Basic Refrigeration Cycle

Principles of Refrigeration
Liquids absorb heat when changed from
liquid to gas
Gases give off heat when changed from
gas to liquid.
For an air conditioning system to operate with
economy, the refrigerant must be used
repeatedly. For this reason, all air conditioners
use the same cycle of compression, condensation,
expansion, and evaporation in a closed circuit.
The same refrigerant is used to move the heat
from one area, to cool this area, and to expel this
heat in another area.
The refrigerant comes into the
compressor as a low-pressure gas, it is
compressed and then moves out of the compressor as a high-pressure gas.
The gas then flows to the condenser. Here the gas condenses to a liquid, and gives off its heat to the outside air.
The liquid then moves to the expansion valve under high pressure. This valve restricts the flow of the fluid, and
lowers its pressure as it leaves the expansion valve.
The low-pressure liquid then moves to the evaporator, where heat from the inside air is absorbed and changes it
from a liquid to a gas.
As a hot low-pressure gas, the refrigerant moves to the compressor where the entire cycle is repeated.
Note that the four-part cycle is divided at the center into a high side and a low side This refers to the pressures of the
refrigerant in each side of the system
The purpose of the compressor is to circulate the refrigerant in the system under pressure, this concentrates the heat it
contains.
At the compressor, the low pressure gas is changed to high pressure gas.
This pressure buildup can only be accomplished by having a restriction in the high pressure side of the system.
This is a small valve located in the expansion valve.
The compressor has reed valves to control the entrance and exit of refrigerant gas during the pumping operation. These
must be firmly seated.
An improperly seated intake reed valve can result in gas leaking back into the low side during the compression
stroke, raising the low side pressure and impairing the cooling effect.
A badly seated discharge reed valve can allow condensing or head pressure to drop as it leaks past the valve,
lowering the efficiency of the compressor.
Two service valves are located near the compressor as an aid in servicing the system.
One services the high side, it is quickly identified by the smaller discharge hose routed to the condenser.
One is used for the low side, the low side comes from the evaporator, and is larger than the discharge hose
The compressor is normally belt-driven from the engine crankshaft. Most manufacturers use a magnetic-type clutch
which provides a means of stopping the pumping of the compressor when refrigeration is not desired.
Compressor Relief Valve
Some compressors have a relief valve for regulating pressure. If the system discharge pressure exceeds rated pressure,
the valve will open automatically and stay open until the pressure drops. The valve will then close automatically.
Compressor Noise Complaints
Many noise complaints can be traced to the compressor mount and drive.
If a unit is noisy at one speed and quiet at another, it is not compressor noise.
Many times this kind of noise can be eliminated or greatly reduced by changing the belt adjustment.
Usually tightening mounts, adding idlers, or changing belt adjustment and length are more successful in
removing or reducing this type of noise, than replacing the compressor.
Noises from the clutch are difficult to recognize because the clutch is so close to the compressor. A loose bolt
holding the clutch to the shaft will make a lot of noise.
The difference, between suction pressure and discharge pressure, also plays an important part on sound level.
o A compressor with low suction pressure will be more noisy than one with a higher pressure.
Consider whether the system is properly charged, whether the expansion valve is feeding properly to use the
evaporator efficiently, and whether enough air is being fed over the evaporator coil.
The purpose of the condenser is to receive the high-pressure gas from the compressor and convert this gas to a
liquid.
It does it by heat transfer, or the principle that heat will always move from a warmer to a cooler substance.
Air passing over the condenser coils carries off the heat and the gas condenses.
The condenser often looks like an engine radiator.
Condensers used on R-12 and R-134a systems are not interchangeable. Refrigerant-134a has a different molecular
structure and requires a large capacity condenser.
As the compressor subjects the gas to increased pressure, the heat intensity of the refrigerant is actually concentrated
into a smaller area, thus raising the temperature of the refrigerant higher than the ambient temperature of the air
passing over the condenser coils. Clogged condenser fins will result in poor condensing action and decreased efficiency.
A factor often overlooked is flooding of the condenser coils with refrigerant oil. Flooding results from adding too much
oil to the system. Oil flooding is indicated by poor condensing action, causing increased head pressure and high pressure
on the low side. This will always cause poor cooling from the evaporator.
Too-High Condensor Pressure
Indicated By: Excessive head pressure on high side gauge.
Caused By: Restriction of refrigerant flow in high side of system or lack of air flow over condenser coils.
