Good Morning

Welcome to Johnson Control Training Courses

1 Reciprocating Compressor Concept By Gholam Reza Khajeh

Courses Subjects

1. Reciprocating compressors
2. Screw Compressors
3. Screw Chillers
4. Screw Chillers with Variable Speed Drive.
5. Centrifugal Compressor
6. Centrifugal Chillers
7. Industrial Refrigeration

Exam for each course

2 Reciprocating Compressor Concept By Gholam Reza Khajeh

1
 Training Means

Training Means : System Training

All Detail should read from specific chiller manual.
After this training you might need to work with one
of experienced Service Technician / Engineers to be a
professional.

3 Reciprocating Compressor Concept By Gholam Reza Khajeh

Reciprocating Compressor

4 Reciprocating Compressor Concept By Gholam Reza Khajeh

2
 Refrigeration System

Four Basic Components

Compressor(s)

Condenser

Evaporator

Expansion Device

5 Reciprocating Compressor Concept By Gholam Reza Khajeh

Refrigeration
Condenser

Expansion Compressor
Valve

Evaporator

6 Reciprocating Compressor Concept By Gholam Reza Khajeh

3
Refrigeration Cycle
Evaporator

High-Pressure Vapor

High-Pressure Liquid
Condenser

Low-Pressure Mixture

Low-Pressure Vapor

7 Reciprocating Compressor Concept By Gholam Reza Khajeh

Introduction to Compressor Types

Positive Displacement

Non Positive Displacement

Positive displacement compressors use a piston or other device to reduce the

volume of refrigerant vapor in a compressor chamber.
PROCESS:

Power is applied

Chamber volume is reduced

Refrigerant pressure is increased

8 Reciprocating Compressor Concept By Gholam Reza Khajeh

4
 Introduction to Compressor Types

Definition: compression chamber reduces in volume
to compress gas

Reciprocating

Scroll

Screw
Unlimited lift

Centrifugal (non-positive displacement)
compressors have a fixed amount of lift for a given set
of operating conditions.

9 Reciprocating Compressor Concept By Gholam Reza Khajeh

Compressors
Hermetic Semi-Hermetic
Scroll Reciprocating

10 Reciprocating Compressor Concept By Gholam Reza Khajeh

5
Reciprocating
Compressor
Parts J COMPRESSOR
Discharge Motor Windings
Cylinder Head
Service Valve Terminal Box

Suction
Service
Valve

Suction
Oil Pump Strainer

Motor Housing
Piston

Crankshaft and Bearings

Sight glass
Un- loaders

11 Reciprocating Compressor Concept By Gholam Reza Khajeh

How does it work?

Suction

12 Reciprocating Compressor Concept By Gholam Reza Khajeh

6
 How does it work?

Volume Enclosed

13 Reciprocating Compressor Concept By Gholam Reza Khajeh

How does it work?

Refrigerant Gas
Compressed

14 Reciprocating Compressor Concept By Gholam Reza Khajeh

7
 How does it work?

Discharge

15 Reciprocating Compressor Concept By Gholam Reza Khajeh

J COMPRESSOR
Discharge Motor Windings
Cylinder Head
Service Valve Terminal Box

Suction Service
Valve

Suction
Strainer

Oil Pump

Motor Housing
Piston

Crankshaft and Bearings

Sight glass
Un- loaders

16 Reciprocating Compressor Concept By Gholam Reza Khajeh

8
Compressor Parameters
Compression ratio Cr = discharge Pressure/ suction Pressure
Volumetric efficiency = 1- 0.05 x Cr
Swept volume 2 to 2400 m³/h
Rotation speed : until 1800 rpm
Single stage until Cr ≅ 6
Double stage Cr > 10 Compound
Maintenance: valve check 5000h
Crankshaft assembly 10000h

17 Reciprocating Compressor Concept By Gholam Reza Khajeh

Pistons and Connecting Rods

18 Reciprocating Compressor Concept By Gholam Reza Khajeh

9
Suction and Discharge Valves

19 Reciprocating Compressor Concept By Gholam Reza Khajeh

Gudgeon Pin and Oil Pump

20 Reciprocating Compressor Concept By Gholam Reza Khajeh

10
Reciprocating Compressor Disadvantage

More rotating parts

Lower reliability and efficiency

More Complex refrigerant piping

Higher Maintenance

21 Reciprocating Compressor Concept By Gholam Reza Khajeh

Periodic Maintenance Reciprocating Compressor

Cleaning Crank Case annually

Cleaning Oil Strainer annually

Oil Change annually

Oil Analysis annually

Suction Valve , Discharge Valve each 5000 Hrs

Crank Case assembly each 10000 Hrs

Cylinder Liner, Piston and Segment check each
20000Hrs

Crank Case Heater

22 Reciprocating Compressor Concept By Gholam Reza Khajeh

11
 Capacity Control

Expantion valve is a device to Maintains constant superheat on the
evaporator. ( EXP is not a capacity controller)

Capacity is a parameter of Compressor and it should be control inside
the compressor.

It may called some times as LOADING / Un LOADING compressor.

The compressor is loaded when the solenoid is de-energized, and
unloaded when the solenoid is energized.

Unloading is accomplished by lifting and holding the suction valve off in
its seat.

All cylinders equipped with un-loaders will remain unloaded on start-up
until the oil pressure has built up to normal.

23 Reciprocating Compressor Concept By Gholam Reza Khajeh

Loading / Unloading Steps

Loading & Unloading the compressor is depended to the number of the cylinder in
compressor and it should be balance unloading, otherwise it will create the noise
in compressor and finally chiller. In JCI- York technology the sequence should
be adjust from the Opti-View panel as per the no of compressor cylinders.

24 Reciprocating Compressor Concept By Gholam Reza Khajeh

12
 Load / Unload Solenoid Valves

25 Reciprocating Compressor Concept By Gholam Reza Khajeh

Chiller
There are so many different
type of the chillers therefore
there are so many different type
of the compressor with different
number of compressors which
might use in chillers.

26 Reciprocating Compressor Concept By Gholam Reza Khajeh

13
Reciprocating compressor inside view

27 Reciprocating Compressor Concept By Gholam Reza Khajeh

Lets look inside a Compressor Click Here.

Note : This pictures are not

JCI- York Compressors.

28 Reciprocating Compressor Concept By Gholam Reza Khajeh

14
 Chiller

How do we able to control the

compressor in a chiller ??

29 Reciprocating Compressor Concept By Gholam Reza Khajeh

Electrical Control Cabinet

30 Reciprocating Compressor Concept By Gholam Reza Khajeh

15
 Component locations
Power Board S1 Dip Switches
(APB)

Clock jump contact

& RT clock/battery back up

EPROM

Input/Output Board
(AIOB)
System switches
S2 - S5
RS485 (ISN)
Micro Board RS232 (printer)
(AMB) Selector Pin

31 Reciprocating Compressor Concept By Gholam Reza Khajeh

Questions ?

Any question on Reciprocating Compressor
working principle ??

We will talk about complete control procedure on

next sessions.

Thank you for your attention.

32 Reciprocating Compressor Concept By Gholam Reza Khajeh

16