Capacity Control

SRC-W & SW series compressors

Oil management
(WA-03-02-E)





3. CAPACITY CONTROL 2
3.1. SW SERIES 2
3.1.1. Working principle and control oil circuit 2
3.1.2. Step capacity control: L4 2
3.1.3. Control sequence: step configuration 6
3.1.4 Infinity capacity control: stepless LZ 7
3.1.4. Control sequence: stepless configuration 9
3.2. SRC-W SERIES 1 1
1
3.2.1. Working principle and control oil circuit 11
3.2.2. Step capacity control 2
3.2.3. Control sequence: step configuration 14
3.2.4. Compressor start and stop procedure 14
3.2.5. Part load application range 15











SRC-W & SW Series - Application and maintenance manual, Technical sheet WA-03-02-E data subject to change 1

Capacity Control
3. Capacity control

The possible need for capacity regulation depends upon the requirements of the whole system. The following
methods are preferably employed:

Parallel operation (see chapter WA-13: Parallel compounding): possibly combined with method given
below;
Frequency converter (please consult RefComp for any details);
Integrated capacity regulation, which will be describe in this chapter.

The integrated capacity regulation of RefComp compressors permits to work both at full and partial load. In particular
for SRC-WS series compressors the L2 three steps configuration is available (50, 75 and 100%) while for the SW
series either the L4 four steps configuration (lowest step, 50, 75 and 100% load), and the LZ stepless
configuration (continuous load change from the lowest step, up to 100% or from 50% to 100%) are available.
Here under both the compressor series are considered separately.

3.1. SW Series
3.1.1. Working principle and control oil circuit

The rotor housing is provided on the top with a longitudinal suction port whose opening is regulated by a slide valve
(item 2 of Picture 3-A). When the port is completely closed the actual compression length is the whole rotor length.
When the slide valve moves towards the discharge side and the port is uncovered, the volume of the working chamber
created by the rotors and the casing is reduced and a corresponding reduced amount of gas is compressed. By
changing the gas volume sucked in by the rotors, the mass flow changes and so the compressor cooling capacity.
The mentioned slide valve is moved by a hydraulic piston (item 3 of Picture 3-A), thanks to the oil pressure and its
working principle is the reduction of the suction volume.
The oil circuit, dedicated to the capacity control, is shown in Picture 3-A and Picture 3-G respectively for the step and
stepless capacity configuration. Its characterized by three solenoid valves normally closed: 14, 15 and 16 in the step
configuration and 14, 15 and 19/16 in the stepless configuration.
With few simple operations, the conversion between step and stepless configuration can be performed by the user. In
chapter WA-16 Capacity control conversion, the operations to switch from a control mode to the other, are
described.

3.1.2. Step capacity control: L4

The slide valve is controlled by a hydraulic piston which can be set in four different positions, according to the
compressor load: 100%, 75%, 50% and lowest step.
As shown in Picture 3-A, the oil circuit dedicated to the capacity control is characterized by three solenoid valve: 14,
15 and 16 (normally closed) which respectively have the purpose to control the three steps: minimum, 50 and 75%.
Here after the description of the working oil circuit in the four step will be found.



Attention!

The actual capacity steps may differ from the nominal values in relation to the working conditions
and compressor type.


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Capacity Control

Picture 3-A: step capacity control oil circuit for SW series compressors;


Key:

1: rotors;
2: slide valve;
3: hydraulic cylinder;
4: external capillary tube;
14, 15, 16: solenoid valves;


MINIMUM STEP CAPACITY (COMPRESSOR STEP FOR START UP AND STOP)

On the Picture 3-B, it is shown how the oil runs inside the control circuit. At the lowest step the solenoid valve 14 is
opened (energized), while the valves 15 and 16 are closed (not energized). Therefore the oil, coming from the oil
separator, flows through the opened port to the suction side, not pressurising the control cylinder. Consequently the
piston is pushed to the end stroke, the longitudinal port is completely opened on the suction side and the length along
which the rotors are working is the shortest.



Attention!

Regarding the step capacity control mode (4 steps), the minimum capacity step can be used only to
start and stop the compressor; it cannot be used to give cooling power.








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Capacity Control


Picture 3-B: Capacity control at lowest step


50% CAPACITY

With reference to Picture 3-C at 50% capacity, the solenoid valve 15 is open while the valves 16 and 14 are closed;
the oil enters the cylinder (through the 1
st
hole on the left) and drives the piston to the position corresponding to the
2
nd
hole, where the oil flows to the suction side. The slide valve also moves and partially closes the longitudinal
opening, thus increasing the effective working length of the rotors.



