Capacity Control System

Capacity control System is a logic

process controller for Refrigeration unit
which mainly maintains two things:
 Compressor (minimum) flow rate
 Compressor load (current motor)

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Capacity Control Block Diagram
 Suction pressure
(PIC XXX03) Capacity
 Starting Ramp Control
 Motor Current Logic
(CIC XXX01)
 Δ P Suction & discharge
Compressor
 PRV (pre-rotation van)
 Hot bypass valve

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 Min. PRV = a(Pk/Po)+b

Pk/Po 2.67 > 20.0 %

a= 23.0
Min. technical
b= -85.0 Position 20.0 %

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 OPENING PRV Bypass=Q0x100/(Min.PRV+K)

Bypass 13.2%
Open

Prerotary

Minimum technical position can be set between 20.0 %

20 % to 30 % Close
0% 100%
18 K= 5.0 %

Min. PRV = 20.0 %

Min. PRV = a(Pk/Po)+b

Pk/Po 2.67 < > 20.0 %

a= 23.0
Min. technical
b= -85.0 Position 20.0 %
>

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 Q0

Q0 = Final2:Output PIC XXX03

Example
Example
If P = 20,: Min. tch Position=20% and starting has
If P =perform
been 100, andinstarting has been
5 minutes perform
Wahat is Q0 ?in 0
minutes
R ....? R =Wahat is Q0 ?
(300(seconds)/20(seconds)x2%)+20%
R ....? R = (0(seconds)/20(seconds)x2%)+20%
30% + 20%
R = 0%
50%+ 20%
R = 20% Q0 = PxR/100
Q0 = PxR/100
Q0= 20*50/100 %
Q0= 100*20/100
1000/100 % %
Q0=
Q0=2000/100
10 % %
WhatQ0= 20opening
is PRV % ?
20%
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 Min. PRV = a(Pk/Po)+b

Pk/Po 2.67 > 20.0 %

a= 23.0
Min. technical
b= -85.0 Position 20.0 %

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Conclusion
• In Normal Operation, PIC XXX03 will control the PRV
Opening while Min. PRV < Output PIC XXX03 < Output
CIC XXX01,
• Min. PRV will limit the minimum opening of PRV,
• While the CIC –XXX01 will limit maximum PRV opening
for control the load.

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 Bypass = Q0x100/(Min.PRV+K)
Q0 = Final Output PIC XXX03
Bypass Example 2:
Example
13.2%
When : bypass fully close ( 100%
Hot
If P = 20, Min. tch Position=20% and starting has
Open If P =closing)
100, and ?starting has been perform in 0
been perform in 5 minutes Wahat is Q0 ?
minutes Wahat is Q0 ?
R ....? R = (300(seconds)/20(seconds)x2%)+20%
R ....? R = (0(seconds)/20(seconds)x2%)+20%
Bypass R== Q0x100/(Min.PRV+K)
30% + 20%
R
100 = 0% + 20%
R== Q0x100/(20+5)
50% Prerotary
R==
100 20%
Q0x100/25Q0 = PxR/100
Q0 = 100x25/100 Q0 = PxR/100
20.0Q0=
% 20*50/100
Q0= 100*20/100
%
%
When Q0 = 25% Q0= 1000/100 %
Q0= 2000/100 %
Close Q0= 10 %%
0% Q0=
100% 20
What is PRV opening ? 20%
What is Hot bypass closing?
KWhat is5.0
Hot%Bypass
= Bypass= closing?
Q0x100/(Min.PRV+K)
Bypass = 10X100/(20+5)
= 20X100/(20+5)
Min. PRV = 20.0 % ==2000/25
1000/25
= =4080%%close
close
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When the compressor has been started for 5
minutes, and we see the hot bypass
closing is 13,2 %.
What is P, Q0, PRV opening ?

Bypass = Q0x100/(Min.PRV+K)
13,2 = Q0x100/25 Bypass 13.2%
13,2 Open
= Q0x4
Q0 = 13,2/4
Q0 = 3,3
Q0 =PxR/100
Prerotary
R = (start time(sec.)/20x2)+20
= (300/20X2)+20 20.0 %
= 30+20
R Close
= 50
Q0 =PxR/1000% 100%
P = Q0X100/R K= 5.0 %
= 3,3X100/50
P = 6,6 Min. PRV = 20.0 %
Opening PRV = 20 %
R =(start time(sec.)/20x2)+Min. PRV
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 finish

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 Trouble shooting

• Vibration problem
• PDALL lube oil pressure
• Main Motor fault (over current)
• High discharge temperature
• Maintain efficient power
• PALL Suction Compressor
• Oil leaks at motor bearing
• Adjust seal gas

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