Electrical

Troubleshooting

E
B 220
I R
Version 1.0 © 2012 Carrier Corporation
 Electrical Safety

ELECTRICAL
Safety
Electrical Safety
1100 People are killed each year in the
United States due to electrocution.

The current of a 100 watt light

bulb is 17 times more current
than is necessary to kill a person.

There have been deaths reported in

circuits as low as 46 volts.
 Electrical Safety

The human body is

considered
E to be a resistive load, it
adheres to Ohm’s Law

I R

Current = Voltage across the body

Resistance of the body
 BODY RESISTANCE
Dry Skin: 100,000 to 600,000 Ohms

Wet Skin: 1,000 Ohms

Internal Body: 400 To 600 Ohms

Ear to Ear: 100 Ohms

E = I\R I = E\R 120 volts\1,000 ohms = .120A or 120ma

83ma
RIP
 BODY RESISTANCE

1/2 ma NO SENSATION

2 - 10 ma MUSCULAR CONTRACTION

5 - 25 ma PAINFUL SHOCK
CAN’T LET GO CURRENT = 16 ma

25 - 50 ma VIOLENT MUSCULAR CONTRACTION

50 - 200 ma HEART CONVULSION

VENTRICULAR FIBRILLATION
DEATH

OVER 100 ma PARALYSIS OF BREATHING

SEVERE BURNS TO BODY
 Current Flow
In order to have safe current flow in any electrical
circuit, three essential elements must be present:

1. Potential Difference
2. Path
3. Electrical Load
 Potential Difference
Loop
Magnet

Voltage is induced
in a conductor
when
it cuts through
magnetic lines of
Sliprings flux

Brushes

Generators convert mechanical energy into electrical energy

Potential Difference
Potential Difference
A 3 generator
is constructed of
three coils of wire,
120 mechanical and
electrical degrees
apart from each
other
 3Ø Motor Application
Three-phase motors are smaller, lighter, and have
higher efficiencies than single-phase motors.
High starting torque is due to the fact that each
leg is 120° out of phase, usually in applications
of about 3 horsepower and above.
Schematic Diagram

Potential Difference

Path

Load
Electrical Loads

R
Factual Ladder Schematic

A Ladder diagram
shows the electrical
relationship between
all components in a
machine.

Using the Sequence of

Operations and the
ladder diagram, a
troubleshooting path
can be determined.
Ladder Schematic
Connection Diagram
 Component Location Diagram

Shows the physical location of the

components used in the machine.
 Legend
AHA - Adjustable Heat Anticipator Marked Wire
C - Contactor Compressor
CAP - -
Capacitor Denotes Connection Point Between
CC - Cooling Compensator Subbase and Thermostat
CH - Crankcase Heater
CLO - Compressor Lockout Terminal (Marked)
DU - Dummy Terminal
EQUIP - Equipment Terminal (Unmarked)
FU - Fuse
GND - Ground Terminal Block Terminal
HC - Heater Contactor (Strip
Heat)
HPS - High-Pressure Switch Field Splice
IFC - Indoor Fan Contactor
IFM - Indoor Fan Motor Splice (Marked)
IFR - Indoor Fan Relay
L - Light
LPS - Low-Pressure Switch Factory Splice
OFM Outdoor Fan Motor Factory Wiring
QT - Quadruple Terminal
RC - Run Capacitor Accessory or Optional Wiring
ST - Starting Thermistor Field Control Wiring
TB - Terminal Block Field Power Wiring
TC - Thermostat, Cooling
To indicate common potential only,
TH - Thermostat, Heating Not to represent wiring
TRAN - Transformer
 Notes
1. Compressor and fan motors are thermally protected. 3-phase motors are
protected against primary single-phasing conditions.
2. If any original wires must be replaced, use 90C wire or equivalent.
3. Numbers indicate the line location of used contacts.
A bracket over (2) numbers signifies a single-pole, double-throw contact.
An underlined number signifies a normally closed contact.
A plain (no line) number signifies a normally open contact.
4. Must use thermostat HH07AT172 or 170 with subbase HH93AZ177 or
179.
5. Heat Anticipator Settings 6. Replacement fuse size for:
1st Stage 2nd Stage
Unit 208/230V Class K5 60A
Amps
4, 5, and 6 ton .4 .3 460V Class T 35A
7½ ton .9 .3
 HVAC Industry Standards

