LESSON

TYPES OF COMPRESSORS

LECTURE
SUB-OBJECTIVE
At the end of this lesson the trainee will be able to:
1.
Identify and state the different types and uses of
compressors used in S.W.C.C. associated with air conditioning.
1.0

EXTERNAL DRIVER COMPRESSORS

An external drive (open) compressor is bolted together. Its crankshaft extends
through the crankcase. A flywheel (pulley) drives the crankshaft and belt or it
can be driven directly by an electric motor.
Fig. 4-4-1 illustrates a cross section through an open compressor. This is a
four-cylinder V-type compressor. An eccentric type crankshaft is used. The
pistons are fitted with rings.

Fig. 4-4-1. Four cylinder external drive V type compressor, air cooled.

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A. Crankshaft, B. Eccentric. C. Connecting rod. D. Piston, E. Piston

rings. F. Cylinder, G. Valve plate. H. Crankshaft Seal, I. Suction service
valve. J. Exhaust service valve. K. Crankcase.
A master connecting rod is mounted on each eccentric and is connected to a
piston in one bank of the "V". The connecting rod which is attached to the
piston in the other bank is connected with a pin through a flange on the
master connecting rod. These connecting rods are somewhat shorter than the
master connecting rod and are called articulated connecting rods.
A crankshaft seal is required where the crankshaft comes through the
crankcase.
2.0

HERMETIC COMPRESSORS
The motor in a hermetic compressor is sealed inside a dome or housing with
the compressor and is directly connected to the compressor. A crankshaft seal
is not needed.
A motor rotor is usually a press fit on the compressor crankshaft. Some motor
compressors are made with the motor at the top, while others have the motor
at the bottom and the compressor at the top.
The unit is usually spring mounted inside the hermetic dome. This prevents
most of the compressor vibration from being felt outside of the dome.
The exhaust and suction lines inside the dome are made flexible. A
connection through the dome provides means of fastening the compressor
lines to the remainder of the system. The electrical connections to the motor
pass through the dome by means of an insulated leakproof seal.
To lubricate the compressor, the return suction gas is fed into a hollow disk
mounted on the motor compressor shaft. Centrifugal force throws the oil and
a liquid refrigerant to the outer rim of the disk and flows over the motor
windings. (Centrifugal force action rotates things to pull spinning particles
away from the center of the rotation.) Only the vapor refrigerant remains at
the center and is drawn into the cylinders of the compressor.
A hermetic motor compressor usually requires an outside electrical relay
starting mechanism. Fig. 4-4-2 shows a section through such a motor.
Some motor compressors are two-speed. These are popular in large systems
and in air conditioning where heat loads change.

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Fig. 4-4-2. Reciprocating hermetic compressor. Compressor is at top and

motor at bottom. Assembly is mounted on springs inside dome.
A.

Motor rotor,

B.

Motor stator.

C.

Compressor cylinder

D.

Compressor piston

E.

Connecting rod.

F.

Crankshaft.

G.

Crank throw.

H.

Compressor shell.

I.
Glass sealed electrical connections through compressor
dome.

3.0

TYPES OF COMPRESSORS

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There are four basic types of compressors in use:

1.
2.
3.
4.
3.1

Reciprocating (piston cylinder)

Rotary
Screw type
Centrifugal

RECIPROCATING COMPRESSORS
The original energy source is usually an electric motor. Its rotary motion must
be changed to reciprocating motion. A crank and a rod connecting the crank
to the piston usually make this change. The complete mechanism is housed
in a leak proof container called a crankcase. It is very efficient. Its
construction resembles, in many ways, that of the automobile engine. A
typical external drive-reciprocating compressor is shown in Fig. 4-4-3.

Fig. 4-4-3.
Large capacity external drive two cylinder reciprocating
compressor. Note eccentric type crankshaft and pistons fitted with rings.
Basically, this compressor is a cylinder and a piston. Fig. 4-4-4 shows the
principle of operation of a reciprocating compressor. In illustration No. 1, the
piston, B, has moved downward in cylinder, A, and has moved refrigerant
vapor from the suction line, C, through the intake valve, E, and into the
cylinder space, G. In illustration No. 2, the piston has moved upward and has
compressed the vaporized refrigerant into a much smaller space (clearance
space) marked H, and has pushed the compressed vapor through valve, F, in
to the condenser.

