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This is the first Article in our new Course HVAC-2: Electrical Rules and Calculations for Air-Conditioning Systems, which will list, explain, and discuss with
examples all the topics covering the Electrical Rules and Calculations for Air-Conditioning Systems which will include but not limited to the following points:
Introduction for Air-Conditioning Systems types,
Introduction for Types of Motors/compressors used for Air-Conditioning Systems,
Electrical Wiring for different Air-Conditioning Systems types,
Types and locations of Disconnecting means,
Sizing of Disconnecting means, Follow Us on

Types of motor-compressor controllers,

Sizing of motor-compressor controllers ratings,
Sizing feeder/branch circuit overcurrent protective devices (OCPDs), Related Posts Plugin for WordPress, Blogger...

Sizing feeder/branch circuit conductors, 

Sizing motor-compressor overload protection.

First: Introduction for Air-Conditioning Systems Types

1- Air-Conditioning Systems Types

As we explained before in our course HVAC-1: An introduction to heating,

ventilation and air conditioning (HVAC) systems that the HVAC system can be
divided to (2) main systems:

1. Heating systems,
2. Cooling systems.

Here, we are interested in the cooling systems or what we will called “ Air
Conditioning systems” in this course, which in turn divided to (4) sub-main systems:

De-centralized systems (individual room systems),

Semi-centralized systems (packaged systems),
Centralized systems (central Hydronic systems),
Special systems.

1.1 De-Centralized Systems (Individual Room Systems)

These systems include:

1. Window air conditioning units,

2. Split air conditioning units,
3. Mini-heat pumps.

Window air conditioning units

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Split air conditioning units

Mini-heat pumps

For more information about Decentralized Systems (Individual Room Systems), please review
Article " Air Conditioning System Configurations – Part One ".

1.2 Semi-Centralized Systems (Packaged Systems)

These systems include:

A- Unitary packaged systems (one pipe systems) which can be divided to:

1. Packaged air conditioners with water cooled condensers,

2. Packaged air conditioners with air cooled condensers.

Packaged air conditioners with water cooled condensers -1

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Packaged air conditioners with water cooled condensers -2

Roof Top Packaged air conditioners with air cooled condensers

B- Ducted split systems (two pipes systems)

Ducted split systems

For more information about Semi-centralized systems (packaged systems), please review Article "
Air Conditioning System Configurations – Part Two ".

Also, the units used in packaged systems can be divided to:

1. Rooftop packaged units,

2. Indoor packaged units,
3. Split units,

A- Roof Top Packaged Units:

Roof top packaged units (RPU) are an all in one air cooled A/C unit that are installed
on top of the roof and can provide cooling and heating. The condensing unit and the
air handler reside inside a single housing. In order to connect the unit to the inside
duct work, an opening on the roof for supply and return air is necessary. The duct work
distributes the air evenly through-out the space. Heating can be provided by reversing
the condensing unit (heat pump) or connecting an electric heater, gas heater, or steam
coil.

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Roof Top Packaged Units

B- Indoor Packaged Units:

Indoor package units (IPU) are similar to rooftop units, but because the unit is located
inside, it requires a different way of cooling the condensing unit. The most common
way, is air-cooled using louvered openings (horizontal angled slats that prevent outside
weather to come inside, but allow air flow) to get fresh outside air. In situations where
there is no access to fresh outside air, water cooled units are the best solution. Indoor
units come in vertical, or space saving horizontal configurations. These units are the
same as roof top units in the way they connect to duct work and have the same
heating options as mention in the roof top packaged units.

Indoor Packaged Units

C- Split Packaged Systems:

Split systems are comprised of a condensing unit (a condensing coil and a compressor) located
outside, and an air handler (pushes air across the evaporator coil) located inside. Refrigerant lines
for high and low pressure are run from the condensing unit to the air handler. Since the high
pressure lines get cold, they are covered with insulation to prevent condensation issues and
having water accumulate inside the space. The air handler comes in different configurations to
best fit the desired installation. Split Systems can be divided to:

1. Ducted (Connected to duct work),

2. Ductless (wall mounted, ceiling suspended, ceiling cassettes, and floor standing).

You may also have multiple air handlers connected to one condensing unit in computer controlled
split systems. 

