembled it must be side of the system. If evaporator and compressor have
Evacuation carefully evacuated (remove air from the system), be- a large volume one-sided evacuation may be used,
fore it is charged with refrigerant. This is necessary to otherwise double-sided evacuation is recommended.
achieve a good repair result.
The main purpose of the evacuation is to reduce the One-sided evacuation is made through the compressor
amount of non-condensable gasses (NCG) in the system, process tube but this method means slightly worse
and secondarily a limited drying will take place. vacuum and slightly higher content of NCG. From the
Moisture in the system may cause ice blocking, reaction discharge side of the refrigeration system the air must
with the refrigerant, ageing of the oil, acceleration of oxida- be removed through the capillary tube, which results
tion processes and hydrolysis with insulation materials. in a substantial restriction. The result will be a higher
Evacuation of refrigerating system. pressure on the discharge side than on the suction
side.
Non-condensable gasses (NCG) in a refrigeration system The main factor for the NCG content after evacuation
may mean increased condensing pressure and thus is the equalized pressure in the system, which is deter-
greater risk of coking processes and a higher energy mined by the distribution of volumes.
consumption. Typically, the volume on the discharge side will con-
The content of NCG must be kept below 1 vol. %. stitute 10-20% of the total volume, and therefore the
high end pressure has less influence on the equalized
The evacuation may be done in different ways depending pressure here than the large volume and low pressure
on the volume conditions on the suction and discharge on the suction side.

Fig. 24: Evacuation process

D a n f o s s C o m p r e s s o r s 11
2.8 Calculation example concerning the amount of NCG Double-sided evacuation must be done until a suffi-
Evacuation (continued) after evacuation in a system with: ciently low pressure is obtained.
• Discharge side: pD = 50 mbar volume VD = 15% These procedures require the components to have a
• Suction side: ps = 0.3 mbar volume Vs = 85% low moisture content when being mounted.
By means of the double-sided evacuation it is possible
Example: to obtain a low pressure in the system within a reason-
After the evacuation: able time. This means that a leak test is possible before
• Total volume V = 2.25 l charging the refrigerant.
• Discharge side p1 = 50 mbar
V1 = 15% = 0.3375 l Fig. 24 shows a typical course of a one-sided evacua-
• Suction side p2 = 0.3 mbar tion from the compressor process tube. It also shows
V2 = 85% = 1.9125 l a pressure difference in the condenser, which may be
remedied by increasing the number of pressure equali-
p1 . V1 + p2 . V2 zations.
pequilized =
Vtotal The broken line shows a procedure where the two
sides are evacuated at the same time. When time is
limited, the final vacuum depends only on the vacuum
. .
pequilized = 50 0.3375 + 0.3 1.9125 = 7.755 mbar pump capacity and the content of volatile components
2.25
or non-condensable gasses in the oil charge.

Typical operating point of example appliance with Fig. 25 shows an example of an evacuation process
R134a. with built-in leak test. The vacuum obtained depends
on the process chosen.
Evaporating temperature –30˚C suction pressure 0.844
bar. Double-sided evacuation gives the best result and must
Condensing temperature +44˚C discharge pressure be recommended.
11.30 bar.
Pressure ratio 13.39. Once a vacuum below 1 mbar is obtained, the system
must be pressure equalized before the final evacuation
NCG will be pumped with the refrigerant, and be com- and charge of refrigerant.
pressed with the same pressure ratio. Normally mbar is used as expression of a vacuum but
other entities are also used, e.g.;
(p .V)NCG = 7.755 . 2.25 = 17.45 mbar I 1 mbar = 0.75 torr = 0.75 mmHg
1 mbar = 100 Pascal = 7.5E2 micron
(p .V)R134a = p1 . V1 + p2 . V2 =
0.844 . 1.9125 + 11.30 . 0.3375 = 5.4279 bar I In a tight system there will always be a certain pressure
rise when the connection to the vacuum pump is
(p . V)NCG 17.45
NCGvol = = 0.0032 = 0.32% closed due to desorption of moisture from inner surfaces
(p . V)R134a 5.4279 . 100
in the system and evaporation of volatile components
from the compressor oil charge. In practice a pressure
This calculation does not take into account the quantity rise of approx. 0.1 mbar is anticipated. This pressure
of air absorbed in the compressor's oil filling, which rise is often used as an indication of the degree of dry-
can vary from 0 to 10 vol.%. This means that the NCG ness and tightness in the system and is very much
content will be slightly higher in practice. used during service.

