🔧 AC Compressor Not Starting? Complete Guide to Fix Capacitor, Relay & Electrical Issues
Problem Overview
Your AC indoor unit works, fan runs normally, but there's no cooling because the compressor in the outdoor unit won't start. You hear the fan spinning but no compressor hum or vibration. This critical issue has several causes: failed capacitor (most common, 60% of cases), faulty relay/contactor, thermal overload protection, seized compressor, or low voltage. The compressor is the heart of your AC—without it running, there's zero cooling despite the fan working perfectly.
Safety First - HIGH VOLTAGE WARNING
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CAPACITOR DISCHARGE HAZARD: Capacitors store lethal high voltage (240-440V) even when AC is OFF. Never touch capacitor terminals without proper discharge. Can cause severe electric shock, cardiac arrest, or death. This is the #1 electrical hazard in AC repair.
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Turn OFF circuit breaker: Always disconnect AC power at the main circuit breaker, not just the AC switch. Wait 5 minutes before opening outdoor unit. Verify power is off with voltage tester before touching any components.
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Do not bypass safety devices: Never bypass thermal overload, relay, or safety switches. These protect expensive compressor from damage. Bypassing causes compressor burnout costing ₹15,000-₹25,000 replacement.
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Compressor replacement is expensive: If compressor seized or burned out, replacement costs ₹8,000-₹20,000 plus labor. Often more economical to replace entire outdoor unit. Get multiple quotes before proceeding.
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Warranty preservation: Opening outdoor unit or attempting capacitor/relay replacement yourself will void warranty. If AC is under warranty (typically 1-5 years on compressor), contact authorized service center only.
🔍 Quick Diagnostic Checks ⏱️ 3-5 minutes
1 Listen Test - Is Compressor Running?
Go to outdoor unit. Fan spinning = good. Listen/feel for compressor hum and vibration. No hum/vibration despite fan running = compressor not starting. Healthy compressor makes steady low-frequency hum you can feel.
2 Touch Test - Temperature Check
Carefully touch outdoor unit metal (when powered, stay away from electrical parts). If compressor running, unit gets hot. If only fan runs, unit stays relatively cool. Also check if air blown is hot (normal) or ambient temp (compressor not working).
3 Clicking Sound Detection
When AC turns on, listen for "click" from outdoor unit (relay/contactor engaging). If you hear click but compressor doesn't start, likely capacitor failure. No click at all = relay/contactor or control board issue.
4 Visual Inspection (Power OFF)
Turn OFF breaker, wait 5 min. Open outdoor unit cover. Look for: bulging/leaking capacitor (top swollen), burned relay contacts, loose wiring, burnt smell. Capacitor failure often visible—domed top instead of flat.
5 Check Supply Voltage
Measure voltage at outdoor unit: should be 220-240V AC (India). Below 200V = insufficient for compressor start (high starting current requirement). Common in areas with voltage fluctuation. Stabilizer may be needed.
6 Thermal Overload Reset
If compressor won't start, it may be in thermal overload protection (prevents damage from overheating). Turn AC completely OFF for 30-60 minutes. If compressor starts after cooling, overload was triggered—investigate root cause.
💡 Common Causes → Solutions
Problem
Failed compressor start capacitor (60% of cases)
Solution
Replace capacitor (₹300-₹800 parts + ₹300-₹500 labor). Capacitor provides starting boost for compressor motor. Typical lifespan 3-5 years. Quick 15-minute repair by technician. Instant fix.
Problem
Faulty compressor relay or contactor (burned contacts)
Solution
Replace relay/contactor (₹500-₹1,500 parts + labor). Relay switches high current to compressor. Contacts pit/burn over time from electrical arcing. Technician checks continuity and replaces if faulty.
Problem
Thermal overload protection triggered (compressor overheated)
Solution
Turn AC OFF for 1 hour to reset overload. If repeatedly trips: clean condenser coils, check refrigerant charge, ensure proper voltage. Overload prevents compressor damage—find and fix root cause, don't bypass it.
