LESSON

MAINTAIN COMPRESSOR UNLOADERS

LECTURE
SUB - OBJECTIVE
At the end of this lesson the trainee will be able to:
learns the need for compressor unloading. He identifies hydraulic, pressure and
solenoid-operated bypass and suction cutoff unloaders, and identifies correct
unloader operation. He adjusts pressure-operated unloaders. He troubleshoots
and repairs solenoid-operated unloaders.
1.0 INTRODUCTION
When an air conditioning system is designed, a compressor capacity is selected to
handle the peak (maximum) load. In most systems the cooling load is constantly
changing, so the typical operating load for a compressor might be only 50% of the peak
load. If a compressor designed to handle a peak load operates at full capacity when the
load is only 50%, it will compress more refrigerant vapor than can be used by the
evaporator. This causes suction pressure to fall. Low suction pressure can cause oil
migration, freeze the evaporator, and/or cause erratic operating conditions which cause
compressor failure.
2.0 MATCHING COMPRESSOR CAPACITY AND LOAD
One way to match compressor capacity and system load is to cycle a compressor on
and off. But this is not the best solution. It involves frequent compressor starts and high
power consumption. It also causes wear and tear on the compressor and its electrical
components.
Another way to adjust compressor capacity to load is to use several smaller
compressors in parallel instead of one large one. As the load rises and drops,
additional compressors are switched on or off to meet it. The disadvantages of this
approach are high initial cost, a greater use of floor space, and increased maintenance
3.0 CAPACITY CONTROL DEVICES
The most efficient and least costly way to match compressor capacity and load is to use
capacity control devices. A capacity control device regulates the amount of refrigerant
going through the compressor. It can either be built into the compressor (compressor
internal) or separate from it (compressor external).
All compressor-internal methods of capacity control decrease a compressor's capacity
while keeping the compressor running.

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3.1 COMPRESSOR UNLOADERS

The most common internal capacity control device is the unloader. An unloader reduces
a compressor's capacity by stopping the flow of refrigerant vapor through some of the
compressor's cylinders. The unloader does this by one of the following methods:
1. Blocking the flow of suction vapor at the cylinder head.
2. Preventing compressed vapor in the cylinder head from being discharged into the
high-pressure side of the system.
3. Preventing compression by keeping the suction valve open.
the first of these unloaders (the type that blocks suction gas from the cylinder) is the
suction cutoff unloader. The second (which prevents compressed vapor from entering
the discharge manifold) is the bypass Unloader. The third (which keeps the suction
valve open) is the hydraulic unloader.
3.2 UNLOADER STAGING
When a compressor's piston moves in its cylinder without compressing refrigerant
vapor or pushing it into the high-pressure side of the system, the cylinder is unloaded.
Cylinders in a compressor are loaded or unloaded one at a time or in groups,
depending on the type of compressor. In four and six cylinder compressors, cylinders
are unloaded in stages, usually in groups of two. Loading and unloading in groups is
called staging. For example, the stages of unloading a system using a six-cylinder
compressor are:
1. 100% capacity, with all six cylinders loaded.
2. 67% capacity, with four cylinders loaded and two unloaded.
3. 33% capacity, with two cylinders loaded and four unloaded.
For a four-cylinder compressor the stages are:
1. 100% capacity, with all four cylinders loaded.
2. 50% capacity, with two cylinders loaded and two unloaded.
Because the motor of a compressor depends on refrigerant vapor for cooling, a
compressor cannot be run completely unloaded. The maximum amount a compressor
can be unloaded and still maintain adequate motor cooling depends on the compressor
model.
3.3 UNLOADER TYPES
There are three main types of unloaders: (1) pressure-operated, (2) solenoid-operated,
and (3) hydraulic. See FIG. 1.1A on the next page. We will cover the pressure, and
solenoid-operated unloaders first.
The pressure-operated, and the solenoid-operated unloaders could unload using one
of the following methods:
1. Bypass
2 . Suction cutoff.
When the bypass method is used, refrigerant is recirculated between the discharge
and suction side of the unloaded cylinder bank. When the suction cutoff method is
used, suction gas is prevented from entering the unloaded cylinder bank. the bypass
and the suction cutoff unloaders differ in appearance and operation. They are easy to
tell apart. As shown in FIG. L.1B, the bypass unloader has depressed areas on each
side of the cylinder head, just beneath the capacity control valve. In ;ontrast, the

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suction cutoff's cylinder head is flat. It has a cover plate and four bolts directly opposite
its capacity control valve.

