Refrigeration Compressors and Air Conditioning Compressors Information

Image Credit: Bitzer US, Inc.

Refrigeration compressors and air conditioning compressors provide air conditioning, heat pumping, and refrigeration for large-scale facilities and equipment.
They use compression to raise the temperature of a low-pressure gas, and also remove vapor from the evaporator. Most refrigeration compressors
(refrigerant compressors) are large, mechanical units that form the heart of industrial cooling, heating, ventilation, and air conditioning (HVAC) systems. Many
air conditioning compressors are also large-scale mechanical devices; however, these compressors are designed specifically for air conditioning systems and
do not provide heating or ventilation functions.

Compressor Operation - The Refrigeration Cycle
Refrigerant compressors work by taking in low pressure gas on the inlet and compressing it mechanically. Different types of compression mechanisms are
what differentiate compressors (discussed below). This compression creates a high temperature, high pressure gas - an essential step in the overarching
refrigeration cycle.

Refrigeration Cycle
The refrigeration cycle or heat pump cycle is the model describing the transfer of heat from regions of lower temperature to regions of higher temperature. It
defines the operating principles behind refrigerators, air conditioners, heaters, and other "heat pumping" devices.

This diagram presents a visual overview of the refrigeration cycle:


Original Image Credit: Air Conditioning and Refrigeration Guide

The letters A-D indicate the different system components. The numbers 1-5 indicate the different physical states of the refrigerant fluid as it moves through
the system.
State 1 is the state after the refrigerant passes through an evaporator (D), where warm air heats the fluid and converts it completel y to vapor.
State 2 is the state after the fluid passes through a compressor (A) which increases the fluid's pressure and temperature up to superheated levels.
States 3 and 4 are when the fluid passes through an evaporator (B), which transfers heat to the ambient and condenses the fluid to liquid.
State 5 is the state after the fluid passes through an expansion valve or metering device (C), which lowers the pressure of the fluid. This cools the fluid
and subsequently turns the liquid into a liquid/vapor mixture.
This video provides further explanation of the refrigeration cycle:

Video Credit: US Supply Company, Inc.

Temperature-entropy and pressure-enthalpy diagrams are often used to construct and describe these systems. They define the properties of the fluid at
different stages in the system.


Temperature-entropy diagram of a typical refrigeration cycle. Image Credit: Keenan Pepper (wikipedia)



Pressure-enthalpy diagram of a typical refrigeration cycle.

Types of Compressors
There are a number of different types of compressors used for refrigeration and air conditioning. Like pumps, all "heat pumps" can first be categorized as
either positive displacement or non-positive displacement (centrifugal). Positive displacement compressors have chambers which decrease in volume during
compression, while non-positive displacement compressors have fixed-volume chambers. This video explains visually:

Video Credit: HVAC Tools

Beyond this distinction, each type differs based on its specific mechanism for fluid compression. The five main types of compressors are piston, rotary, screw,
scroll, and centrifugal.

Piston Compressors
Piston compressors, also called reciprocating compressors, use a piston and cylinder arrangement to provide compressive force - like combustion engines or
piston pumps. The reciprocating motion of the piston due to external power compresses the refrigerant inside the cylinder. Piston compressors have a low
initial cost and a simple, easy to install design. They have a large power output range and can reach extremely high pressures. However, they have high
maintenance costs, potential vibrational issues, and are not typically designed to run continuously at full capacity.


Image Credit: Direct Industry


Piston compressor diagram. Image Credit: Technical Training Associates

Rotary Compressors
Rotary compressors have two rotating elements, like gears, between which the refrigerant is compressed. These compressors are very efficient because the
actions of taking in refrigerant and compressing refrigerant occur simultaneously. They have very few moving parts, low rotational speeds, low initial and
maintenance costs, and are forgiving in dirty environments. However, they are limited to smaller volumes of the gas and produce less pressure than other
types of compressors.

Image Credit: Direct Industry


Rotary vane compressor diagram. Image Credit: Technical Training Associates

Screw Compressors
Screw compressors use a pair of helical rotors or screws which mesh together to compress the refrigerant between them. They can produce high pressure for
a small quantity of gas and consume less power than reciprocating compressors. They have low to medium initial and maintenance costs and few moving
parts. However, they have difficulty in dirty environments, high rotational speeds, and shorter life expectancies than other designs.

Image Credit: Direct Industry


Screw compressor diagram. Image Credit: Technical Training Associates

Scroll Compressors
Scroll compressors use two offset spiral disks nested together to compress the refrigerant. The upper disk is stationary while
the lower disk moves in orbital fashion. Scroll compressors are quiet, smooth-operating units with few moving parts and the highest efficiency ratio of all
compressor types. They also are more flexible for handling refrigerants in the liquid. However, as fully hermetic designs, scroll compressors cannot be easily
repaired. They also typically cannot rotate in both directions. Scroll compressors are commonly used in automobile air conditioning systems and commercial
chillers.