Problem
Low voltage preventing compressor startup (high inrush current)
Solution
Install voltage stabilizer (₹3,000-₹7,000) to ensure 220-240V supply. Compressor needs 3-5x normal current at startup. Below 200V insufficient. Check voltage during peak hours when compressor won't start. Stabilizer essential in low-voltage areas.
Problem
Compressor seized/locked (mechanical failure, bearing damage)
Expensive Repair
Compressor replacement ₹8,000-₹20,000 + labor ₹2,000-₹4,000. For ACs 7+ years old, consider replacing entire outdoor unit or whole AC. Seized compressor often from: liquid refrigerant flooding, bearing failure, contamination. Get professional assessment.
Problem
Compressor winding open/shorted (electrical failure inside compressor)
Solution
Technician tests with ohmmeter (should read 2-10 ohms between terminals). Open circuit (infinite resistance) or short (near-zero resistance) = compressor replacement needed. Caused by: voltage spikes, overheating, insulation breakdown. No repair possible—full replacement only.
Problem
Wiring issues: loose connections, burned terminals, broken wires
Solution
Visual inspection (power OFF) for: discolored/melted connectors, loose terminal screws, rodent damage to wires. Tighten all connections, replace damaged wires. Common in outdoor units exposed to weather, moisture, pests. Technician repairs wiring ₹500-₹1,500.
Problem
PCB/control board failure (not sending start signal to compressor)
Solution
Technician checks output signal to compressor contactor. If control board faulty, repair ₹1,500-₹3,500 or replacement ₹3,000-₹8,000. Common in inverter ACs with complex electronics. Caused by: power surges, moisture, component aging. Professional diagnosis essential.
🛠️ Step-by-Step Diagnostic Process
Confirm Fan Works But Compressor Doesn't
• Set AC to coldest setting (16-18°C) and maximum fan speed
• Go to outdoor unit—fan should be spinning visibly
• Listen closely for compressor hum (steady low-frequency sound)
• Place hand on outdoor unit metal—should vibrate when compressor runs
• If fan spins but NO hum/vibration = compressor not starting (confirmed)
• Check air temperature from outdoor unit: should blow HOT air if compressor works, ambient temp if not
Check for Clicking Sound (Relay/Contactor Test)
• Turn AC OFF, wait 5 minutes, then turn ON again
• Stand near outdoor unit and listen carefully during startup
• Should hear distinct "CLICK" sound (relay/contactor engaging)
• Click present + compressor doesn't start = capacitor likely failed
• NO click sound = relay/contactor faulty OR control board not sending signal
• Multiple rapid clicks = low voltage or stuck relay
Visual Capacitor Inspection (POWER OFF)
⚠️ SAFETY FIRST: Turn OFF circuit breaker, wait 5 minutes, verify with voltage tester
• Remove outdoor unit cover (usually 4-6 screws)
• Locate capacitor: cylindrical metal can, usually with wires attached
• Healthy capacitor: flat or slightly concave top
• Failed capacitor signs: bulging/swollen top (domed shape), leaking oil/fluid, rust, burn marks, cracked casing
• Note capacitor ratings (µF and voltage) for replacement
• If visibly damaged, capacitor replacement needed
Test for Thermal Overload Protection
• If compressor won't start, it may be in thermal protection mode
• Turn AC completely OFF at breaker for 60 minutes (compressor needs to cool)
• After cooling period, turn AC back ON and test
• If compressor starts after cooling period: thermal overload was triggered
• Thermal overload triggers indicate: dirty condenser coils, low refrigerant, overworking, high ambient temperature
• If repeatedly goes into overload: root cause MUST be found and fixed
Measure Supply Voltage (LOW VOLTAGE TEST)
Equipment needed: Digital multimeter
