During long-term operation, refrigeration compressors are susceptible to various malfunctions due to factors such as fluctuating operating conditions, improper maintenance, and component aging. Timely troubleshooting and resolution of these malfunctions can prevent them from escalating and reduce losses. The following are the most common faults and corresponding troubleshooting methods, covering core issues such as abnormal operation, insufficient cooling capacity, abnormal noise and vibration.
Fault 1: The compressor cannot start. Troubleshooting direction: Firstly, check whether the power supply is normal (whether the voltage and current meet the standards, and whether the circuit is open or short circuited); Next, check if the motor is damaged (burnt windings, stuck bearings), and use a multimeter to measure the resistance of the motor winding; Finally, check whether the control circuit (contactor, relay, temperature controller) is faulty. If the control components are damaged, they should be replaced in a timely manner. Solution: Repair the power circuit, replace damaged motors or control components, and ensure that the power supply and control circuits are functioning properly.
Fault 2: Insufficient cooling capacity. Troubleshooting direction: refrigerant leakage (check sealing parts, pipeline interfaces, and detect refrigerant pressure); The suction filter is clogged (cleaning impurities in the filter); Wear of compression mechanism (wear of piston rings, rotors, and vortex discs, resulting in air leakage); Poor heat dissipation of the cooling system (blocked heat sinks, accumulation of cooling water scale); The operating parameters deviate from the rated values (high evaporation temperature, high condensation temperature). Solution: Investigate and repair the leakage point, replenish refrigerant; Clean the filter and cooling system; Replace worn compression mechanism components; Adjust the operating parameters to match the rated operating conditions of the compressor.
Fault 3: Abnormal noise and excessive vibration during compressor operation. Troubleshooting direction: Insufficient lubricating oil or poor oil quality (supplement or replace lubricating oil); Bearing wear and jamming (replacement of bearings); Compression mechanism failure (piston impact on cylinder, poor rotor engagement, damaged scroll); Motor imbalance (correction motor); The installation is not firmly fixed (tighten the anchor bolts and pipeline brackets). Solution: Targeted replacement of damaged parts, replenishment of lubricating oil, reinforcement of installation, and calibration of motor balance.
Fault 4: Compressor overheat protection shutdown. Troubleshooting direction: Cooling system malfunction (poor heat dissipation, damaged cooling fan/water pump); Exhaust pressure is too high (condensation pressure is too high, check the condenser and refrigerant charging amount); Excessive suction superheat (adjust throttle device, increase suction volume); Insufficient lubricating oil, poor lubrication (supplement lubricating oil); Motor winding overheating (check motor load, winding resistance). Solution: Repair the cooling system, adjust the exhaust pressure and suction superheat, replenish lubricating oil, and repair or replace the motor.