Picture 3-C: Capacity control at 50% step

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Capacity Control
75% CAPACITY

At 75 % capacity, see Picture 3-D on the following page, the situation is similar to the previous one, but now the
solenoid valve 16 is open while the valves 15 and 14 are closed; the control piston is thus positioned corresponding to
the 3
rd
hole, the slide valve closes the opening further and increases the working length of the rotors.


Picture 3-D: Capacity control at 75% step

100% CAPACITY

At 100% capacity, see Picture 3-E, all the solenoid valves are closed; the oil can no longer leave the cylinder and
pushes the piston to the limit on the right side and the slide valve completely closes the longitudinal opening, meaning
that the compression occurs along the entire length of the rotors.


Picture 3-E: Capacity control at 100% step
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Capacity Control
3.1.3. Control sequence: step configuration
The oil outflow is controlled by the three solenoid valves 14, 15 and 16 (normally closed), set on the compressors
casing, see Picture 3-F. The control logic follows the sequence as in Table A.


Solenoid valve 14
Valvola solenoide 14
Solenoid valve 15
Valvola solenoide 15
Solenoid valve 16
Valvola solenoide 16
Picture 3-F: solenoid valve position on the SW series compressors: step capacity control;

SOLENOID VALVES
Load (capacity steps) 16 15 14
100% OFF OFF OFF
75% ON OFF OFF
50% OFF ON OFF
Minimum step
(start up and stop)
OFF OFF ON
OFF= not activated solenoid valve (close valve);
ON= activated solenoid valve (open valve);
Table A: step configuration control logic for the solenoid valves;
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Capacity Control
3.1.4 Infinity capacity control: stepless LZ

Infinite capacity control is recommended whenever the cooling capacity of the system has to be controlled with a
high degree of precision, while it is not very useful in systems featuring high inertia, where step capacity control is
more suitable. With reference to the Picture 3-G which highlight the oil circuit lay-out in the stepless configuration,
the LZ capacity control is achieved by installing a solenoid valve in the position 19 of the oil circuit. This solenoid
valve, which is the same that controls the 75% capacity step in the step lay-out (valve solenoid 16), will now control
the amount of oil that flow to the cylinder control of the slide valve.
So the oil circuit for the stepless capacity control is characterised by the three solenoid valve 14, 15 and 19, which
work as following:

19: loading of the oil cylinder when the cooling capacity increases;
14, 15: unloading of the oil cylinder (respectively down to the minimum step or to the 50% step), when the
cooling capacity decreases.

This brings about continuous control of the flow processed by the compressor, from the minimum value to the
maximum one.


Picture 3-G: infinite capacity control oil circuit (stepless configuration) for SW series compressors;


Key:

1: rotors;
2: slide valve;
3: hydraulic cylinder;
4: external capillary tube;
5: orifice;
14, 15, 19: solenoid valves;

For details on how to convert from the step to the stepless configuration, see chapter WA-16 Capacity control
conversion.
In the stepless configuration the oil channels must be throttled to achieve slower motion and more accurate
positioning of the control piston. With reference to the Picture 3-G, the load channel can be throttled by installing a
modified capillary tube (4). The unload channel can be throttled by installing an orifice (5) upstream the solenoid
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Capacity Control
valve. Both items are supplied on request as they belong to the conversion kit from the configuration step to the
stepless one, and have to be assembled by the user.
T1 T1
T0 T0
valve/valvola 19
valves/valvole14 or 15
Inlet signal
Segnale di
ingresso
Compressor
cooling
capacity
Capacit frigo
erogata dal
compressore
ON
OFF
Control range
Range di controllo
Stationary working condition
Condizioni di lavoro stazionarie
Decrease
Decremento
Increase
Incremento

Picture 3-H: infinite capacity control logic;

With reference to Picture 3-H, the capacity delivered by the compressor is controlled by using a control device that, in
response to a variation in the load required by the users, opens the solenoid valves 14, 15 and 19 described above. In
particular, these valves are energized by pulse signals and, as regards the control device input signal, the chosen
parameter should be sensitive to the variation in the load required by the users. For instance the suction pressure or
the air/water temperature at the evaporator can be used.
Picture 3-H shows the series of impulses that energize the valves 14, 15 and 19 and used to adapt the delivered mass
to the required cooling capacity. You can note that when the value of the input variable does not move outside of the
range of control (differential), the system does not react and the compressor operates in stationary conditions.
The solenoid valves should be energized by brief impulses (T1=0.5-1 sec). Usually, the energizing period of solenoid
valve 19 can be shorter than the energizing period of solenoid valves 14 or 15. The series of impulses continues until
the value of the control variable returns within the range of control (differential).
The time interval between two impulses (T0) must be set to optimize the control, according to the inertia of the
system.