• Set multimeter to AC voltage (200-300V range)
• Measure voltage at outdoor unit terminals: should be 220-240V in India
• Voltage below 200V = insufficient for compressor start (requires 3-5x normal current)
• Check voltage during peak hours (evening) when compressor fails to start
• Low voltage common causes: weak supply, long cable run, undersized wiring, area-wide voltage drops
• Solution: Voltage stabilizer (₹3,000-₹7,000) mandatory in low-voltage areas
Inspect Relay/Contactor Condition
⚠️ Power OFF, verified with tester
• Locate relay/contactor (black box with wires, often near capacitor)
• Visual check: look for burned/pitted contacts, melted plastic, carbon buildup
• Smell test: burning smell indicates overheated relay
• Manual test: with power OFF, can you manually close contacts? (should move smoothly)
• Stuck contacts or severe pitting = replacement needed
• Relay failure caused by: voltage spikes, contact arcing, moisture, overheating
Test Compressor Windings (Advanced Diagnosis)
For technicians with multimeter:
• Turn OFF power, discharge capacitor safely
• Locate compressor terminals: C (common), S (start), R (run)
• Measure resistance between terminals with ohmmeter:
- C to R: Should read 2-4 ohms
- C to S: Should read 3-6 ohms
- R to S: Should read 5-10 ohms (sum of C-R and C-S)
• Infinite resistance (open circuit) = winding burned out
• Near-zero resistance (short circuit) = winding shorted
• Either case = compressor replacement needed (₹8,000-₹20,000)
Check for Mechanical Seizure (Hard Start Test)
Signs of seized compressor:
• Loud humming sound when trying to start but doesn't run (locked rotor)
• Circuit breaker trips immediately when compressor tries to start
• Very high current draw but no rotation (detectable by ammeter)
• Compressor extremely hot to touch after attempted start
• Smell of burning insulation from compressor
Causes: Liquid refrigerant flooding, bearing failure, lack of oil, refrigerant contamination
Solution: Compressor replacement (₹8,000-₹20,000) + refrigerant + labor
Verify Control Board Signal (Inverter ACs)
For inverter ACs with electronic control:
• Control board sends variable frequency signal to compressor
• Technician checks: voltage output to inverter module (usually 280-320V DC)
• Checks: control signal presence, error codes on display
• Faulty inverter board symptoms: no output, fluctuating voltage, error codes
• Board repair: ₹2,000-₹4,000 / Replacement: ₹4,000-₹10,000
• Common in inverter ACs—more complex electronics than standard ACs
Final Assessment & Professional Diagnosis
If you've completed above checks and compressor still won't start:
• 60% probability: Capacitor failed (₹300-₹800 fix) ✓ COMMON & CHEAP
• 20% probability: Relay/contactor faulty (₹500-₹1,500 fix) ✓ COMMON & CHEAP
• 10% probability: Low voltage issue (₹3,000-₹7,000 stabilizer)
• 5% probability: Control board failure (₹2,000-₹10,000)
• 5% probability: Compressor seized/failed (₹10,000-₹25,000 total) ✗ EXPENSIVE
Call qualified technician for: Capacitor testing/replacement, compressor diagnosis, refrigerant checks
📞 When to Call a Professional (HIGH PRIORITY)
⚡ Electrical Hazards - NO DIY
- • Capacitor testing/replacement (stores 440V, can kill)
- • Relay/contactor replacement (high voltage/amperage)
- • Compressor winding testing (shock hazard)
- • Control board diagnosis (complex electronics)
- • Any wiring repairs in outdoor unit
- • Working inside outdoor unit without training
🔧 Compressor Issues - Specialist Required
- • Compressor makes loud humming but won't start (seized)
- • Burning smell from outdoor unit
- • Circuit breaker trips when compressor attempts start
- • Compressor extremely hot to touch
- • Repeated thermal overload protection triggering
- • Suspected refrigerant system issues