FIG. 1.1 UNLOADER TYPES

3.4 BASIC UNLOADER OPERATION

FIG. 1.2 shows the difference between the operation of a bypass and suction cutoff
unloader. In a bypass unloader (Figure A, FIG. 1.2) the discharge manifold is closed by
a check valve. The compressor's piston draws refrigerant vapor from the suction line
into the cylinder head and pushes it back into the suction line. The refrigerant vapor is
recirculated between the discharge and suction side of the unloaded cylinder. In a
suction cutoff unloader (Figure B, FIG. 1.2) the cylinder head is cut off from the suction
line by an unloader piston. Suction gas is prevented from entering the cylinder bank.
Because refrigerant gas is not drawn into the suction cutoff unloader's cylinder, its
piston moves up and down with little resistance. As a result, its compressor consumes
less power and runs more efficiently than a compressor with a bypass unloader. The
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operating temperature of a suction cutoff unloader is also reduced at part load, while
the bypass unloader's operating temperature remains the same.

FIG. 1.2 BASIC OPERATION OF BYPASS AND SUCTION CUTOFF UNLOADERS

3.5 FIVE BASIC PARTS OF UNLOADERS

Bypass and suction cutoff unloaders have five basic parts, as shown in FIG. 1.3. The
five basic parts are: (1) capacity control valve, (2) unloader cylinder head, (3) unloader
head gasket, (4) unloader valve plate, and (5) valve plate gasket' (common to both
unloaders). We will look at each of these five components in turn.

FIG. 1.3 basic parts

3.6 THE FIVE BASIC UNLOADER COMPONENTS

3.6.1 CAPACITY CONTROL VALVE

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An unloader's operation is controlled by a capacity control valve. The control valve

triggers the loading and unloading of all cylinders in a particular bank. On start-up the
controlled cylinders are unloaded to reduce starting torque.
A capacity control valve is either/or:
A. Pressure-operated (activated by a drop in suction pressure).
B. Solenoid-operated (activated by electrical signals from a pressurestat, thermostat, or
step controller). The pressure-operated and solenoid-operated capacity control valves
are used with either bypass or suction cutoff unloaders. Although the two valves look
different mounted on the unloader cylinder head, as shown in FIG. 1.4, they have
similar valve bodies.

SOLENOID-OPERATED
PRESSURE-OPERATED
FIG. 1.4 SOLENOID-OPERATED AND PRESSURE-OPERATED CAPACITY
CONTROL VALVES

The pressure-operated control valve has a diaphragm that operates the poppet valve
and piston inside the valve body. But the solenoid-operated valve is activated by an
electric signal. Therefore, it does not have the diaphragm or control set point
adjustment nut. We will look first at the pressure-operated capacity control valve.
3.6.1.1 Pressure-Operated Capacity Control Valve
FIG. 1.5 shows a pressure-operated capacity control valve. This valve is easy to
recognize by its diaphragm and control set point adjustment nut. It can be used with
both bypass and suction cutoff unloaders.

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BYPASS CAPACITY CONTROL VALVE SUCTION CUTOFF CAPACITY CONTROL

WITH PISTON)
VALVE
( (PISTON REMOVED)
FIG. 1.5 PRESSURE-OPERATED CAPACITY CONTROL VALVES

The valve has two parts: (1) the basic valve (comprised of the control set point
adjustment nut, diaphragm, and valve body), and (2) the bypass piston. The bypass
piston is only used with the bypass unloader. When the control valve is used with the
suction cutoff unloader, the bypass piston is removed and discarded. FIG. 1.6 shows a
cutaway view of a pressure-operated control valve with the bypass piston. The valve
consists of: (1) control set point adjustment nut, (2) control set point spring, (3)
diaphragm, (4) poppet valve centering spring, (5) poppet valve drive spring, (6) poppet
valve, (7) bleed orifice, (8) pressure differential adjustment screw, (9) bypass piston,
and (10) bypass piston drive spring.

FIG. 1.6 CUTAWAY VIEW OF PRESSURE-OPERATED CAPACITY CONTROL VALVE

3.6.1.2 Solenoid- Operated Capacity Control Valve

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The solenoid-operated control valve is also called an electric capacity control valve. As
shown in FIG. 1.7, it has a solenoid coil and wire leads. It operates with the unloader in
the same way as a pressure-operated valve, except it is electrically energized from an
external source (thermostat, pressurestat, or step controller). When the control valve is
energized, the compressor cylinder bank unloads.
The solenoid-operated valve is a simple on-off switch. The setting of the external
control device (which energizes the solenoid valve coil) determines the point of loading
and unloading.