One-sided evacuation must be done until a sufficiently

low pressure is obtained in the condenser. Here it
might be necessary with one or more short evacua-
tions with intervening pressure equalizations.

Fig. 25: Evacuation process with leak test

D a n f o s s C o m p r e s s o r s 12
2.9 In order to perform a sufficient evacuation a good There is no point in having a suitable vacuum pump
Vacuum pump and vacuum pump must be available. See fig. 26. available if the vacuum obtained cannot be measured.
vacuum gauge Therefore it is strongly recommended to use an appro-
priate robust vacuum gauge (fig. 27) able to measure
pressure below 1 mbar.

Fig. 26: Vacuum pump

For stationary use a two-stage 20 m3/h vacuum pump

can be recommended but for service a smaller two- Fig. 27: Vacuum gauge
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, and also a compressor used as a vacu-
um pump would be overheated and damaged.
The insulation resistance of the air is reduced at falling
pressure, and therefore there electrical breakdown at
the current lead-in or in the motor of the hermetic com-
pressor 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 refrige-
ration systems containing the flammable refrigerants
R600a and R290.

D a n f o s s C o m p r e s s o r s 13
3.0 To ensure a reasonable refrigeration system life the Do not use open fire near the refrigerants R600a and
HANDLING OF refrigerant must have a maximum moisture content of R290.
REFRIGERANTS max 20 ppm (20 mg/kg). The refrigeration systems must be opened with a tube
Do not fill refrigerant from a large container into a filling cutter.
bottle through several container sizes, since with every
drawing-off the water content in the refrigerant is in- Conversion from refrigerants R12 or R134a to R600a is
creased considerably. not permitted, since the refrigerators are not approved
for operation with flammable refrigerants, and the elec-
Flammable refrigerants R290 and R600a trical safety has not been tested according to existing
R600a must be stored and transported in approved standards either. The same applies to conversion from
containers only and must be handled according to refrigerants R22, R502 or R134a to R290.
existing guidelines.

3.1 Normally, charging with refrigerant is no problem with If the charging amount is unknown, charging must be
Charging with a suitable charging and provided that the equipment done gradually until the temperature distribution above
refrigerant present charging amount of the refrigeration system is the evaporator is correct. However, mostly it will be
known. See fig. 28. 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 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. Thus transfer of
moisture to the refrigerator insulation is avoided. See
fig. 29.

Fig. 28: Charging board for refrigerant

Always charge the refrigerant amount and type stated

by the refrigerator manufacturer. In most cases this in-
formation 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 correct the amount of refrigerant.
Charge of refrigerant can be made by weight or by Fig. 29: Evaporator temperatures
volume.
Flammable refrigerants like R600a and R290 must al- Systems with expansion valve must be charged with
ways be charged by weight. refrigerant until there are no bubbles in the sight glass,
Charging by volume must be made with a refrigerant which should be placed as close to the expansion
charging cylinder. valve as possible.
The refrigerant R404A and all other refrigerants in the
400 series must always be charged as liquid.

3.2 If the permissible limit of refrigerant charge stated in the Please also refer to the compressor data sheets, as the
Maximum refrigerant compressor data sheet is exceeded the oil will foam in present maximum refrigerant charge may deviate on
charge the compressor after a cold start and may result in a single types from the statements in the form.
damaged valve system in the compressor. The maximum charge of 150 g for R600a and R290
The refrigerant charge must never exceed the amount is an upper safety limit of the appliance standards,
that can be contained in the condenser side of the whereas the other weights are stated to avoid liquid
system. hammer.

Compressor
Max. refrigerant charge
Type
R134a R600a R290 R404A
P 300 g 120 g
T 400 g 150 g 150 g 600 g
TL….G 600 g 150 g 150 g
N 400 g 150 g 150 g
F 900 g 150 g 850 g
SC 1300 g 150 g 1300 g
SC-Twin 2200 g

D a n f o s s C o m p r e s s o r s 14
3.3 Before finishing a repair the complete refrigerator must thermostat differential allows for sufficient standstill
Test be tested to make sure that the expected result has periods for pressure equalization so an LST compres-
been achieved. It must be ensured that the evaporator sor (low starting torque), if any, can start and operate
can be cooled down and thus enable the requested without tripping on the motor protector.
temperatures to be obtained. In areas where undervoltage may occur it is important
For systems with capillary tube as throttling device it is to test operating conditions at 85% of the nominal volt-
important to check if the compressor runs satisfactorily age, since both starting and stall torque of the motor
on the thermostat. Further it must be checked if the will decline when the voltage is falling.