💰 Repair Cost Guide (2025 India - Parts + Labor)
✓ Capacitor Replace: ₹500-₹1,200
✓ Relay/Contactor: ₹800-₹2,000
✓ Thermal Overload: ₹600-₹1,500
✓ Wiring Repair: ₹500-₹1,500
⚠ Voltage Stabilizer: ₹3,000-₹7,000
⚠ Control Board Repair: ₹2,000-₹4,000
⚠ Inverter Board: ₹4,000-₹10,000
⚠ Complete Service: ₹1,500-₹3,000
✗ Compressor Replace: ₹8,000-₹20,000
✗ + Installation Labor: ₹2,000-₹4,000
✗ + Gas Refill: ₹2,000-₹4,000
✗ Total: ₹12,000-₹28,000
🔍 Questions to Ask Technician
- • Exact diagnosis: "What component failed and how did you verify it?" (Ask to see the failed part)
- • Capacitor test: "What is capacitor µF reading vs rated value?" (Should be within 10%)
- • Voltage check: "What voltage are you measuring at the unit?" (Should be 220-240V)
- • Compressor test: "Did you test compressor winding resistance?" (Get ohm readings for each terminal)
- • Cost breakdown: "Separate parts cost vs labor charge?" (Itemized quote)
- • Warranty: "What warranty on replaced parts and labor?" (Minimum 3-6 months expected)
- • Repair vs replace: "Is compressor replacement worth it on this X-year old AC?" (Honest assessment)
📊 Compressor Start Failure - Diagnosis Matrix
| Symptom | Sound/Behavior | Most Likely Cause | Repair Cost |
|---|---|---|---|
| Click heard, compressor silent | Relay clicks, nothing else | Failed Capacitor | ₹500-₹1,200 |
| No click, compressor silent | Complete silence at startup | Relay/Control Board | ₹800-₹3,000 |
| Loud hum, doesn't run | Buzzing/humming, no rotation | Seized Compressor | ₹12,000-₹28,000 |
| Starts then stops (30 sec) | Brief run, then shuts off | Thermal Overload | ₹600-₹1,500 |
| Repeated clicking, no start | Click-click-click rapidly | Low Voltage | ₹3,000-₹7,000 (stabilizer) |
| Trips circuit breaker | MCB trips at startup | Short/Seized Compressor | ₹12,000-₹28,000 |
| Works after long OFF time | Starts after 1+ hour cooling | Overload/Overheating | ₹1,000-₹3,000 |
⚡ Understanding Capacitors - The Most Common Failure
What Capacitors Do
Compressor motors need HUGE starting torque. Capacitor provides electrical "kick" to overcome initial inertia. Think of it like push-starting a car—capacitor provides that initial push.
- • Start Capacitor: Boosts starting torque (300-500% normal)
- • Run Capacitor: Improves running efficiency (some ACs have dual)
- • Rated Value: Measured in microfarads (µF), e.g., 35µF, 50µF
- • Voltage Rating: Usually 440V AC for Indian ACs
Why Capacitors Fail
- • Age: Typical lifespan 3-5 years (electrolytic fluid dries out)
- • Heat: Outdoor unit heat (50°C+) accelerates degradation
- • Voltage Spikes: Power surges damage internal dielectric
- • Overwork: Frequent starts, long run hours wear it out
- • Manufacturing Defects: Some fail within 1-2 years (warranty claim)
Visual Capacitor Diagnosis (Power OFF Only)
✓ Healthy Capacitor:
- • Flat or slightly concave top
- • Clean, no rust or corrosion
- • No oil leakage around base
- • Terminals clean and tight
✗ Failed Capacitor:
- • Bulging/swollen top (domed)
- • Oil leakage or wet appearance
- • Rust, corrosion on casing
- • Cracked or split casing
⚠ Failing Capacitor:
- • Slight bulge on top
- • Discoloration (heat damage)
- • Inconsistent compressor starts
- • Replace preventively (cheap)
🛡️ Preventive Care & Maintenance
Annual Maintenance
Professional service: capacitor testing, relay contact check, wiring inspection, voltage measurement, thermal overload test, compressor current measurement
Electrical Protection
Install voltage stabilizer (₹3,000-₹7,000), use surge protector, ensure proper earthing, check supply voltage regularly, upgrade wiring if undersized
Reduce Compressor Load
Clean condenser coils biannually, ensure proper refrigerant charge, fix gas leaks promptly, don't run AC at 16°C unnecessarily, adequate clearance around outdoor unit
