Puzzle: new wire appeared after capacitor replacement on Starcool

[dorothyt7]

Hi All,
So I've read EVERY thread in this forum on the Starcool system, and with all of your awesome knowledge decided to replace the capacitor in my Starcool II because it was not working on shore power. Its a Tecumseh compressor (Starcool switched from Tecumseh to Danhard in mid 1995 - the year of my van) I know this because Mark Nation at Danhard is amazing.

Short Version of my request for help: There is a new wire that wasn't there when I took it apart. I took pictures and labeled the wires, but some how I have an extra after putting everything back together. Help would be greatly appreciated.

Before picture

And after

Seems like my images aren't showing - but the album is here
https://www.sportsmobileforum.com/forums/members/6033-albums1686.html

Any idea where this mystery gray wire should go? Its the only one that doesn'y have a little sleeve on it and why I really can't see it in the original picture.
I wish I could at mention members because I know @BrianW and @Scalf77 have lots of knowledge on this topic.
Thanks in advance for any assistance!

 

[BeeDub-ClassB]

Hmmm, sorry, no idea! It clearly has a ring terminal on it so it must have gone on one of those terminals. Was there maybe a screw on the copper terminal at bottom right of your first photo that fell off? @Scalf77 will probably know and have several well-drawn schematics to illustrate

 

[dorothyt7]

Thanks Brian - We had that thought be it looks unused so afraid to try not knowing any better? Scalf77 did respond to my PM that he didn't know either

I've left 3 messages and 2 emails to Tecumseh tech support with no response. Very disappointing.

 

[Scalf77]

Can you trace that wire back to something? It is difficult decide where it may go without know where to or from the other end goes. I take it this the connection to the Compressor. There is a variety of drawings out there for different compressors, do you have a number?

I am still kind of blown away on the relay wiring, being that they switch colors midstream. Black input to white output.

 

[dorothyt7]

After more time looking .... the three wires that come off the compressor are the red, yellow, and dark grey (the new mystery wire). I believe that the red is the run, the yellow is the start, and the dark grey is the common. The yellow is connected to the start capacitor on the AC start relay, and the red appears to charge the capacitor. The big question is where does that dark grey wire connect?
I spoke with TWO separate RV air conditioning 'pros' and, after reviewing the photos, they both said that maybe the gray wire had never been connected and to try leaving the gray wire disconnected and try powering on shore / 110v power.
DID NOT WORK. There was terrible buzzing / ruckus from the relay box but the compressor did not run.
So the search for WHERE does the gray wire connect ? ... continues.
Found this video on just standard HVAC, and the 3 wires coming off the compressor match this, so thinking it probably connects to the start relay.
Any other thoughts? We're going to try that next time we can take the van apart Had to put it back together for a weekend Morel hunting in the Blue Mountains, spring is short!
https://youtu.be/g2ADgrUhb7Y?si=W6JtjUZT4o_vSxye

 

[Scalf77]

My best guess would be the top right connection, which I believe is Line voltage. I assume this is also the white wire coming from the Starcool Relay also in your pictures

 

[Scalf77]

Did you ever get this figured out?

I made a schematic of the connections

It looks like your wire should go to terminal 5 of the Potential Relay as described in previous post.

Another thread with good data here https://www.sportsmobileforum.com/forums/f34/starcool-iii-compressor-cycling-32838-2.html#post334247