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GLOSSARY
Air-Cooled Condenser
Ambient Temperature
Atmospheric Pressure
Capacity Control
Compressor
Condenser
Condensing Pressure
Defrost
Desuperheat
Discharge Pressure
Discharge Temperature
Drier
Evaporating Pressure
Evaporating Temperature
Evaporator
Fin block
Heat Exchanger
High-Pressure Switch
Liquid Back
Low-Pressure Switch
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Oil Separator
Open Compressor
Operating Conditions
Reciprocating Compressor
Refrigeration Capacity
Saturation
Semi-Hermetic
Compressor
Shut-off Valve
Sight Glass
Suction
Suction Accumulator
Suction Return
Temperature
Superheat
Temperature difference
Thermostat
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Thermostatic expansion
Valve
Ventstream Duct
Interleaved conveyor
X Stream
Crust Freezer
Flo-Stream
Impingemen:
Displacement Cooling
Occupied zone
The region between 2.0m and the floor of a production area being
the temperature controlled by Pennine in their Displacement
Ventilation systems.
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SAFETY DEVICES
COMPRESSOR
Each compressor is protected by a series of safety devices that will not allow the compressor to run
should a fault condition arise, they are as follows:
High Pressure Switch stops the compressor if the discharge pressure rises above a pre set
value this switch is manually reset.
Low Pressure Switch stops the compressor if the suction pressure drops below a pre set
value this is also manually reset.
Oil Flow Switch stops the compressor if the oil flow drops too low.
Oil Pressure Differential Switch stops the compressor if the oil pressure from the pump drops below a
pre-determined pressure above suction pressure.
High Discharge Temperature Thermistor stops the compressor if the discharge gas
temperature exceeds a pre set level. Manual reset.
Thermistor (hermetic/semi hermetic compressors and motors to driven compressors) stops the
compressor if winding temperature exceeds a pre set level. Resets on temperature drop
below pre set level and reset button pressed if fitted.
CONDENSER / RECEIVER
Pressure Relief Valve discharges gas from system if pressure exceeds a pre set level.
Closes automatically on pressure drop below pre set level. Change this if it blows.
High Pressure Switch see above.
Frost Protection Thermostat (Evaporative Condensers) stops water pump when coolant
temperature drops below pre set level.
EVAPORATOR
Defrost Termination stops defrost sequence after pre set temperature is reached.
Defrost Termination Safety Timer stops defrost after pre set time if termination temperature
is not reached within that time.
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The refrigerant which has now condensed into a saturated liquid, drains into the receiver where it is
stored until required. The receiver includes sight glasses from which the refrigerant level can be
determined, and two pressure relief valves which in an emergency will relieve pressure in the system if it
exceeds a pre set level.
As required the liquid leaves the receiver where it passes through a liquid filter drier, sight glass (which
shows if the refrigerant contains moisture) and solenoid valve (which is de-energised to pump down the
system. Also should the compressors fail the solenoid valve is usually de-energised by means of safety
relay to arrest the flow of refrigerant).
After leaving the solenoid valve the saturated liquid passes through to the system.
Capacity control is usually maintained by a neutral zone pressure switch which senses suction pressure
and signals a step controller which energises or de-energises the compressor loading solenoids to
demand.
Head pressure is maintained within a set band by sensing discharge pressure and controlling the air
cooled condenser fans accordingly.
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The refrigerant that has now condensed into a saturated liquid drains into the receiver where it is stored
until required. The receiver includes sight glasses from which the refrigerant level can be determined, and
two pressure relief valves which in an emergency will relieve pressure in the system if it exceeds a pre set
level.
As required the liquid leaves the receiver where it passes through a liquid filter drier, sight glass (which
shows if the refrigerant contains moisture) and solenoid valve (which is de-energised to pump down the
system). Also, should the compressors fail the solenoid valve is de-energised by means of safety relay to
arrest the flow of refrigerant.
After leaving the solenoid valve the saturated liquid passes through to the direct expansion evaporators
and the vent stream surge drum.
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Capacity control is maintained by a neutral zone pressure switch that senses suction pressure and
signals a step controller that energises or de-energises the compressor loading solenoids to demand.
Head pressure is maintained by a proportional fan speed controller which senses discharge pressure and
modulates the speed of the evaporative condenser fan to slow if discharge pressure is low and quicken if
discharge pressure is high. An ambient thermostat will operate the water pump irrespective of load if the
ambient temperature should fall below a pre set level.
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The refrigerant that has now condensed into a saturated liquid drains into the high pressure receiver
where it is stored until required in the system.
The refrigerant leaves the receiver through a filter drier (to ensure cleanliness), sight glass and solenoid
valve. The solenoid valve is closed to pump down the system. In the event of a failure of the compressor,
the solenoid will be de-energised automatically to arrest the flow of refrigerant.
The liquid refrigerant is then distributed to the thermostatic expansion valves, which meter the flow of
refrigerant into the room evaporators. As the refrigerant picks up heat from the room, its state changes to
superheated gas, it is then drawn back to the compressors.