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Fig. 4-4-4. Basic construction of reciprocating compressor.

A. Cylinder. B. Piston. C. Intake port from suction line. D. Exhaust port to
condenser. E. Intake valve. F. Exhaust valve. G. Piston displacement
indicates volume of vapor drawn into cylinder on intake stroke. H. Clearance
space at end of compression stroke. Left-hand illustration shows intake stroke;
right-hand the exhaust stroke.
4.0

CYLINDERS
Compressor cylinders for external drive compressors are usually made of cast
iron. The cast iron must be dense enough to prevent the seepage of
refrigerant through it. Some nickel is usually added to give the casting this
density.
The body is a casting using lightweight alloy. Cast iron cylinder liners
are permanently cast into crankcase body.
Small compressors usually have fins cast with the cylinders to provide better
air cooling larger compressors may have water jackets surrounding the
cylinders for cooling. Some compressors are built with cylinder liners or
sleeves, which may be replaced when worn.
Usually, the crankcase is part of the same casting as the cylinder. This
practice cuts down the number of joints that might leak. It also permits close
alignment between crankshaft main bearings and cylinder. The main bearings
are ball type. Construction is shown in Fig. 4.4.5. The cylinder arrangement
is commonly used on open compressors.

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Fig. 4.4.5 Cutaway view of small, external drive, two cylinder reciprocating
compressors
Hermetic (sealed) compressors usually have cast iron cylinders. Some may
be of aluminum or other materials.
This is typical of hermetic compressor cylinders shown in C in Fig. 4.4.2.
Another type of hermetic compressor is pictured in Fig. 4.4.6. This is a bolted
type hermetic and can be dismantled easily for servicing.

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Fig. 4.4.6 Bolted type hermetic motor compressor assembly. Motor is at left
and compressor at right.
5.0

PISTONS AND PISTON RINGS

Piston used in external drive compressors is usually made of cast iron, while
in small high-speed hermetic compressors they are of die-cast aluminum.
Smaller sizes do not have piston rings.
Since the temperature of pistons seldom goes higher than 250 F. (121 C.)
there is not much expansion of either piston or cylinder. Pistons may be fitted
with as little as .0002 in. (.0051 mm) clearance for each inch in diameter.
The smaller pistons have oil grooves cut in them. Fig. 4.4.7 illustrates a
common piston connecting rod assembly.
Fig. 4.4.8 illustrates a commercial type piston and connecting rod assembly.
This one is fitted with piston rings.
There are two types of piston rings. The upper ring or rings are known as
compression rings and the lower is designed to control the oil "flow" past the
piston. It is an oil ring.

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Fig. 4.4.7 Piston and connecting rod assembly. Note oil grooves cut in piston.
Piston rings are usually made of cast iron. Some bronze rings have been
used, however.
Rings should be fitted to the groove as closely as possible and still allow
movement. A 45 deg. tapered or angled ring gap permits the ring to push out
against the cylinder wall.
This gap should be about .001 in. (.0254 mm) for each inch of piston diameter.
Piston pins are made of case hardened high carbon steel accurately ground to
size. They are hollow to reduce weight.

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Fig. 4.4.8 Compressor piston and, connecting rod assembly. Note how
connecting rod's lower (left) end is split and then bolted together, to provide
bearing to fit crankshaft journal.

