Chapter 1

Basic Refrigeration Systems

This chapter describes and illustrates basic refrigeration systems that may be classified in several
ways: by type of refrigerant control, type of motor control, compression system, absorption
systems and so on. Similar systems will be grouped together.
Each basic refrigeration system explanation:
1.
2.
3.
4.
5.

Names the system.

Shows a schematic diagram of the system.
Describes how the system works.
Names some common uses.
Names the motor controls used.

It is important that one become familiar with the fundamental operating principles of the
common systems described.
The illustrations are not intended to show the exact parts and uses of actual units. Instead, they
explain the fundamentals of construction and operation. Details and actual uses will be shown
and described later.

[1-1]

Fig. 1-1 : Compression system using automatic expansion valve refrigerant control.

Compression System Using Automatic Expansion Valve Refrigerant Control (AEV)

The operation of an automatic expansion valve refrigerant control (AEV) refrigerating
mechanism is shown in Fig. 1-1.
Compressor, motor and condenser (condensing unit) are in the base. Liquid refrigerant (see red)
flows from the liquid receiver through the liquid line, through the filter to the automatic
expansion valve.
The automatic expansion valve is designed so that no liquid refrigerant will flow through it
unless the pressure in the evaporator is reduced by the running of the compressor. As the
compressor runs and liquid refrigerant flows through the automatic expansion valve, it is sprayed

[1-2]

into the evaporator (see blue). Here, due to low pressure, it boils rapidly and absorbs heat. This
vaporized refrigerant moves back to the compressor through the suction line.
In the compressor, it is compressed to the high-side pressure as vapor. While flowing through the
condenser it is cooled, gives up the heat that it absorbed in the evaporator and returns to a liquid.
It then flows into the liquid receiver ready to repeat the cycle.
The motor control thermal element is clamped to the end of the evaporator at the beginning of
the suction line. After the evaporator is cooled to its proper temperature, the control bulb
pressure causes the motor control to turn off the current to the driving motor. The compressor is
stopped.
The operating characteristics of this system are quite satisfactory. The refrigerant oil is circulated
without trouble. The temperature control limits can also be kept quite close.
This type of refrigeration cycle is used widely in small commercial applications. Because the
pressures do not balance on the off cycle, the motor compressor must start under load.
If the needle or seat in the expansion valve is faulty and refrigerant leaks through the valve on
the off cycle, liquid refrigerant may flow into the suction line. When the compressor starts, this
will be indicated by frosting of the suction line. If the trouble is severe, it may result in liquid
refrigerant entering the compressor through the suction line. This may cause the compressor to
knock severely.

[1-3]

Fig 1-2 : Compression system using thermostatically controlled expansion valve

Compression System Using Thermostatically Controlled Expansion Valve (TEV)
A schematic diagram of a thermostatically controlled expansion valve (TEV) refrigeration cycle
is shown in Figure 1-2. The liquid refrigerant (see red) flows from the liquid receiver through the
liquid line to the filter-drier and to the thermostatic expansion valve.
The operation of the thermostatic expansion valve is controlled by both the temperature of the
TEV control bulb and the pressure in the evaporator. The temperature of the TEV control bulb
must be higher than the evaporator refrigerant temperature before the valve will open. The
amount of opening will be governed by the temperature of the evaporator. If the evaporator is
quite warm, the needle will open quite wide allowing a rapid flow of liquid into the evaporator.
In this way cooling is speeded up. As the temperature of the evaporator drops, the TEV needle
valve will cut down the flow of refrigerant.

[1-4]

Vaporized refrigerant from the evaporator moves back into the compressor where it is
compressed back to the high side pressure. As it flows through the condenser, it gives up the
heat absorbed in the evaporator. Now cooled, the refrigerant is condensed to a liquid and flows
back into the liquid receiver. The refrigerating cycle is repeated.
When the evaporator reaches the desired temperature, the motor control will turn off current to
the motor to stop the compressor. When this happens, the TEV needle valve will close, allowing
no more refrigerant to flow through it until the compressor again lowers the pressure in the
evaporator.
This system is used on large commercial refrigerators as well as on many air conditioning
applications.
Since pressures do not balance on the off cycle, it is necessary to provide a motor compressor
which will start under load.
The TEV control remains closed unless the evaporator is under reduced pressure and the
temperature is above normal. A leaking valve will usually be indicated by a frosted or sweating
suction line.

[1-5]

Fig 1-3 : Compression system using capillary tube type refrigerant control
Compression System Using Capillary Tube Refrigerant Control
The capillary tube system, fig 1-3, is one of the most popular of the compression type systems.
Liquid refrigerant flows from the condenser up through the liquid line to the filter (which may
also be a drier). From the filter, refrigerant flows through the capillary tube refrigerant control
into the evaporator. The pressure of the liquid refrigerant, as it enters the capillary tube at the
filter end, is at a high pressure. This is the high-pressure side. The pressure in the evaporator is
low.
[1-6]

The design of the capillary tube is that it maintains a pressure difference while the compressor is
operating. The compressor maintains a low pressure in the evaporator and the refrigerant boils,
rapidly absorbing heat. The vaporized refrigerant moves through the suction line back to the
compressor. Here it is compressed to a high pressure and discharged into the condenser. It is
cooled in the condenser and returns to a liquid and again flows into the liquid line.
This operation continues until the thermal element has been cooled to a preset low temperature.
When that temperature is reached, the thermal element operates the motor control mechanism
and turns off power to the motor. The refrigeration cycle stops. It will remain off until the
thermal element warms up and the thermal bulb pressure closes the motor control contacts to
again operate the compressor.
On the off cycle the capillary tube allows the pressure to balance between the high and low sides.
It is not usually necessary, then, to use a motor with a high starting torque.
This system is commonly used in household refrigerators, freezers, air conditioners,
dehumidifiers and many small commercial applications. This type of cycle is quite satisfactory
for most refrigerating applications.

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