💡 Capacitor Life Extension Tips:
- • Voltage stabilizer: Prevents voltage spikes that damage capacitors—extends life 2-3x
- • Avoid frequent cycling: Each start stresses capacitor—run continuously instead of on/off/on
- • Shade outdoor unit: Reduce heat exposure—capacitors last longer in cooler environments
- • Annual testing: Technician tests capacitance value (should be within 10% of rating)—replace if degraded
- • Quality replacement: Use genuine/branded capacitors (₹100 more) vs cheap alternatives—lasts 3x longer
- • Clean condenser: Dirty coils make compressor work harder—more stress on capacitor
📋 Compressor Health Checklist
✓ Listen for unusual compressor sounds
✓ Verify outdoor unit blows hot air
✓ Check for vibration when running
✓ Monitor cooling performance
✓ Clean outdoor unit externally
✓ Capacitor capacitance test (µF reading)
✓ Compressor current draw measurement
✓ Refrigerant pressure check (65-70 PSI)
✓ Relay/contactor contact inspection
✓ Thermal overload function test
❓ Frequently Asked Questions
Q1: How do I know if capacitor failed without opening outdoor unit?
Classic symptom: You hear relay "click" when AC turns on, outdoor fan spins normally, but compressor absolutely silent (no hum, no vibration). This is 80% likely capacitor failure. Capacitor provides starting boost—without it, compressor motor can't overcome initial inertia to start rotating. Other signs: capacitor worked fine yesterday, suddenly stopped today (capacitors fail abruptly, not gradually).
Q2: Can I replace AC capacitor myself to save money?
Absolutely NOT recommended. Capacitors store 240-440V even when AC is OFF for hours. Touching terminals = instant shock, possible death. Professional capacitor discharge requires: insulated tools, proper resistor, safety training. One mistake = fatal. Professional replacement costs ₹500-₹1,200 (15 min job). Your life worth more than saving ₹500. Additionally, wrong capacitor value damages compressor (₹15,000 replacement). Let technician handle this.
Q3: Compressor starts after AC is OFF for 1 hour but not continuously. Why?
Thermal overload protection triggering. Compressor overheating causes safety overload to cut power. After cooling for 1 hour, overload resets, compressor starts again. Root causes: (1) Dirty condenser coils (compressor works harder, overheats), (2) Low refrigerant (compressor runs hot), (3) High ambient temperature (45°C+ summers), (4) Failed fan motor (no cooling of compressor). Solution: Clean coils, check refrigerant, ensure fan works. Don't bypass overload—will burn compressor permanently.
Q4: AC worked fine until voltage dropped. Now compressor won't start. Voltage issue or capacitor?
Low voltage problem, not capacitor. Compressor needs 220-240V and 30-50 amps startup current. At 180-200V, insufficient power for startup (fan works fine—low current requirement). Test: Check voltage when compressor fails to start. Below 200V = voltage issue. Solution: Voltage stabilizer (₹3,000-₹7,000) maintains 220V output even with 140-280V input. Common in areas with transformer overload during peak hours. Stabilizer fixes this completely.
Q5: Compressor makes loud humming sound but doesn't run. What's wrong?
Seized/locked compressor—serious problem. Humming = motor receiving power but rotor can't turn (mechanically stuck). Causes: (1) Liquid refrigerant in cylinder (liquid doesn't compress—locks piston), (2) Bearing seizure (lack of oil, metal-on-metal), (3) Debris in compressor. This is locked rotor condition—draws massive current, trips breaker. Expensive repair: compressor replacement ₹12,000-₹28,000 total. For 7+ year old AC, consider replacing entire unit instead—more economical.
