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According to leading compressor manufacturers, most HVAC/R compressor failures aren’t caused by defective compressors, but by different system-related issues. In fact, up to 80% of compressor failures are the result of inadequate maintenance, misdiagnosed problems within HVAC/R systems, or unaddressed mechanical and/or electrical failures that have progressed into more serious issues. Additionally, Emerson Electric Co. has recently stated that approximately 30% of the Copeland scroll compressors returned for failure don’t have any defects.

When assessing the efficiency of an HVAC/R system, all operating expenses should be considered, including the cost of energy consumption, maintenance, repairs, and eventually equipment replacement. Although a variety of factors can affect the efficiency of HVAC and refrigeration systems, the compressor plays a major role in the overall performance of these systems. The consequences of using an underperforming compressor can be multi-faceted and damaging to your company’s bottom line. By reading the rest of this post, you’ll find out how an inefficient compressor can decrease your profit margin.  

The efficiency of an HVAC/R compressor depends largely on the performance of its suction and discharge valve assemblies. Because valve assemblies act as seals between different pressure zones in a compressor, allowing the refrigerant to flow from low pressure to high pressure regions, a faulty valve assembly can negatively affect the operation of a compressor, increasing energy consumption over time and even leading to premature failure of the compressor.

Ice accumulation on evaporator coils is a common occurrence in refrigeration systems that operate below 40°F. To prevent excessive ice buildup on the evaporator coil and ensure optimal operation of refrigeration systems, a reliable and efficient means of defrost is often required. Two commonly used defrosting methods are the electric defrost and hot gas defrost.

Common Causes of Compressor Motor Burnout and How to Prevent Them

With adequate maintenance, an HVAC/R compressor can last longer than its expected lifespan. However, any compressor will eventually reach the end of its service life. When a compressor needs to be replaced, the technician must identify the cause of failure before installing a replacement compressor. This is extremely important because if the issue that has caused the initial breakdown is left unaddressed, it may affect the compressor replacement as well.

Ensuring Food Safety and Quality with Accurate Temperature and Humidity Control

Under the new FDA Food Code, the businesses operating in the Food Industry are required to ensure appropriate control measures in order to eliminate or reduce the risk of foodborne illness at the consumer level. To ensure food safety, the perishable foods susceptible to spoilage by disease-causing microorganisms, such as bacteria, fungi, and viruses, must be kept in adequate containers, at safe temperatures during processing and transportation.

A conventional compressor operates more efficiently if the pressure trapped inside the cylinder head assembly and/or discharge line is released after each cycle. As pressure adds load to the compressor start-up process, finding a way to release it will result in smoother compressor start-ups and a lower starting torque of the motor. These translate into maximum operational reliability, increased system efficiency, and less wear and tear on components.

Heat is a normal consequence of the compression process. However, a compressor that runs too hot is cause for concern mainly because it will need to work harder, for longer periods. Besides consuming more energy, a compressor that operates under intermittent or continuous overheating conditions may fail before its time and, more importantly, when least expected. Currently, compressor overheating is one of the most common causes of commercial refrigeration problems.

When it comes to commercial compressors, an undercharge or overcharge of refrigerant may have many undesirable consequences. That’s because both conditions prevent the compressor from operating at peak performance, eventually leaving you with a malfunctioning system that can negatively affect your business.

Troubleshooting undercharge and overcharge conditions for commercial compressors requires a thorough knowledge of HVAC/R systems and their functions. However, the ability to correctly identify the symptoms of an undercharged or overcharged system is key to determining and fixing the exact cause of system malfunction before it escalates into a more serious problem.

A motor protection module is a key component in any healthy compressor system. Many people have never heard of a motor protection module, and have no idea how this particular component helps protect their compressors in the long run. We're here to explain the importance of this part and how it works for you.