[C4ENG]

I first experienced a burning electrical smell in the ER and went ripping through everything looking for the source until I found this..a loose wire conection on a 10 ton chiller compressor.. The compressor was still running when I found it. I cleaned it up a bit and cut back the melted wire before the photo trying to see how much damage there was.

Can a new conection block be fitted on this compressor for the supply wiring?

Do you think this compressor can be saved?

[Dan Evans]

If it was still operating correctly when you found it then chances are its still good. However, when there is any doubt about something working out at sea would you really like to take the chance of it not turning on one day? I would have an electrician or Emerson technician take a look at it. Make sure you trace the wires to make sure that is the only damaged spot. Good luck!

Dan

[vornado]

Originally Posted by C4ENG

Can a new connection block be fitted on this compressor for the supply wiring?

Do you think this compressor can be saved?

That is a Hermetic compressor. A new connection block can not be fitted as far as I know. So, if the connection block is damaged ( I can not really see in the pic) you are out of luck.

[Capt J]

Try calling a place that rebuilds compressors, they might be able to weld a new post to it, or a new box..........

[wdrzal]

They do make a varity of replacement terminal repair kits. Some are as simple as a set screws that tightens on the pin or whats left of the lug. To some that need the electrical connections soldered on and then the entire connection is covered with a resin based putty (epoxy)that hardens to lend support making it permenant.

You can find these repair kits at refrigeration or HVAC specility shops.

Be sure to First get the nomenclature off the compressor & take it with you.(the line above the bar code that ends in 250). If you don't have the schemetics go to the Emerson site (bought copeland) and look up what the ohms between terminals is and test with a multimeter set to RX1. Also test for direct shorts (terminal to ground). More extensive testing can be done with a Megometer if you have one,this will test for leakage/damage of the internal electrical windings (state of the insulation).

Just from the picture I believe that compressor can be saved as long as their is no internal damage.

[scott49]

One thing to also think about is not only can it be fixed but what caused it. You said loose connection, make sure that that was it. You don't want to put a new connection block (terminal repair kit) and have a fire later.

[wdrzal]

Scott is correct,you just can't assume it was a loose connection. Many times people fix a problem without finding the true cause. Other than a loose connection,too high superheat or un-balanced power supply or power supplied out of design parameters,loss of capacity should be high on the list,along with previous mentioned checks to verify the internal windings are OK.

I didn't mention that it is also possible to completly cut out the ceramic terminal block that passes through the shell & a new one welded in. This should be done by a professional. This requires refrigerant recovery,oil removal & shielding gases used for welding,then evacuation & recharge with oil and refrigerant. Keep in mind your working on a pressure vessel where high pressure gas and oil can be expelled. There is a rare occurance know as high pressure pin ejection,this happens when the ceramic is dammaged/cracked and there is still pressure inside the shell and the terminal is shot out like a bullet,it's very rare ,but does happen. So as long as the unit is charged becarful,wear safety glases and keep your body away from in front of the terminals.

You said the unit is 10 ton (120,000 btu), is that a single compressor or multiply units in a rack system. I ask becasue AFAIK all compressors over 5 ton are 3 phase. Severial small units may be single phase powered in tandem. They have capacitors and starting gear that also could be at fault.

One final note copeland on many of it's models offered long warrentys 5 to 10 years to get people to try scroll compressors. Some model lines had failure rates @~60%. Many of those were smaller units under 5 ton.