Althouse Turnquist Bracciano

PowerPoint Presentation by: Associated Technical Authors

Publisher

The Goodheart-Willcox Company, Inc.

Tinley Park, Illinois

Chapter 4

Compression Systems Compressors

 Study the five thermal laws relating to refrigeration.  Explain the compression cycle for a domestic refrigerator.  List the components of a refrigeration compression system.  Explain the operation of each component of a compression system.  Trace the flow of refrigerant through a complete refrigeration system.

 Name the two types of motor controls and discuss their operation and purpose.  Describe the five principal types of refrigerant controls and their operation.  Name four different types of compressors.  Explain how compressors operate.  Identify the internal parts of a compressor.  Follow approved safety procedures.

Chapter 4

4.1

Laws of Refrigeration
Fluids absorb heat while changing from a liquid to a vapor state. Fluids give up heat in changing from a vapor to a liquid. The temperature at which a change of state occurs is constant during the change, providing pressure remains constant. Heat flows only from a body that is at higher temperature to a body that is at a lower temperature (hot to cold).

4.1

Laws of Refrigeration
Metallic parts of the evaporating and condensing units use metals that have high heat conductivity (copper, brass, aluminum). Heat energy and other forms of energy (electrical, mechanical) are interchangeable.

4.2

Compression Cycle
The compressor changes the refrigerant vapor from low pressure to high pressure during the compression cycle. This transfers heat from the inside of the cabinet to the outside. Refrigerating system consists of a high-pressure side and a low-pressure side.

4.2

Compression Cycle

4.2.1

Operation of Compression Cycle

Note high side and low side. The evaporator is on the low side. Heat is absorbed in the low side. The condenser is in the high side. This is where the heat is released from the refrigerant.

4.2.2

Temperature and Pressure Conditions in the Compression Cycle

Upon starting, compressor moves refrigerant molecules from the low-pressure side to the highpressure side. It is necessary to speed up the molecules by increasing their temperature. With each stroke of the compressor, more vapor molecules squeeze into the condenser, increasing pressure and temperature. During compression, pressure increases. At the same time, temperature increases.

4.2.2

Temperature and Pressure Conditions in the Compression Cycle

4.2.2

Temperature and Pressure Conditions in the Compression Cycle

continued

The higher temperature causes a flow of heat to the surrounding metal and air. Heat moves from the vaporized refrigerant to the cooling medium.

4.2.2

Temperature and Pressure Conditions in the Compression Cycle

4.2.2

Temperature and Pressure Conditions in the Compression Cycle

Cooling continues until heat loss causes some vapor molecules to become liquid molecules. The liquid molecules collect and flow into the liquid receiver. Temperature and pressure increase until a balance is reached.

4.2.2

Temperature and Pressure Conditions in the Compression Cycle

Questions
When does a fluid give up latent heat? When it changes from a gas to a liquid. Heat always flows from a __________ warmer substance to a cooler ______________ substance. What is the purpose of a compressor? It changes a low-pressure, low-temperature gas to a high-pressure, high-temperature gas. Into which part of the system is the heat absorbed: the high side or the low side? The low side.

Questions
continued What main component absorbs heat? The evaporator. During the compression cycle, as the refrigerant temperature also increases. pressure increases, its ____________ When heat transfers from the high-pressure hightemperature refrigerant gas as it flows through the condenser, what happens to the refrigerant? It changes to a liquid.

4.3

Evaporator
Two main types of evaporators: Dry System Evaporators are fed refrigerant as quickly as needed to maintain desired temperature. This system usually has a superheated gas leaving the evaporator. Flooded System Evaporators are always filled with liquid refrigerant. The type of refrigerant control used determines the type of evaporator used.

4.3

Evaporator
continued Four styles of evaporators for residential refrigerators/freezers: Shell-type.

Shelf-type.

Wall-type (used with chest freezers). Fin tube-type with forced circulation (used with frost-free construction).

4.3

Evaporator

4.3

Evaporator

4.3

Evaporator

4.3

Evaporator

4.4

Accumulator
A safety device. Prevents liquid refrigerant from flowing back into the compressor. Liquid refrigerant that flows into the accumulator will be evaporated. This vapor will flow into the suction line.

4.4

Accumulator

4.5

Suction Line
Carries the refrigerant vapor from the evaporator to the compressor. Must be large enough to avoid resistance of refrigerant flow. Should slope from the evaporator or accumulator down to the compressor to avoid oil pockets. May be in contact with all or part of liquid line to reduce flash gas in evaporator.