In order to read and understand

an electrical diagram you need
to know how different controls
and loads are drawn
 High Voltage Contactors & Low Voltage Control Relays

Single Pole – with shunt

2 - Pole 3 - Pole

Single Pole – Single Throw Single Pole – Double Throw Double Pole–Double Throw
 Relays or Contactors
R

Normally Closed Contact

R

Normally Open Contact

Relay Coil Relays

C Contactor Coil
Contactors
 Relays
L2

120v
M

24v

c
 Relays
L2

Large Current
120v
M

24v
Small Current

c
 Relays or Contactors
1. THE CONTACTS OF A RELAY OR CONTACTOR ARE DRAWN
IN A DE-ENERGIZED CONDITION
 Relay Contact Information

87, 87
ONE SET OF CONTACTS
CIRCUIT
– SINGLE POLE,
NUMBER
DOUBLE THROW

87
 Pressure Switches
High-
Pressure
Switch
SPST Opens on Rise
(Safety Control)

Low-Pressure
SPST Opens on Drop Switch
(Safety Control)
 Pressure Switches

Air Pressure
SPST Closes on Drop
(Operating Control) Switch

SPST Closes on Rise Fan Cycling

(Operating Control)
Pressure Switch
 Pressure Switches

Differential
Air Pressure Switch
SPST Closes on Rise
(Differential)

Differential
Refrigerant
Pressure
SPST Opens on Rise
(Differential) Switch
Differential
Oil Pressure
Switch
 Pressure Switches
2. THE CONTACTS OF A SAFETY CONTROL ARE DRAWN IN
THE NORMAL RUN POSITION, USUALLY CLOSED
 Temperature Switches

Defrost Thermostat
SPST Closes on Drop

SPST Closes on Rise

Return Water
Temperature Controller
 Temperature Switches

SPST Opens on Rise

(Safety Control)
Overtemperature
Limit Switch

SPST Opens on Drop

(Safety Control)

Freeze Protection Thermostat

 Temperature Switches

SPDT Temperature
(Safety or Operating)

Low-Water Temperature Cutout Control

Klixon
Bi-Metal Temperature Overtemperature
(Safety) Cutout Control
 Humidity Control

SPST Humidistat
Closes on Drop
(Operating Control)

SPST De-Humidistat
Closes on Rise
(Operating Control)
 Time Delay

Time Delay Relay

Delays Closing Time Delay Relay
(Mechanical/Thermal)
(Electronic) (Electronic)

Time Delay Relay

Time Delay Relay (Mechanical)
Delays Opening
(Mechanical/Thermal)
(Electronic) Time Delay Relay
(Thermal)
 Manual Switches

SPST Normally Open

Manually Operated
Push Button

SPST Normally Closed

Manually Operated Momentary Push Button
Push Button

SPDT Switch
Single-Pole
Double-Throw
Switch
 Flow Switches

Sail Switch

SPST Flow Switch

Opens on Rise
(Safety Control)

Flow Switch

SPST Flow Switch

Closes on Rise
(Safety and Operating)
 Capacitors
Run Capacitor

Run Capacitor
(Marked Terminal) Dual Run
Capacitor

Start
Start Capacitor Capacitor
 Fuses

One Time Fuse

(Fusible Link)

Fuse
Fusible Link
Rated Amps
One Time
Fuse
Transformers
 Transformers

TRANSFORMERS ARE USED TO RAISE OR LOWER

VOLTAGE LEVELS
AND CONSIST OF TWO OR MORE COILS OF WIRE
WOUND AROUND A COMMON IRON CORE
 Transformers

If Secondary has: Voltage is:

Stepped-
Fewer windings
down
More windings Stepped-up
 Transformers

Secondary
Volt Amps Voltage

How to calculate available amps from a transformer

VA Rating
Amperage =
Secondary Voltage
75VA
3.1 Amps =
24V
Meters
 Multimeters

Analog Meters Digital Meters

 Multimeters

V Voltmeter

A Ammeter

Ohmmeter
 Voltmeter

The voltmeter tells us if there is potential difference

available to energize a load
 Voltmeter

120Volt

120
 Voltmeter

120Volt

?
120.0
120.0
 Voltmeter

120Volt

?
0.0
 Voltmeter

120Volt
0.0

0.0
Ohm’s Law
 Voltmeter
How Many Watts ? Volts x Amps = Watts

120v X 0.5 a = 60W

60W
120Volt

0.5 120
Clamp on Ampmeter
Clamp on Ampmeter
 Small Amp Readings
DC Amperage is measured in series with the circuit being tested