FIG. 1.7 SOLENOID-OPERATED CAPACITY CONTROL VALVE

Left: Mounted in unloader head
Right: Removed, without solenoid

3.6.2 UNLOADER CYLINDER HEAD

Although both the bypass and suction cutoff unloaders use the same capacity control
valves, their cylinder heads and cylinder head gaskets are not the same. They cannot
be interchanged. The bypass cylinder head has depressions on each side of it, just
below the capacity control valve. The suction cutoff unloader head, on the other hand,
is flat with a cover plate opposite the capacity control valve. With the cover plate on the
suction cutoff cylinder head removed (FIG. 1.8) you see what makes it different from
the bypass unloader. The suction cutoff head contains: (1) piston assembly, (2) piston
arm, (3) unloader valve body, and (4) unloader valve spring.

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FIG. 1.8 SUCTION CUTOFF UNLOADER 'S INTERNAL PISTON ASSEMBLY

3.6.3 UNLOADER HEAD GASKET

As shown in FIG. 1.9, the unloader head gaskets are different. They are not
interchangeable.

FIG. 1.9 BYPASS AND SUCTION CUTOFF UNLOADER HEAD GASKETS

3.6.4 UNLOADER VALVE PLATE

FIG. 1.10 shows the difference between the bypass and suction cutoff valve plates.
Only the bypass plate has slot for the check valve which opens and closes the
discharge manifold to the compressor cylinder head.
The valve plates are not interchangeable.

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FIG. 1.10BYPASS AND SUCTION CUTOFF VALVE PLATES AND GASKET

3.6.5 VALVE PLATE GASKET

As shown in FIG. 1.10, the bypass and suction cutoff unloaders have the same valve
plate gasket. Now we will look at how each valve operates.
3.7 BASS UNLOADER OPERATION
FIG. 1.11 shows a cutaway view of a bypass unloader. The valve is unloaded, as it
would be at start-up. Study FIG. 1.11 carefully. Learn the names of each of its parts.
Then follow the description of how the valve operates by looking at the simplified
diagram below.

FIG. 1.11 CUTAWAY VIEW OF BYPASS UNLOADER

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3.8 LOADING THE BYPASS VALVE

1. In Part A of FIG. 1.12 the valve is unloaded. Suction pressure is low, so the control
valve's diaphragm (point 2) is pushed to the right by the control set point spring (point
1). The diaphragm has pushed the poppet valve to the right, opening the bypass
passage (point 3). This allows discharge gas to vent to the suction side of the cylinder
(point 4). Since there is no pressure buildup behind the bypass piston, its internal
spring has seated it to the left, against the control valve body (point 5). The seated
piston has opened another, larger path for compressed gas to vent to the suction side
of the cylinder (point 5) . The low pressure in the cylinder head has allowed the internal
spring within the check valve to push i. upwards, closing the discharge manifold (point
6).

FIG. 1.12 LOADING THE UNLOADED BYPASS VALVE

2. When the suction pressure rises to a point that is above the control set point spring
tension, the pressure against the diaphragm forces it to the left (point 1 in Part B of
FIG. 1.12) .
3. This movement of the diaphragm leaves a free space at the left of the poppet valve,
allowing the poppet valve drive spring to close (point 2, Part B) .
4. When the poppet valve closes, it prevents discharge gas from passing to the suction
side through the bypass passage (point 3, Part B) .
5. The discharge gas passing through the bleed orifice (point 4, Part B) builds up
pressure behind the bypass piston. When the discharge pressure becomes greater
than the force of the piston's internal spring the piston moves to the right point 5, Part B
6. The piston closes the port in the unloader head that allows discharge gas to vent to
the suction side of the cylinder (point 6, Part B).
7. Now that discharge gas cannot vent to the suction side of the cylinder, pressure
builds up in the high side of the head. This pressure overcomes the tension of the
spring inside the check valve, forcing the valve open (point 7, Part B).
8. Discharge gas can now enter the discharge manifold. The cylinder is loaded.

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3.8.1 UNLOADING THE BYPASS VALVE

The loaded bypass valve is shown in Part A of FIG. 1.13. Here is how the valve is
unloaded:
1. When the suction pressure drops below the set point of the control spring, the force
of the spring will be greater than the refrigerant vapor pressure exerted on the control
valve diaphragm (point 1 in Part B, of FIG. 1.13).
2. The diaphragm moves to the right, pushing the poppet valve off its seat point 2, Part
B).