4.5.1

Low-Side Filter-Drier
Included at the compressor end of the suction line on some systems. May be placed in the system for a short period to clean the refrigerant within the system. Should offer little resistance to vaporized refrigerant flow.

4.5.1

Low-Side Filter-Drier

4.5.2

Compressor Low-Side or Suction Service Valve

Allows the technician to connect gauges to the system. Allows for checking pressures and adding or removing refrigerant or oil. Sealing caps protect the opening when valve is not in use. Most new domestic models do not have service valves. Saddle valves are used instead.

4.5.2

Compressor Low-Side or Suction Service Valve

Questions
What are two main types of evaporators? A dry system evaporator and flooded system evaporator. Which component determines whether an evaporator is considered dry or flooded? The metering device. Name four styles of evaporators for residential refrigerator/freezers. Shell-type, shelf-type, wall-type, and fin tube-type.

Questions
continued What is the purpose of an accumulator? It prevents liquid refrigerant from flowing back into the compressor. Where is the suction line located on a refrigeration system? Between the evaporator and the compressor. Where is the low-side filter-drier placed in a system? In the suction line.

Questions
continued What is the purpose of the suction service valve? To allow a technician to access the system for charging, removal of refrigerant, evacuation, and adding refrigerant oil.

4.6

Compressor
A motor-driven device. Removes heat-laden vapor refrigerant from the evaporator. Compresses the vapor into a small volume at a high temperature.

4.6.1

Compressor High-Side Service Valve

Provides a shutoff between the compressor and the condenser. Provides an opening for a high-pressure gauge or a gauge manifold.

4.6.1

Compressor High-Side Service Valve

4.7

Oil Separator
Separates the oil from the hot, compressed vapor. Placed between the compressor exhaust and the condenser. Contains a series of baffles or screens that collect the oil. Oil is returned to the compressor crankcase by the use of a float-type valve. Commonly used in large commercial installations.

4.7

Oil Separator

4.8

Condenser
Removes the condensation heat from the refrigerant vapor. This heat is picked up in the evaporator and the compressor.

4.8

Condenser
Condensers commonly used in domestic refrigeration: Finned-static (natural convection). Finned-forced convection. Wire-static. Plate-static.

4.8

Condenser

4.8

Condenser

4.8

Condenser
Condensers commonly used in commercial systems: Finned-static, air-cooled. Finned-forced convection, air-cooled. Water-cooled, tube-in-a-tube, shell and coil, shell and tube, and evaporative type. Plate-static.

Questions
What is the purpose of the compressors high-side service valve? It provides shutoff between the compressor and the condenser and provides access to the high side for a service technician. What is the purpose of an oil separator? It separates the refrigerant oil from the high-pressure gas leaving the compressor.

Questions
continued Where is an oil separator located? In the discharge line between the compressor and the condenser. What type of valve is used in an oil separator? A high-side float. What is the purpose of the condenser? It removes the heat that is picked up in the evaporator and the compressor.

Questions
continued Name two condensers commonly used in domestic refrigeration. Wire-static and finned-force convection. Name two types of condensers used in a commercial system. Finned-force convection and water-cooled.

4.9

Liquid Receiver
A storage tank for liquid refrigerant. Most have service valves. Often found in systems using a low-side float or expansion valve-type refrigerant control. Not used in capillary-tube systems. Seldom used in domestic systems or small commercial units.

4.9

Liquid Receiver

4.10

Liquid Line
Usually made of copper tubing. Domestic units use steel. Used to carry liquid refrigerant from the condenser to the evaporator. Avoid pinching or buckling these lines.

4.10.1

Liquid Line Filter-Drier

Often installed in liquid line. Keeps moisture, dirt, and metal from entering refrigerant flow control. Drying element in filter removes moisture. Some equipped with sight glass to indicate refrigerant level. May contain chemical that changes color to indicate moisture in system.

4.10.1

Liquid Line Filter-Drier

Questions
What is the purpose of a liquid receiver? It is a storage tank for refrigerant within the system. Does a capillary tube system require a liquid receiver? No. Does a TXV system require a receiver? Yes. Where is the liquid line located on a refrigeration system? Between the condenser (or receiver) and the metering device.

Questions
continued What is the purpose of a liquid line filter drier? To clean the system of moisture and small particles. What is commonly used with a filter drier that determines refrigerant charge in a system? Sight glass.

4.11

Refrigerant Flow Control

Allows liquid refrigerant to enter the evaporator. Maintains the required evaporating pressure in the evaporator.