A working Flame Sensor

will measure 4-6 DC
microamps
4.0

4.0

Disconnect the flame sensor wire

from the flame senor. Connect
meter leads to the sensor and the
disconnected wire
 Multimeters

Analog Meters Digital Meters

 Ohmmeters
No resistance to current flow
between the two points

No Voltage
Power is
Disconnected

OHM
 Ohmmeters
40Ω

No Voltage
40Ω
Power is
Disconnected

40

OHM
 Ohmmeters

40Ω

No Voltage
40Ω
Power is
Disconnected

OHM
 Ohmmeters
When checking Ohms, 2 resistance values
in series will add the resistance values
40Ω

No Voltage
40Ω
Power is
Disconnected

80

OHM
Ohmmeter

Normally Closed
Common
Normally Open

Coil Connections
 Ohmmeters

OL 0

Normally Normally
Open Closed

22.0

Coil
 Ohmmeters
Identifying Terminals of a Single-Phase Motor
HIGHEST RESISTANCE WILL BE
START (S) TO RUN (R) TERMINALS
THE 3rd TERMINAL
IS COMMON (C)

COMMON TO START WILL BE THE NEXT HIGHEST READING

COMMON TO RUN WILL BE THE LOWEST RESISTANCE
 Ohmmeters
Motor Winding Resistance
MEASURABLE RESISTANCE
 Ohmmeters
Motor Winding Resistance Ground
INFINITE OR HIGH RESISTANCE (1,000 OHMS PER VOLT)
SCHEMATICS
 Schematics

Introduction
L1 Power Off L2

220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Power On
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Cooling Off
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Cooling Call
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Fan Relay Energized
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Fan Relay Contacts
Close 220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Fan Motor Starts
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Control Relay Energized
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Control Relay Contacts L2

Close 220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Condenser Fan Energized
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Contactor Energized L2

220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Contactor Closes
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Compressor Energized
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 EVERYTHING ON
220 V

TSC 24 V
CR
AUTO
FAN EFR
ON

CH

EFR
EFM

CR
CFM

C HPS LPS
COMP
 Electrical Troubleshooting

Using an alligator clip, place one voltmeter probe on

the load side and then check for circuit potential
 Electrical Troubleshooting

If 230 VAC – Safeties OK

Check Contactor/Compressor
If 0 VAC – Hopscotch Safeties

Next check voltage directly to the load in

question
 Electrical Troubleshooting

If 230 VAC – CR1 is closed

If 0 VAC – CR1 is open

Troubleshoot the safety circuit, working from the

“line side” toward the load in question
 Electrical Troubleshooting

If 230 VAC – LP1 is closed

If 0 VAC – LP1 is open

Troubleshoot the safety circuit, working from the

“line side” toward the load in question
 Electrical Troubleshooting

If 230 VAC – HP1 is closed

If 0 VAC – HP1 is open

Troubleshoot the safety circuit, working from the

“line side” toward the load in question
 Electrical Troubleshooting

If 230 VAC – OL1 is closed

If 0 VAC – OL1 is open

Troubleshoot the safety circuit, working from the

“line side” toward the load in question
 Electrical Troubleshooting

If 230 VAC – OL1 is closed

If 0 VAC – OL1 is open

Troubleshoot the safety circuit, working from

the “line side” toward the load in question
 Electrical Troubleshooting

If 230 VAC – CTH1 is closed

If 0 VAC – CTH1 is open

Troubleshoot the safety circuit, working from the

“line side” toward the load in question
MICROPROCESSOR DAMAGE
MICROPROCESSOR DAMAGE
 ELECTROSTATIC DISCHARGE

If you can feel it there are 4,000 Volts on your body

For an ESD to jump ¼ inch, 25,000 Volts are required

 ELECTROSTATIC DISCHARGE

AS LITTLE AS 30 VOLTS
CAN CAUSE DAMAGE

CATASTROPHIC
Permanently Damaged

LATENT
Device Degradation
 ELECTROSTATIC DISCHARGE

10,000X Magnified

Static Electricity Burn

 ELECTROSTATIC DISCHARGE

• DO NOT TOUCH THE CONTROL OR ANY

WIRES CONNECTED TO THE BOARD
PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE.

