BASIC REFRIGERATOR SYSTEMS

LEARNING SIMULATION
 Basic Refrigerator Systems Learning Simulation

CONTENT

1. Fundamentals of refrigeration ............................................................................................... 2

How a Mechanical Refrigerator Operates ........................................................................................... 2
2. Basic Refrigeration System ................................................................................................... 2
Ice Refrigeration ................................................................................................................................. 2
Evaporative Refrigeration ................................................................................................................... 3
Compression System........................................................................................................................... 4
Using Capillary Tube Refrigerant Control...................................................................................... 4
3. Refrigeration Process ............................................................................................................ 6
Refrigeration Cycle ............................................................................................................................. 7
4. Domestic Refrigerator and Freezer ....................................................................................... 8
Preserving Foods by Refrigeration and Freezing................................................................................ 8
Refrigerator and Freezer Insulation .................................................................................................... 9
Refrigerator-Freezer ............................................................................................................................ 9
Manual Defrost ............................................................................................................................... 9
Automatic Defrost ......................................................................................................................... 11

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FUNDAMENTALS OF REFRIGERATION

How a Mechanical Refrigerator Operates

There are four basic parts in a mechanical refrigeration system. The Compressor pumps refrigerant
vapor, the Condenser releases heat from the refrigerant, similar to a vehicle's radiator in releasing
heat from the cooling system. The Refrigerant Control releases liquid refrigerant when it is needed.
Finally, the Evaporator is the area that absorbs heat.

Removing heat from inside a refrigerator is somewhat like removing water from a leaking canoe. A
sponge may be used to soak up the water in the canoe. The sponge is held over the side, squeezed, and
the water is released overboard. The operation may be repeat as often as necessary. This transfers the
water from the canoe into the lake.

In a refrigerator, heat instead of water is transferred. Inside the refrigerating mechanism, heat is
absorbed. It is "soaked up" by evaporating the liquid refrigerant in the evaporator (cooling unit). This
occurs as the refrigerant changes from a liquid to a vapor (gas). The refrigerant, which has absorbed
heat, has now turned into a vapor. It is pumped into the condensing unit located outside the
refrigerated space. The condenser works the opposite of the evaporator. In the evaporator, the
refrigerant enters as a liquid, absorbs heat, and flows out the other end as a vapor. By the time it
reaches the end of the evaporator, it is all a vapor. Now this vapor flows into the condenser under a
high pressure and high temperature. The vapor gives up its heat to the surrounding air. As it reaches
the end of the condenser, the refrigerant is now cooled. It has become a liquid again. We say that, in
the condenser, the heat is "squeezed out." This cycle repeats until the desired temperature is reached.

Heat enters a refrigerator in many ways. It leaks through the insulated walls or enters when the door is
opened. Still more heat is introduced when warm substances are placed in the refrigerator. Heat is not
destroyed to make the refrigerator cold. It is simply removed from the refrigerated space and released
outside.

BASIC REFRIGERATION SYSTEM

Ice Refrigeration
For years, ice (frozen water) was the only refrigerating means available. It is still used in many
refrigerating applications. The typical ice refrigerator, Figure 1 is an insulated cabinet equipped with
a tray or tank at the top for holding blocks or pieces of ice (aqua). Shelves for food are located below
the ice compartment. Cold air (green striped arrows) flows downward from the ice compartment. It
cools the food on the shelves below. The air becomes warmer and rises from the bottom of the cabinet
(red striped arrows). It travels up the sides and back off the cabinet. Flowing over the ice, it cools and
again flows down over the shelves.

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Figure 1. Basic design and operation of an ice refrigerator

Ice refrigeration has the advantage of maintaining the interior of the cabinet at a fairly high humidity
(moisture level). Food stored in this type of refrigerator does not dry out rapidly.
Until the development of the mechanical refrigerator, natural ice refrigeration was quite widely used.
Since then, artificial ice has been manufactured for refrigeration. Temperatures inside an ice
refrigerator are controlled by air flow. The air flows over the ice and through the cabinet.
Temperatures usually range between 40°F and 50°F (4.4°C and 10°C).
When it is necessary to use ice for cooling temperatures below 32°F (0°C), ice and salt mixtures may
be used. Temperatures down to 0°F (-18°C) may be obtained with ice and salt mixtures.