RefComp suggests:

not to operate with a capacity below 50% for longer than around 5 minutes, so as to avoid
excessive overheating of the electrical motor;
not to switch rapidly from full load conditions to minimum load, but rather to remain for a
minimum time of 3 minutes at 50%. Otherwise liquid may enter the compressor causing
damage;
to check and if necessary adjust the timers on the control device when a continuous
variation in the compressor capacity is not related to appreciable variations in the load
required by the users.







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Capacity Control
3.1.4. Control sequence: stepless configuration
The oil outflow is controlled by the three solenoid valves 14, 15 and 19/16 (normally closed), set on the compressors
casing, see Picture 3-I. The control logic follows the sequence as in Table B.



Solenoid valve 14
Valvola solenoide 14
Solenoid valve 15
Valvola solenoide 15
Solenoid valve 16
Valvola solenoide 16
Picture 3-I: solenoid valve position on the SW series compressors: stepless capacity control;

INFINITY CONTROL
100-50%
INFINITY CONTROL
100%-MINIMUN STEP
Solenoid valve Solenoid valve
Capacity variation 14 15 16/19 Capacity variation 14 15 16/19
Load OFF OFF ON Load OFF OFF ON
Stationary work OFF OFF OFF Stationary work OFF OFF OFF
Unload down to 50% OFF ON OFF
Unload down to
minimum capacity
ON OFF OFF
(Start/Stop) ON OFF OFF (Start/Stop) ON OFF OFF
OFF =solenoid not energized (close valve); ON =solenoid energized (open valve);
Table B: stepless configuration control logic for the solenoid valves;
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Capacity Control



Warning!

The working at partial load condition is allowed according to the application limits reported in the
chapter WA-10: Application limit.
Particularly, the compressor can work at the minimum capacity step only during the start up phase,
the stop phase (see paragraph 3.3) and in any case for short period of time (see previous pages).
At any rate the part load operation requires specific actions to prevent:
the insufficient return of oil due to the reduced speed of the gas;
higher temperatures on the discharge side, caused by the compression lower efficiency and
by the lower refrigerant mass flow;
an overheating of the electrical motor that might occur whenever the tension value is out
of the given range.

Thorough and extensive testing is recommended.

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Capacity Control
3.2. SRC-W Series
3.2.1. Working principle and control oil circuit

Referring to the Picture 3-J , the capacity control takes place by means of two pistons (1) (independent), which open
and close the compressor inner channels (2). These pistons are activated by the high and low pressure through two
solenoid valves 20 and 21. When the load modulation takes place, those channels allow that some compressed
refrigerant is bypassed back to the suction side and therefore the compressor discharge is only the 50% or the 75% of
the total mass flow aspirate. The cooling capacity produced by the compressor is modulated by bypassing part of the
mass flow compressed.
In particular the solenoid valves 20 and 21 work as following:

20: drive the above piston;
21: drive the below piston.

In the following paragraph the 50%, 75% and 100% load capacity steps are considered and in the below Picture 3-J
you can see the oil circuit which permit the compressor capacity modulation.


Picture 3-J: working principle for the capacity control on SRC-W series compressors;


Key:

1: pistons;
2: compressor inner channels;
3: rotors;
HP: high pressure;
LP: low pressure;
20, 21: solenoid valves.


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Capacity Control
3.2.2. Step capacity control

For what concerns the SRC-W series compressors, three steps capacity regulation are available, corresponding to the
50%, 75% and 100% load.

50% CAPACITY

The solenoid valves 20 and 21 are excited (see Picture 3-K). This sets the cylindrical pistons lodging in
communication with the suction pressure (LP). The pistons (1) are then moved on the left side by the rotors discharge
pressure, opening the ports (2) which bypass 50% (25%+25%) flow to the suction side. In this way the load
regulation to 50% is achieved.


