Form 10-207
August 2005
Compressor Overheating
Still Today’s Most Serious Field Problem?
By Dave Demma, Senior Application Engineer – Supermarket Refrigeration, Sporlan Division of Parker Hannifin.
More than 20 years ago an application bulletin enti-
tled “Compressor Overheating: Today’s Most Serious
Field Problem” was published by a major compressor
manufacturer. At first look, it might seem that com-
pressor overheating would not be a major factor in
the many refrigeration compressors that fail on any
given day. Closer inspection, however, would reveal
that many compressors suffering mechanical/electri-
cal failures have their roots in overheating.
Why does overheating have such a devastating affect
on a compressor? The answer is twofold:
1. Loss of lubrication film: Refrigeration oils have
been highly refined in an effort to elevate the tem-
perature at which chemical decomposition will
occur. As such, they are vulnerable to losing the
lubrication film necessary to prevent metal to
metal contact between bearings and journals, or
piston rings and cylinders, prior to the tempera-
ture at which decomposition begins. With mineral
oil this will occur approximately between 310ºF
and 330ºF. When these temperatures are
achieved, the probability of extreme piston and
ring wear is imminent.
2. Chemical decomposition: This happens at elevat-
ed temperatures, and is accelerated in the pres-
ence of other contaminants such as air or water.
18 is an important number to remember, for the
rate of chemical reaction doubles with every 18ºF
temperature increase.* For example, a chemical
reaction that takes 10 years to complete at 100ºF,
will only take 5 years to complete at 118ºF. At
136ºF it would be complete in 2-1/2 years, and so
forth. The process by which the refrigerant and/or
oil chemically breaks down can occur in a matter
of seconds if there have been enough 18° tempera-
ture increases.
Mineral oil will start to decompose at approximately
350ºF (400ºF for POE oil). As temperatures increase
above this threshold, the oil starts to polymerize. In
plain English this means that the molecules that con-
stitute the oil’s makeup will start to combine into
larger and larger molecules. First the oil is trans-
formed into a dark thick oil, then a sludge, and final-
ly a solid powder.
The presence of oil breakdown in the refrigeration
system has many negative side effects. Sludge and
solid particulate can plug up the oil inlet screen in the
* The Arrhenius Equation
compressor sump or the lubrication passages in the
crankshaft. Each of these will have the same devas-
tating consequence: loss of lubrication, and ultimate-
ly failed bearings.
Oil breakdown deposits can also attach themselves to
the internal surfaces of the refrigeration system. The
inner walls of the piping, compressor, and control
valves are all subject to this problem. While this will
cause TEVs to stick/plug, and restrict the lubrication
passages, oil breakdown on the interior walls of the
piping may remain undisturbed for years (Figure 1).
Converting a system such as this from R-22/mineral
oil to R-404A/POE oil will awaken the oil breakdown
like a sleeping giant. With POE’s solvent-like abili-
ties, its presence in the system will literally clean
these deposits from the interior surfaces and bring
them back into circulation. One can expect contami-
nant problems after a refrigerant retrofit where the
mineral oil has been replaced by POE oil: the new oil
that was added to the compressor will likely be dark
the next morning, and the odds are that a few TEVs
will plug. Several filter-drier/oil filter/oil changes
may be necessary before the problem is resolved.
While unpleasant, it is simply a natural consequence
of excessive discharge temperatures causing oil
decomposition, and the solvent-like properties of POE
bringing it back into circulation.
Figure 1 — Oil Breakdown Deposits on Inner Walls of
System Piping
Now, let’s take a look at a real world scenario in how
destructive discharge temperatures can be. Most
journeymen technicians have heard a compressor
operating with what I’ll term a “jackhammer inside
the cylinder” syndrome. It is the result of a connect-
ing rod wrist pin bore with excessive wear (Figure 2).
The extra play allows the wrist pin to slap against
Page 2 / Form 10-207
both ends of the bore. In addition, the piston may hit
the bottom of the valve plate at the end of each com-
pression cycle.
Figure 2 — Worn Wrist Pin Bore
Now here is the shocker…this mechanical failure was
the result of excessive discharge temperatures. When
this system was started, the installing contractor was
pressed for time and neglected to set the thermostat-
ic expansion valves (TEV). The resulting high super-
heat at the evaporator outlets translated into a
higher suction superheat at the compressor inlet. For
every 1ºF increase in the suction temperature an
approximate 1ºF increase in the discharge tempera-
ture will be realized.
Now jump ahead a year or so. This system is suffer-
ing from lack of maintenance in the form of a dirty
condenser (Figure 3). The consequence is a higher
condensing temperature. According to EPA research,
a heat transfer coil with a meager .042” film of dirt on
its surface will result in up to a 21% loss of heat
transfer capacity.*
Figure 3 — Dirty Condenser
The increased suction temperature (from underfeed-
ing TEVs) plus the higher condensing temperature
(dirty condenser) add up to a system operating with
* Contracting Business — September 2003
excessive discharge temperatures, and ripe for oil
decomposition. After some period of time, what used
to be clean looking straw colored oil in the crankcase
will become thick and black. Some of this oil break-
down will be deposited on the valve plates (Figure 4),
preventing the reed valves from sealing properly.
Figure 4 — Valve Plate with Oil Breakdown Deposits
Clearly, the oil breakdown deposits are the result of
high discharge temperatures. Let’s see what the full
implications are. It starts with a discussion on how the
piston wrist pins and their bearings are lubricated.
There is a small oil reservoir (hole) on the top of the
wrist pin end of the connecting rod (Figure 5). Its
function is simply to collect oil from the oil/refriger-
ant mist that is present in the crankcase. This oil is
then supplied to the wrist pin bore by means of an oil
groove, centered in the wrist pin bearing. In the case
of this aluminum connecting rod, the precisely
machined wrist pin bore (with oil groove) serves as
the wrist pin bearing too.
As shown in Figure 6, when the piston is traveling
down (suction), the point of contact creating the pis-
ton travel is between the top of the wrist pin and
wrist pin bore. This allows the clearance to transfer
to the bottom of the wrist pin/wrist pin bore. Oil from
the wrist pin bore groove will flow into the clearance
between these two moving metal parts, creating a
lubricating film. This is how the bottom half of the
wrist pin and bearing receives lubrication.
When the piston is traveling up (compression), the
point of contact creating piston travel shifts to the
bottom of the wrist pin and wrist pin bore. This now
allows the clearance to shift to the top of the wrist pin
and wrist pin bore. Oil that has accumulated in the
reservoir can now flow into this clearance, lubricating
the top portion of the wrist pin and bearing.
It is imperative that the point of contact between the