4.11

Refrigerant Flow Control

continued There are five types of refrigerant flow controls: Capillary (CAP) Tube. Automatic Expansion Valve (AEV). Thermostatic Expansion Valve (TEV). Low-Side Float (LSF). High-Side Float (HSF).

4.11

Refrigerant Flow Control

continued Capillary (CAP) Tube Long length of small diameter tubing. Reduces pressure by reducing the flow of refrigerant through its length. Does not use a check valve or a direction control valve. High and low pressures equalize during the off part of the cycle.

4.11.1

Capillary (CAP) Tube

4.11.2

Refrigerant Flow Control

continued Automatic Expansion Valve (AEV) Used only with the temperature-operated motor control. Maintains constant pressure in the evaporator when the system is running. Operates independently of the amount of refrigerant in the system. Division point between high side and low side. Adjustable to the correct evaporator pressure. Refrigerant flows only when the compressor is running.

4.11.2

Automatic Expansion Valve (AEV)

4.11.3

Refrigerant Flow Control

continued Thermostatic Expansion Valve (TEV) Sensing bulb mounted at the evaporator outlet. Bulb temperature controls the operating of the thermostat valve needle. Sensing bulb is the opening force; spring and evaporator pressure are the closing forces. Evaporator fills more quickly and permits more efficient cooling. Used with pressure- or temperature-operated motor control. Can be used with a multiple evaporator system.

4.11.3

Thermostatic Expansion Valve (TEV)

4.11.4

Refrigerant Flow Control

continued Low-Side Float (LSF) Used on a flooded system. May use either a temperature- or pressureoperated motor control. Usually has a large liquid receiver. Can be used in multiple evaporator systems.

4.11.4

Low-Side Float (LSF)

4.11.5

Refrigerant Flow Control

continued High-Side Float (HSF) Float is located in the liquid receiver tank or in a chamber in the high-pressure side. Float controls level of liquid refrigerant on the highpressure side. Amount of refrigerant in system must be carefully measured. Extra refrigerant will overcharge the evaporator and cause frosting of the suction line. Can be used with a pressure- or temperatureoperated motor control.

4.11.5

High-Side Float (HSF)

Questions
What is the purpose of a refrigerant flow control? It separates the high side from the low side and changes a high-pressure liquid to a low-pressure liquid. On a capillary tube system, what happens to the high- and low-side pressures during the off cycle? They equalize. What is the purpose of an AEV (automatic expansion valve)? It maintains a constant pressure in the evaporator. Which type of compressor motor control is used with an AEV? A temperature-operated motor control.

Questions
continued What are three operating pressures of a TEV (thermostatic expansion valve)? Sensing bulb (opening force), the spring, and evaporator pressure (closing force). Which type of motor control is used with a TEV? A pressure- or temperature-operated motor control.

Questions
continued Which type of system uses a low-side float? A flooded evaporator system. Name two metering devices that are used on critically charged refrigeration systems. The high-side float and the capillary tube system.

4.12

Motor Control
Two types: Temperature-operated motor control (thermostatic). Sensing bulb connected to a toggle or snapaction switch. Adjustment permits differences in operating temperatures. Pressure-operated motor control (low-side pressure).

4.12

Motor Control

Chapter 4

4.13

External-Drive Compressors
Bolted together. Crankshaft extends through the crankcase and is driven by a flywheel (pulley) and belt. May be driven directly by an electric motor or gas engine. Requires a crankshaft seal. Seldom used today.

4.13

External-Drive Compressors

4.14

Hermetic Compressors
Motor is sealed inside a dome or housing. Motor is directly connected to the compressor no crankshaft seal needed. Usually is spring-mounted inside the hermetic dome, reducing vibration.

4.14

Hermetic Compressors

4.15

Types of Compressors
Reciprocating. Rotary. Scroll. Screw. Centrifugal.

4.15.1

Reciprocating Compressor
Used in majority of domestic, commercial, and industrial HVAC systems. Basic components include a cylinder and a rod. Can be classified by cylinder arrangement, number of cylinders, type of crankshaft, or construction. May be multicylinder, thereby increasing pumping capacity. Cylinders are usually made of cast iron. Usually, crankcase is part of same casting as the cylinder.

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor
continued Piston is designed to come as close as possible to the cylinder head without touching it. This forces as much of the vapor into the high-pressure side as possible. A valve plate under the cylinder head contains both the intake and exhaust valves.

A connecting rod attaches the piston to the crankshaft.

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor
continued Several compressor valve designs are used. The intake valve operates at a relatively cool temperature and is constantly lubricated by oil circulating with the refrigerant vapors. The exhaust valves operate at high temperatures and must be leakproof. Valves open about .010" (.254mm). If movement is greater, valve noise develops.

