2.

Fixed Orifice Tube Cycling Clutch System Theory Support

Fixed Orifice Tube Cycling Clutch

System (FOTCC)
Automotive – Heating & Air Conditioning

Topics covered in this presentation:

 Basic FOTCC System Components
 Basic FOTCC System Operation

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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Introduction
Automotive – Heating & Air Conditioning

The “Fixed Orifice Tube Cycling Clutch System” (FOTCC) provides an

economical way of producing a vehicle Air Conditioning System (A/C).

Because the Thermal Expansion Valve (TXV) is complex and expensive to

produce, some valves costing as much as the whole of the rest of the
system and compressors sapping power from the engine, A/C used to be
found only on high powered luxury vehicles.

Today, however, A/C is found on all types of vehicles, this is partly because
smaller engines are able to handle the extra load of the compressor, using
their complex engine management systems and advances in A/C control.

The TXV system works by varying the amount of refrigerant sprayed into the
evaporator to control the system.

The FOTCC system works by having a constant spray of refrigerant into the
evaporator and turning the compressor on and off (cycling the clutch) to
control the system.
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Basic FOTCC System Components

Automotive – Heating & Air Conditioning

Component and layout used with a FOTCC system.

Condenser

Evaporator

Clutch cycling
pressure switch Compressor

Fixed orifice
Suction accumulator
tube
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Basic FOTCC System Operation - 1

Automotive – Heating & Air Conditioning

Compressor starts and creates High

high and low pressure sides in the Air flow
pressure
FOTCC system.
High pressure vapour
refrigerant flows from the
pump to the condenser.
Vapour is cooled
within the condenser,
turning to a liquid.
High pressure liquid
leaves the condenser.
The fixed orifice tube restricts the
flow of the high pressure liquid.
The high pressure hose has a service
valve connection for a pressure gauge.
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Basic FOTCC System Operation - 2

Automotive – Heating & Air Conditioning

High pressure liquid flows into the fixed orifice tube and
enters the evaporator as a vapourised liquid.
Air flow
The vapourised liquid within the
evaporator absorbs heat energy,
and most of the refrigerant turns
to low pressure vapour.
The vapour is then
sucked into the
accumulator/ drier by the
compressor, where any
moisture is removed.
The low pressure refrigerant
vapour is then sucked into the Low
compressor and pumped on to pressure
the condenser. The cycle repeats. Accumulator
The low pressure hose has a service valve
connection for a pressure gauge. 5 of 15
2. Fixed Orifice Tube Cycling Clutch System Theory Support

Fixed Orifice Tube Construction

Automotive – Heating & Air Conditioning

Evaporator core Fixed orifice tube

High pressure
refrigerant liquid

Internal diameter
of fixed orifice

Output filter

Input filter

Low pressure
refrigerant spray O rings
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Fixed Orifice Tube Operation

Automotive – Heating & Air Conditioning

The fixed orifice tube provides a restriction against liquid refrigerant flow,
builds pressure in the condenser and lowers pressure in the evaporator.

It also meters the flow of refrigerant spray into evaporator. If flow is not
metered, the following may occur:

Starved Evaporator
If refrigerant flow is too low, all of it is vapourised before it reaches the
evaporator outlet.

Cooling is insufficient, because not all surrounding heat is absorbed.

Flooded Evaporator
If refrigerant flow is too high, less vapourisation takes place because there is
no room for complete vapourisation and expansion.

Cooling is insufficient, because of less vapourisation.

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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Cycling Clutch Pressure Switch Construction

Automotive – Heating & Air Conditioning

Cycling clutch Suction

pressure switch accumulator/drier

Supply from function

selector switch

Feed to compressor
magnetic clutch field coil 8 of 15
2. Fixed Orifice Tube Cycling Clutch System Theory Support

Cycling Clutch Pressure Switch Operation

Automotive – Heating & Air Conditioning

Uncontrolled, the A/C system will run continuously, and temperature in the
evaporator will drop below freezing. Ice forming on the fins will block airflow
through the evaporator.

The pressure switch controls

evaporator temperature at just
above freezing,
stopping ice forming.

The switch opens and closes

in response to refrigerant
pressure changes in the
suction accumulator.

The switch opens at suction pressure

below 1.5 to 1.7 BAR, depending on the system.

Switch remains open until pressure rises above 3 BAR.

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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Suction Accumulator/Drier Construction

Automotive – Heating & Air Conditioning

Pressure switch fitting

From
evaporator To compressor

Plastic
cap

Vapour return
tube

Desiccant
bag

Refrigerant
Oil filter oil
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Suction Accumulator/Drier Operation

Automotive – Heating & Air Conditioning

Refrigerant from evaporator is Inlet from Outlet to

mostly vapour with small evaporator compressor
amounts of liquid.

Plastic cap
Refrigerant enters from top,
vapour refrigerant swirls around
plastic cap, and exits to
compressor via vapour return tube.
Vapour
return
The heavier liquid refrigerant tube
drops to bottom and then has a
Desiccant
second chance to vapourise. bag

Oil mixes with vapour in the vapour

return tube to lubricate system. Refrigerant
The desiccant bag removes Oil
oil
filter
moisture from the system. 11 of 15
2. Fixed Orifice Tube Cycling Clutch System Theory Support

Compressor Clutch Components

Automotive – Heating & Air Conditioning

Compressor

Pulley
Circlip

Lock
nut

Nut
Clutch field coil

Bearing

Shims

Hub
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Compressor Clutch Assembly

Automotive – Heating & Air Conditioning

Pin Pulley
Coil Circlip
supply Nut

Shims

Lock Hub
nut
Coil Bearing
Compressor

Clutch field coil locks onto compressor with circlip. It is prevented from
turning by a pin in the end of the compressor. The coil has two supply wires.

Clutch pulley is fitted to a bearing on the compressor shaft, and rotates freely.

The clutch hub is keyed and locked onto the compressor shaft with a nut.
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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Compressor Clutch Operation - 1

Automotive – Heating & Air Conditioning

Final assembly is shown opposite.

A drive belt is attached to the pulley.

Pulley

When the engine is started,

the drive belt rotates the pulley.

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2. Fixed Orifice Tube Cycling Clutch System Theory Support

Compressor Clutch Operation - 2

Automotive – Heating & Air Conditioning

When the coil is energized the hub

is pulled toward the pulley by the
resulting magnetic field.

The magnetic force locks the hub

and pulley together, and the
compressor shaft rotates.

When the coil is de-energized, the

hub is pulled away from the pulley
by springs, or a rubber bush.

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