wrist pin and wrist pin bore continue to shift from the
top to bottom in this manner, as it allows the clear-
ance to shift as well. Without the clearance shifting,
the ability to lubricate the top and bottom of the wrist
pin and bearing would be compromised.
Figure 5 — Connecting Rod Wrist Pin Bore
Oil
Collection
This is where the valve plate in Figure 4 comes into
play. After the compressed vapor exits the cylinder,
the discharge reeds should seat tightly, preventing
any leakage back into the cylinder. Unfortunately, the
oil breakdown deposits prevent this, allowing high
pressure vapor to enter the cylinder during the down-
stroke (suction). Not only does this rob the compres-
sor of its pumping capacity, it keeps high pressure on
the top of the piston at all times. This is ultimately
what causes the wrist pin bore to wear.
Continuous high pressure on top of the piston prevents
the wrist pin clearance from shifting, keeping the point
of contact at the lower portion of the wrist pin/wrist pin
bore (Figure 6). Because of this, the lower portion of
the wrist pin/wrist pin bore is unable to receive any oil,
and the resulting metal to metal contact causes an
abnormal wear pattern to the wrist pin bore.
Figure 6 — Normal Lubrication of Wrist Pin/Wrist Pin Bore
Downstroke Upstroke
Point of
Contact
Wrist
Pin
Clearance Allows Connecting
Rod
Lubrication
Form 10-207 / Page 3
This is most certainly a mechanical failure. A review
of the steps that led to this failure will reveal that its
roots are in excessive discharge temperatures.
1. High suction vapor temperature, resulting from
underfeeding TEVs. The higher suction tempera-
ture increases the discharge temperature.
2. A dirty condenser raises the condensing tempera-
ture (and pressure), resulting in even higher dis-
charge temperatures. Safe temperatures have
now been exceeded, causing the oil to decompose.
3. The oil breakdown is deposited on the discharge
reeds, preventing them from seating. Discharge
vapor can now leak back into the cylinders during
the suction stroke.
4. The constant high pressure exerted on the piston
dome prevents the wrist pin/wrist pin bore clear-
ance from shifting. The bottom portion of the wrist
pin/wrist pin bore becomes the constant point of
contact during upstroke and downstroke, prevent-
ing complete wrist pin/wrist pin bore lubrication.
5. After some period of time, the metal to metal con-
tact causes abnormal wear to the softer aluminum
wrist pin bore, resulting in the elongated bore.
Maintaining normal discharge temperatures would
have extended the life of this compressor and reduced
its electrical consumption.
Before prevention measures can be implemented, one
must know what caused the excessive discharge tem-
peratures in the first place. While many sources can
be attributed, four main root causes lead to excessive
discharge temperatures:
1. High Suction Superheat: One of the built-in inef-
ficiencies in the vapor-compression cycle is the
Figure 7 — Loss of Lubrication to Lower Portion
of Wrist Pin/Wrist Pin Bore
(Constant high pressure
on piston dome)
Downstroke Upstroke
Point of
Contact
Wrist
Pin
Clearance Allows Connecting
Rod
Lubrication
Page 4 / Form 10-207