3.4 A hermetic refrigeration system must be tight, and if a If no electronic detector (fig. 30) is available the joints
Leak test refrigerator is to have a reasonable lifetime it is neces- may be examined with soapy water or with spray,
sary to keep any leaks below 1 gram refrigerant annu- but of course small leaks cannot be found with these
ally. methods.
Since 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 a high-quality electronical test equipment
that can measure these small leak rates.
It is relevant to test all soldered 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 ex-
amined while the compressor is not operating and the
pressure in the system is equalized, since this results in
the highest pressures here. See fig. 30. Fig. 30: Leak detector

D a n f o s s C o m p r e s s o r s 15
4.0 In the following a procedure for replacement of a de- During fault finding the compressor is found to be de-
REPLACEMENT fective compressor in a hermetic refrigeration system is fective. If it turns out that the motor has burnt resulting
OF DEFECTIVE outlined, following the fundamental rules. in strong contamination of the system another proce-
COMPRESSOR A precondition is that there is a refrigerant overpressure dure is required.
in the system and that the system is not contaminated
with moisture. The refrigerant must correspond to the
original refrigerant.

4.1 By starting with preparation of the replacement com- By doing so the later connection of the suction tube
Preparation of ponents later delays with opened system are avoided, to the compressor can take place further away from
components and thus also increased risk for admission of moisture the compressor if mounting conditions in the machine
and impurities. compartment are narrow.
A process tube with process valve must be mounted When the compressor is ready process valve and con-
into the process connector of the new compressor. nectors must be closed. Further, the correct filter drier
In some case it may be an advantage to mount a piece type must be ready but the cover must remain intact.
of connecting tube into the compressor suction con-
nector.

4.2 Place a piercing valve with connection to a recovery

Removal of charge unit on the compressor process tube. Puncture the
tube and collect the refrigerant according to guidelines.
Follow the rules described earlier.

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

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

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

4.6 Soldering silver must be removed from the condenser Before soldering the capillary tube into the filter a slight
Cleaning of solder joints outlet. This is best done by brushing it off while the sol- stop must be produced on the tube as described earlier
and reassembly dering silver is still liquid. to ensure the tube end to be at the right place in the
The other tube ends are to be prepared for soldering filter to avoid blockings.
in case this was not yet done. Take care that dirt and Be careful during soldering of the capillary tube and
metal grains are not admitted to the system when trim- avoid burnings.
ming soldered joints. Mount the compressor, which already during prepara-
If necessary, blow through with dry nitrogen while trim- tion must be provided with rubber grommets.
ming. Mount the electrical equipment and connect the wires.
The new filter drier must be mounted at the condenser Evacuation and charge are to be made as described in
outlet, and the filter must be kept covered until assembly paragraphs 2.8 and 3.1.
can take place. Avoid heating the filter enclosure itself Test to be made as described in paragraphs 3.3 and
with the flame. 3.4.
When the process tube is squeezed and soldered the
process valve must be removed.

D a n f o s s C o m p r e s s o r s 16
5.0 As long as new or recycled R12 refrigerant is available It is hardly worth it to repair old small refrigeration sys-
FROM R12 this should be used. Is it impossible to provide R12 or tems if it involves replacement of the compressor.
TO OTHER is it illegal to use it, it should be thoroughly considered Another consideration is use of an alternative refrige-
REFRIGERANTS whether repair is worth while. rant instead of R12.

5.1 For low and medium evaporating temperatures R401A If R12 is not available or if it is not permitted to use,
From R12 to alternative and for low evaporating temperatures R401B has been R134a is recommended. See also paragraph 1.5.
refrigerant used as replacement for R12, however, use of these
so-called refrigerant blends cannot be recommended.

5.2 A conversion from R12 to R134a involves a consider- • Perform the repair.
From R12 to R134a able risk of possible residues of decomposed refrige-
rant, especially chlorine ions, or intact refrigerant and • Mount a new R134a compressor with corresponding
residues of mineral oil or alkylbenzenes staying in cooling capacity.
the system. Therefore a procedure must be estab-
lished during which these undesirable substances are • Mount a new filter drier with desiccant 4AXH7 or
brought down to a level not causing substantial incon- 4AXH9 or equivalent.
venience in the repaired refrigeration system.
Before starting conversion to R134a it must be en- • Evacuate and charge the system with R134a.
sured that the original compressor motor has not
”burnt”. If this is the case, the compressor should not For LBP systems the optimum R134a charge will
be replaced since the contamination risk is too high. be smaller than the original R12 charge. It is recom-
Conversion to R134a always requires a compressor mended to start by charging 75% of the original
replacement since an original R134a compressor must charge and then gradually increase the charge until
be mounted even if the R12 compressor is intact. the system is balanced.

