City University of Hong Kong

Division of Building Science and Technology

Associate of Science in Building Services Engineering

BST20532 HVAC SERVICES 2

VAPOUR COMPRESSION
REFRIGERATION SYSTEMS (1)

AIMS & OBJECTIVES

After studying this lecture notes, students are expected to:
• distinguish the two main types of reciprocating refrigeration systems - DX and packaged unit;
• understand the functions of common accessories in refrigeration systems;
• appreciate the capacity control and different safety controls of reciprocating systems;
• develop insight in system performance through traditional system analysis approach.

OUTLINE
1. DX System

2. Packaged Type Air-Cooled Reciprocating Chiller

3. Accessories

4. Capacity Control of Reciprocating Compressor

5. Safety Controls

Tutorial - System Analysis of Refrigeration System

BST20532 HVAC Services 2 - Vapour Compression Refrigeration Systems (1)

RECIPROCATING VAPOUR COMPRESSION

REFRIGERATION SYSTEMS

2 main types of reciprocating vapour compression refrigeration systems:

• Direct expansion DX system (Remote condenser)

• Air-cooled reciprocating chiller (Packaged type)

1. DX SYSTEM

Characteristics of DX system:
• Evaporator : DX coil.
• Air-cooled condenser may be combined with reciprocating compressor to form
the 'condensing unit'.
• Also called 'split system' since condensing unit is installed outdoors, e.g. roof-top
unit.
• Used in small and medium-size installations.

2. PACKAGED TYPE AIR-COOLED RECIPROCATING CHILLER

Characteristics of packaged type air-cooled reciprocating chiller:

• Evaporator: shell-and-tube liquid chiller in which refrigerant evaporates inside the
metal tube and chilled water fills the shell.
• All main components and accessories enclosed in one metal casing.
• Air-cooled condenser coils installed at 2-sides of casing and integrated with sub-
cooling coils at bottom.
• Widely used in centralized air-conditioning systems.

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3. ACCESSORIES

a. Filter Driers

To filter the dirt and control the corrosive water content of both the refrigerant
and the oil.

b. Sight Glass

A small glass port for inspecting liquid refrigerant flow; its purposes include:
(i) moisture indicator - chemical substance in it changes colour if
moisture content becomes excessive.
(ii) liquid indicator - bubbles indicates presence of flash gas which may be
caused by refrigerant shortage or insufficient subcooling.
(iii) liquid level indicator - shows levels of liquid refrigerant in the
condenser and the receiver when mounted on them.

c. Service Valves

To control the refrigerant flow either automatically or manually, including:

(i) solenoid valve - to provide on-off control.
(ii) charge valve - a normally operated shut-off valve only used during
charge of refrigerant.
(iii) pressure relief valve - to prevent explosion caused by high refrigerant
pressure.

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4. CAPACITY CONTROL OF RECIPROCATING COMPRESSOR

There are 4 types of capacity control listed as follows:

a. On-off Control
• used in compressors of capacity < 10 kW.
• often causes severe temperature fluctuation of air flow through DX coil.

b. 2-speed
• use 2-speed motor so that both running speed & power input can be
reduced at part-load.

c. Cylinder Unloader
• refrigerant vapour enters & leaves the cylinder without compression.
• for a 4-cylinder compressor, capacity can be reduced to 25%.
• energy is saved.
• most commonly used.

d. Hot Gas Bypass

• often employed in medium-size DX system.
• adds artificial load during part load by injecting hot refrigerant gas directly
into the evaporator.
• no energy saving and therefore not recommended as major capacity
control method.
• used with systems that must operate continuously at, or below, the
minimum step of compressor unloading.

5. SAFETY CONTROLS

Safety controls are used to shut down the refrigeration system during a malfunction
and also to prevent damage of the system components. Since all these safety
controls are commonly encountered during operation of the reciprocating
refrigeration systems, attention should be paid to the importance and functions of
such control strategies.

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Recently developed microprocessor-operated DDC panels combine all safety control

mechanisms with other control systems of a reciprocating refrigeration system in one
package. The DDC panel senses, analyzes, and operates the safety control systems
in coordination with other systems with far more functions and more sophisticated
comprehensive controls.

a. Low-Pressure and High-Pressure Controls

These controls are very essential to the safety operation of the refrigeration
systems. The purpose of low-pressure control is to stop the compressor
when the suction pressure drops below a preset value or when the refrigerant
flow rate is too low to cool the compressor motor. On the other hand, the
purpose of high-pressure control is to stop the compressor when discharge
pressure of the hot gas approaches a danger level.