heat added to the refrigerant between the evapo- entropy), the higher the heat of compression.
rator outlet and the compressor discharge. A large
amount of this can be attributed to the compres- For example, the system in Figure 8 represents an
sion process. While the amount of heat added will R-22 low temperature system operating at -20ºF
vary depending on the refrigerant and system saturated suction temperature (SST) and 100ºF
conditions, this “heat of compression” cannot be saturated condensing temperature (SCT), with an
eliminated by any procedure. It is inherent in the open drive compressor. The refrigerant vapor tem-
compression process. perature at the evaporator outlet is -15°F (5°
superheat) The orange line reflects 40º of super-
The compression process somewhat follows the heat at the compressor inlet, and the heat of com-
constant entropy line on the P-H diagram (Figure pression (HOC) is 27 Btu/lb. The discharge
8). The constant entropy lines extend at an angle temperature is 215ºF.
from the saturated vapor line, and become less
vertical with each succeeding (or increasing value) The system in Figure 9 represents a system with
line. So, the greater the value of the constant the same operating conditions, using a suction
entropy line, the farther it will travel horizontally cooled hermetic compressor. The cool suction
between two pressure points. It is this horizontal vapor must now travel across the warm compres-
travel that represents the increase in the refriger- sor motor windings, experiencing an approximate
ant’s heat content in Btu/lb. The entropy of a 80ºF temperature increase in the process. The
vapor will increase as its temperature increases. vapor temperature entering the cylinders is 100ºF
Therefore, it is the vapor’s temperature (which, is (120º of superheat). The resulting discharge tem-
partially influenced by the amount of suction perature is 295ºF.
superheat) that will determine the constant
entropy line from which the compression process Note that the suction temperature of the system
follows. The laws of physics in this scenario never in Figure 9 was 80ºF higher than that of the sys-
change: the higher the suction vapor temperature tem in Figure 8. This translated into an 80ºF
entering the compressor (resulting in a higher increase in the discharge temperature. For every

Figure 8 — Pressure-Enthalpy Diagram Open Drive Compressor

SCALE CHANGE

-30 -20 -10 0 10 20 30 40 4050 60 70 80 90 103

100 108
110 120 130 135
140 150 160 170 180 190 200

14 15 16 17 18 19 20 21 22 23
12

13

0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2
0.

0.

