Compressor Basics

Refrigeration Basics

Expansion Device

Condenser

Low Temperature
High Pressure
Liquid
High Temperature
High Pressure Gas Evaporator

Low Temperature
Low Pressure Gas

Compressor
Different Terminologies Used
 Low-Pressure Applications
–  The application in which the suction pressure is in the range of
0-10 PSIG with an equivalent evaporation of -30 to -14 C .
– Generally used for low-pressure applications like Deep freezer.

   Medium-Pressure Applications
– The application in which the suction pressure is in the range of
17 - 40 PSIG with an equivalent evaporation of -15 to +15 C
– Generally used for low-pressure applications like bottle coolers.

   High Back Pressure

– The application in which the suction pressure is in the range of
25 - 55 PSIG in R-12 / R- 134a and +25 to 95 in R-22 with an
equivalent evaporation of - 6.7 to -+12.8 C
Types Of HVAC Compressors
 Compressor Classification
– According To Displacement
• Positive Type
• Non-Positive Type
– According To Method Of Drive
• Direct Drive
• Belt Driven
– According To Cooling System
• Water Cooled
• Air Cooled
• Oil Cooled
• Refrigerant Cooled
– According To Type Of Construction
• Open Type
• Hermetic Compressors
• Semi Hermetic Compressor
Mechanism
 Screw Compressors

Suction Compression Compression Discharge

Cont…
 Scroll
Cont…
 Rotary Compressor

Fixed Vane

Rotating Vane
Reciprocating Compressor
A B C D A
Interior Of The Compressor
Crank Case / Body Cylinder Head

Suction Muffler

Shaft Rotor
Stator

Discharge
Tube

Oil Puck-Up
Mounting Spring Tube
Cont…
Shell
Discharge Muffler

Suction Tube

Shock-Loop
Process Tube
Components Of Compressors
 Crank Case
Cont…
 Crank Shaft
Cont…
 Connecting Rod
Cont…
 Piston
Cont…
 Valve Plate Assembly
General Material Specs Of Compressor Part
Component Material

Crank Case Grey Cast Iron

Crank Shaft SG Iron

Connecting Rod Sintered / Aluminium / Cast Iron

Piston SG Iron / Sintered

Valve / Reed Flapper Valve Steel

Piston Pin Special Alloy Steed

Roll Pin Hardened And Tempered Steel

Cylinder Head Aluminium / Cast Iron

Suction Muffler Nylon66

Different Terminologies Used As Per
Application
 Low-Pressure Applications (LBP)
–  The application in which the suction pressure is in the range of
0-10 PSIG with an equivalent evapouration of -30 to -14 C .
– Generally used for low-pressure applications like Deep freezer.

   Medium-Pressure Applications (CBP/MBP)

– The application in which the suction pressure is in the range of
17 - 40 PSIG with an equivalent evapouration of -15 to +15 C
– Generally used for low-pressure applications like bottle coolers.

   High Back Pressure (HBP)

– The application in which the suction pressure is in the range of
25 - 55 PSIG in R-12 / R- 134a and +25 to 95 in R-22 with an
equivalent evapouration of - 6.7 to -+12.8 C
Effect Of Various Parameters On
Compressor Performance
 Volumetric Efficiency
– Clearance Volume Because Of Gasket Selection
And Discharge Port
– Suction And Discharge Valve Stiffness / Valve
Losses
– Suction Gas Superheat
– Suction And Discharge Gas Pressure Drop

 Mechanical Efficiency
– L/D Ratio
– Bearing Characteristics
– Piston Fit Selection
– Surface Finish
Cont…
 Electrical Efficiency
– Electric Circuits
– Material Grade Of Lamination
– Lamination Thickness
– Motor Thermal Loading
– Voltage Range
– Lamination Selection
Effect Of Various Parameters On
Compressor Performance
 Volumetric Efficiency
– Clearance Volume Because Of Gasket Selection
And Discharge Port
– Suction And Discharge Valve Stiffness / Valve
Losses
– Suction Gas Superheat
– Suction And Discharge Gas Pressure Drop

 Mechanical Efficiency
– L/D Ratio
– Bearing Characteristics
– Piston Fit Selection
– Surface Finish
Effect Of Clearance Volume
Evaporating Temp. (-)23.3°C* (-)30°C*