Too-Low Condensor Pressure
Indicated By: Higher than normal pressure on low side gauge.
Caused By: Failed compressor reed valve or piston. Heat exchange in the condenser will be cut down, and the
excessive heat will remain in the low side of the system.
Evaporator
The evaporator works the opposite of the condenser, here refrigerant liquid is
converted to gas, absorbing heat from the air in the compartment.
When the liquid refrigerant reaches the evaporator its pressure has been reduced,
dissipating its heat content and making it much cooler than the fan air flowing
around it. This causes the refrigerant to absorb heat from the warm air and reach its
low boiling point rapidly. The refrigerant then vaporizes, absorbing the maximum amount of heat.
This heat is then carried by the refrigerant from the evaporator as a low-pressure gas through a hose or line to the low
side of the compressor, where the whole refrigeration cycle is repeated.
The evaporator removes heat from the area that is to be cooled. The desired temperature of cooling of the area will
determine if refrigeration or air conditioning is desired. For example, food preservation generally requires low
refrigeration temperatures, ranging from 40F (4C) to below 0F (-18C).
A higher temperature is required for human comfort. A larger area is cooled, which requires that large volumes of air be
passed through the evaporator coil for heat exchange. A blower becomes a necessary part of the evaporator in the air
conditioning system. The blower fans must not only draw heat-laden air into the evaporator, but must also force this air
over the evaporator fins and coils where it surrenders its heat to the refrigerant and then forces the cooled air out of the
evaporator into the space being cooled.
Fan Speeds
Fan speed is essential to the evaporation process in the system. Heat exchange, as we explained under condenser
operation, depends upon a temperature differential of the air and the refrigerant. The greater the differential, the
greater the amount of heat exchanged between the air and the refrigerant. A high heat load, as is generally encountered
when the system is turned on, will allow rapid heat transfer between the air and the cooler refrigerant.
A blower fan turned on to its highest speed will deliver the most air across the fins and coils for rapid evaporation.
For the coldest air temperature from the evaporator, operate the blower fan at the lowest speed so the heat will be
absorbed by the refrigerant from the air
Problems of Flooded or Starved Evaporator Coils
Changing the state of the refrigerant in the evaporator coils is as important as the air flow over the coils. Liquid
refrigerant supplied to the coils by the expansion valve expands to a vapor as it absorbs heat from the air. Some liquid
refrigerant must be supplied throughout the total length of the evaporator coils for full capacity.
A starved evaporator coil is a condition in which not enough refrigerant has been supplied through the total coil length.
Therefore, expansion of the refrigerant has not occurred through the whole coil length, resulting in poor coil operation
and too-low heat exchange.
A flooded evaporator is the opposite of the starved coil. Too much refrigerant is passed through the evaporator coils,
resulting in unexpanded liquid passing onto the suction line and into the compressor.
AIR HANDLER / BLOWER UNITS (AHU) (shown at left above and in theCarson Dunlop sketch below) which
typically includes the following
o Condensate system: water, or condensate is produced when we cool warm moist air by blowing it over
the evaporator coil. The condensate runs down the coil to a collecting pan which drains to piping used to
route condensate to an approved drain for disposal
o Condensate pump on some air conditioning systems a small pump is used to collect and then pump
condensate up to a building drain or other location for disposal. Condensate pumps are needed for
systems which cannot dispose of the condensate by simple gravity flow down a drain line.
o Condensate overflow pan or tray is a container placed below the air handler when that unit is located in
an attic or in other building locations where condensate leakage or overflow would otherwise spill onto
building floors or into a building ceiling. The condensate overflow pan is a safety device intended to
prevent unwanted spillage; normally it does not contain condensate. The condensate overflow pan
should have either an independent drain to an approved location or a float switch to shut down the air
conditioner should the pan become full.
o Blower fan (evaporator fan) in a blower compartment circulates building air into itself from the return
ducts and return plenum, and moves that air across the evaporator coil and onwards to the supply
plenum and supply ducts in the building. Blowers may be single speed, multiple speed, or variable
speed, and may need to move air at different rates if the blower is used for both heating and cooling in
the same duct system. Some air blowers are also rated for continuous operation.
o Electrical controls for an air conditioning system include shut-off switch(es) for service at the unit and
fuses or circuit breaker(s) at the electrical panel. The fuse or circuit breaker protects the air conditioner
circuit from overheating due to an overcurrent or other electrical failure.

