The document summarizes a presentation given at the 8th International Conference on Compressors in Smolenice, Slovakia from September 2-4, 2013. The presentation discusses the new generation of semi-hermetic piston compressors, including their operating envelope for various refrigerants, digital modulation capabilities, advantages over conventional modulation methods, advanced diagnostics and protection features, communication capabilities, and sound emissions reductions from the addition of sound shells.

1. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
The new generation of semi-
hermetic piston compressors
Presented by:
Gábor Böszörményi, Ph. D.

2. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Contents
• Capacity range, envelope
• Valve plate design
• Digital modulation
• Digital vs. conventional concepts
• Advanced diagnostics and protection
• Communication capabilities
• Sound emissions

3. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Capacity range
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MediumTemperatureLowTemperature
R404A LT Cooling Capacity @ -35/40/20/0
R404A MT Cooling Capacity @ -10/45/20/0
Discus D4D
Stream 4M & Digital 4M
Discus D6D
Stream 6M & Digital 6M
Discus D4D
Stream 4M
Discus D6D
Stream 6M

4. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Operating envelope w. R404A
 Dedicated To Refrigeration MT/LT
 No Need For Head Fan In Low Temp
 Advantage Of 5°C low condensing
Limit For Higher Energy Efficiency
 Ideal For Higher Evaporating Temp
 Ideal For Inverter Applications
 Advantage Of 10°C Low Condensing
Small Motor Version Large Motor Version

5. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Operating envelope w. R134a
Stream 4M & 6M
 Small Motor & Large Motor Envelopes
‒ 10 °C Condensing Temperature Limit
‒ Large Motor For Higher Evap/Condensing Limits
Small Motor Version Large Motor Version

6. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Operating envelope w. R407F
 Limited evap. temperatures as
compared to R404A because of the
limiting discharge temperature
 On the other hand, the envelope is
extended to higher condensing
temperatures vs. R404A
 Identical condensing temperature limit
as compared to R404A
 At lowest evaporating temperatures,
20 K suction SH required or demand
cooling necessary
Small Motor Version Large Motor Version

7. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Operating envelope w. CO2 TC
• Standard Envelope Across The Range
• Some restriction When Using Inverters
30
40
50
60
70
80
90
100
110
120
130
-25 -20 -15 -10 -5 0 5 10
DischargePressure(bara)
Evaporating Temperature ( C)
Operating Envelope R744
30
40
50
60
70
80
90
100
110
120
130
-25 -20 -15 -10 -5 0 5 10
DischargePressure(bara)
Evaporating Temperature ( C)
Standard Envelope Disch. Temp Inverter 50 Hz
Disch. Temp Inverter 30 & 70Hz MOC Limit @ 60Hz
MOC Limit @ 70Hz
Operating Envelope R744
With Inverter
Max.
Operating
bar
Design
bar
Burst
bar
4MTL-12X 12 9,5 18,9 1,7 170 26,5
4MTL-15X 15 12,5 24,9 1,8 170 34,8
4MTL-30X 30 17,9 36,5 1,8 175 50,0
Evaporating -10 °C, Gas Coller Exit: 35 °C / 90 bar, Suction Superheat 10 K, Subcooling 0 K
420 / 287 368 x 256
AWM/D
(PWS)
Pressure (high/low side)
Net
Weight
Kg
Footprint
mm
Motor
MOC
A
COP
120 / 90 135 / 90
Model
Motor
Size
(hp)
Displ.
m³/h
Cooling
Capacity
kW

8. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Valve plate design
• Smaller Valve -> Higher Pressure Drop
• Bigger Valve -> Smaller Expansion Vol.
• Necessary to Find a “Compromise”
– Differs by operating conditions
– Depends On Refrigerant
The discharge valves of a compressor generate two types of losses:
 Pressure drop through the valve: at equal opening and closing timing, the valve that
opens the most generates the least pressure losses
 Re-expansion volume of compressed gas in the compression chamber – the larger the
re-expansion volume, the larger the losses
 Larger valve -> lower pressure drop
 Valve Is integrated in valve plate - there is
no re-expansion volume whatever the
refrigerant or the operating condition
 Increasing the valve size does not lead to a
compromise with re-expansion volume

9. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Digital modulation
Principle
Loaded Operation
1. Gas Enters the Compressor
2. Passes through Body
3. Into Valve Plate
4. Compressed by Pistons
5. Exits Compressor
Unloaded Operation
1. Gas Enters the Compressor
2. Passes through Body
3. Unloader Mechanism Blocks Gas
before entering Valve Plate
1
2
3
4
5
1
2
Loaded operation Unloaded operation

10. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
• Digital Is Applicable On New 4-6-cyl. SH
compressors
• Simple Technology
– Can Be Retrofitted (Cylinder Heads)
– Constant Speed, Safe Oil Return
– No Mechanical Stress and Vibrations
– Easy To Design Into the System
TimeTemperature
Tightens Temperature Control
Digital Driver
Time (sec)
10 10 10 101010
0 20 40 60
50 % Nominal
Capacity
System Needs 50 %
Nominal Capacity
Delivers 50 % Nominal
Capacity By Controlling
Cylinder Head Solenoid Valve
Energy
Saving
Modulation Range
• 4MD Stream Digital 50-100 %
of nominal capacity
• 6MD Stream Digital 33-100 %
of nominal capacity
0-10 V
Output
Cycle
Reduction
Longer
Life Time
T & P
Control
Digital modulation
Principle

11. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Digital vs. conventional methods
Test description
Test stand for assessing different modulation concepts and
their combinations (On/Off, Blocked suction, Digital) under
quasi-supermarket conditions
The principle of capacity modulation by
means of two semi-hermetic Stream
compressors

12. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Digital vs. conventional methods
Incremental Load Increase
Result: It was not possible to keep the suction pressure in the desired range with On/Off cycling.
The only method that proved to ensure smooth control was always a combination with Digital.
Water mass flow rate
Cooling capacity
Ambient temperature

13. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Digital vs. conventional methods
Constant Load Test
Result: Similarly to the incremental load test, the constant load test proved that the modulation
method based on Digital ensures the smoothest suction pressure control. The average suction
pressure differed significantly by control method used.

14. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Digital vs. conventional methods
Efficiency rating
Modulation concepts’ efficiency very difficult to rate because of
large suction pressure fluctuation primarily with On/Off method

15. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Advanced diagnostics & protection
Sensor Module inside T-Box
- Reads and processes phase voltages, current values
by using voltage sensing leads and current sensor
module
- Supplies information to CoreSense Control Module
- Sensor Module provides following features
- Locked Rotor Protection
- Low Voltage Protection
- Single Phasing Protection
- Voltage Imbalance Protection
- Crankcase Heater Control
- Power Consumption Monitoring
- Power Factor ValueCoreSense Control Module
- Motor Overheat Protection
- Oil Pressure Protection
- Discharge Temperature Protection
- Communication to Pack Controller via Modbus
- Sensor Module Communication
- Compressor Run Status (Proofing)
- EEPROM Memory
- Alarm History, Compressor Operating History
- Local and Remote Reset capability
- Multi-color LEDs to indicate alarms
Current Sensor in T-Box
- Reads current values and sends an input for the
Sensor Module values as an input for Sensor
1
3
2
1
2
3
Discharge Temp. Sensor(NTC)
Oil Pressure Sensor
(differential) Motor Temperature Sensor (PTC)

16. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Advanced diagnostics & protection
Burned motor due to overheating Crankshaft failure due to oil
loss
Worn-out piston rings
Spot burn
Valve plate failure
Crankshaft failure due to
locked rotor

17. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Communication capabilities
B) Connect to Pack
Controller
C) Connect To Computer
1. Modify User Adjustable Features
2. Review/Download Compressor
History
3. Use As Data Logger
A) External LED On
CoreSense
1. Modify User Adjustable Features
2. Review/Download Compressor
History
3. Use As Data Logger
1. Multi-color LEDs indicate type of
failure
2. Enables quick troubleshooting

18. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Communication capabilities
Multi-color LEDs display
the different alarm codes
Alert
Trip with Auto reset
Lockout with Manual reset

19. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Sound emissions

20. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Sound emissions
Operating envelope
Limited compressor
envelope only in case
of SGRT > 0 °C,
otherwise the
envelope remains
identical.
w/o Sound Shell
with Sound Shell
Small Motor Version Large Motor Version

21. COMPRESSORS 2013
8th International Conference, September 2 – 4, 2013
Častá Papiernička, Smolenice Slovakia
Thanks for your kind attention!