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Compressorprotectionstartswithaknowledgeofrefrigerantoilbasics

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Inlightoftodaysneedformoreenergyefficientrefrigeration,airconditioning,andheatpumpsystems,we
findrefrigerantcontrolbecomingamoreimportantfactoringainingreliability.
Theresultantreductionincompressionratio,callingforlargercondensersandlargerrefrigerantcharges,all
pointtotheneedtoreemphasizerefrigerantcontroloneofthemajorcausesofcompressorfailureisdamage
causedbyliquidrefrigerantenteringthecompressorinexcessivequantities.
Awelldesigned,efficientcompressorforrefrigeration,airconditioning,andheatpumpdutyisprimarilya
vapormovingpumpdesignedtohandleareasonablequantityofliquidrefrigerantandoil.
Designingandbuildingapumptohandlemoreliquidwouldrequireaseriouscompromiseononeormoreof
thefollowing:size,weight,capacity,efficiency,andnoise,nottomentiontheoverallimportantfactorofcost.
Regardlessofthedesign,therearelimitstotheamountofliquidacompressorcanhandletheselimitsdepend
onfactorssuchastheinternalfreevolumeofthecompressor,oilcharge,typeofsystemandcontrols,and
normaloperatingconditions.
Propercontrolofliquidrefrigerantisanapplicationproblem,andlargelybeyondthecontrolofthecompressor
manufacturer.
Thepotentialhazardincreaseswithsizeoftherefrigerantchargeandusuallythecauseofthedamagecanbe
tracedtooneormoreofthefollowing:
Excessiverefrigerantcharge
Frostedevaporator
Dirtyorpluggedevaporatorfilters
Failureofevaporatorfanorfanmotor
Incorrectcapillarytubeselection
Incorrectselectionoradjustmentofexpansionvalvesand/or
Refrigerantmigration.

RefrigerantOilRelationship
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Tocorrectlyanalyzesystemmalfunctions,andtodetermineifasystemisproperlyprotected,aclear
understandingofthebasicrefrigerantoilrelationshipisessential.
Inrefrigerationcompressors,oilandrefrigerantmixcontinuously.Refrigerationoilsaresolubleinliquid
refrigerantandatnormalroomtemperaturestheywillmixcompletely.
Sinceoilmustpassthroughthecompressorcylinderstoprovidelubrication,asmallamountofoilisalwaysin
circulationwiththerefrigerant.Oilandrefrigerantvapordonotmixreadily,andtheoilcanbeproperly
circulatedthroughthesystemonlyifgasvelocitiesarehighenoughtosweeptheoilalong.
Ifrefrigerantvelocitiesarenotsufficientlyhigh,oilwilltendtolieinthebottomoftheevaporatortubing,
decreasingheattransferandpossiblycausingashortageofoilinthecompressor.
Asevaporativetemperaturesarelowered,thisproblembecomesmorecritical,sincetheviscosityoftheoil
increaseswithadecreaseintemperature.Forthesereasons,properdesignoftubingisessentialforsatisfactory
oilreturninarefrigerationsystem.
Oneofthebasiccharacteristicsofarefrigerantoilmixtureinasealedsystemisthefactthatrefrigerantis
attractedbytheoilandwillvaporizeandmigratethroughthesystemtothecompressor,eventhoughno
measurablepressuredifferenceexiststocausethemovement.
Onreachingthecompressor,therefrigerantwillcondenseintoaliquid.Thismigrationwillcontinueuntilthe
oilissaturatedwithliquidrefrigerant.Theamountofrefrigeranttheoilwillattractisprimarilydependenton
temperature,increasingrapidlyasthetemperatureincreasesandapproachingamaximumatnormalroom
temperature.
Whenthepressureonasaturatedmixtureofrefrigerantandoilissuddenlyreducedashappensina
compressoronstartuptheamountofliquidrefrigerantrequiredtosaturatetheoilisdrasticallyreducedand
theremainderoftheliquidrefrigerantflashesintovapor,causingviolentboilingoftherefrigerantandoil
mixture.
Thiscausesthetypicalfoamingoftenobservedinthecompressoronstartup,whichcanmovealloftheoilout
ofthecompressorinlessthanaminute.(Notallfoamingistheresultofrefrigerantinthecompressoragitation
oftheoilcanalsocausefoaming.)
Oneconditionthatissomewhatsurprisingwhenfirstencounteredbyservicepersonnelisthefactthatthe
introductionofexcessiveliquidrefrigerantintothecompressorcancausealossofoilpressureoroildeliveryto
thebearings,eventhoughtheleveloftherefrigerantandoilmixturemaybeobservedinasightglass.
Thehighpercentageofliquidrefrigerantenteringthecompressornotonlyreducesthelubricatingqualityofthe
oil,butonenteringtheoilpumpintakemayflashintovapor,restrictingtheentranceofadequateoiltomaintain
properlubricationofthecompressorbearings.
Shouldthisoildilutioneffectcontinue,compressorfailureoccurs.