The following procedure must be performed continu- • Seal the process tube.
ously. If interruptions should occur anyway, all open
tubes and tube connections must be plugged. It is • Check if there are leaks.
assumed that the system is clean and that there is a
simple evaporating circuit. • Operate the system.

• If the system has lost its charge the leak must be • After finished repair it should always be marked on
traced. the system which refrigerant and compressor oil
type it contains.
• Mount a service valve on the compressor process
tube. • After reassembly the system will be functional but
minor oil residues from the R12 system will circu-
• Collect the refrigerant which is left. late, which may in periods disturb injection in the
evaporator, especially in capillary tube systems.
• Equalize to atmospheric pressure with dry nitrogen. Whether this is vital for the practical use of the re-
frigeration system depends on the amount of the oil
• Remove compressor and filter drier from the system. residue.

• Flush through all system components with dry ni-

trogen.

5.3 A procedure corresponding to the one described in Note that the R12 charge will be bigger than the origi-
From R134a to R12 paragraph 5.2 can be used. Use an original R12 com- nal R134a charge and that in most countries the use of
pressor, R12 refrigerant and a filter drier of the type 4A- R12 is not permitted, but in some special cases it can
XH6, 4A-XH7 or 4A-XH9. be an alternative.

5.4 It is assumed that the compressor is defective and has If the system is very contaminated it must be thoroughly
From R502 to R404A to be replaced by an original R404A compressor but flushed with dry nitrogen.
the new compressor must be charged with approved In exceptional cases the compressor oil can be re-
Polyolester oil. placed.
The filter drier must be replaced by a new filter with a The subsequent procedure is as described in para-
desiccant of the type 4A-XH9. graph 5.2.
Oil residues from the original compressor, mineral oil
or alkyl benzene, must be removed from the system
components.

D a n f o s s C o m p r e s s o r s 17
6.0 For systems contaminated with moisture it applies that Systems with a low degree of contamination are intact
SYSTEMS the degree of contamination may be very varying, and and maintain a refrigerant overpressure.
CONTAMINATED the scope of the repair will vary accordingly. Systems with a high degree of contamination, however,
WITH MOISTURE Systems containing moisture can be divided into two are characterized by having been in contact with the
categories, namely the ones with a low degree of atmosphere or moisture has been added directly. The
contamination and the ones with a high degree of con- two types of defect will be treated independently.
tamination.

6.1 This defect is usually characterized by the cooling often b) After collecting the refrigerant the system must be
Low degree of being interrupted due to ice blocking in the capillary blown through with dry nitrogen. Nitrogen injection
contamination tube or in the expansion valve. With heat supply the must take place through the compressor process
ice blocking is gradually removed, but if the refrigerant tube, and first the suction side and then the dis-
circulates the blocking will quickly build up again. charge side must be blown through, first directing
This defect may be due to following reasons. the nitrogen flow from the compressor through
The system has not been assembled carefully enough. the suction tube and evaporator and out through
The components used may have been moist. the capillary tube, then through compressor and
A refrigerant with too high a moisture content may have condenser and out through the filter drier at the
been used. condenser outlet.
The system will often be new or it has just been repaired. It is an advantage to blow through with so much
Usually the moisture amounts are small, and therefore pressure that any oil in the components is removed.
the defect can normally be remedied by replacement of
refrigerant and filter drier. The procedure is as follows. c) Replace filter drier and process tube as described
earlier. It pays to use an oversized filter drier.
a) Open the system at the process tube and collect
the refrigerant. d) When the system is reassembled, evacuation must
It is an advantage to first let the compressor run be carried out very carefully.
until it is hot. In this way the moisture and refrigerant Charge and test according to earlier mentioned
amount left in the motor or in the oil is reduced. guidelines.
When ice is blocking capillary tube or expansion
valve it is possible to run the compressor hot but
the system will not run.
If capillary tube or expansion valve are accessible,
the place of blocking may be kept hot with a heating
lamp or a cloth with hot water to obtain circulation
of the refrigerant.
The evaporating temperature in the system may also
be increased by heating the evaporator. Do not use
an open flame for heating.

