LESSON

COMPRESSION SYSTEM

LECTURE
SUB-OBJECTIVE
At the end of this Lesson the Trainee will be able to:
1.

Identify the functions of the compression systems used in air

conditioning and refrigeration units.
2.
Identify the parts of compression
conditioning and refrigeration units.

1.0

systems

in

air

3.

Troubleshoot for minor & major problems in the above.

4.

Maintain compression systems related to air conditioning and

refrigeration systems.

COMPRESSION SYSTEM
REFRIGERANT CONTROL

USING

AUTOMATIC

EXPANSION

VALVE

The operation of an automatic, expansion valve, refrigerant control (AEV)

refrigerating mechanism is shown in Fig. 3-2-1.
Compressor, motor and condenser (condensing unit) are in the base of the
cabinet. Liquid refrigerant flows from the liquid receiver through the liquid line,
through the filter to the automatic expansion valve.
The automatic expansion valve is designed so that no liquid refrigerant will
flow thorough it unless the pressure in the evaporator is reduced by the
running of the compressor.
As the compressor runs and liquid refrigerant flows through the automatic
expansion valve, it is sprayed into the evaporator. Here, due to low pressure,
it boils rapidly and absorbs heat.
This vaporized refrigerant moves back to the compressor through the suction
line.
In the compressor, it is compressed to the high side pressure as vapor.

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LESSON 2 PAGE 1

While flowing through the condenser it is cooled, gives up the heat that it
absorbed in the evaporator and returns to a liquid. It then flows into the liquid
receiver ready to repeat the cycle.
The motor control thermal element is clamped to the end of the evaporator at
the beginning of the suction line.
After the evaporator is cooled to its proper temperature, the control bulb
pressure causes the motor control to turn off the current to the motor. The
compressor is stopped.
The operating characteristics of this system are quite satisfactory. The
refrigerant oil is circulated without trouble. The temperature control limits can
also be kept quite close.
This type refrigeration cycle is used widely in small commercial applications.
Because the pressures do not balance on the off cycle, the motor compressor
must start under load.
If the needle or seat in the expansion valve is faulty and refrigerant leaks
through the valve on the off cycle, liquid refrigerant may flow into the suction
line.
When the compressor starts, frosting of the suction line will indicate this. If
the trouble is severe, it may result in liquid refrigerant entering the compressor
through the suction line.
This may cause the compressor to knock severely.

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BASIC REFRIGERATION SYSTEMS

Fig. 3-2-1. Compression system using automatic expansion valve refrigerant

control (AEV)

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LESSON 2 PAGE 3

Either a temperature or pressure motor control may be used on this

refrigeration cycle.
This system is most used in commercial applications where high operating
efficiency is desired.
2.0

COMPRESSION SYSTEM USING THERMOSTATICALLY CONTROLLED

EXPANSION VALVE
A schematic diagram of thermostatically controlled expansion valve (TEV)
refrigeration cycle is shown in Fig. 3-2-2. The liquid refrigerant flows from the
liquid receiver thorough the liquid line to the filter drier and the to the
thermostatic expansion valve.
Both the temperatures of the TEV control bulb and the pressure in the
evaporator control the operation of the thermostatic expansion valve.
The temperature of the TEV control bulb must be higher than the evaporator
refrigerant temperature before the valve will open.
The temperature of the evaporator will govern the amount of opening. If the
evaporator is quite warm, the needle will open quite wide allowing a rapid flow
of liquid into the evaporator. In this way cooling is speeded up.
As the temperature of the evaporator drops, the TEV needle valve will cut
down the flow of refrigerant.
Vaporized refrigerant from the evaporator move back into the compressor
when it is compressed back to the high-side pressure. As it flows through the
condenser, it gives up the heat absorbed in the evaporator.
Now cooled, the refrigerant is condensed to a liquid and flows back into the
liquid receiver. The refrigerating cycle is repeated.
When the evaporator reaches the desired temperature, the motor control will
turn off current to the motor to stop the compressor. When this happens, the
TEV needle valve will close, allowing no more refrigerants to flow thorough it
until the compressor again lowers the pressure in the evaporator.
This system is used on large commercial refrigerators as well as on many air
conditioning applications.
Since pressures do not balance on the off cycle, it is necessary to provide a
motor compressor, which will start under load.
The TEV control remains closed unless the evaporator is under reduced
pressure and the temperature is above normal. A frosted or sweating suction
line will usually indicate a leaking valve.

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Fig. 3-2-2. Compression system using thermostatically controlled expansion

valve (TEV).

3.0

COMPRESSION SYSTEM USING CAPILLARY TUBE REFRIGERANT

CONTROL
The "capillary tube" system, Fig. 3-2-3, is one of the most popular of the
compression type systems.