TypicalDefectsOfImproperControl
Liquidrefrigerantproblemscantakeseveralforms,eachwithitsown,distinctivecharacteristics.Followingare
descriptionsofthevariousproblemsyoumayencounter.
Refrigerantmigration:Refrigerantmigrationisatermusedtodescribetheaccumulationofliquidrefrigerant
inthecompressorduringperiodswhenthecompressorisnotoperating.
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Itcanoccurwheneverthecompressorbecomescolderthantheevaporator,sinceapressuredifferentialthen
existstoforcerefrigerantflowtothecolderarea.
Althoughthistypeofmigrationismostpronouncedincolderweather,itcanalsoexistatrelativelyhigh
ambienttemperatureswithremotetypecondensingunitsforairconditioningandheatpumpapplications.
Liquidrefrigerantflooding:Ifanexpansionvalveshouldmalfunction,orintheeventofanevaporatorfan
failureorcloggedairfilters,liquidrefrigerantmayfloodthroughtheevaporatorandreturnthroughthesuction
linetothecompressorasaliquidratherthanvapor.
Duringtherunningcycle,liquidfloodingcancauseexcessivewearonthemovingpartsbecauseofthedilution
effectontheoilandthelossofoilfromthecompressor.
Duringtheoffcycle,afterrunninginthiscondition,migrationofrefrigeranttothecompressorcanoccur
rapidly,resultinginliquidsluggingwhenstarted.
Liquidrefrigerantslugging:Liquidsluggingisthetermusedtodescribethepassageofliquidrefrigerantand
oilthroughthecompressorssuctionanddischargevalves.Itisevidencedbyaloudmetallicclatterinsidethe
compressor,possiblyaccompaniedbyextremevibrationoftheunit.
Sluggingcanresultinbrokenvalves,blownheadgaskets,brokenconnectingrods,andothermajorcomponent
damage.Sluggingfrequentlyoccursonstartup,whenliquidrefrigeranthasmigratedtothecompressor.
Onsomeunits,becauseofthetubingconfigurationandlocationofthecomponents,liquidrefrigerantandoil
cancollectinthesuctionlineorevaporatorduringtheoffcycle,returningtothecompressorasasolidliquid
withextremevelocityonstartup.
Thevelocityandtheweightoftheliquidslugmaybeofsufficientmagnitudetooverrideanyinternalantislug
protectiondevicesdesignedwithinthecompressor,againcausingmajordamage.

CorrectiveAction
Thepotentialhazardtorefrigerationorairconditioningsystemsisalmostdirectlyproportionaltothesizeofthe
refrigerantchargeinuse.Itisdifficulttodeterminethemaximumsaferefrigerantchargeofanysystemwithout
actuallytestingthesystemwithitscompressorandothermajorcomponents.
Thecompressormanufacturercandeterminethemaximumamountofliquidthecompressorwilltolerate
withoutendangeringtheworkingparts,butthemanufacturerhasnowayofknowinghowmuchofthetotal
systemchargewillactuallybeinthecompressorunderthemostextremeconditions.
Themaximumamountofliquidacompressorcantoleratedependsonitsdesign,internalvolume,andoil
charge.Whereliquidmigration,flooding,orsluggingcanoccur,correctiveactionmustbetaken.Thetypeof
actionisnormallydictatedbythesystemsdesignandtypeofrefrigerantcontrolproblemincurred.
Table1(page18)listsrefrigerantchargelimitationsforBristolcompressorsthatmaybeusedwithoutsome
meansofliquidrefrigerantcontrol.Itispossibleonsomesystemdesigns,particularlysystemswherelarge
quantitiesofliquidcangettothecompressoronstartup,thateventhoughthesystemcontainsrefrigerant
chargessmallerthanthelimitslistedinthistable,someprotectiveactionmayberequired.
Whenliquidrefrigerantcontrolbecomesaproblem,oneormoreofthefollowingtypesofcorrectiveactionmay
benecessary.
Minimumrefrigerantcharge:Thebestcompressorprotectionagainstallformsofliquidrefrigerantproblems
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istokeepthechargewithinthecompressorslimits.Evenifthisisnotpossible,thechargeshouldbekeptas
lowasreasonablypossible.
Usethesmallestpracticaltubesizeincondensers,evaporators,andconnectinglines.Receiversshouldalsobe
assmallaspossible.
Chargewiththeminimumamountofrefrigerantrequiredforproperoperation.Bewareofbubblesshowingin
thesightglass,whicharecausedbysmallliquidlinesandlowheadpressure.Thiscanleadtoserious
overcharging.
Pumpdowncycle:Themostpositiveanddependablemeansofproperlycontrollingtheliquidrefrigerant,
particularlyifthechargeislarge,isbymeansofapumpdowncycle.
Byclosingaliquidlinesolenoid,therefrigerantcanbepumpedintothecondenserandreceiver,andthe
compressoroperationiscontrolledbymeansofalowpressurecontrol.Therefrigerantcanthusbeisolated
duringperiodswhenthecompressorisnotinoperation,andmigrationtothecompressorandcrankcaseis
prevented.