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor
continued If a system uses an external motor to drive the compressor, a crankshaft seal is necessary. All seals use two rubbing surfaces that must be lubricated to prevent wear and leakage.

External drive compressors are driven by a V-belt. These are usually driven at less than the motor speed. Therefore, the motor belt pulley will be smaller than the compressor pulley. More than one belt may be used in large-capacity installations.

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor
continued Some compressors use an eccentric-type crankshaft mechanism. This construction reduces vibration and the need for connecting rod caps and bolts.

A scotch yoke mechanism may be used to connect the piston to the crankshaft. No connecting rod is used. The cylinder and piston are quite long.

The scotch yoke is popular in small high-speed compressors.

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor
continued The reciprocating compressor used on automobile air conditioning systems is known as a swash plate (or wobble plate) compressor. No connecting rod is used. The swash plate compressor usually has three or more cylinders arranged in a circle around the drive shaft. The swash plate compressor is double-acting a three-cylinder compressor gives a pumping action like a six-cylinder conventional compressor.

4.15.1

Reciprocating Compressor

4.15.1

Reciprocating Compressor
continued Compressor housings support the cylinders, crankshaft, valves, oil pump, lubrication lines, and the refrigerant inlet and exhaust openings. In hermetic compressors, the housing also supports and aligns the driving motor.

4.15.2

Rotary Compressor
Two basic types: Stationary blade. Rotating blade.

4.15.2

Rotating Blade
Blades rotate with the shaft. Operation: Low-pressure vapor from the suction line is drawn into the opening. The vapor fills the space behind the blade as it revolves. Trapped vapor in the area ahead of the blade is compressed until it can be pushed into the exhaust line to the condenser.

4.15.2

Rotating Blade

4.15.2

Rotating Blade
continued Frequently used as the booster compressor in cascade systems. Advantages: Provides a large-size opening into the suction line. Provides large inlet port openings. Has a very small clearance volume.

4.15.2

Stationary Blade
Blade remains stationary and is part of the housing assembly. Operation: An eccentric shaft rotates an impeller in a cylinder. The impeller constantly rubs against the outer wall of the cylinder. The blade traps vapor as the impeller revolves. The vapor is compressed into a smaller space. The pressure and temperature increase. The vapor is forced through the exhaust port, entering the condenser.

4.15.2

Stationary Blade

4.15.2

Stationary Blade

4.15.2

Rotary Cylinder Construction

Made of cast iron. Has intake and exhaust ports. Usually mounted on an end plate. Exhaust valve reed is mounted on the exhaust port outlet of the compressor.

4.15.2

Rotary Compressor Construction

Rotating blade compressor rotor is a fixed part of shaft. Stationary blade compressor rotor accurately fits the eccentric. The eccentric is a fixed part of the shaft.

4.15.3

Scroll Compressor
Very few moving parts. Smooth compression cycle with low torque. Low noise and low vibration levels.

4.15.3

Scroll Compressor Operation

Generates a series of crescent-shaped gas pockets between two scrolls. One scroll remains stationary. The other scroll the orbiting scroll rotates through the use of the swing link. Pockets of gas are slowly pushed to the center, reducing their volume. When the pocket reaches the center of the scroll, the gas is at high pressure. Discharge is through the center port.

4.15.3

Scroll Compressor Operation

4.15.3

Scroll Compressor Operation

4.15.4

Screw Compressor
Two basic types: Open, externally driven compressor, used most often with ammonia systems. Hermetic, internally driven compressor, using halocarbon refrigerants.

4.15.4

Screw Compressor Operation

A pair of helical rotors trap and compress air as they revolve in an accurately machined cylinder.

The male rotor is driven by the motor and has four lobes. The female rotor has six lobes. It meshes with and is driven by the male rotor. The refrigerant vapor is drawn in by the meshing rotors.

4.15.4

Screw Compressor Operation

AMale rotor. BFemale rotor

4.15.3

Screw Compressor Operation

4.15.4

Screw Compressor Operation

continued The rotors provide a continuous pumping action, trapping and compressing the refrigerant. A capacity control device provides for variable unloading and accurate temperature control of a conditioned space.

4.15.5

Centrifugal Compressor
Used in large-capacity systems from 50 to 5,000 tons. Simple design no valves, pistons, or cylinders. Pumping efficiency increases with speed.