Picture 3-K: 50% capacity modulation. LP: low pressure; HP: high pressure;

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Capacity Control
75% CAPACITY

The solenoid valve 20 is not excited while the solenoid 21 is excited (see Picture 3-L). This sets the upper and the
lower cylindrical pistons lodging in communication respectively with the discharge pressure (HP) and the suction
pressure (LP). The upper pistons is then moved on the right side by the rotors discharge pressure closing the port (2)
while the lower piston is moved on the left side opening the port which bypass 25% flow to the suction side. In this
way the load regulation to the 75% is achieved.


Picture 3-L: 75% capacity modulation. LP: low pressure; HP: high pressure;

100% CAPACITY

In this case (see Picture 3-M), the solenoid valves 20 and 21 are not excited. Consequently the control piston
chambers are set on the high discharge pressure HP. This pressure pushes both the pistons on the right side closing
the ports which were bypassing the refrigerant. All the refrigerant compressed by the rotors reaches the compressor
discharge side, so reaching the 100% load.


Picture 3-M: 100% capacity modulation. LP: low pressure; HP: high pressure;
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Capacity Control
3.2.3. Control sequence: step configuration

The refrigerant flow in the capacity control circuit is controlled by the valves 20 and 21 which are set on the top of
the compressor case (see Picture 3-N) and have to be excited according the logic on Table C.


Picture 3-N: solenoid valve 20 and 21 position on the compressor, for the capacity control on SRC-W series;




SOLENOID VALVES
Load
(capacity steps)
20 21
100% OFF OFF
75% OFF ON
50% ON ON
OFF =solenoid not energized (close valve);
ON =solenoid energized (open valve);
Table C: step configuration control logic for the solenoid valves;



3.2.4. Compressor start and stop procedure

In order to limit the starting current, the electrical motor is set on part-winding (see chapter WA-05: Electrical
devices). Since this implies a weaker starting torque, also the resistant torque on the rotors has to be lower. For this
reason, RefComp suggests to start the compressor on the partial load lowest step (see picture 3-Q).
For what concerns the SW compressors series, it must be distinguished between the step and the stepless
configuration.
For the 4 step regulation, during compressor standstill the slide valve moves automatically to the lowest step, since
the oil can flow through the load channel on picture 3-A, because of the pressure difference.
On stepless configuration, the mentioned duct is normally closed by the valve 19, see picture 3-G. Therefore, before
stopping the compressor, the solenoid valve 14 must be excited, otherwise the oil cannot flow out from the control oil
chamber, and the compressor cannot be downloaded.
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Capacity Control
For this reason, in order to stop and restart the compressor at the lowest capacity step, see Picture 3-O, it is mandatory
to keep the solenoid valve 14 excited for about 25 sec. before shutting off the compressor. It is suggested to keep the
valve 14 excited during the compressor standstill.
The starting and stopping procedure indicated in Picture 3-O has to be followed for all the screw compressors, both in
the step and in the stepless version, as this avoids noisy stopping due to the temporary reverse rotation with high mass
flow.



Warning!

On emergency stops, the compressor stays on the working step on which it was when the emergency
stop occurred. Therefore, for the stepless configuration, must be checked that the compressor is set
on the lowest step.



t ime
start stop
Starting
Avviamento
Shut down
Arresto
25 sec >3min 25 sec
Steady state
running
Funzionamento
continuo
Lowest
capacity
Capacit
minima
50-100%
Capacity
Capacit

Picture 3-O: start and stop procedure;

On the other side compressors of SRC-W series do not have the slide valve. Therefore the start up simple occurs by
exciting the solenoid valves 20 and 21 for a period of 25 seconds.
In addition to the above mentioned method, the start unloading can be achieved by means of a off cycle bypass (see
chapter WA-02: Oil management, paragraph 2.1) with low temperature operation in conjunction with a pressure
limiting valve or a crankcase pressure regulator.




Attention!

An external bypass start unloading from the high to low pressure (as is often used with reciprocating
compressors) is not permissible with screw compressors due to the danger of damaging it.


3.2.5. Part load application range

By working at part load, the discharge temperature increases (it is mandatory not to exceed 80C or 100C discharge
temperature, see chapter WA: Oil management, table C) and the efficiency is slightly lower than full load.
In particular the discharge temperature increases if:

the condensing temperature increases;
the evaporating temperature decreases;
the suction gas temperature increases (overheating).

For the part-load operation limits please consult RefComp.
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