FIG. 1.13 UNLOADING THE LOADED BYPASS VALVE

3. With the poppet valve open (point 3, Part B) discharge gas passes through the
bypass passage into the suction manifold (point 4, Part B).
4. Venting discharge gas reduces pressure behind the bypass piston. This allows the
piston's internal spring to force the piston to the left (point 6, Part B).
5. The seating of the bypass piston against the control valve's body opens the bypass
port. This provides a path for the refrigerant gas to vent to the suction side of the
cylinder (point 5, Part B).
6. A reduction in discharge pressure allows the check valve's internal spring to move
the check valve upward and seat it against the valve plate. This isolates the cylinder
from the discharge manifold (point 7, Part B). The cylinder is now unloaded. As long as
the compressor operates, the cylinders without Unloaders keep the discharge manifold
at discharge pressure. However, the discharge gas cannot move the unloaded
cylinder's Bypass piston to close the port. This is because the open poppet Valve
bleeds the discharge gas to the suction side.
3.8.1 SUCTION CUTOFF UNLOADER OPERATION
FIG. 1.14 is a cutaway view of a suction cutoff unloader. Like the bypass unloader, it is
comprised of a capacity control valve, Unloader head and gasket, and valve plate.
The differences between the two unloaders are: (1) the bypass piston has been
removed from the control valve, and (2) unloading is achieved by a larger assembly
made up of a piston, piston arm, unloader valve body, and unloader valve spring. The

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piston assembly is installed, removed, and serviced through the cover plate on the
opposite side of the unloader head from the capacity control valve.
This unloader entirely shuts off suction gas from the cylinder head when it is closed
(unloaded

FIG. 1.14 CUTAWAY OF SUCTION CUTOFF UNLOADER

3.8.2 LOADING THE SUCTION CUTOFF VALVE

1. The valve in Part A of FIG. 1.15 is unloaded. Suction pressure is low, so the control
valve's diaphragm is pushed to the right by the control set point spring (point 1, Part A).
The diaphragm has pushed the poppet valve to the right (point 2, Part A). This opens
the bypass passages allowing discharge gas to vent to the suction side of the cylinder.
Since there is no pressure buildup in front of the unloader piston (point 3, Part A), the
unloader valve spring (point 4, Part A) has pushed the piston to the left, cutting off the
suction manifold from the cylinder head (point 5, Part A).

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FIG. 1.15 LOADING THE UNLOADED SUCTION CUTOFF VALVE

2. When the suction pressure rises to a point above the control set point spring
tension, the pressure against the diaphragm forces it to the left (point 1 in Part B of
FIG. 1.15).
3. This movement of the diaphragm leaves a free space at the left of the poppet valve,
allowing the poppet valve drive spring to move left and close (point 2, Part B).
4. When the poppet valve closes, it blocks off the bypass port (point 3, Part B). This
prevents discharge gas (point 4, Part B) from passing into the suction manifold.
5. With the bypass port blocked, the discharge pressure builds up in back of the
unloader piston (point 5, Part B). This forces the piston and valve body to the right. This
opens the suction port (point 6, Part B), allowing the suction gas to pass into the
cylinder bank. The cylinder is loaded.
3.8.3 UNLOADING THE SUCTION CUTOFF VALVE
The suction cutoff valve in Part A of FIG. 1.16 is loaded. Here is how the valve is
unloaded:
1. When the suction pressure drops below the set point of the control spring (point 1 in
Part B of FIG. 1.16) , the force of the spring is greater than the refrigerant vapor
pressure exerted on the control valve diaphragm (point 2, Part B).
2. The diaphragm moves to the right, pushing the poppet valve off its seat (point 3, Part
B) .
3. With the poppet valve open, discharge gas passes through the bypass passage into
the suction manifold (point 4, Part B).
4. Venting discharge gas reduces the pressure behind the unloader piston head (point
5, Part B). This allows the spring to move the valve body to the closed position (point 6,
Part B).
5. With the valve body in the closed position, suction gas can no longer enter the
cylinder head (point 7, Part B). The cylinder is unloaded.

FIG. 1.16 UNLOADING THE LOADED SUCTION CUTOFF VALVE

3.8.4 ADJUSTING PRESSURE-OPERATED UNLOADERS

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A pressure-operated unloader is controlled by suction pressure and actuated by

discharge pressure. There are two adjustments to determine which pressure will load
and unload the cylinders. The two adjustments are: (1) control set point, and (2)
pressure differential. The location of these adjustment points is shown in FIG. 1.17.

FIG. 1.17 UNLOADER ADJUSTMENT POINTS

The control set point is the point at which the cylinder loads. It is adjustable from 0 to
86 psig. Selecting a control set point depend on refrigerant used in the system, and
ambient conditions. The pressure differential between cylinder loading and unloading is
adjustable from 7.4 to 18.6 psig for bypass unloaders, and 6.3 to 15.8 for suction cutoff
unloaders. Following is the procedure for setting and adjusting the control set point and
pressure differential.
3.9 ADJUSTING THE CONTROL SET POINT
To adjust the control set point of a pressure operated unloader, follow these steps:
1. Turn the control set point adjustment nut clockwise to its bottom stop. In this
position the set point is 86 psig.(See FIG. 1.18.)