Fig. 4.4.9. Cross section through compressor cylinder showing cylinder, piston,
valve plate, valves, gaskets and cylinder head
There is a valve plate under the cylinder head with both the intake and
exhaust valve located in it, Fig. 4.4.9

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In hermetic systems, the construction of the pistons and rings, if used, are
much the same as those used in external drive compressors.
However, since the hermetic compressors usually run at a higher speed than
external drive compressors, the pistons are smaller in diameter and are made
as light as possible.
Cool refrigerant vapor from such line flows over motor windings to aid in
cooling motor. Compressor uses Scotch yoke piston crank mechanism.
Compressor is inverted and a horizontal motor shaft is used.
Note position of motor crankshaft, piston, cylinder and connecting rod,.
Compressor is spring mounted within dome to minimize vibration. Refrigerant
vapor inlet at top protects compressor from possible surge of liquid refrigerant.
6.0

CYLINDER HEAD
Cylinder heads for both external drive and hermetic compressors are usually
made of cast iron.
The head serves as a pressure plate to support and hold the valves and valve
plate in position. It also provides the vapor passages into and out of the
compressor.
The pressures of compression may amount to as much as 300 psi (21 kg/cm)
depending upon the kind of refrigerant used.
The valve plate must, therefore, have good support so that there will be no
leakage at the gaskets on either side of the valve.

7.0

VALVES AND VALVE PLATES

The usual valve assembly consists of a valve plate, an intake valve, an
exhaust valve and the valve retainers. See Fig. 4.4.10

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1.
B.

Fig. 4.4.10 Typical compressor valve plate.

Intake valve.
Exhaust valve. Heavy springs on exhaust valve cage permit a
greater valve lift to protect compressor in case of severe liquid
refrigerant or oil pumping.

Valve plates are some times made of cast iron, but hardened steel is also
used, as plates can be thinner with longer wearing valve seats.
Compressor valves are usually made of high carbon alloy steel. They are,
heat treated to give them the properties of spring steel and ground to a
perfectly flat surface.
The intake valve is usually kept in place by small pins or the clamping action
between the compressor head and valve plate. The exhaust valve may be
clamped in the same way.
Some different valve designs are displayed in Fig. 4.4.11, 4.4.12 shows a
typical valve plate assembly.

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Fig. 4.4.11 Some typical compressor valve designs. A. Reed valve, spring
closed. B. Poppet valve, spring closed. Used on some large compressors. C.
Reed valve. Pressure difference keeps valve closed.

Fig. 4.4.12 A Typical cast iron valve plate construction.

A. Inlet port. Note extension to prevent oil from entering intake. B.
Exhaust port. Note wire lock used in the two exhaust valve screws. C.
Oil return to the crankcase.

The valve disks or reeds must be perfectly flat. A defect of only .0001 in.
(0.00254 mm) will cause valves to leak.

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Of the two valves, the intake gives the least trouble. This is because it is
constantly lubricated by oil circulating with the cool refrigerant vapors. Also, it
operates at a relatively cool temperature.
The exhaust valve must be fitted with special care. it operates at high
temperatures and must be leak proof against a relatively high pressure
difference.
Because of the high vapor pressures and the high temperatures, there is a
tendency for the heavy ends (heavy molecules of hydrocarbon oils) to collect
on the valve and valve seat as carbon.
The valves open about .010 in. (0.254 mm). If the movement is more, a valve
noise develops. If the movement is too little, not enough vapor can move past
the valve.
In small high-speed hermetic compressors, the intake valves are made very
light and as large as possible. Greater amounts of refrigerant vapor are thus
allowed to enter the cylinder during the very small fraction of a second that the
intake valve is open.
8.0

CRANKSHAFT SEAL
Refrigerating systems that use an external motor (open type to drive the
compressor) needs a leak proof joint where the crankshaft comes out of the
compressor crankcase. This is absolutely necessary as the pressures very
greatly in the crankcase.
This joint requires seals that are carefully designed and installed, for its is a
place where the shaft rotates part of the time and then is at rest part of the
time.
All seals use two rubbing surfaces. One surface turns with the crankshaft and
is sealed to the shaft with an O-ring of synthetic material. The other surface is
stationary and mounted on the housing with leak proof gaskets.
The surface materials (accurate to .000001 in. (.0000254 mm) and optically
flat) are made of these different combinations: hardened steel and bronze,
ceramics and carbon. The two rubbing surfaces must be lubricated or they
will wear and start to leak.
Teflon is often used as a gasket material on automobile air conditioning
compressors. The crankshaft seal must operate at a high temperature. It is
usually made of carbon and ceramic.

