Preventing Common Failures in Scroll Compressors

Scroll refrigeration compressors are efficient, reliable, and widely used in various cooling systems. Despite their robust design, they are still susceptible to specific types of failures, especially when maintenance is overlooked. By understanding these common issues, users can take preventive steps to avoid expensive repairs and extend the lifespan of their equipment. Here, we’ll explore four frequent failure types, their symptoms, and ways to prevent them.

1. Lack of Lubrication

Proper lubrication is essential for scroll compressors, as it reduces friction and helps in sealing components. When oil levels are too low or the oil becomes degraded, it can lead to high temperatures, increased wear, and even motor damage. Signs of poor lubrication include unusual noises, high compressor temperatures, or tripped circuit breakers.

Common causes include frequent on-off cycling, which can prevent oil from returning to the compressor, and moisture or air in the system, which can degrade the oil over time. To prevent these issues, make sure to regularly check for leaks and maintain correct oil levels. Simple measures like ensuring proper system operation and regular oil checks can go a long way in avoiding lubrication-related problems.

2. Liquid Floodback

Liquid floodback happens when unvaporized refrigerant flows back into the compressor, potentially damaging internal components. This issue is particularly harmful, as it can cause the scroll plates to crack or damage the motor’s insulation, resulting in sudden shutdowns.

Causes of liquid floodback include low airflow, blocked filters, dirty heat exchangers, or an overfilled refrigerant system. Symptoms of floodback include abnormal noises during operation, or the compressor starting and stopping unexpectedly. Routine maintenance, such as cleaning filters, checking airflow, and monitoring refrigerant levels, can help prevent floodback and keep your compressor running smoothly.

3. Overheating and Burnout

Overheating is a frequent issue that, if unchecked, can lead to compressor burnout. This problem often arises from low refrigerant levels, blocked air filters, or poor airflow. When refrigerant is too low, the compressor lacks the cooling effect it needs, causing temperatures to rise excessively. External factors, such as high ambient temperatures or overly long refrigerant pipes, can further exacerbate overheating.

Signs of overheating include an unusually high temperature at the compressor’s discharge port, strange smells, or frequent circuit breaker trips. To prevent overheating, make sure to maintain optimal refrigerant levels, clean or replace filters regularly, and keep the airflow unblocked.

4. Electrical Coil Burnout

The compressor’s electrical coils are essential for motor function, but they can burn out over time due to issues like short circuits or voltage instability. Electrical failures often show up as tripped circuit breakers, melted contacts, or poor motor performance.

This problem is commonly caused by abnormal wear, power surges, or poor electrical connections. Regularly checking electrical connections and maintaining stable voltage levels can significantly reduce the risk of coil burnout. Additionally, it’s essential to avoid sudden power fluctuations and to ensure that the voltage stays within the compressor’s recommended range.