• FIRMLY TOUCH A CLEAN UNPAINTED

METAL SURFACE ON THE FURNACE
CHASSIS.
 Sequence of Operation

Knowing the sequence of operation, will help to troubleshoot

a control board. Read the sequence of operations first.

Control Board
Gas Furnace

The manufacturer’s literature should provide

a sequence of operation and wiring diagram.
 Sequence of Operation

Ready-to-Start
GAS FURNACE
SEQUENCE OF OPERATION
• CALL FOR HEAT
• DRAFT INDUCER STARTS
• PRESSURE SWITCH CLOSES
• HOT SURFACE IGNITOR
ENERGIZES
• GAS VALVE ENERGIZES
• FLAME
Ready-to-Start

24 VOLT POWER
TO BOARD
 Sequence of Operation

Call for Heat GAS FURNACE

SEQUENCE OF OPERATION
• CALL FOR HEAT
• Check for 115vac at PL2-2
• DRAFT INDUCER STARTS
• PRESSURE SWITCH CLOSES
• HOT SURFACE IGNITOR
ENERGIZES
• GAS VALVE ENERGIZES
• FLAME SENSING
Sequence of Operation

POWER
TO
INDUCER

CALL
FOR
HEAT
 Sequence of Operation

HSI Energized GAS FURNACE

SEQUENCE OF OPERATION
• CALL FOR HEAT
• DRAFT INDUCER STARTS
• PRESSURE SWITCH CLOSES
• HOT SURFACE IGNITOR
ENERGIZES
• GAS VALVE ENERGIZES
• FLAME SENSING
Sequence of Operation

POWER
TO
IGNITER

PRESSURE
SWITCH
MAKES
 Sequence of Operation

Gas Valve Energized GAS FURNACE

SEQUENCE OF OPERATION
• CALL FOR HEAT
• DRAFT INDUCER STARTS
• PRESSURE SWITCH CLOSES
• HOT SURFACE IGNITOR
ENERGIZES
• GAS VALVE ENERGIZES
• FLAME SENSING
Sequence of Operation

GAS VALVE
ENERGIZED
 Sequence of Operation

Flame Sensing GAS FURNACE

SEQUENCE OF OPERATION
• CALL FOR HEAT
• DRAFT INDUCER STARTS
• PRESSURE SWITCH CLOSES
• HOT SURFACE IGNITOR
ENERGIZES
• GAS VALVE ENERGIZES
• FLAME SENSING
 Sequence of Operation

Flame Sensing GAS FURNACE

SEQUENCE OF OPERATION
• CALL FOR HEAT
• DRAFT INDUCER STARTS
• PRESSURE SWITCH CLOSES
• HOT SURFACE IGNITOR
ENERGIZES
• GAS VALVE ENERGIZES
• FLAME SENSING
Microamps DC
4.0 to 6.0
Integrated Gas Control (IGC)
 Integrated Gas Control (IGC)

IGC Board
 Integrated Gas Control (IGC)

•Controls Unit Combustion Functions

•Controls Burner Ignition Sequence
•Monitors Combustion Safety Features
•Controls Indoor Blower Motor Timing On/Off
•Contains Diagnostics via Flashing LED
Integrated Gas Control (IGC)
Integrated Gas Control (IGC)
Call For Heating Combustion blower

CR Energizes Induced
Draft Motor
Hall Effect Sensor
Limit + Rollout Switch
Complete Safety Circuit
Safety Logic Energizes Main
Gas Valve, High Voltage
Transformer sparks for
5 Seconds to Ignite Burners
2 Second Flame Sense
Trial for Ignition
>2 microamp Flame Signal
Spark Stops, Normal Heat
<2 microamp Flame Signal
IGC De energizes MGV
20 Sec Heat Exchanger Purge & Retry for Ignition
Cycle can continue for 15 min resulting in 33 attempts then unit locks out
 Flame Rectification
The combustion (outer) area of the
flame is where a series of small
“Controlled explosions” occur which
cause the immediate surrounding
Atmosphere to be ionized.
This ionization causes the atmosphere
to become conductive. This
characteristic is what is used in flame
rectification.

Gas Flame
 Flame Rectification

The flame acts like a diode, only passing DC voltage

A short would pass AC voltage
Flame Rectification
Checking
Proof of
Flame Sensing
Signal
 Flame Sensing
Normal Flame Flame Sensor
Proving Signal
Should Be At Least
4 Microamperes
2UA
 What is a Hall Effect Sensor ?
Dr. Hall discovered the effect in the 1920’s, Hall effect sensors
are used to accurately sense position, RPM, velocity,
and acceleration.