Evaporative Refrigeration
When a fluid evaporates, heat is absorbed. Evaporation of water is an example. This is why human
and animals perspire. Evaporation of moisture from the skin surface helps to keep a person cool.
Another example of the evaporative principle is the desert bag used to keep drinking water cool. This
bag made of a tightly woven fabric, is filled with drinking water. Since the bag is not waterproof,
some water seep through. Thus, the outside surface of the bag remains moist. Desert conditions are
usually both hot and dry. Moisture on the surface of the bag evaporates rapidly. Much of heat which
cause this evaporation come from the bag and its water. This heat removal cools the drinking water
inside the canvas. The water temperature is now several degrees below the temperature of the
surrounding air.
Another common application of water evaporation refrigeration is the method of making artificial
snow for ski slopes. A snow machine, Figure 2, consists of a water nozzle into which a high-pressure
jet of air is inserted. Water flows from the nozzle. The air under high pressure causes the water to
break up into tiny droplets. The droplets are similar to a fog. The surrounding air temperature must be

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near freezing or below freezing for snow to form. The droplets of water will tend to evaporate and
rapidly cool. At this point, tiny drops of ice are formed.

Figure 2. A water/ compressed air nozzle is used for making artificial snow.
Using this method, artificial snow can be made when the temperature of the surrounding air
temperature is 32°F (0°C) or lower. In low humidity, artificial snow can be made when the
temperature is as high as 34°F (1°C). This is possible because of the rapid evaporation and
evaporative cooling caused by the low humidity.
Another example of evaporative cooling is an evaporative condenser. Evaporative condensers are
often used in connection with air conditioners.

Compression System

Using Capillary Tube Refrigerant Control

The capillary tube system, shown in Figure 3 is one of the most popular compression-type systems.
This system is commonly used in household refrigerators, freezers, air conditioners, dehumidifiers
and small commercial applications.
Liquid refrigerant flows from the condenser up through the liquid line. Then it flows through the filter
(which may also be a drier). From the filter, refrigerant flows through the capillary tube refrigerant
control into the evaporator. The liquid refrigerant, entering 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.
The capillary tube is designed so that it maintains a pressure difference while the compressor is
operating. The compressor maintains a low pressure in the evaporator. 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. The vaporized refrigerant
is cooled in the condenser and returns to a liquid. Again, it flows into the liquid line.

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EVAPORATOR

Filter
Capillary Drier
Tube

Thermal
Element
Accumulator

CABINET

Power
Line

Temperature
Motor Control

Insulation

Suction
Line
Motor
Wires
CONDENSER

Discharge
Line

: HIGH PRESSURE GAS

: HIGH PRESSURE LIQUID
: LOW PRESSURE LIQUID
COMPRESSOR Liquid Receiver
: LOW PRESSURE GAS

Figure 3 Compression system using capillary tube refrigerant control.

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. It turns off
power to the motor. The refrigeration cycle stops. It will remain stopped until the thermal element
warms up. The thermal bulb pressure will close the motor control contacts to again operate the
compressor. This type of cycle is quite satisfactory for most refrigerant applications.
In the off cycle, the capillary tube allows the pressures to balance between the high and low sides. It is
not usually necessary, then to use a motor with a high starting torque.

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REFRIGERATION PROCESS

Refrigeration is defined as the process of extracting heat from a lower-temperature heat source,
substance or cooling medium and transferring it to a higher-temperature heat sink. Refrigeration
maintains the temperature of heat source below of its surroundings while transferring the extracted
heat, and any required energy input, to a heat sink, atmospheric air, or surface water. A refrigeration
system is a combination of component and equipment which is connected in a sequential order to
produce the refrigeration effect.