Ducted Split Packaged Systems

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Ductless Split Packaged Systems

1.3 Centralized Systems (Central Hydronic Systems)

These systems include:

1. Centralized duct “All air” systems,

2. Centralized fluid based hydronic systems “all water systems”,
3. Combined (hybrid) water and air systems.

Centralized duct “All air” systems Concept

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Centralized “all water systems” Concept

Combined (hybrid) water and air systems Concept

For more information about Centralized systems (central Hydronic systems), please review the
following Articles:

Air Conditioning System Configurations – Part Two.

Air Conditioning System Configurations – Part Three.

1.4 Special Systems

These systems include:

1. Evaporative cooling systems,

2. Central air washer (central evaporative air) cooling systems.

Evaporative cooling systems

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Fixed Evaporative cooler

Central air washer (central evaporative air) cooling systems

For more information about Special systems, please review Article " Air Conditioning System
Configurations – Part Three ".

Second: Introduction for Types of Motors/Compressors used in Air-Conditioning

Systems

2- Types of Motors/Compressors used in Air-Conditioning Systems

The types of Motors/compressors used for Air-Conditioning systems can be divided

to:

A- Positive-Displacement Compressors:

They physically compress the vaporized refrigerant into a smaller volume and higher
pressure, and include reciprocating, rotary, and scroll types. These deliver a
constant volume of gas under a constant speed. They can be divided to:

1. Reciprocating compressors,
2. Screw Compressor,
3. Scroll Compressors.

B- Dynamic Compressors:

They increase vaporized refrigerant pressure by the kinetic energy imparted on

refrigerant by a rotating impeller. A centrifugal compressor is a dynamic compressor
and is not a constant displacement type. This type includes:

1. Centrifugal Compressors.

2.1 Reciprocating Compressors

Reciprocating compressors are driven by a motor and use pistons, cylinders and valves to
compress the refrigerant. Reciprocating compressors are usually used in smaller systems up to
100 tons.

These compressors are available in (2) configurations namely:

1. Hermetic Refrigerant Motor-Compressor (welded Hermetic),

2. Non- Hermetic Refrigerant Motor-Compressor, which can be divided to (2) sub-

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configurations:

Semi-hermetic Refrigerant Motor-Compressor (Bolted Hermetic),

Open type (Direct driven) Motor-Compressor.

Reciprocating Compressors Types

2.1.A Hermetic Refrigerant Motor-Compressor (welded Hermetic)

Hermetic Refrigerant Motor-Compressor

Construction:

A combination consisting of a compressor and the driving motor, both of which are
enclosed in the same welded steel casing (housing) and the two are connected by a
common shaft with no external shaft or shaft seals. This makes the whole compressor
and the motor a single compact and portable unit. But since the components
(compressor and motor) are not accessible for repair, the entire compressor unit must
be replaced if it fails.

Usage:

It is widely used for the refrigeration and air conditioning applications like the
household refrigerators, deep freezers, window air conditioners, split air conditioners,
most of the packaged air conditioners.

Window air conditioners with Hermetic Refrigerant Motor-Compressor

Capacity:

It is used with motor power requirements from 1/20 (for small refrigerator

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compressors) to to several hundred HP (for centrifugal chillers). With cooling capacity

for one single unit about 10 ton but if more cooling capacity is needed, several
hermetic motor-compressor can be installed in the same air conditioning unit.
The smaller motors up to about 3 HP are usually of single phase design, while larger
motors are invariably three phase.

Advantages of the hermetic motor-compressors are:

They are smaller, more compact and have less vibration than the open compressor,
They have no external shaft; this eliminates mechanical problems with shafts, belts,
and sheaves and concern of refrigerant leakage,
In a hermetic unit the motor is located within the refrigerant atmosphere. So, the
motor is continuously cooled by the refrigerant vapor flowing to the compressor
section valves,
Lubrication is also simplified since both the motor and the compressor operate in the
same closed space with the oil.
The shaft is shorter and more rigid, the bearing arrangement is simplified, the machine
is quieter.