EVAPORATOR COIL or COOLING COIL (also called the "cooling coil" is connected to high pressure and low pressure
(suction) refrigerant lines.

High pressure refrigerant liquid, released into the cooling coil by the thermal expansion valve changes state from a liquid
to a gas, causing a drop in temperature of the refrigerant and thus cooling the evaporator coil so that when we move air
across the coil the air will, in turn, be cooled.

Sketch courtesy of Carson Dunlop
Return Plenum, connected to return duct system, is the air receiving compartment which provides air to the
blower fan.
Supply plenum connected to supply duct system, is the air collecting compartment to which building supply
ducts are connected. Think of the return plenum and supply plenum as junction boxes to which return ducts or
supply ducts respectively can be connected.
Support system is the means by which an attic-mounted air handler is supported or held in place, for example
by being suspended from the roof rafters (a quiet installation) or perhaps by being placed on supporting wood
beams laid across ceiling joists.
Thermal expansion valve: an air conditioner thermal expansion valve is a device located at the cooling coil and
connected between the incoming refrigerant line and the refrigerant inlet to the cooling coil in the air handler.

The air conditioning system thermal expansion valve or "TEV" is a metering device which regulates the flow of
refrigerant from the incoming high pressure side (from the compressor/condenser) into the low pressure side (in
the cooling coil).
Air Filters located at the return duct air inlets, at one or more central return air inlets, or at the air handler unit
itself are used to remove dust and debris from building air.
Access ports to duct interior Commercial ducts and some residential duct systems may have inspection/cleaning
access ports; residential HVAC ducts may have plugs indicating that the ducts have been cleaned in the past.
Ductless air conditioning systems, which may also be
called "split A/C systems" may employ one or more wall
mounted cooling units such as shown at right above
Return air ducts and registers collect warm moist air
from the occupied space and return it to the air handler unit.
Some air conditioning installations do not provide return air
registers and ducts in every room and use one or more "central
air return inlets" instead.

Central air returns are most common on air conditioning retrofit
installations (adding A/C to an existing building). Sketch courtesy
of Carson Dunlop [Click to enlarge any image]
Supply air ducts and supply air registers deliver cooled
air to the occupied space.

Supply registers have the dual function of spreading out and directing the air flow into a location and permitting
the regulation of air flow by opening or closing the register. Some air conditioning duct systems use small-
diameter, "high velocity" ducts to deliver conditioned air to the living space.
Supply air balancing dampers, manual and motorized zone dampers may be installed inside the supply ducts at
varying locations in to permit balancing the air flow among different duct sections and thus among different
building areas.
Thermostat(s) are used to turn the air conditioning on and off and to set the desired indoor temperature. One
thermostat will be located in each different air conditioning zone and will control an individual air handler unit's
operation.
These components are discussed in detail and are illustrated by photographs and drawings throughout this website
using the links at the left of these pages.
List & Photos of Outdoor Air Conditioning & Heat Pump System Components
Above we show two ypical compressor/condenser units
outdoors. The main internal components of the
compressor/condenser unit are listed below:
Compressor motor - on residential units this is normally a
hermetically-sealed motor-compressor combined in a single unit
like the Carrier(TM) unit shown at above left. If a ductless split-
system is installed an outside compressor/condenser unit is still
required, typically containing the very same functions but
perhaps more compact, looking like the Sanyo(TM) unit shown at
above right. Sketch courtesy of Carson Dunlop Associates.