FIG. 1.18 BACKSTOPPING THE CONTROL SET POINT

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FIG. 1.19 CONTROL SET POINT CHART

2. Refer to the Control Set point Chart in FIG. 1.19. Find the pressure set point you
want in the left-hand column. For example, we have selected a set point of 57 psig
(point 1 in the chart).
3. Draw a horizontal line from the desired pressure to the solidline curve in the graph.
The dotted lines on both sides of the solid line indicate the tolerance.
4. At the point of intersection (point 2 in the chart) draw a vertical line down to the
bottom coordinate of the graph.
5. The point at which the vertical line intersects the bottom coordinate (point 3 in the
chart) is the number of counterclockwise turns required for the adjusting nut to obtain
the desired set point. In this instance it is four turns.
6. Turn the control set point adjustment nut counterclockwise four full turns to set the
control valve at 57 psig. Each full turn decreases the set point by 7 psig. This Control
Set Point Chart can be used for setting both bypass and suction cutoff unloaders.
3.10 ADJUSTING THE DIFFERENTIAL SET POINT
Adjusting the differential set point is almost the same as setting the control set point.
But there are two major differences:
(1) a screwdriver is used to adjust the differential set point, and
(2) the differential set point is different for bypass unloaders and suction cutoff
unloaders. (That is to say, there is one chart to use for bypass unloaders and another
chart for suction cutoff unloaders.)

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FIG. 1.20 BACKSTOPPING THE PRESSURE DIFFERENTIAL SCREW

To adjust the differential to the pressure at which you want the cylinder to unload, follow
these steps. The steps refer to FIG. 1.20 and to the Bypass Differential Curve Chart in
FIG. 1.21.
1. Turn the sealing cap.
2. Turn the differential adjusting screw counterclockwise to its backstop position, as
shown in FIG. 1.20. In this position, the differential is 7.4 psig for bypass unloaders and
6.3 psig for suction cutoff unloaders.
3. Refer to the Differential Set point Chart in FIG. 1.21.
The differential range is not the same for bypass and suction cutoff unloaders. Be sure
to use the right chart. Here, we are using the chart for bypass unloaders.
4. Locate the desired differential setting on the left side of the curve. In this instance,
we have chosen a differential setting of 8 (point 1 in the graph) . This means the
bypass cylinder will unload at 49 psig. (Remember, the set point is 57 psig, so 57 - 8 =
49 psig.)
5. Draw a horizontal line from the 8 to intersect the solid curve in the graph, as shown
at point 2.
6. Draw a vertical line down to the bottom of the graph to intersect with the lower
coordinate (point 3 on the graph). The vertical line intersects the lower coordinate at 1.
7. This means you must then turn the differential adjustment screw clockwise one
complete turn to obtain a differential pressure of 8 psig. When you complete the
adjustment, replace the sealing cap on the differential adjusting screw. This reduces the
possibility of refrigerant leakage.

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FIG. 1.21 BYPASS PRESSURE DIFFERENTIAL CHART

3.11 CHECKING SET POINT AND DIFFERENTIAL ADJUSTMENTS

Once you have set the valve's control set point and differential, you must check them
for proper operation:
1. Place an artificial load on the system to raise the suction pressure above the control
set point.
2. Attach a compound pressure gauge to the suction port.
3. Attach an ammeter to the compressor. Once you have attached the compound
pressure gauge and ammeter to the compressor, slowly close the suction service valve
to lower the suction pressure. Continue closing the valve until the cylinder unloads.
When the compressor unloads, there is a change in the sound level and a drop in the
current draw.
3.12 TROUBLESHOOTING UNLOADER OPERATION
If the unloader is not operating according to the control set point and pressure
differential settings, there are several steps to take to find and fix the problem.
3.12.1 PRESSURE-OPERATED BYPASS
1. Check the control set point and pressure differential.
Re-adjust these if necessary. If the set point and differential cannot be adjusted, go to
Step 2.
2. Check the strainer in the bleed orifice, as shown in FIG. 1.22. If it is dirty, clean or
replace it.
3. Make sure the check valve, which prevents refrigerant from entering the
discharge manifold, is moving freely, as shown in FIG.1.23. If it is faulty, replace it.
4. If items in steps 2 and 3 are okay, the capacity control valve body is bad and should
be replaced.