4.15.5

Centrifugal Compressor Operation

Vapor is fed into housing near the center of the compressor. Rapidly rotating impellers move the vapor outward, forcing it against the outer diameter and increasing its pressure. Several impellers are put in series to multiply the pressure increase and further compress the vapor.

4.15.5

Centrifugal Compressor Operation

4.16

Compressor Motors
External drive compressor. Motor connected to compressor by one or more V-belts or by direct drive. Hermetic compressor. Motor is mounted under the same dome as compressor.

4.18

Mufflers
Used on most hermetic units and many external-drive systems to reduce noise. May be located at both the intake and the exhaust openings of the compressor. Constructed of brazed cylinders with baffle plates mounted inside.

4.18

Mufflers

Note discharge and suction (intake) mufflers.

4.20

Lubrication
Specific lubricating oils are available for reciprocating and rotary compressors. A small pump is used for force-feed or pressure systems. It is usually mounted on one end of the crankshaft.

4.20

Lubrication

4.21

Compressor Volumetric Efficiency

For efficient operation, the volumetric efficiency must be as high as possible. Items such as head pressure, clearance space, and size and condition of the valve openings impact volumetric efficiency. Formula: Volumetric efficiency = (Calculated volume ) X 100
__Actual volume__

4.22

Compression Ratio
The relationship of the high-side absolute pressure to the low-side absolute pressure. Ratios vary up to 10:1.

4.23

Check Valves
Prevent refrigerant vapor, oil, or liquid refrigerant from backing up into the evaporator or other devices.

4.23

Check Valves

4.24

Unloader
Makes it easier to start the compressor by temporarily reducing high-side pressure at the cylinder head. May be operated mechanically, electrically, hydraulically, or by a solenoid valve.

4.24

Unloader

4.25

Gaskets
May be made of special paper, synthetic material, plastic, or lead. Used between bolted parts such as cylinder heads, valve plates, and crankcase openings.

4.26

O-ring
Sealing device. Material used for O-ring depends on temperature, pressure, fluids to be controlled, and useful life required.

The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.

4.26

O-ring

4.27

Crankcase Heater
Evaporates liquid refrigerant trapped in the oil. Required on remote installations where ambient temperature is lower than evaporator temperature. Reduces risk of oil slugging.

The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.

4.27

Crankcase Heater

Questions
Name two types of compressor motor controls. Temperature-operated and pressure-operated. Name two types of compressor drives. Direct drive and belt drive. Name five types of compressors. Reciprocating, rotary, scroll, screw, and centrifugal. On a reciprocating compressor, where are the discharge and suction valves located? In a valve plate under the compressor head.

4.28

Safety
Always be alert to hazardous situations or procedures and equipment that may be dangerous. Always follow recommended procedures. Always wear goggles when working on a refrigerating system. Handle all parts with care. Clean and dry each part that is dismantled. Do not allow moisture to enter the refrigerating mechanism.

4.28

Safety
continued Make sure settings and adjustments are done correctly. Improper temperatures cause food to spoil. Take care when tightening tube connections, installing gaskets, replacing electrical terminals, and soldering fittings.

Glossary
accumulator Storage tank that receives liquid refrigerant from the evaporator and prevents it from flowing into the compressor before vaporizing. centrifugal compressor Pump that compresses gaseous refrigerants by centrifugal force. check valves Allow fluid to flow in only one direction in a system. clearance space The space left in the cylinder when the roller or piston ends its compression stroke.

Glossary
compression ratio Ratio of the total volume of the cylinder to the clearance space. compressor Pump of a refrigerating mechanism that draws a low pressure on the cooling side of the refrigerant cycle and squeezes or compresses the gas into the high-pressure or condensing side of the cycle. compressor volumetric efficiency The relationship between the actual performance of a compressor and theoretical performance of the pump based on its displacement.

Glossary
condenser The part of the refrigeration mechanism which receives hot, highpressure refrigerant gas from compressor and cools gaseous refrigerant until it returns to its liquid state. evaporator Part of a refrigerating mechanism in which the refrigerant vaporizes and absorbs heat.

Glossary
head pressure The pressure the compressor must pump against. liquid receiver Cylinder (container) connected to condenser outlet for storage of liquid refrigerant in a system. oil separator Device used to remove oil from gaseous refrigerant. rotary compressor Mechanism that pumps fluid by using rotating motion.

Glossary
screw compressor Compressor constructed of two mated revolving screws. scroll compressor A compressor that uses the interaction of two spiral coils (scrolls) to compress a vapor. suction line Tube or pipe used to carry refrigerant gas from evaporator to compressor. unloader Temporarily reduces the high-side pressure at the cylinder head during compressor startup.