The disadvantages of hermetic motor-compressors are:

They are limited on capacity,

They are limited on speed because the compressor has to run at the motor speed
(direct drive),
If the control of the related air conditioning system is poorly designed or ineptly
operated, or if the compressor is allowed to start too frequently, there is a greater risk
of motor burn-out than with open machines,
They are not a field serviceable. Therefore, if a motor burns out in a hermitic
compressor, or any other internal problem occurs, the maintenance trend is for a
complete replacement of the unit. Otherwise, the entire unit must be returned to the
shop or factory to be dismantled and reconditioned.

2.1.B Semi- Hermetic Refrigerant Motor-Compressor (bolted Hermetic)

Semi- Hermetic Refrigerant Motor-Compressor

Construction:

Semi-hermetic Motor-Compressor is similar to the hermetic type but have a removable

cover bolted on to the end of the casing to facilitate occasional maintenance. The
motor is also part of the unit, however it is not sealed. So, Semi-hermetic compressor
is almost completely accessible.

Capacity and Usage:

Welded, hermetic machines are used for the smaller duties, up to about 70 kW of
refrigeration and bolted, semi-hermetics are used for larger loads. Packaged, water
chilling units having multiple, semi-hermetic compressors are used with capacities up
to about 700 kW of refrigeration.

Advantage of Semi-Hermetic compressors over hermetic compressors:

Semi-Hermetic compressors can be taken apart to do maintenance work or re-built a

number of times if necessary giving a much longer service life.
Semi- Hermetic Refrigerant compressors are direct drive and hermetic sealing.

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2.1.C Open Type (Direct Driven) Motor-Compressor

Open Type (Direct Driven) Motor-Compressor

Construction:

Open type of Motor-Compressor in which the compressor and the motor are different
entities and the compressor is driven by external power source, such as an electric
motor, an engine or a turbine through a direct coupling or a vee-belt. Power shaft
protrudes through the compressor housing and seal is required to prevent refrigerant
from leaking out of the compressor housing. Motor is cooled in a conventional manner
by air that is drawn in from the surrounding.

Usage and Capacity:

Open Type (direct driven) Motor-Compressors use as an older technology (The motor
and compressor are separated by a flexible coupling), so they are not commonly used
today.
The capacities for Open type of Motor-Compressors vary from a fractional ton to 400
ton in a single machine.

Comparison between Open and Semi-hermetic / Hermetic Systems

Open Semi-hermetic / Hermetic

Open systems have motor separately
connected to compressor. Not connected
with refrigerant and oil charge in the system.
Compressor being open design, can be
inspected / opened by just closing the
isolation valves. No botheration of removal /
loss of refrigerant gas.
Since these can be attended to at site, down
time is very minimal.
Since motors are outside the refrigerant
environment, wide choice of makes and type
possible.
Motor windings are cooled by ambient air.
Open machines are costlier compared to
hermetic.
Open motors do not require any refrigeration
effect and thus do not reduce the capacity of
the system
Any problem in motor affects refrigerant
charge and oil charge.
Motor and compressor are in the same
casing. Maintenance at site in case of
hermetic is impossible and very difficult for
semihermetic machines. Some of the
internationally well known brands
recommend opening of semi-hermetic also
only at the factory / service centre and not
at site.
If the compressor has to be taken to factory,
long unavoidable delays will result and
disrupt complete cooling.
Hermetic compressors are not a field
serviceable.
Semi-Hermetic compressors can be taken
apart to do maintenance work or re-built a
number of times if necessary giving a much
longer service life.
Motor windings are in the refrigerant vapour
surroundings.
Hermetic machines were basically introduced
to reduce manufacturer's first cost. Motor is
smaller and cheaper as it is cooled by the
refrigerant. Copper and iron content are
about half that of an open design.
Hermetic motors consume cooling energy
produced by the refrigerant. These vapours
are to be compressed by the same
compressor; Hence, effectively some cooling
capacity is lost in motor cooling itself.