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FIG. 1.22 STRAINER IN BLEED ORIFICE

FIG. 1.23 TESTING CHECK VALVE FOR FREE MOVEMENT

3.12.2 PRESSURE-OPERATED SUCTION CUTOFF

1. Perform steps 1 and 2 above.
2. Remove the cover plate and check to see if the unloader piston is moving freely. If it
is not, replace it.
3. If the piston assembly is moving freely and the set point and differential cannot be
adjusted, replace the control valve.
3.12.3 ELECTRIC-OPERATED BYPASS
1. Check the operation of the external control source which energizes the unloader
solenoid. Replace it if it is faulty.
2. Check the electric solenoid. This is done in one of two ways. With the solenoid
energized, hold a screwdriver to the top of the solenoid coil to check for magnetism, as
shown in FIG. 1.24. The second method is to place a clamp-on ammeter around the
electric lead to the solenoid and check for current, as shown in FIG. 1.25. If magnetism
or current is not detected, replace the solenoid.
3. Check the strainer in the bleed orifice.
4. Make sure the check valve is moving freely.
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5. If steps 1 through 4 are okay, replace the capacity control valve.

FIG. 1.24 CHECK SOLENOID FOR MAGNETISM CHECK SOLENOID FOR CURRENT

3.12.4 ELECTRIC-OPERATED SUCTION CUTOFF

1. Perform steps 1 and 2 for the electric-operated bypass valve.
2. Check the strainer in the bleed orifice.
3. Remove the cover plate and check the piston assembly for free movement.
4. If steps 1 through 3 are okay, replace the capacity control valve.
3.12.5 HYDRAULIC UNLOADER
The hydraulic unloader is activated by the crankcase pressure, but powered by the
compressor lubrication system. It controls capacity by holding the suction valve disc off
its seat. This ensures that no refrigerant gas is pumped when the cylinder is unloaded.
The major components of a hydraulic unloader system are:
1. Capacity control valve
2. Hydraulic relay
3. Unloader power element
4. Valve lifting mechanism.
View A of FIG. 1.26, shows the hydraulic unloader components simplified. View B
shows the details and location of components. Note that the surge chamber, shown in
view B, is used in large capacity compressors only. It dampens rapid changes in
crankcase pressure to reduce rapid cycling.
(FIG. 1.1A, shows the external view of the hydraulic unloader.)

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FIG. 1.26 HYDRAULIC UDILOADBR COKPODIENTS

3.12.6 HYDRAULIC UNLOADER OPERATION

At start-up, all controlled cylinders are unloaded. They remain unloaded until the oil
reaches the unloader mechanism. Hydraulic Unloader Operation from Start-up to
Loading(The following simplified FIG. make the explanation easier, but they do not
show the location of the actual components.)
1. See FIG. 1.27. When the evaporator load increases, the crankcase pressure against
the capacity control valve bellows at 1 also increases. If the pressure on the bellows is
high enough to overcome the range adjustment spring tension, the bellows expand and
move to the left. This allows the push pins at 2, and the control needle valve at 3 to
move to the left.

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FIG. 1.27 CONTROL OIL DRAIN OPEN

3. The increase in control oil pressure at the left side of the hydraulic relay piston, at 7,
causes it to move to the right.
2. See FIG. 1.28. As the needle valve moves towards the valve seat, the flow of control
oil to the crankcase through the oil drain, at 4, is reduced. This causes the control oil
pressure to increase as oil from the compressor oil pump circuit, at S, flows through the
orifice, at 6, to the hydraulic relay.

FIG. 1.28 CONTROL OIL DRAIN CLOSES

4. See FIG. 1.29. Moving the relay piston to the right allows the compressor oil pump,
at 8, to feed oil into the unloader power element, at 9. The pump oil pressure in the
unloader power element forces the piston upwards and pivots the lifting fork, at 10,
downwards. This causes the lifter pins, at 11, to drop, allowing the suction valve to seat
and load the cylinder.

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FIG. 1.29 SUCTION VALVE SEATED

3.12.7 Unloader Operation from Loaded to Unloaded

1. See FIG. 1.30. A drop in the evaporator load decreases the crankcase pressure.
Thus, the crankcase pressure against the bellows, at 1, also decreases.
2. This allows the range adjustment spring to move the push pins, at 2, to the right,
compressing the control valve spring, at 3.
3. The needle valve moves off its seat, at 4.
4. This allows the control oil to bleed from the hydraulic relay and the capacity control
valve through the oil drain, at 5, to the crankcase.

FIG. 1.30 DROP IN CRANKCASE PRESSURE

5. See FIG. 1.31. Allowing the control oil to drain from the capacity control valve
reduces the pressure on the hydraulic relay piston, at 6.
6. This allows the piston to move to the left and stop the flow of oil from the oil pump to
the cylinders power element, at 7.
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7. See FIG. 1.32. As the oil pump pressure to the power element drops, the unloader
piston, at 8, moves downward draining oil, at 9, to the crankcase.
8. The lifting fork, at 10, pivots upwards lifting the pins which cause the suction valve to
be raised off its seat. This is the unloaded condition. In this condition there is no
compression. The refrigerant is only moving back and forth between the cylinder and
the suction side of the compressor.