The refrigeration systems which are commonly used for air conditioning can be classified by the type
of input energy and the refrigeration process as follows:

• Vapor compression systems. In vapor compression systems, compressors activate the

refrigerant by compressing it to a higher pressure and higher temperature level after it has
produced its refrigeration effect. The compressed refrigerant transfers its heat to the sink and
condensed to the liquid form. This liquid refrigerant then throttled to a low-pressure, low
temperature vapor to produce refrigerating effect during evaporation. Vapor compression
systems are the most widely adopted refrigeration systems in both comfort and process air
conditioning.
• Absorption systems. In an absorption system, the refrigeration effect is produced by thermal
energy input. After absorbing the heat from cooling medium during evaporation, the vapor
refrigerant is absorbed by an absorbent medium. Then, this solution is heated by direct-fired
furnace, waste heat, hot water, or steam. The refrigerant is again vaporized and then
condensed into liquid to begin the refrigeration cycle.
• Air or gas expansion systems. In an air or gas expansion system, air or gas is compressed to a
high pressure by mechanical energy. Then it is cooled and expanded to a low pressure.
Because of the temperature of air or gas drops during expansion, a refrigeration effect is
produced.
Refrigeration processes indicate the change of thermodynamic properties of refrigerant and energy
transfer between refrigerant and the surroundings. The following refrigeration processes occur during
the operation of vapor compression refrigerating system:

• Evaporation. In this process, the refrigerant evaporates at lower temperature then heat of its
surroundings, absorbing its latent heat of vaporization.
• Superheating. Saturated refrigerant vapor is usually superheated to ensure that liquid
refrigerant does not flow into the compressor.
• Compression. Refrigerant is compressed to a higher pressure and temperature for
condensation.
• Condensation. Gaseous refrigerant is condensed to the liquid form by being de-superheated,
then condensed, and finally sub cooled, transferring its latent heat of condensation to a
coolant.
• Throttling and expansion. The higher-pressure liquid refrigerant is throttled to the lower
evaporation pressure and is ready for evaporation.

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Refrigeration Cycle
A schematic vapor compression system is shown in Figure 4A. It consists of a compressor, a
condenser, an expansion device for throttling and an evaporator. The compressor-delivery head,
discharge line, condenser and liquid line form the high-pressure side of system. The expansion line,
evaporator, suction line and compressor-suction head form the low-pressure side of system.

Most refrigerants undergo a series of evaporation, compression, condensation, throttling and

expansion process, absorbing heat from a lower-temperature reservoir and releasing it to a higher-
temperature reservoir in such a way that the final state is equal in all respects to the initial state. It is
said to have undergone a closed refrigeration cycle. When air or gas undergoes a series of
compression, heat release, throttling, expansion, and heat absorption processes, and its final state is
not equal to its initial state, it is said to have undergone an open refrigeration cycle. Figure 4B shows
the refrigeration cycle on a pressure-enthalpy (p-h) diagram.

Figure 3.6. Vapor Compression System Schematic and Refrigeration Cycle on Pressure-Enthalpy
Diagram.

The pressure-enthalpy diagram is the most common graphical tool for analysis and calculation of the
heat and work transfer and performance of a refrigeration cycle. A single-stage refrigeration cycle
consists of two regions: the high-pressure region (high side) and the low-pressure (low side). The
change in pressure can be clearly illustrated on the p-h diagram. Both heat and work transfer of
various processes also can be calculated as the change of enthalpy and easily shown on the p-h
diagram.

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50.00
40.00
30.00
Sub cooled liquid Superheated vapor
20.00
region

n
region

ctio
Pressure p (Bar)

ure line
fra
10.00 e
lin

ss
iu d

ne

r line

at
dr y
liq

Constant temper
5.00

t
ed

tan

vapo
rat

s
tu

Con

rated
3.00
Sa

2.00 Two-phase region

Satu
1.00
tv olume line
Constan
0.50
0 20 40 60 80 100 140 180 220 260 300 340
Enthalpy (kJ/kg)

Figure 5 Skeleton of Pressure-Enthalpy Diagram.