Image Credit: Direct Industry


Rotary vane compressor diagram. Image Credit: Technical Training Associates

Centrifugal Compressors
Centrifugal compressors use the rotating action of an impeller wheel to exert centrifugal force on refrigerant inside a round
chamber (volute). Unlike other designs, centrifugal compressors do not operate on the positive displacement principle, but have fixed volume chambers. They
are well suited to compressing large volumes of refrigerant to relatively low pressures. The compressive force generated by an impeller wheel is small,
so systems that use centrifugal compressors usually employ two or more stages (impellers wheels) in series to generate high compressive forces. Centrifugal
compressors are desirable for their simple design, few moving parts, and energy efficiency when operating multiple stages.
Image Credit: SKF Group


Centrifugal compressor diagram. Image Credit: Technical Training Associates

Refrigerants
Usually compressors are designed to work with a particular type of refrigerant. Selecting a proper refrigeration compressor or air conditioning compressor
requires finding a compressor rated for the desired refrigerant for the application. Refrigerants are given names such as R-12 or R-134a from the American
Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE). Ideal refrigerants have favorable thermodynamic properties and are chemically
inert (noncorrosive), environmentally friendly (degradable), and safe (nontoxic, nonflammable). The desired fluid should have a boiling point somewhat below
the target temperature, a high heat of vaporization, moderate liquid density, high gas density, and a high critical temperature.

Specifications
There are a number of specifications to consider when selecting compressors. These include capacity, condensing temperature, evaporating temperature,
flow rate, and power.
Capacity(Btu/hr) measures the ability of a refrigerant compressor to remove heat from the refrigerant gas. Nominal capacity ratings are based on a
standard set of conditions which include condensing temperature (CT), evaporative temperature (ET), refrigerant, and motor revolutions per minute (rpm).
Typically, refrigeration compressors and air conditioning compressors can run at many different values for these parameters, with corresponding changes
in their cooling capacity. Once in use, compressors can be tweaked and adjusted to the desired capacity and operating conditions. Charts like this one
are provided by the compressor's manufacturer, allowing engineers to make these adjustments properly once in the system:

Image Credit: Carlyle Compressor Company
Condensing temperature is the range of condensing temperatures over which the compressor is rated to operate.
Evaporating temperature is the range of evaporative temperatures over which the compressor is rated to operate.
Flow rate is the rate (by mass) at which the fluid is passed through the compressor, measured in pounds per hour (lb/hr) or kilograms per hour (kg/hr).
Power (W) is the input power required to run the compressor motor at a specific operating point.
Refrigeration compressors and air conditioning compressors also carry power-source specifications defined by voltage / frequency / phase. Common choices
include 12 VDC and 24 VDC, as well as 115/60/1, 230/50/1, 208-230/60/1, 208-230/60/3, 380/50/3, 460/60/3 and 575/60/3.

Features
Refrigeration compressors and air conditioning compressors can incorporate a number of features which may be important for certain applications.
Thermal shut off - compressor features controls which turn the compressor off at high temperatures to prevent it from overheating. They also can
provide restart once the compressor has cooled down below a certain temperature.
Sealing - describes how the compressor and motor drive are situated in relation to the gas or vapor being compressed. Sealed compressors do not allow
the gas a route to leak out of the system. Compressors may be one of three types: open, hermetic, and semi-hermetic.
Open types have a separate housing for the compressor and the motor. They rely on lubricant in the system to splash on pump components and seals. If
not operated frequently, the system can leak its operating gases. Open compressors can be driven by non-electric power sources such as combustion
engines.
Hermetic types seal the compressor and motor together in the same housing. These compressors are leak-free and can sit for long periods unused, but
cannot be maintained or repaired.
Semi-hermetic types also contain the motor and compressor in one housing, but instead of a one-piece housing they incorporate gasketed/bolted covers.
These can be removed for maintenance and repair of the compressor or motor.
Low noise - compressor operation generates less noise for applications where a quiet environment is desired.
Light weight - compressor is compactly built or constructed with low-density materials for cooling systems which require low weight components.
Variable speed - compressor has speed adjustment for running at various operating flow rates and conditions.
Standards
Standards related to refrigeration and air conditioning compressors include:

BS EN 13771-1 (Compressor And Condensing Units for Refrigeration - Performance Testing and Test Methods - Part 1: Refrigerant Compressors)