15CC 11CC 10CC 15CC 11CC 10CC

Model
Model Model Model Model Model Model
20% 20%
Clearance Volume Existing Same
Less Less

Displacement (CC) 15.3 11.1 10.1 15.3 11.1 10.1

Capacity (BTU/Hr) 1260 980 982 710 530 690

Wattage (W) 325 245 229 273 178 184

EER (BTU/W-Hr) 3.87 4.00 4.28 2.60 2.97 3.75

BTU/CC 82 88 97 46 47.1 68

* As Per ASHRAE Test Condition

Current Practice To Reduce Clearance
Volume
Valve Losses
 Valve Operate On Pressure Differential, No Separate Mechanism Is
Used

 Valve Stiffness And Valve Geometry, Port Geometry Plays Important

Role In Efficiency
Current Practice To Reduce Valve Losses
Suction Gas Superheat
 Undesirable Superheating Of Refrigerant Inside Of Compressor

 Reduces Density Of Refrigerant Thereby Reducing Refrigeration

Effect

Model 10CC Model

Suction Inlet Type Indirect Semi Direct Direct

Suction Superheat
72 64 48
Temperature

Capacity (BTU/Hr) 930 960 1025

Wattage (W) 245 248 260

EER (BTU/W-Hr) 3.80 3.87 3.94

Various Electric Circuits
 RSIR (Resistance Start, Induction Run)
– PTC Or Relay And Current Relay As A Starting Device
– Low Starting Torque
– Generally Used With Capillary Tube Where Pressure
Equalization Takes Place
– Lower Cost But Lower Motor Efficiency

 RSCR (Resistance Start, Capacitor Run)

– PTC With Run Capacitor
– Low Starting Torque
– Higher Motor Efficiency Than RSIR

 CSIR (Capacitor Start And Induction Run)

– High Starting Torque
– High Motor Efficiency
– Used Be Used With Capillary Or Expansion Valve
Different Bearing Design
OBB
Counter
Weight

Dual Bearing Design Single Bearing Design

Robust Design, High Reliability
Risk Of Capacity Loss Due To High
Liquid Pumping Is Very Less
Higher Frictional Loss
Higher Cost
At Risk For Flooded Start
Risk Of Capacity Loss Due To High
Liquid Pumping Is High
Lower Frictional Loss
Cost Is Less
Basic
Basic Issues
Issues With
With Refrigeration
Refrigeration
Reciprocating
Reciprocating Compressors
Compressors
 Higher De-Rating At Lower Evaporating Temp – Can Not Have Pull
Down Temperature Below (-)25°C Because Of Higher De-rating In
Capacity
 With Current EER & Above Issue Makes It Difficult To Match 24 Hour
Energy Consumption
 Lower Volumetric Efficiency & Higher Thermal Motors , Product
Performance / Reliability Is Inferior Under Limited Compressor Cooling
On Appliances
 Round Shell & Tube Locations Makes The Fitment Difficult On Compact
Appliances
 Lower BTU/CC Ratio Leads To Higher Displacement
 Higher Frictional Loss Leads To Higher Wattage And Starting Torque
Advancements In
Compressor Technology
Modulated
Modulated Compressor
Compressor Technologies
Technologies
 Capacity Modulation
Need For Capacity Modulation
 Energy Norms – To Reduce The Energy Consumption

 Load Fluctuation

 Higher Output Is Required To Cool The Product Quickly From

Startup, May Require Less As The Desired Temperature Is
Reached
Modulation Techniques
 Simplest Technique – On/Off Cycling
– Not Suitable For Current Requirement

 Advanced Methods
– Cylinder Unloading/ Valve Action
– Variable Speed Compressors
– Bypass Technologies
– Variable Compression Process
Cylinder Unloading/ Valve Action
 Most Compressor Types Are Dependent On Valves To Regulate
Compression

 Valve Action Can Make Cylinder Ineffective

 Suitable For Screw Compressors As Valve Can Control The

Volume Available For Compressors

 Not Suitable Refrigeration Reciprocation Compressor Because

Of Valve Construction
Hot Gas Bypass