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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
Fig. 4-4-1. Four cylinder external drive V type compressor, air cooled.
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 1
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.
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
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 3
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.
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.
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 5
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.
Fig. 4.4.6 Bolted type hermetic motor compressor assembly. Motor is at left
and compressor at right.
5.0
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AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 7
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.
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
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 9
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
1.
B.
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.
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 11
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.
The valve disks or reeds must be perfectly flat. A defect of only .0001 in.
(0.00254 mm) will cause valves to leak.
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.
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 13
9.0
1.
B.
C.
SCOTCH YOKE
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.
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
MODULE 4
AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 15
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.
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.
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AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 17
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COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 19
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
B.
Beginning of compression.
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AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 21
13.0
C.
D.
E.
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.
Water-cooled motor.
Labyrinth seal.
Cross-over connection.
10
Volute casing.
11
13.1
STATOR CONSTRUCTION
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AIR CONDITIONING AND REFRIGERATION
COMPRESSION SYSTEMS AND COMPRESSOR
LESSON 4 PAGE 23
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.