5000
0.01 0.018 0.020 0.022 5000
0.017 0.2
5
4000 0.025 6
4000

3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
0.05
200

0
Open Drive Compressor 50
52
0 0.2
8
180

1400 0.07 0 1400

40°F Suction S.H. @ Comp. Inlet
48
0
46

0.10 1000
1000
215°F Discharge Temp. Heat of
0
44
160F

800 800
0

Compression
42

0.14
200 –
0
40

600 600
0

180 –
Co
38

180 0.2
0

ns
36

160 – 160 –
tan
0
34

400 0.3 400

0

140 – 140 –
t Te
320

300 0.4 300

30 0

m pe r

120 – 120 –
215°F Discharge Temp.
280

0.5
100 – 200
ature (°

200
260

80 – 0.7
or

80 –
240

140
Vap
Pressure (psia)

140
220

F)

60 – 60 – 1.0
ted

200
id

100 100
iq u

ura

180

80 40 – 40 – 1.4 80
dL

Sat

160
ate

60 20 – 20 – 2.0 60
tur

140
Sa

120

40 0– 0– 3.0 40
100

30 4.0 30
80

-20 – -20 – 5.0

60

20 20
7.0
40

-40 – -40 –
14 14
20

10.0
10
0

-60 – -60 – 14
8.0 8.0
-20

) 6.0
6.0 -F 20
-40

-80 – -80 – /lb

tu
-60

4.0 (B 4.0
30
py
ro
-80

3.0
E nt 3.0
40
-100 – -100 – nt
s ta
50 Specific Volume (ft3/lb)
2.0
C on 2.0

37 38 0.
39 .40
5 36 0. 0. 0
1.4
1.4 .3 0. 70
34

0
33

0.
2

-120 – -120 –
0.

1.0
1

0.3

1.0
0.3
0
0.3
9

0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2

0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE

Enthalpy (Btu per lb above saturated liquid at -40°F)

 Form 10-207 / Page 5

Figure 9 — Pressure-Enthalpy Diagram Suction Cooled Hermetic Compressor

SCALE CHANGE

-30 -20 -10 0 10 20 30 40 4050 60 70 80 90 103

100 110 120 121 130 140 150 152 160 170 180 190 200

14 15 16 17 18 19 20 21 22 23

12

13
0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2

0.

0.
5000 0.020 0.022 5000
0.01 0.017 0.018 5
0.025 0.2 4000
4000 6
3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
Hermetic Compressor 0.05

200
52 0
8
50 0 0.2

180
1400 40°F Suction S.H. @ Comp. Inlet 0.07 0 1400

48
160F

0
295°F Discharge Temp.

46
1000 0.10 1000

0
44
800 800

0
42
0.14
200 –

0
40
600 600

Co
0
180 –

38
180 0.2

ns
0
36
160 – 160 –

tan
0
34
400 400
0.3

t Te
0
140 – 140 –

320
300 300

m pe
0.4

30 0
120 – 120 –

280
0.5

rature
200
100 – 295°F Discharge Temp. 200

260
80 – 80 – 0.7

por

240

(
140 140

°F)
Pressure (psia)

220
d Va
60 – 60 – 1.0

200
uid

100

rate
100
Liq

180
80 40 – 40 – 1.4 80

u
Sat
d

160
ate

60 20 – 20 – 2.0 60
tur

140
Sa

120
40 0– 0– 3.0 40

100
30 4.0 30

80
-20 – -20 – 5.0

60
20 20
7.0

40
-40 – -40 –
14 14
120°F Suction Superheat, 80°F Vapor Temperature
20
10.0
10
increase from hermetic motor windings
0
-60 – -60 – 14
8.0 8.0
-20

) 6.0
6.0 -F 20
-40

-80 – -80 – /lb

tu
-60

4.0 (B 4.0
py 30
ro
-80

3.0 E nt 3.0
40
-100 – -100 – nt
s ta
50 Specific Volume (ft3/lb)
2.0
C on 2.0

37 38 0.
39 .40
5 3 6
0. 0. 0
1.4
1.4 .3 0. 70
34

0
33

0.
2

-120 – -120 –
0.