Arecyclingtypeofpumpdowncontrolisrecommendedtoprovideprotectionagainstpossiblerefrigerant
leakagethroughcontroldevicesduringtheoffcycle.Withthesocalledonetimepumpdown,ornonrecycling
typeofcontrol,sufficientleakagemayoccurduringlongoffperiodstoendangerthecompressor.
Althoughthepumpdowncycleisthebestpossibleprotectionagainstmigration,itwillnotprotectagainstliquid
floodingduringoperation.Ifapumpdowncycleisused,anapprovedstartcapacitorandrelaymustbeusedon
allcompressorshavingsinglephase,permanentsplitcapacitor(PSC)motors.
Crankcaseheaters:Onsomesystems,operatingrequirements,cost,orcustomerpreferencemaymaketheuse
ofapumpdowncycleundesirablecrankcaseheatersarefrequentlyusedinsuchcasestoretardmigration.
Thefunctionofacrankcaseheateristoholdtheoilinthecompressoratatemperaturehigherthanthecoldest
partofthesystem.Refrigerantenteringthecompressorwillthenbevaporizedanddrivenbackintothesuction
line.
However,inordertoavoidoverheatingandcarbonizationoftheoil,thewattageinputofthecrankcaseheater
mustbelimited.Also,inambienttemperaturesapproaching0Forwhenexposedsuctionlinesandcoldwinds
imposeanaddedload,thecrankcaseheatermaybeoverpoweredandmigrationcanstilloccur.
Onsuchsystems,innoeventshouldacompressorbestartedunlessthecrankcaseheaterhasbeenenergized
foraperiodofatleast12hrsimmediatelypriortostartup.
Crankcaseheatersareeffectiveincombatingmigrationifconditionsarenottoosevere,buttheywillnot
remedyallsluggingwhereliquidfloodbackhasnegatedtheheatinputofthecrankcaseheater.
Suctionlineaccumulators:Onsystemswhereliquidfloodingisapttooccur,asuctionaccumulatorshouldbe
installedinthesuctionline.Basically,theaccumulatorisavesselthatservesasatemporarystoragecontainer
forliquidrefrigerantthathasfloodedthroughthesystem,withaprovisionformeteringthereturnoftheliquid
tothecompressorataratetowhichthecompressorcansafelytolerate.
Thistypeoffloodingtypicallycanoccuronheatpumpsatthetimethecycleisswitchedfromcoolingto
heating,orfromheatingtocooling.Asuctionlineaccumulatorismandatoryonallheatpumpsystemsunless
otherwiseapprovedbythemanufacturersengineeringdepartment.
Systemsusinghotgasdefrostarealsosubjecttoliquidfloodingeitheratthestartortheterminationofthehot
gascycle.Compressorsonlowsuperheatapplications,suchasliquidchillersandlowtemperaturedisplay
cases,aresusceptibletooccasionalfloodingfromimproperrefrigerantcontrol.
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Sinceeachsystemwillvarywithrespecttothetotalrefrigerantchargeandthemethodofrefrigerantcontrol,the
actualneedforanaccumulatorandthesizerequiredis,toalargeextent,dictatedbyindividualsystem
requirements.
Iffloodingcanoccur,anaccumulatormustbeprovidedwithsufficientcapacitytoholdthemaximumamount
ofrefrigerantfloodingwhichcanoccuratanyonetimeinsomecasesthiscanbewellover50%ofthetotal
systemcharge.
Ifaccuratetestdataastotheamountofliquidfloodbackisnotavailable,then50%ofthesystemcharge
normallycanbeusedasaconservativedesignguideorstartingpoint.
Oilseparators:Oilseparatorscannotcureoilreturnproblemscausedbysystemdesign,norcantheyremedy
liquidrefrigerantcontrolproblems.However,intheeventthatsystemcontrolproblemscanberemediedby
othermeans,oilseparatorsmaybehelpfulinreducingtheamountofoilcirculatedthroughthesystem.
Theycanoftenmakesafeoperationpossiblethroughcriticalperiodsuntilsuchtimeassystemcontrolcanbe
returnedtonormalconditions.Forexample,onlowtemperatureapplicationsoronfloodedevaporators,oil
returnmaybedependentondefrostperiodstheoilseparatorcanhelpmaintaintheoillevelinthecompressor
duringtheperiodbetweendefrosts.
Insummary,closeattentionmustbepaidtothecapacitiesandcapabilitiesofsystemcomponentssuchasthe
compressorandcondensingunit.
Onuniquesystems,itisstronglyrecommendedthattheequipmentbefieldtestedpriortobeingplacedintothe
marketplace,toensureitsreliability.
ArticleprovidedbytheApplicationEngineeringDepartmentofBristolCompressorsInc.,15185Industrial
ParkRd.,Bristol,Va.242025404664121.
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