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Liquid refrigerant flows from the condenser up through the liquid line to the
filter (which may also be a drier).
From the filter, refrigerant flows through the capillary tube refrigerant control
into the evaporator. The pressure of the liquid refrigerant, as it enters the
capillary tube at the filter end, is at a high pressure.
This is the high-pressure side. The pressure in the evaporator is low.
The design of the capillary tube is such that it maintains a pressure difference
while the compressor is operating. The compressor maintains a low pressure
in the evaporator and the refrigerant boils, rapidly absorbing heat.
The vaporized refrigerant moves through the suction line back to the
compressor. Here it is compressed to a high pressure and discharged into the
condenser.
It is cooled in the condenser and returns to a liquid and again flows into
the liquid line.
This operation continues until the thermal element has been cooled to a
preset low temperature. When that temperature is reached, the thermal
element operates the motor control mechanism and turns off power to the
motor.
The refrigeration cycle stops. It will remain stopped until the thermal element
warms up and the thermal bulb pressure closes the motor control contacts to
again operate the compressor.
On the off cycle the capillary tube allows the pressures to balance between
the high and low sides. It is not usually necessary, then, to use a motor with a
high starting torque.
This system is commonly used in household refrigerators, freezers, air
conditions, dehumidifiers and many small commercial applications. This type
of cycle is quite satisfactory for most refrigerating applications.

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Fig. 3-2-3. Compression system using capillary tube type refrigerant control.

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4.0

MULTIPLE EVAPORATOR SYSTEM

Some commercial refrigerating systems have one condensing unit connected
to two or more evaporators.
Liquid refrigerant flows through the thermostatic expansion valves to the
evaporators.
The evaporators may have the same evaporator temperatures or they may
evaporate the refrigerant at different temperatures.
If the evaporator temperatures are the same, the system uses only a low-side
float or the thermostatic expansion valve to control the refrigerant.
If two or more evaporating temperatures are desired, a frozen foods
temperature and a water cooling temperature (for example), a device must be
used to keep one of the evaporators at a higher low-side pressure.
Look at schematic, Fig. 3-2-4.
A two-temperature valve in the suction line (upper left) keeps the low-side
pressure refrigerant liquid and vapor in evaporator B at a higher pressure than
at evaporator A.
The evaporator temperature is governed by the evaporating pressure The
lower the pressure, the lower the temperature.

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Fig. 3-2-4. A multiple evaporator system.

Evaporator A operates at 0 F. (-18 C.)
Evaporator B operates at 25 F. (-4 C).
A check valve in the suction line coming from the colder evaporator, A,
prevents the warmer, higher pressure low-side from moving into the colder
evaporator, A, during the off cycle.
The vaporized refrigerant is returned to the motor compressor. It is
compressed to a high-pressure and high-temperature vapor. This vapor is
cooled in the condenser becoming a high pressure liquid to be stored in the
receiver until needed.

Note the filter-drier on the liquid line. It keeps the refrigerant clean and
dry.

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A liquid indicator (slight glass) is often included in the liquid line. The service
technician may then check to see if there is enough refrigerant in the system.
Bubbles will indicate a refrigerant shortage this system, as shown uses a
pressure motor control. The operating pressure is taken from the low side of
the system.
A line from the high-pressure side also enters the motor control. This operates
a safety device which stops the motor if the condensing pressure (high side)
goes too high.
Multiple (two or more) evaporator refrigeration systems are commonly used in
commercial refrigeration applications.
5.0

COMPOUND REFRIGERATING SYSTEMS

In compound refrigerating systems, two or more compressors are connected
in series, Fig. 3-2-5.
In this illustration:
Compressor No. 1 discharges into the intake side of
compressor No.2.
Compressor
condenser.

No.

then

discharges

into

the

Here the vapor condenses then the liquid refrigerant

(see red) flows into the liquid receiver.

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Fig. 3-2-5. Compound refrigerating system.

From the liquid receiver the liquid refrigerant flows up to the thermostatic
expansion valve and into the evaporator.

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In the evaporator the refrigerant boils and absorbs heat. From the evaporator
the vaporized refrigerant flows back to compressor No.1. From here the cycle
is repeated.
Such a compound system increases capacity then, pulling down to such a low
pressures (low temperature) that one compressor cannot do it well.
Refrigerant vapor is not condensed between compressors. An inter cooler
lowers the vapor temperature. This type of installation usually requires an oil
separator for each compressor.
A single-temperature motor control operates all motors and a thermostatic
expansion valve controls the liquid refrigerant flow into the evaporator.
Since the pressures do not balance on the off cycle, motors capable of starting
under load are required.
Compound installations usually operate under rather heavy service
requirements. Condensers and refrigerant must be kept clean. Compressor
valves must be kept in good condition.

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