1.0
1

0.3

1.0
0.3
0
0.3
9

0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2

0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE

Enthalpy (Btu per lb above saturated liquid at -40°F)

1ºF increase to the suction temperature, you can 3/8” wall thickness insulation. This should be
expect an approximate 1ºF increase in the dis- avoided. On long piping runs, or where the suc-
charge temperature. Simply stated, any system tion piping is routed through an attic, 1/2” or 1”
condition that causes an increase in suction tem- wall thickness is recommended.
perature will result in a nearly equal increase to
the discharge temperature. C. Liquid to suction heat exchangers. This is the
classic “rob Peter to pay Paul” situation. The
Some of the more common system conditions that cool suction vapor subcools the liquid, which
are cause for increased suction temperatures are: will ensure vapor free liquid feeding the TEV. It
does so at the expense of higher suction vapor
A. High TEV superheat setting. This should temperatures. Not only does this lead to
always be checked at startup and set to the increased discharge temperatures, the higher
equipment manufacturer’s specification. The suction vapor temperatures reduce compressor
system TEV is not designed to regulate refrig- efficiency. This cancels any efficiency gained
erant vapor temperature at the compressor from the subcooled liquid.
inlet. Allowing the system TEV to operate at a
flood-back condition to ensure proper vapor 2. Insufficient Condenser Capacity: On rare occa-
temperature at the compressor inlet is danger- sions this might be the result of an undersized
ous (the potential for compressor damage) and condenser. However, for every undersized con-
inefficient (refrigerating the suction line adds denser in service, probably thousands more have
operating expense, yet has no effect on product not been maintained. As the condenser fins
temperature). When set properly, the system become restricted with dirt, the airflow necessary
TEV will maintain the lowest compressor suc- to deliver the condenser’s rated capacity is com-
tion temperature without sacrificing compres- promised.
sor safety or system efficiency.
Figure 11 shows the system mentioned previously,
B. Ineffective or missing insulation (Figure 10). but with a dirty condenser. The condensing tem-
There may be a temptation to use the lower cost perature has increased from 100ºF to 120ºF, and
Page 6 / Form 10-207

Figure 11 — Typical Cycle With Dirty Condenser

SCALE CHANGE

-30 -20 -10 0 10 20 30 40

45
50 60 70 80 90 103
100 110 120
121 130 140 150
155
160 170 180 190 200

14 15 16 17 18 19 20 21 22 23

12

13
0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2

0.

0.
5000 0.01 0.018 0.020 0.022 5000
0.017 0.2
5
4000 0.025 6
4000

3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
0.05

200
52 0
Dirty Condenser - 120°F Cond. Temp 50 0 0.2
8

180
1400 0.07 0 1400
Hermetic Compressor

48
0
46
1000 0.10 1000

0
120°F S.H. @ Cylinder Inlet

44
160F
800 800

0
42
0.14
200 –

0
40
600 600

0
180 –

Co
38
180 0.2

ns
36
160 – 160 –

tan
0
34
400 0.3 400

0
140 – 140 –

t Te
320
300 0.4 Temp.
320°F Discharge 300

30 0

m pe
120 – 120 –

280
0.5

rature
100 – 200
200

260
0.7

or
80 – 80 –

240
140

Vap

(
Pressure (psia)

140

° F)
220
60 – 60 – 1.0

ted

200
100 100

ura

180
80 40 – 40 – 1.4 80

Sat

160
60 20 – 20 – 2.0 60

140
120
40 0– 0– 3.0 40

100
uid

30 4.0 30

80
Liq

-20 – -20 – 5.0

d

60
20 20
rate

7.0
40
u

-40 – -40 –
Sat

14 14
20

10.0
10
0

-60 – -60 – 14
8.0 8.0
-20

)
6.0 -F 20 6.0
-40

-80 – -80 – /lb

tu
(B
-60

4.0 4.0
y 30
op
tr
-80

3.0 n 3.0
n tE 40
-100 – -100 – ta
2.0 ns 50 Specific Volume (ft3/lb) 2.0
Co
37 38 0.
39 .40
36 0. 0. 0
1.4
1.4 35 0. 70
0.
34
33

0.
2

-120 – -120 –
0.