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Fig. 4.4.13 Crankshaft seal construction for external drive compressors.

9.0

1.

Seal used in commercial compressors.

B.

Seal used with an automobile air conditioning compressor.

C.

Replacement seal. D. Bellows type seal.

SCOTCH YOKE

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The Scotch yoke mechanism has no connecting rod. The cylinder and piston
are both quite long, and even at the lower end of the stroke the piston is still
guided by the cylinder wall.
The crankshaft pin, also called the crank throw, connects to the lower end of
the piston by means of a floating bearing.
See Fig. 4.4.14.
compressors.

The Scotch yoke is popular in small high-speed

Fig. 4.4.14. Hermetic compressor using Scotch yoke mechanism.

A. Crank throw and Scotch yoke. B. Hollow Piston. C. Combined motor
shaft and crankshaft. D. Crankshaft thrust bearing. E. Internal mounting
spring. F. Oil reservoir.
10.0

SWASH PLATE
A popular type of reciprocating compressor used on many automobile air
conditioning systems is known as a "swash" plate or "wobble" plate
compressor.
No connecting rod is used in this type of compressor. The cylinder and
pistons are mounted as in Fig. 4.4.15.
As the shaft revolves, the swash plate causes the pistons to reciprocate in the
cylinders.
Usually the swash plate compressor has three or more cylinders arranged in a
circle around the drive shaft.
Since the compressor is double acting, that is, compression takes place at
each end of the stroke, a three-cylinder compressor will give a pumping action
like a six cylinder conventional compressor of the same cylinder and stroke

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dimensions. This is an external drive compressor. It requires a seal where

the drive shaft passes through the compressor housing.

Fig. 4.4.15. Cross section through a "swash" plate type of reciprocating

compressor.
A. Drive shaft. B. Swash plate. C. Piston. D. Cylinder Wall E. Drive ball.
F. Ball shoe. G. Valve plate (valve not shown). H. Thrust bearing J.
Piston stroke. As drive shaft and swash plate revolve, double end piston
is moved back and forth in cylinder.

11.0

ROTARY COMPRESSOR
There are two basic types of rotary compressors. One has blades that rotate
with the shaft.
The other has a stationary blade. The rotary blade compressor using two
blades, shown in Fig. 4.4.16 is typical of this type.

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The low-pressure vapor from the suction line is drawn into the opening and
fills the space behind the blade as it revolves.
As the blades revolve, trapped vapor in the space ahead of the blade is
compressed until it can be pushed into the exhaust line to the condenser.

Fig. 4.4.16. A rotary blade compressor.

Black arrows indicate direction of rotation or rotor.
refrigerant vapor flow.

Red arrows indicate

A commercial rotary blade compressor, using eight blades, is pictured in Fig.

4.4.17. The basic operation of the eight-blade compressor is the same as the
two blade.

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Fig. 4.4.17 Eight bladed rotary compressor.

Black arrows indicate direction of rotation.
Red arrows indicate direction of flow of vapor.
C. Exhaust port, D. Displacement. E. Exhaust. I. Inlet port. S. Suction. Inlet
port is considerably larger than exhaust port.
This is because inlet pressure (suction) is considerably less than exhaust
pressure. (FES).
Rotating vane compressors are frequently used as the "booster" compressor
in cascade systems.
This is the name commonly given to the first compressor in a cascade system.

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Fig. 4.4.18 Rotary compressor. Stationary blade or divider block is in contact

with a roller (impeller)

A. Identification of parts B. Operation.

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These compressors have three advantages:

1.
2.
3.

They provide a large size opening into the suction line.

They provide large inlet port openings.
They have a very small clearance volume.