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Open system is about 10% more efficient
considering loss in cooling motor and penalty
in power for compressing vapour.
Open motors are more efficient as they are
cooled / ventilated by ambient air.
Power fluctuations are not highly detrimental
to open motors.
Insurance premia charged for open systems is
much less as the damages are not
catastrophic and not for long.
Overall maintenance is very fast, quick and
without any problem on refrigerant side.
The refrigerant NH3 is very cheap
(economical).
Oil being heavier than refrigerant, can be
drained easily even during running.
Net effectiveness of cooling capacity and
power consumption is about 10% poorer due
to hermetic / semi-hermetic design.
Hermetic motors are less efficient as they
are cooled by refrigerant and are loaded
beyond peak efficiency point. These motors
are rotating in a much denser refrigerant
atmosphere and have higher windage loss.
Power fluctuations and electrical transients
can produce a flash in the refrigerant
atmosphere, which can break down into
carbon, fluorine, chlorine etc. and will be
carried into the system. When combined with
moisture, hydrochloric and hydrofluoric acids
are formed which can cause large – scale
contamination.
Hermetics will take very long before they are
put back into operation, hence the insurance
companies charge much higher premium as
the refrigerant and oil invariably need to be
replaced.
Heavy maintenance in case of burnouts such
as cleaning, flushing, vacuumising, pressure
testing and recharging fresh refrigerant and
oil.
HFC refrigerants are very costly and cannot
return to soil if leaked. ODP and/or GWP
problems are plenty.
Oil is partially miscible and oil recovery and
maintaining the oil level is a big problem.

2.2 Scroll Compressors

Scroll compressors features two involutes scrolls, one stationary and one orbiting
around the first. This movement draws gas into the outer pocket and the gas is forced
toward the center of the scroll, creating increasingly higher gas pressures. The upper
limit of the refrigeration capacity of currently manufactured scroll compressors is 60
tons.

2.3 Screw Compressors

Screw compressors are based on a mechanism made up of two threaded

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rotors (screws) that are coupled together. The gas is compressed due to
the progressive overlapping of the lobes, causing a reduction in the
volume occupied by the gas. Continuous and step-less capacity control is
provided by moving a sliding valve toward the discharge port, which
opens a shortcut re-circulating passage to the suction port.
The refrigeration capacity of twin-screw compressors is 50 to 1500 tons
but is normally used in the 200 tons to 800 tons range.

2.4 Centrifugal Compressors

Centrifugal compressors are made up of a rotor located inside a special

chamber. The rotor is rotated at high speed, imparting high kinetic
energy to the gas, which is forced through the narrow outlet opening,
thus increasing its pressure. The characteristics of a centrifugal
compressor make it ideal for air conditioning applications because it is
suitable for variable loads, has few moving parts, and is economical to
operate.
The available refrigeration capacity for centrifugal compressors ranges
from 100 to 2,000 tons.

Important Notes

1- Compressor Capacities:

The size of refrigeration compressors is given in either of the following:

Motor input horse power (HP),

Motor input kilowatts (kW input),
Refrigeration cooling capacity (kW cooling),
British Thermal Units per hour (Btu/h) or
Tons of refrigeration (TR): A refrigeration ton is equal to heat extraction
rate of 12,000 BTU's/hr; therefore a 3 TR chiller can remove 36,000
BTU's/hr.

2- Usage Of Reciprocating Compressors

hermetic Motor-Compressors is widely used for the refrigeration and air

conditioning applications like the household refrigerators, deep freezers,
window air conditioners, split air conditioners, most of the packaged air
conditioners.
Semi-hermetic Motor-Compressors are used with Packaged, water
chilling units having multiple, semi-hermetic compressors with capacities
up to about 700 kW of refrigeration.
Open Type (direct driven) Motor-Compressors use as an older
technology (The motor and compressor are separated by a flexible
coupling), so they are not commonly used today.

In the next Article, I will explain Electrical Wiring for different Air-Conditioning Systems Types. So, please keep following.

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