1.0
1

0.3

1.0
0.3
0
0.3
9

0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2

0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE

Enthalpy (Btu per lb above saturated liquid at -40°F)

Figure 12 — Typical Cycle With Dirty Condenser and Lowered Suction Pressure
SCALE CHANGE

-30 -20 -10 0 10 20 30 40 45

50 60 70 80 90 103
100 110 120 124
130 140 150 160 165
170 180 190 200

14 15 16 17 18 19 20 21 22 23
12

13

0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2
0.

0.

5000 0.020 0.022 5000

0.01 0.017 0.018 5
0.025 0.2 4000
4000 6
3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
0.05
200

0
Dirty Condenser - 120°F Cond. Temp 50
52
0 0.2
8
180

1400 0.07 0 1400

Hermetic Compressor
48
0
46

1000 0.10 1000

130°F S.H. @ Cylinder Inlet
0
44
160F

800 800
0
42

0.14
Suction Pressure lowered
200 –to 20 psia (-29°F) Discharge temperature lowered
0
40

600 600
0

180 –
Co
38

0.2
180 to 280°F with liquid injection
0

ns
36

160 – 160 –
ta n
0
34

400 400
0.3
0

140 – 140 –
t Te
320

300 0.4 300

365°F Discharge Temp.
30 0

m pe r

120 – 120 –
280

0.5
100 – 100 – 200
ature (

200
260

80 – 80 – 0.7
or

240

140
Vap

140
Pressure (psia)

°F )
220

60 – 60 – 1.0
ted

200

100 100
ura

180

80 40 – 40 – 1.4 80
Sat

160

60 20 – 20 – 2.0 60
140
120

40 0– 0– 3.0 40
100
id

30 4.0 30
iqu

80

-20 – -20 – 5.0

dL

60

20 20
te
ura

7.0
40

-40 – -40 –
Sat

14 14
20

Liquid injection at compressor 10.0

10
0

8.0
-60 – -60 – inlet with Y1037 TREV 14 8.0
-20

) 6.0
6.0 -F 20
-40

/ lb
-80 – -80 – tu
-60

4.0 (B 4.0
y 30
op
tr
-80

3.0 3.0
t En 40
-100 – -100 – an
n st 50 Specific Volume (ft3/lb) 2.0
2.0
Co
37 38 0.
39 .40
5 36 0. 0. 0
1.4
1.4 3 0. 70
0.
34
33

0.
2

-120 – -120 –
0.

1.0
1

0.3

1.0
0.3
0
0.3
9

0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2

0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE

Enthalpy (Btu per lb above saturated liquid at -40°F)

 Form 10-207 / Page 7

Figure 13 — Sporlan Y1037 Temperature Responsive Expansion Valve

Evaporator

Y1037

Y1037 Condenser

Compressor Receiver

the resulting discharge temperature has increased
to 320ºF.
Figure 3 shows an example of this condition; it’s a
compressor waiting to fail. Sadly, this is
easily…and completely…preventable.
4. Refrigerant Type: Many criteria are used in the
Figure 10 — Missing Suction Line Insulation
Missing
Insulation
lowered from 10 psig to 5.5 psig, while maintain-
ing a condensing temperature of 120ºF. The result
is a higher discharge temperature; 365ºF. It is
important to operate the system with the highest
possible suction pressure.
selection of a refrigerant for a given application:
cost, availability, performance, and environmental
issues. When R-502 joined the endangered species
list, and suitable replacements for refrigeration
applications were needed, it seemed logical to
enlist R-22 as a replacement. It had been used for
refrigeration applications before R-502 was devel-
oped in the 1960s.