An air conditioning compressor is a specialized pump which
draws refrigerant gas back to the compressor/condenser unit
from the in-building air handler and evaporator coil. The
compressor compresses the returning low-pressure refrigerant
gas to a high pressure (and high temperature) form.

In a "split" air conditioning system, multiple indoor evaporator
coils and blower units may be served by a single outdoor
compressor unit such as the Sanyo unit shown at the top of this page. That unit was handling the compressor/condenser
function for two wall-mounted, ductless indoor cooling units, one of which is shown in the right hand photo at "List of
Indoor Components" above. Split systems like this do not make use of ductwork.
Condensing coil receives high pressure refrigerant gas from the compressor and cools this refrigerant gas back to a
liquid state.
Electrical controls: shut-off switch(es) for service at the unit are provided to permit maintenance and repair of the
equipment. Circuit breaker(s) at the electrical panel protect the circuit supplying power to the air conditioning system.
Fan an outdoor cooling fan in the compressor/condenser unit moves outdoor air across the condensing coil to cool it
and assist in condensing the high pressure, high temperature refrigerant gas back into a liquid. It is this process which
completes the transfer of heat through the refrigerant from indoor air to outdoor air as the compressor/condenser unit
compresses and then cools the refrigerant back to a liquid.
Refrigerant lines: these pipes, typically made of copper, include a low-pressure "suction line" which returns low
pressure refrigerant gas from the indoor evaporator coil (cooling coil) outlet to the outdoor compressor motor inlet.

The high pressure refrigerant line connects the compressor outlet to the outdoor condensing coil inlet (gas) and further
connects the condensing coil outlet to the indoor thermal expansion valve which meters high pressure refrigerant into
the "low-side" evaporator coil (cooling coil) in the air handler unit in the building.

Service valves or ports are usually present on the refrigeration lines near the compressor. These valves permit testing
the condition of the air conditioning system and permit removal, replacement, or additions to the refrigerant in the
system.

This photograph of a split system compressor/condenser outdoor unit shows four refrigerant lines and their sets of
service ports. The larger diameter copper pipes are the low pressure or suction lines and the smaller diameter pipes are
the high pressure lines returning refrigerant to the indoor cooling units.

The screw caps visible at the piping connectors where they enter the unit can be removed to provide access to special
connecting valves to which the service technician can connect her set of gauges to measure system operating pressures
on these lines.

Do not mess with these refrigerant service ports unless you're a trained A/C service technician. You may lose refrigerant
or contaminate the system, leading to improper system operation or a costly service call.
These components are discussed in detail and are illustrated by photographs and drawings throughout this website
using the links at the left of these pages.
The 7 Main Differences Between Pipes and Tubes
Tubes can come in different shapes like square, rectangular and cylindrical. Pipe is always cylindrical or round.
While rigid tubes are frequently used in structural applications, copper and brass tubes can be rather flexible.
Pipes are typically always rigid and resistant to bending.
When it comes to classification, pipes use schedule
and nominal diameter. For example, a pipe could have a
250mm nominal diameter and a schedule of 80. Tubes are
classified by their outside diameter measurement and
thickness. A copper tube, for instance, could be 10 mm with
a 2 mm thickness.
Pipes accommodate larger applications with sizes that
range from a half-inch to several feet. Tubes are generally
used in applications that require smaller diameters. While 10-inch pipes are common, its rare that you will come
across a 10-inch tube.
Tubes are often put to use in applications that require precise outside diameters, like with cooler tubes, heat
exchanger tubes and boiler tubes.
Pipes have a pressure rating and are schedule, which is why they are often used to carry fluids that must be
contained.
The thickness of tubes increases in standard increments such as 1 mm or 2 mm. Pipe thickness depends on the
schedule, so there is no fixed increment.
Joining pipes is more labor intensive as it requires welding, threading or flanges. Tubes can be joined quickly and
easily with flaring, brazing or couplings, but for this reason, they dont offer the same stability.