The sensor is used to prove inducer motor operation

and is an input to the IGC board.
Hall Effect Sensor

Hall Effect Sensor

 Hall Effect Sensor

Troubleshooting
the
Hall Effect Sensor

Safety switch
 Replace IGC Board if Readings Power On
Are Outside This Range (2 - 3)
Power On
21-24
(1 - 3)
VDC

7.5 - 10 VOM
VDC +
-
VOM
+
-

Disconnect
 Power On Replace Hall Effect Power On
(1 - 3) Sensor if Readings (2 - 3)
Rotate Inducer Are Outside Range
½ Turn
16.5 - 21
then
VDC
Other ½ Turn
VOM
+
<1 6.5 - 9 -
VDC VDC
VOM VOM
Other +
½ Turn +
- ½ Turn -

Re-Connect
Solid State Timer
 Solid State Timer
Solid State Timer
1. Provides a timed off cycle of 5 minutes between
compressor starts to prevent short cycling and
allow pressure equalization to occur.
2. Splits the starting time between major loads
to reduce the starting inrush of current.
For example: On a call for cooling, start the
indoor fan and delay the compressor and
outdoor fan for three seconds.
 Solid State Timer

⚫ T1 to T2 normally open
contacts
⚫ T1 to T3 logic circuit
⚫ High pressure & Low
pressure switch safeties
wire in series between “Y”
from the thermostat and
terminal T1 on the SSTG II
Solid State Timer
Solid State Timer

Condition of
System:
• Indoor fan is ON
• Compressor and
OFM are OFF
 Capacitors
and
Single-Phase Motors
Motor Windings
Motor Windings
Start Winding

Run Winding
 AC Sine Wave
Oscilloscope
Resistive Load
+ In-Phase

Inductive Load
Volt Leads
Current 90°
–
Capacitive Load
Current Leads
Voltage 90°
 Resistive Loads
As current passes through a resistive
load,
either heat or light is created.
The voltage and current sine waves are
in phase with each other.
(Voltage)

(Current)

Watts= Volts× Amps

 Inductive Loads

(voltage)
(current)
 Capacitive Loads

(voltage)
(Current)
 Capacitive Loads
A load that has a capacitor wired in
series with it is called a capacitive load.
Adding a capacitor to the start winding of a motor
makes it a capacitive load.
The capacitor is a phase shifting device that causes
the current to lead the voltage in the circuit,
increasing torque. Capacitive loads are abbreviated
as the letter “C”.

Start Capacitor Start Relay Run Capacitor

 Single Phase Motor
ELI
 Single Phase Motor
Single-Phase Motor

90°
 Single Phase Motor
Single-Phase Motor

180°
 Single Phase Motor
Single-Phase Motor

270°
 Single Phase Motor
Single-Phase Motor

360°
 Single Phase Motor
Single-Phase Motor

90°
 Capacitors
⚫ Electrical device that receives
and stores an electrical charge

⚫ Size varies from a pin head

to a garbage can

⚫ Constructed of two plates which are

conductive to alternating current flow, but
are separated
by an insulation called a dielectric
 Capacitors

Capacitor Ratings

⚫ Voltage –
– Maximum applied to plates
before arc over occurs.
⚫ µF –
Micro farad (millionth of farad)
– Measurement of ability to hold
and store an electrical charge.
 Capacitors
Applying voltage to a capacitor that is in excess of it’s
stamped voltage rating results in “arc-over” between
the plates, heat generation, and pressure buildup.
The can may blow out, possibly rupturing
and releasing oil, which is combustible.

Do Not Exceed the Stamped Voltage Rating of a Capacitor

 Capacitors
All capacitors are wired in series with the start
winding.

They are phase shifting devices that cause the

current to lead the voltage in the start winding.

They increase the starting torque of the motor.