You have to wonder, “If R-22 was a good refriger-

3. Lowering the Suction Pressure: As mentioned
above, the compression process roughly follows
the constant entropy line on the Pressure-
Enthalpy diagram.
With a constant discharge pressure, when the
compression process starts on a constant entropy
line of a higher value, the resulting discharge tem-
perature is higher. Starting the compression
process on a higher constant entropy line can
occur in two ways: higher suction temperature OR
lower suction pressure. The system in Figure 12 is
operating at a lower suction pressure; it has been
ant for refrigeration applications, why was R-502
developed?” The answer is that R-22 has some lim-
itations as a “refrigeration” refrigerant, particu-
larly in low temperature applications. It is subject
to higher compression ratios, which put increased
stress on bearing surfaces and render the com-
pression process less efficient. This can be over-
come using a two-stage compression process;
either a compound compressor or two separate
compressors that compress the vapor in “two
stages.”
More importantly, in low temperature applica-
tions R-22 has the potential for devastatingly
high discharge temperatures. If the system is
Page 8 / Form 10-207
running per design...meaning that the condenser
is sized correctly AND is clean, the TEV super-
heat is set correctly, the suction line is well insu-
lated, and the suction pressure is operating at
the highest possible level, it will still operate
with high discharge temperatures. This is simply
due to the physical properties and characteristics
of R-22.
Because of this limitation, if R-22 is chosen as a
low temperature refrigerant, something must be
done to neutralize its “natural” high discharge
temperature problem. A compressor body cooling
fan motor is a start, as it can reduce the discharge
temperature perhaps 15-25 degrees.
The real “something” will be to attack the problem at
the compressor inlet. Recall that for every 1ºF change
in the suction vapor temperature, there will be an
approximate corresponding 1ºF change in the dis-
charge temperature. This can either be an increase
OR a reduction. Knowing this, it becomes rather easy
to control the discharge temperature by controlling
the suction temperature. Hence, the birth of the liq-
uid injection valve.
Figure 13 shows the application of a liquid injection
valve; a Sporlan Y-1037 Temperature Responsive
Expansion Valve. Its function is quite simple: to mon-
itor the compressor discharge temperature via a sens-
ing bulb. As the discharge temperature exceeds the
setting of the Y-1037, it injects a mixture of saturated
liquid and vapor into the suction line. This will
decrease the suction vapor temperature, which in
turn reduces the discharge temperature. Knowing
that the sensing bulb location is 50-75 degrees less
than the actual discharge temperature, a technician
can easily select a Y-1037 setting based upon the
desired maximum discharge temperature. If the
desired point for the valve to start injecting is a 280ºF
discharge temperature, then the Y-1037 setting
would be 205ºF (280 – 75). The system in Figure 12
illustrates the benefit of liquid injection.
The Y-1037 TREV responds to temperature only.
Printed in U.S. of A. © Copyright 2005 Parker Hannifin Corporation
There is no equalizer connection, and pressure does
not influence its operation. The sensing bulb should
be securely attached 6 inches from the compressor
service valve for accurate control. Insulating the bulb
is recommended to eliminate ambient temperatures
from influencing the bulb temperature. The Y-1037
inlet should be connected to a vapor free source of liq-
uid refrigerant; the outlet should be piped to the suc-
tion line 12”-18” from the compressor suction service
valve. Because of the Y-1037s positive shut off capa-
bility, an additional solenoid valve is not typically
required.
Liquid injection can be used to reduce excessive dis-
charge temperatures on a single stage compression
process, or to control the interstage temperature on a
two stage compression process.
Conclusion: As stated more than two decades ago,
compressor overheating IS today’s most serious field
problem. Many system problems and compressor fail-
ures can be directly traced to high discharge
temperatures.
Several causes exist for this condition and most can be
remedied by proper diagnosis and action. Condensers
should be cleaned as needed to keep them operating at
their rated capacity. The suction vapor temperature
should be kept within acceptable limits by setting the
system TEV correctly and insulating the suction line
properly. Compressors should not be allowed to oper-
ate at abnormally low suction pressures, as this will
lead to higher discharge temperatures.
With some refrigerants and applications, additional
methods are required to alleviate high discharge
temperatures. This can be accomplished to a degree
with a compressor body cooling fan motor. For com-
plete control in preventing this problem, a
Temperature Responsive Expansion Valve, which
monitors the discharge temperature, can be used.
Injecting saturated liquid/vapor into the suction line
will reduce the temperature of the superheated suc-
tion vapor, and in turn reduce the excessive dis-
charge temperatures.
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