Since the low-side pressure may be quite low, this means that the low-side
vapor will be drawn into the compressor. Fig. 4.2.18 represents a stationary
blade (often called a divider block) rotary compressor. An eccentric shaft
rotates an impeller in a cylinder. This impeller constantly rubs against the
outer wall of the cylinder.
As the impeller (or roller) revolves, the blade traps quantities of vapor. The
vapor is compressed into a smaller and smaller space, building up the
pressure and temperature. Finally the vapor is forced through the exhaust
port into the high-pressure side of the system (condenser).
In rotary compressors, check valves are usually used in the suction line to
prevent the high-pressure vapor and compressor oil from flowing back into the
evaporator.
12.0

SCREW TYPE COMPRESSOR

The screw type compressor uses a pair of special helical rotors. They trap
and compress air as they revolve in an accurately machined compressor
cylinder. These compressors are available in either external drive or hermetic
construction. They are used in large system (20 tons and up).
Fig. 4.4.19 illustrates a cross section. The two rotors are not the same shape.
One is male, the other female. The male rotor, A, is driven by the motor. The
female rotor, B, meshes with and is driven by the male rotor. It has six
interlope spaces. The cylinder, C, encloses both rotors.

Fig. 4.4.19. Cross section of screw-type compressor.

A. Male rotor. B. Female rotor. C. Cylinder. Vaporized refrigerant eneters
at one end and exhausts at other end. (Stal Refrigeration AB)
In operation, the refrigerant vapor is drawn in as shown in Fig. 4.4.20. The

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intake (low-pressure vapor) enters at one end of the compressor and is

discharged (compressed vapor) at the opposite end.
Since there are four lobes on the male rotor and six on the female rotor, the
male rotor, the male rotor will revolve more rapidly than the female rotor. The
rotors are helixes so the pumping action will be a continuous action rather
than pulsating as with a reciprocating compressor. In the absence of this
reciprocating motion there is very little vibration during

Fig. 4.4.20. Basic operation of screw type compressor.

Revolving rotor compressor vapor:
A.

Compressor interlopes spaces being filled.

B.

Beginning of compression.

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13.0

C.

Full compression of trapped vapor.

D.

Beginning of discharge of compressed vapor.

E.

Compressed vapor fully discharged from interlopes spaces.

CENTRIFUGAL COMPRESSORS
Centrifugal compressors are used successfully in large refrigerating systems.
In this type compressor, vapor, as it is moved rapidly in a circular path, moves
outward. This action is called centrifugal force.
The vapor is fed into housing, near the center of the compressor. A disk with
radial blades (impellers) spins rapidly in this housing forcing vapor against the
outer diameter.
The pressure gained is small so that several of these compressor wheels or
impellers are put in series to create greater pressure difference and to pump a
sufficient volume of vapor.
This type of compressor looks like a steam turbine or an axial flow air
compressor for a gas turbine engine.
The centrifugal compressor has the advantage of simplicity. There are no
valves or pistons and cylinders.
The only wearing parts are the main bearings. Pumping efficiency increases
with speed so compressors operate at high speeds.
Fig. 4.4.21 is a cross-section through a two-stage centrifugal type compressor.
The driving motor is mounted between stages.

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Fig.4.4.21 Two stage centrifugal compressor.

1

Second stage variable inlet guide vane.

First stage impeller.

Second stage impeller.

Water-cooled motor.

Base, oil tank and lubricating oil pump assembly.

First stage guides vanes and capacity control.

Labyrinth seal.

Cross-over connection.

Guide vane actuator.

10

Volute casing.

11

Pressure lubricated sleeve bearing.

shown.

13.1

STATOR CONSTRUCTION

Note discharge opening is not

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The stator or casing of a centrifugal compressor is usually made of cast iron.

It has a changing radius inside to adapt itself to the vapor pickup by the
impellers.
The casing (cylinder) also holds the main bearings, the oil pressure producing
pump as well as the refrigerant vapor intake and exhaust ports. It also holds
the shaft seal where the shaft extends or sticks out from the casing for the
power drive, when an external motor is used. Both the first stage and second
stage have adjustable inlet vanes to control the capacity of the pump.
13.2

ROTOR CONSTRUCTION
The rotor or impeller in a centrifugal compressor is keyed to the compressor
shaft. It is made of cast iron or steel and is specially designed to move the
vapors without going above gas velocity limits and without having vapor
trapping pockets. A typical rotor is shown in Fig. 4.4.22.

Fig. 4.4.20 Impeller from centrifugal compressor.

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