DOMESTIC REFRIGERATOR AND FREEZER

A modern domestic refrigerator or freezer consists primarily of three parts:

• The cabinet.
• The refrigeration mechanical components.
• The electrical circuit.
The cabinet contains and supports the evaporator and condensing unit. It also supplies shelving and
storage space for the foods or beverages.
The refrigeration mechanical components consist of the condensing unit and the evaporator. In the
evaporator, the liquid refrigerant expands and becomes a vapor. This vapor absorbs heat from the
foods or beverages in the cabinet. The condensing unit removes the heat absorbed in the evaporator.
The liquid refrigerant then returns to the evaporator to repeat the refrigerating cycle.
The electrical circuit includes all circuits, relays, over current protection and other devices which
direct the flow of current throughout the refrigerator and freezer. The circuit extends from the
grounded extension cord and plug to the final load either inside or outside of the cabinet.

Preserving Foods by Refrigeration and Freezing

Foods (vegetables and fruits) last longer when kept at temperatures just above freezing. These
temperatures slow down oxidation of the food. This reduces the multiplication of the bacteria in the
cells and fibers. It also reduces the evaporation (loss of fluid) from the food.

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Refrigerator and Freezer Insulation

Insulation lines the walls of the refrigerator and the freezer cabinet. Insulation prevents heat from
leaking through the walls and into the cabinet. The most common insulation materials used in
household refrigerators and freezers are urethane foam or fiberglass. Other insulating materials are
used in some commercial and industrial systems.

Refrigerator-Freezer

Manual Defrost
All refrigerator evaporates will build-up a frost layer from moisture in the cabinet. This frost layer
must be removed to permit the evaporator to properly remove heat from the cabinet. Early
refrigerators did not include electrical components for automatically defrosting the evaporator. When
a significant amount of frost builds up on the evaporator of this type of system, the unit must be
turned off. On full-size units, placing a pot of warm water on the evaporator may reduce the
defrosting time. When all frost is removed, normal operation of the unit can begin.
A refrigerator-freezer, Figure 6, consists essentially of two refrigerated spaces. It has a freezer
compartment across the top of the cabinet for frozen foods. The temperature in this compartment is
kept at approximately 0°F (-18°C). A refrigerator compartment is located below the freezer
compartment for fresh foods. The refrigerator compartment maintains a temperature about 35°F to
45°F (2°C to 7°C).

Figure 6. Double-door refrigeration-freezer with freezer at the top. Note the evaporator in the upper
part of the refrigerator compartment.
Each of these compartments has a separate door. The condensing unit is usually in the bottom of the
cabinet. The condenser is either in the bottom or at the back. Refrigerator-freezers provide shelves in

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both compartments. A butter conditioner is usually located in the door of the refrigerator
compartment. Doors of both compartments are often fitted with narrow shelves for storage of small
containers.
• Cabinets
Cabinet construction for refrigerator-freezers is similar to that of simple refrigerators. However,
thicker insulation of the cabinet is required. This added insulation maintains the lower temperatures
necessary in the freezer compartment. A separate freezer door is provided to maintain low
temperatures when the refrigeration door is opened.
The motor control, temperature control, light switch, shelf support and crisper are the same as those
on the fresh food refrigerator. The finish is usually a good grade of lacquer. Some cabinets have
porcelain finished interiors.

• Refrigeration Mechanical Components

Refrigerators with a freezer compartment have a hermetic compressor in the base of the cabinet. The
condenser is either at the bottom or the back of the cabinet. The liquid refrigerant flows from the
capillary tube into the evaporator in the freezing compartment.
Typical manual defrost system components are illustrated in Figure 7. The refrigerant charge is
usually sufficient to keep the freezer evaporator, A, filled. Enough is needed for spillover from the
freezer evaporator, B. This evaporator is usually located at the side of the refrigerator compartment. It
has a rather large accumulator. Any possible spillover from this enters a third evaporator, C. The third
evaporator is usually located at the side of the refrigerator compartment. The third evaporator is also
fitted with an accumulator. This assures that all refrigerant is evaporated before vapor is allowed to
enter the suction line.