FIG. 1.13 NO FLOW TO POWER ELEMENT

FIG. 1.32 SUCTION VALVE OPEN (UNLOADED)

Look at the port above the adjusting stem in FIG. 1.33. This port is for a pneumatic
control connection, which resets the control point based on the operating conditions.
DO NOT plug this port if pneumatic control is not used.
2. Connect a gauge to the suction service valve and operate the compressor., The
suction pressure must be higher than the desired control point.

3.12.8 ADJUSTING THE HYDRAULIC UNLOADER

The only adjustment a hydraulic unloader requires is setting the control point of the
capacity control valve. The control point is the first step of unloading. This control point
is from 0 to 85 psig, with R-22 refrigerant.

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To adjust the control point:

1. Remove the cap from the external adjusting stem. When the compressor is shipped,
the capacity control adjusting stem is backseated. The compressor is fully loaded
under all conditions, except at start-up. Make sure the stem is backseated before
adjusting.
2.

FIG. 1.33 PNEUMATIC CONTROL PORT

3. Close the suction service valve slowly, to lower the suction pressure. Keep closing
the service valve until the suction pressure drops to the desired control point pressure.
4. Turn the external adjusting stem clockwise until the first step of unloading is reached.
This is indicated by a change in the compressor sound level, a drop in the control oil
pressure, and a drop in the compressor current draw. One full clockwise turn of the
adjusting stem raises the control point approximately 10 psig with R-22 refrigerant.
5. Replace the cap on the adjusting stem to minimize refrigerant leakage after setting
the control point. Reopen the suction service valve.
6. The remaining steps of unloading are fixed and determined by the hydraulic relay.
3.13 TROLIBLESHOOTINC HYDRAULIC UNLOADER FAULT
Compressor dose not load. This could be due to:
1. Capacity control valve stuck open.
2. Lifter pins stuck in the up position.
3. Oil pressure too low.
4. Plugged/closed pneumatic opening.
Compressor dose not unload. This could be due to:
1. Lifter pins stuck in the down position.
2. Stuck hydraulic relay valve.
Rapid unloader cycling could be caused by a partially plugged control oil strainer.
3.14 TROUBLESHOOT MECHANICAL FAULTS
This module covers mechanical component malfunctions in reciprocating chillers.
Some symptoms covered in this module could be due to electrical problems.

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3.15 COMPONENT MALFUNCTIONS AND THEIR SYMPTOMS

3.15.1 SEMI-HERMETIC RECIPROCATING COMPRESSORS
Cause of Malfunction
1. Stuck compressor

Symptom(s)
1.1 Electric system checks out okay,
but compressor does not start.

2. Defective valves

2.1 High suction pressure, low

discharge pressure
2.2 No change in system pressure
with unit running
2.3 Considerable noise in cylinder
head
2.4 Different head temperature in
multi - cylinder compressors
3.1 Noisy compressor. hold-down
bolts

3. Loose compressor
3.15.2 UNLOADERS
1. Stuck check valve
2. Stuck piston assembly (suction
cutoff-type)
3. Defective control valve body
(both types)
4. Defective control valve body
and/or check valve; and/or piston
assembly (solenoid-type)
5. Capacity control valve stuck
open or lifter pins stuck in the up
position or plugged/closed
pneumatic opening (hydraulic type).
6. Stuck unloader element
or
lifter pins stuck in the down position
(hyd type).
7. Partially plugged control
oil
strainer (hyd type).

1.1 No response to load changes

(bypass-type) or adjustment.
2.1 No response to load changes
or adjustment.
3.1 Compressor will remain loaded
or unloaded.
4.1 Electrical parts check out okay,
but compressor does not load after
starting.
5.1 Compressor does not load.

6.1 Compressor does not unload.

7.1 Rapid unloader cycling.

3.15.3 OIL
1. Too much oil in
2. Low oil level

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1.1 Pounding noise in the

crankcase crankcase.
2.1 Unit tripping on oil pressure
control.

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LESSON 3 PAGE 25

3. Cold oil and refrigerant

mixture in the crankcase
4. Wrong oil type for the unit
5. Contaminated oil

2.2 Knocking noise in

compressor.
3.1 Oil foaming in the crankcase.
4.1 Wax formation in the
expansion valve and tubing.
5.1 Corroded parts.