Run Capacitor
⚫ Lowers the running current of the
motor
⚫ Improves the running efficiency
⚫ Reduces the motor winding
temperature
⚫ Extends the life of the motor
⚫ Continuous duty – Series start
winding
⚫ Metal casing and oil help to dissipate
heat
Start Capacitor
⚫ Short time in circuit –
⚫ A Potential type start relay (3
seconds)
⚫ Series with start winding
⚫ High µF rating – Physically small
⚫ High starting torque for motor
⚫ Bakelite casing (non-conductive)
Capacitor Testing
 Capacitor Testing With Analog Meter

SWINGS TOWARDS 0Ω
NEEDLE STAYS AT  SWINGS TO 0Ω
THEN TOWARDS 

GOOD OPEN SHORTED

Capacitor Testing With Digital Meter
Start Capacitor Testing
15,000Ω – 18,000Ω
Bleed Resistor
 Start Capacitor Testing

The bleed resistor should

be removed for testing.

If not:
CAPACITOR
OBSERVATION
CONDITION
OPEN READS 15,000Ω - 18,000Ω RESISTOR
SHORTED READS 0Ω
SWINGS TOWARD 0Ω THEN READS
GOOD
15,000Ω - 18,000Ω RESISTOR
 Rules for Capacitor Replacement
Always try to use an exact replacement
capacitor
with respect to voltage and capacitance.
Any changes or deviations from the original
must be marked.
1. The voltage rating on the replacement capacitor must be
equal to or greater than the voltage rating on the original
capacitor.
2. The Start capacitor must be equal to or no more than
+20%* of the original capacitance.
The Run capacitor must be within ± 10% of the original.
* If the start capacitor is undersized, the motor might not start.
If the start capacitor is oversized, the high current may
burn out the motor.
 PSC Motor
Permanent split capacitor motor
L2 L1

L2 L1
 Marked Terminal
To Start Terminal To Run Terminal

From L2
 Marked Terminal
L2 L1

CORRECT WIRING
Motor starts and runs
as designed.

Result if Capacitor Shorts

Shorted capacitor
will pass current directly
to ground and not
through the motor.
 Marked Terminal
L2 L1

INCORRECT WIRING
Motor starts and runs
as designed.
Result if Capacitor shorts
Shorted capacitor
will pass current
through start winding
to ground.
 Capacitor Grounding

Grounding
Strap

Grounding
Terminal
 Soft Start vs. Hard Start

MOTOR TORQUE

PSC 75 FT/LB

PSC S
O
+ 154 FT/LB F
POW-R-PAK T

PTC 172 FT/LB

H
A
CSR 300 FT/LB R
D
 Common Electrical Motors

Characteristics Component Parts Application

Motor
Type Starting Running
RC SC SR
Torque Efficiency
Compressors
PSC Moderate Excellent X
Fans/Pumps

Permanent Split Capacitor

 Common Electrical Motors

Characteristics Component Parts Application

Motor
Type Starting Running
RC SC SR
Torque Efficiency
CSR High Excellent X X X Compressors

Capacitor Start Capacitor Run

Common Electrical Motors

CSR

CSIR

PSC

What types of motors are shown ?

Be Motor Wise!
Troubleshooting the Start Gear
 CSR Motor Circuit Failures
1. Start relay contacts stuck open

0 - amps when the

compressor tries to start

?
The Motor may start, depending on conditions.
It has lost the starting torque the start capacitor provides
 CSR Motor Circuit Failures

2. Start relay contacts welded closed

Amp draw after

? compressor starts

The motor will start, but will soon overheat

or burn out the start winding
Potential Type Start Relay
 CSR Motor Circuit Failures
3. Run capacitor shorted plate to plate

Checking the capacitors with multi-meter

? would find the cause

Compressor probably won’t start , the start capacitor

is bypassed and will not help starting torque.
The motor will overheat or burnout the start winding.
 CSR Motor Circuit Failures

4. Run capacitor is open

Checking the capacitors with a multi-meter

Would find the cause.

? Also there would be no amp draw

on the start winding after start-up

Motor would start and may stay running, depending on load.

It would run hotter than normal.
 CSR Motor Circuit Failures

5. Start capacitor shorted plate to plate

? Checking the capacitors with multi-meter

would find the cause

Compressor may start as a resistive start type motor which has low
Starting torque, if it did start it would continue to run
 CSR Motor Circuit Failures

6. Start capacitor open

Checking the capacitors with multi-meter

? would find the cause

Also there would be no amp draw at start-up
Through the start capacitor.

Compressor may start depending on load, Starting torque was lost.

If it starts it should continue to run.
 CSR Motor Circuit Failures

7. Start relay coil open

? There will be a amp draw through the

Start capacitor after start-up

Compressor will start, but will overheat

or burnout the start winding.
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