Figure 7 Cycle diagram for a manual defrost refrigerator-freezer

From this accumulator, vaporized refrigerant is drawn back to the suction line into the compressor.
The vapor is compressed and pumped first into a small condensing coil, D. From here the high-
pressure vapor is pumped through a loop in the base of the compressor. This serves as an oil cooler.

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From here the compressed vapor flows into condenser, E, at the bottom or at the back of the
refrigerator.
At this point, the heat of the vapor is radiated to the surrounding air. Then The refrigerant is
condensed back to a liquid. The liquid flows from the bottom of the condenser through the filter-drier.
Then It flows into the capillary tube attached to the suction line. The capillary tube controls the
refrigerant flow into the freezer evaporator, A. Then The cycle is repeated.

Automatic Defrost
All air contains some moisture. Air can come in contact with an evaporator surface, which is below
the freezing temperature. Moisture will condense and form ice on the evaporator. Frequently, it is
necessary to defrost the evaporator in order to maintain good refrigerating efficiency. This applies to
the evaporator for both the refrigerator and the freezer compartments.
The owner usually considers it a chore to manually defrost the refrigerator. As a result, most
refrigerators provide a system for automatic defrosting. There are two basic systems used in automatic
defrosting. The hot gas system accomplishes this through the use of solenoid valves. Heat from vapor
in the compressor discharge line and condenser is used for evaporator defrosting. The other system
uses electric heaters to melt the ice on the evaporator surface. A section in this chapter will be devoted
to each of these systems.

a. Electric Heater Automatic Defrost

Figure 3.13 illustrates a typical refrigerator with a freezer compartment. This refrigerator uses an
automatic defrost. As in most domestic refrigerators, the condensing unit is mounted in the cabinet
base. Some refrigerators have the condensing unit located at the back of the cabinet. Shelving is
provided in both the refrigerator compartment and the freezer compartment.

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Figure 3.13. Automatic defrost refrigerator-freezer. Evaporator in freezer compartment serves as fast-
freezing shelf. Automatic ice cube maker is located in freezer compartment. Refrigerator
compartment provides butter conditioner, fresh meat storage and vegetable crisper.
Some refrigerators operate on what is called “frost-free” or “no-frost” cycle. In these refrigerators, the
evaporator is located outside the refrigerated compartment. During the running part of the cycle, air is
drawn over this evaporator. It is forced into the freezer and refrigerator compartment by a motor-
driven fan. During the Off part of the cycle, these evaporators automatically defrost.
Such refrigerators may use a single evaporator for both the freezer and the refrigerator compartments.
However, a separate evaporator may be used in each compartment for some models. Evaporator
condensation, which melts during the Off cycle, is carried to an evaporating pan. It may be carried to
a collecting surface directly over the compressor and condenser. The heat from the compressor
evaporates this moisture, allowing it to return to the room’s atmosphere. There is never any visible
frost accumulation in this type of frost control.
• Cabinets
Cabinet construction for automatic defrosting refrigerator-freezers is different than manual defrost
models. The condensation, which collects on the evaporator, must be melted from time to time.
Different methods are used for disposing of this condensation. The cabinet must have tubing to
conduct this moisture to the top of the motor compressor. Usually, it is collected on a plate or surface
just over the motor compressor. This surface or plate heated by the motor compressor and by heat
from the condenser. The moisture then evaporates and goes back into the room.

Figure 8 Air Circulation in refrigerator-freezer. Evaporator fan forces circulation of cooled air
through various compartment. Dampers control air duct openings and thus control cabinet
temperatures.