Q6: How long do AC capacitors last? When should I replace proactively?
Typical lifespan: 3-5 years, varies by usage/conditions. Factors affecting life: ambient heat (outdoor units in sun die faster), voltage quality (spikes damage capacitor), run hours (heavily used ACs wear faster), quality (branded capacitors last 2x longer). Proactive replacement timing: After 4 years, have technician test capacitance annually. If reading drops below 85% of rated value, replace preventively. Cost: ₹800 preventive replacement vs ₹5,000+ emergency call + potential compressor damage. Smart economics: replace capacitor every 4-5 years during routine service.
Q7: Is voltage stabilizer really necessary? AC worked fine for 3 years without one.
Essential in areas with voltage fluctuation (180-260V range). Low voltage symptoms: compressor won't start (insufficient startup current), frequent thermal overload trips, capacitor/relay premature failure (stress from repeated failed start attempts). High voltage (260V+) damages: control boards, compressor windings, burns capacitor. Stabilizer maintains steady 220-240V output. Cost ₹3,000-₹7,000 vs ₹15,000 compressor replacement. If your area has frequent voltage issues or inverter AC, stabilizer is mandatory protection, not optional.
Q8: Technician says compressor replacement needed but AC only 4 years old. Get second opinion?
ALWAYS get 2-3 opinions for expensive diagnosis. Compressor failure at 4 years unusual (should last 7-10 years). Verify diagnosis: Ask technician to show you test results (winding resistance readings, capacitor test, current draw measurement). Ensure they tested: capacitor (most common cause), relay, voltage, thermal overload BEFORE declaring compressor dead. Unethical technicians sometimes push expensive repair when simple ₹800 capacitor fix would work. Get itemized quote, check if compressor under warranty (5-year compressor warranty common), compare with new AC cost.
Q9: What's the difference between start capacitor and run capacitor?
Start capacitor: Provides huge boost (300-500%) for initial startup, disconnects after compressor reaches speed (2-3 seconds). High µF value (100-300µF), smaller physical size. Run capacitor: Stays in circuit during operation, improves efficiency and power factor. Lower µF value (30-60µF), larger cylinder. Many ACs use dual capacitor (combines both functions, two sections in one unit). If start section fails = compressor won't start. If run section fails = compressor starts but runs inefficiently, overheats. Both symptoms require capacitor replacement.
Q10: Should I repair or replace AC if compressor replacement costs ₹20,000?
Economics calculation: If AC is 7+ years old and repair costs 50%+ of new AC price, replacement makes more sense. Example: ₹20,000 compressor repair vs ₹35,000 new 1.5 ton inverter AC. New AC gives: 5-year warranty, 30% better efficiency (₹3,000/year savings), latest features, no old-unit failures. Even at 5 years old, consider: remaining lifespan (maybe 3-5 more years), other components aging (PCB, coils might fail next), efficiency loss (old AC consumes 20% more power). Get multiple quotes, calculate 3-year total cost of ownership (repair cost + likely additional repairs + higher electricity). Often replacement is smarter investment.
⚠️ Disclaimer: This troubleshooting guide is for informational and diagnostic purposes only. AC compressor systems involve HIGH VOLTAGE electricity (240-440V) that can cause FATAL electric shock. Capacitors store lethal voltage even when AC is turned OFF. NEVER attempt to touch, test, or replace capacitors, relays, or any outdoor unit components without proper training and safety equipment. Compressor repairs require certified HVAC technicians with specialized tools and knowledge. Incorrect repairs can cause equipment damage, fire hazard, personal injury, or death. If AC is under warranty, only use authorized service centers. When in doubt, always call a qualified professional technician. Your safety is paramount—no repair is worth risking your life.
Important Safety Reminder
If you're not comfortable with any step, or if the problem persists after trying these solutions, please contact a qualified technician. Safety should always be your first priority when dealing with electrical appliances.
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