6.2 If there is a rupture in a refrigeration system and the b) Break the capillary tube at the condenser outlet,
High degree of refrigerant overpressure escapes, moisture contamina- and blow through the condenser with dry nitrogen
contamination tion will take place. The longer time the system is open as protective gas.
to the atmosphere the higher the degree of contamina- Remove the filter drier.
tion. If the compressor is operating at the same time, Repeat the blow-through with increased pressure
conditions are further worsened. The admitted mois- to remove oil from the condenser, if any. Cover con-
ture amount will distribute in compressor, filter drier and denser inlet and outlet.
other system components depending on their ability to
hold the moisture. c) Treat suction line heat exchanger and evaporator in
In the compressor it will especially be the oil charge the same way. The opportunity of an efficient blow-
that absorbs the water. In evaporator, condenser and through is improved if the capillary tube is broken
tubes the contamination will primarily be determined by off at the evaporator inlet. Blow-through with nitro-
the oil amounts present here. gen will then take place in two paces; first suction
Of course the largest water amounts will be in com- tube and evaporator, then capillary tubes.
pressor and filter drier. There is also a high risk that If the reason for the repair is a broken capillary tube
valve coking has started damaging the compressor the operations must be changed to replace the en-
Therefore compressor and filter drier must be replaced tire heat exchanger.
during the normal repair procedure. d) Reassemble the system with a new compressor
and a new filter drier in the right size.
a) Remove the compressor from the system with a
tube cutter.

D a n f o s s C o m p r e s s o r s 18
6.2 Evacuation must be done with special care, and h) When the system, excl. compressor, is intact again
High degree of subsequently charge and test according to normal carry out a drying.
contamination rules. The outlined procedure is best suited for sim- This is made by at the same time connecting suc-
ple refrigeration systems. tion and discharge tube to a vacuum pump and
If the system has difficult access and the design evacuate to a pressure lower than 10 mbar.
is complex the following procedure may be better Pressure equalize with dry nitrogen.
suited. Repeat evacuation and pressure equalization.

e) Remove the compressor from the system and treat i) Mount the new compressor.
it according to point a. Then evacuate, charge and test.

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.

6.3 In some markets it may be necessary to repair a moist dered joints or by use of a suitable vacuum hose.
Drying of compressor compressor in a workshop, and one is then obliged to Bring the compressor up to a temperature between
manage somehow. 115°C and 130°C before starting the evacuation. Then
The drying process described here can give the want- start the evacuation that must bring the pressure in the
ed result, provided that the process is closely complied compressor down to 0.2 mbar or lower.
with. The joints in the vacuum system must be tight in order
Draw off the compressor oil charge. to achieve the required vacuum. The moisture content
Then flush the compressor inside with ½-1 litres of a in the compressor will also influence the time for reach-
non-flammable low pressure refrigerant or solvent. ing the vacuum.
Plug the compressor with the solvent inside and shake If the compressor is highly contaminated a few pressure
it thoroughly in all directions to get the refrigerant in equalizations with dry nitrogen to atmospheric pressure
touch with all inside surfaces. will enhance the process.
Collect the solvent as stipulated. Shut off the connection to the vacuum instrument during
Repeat the operation once or twice to ensure that no the pressure equalization.
substantial oil residues are left in the compressor. Temperature and vacuum must be maintained for ap-
Blow through the compressor with dry nitrogen. prox. 4 hours.
Connect the compressor to an arrangement as shown On finishing the drying process the pressure in the
in fig. 31. compressor must be equalized to atmospheric pressure
with dry nitrogen and the connectors must be sealed.
Plug the discharge connector. Charge the compressor with the specified oil type and
The connections to the compressor suction connector amount and mount it into the refrigeration system.
must be vacuum tight. This can be achieved by sol-

Fig. 31: Drying of compressor

6.4 In some cases it can be necessary to replenish a com- It is absolutely essential to use the oil approved for
Oil charge pressor with oil if it has lost some of the charge. the compressor in question. If a lost oil charge in a
On some Danfoss compressors the amount of oil is compressor must be replaced, it must generally be
stated on the type label, however, not on all, so the assumed that approx. 50 ccm of the oil charge will be
present oil type and amount must be found in the com- left in the compressor when it is emptied completely by
pressor datasheet. draining oil off from a connector.