b. Low-Temperature Control

Low-temperature control is to prevent the temperature of chilled water in the

liquid cooler from falling below a certain limit in order to protect the water
from freezing. Freezing water would definitely damage the liquid cooler.

c. Frosting Control

The purpose of frosting control is to prevent the formation of frost on the

outer surface of the DX-coil. Usually, a temperature sensor is used to sense
the outer surface temperature of the DX-coil. When the temperature drops to
0°C, the controller actuates a relay, which opens the circuit and stops the
compressor.

d. Oil Pressure Failure Control

Oil pressure failure control is to stop the compressor when the oil pressure
drops below a certain limit and fails to lubricate the main bearing and other
components.

e. Motor Overload Control

The purpose of motor overload control is to protect the motor from dangerous
overheating caused by long periods of overloading or failure of the
compressor to start. Thermal protectors with bimetal or thermistor sensors
are installed inside the motor or mounted on the outer surface of the motor
shell. These sensors sense the temperature or both the temperature and
electric current supplied to the motor windings. If dangerous overheating
and overloading occur, a controller breaks the circuit.

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f. Pump-Down Control

Pump-down control acts as safety control to protect the compressor from

damage from liquid slugs. It is an effective means of preventing migration of
refrigerant from the evaporator to the crankcase of the compressor during the
shutdown period. When a compressor starts, migrated refrigerant tends to
mix with the oil and form slugs, which may damage the compressor.

On the other hand, pump-down control acts as a capacity control by

controlling discharge temperature or suction pressure. When the discharge
air temperature or suction pressure drops below a preset limit and is sensed by
a sensor, the chiller control panel deenergizes the liquid line solenoid valve
and the valve closes. The compressor pumps all gaseous refrigerant to the
condenser, where it condenses into liquid. When the vapour pressure in the
evaporator falls below a certain value, the low-pressure control break the
electric circuit and stops the compressor.

If cooling is again required, a temperature sensor senses the increase of

discharge temperature or a pressure sensor senses the rise of suction pressure
over a preset value and the control panel energizes the liquid line solenoid
valve. Liquid refrigerant then flows into the evaporator where it evaporates.
Vapour pressure builds up. When the pressure exceeds the cut-in pressure of
the low-pressure control, the compressor starts again.

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TUTORIAL
- System Analysis of Refrigeration System

Two approaches of system analysis have been developed:

• Traditional approach - determination of balance points (intersection of curves on
graphs)
• New approach - system simulation through computer (simultaneous solution of
equation sets)

An illustration of the traditional approach for air-cooled chiller is shown in the

ensuing sections.

1. Performance of Reciprocating Compressor

Trends of refrigerant capacity Qe and power requirement P of one particular

compressor are given in graphical form.

Figure 2 shows the heat rejection rate of the compressor by referring to Figure
1 and the following relationship:

Qc = Qe + P

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Tc ↓ & Te ↑ ⇒ Qe ↑

Figure 1: Trends of Refrigeration Capacity & Power Requirement of Compressor

Figure 2: Heat Rejection Rate of Compressor

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Figure 3 illustrates the heat rejection rate of condenser:

Figure 3: Performance of Condenser

2. Performance of Condensing-Unit Subsystem (Compressor + Condenser)

The superposition of performance curves in Figures 2 and 3 can quantify the

behaviour of condensing unit for a given ambient temperature (e.g. 35oC):

Figure 4: Behaviour of Condensing Unit

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At one balance point when te = 10oC,

tc = 50.8 oC (from Fig. 6.4)
Qe = 115.5 kW (from Fig. 6.1)

Following the similar procedure for other balance points, a performance curve
for the condensing unit can be developed.

Figure 5: Performance Curves for the Condensing Unit

3. Evaporator Performance

Te ↓ ⇒ Qe ↑
m& w ↑ ⇒ Qe ↑
Tw ↑ ⇒ Qe ↑

Figure 6: Evaporator Performance

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4. Complete System

Superposition of Figures 5 and 6 gives:

Figure 7: Performance of Complete System

Performance of the complete system can then be predicted (assuming the

expansion device functions well).

5. Summary of System Analysis

Compressor Characteristic
Qe Vs Te
P Vs Te
(Fig. 6.1)

Compressor Characteristic Condenser Characteristic

Qc Vs Tc Qc Vs Tc
(Fig. 6.2) (Fig. 6.3)

Condensing Unit Characteristic

Qc Vs Tc
(Fig. 6.4)

Condensing Unit Characteristic Evaporator Characteristic

Qe Vs Te Qe Vs Te
(Fig. 6.5) (Fig. 6.6)

Complete System Characteristic

Qe Vs Te
(Fig. 6.7)

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