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Some refrigerators use electric defrost. Provisions must be made in the cabinet for housing electric
heaters and their controls. Figure 8 shows a refrigerator-freezer it provides other temperatures besides
that of the freezer and the refrigerator compartments. The air circulation provides lower temperatures
to areas reached first. It provides higher temperatures to those areas reached last.
The evaporator is beneath the fast-freezing shelf at the bottom of the freezing compartment. All of the
refrigerating effect comes from this evaporator. The air circulation system, consist of a fan, ducts and
a damper. These are located at the back of the cabinet. It provides the necessary airflow to give the
temperature desired in each compartment. The condensing unit is located in the bottom of the cabinet.
• Refrigeration Mechanical Components
Some mechanical components provide more than two temperatures in the refrigerator with a freezer
compartment. A typical system is shown in Figure 9
The evaporator is located at the back of the shelf. It separates the freezer compartment from the
refrigerator compartment. The refrigerant used is R-12 or R-134a. Refrigerant evaporation in the
evaporator provides the heat absorption (cooling) required in the cabinet. Usually, a motor-driven fan
forces air over the evaporator surface. Air is forced through the various ducts. This provides all the
necessary refrigerator temperatures for the compartments.
The suction line from the evaporator extends down the wall of the cabinet. It extends to the inlet side
of the hermetic motor compressor in the cabinet base. The condenser is a wire-and-tube type. Forced
air circulation is provided by a motor and fan. They are located at the back of the compartment
containing the compressor and the condenser.
The refrigerant is condensed in the condenser. It flows through a high-side filter-drier into a capillary
tube. The capillary tube is attached to a section of the suction line. This provides a heat exchange
between the capillary tube ad the suction line. The refrigerant from the capillary tube then flows into
the evaporator. The cooling cycle is completed.

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Figure 10 Automatic electric defrost refrigerator-freezer that provides multiple temperatures in the
refrigerator compartment. Correct operation may be checked by determining temperatures at test
points, T1, T2 and T3. Recommended operating temperatures are: T1= -15°F to -13°F (-26°C to -
25°C), T2= -15°F to -14°F (-26°C), T3= 80°F to 103°F (27°C to 39°C). Temperature T3 is high
because the capillary tube is in contact with suction line to transfer excess condenser heat to the
suction. This increases the superheat at the compressor inlet.

Only the refrigerator compartment has a light. It is operated by a switch, which is activated by the
door movement. The butter conditioner temperature is slightly above the cabinet temperature. There
are control dampers for the refrigerator and the freezer compartments. These dampers regulate flow of
cold air from the evaporator.
Several heating devices are used as driers. An electrical resistance heater is located at the top of the
cabinet, inside the outer case. This keeps the outside of the cabinet warm so that it will not collect
condensation during damp days.
A second drier wire is placed inside the center mullion to keep its surface dry. A third heating device
is around the freezer flange (freezer door opening). A fourth heater is placed in the drip pan. It
evaporates the condensation which flows into the drip pan after automatic defrost.
A “power-saver” switch is located inside the cabinet. It provides a means of disconnecting these
heaters when temperature and humidity conditions allow it. Normally, the heaters are in continuous
operation.
The evaporator is automatically defrosted by an electric resistance heater. This occurs every six hours
of compressor running time. The heater is located in the fin area on the underside of the evaporator. A
timer activates the switch, which turns on the defroster. A thermostat attached to the evaporator opens
the defrost heater circuit. This ends defrosting when the evaporator temperature reaches 50°F (10°C).
(Temperature may be ± 6°F [3°C]). After 28 minutes from the start of the defrost cycle, the timer
restores the compressor operation. It also restores the air-circulating fan operation. The defrost
terminator contacts close at 20°F (-7°C), ± 8°F (4°C). The temperatures of the cabinet are regulated
by the temperature control. This control is mounted in the rear wall of the freezer compartment. The
temperature of the evaporator tubing near the end of a running cycle may vary. It may vary from -
13°F to -25°F (-24°C to -32°C). The difference between the evaporator inlet and outlet temperature
will not vary more than about 3°F (2°C).

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