D a n f o s s C o m p r e s s o r s 19
7.0 The term “lost charge” covers cases where the wanted The main steps in the repair procedure can be as
LOST cooling function is not achieved because there is not follows (only for non-flammable refrigerants).
REFRIGERANT sufficient amount of refrigerant in the system.
CHARGE The repair procedure implies a refrigerant overpressure a) Mount a service valve on the compressor process
in the system so that the contamination problems that tube.
may be caused by penetrating moisture can be disre- Mount a pressure gauge and use this for fault de-
garded. termination.
“Lost charge” is characterized by the fact that the
intended cooling is not achieved. The running time is b) Increase the refrigerant pressure in the system to 5
long, and the compressor may run continuously. The bar.
build-up of rime on the evaporator is only partly and
perhaps only around the injection place. The compres- c) Examine all joints to see if there is any oil oozing
sor will operate at low evaporating pressures, and this out.
means low power and current consumption. The com- Perform a thorough search with leak test equipment
pressor will have a higher temperature than normal due until the leak is found.
to the reduced refrigerant transport.
The difference between “lost charge” and “blocked d) Release the overpressure from the system.
capillary tube” consists in the prevailing condenser Break the capillary tube at the condenser outlet.
pressure, however, after some time the pressure will be Blow through the system with dry nitrogen.
the same in both cases.
“Blocked capillary tube” results in the refrigerant be- e) Replace filter drier as described earlier.
ing pumped into the condenser, and the pressure will Replace the process tube and repair the leak.
become high. As the evaporator is pumped empty,
however, the condenser will become cold. f) Evacuate the system and charge it with refrigerant.
If the blocking is complete no pressure equalization will Subsequently make a new leak test and test out the
take place during standstill. With “lost charge”, how- system.
ever, the pressure in the condenser will be lower than After a pressure test of the system with high pres-
normal. sure perform a slowly starting evacuation with a
A considerable part of the repair procedure consists of large vacuum pump since otherwise the oil can be
finding the cause of the defect. If this is not done it will pumped out of the system.
only be a question of time until the defect occurs again.
In case of blocking of the capillary tube in small sys-
tems they will normally be scrapped, but if large ex-
pensive systems are concerned a replacement of the
suction line heat exchanger may be approproate.

D a n f o s s C o m p r e s s o r s 20
8.0 A burnt motor has destroyed wire insulation By burning Winding protectors placed directly in most motors pro-
BURNT is meant motors where the wire insulation is decom- vide a better protection in this situation, since they are
COMPRESSOR posed. primarily activated by the motor winding temperature.
MOTOR If the wire insulation is decomposed very high tempera-
A real burning is characterized by the wire insulation tures will arise at the short-circuited wires. This may
in the motor having been exposed to critical tempera- cause further decomposition of refrigerant and oil. As
tures for a long time. long as the compressor is functional, the entire process
If the temperature conditions in a compressor are may cause circulation of breakdown products and thus
changed in a way that the insulation material assumes contaminate the system.
a critical temperature for long time a burning will take When certain refrigerants are breaking up acid may be
place. generated. If no cleaning is made in connection with a
Such critical conditions may arise when the ventilation compressor replacement, the start of the next break-
conditions are reduced (e.g. due to a defective fan), down is already programmed.
when the condenser is dirty or at abnormal voltage Motor defects in hermetic compressors in household
conditions. refrigerators are relatively rare.
The fault “lost charge” may have a corresponding effect. Normally, failures in the start winding are not causing
Part of the motor cooling is done by means of the cir- contamination of the system but a short-circuit in the
culating refrigerant. When the refrigeration system loses main winding may very well result in contamination.
charge the evaporating pressure becomes abnormally
low, less refrigerant is circulated per time unit, and the
cooling is reduced.
In many cases a motor protector mounted in the elec-
trical 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 tem-
perature difference between motor and compressor
housing will increase due to the poorer heat transmis-
sion.

8.1 Since a burnt motor may result in contamination of the moved from the system the compressor oil will show
Oil acidity system with acid products, the acidity can be taken contamination or acidity.
as a criterion whether the system requires a thorough A simple assessment can be made with an oil sample
cleaning. in a clean test glass. If the oil is dark, sludgy and per-
The compressor itself and the discharge side of the haps contaminated with decomposed particles from
system up to the filter drier will be the most contami- the motor insulation, and if it also smells acidly there is
nated part of the system. Once the refrigerant is re- something wrong.

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

D a n f o s s C o m p r e s s o r s 21
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 Danfoss Compressors GmbH
For further information please visit: Mads-Clausen-Strasse 7
compressors.danfoss.com P.O.Box 1443, D-24939 Flensburg
Tel: +49 461 4941-0
Fax: +49 461 44715

DEHC.PF.640.A1.02 520N0026 Produced by Danfoss Industri Serivce - Advertising 05.05.LN.BPV.RO