3.15.4 OIL SEPARATORS

1. Float valve stuck shut
2. Float valve stuck open

1.1 Compressor loses oil.

2.1 High suction pressure,
normal discharge pressure.

3.15.5 OIL PUMPS

1. Faulty oil pump or blocked
pump strainer

1.1 Unit tripping on oil

pressure control.

3.17 MAINTAIN COMPRESSOR UNLOADERS

3.17.1 SPECIAL PRECAUTIONS
Purge hose when connecting the gauge manifold.
3.17.2 TOOLS AND MATERIAL3
Compressor or AC unit with hydraulic unloader.
Compressor or AC unit with pressure-operated unloader and adjustment graphs.
Compressor or AC unit with solenoid-operated unloader.
Gauge manifold.
Multimeter/Clamp-on ammeter.
Standard set of AC hand tools.
3.18 EXERCISE A: ADJUST PRESSURE-OPERATED UNLOADER STEPS
1. Determine the type of pressure-operated unloader (bypass or suction cutoff).
2. Front seat the set point adjustment nut.
3. Calculate the number of turns for a set point of 55 psig, using the graph for the
control set point on FIG. 1-34.
4. Write the number of turns here . Ask the Trainer to check your answer.
5. Turn the set point adjustment nut counterclockwise the full number of turns approved
by the Trainer in step 4.
6. Remove sealing cap from the differential adjustment screw.
7. Backseat the differential adjustment screw.
8. Find the differential graph that pertains to the type of unloader you are working
9. Find the number of turns for a differential of 10 psig
(so the unit will unload at 55 -10 = 45 psig).
10. Write the number of turns here Ask the Trainer to
check your answer.
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11. Turn the differential adjustment screw clockwise the full number of turns approved
by the Trainer in step 10.
12. Screw on the sealing cap of the differential adjustment screw.
13. Connect the compound gauge to the suction line.
14. Connect the clamp-on ammeter to the compressor.
15. Increase the suction pressure above the control set point by placing an artificial
load on the unit, if needed.
16. Check your adjustment by closing the suction service valve, slowly, until the unit
unloads. Unloading is indicated by a change in sound level and a drop in current draw.
17. Note the suction pressure that caused the unit to unload, then compare it to the
required 45 psig.
18. Note the suction pressure that caused the unit to load, then compare it to the set
point of 55 psig.
19. Report your findings to the Trainer and ask for your next assignment.

TURNS OUT FROM BOTTOM STOP -- COUNTERCLOCKWISE CONTROL SET POINT

CURVE CHART FIG.1.34

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TURNS IN FROM BACKSTOP CLOCKWISE BYPASS PRESSURE DIFFERENTIAL CURVE

FIG. 1.35

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SUCTION CUTOFF PRESSURE DIFFERENTIAL CURVE

FIG. 1.36TURNS IN FROM BACKSTOP CLOCKWISE

EXERCISE B:
3.19 TROUBLESHOOT AND REPAIRA SOLENOID OPERATED UNLOADER STEPS
1. Check the operation of the external control source which energizes the unloader
solenoid. Replace if faulty.
2. Check the wiring for continuity between the control source and the solenoid. Replace
if defective.
3. Check the solenoid for proper operation. If there is power at its terminals but it does
not work, check the solenoid coil. Replace the coil if it is open or shorted.
4. Perform the following steps if all the electrical parts are' okay but the unloader still
does not work.
5. Remove the capacity control valve.
6. Check the strainer in the bleed orifice for blockage.
7. Make sure the check valve is moving freely (if you are working on a bypass-type
unloader).
8. Remove the cover plate from the unloader piston assembly (if you are working on a
suction cutoff-type unloader).

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9. Replace the piston assembly if it is not moving freely.

10. Replace the capacity control valve if steps 6, 7, or 9 were okay.
11. Test the operation of the unloader you have serviced.
12. Ask the Trainer for your next assignment.
3.20 PROCEDURE TO ADJUST HYDRAULIC UNLOADER
This procedure can only be performed on an operating system. You are required to
remember the steps sequence for on-job application. Steps 1, 2, 9, and 10 can be
simulated on the given open compressor.
3.20.1 STEPS
1. Remove cap from adjusting stem.
2. Backseat the adjusting stem.
3. Connect a gauge manifold to the suction service valve.
4. Connect a clamp-on ammeter to the compressor.
5. Start the compressor.
6. Determine a control point (at which the compressor should start to unload).
7. Increase the suction pressure if it is below the specified control point. You may
switch off the condenser fan to increase the suction pressure.
8. Lower the suction pressure to the specified control point by gradually closing the
suction service valve.
9. Turn the adjusting stem clockwise until the first step of unloading. This is indicated
by a change in sound and a drop in current draw.
10. Screw the cap of the adjusting stem and reopen the suction service valve.

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