During a fluctuating load, a steady suction pressure is maintained by electrically selecting and loading
solenoids in the compressor. These effectively negate some of the compressive effect and are generally
known as unloading or capacity control.
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As the load fluctuates thereby causing the compressors to load and unload, the condenser capacity
varies proportionally. In order to maintain a condensing pressure within a control band, the fans are
simply switched on and off. With an evaporative condenser the air stream running from the centrifugal
fans is dampered at the demand of a stepless proportional controller.
When using some screw compressors it is necessary to maintain a minimum discharge pressure at the oil
separator to circulate the oil. This is achieved by fitting a pressure regulating valve in the discharge line.
This valve would also be used to maintain a discharge pressure if hot gas defrosting of evaporators is
utilised.
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In some applications there is a requirement for heating (Monday morning start for instance). When this
applies the heaters are controlled either with a separate thermostat, which would normally be set to bring
the heaters on at a temperature of about +6C and switch them off at about +8C. It must be noted that
the thermostat that controls the heaters should not overlap the cooling thermostat. Where heating/cooling
control is required, a neutral zone thermostat is usually employed.
On applications where equipment cooling production areas is connected to chill ring mains, an
evaporating pressure regulator is required. This will maintain an artificially high pressure within the cooler
(normally between 3.8 bar and 4.0 bar for R22 and 4.8 bar and 5.0 bar for R404A). In maintaining an
equivalent temperature within the cooler of approximately 1C the cooler will not ice up and therefore will
not require defrosting. (If the cooler does ice up there is a problem.)
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On application where equipment cooling production areas is connected to chill ring mains, an evaporating
pressure regulator is required. This will maintain an artificially high pressure within the cooler (normally
between 3.8 bar and 4.0 bar for R22 and 4.8 bar and 5.0 bar for R404A). In maintaining an equivalent
temperature within the cooler of approximately 1C the coil block will not ice up and therefore will not
require defrosting. (If the cooler does ice up there is a fault.)
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In order to provide a safety backup there is a timer in circuit that terminates the defrost heating after about
30 minutes whether or not the defrost termination thermostat has operated. This is to stop the cooler from
cooking if the defrost termination set up is faulty.
The probe of the defrost termination thermostat should be positioned where the coil has ice last. This is
usually at the bottom of the block or on the distributor.
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At a pre-set temperature (usually around 10C) the coil block is generally free of ice. The defrost
termination thermostat senses this from its usual probe position either on the spider or on a return bend
at the bottom of the coil block.
In any case the probe should be positioned at the last point where the ice melts.
At Defrost termination the hot gas solenoid C is de-energised and the cooler usually will stand for a
period with all valves closed. At the end of this drip time the suction solenoid B will open which will
relieve the pressure in the cooling coil back to suction. It maybe that on larger coils a pilot solenoid is
opened first to relieve the pressure otherwise there could be a rush of refrigerant back to the compressors
(and a sound like the clap of doom).
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Bear in mind that at the end of defrost the coil is virtually full of high pressure liquid and as soon as
pressure is relieved (when the suction line opens) the liquid will boil furiously
At the compressors there should be a knock out pot or suction accumulator that will stop this surge of
liquid entering the compressor, provided that defrosts on different coils are not too close together.
There should be a period after the suction line solenoid B opens and before the liquid line solenoid
energises. This period should be long enough to boil off the greater proportion of refrigerant liquid in the
cooling coil (DX coolers normally run 25% wet).
When the liquid line solenoid A is energised, normal cooling operation is re-established.
If the cooler is not clear of ice in 15 minutes after the hot gas solenoid C is energised, there is a fault.
The total defrost period, including rests should be 30 minutes.
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A way to overcome this phenomenon is to cool the refrigerant liquid to a temperature that is below its
saturation or boiling point.
This will compensate for heat pick up or excessive pressure drop.
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The characteristics of the screw compressor enables the introduction of more refrigerant suction gas
some way down the rotors than can be initially introduced through the dry suction connection. (The
pressure at this point is similar to that of the intermediate pressure of a two-stage system). The additional
mass flow of gas through the compressor provides the additional capacity but at a greatly reduced power
penalty due to the now increased suction pressure condition. (While the power demand goes up, it only
slightly increases in comparison to greatly increased capacity). In addition to the increased performance
of the compressor the system efficiency can be increased by means of subcooling the refrigerant supply
to the coolers.
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The oil rich mixture boils and the refrigerant element turns to superheated gas, the gas /oil mix is
returned to the dry suction line which feeds directly back to the compressor. The superheat measurement
of the gas/oil mix should be in the region of 10 - 20K.
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The pump then pumps the liquid refrigerant into the pumped liquid line and out to the evaporator matrix
where heat from the surrounding air vaporises some of the liquid refrigerant. This liquid/vapour
combination rises up through the evaporator boiling as it goes and leaves the evaporator to return to the
surge drum down the wet return pipe at a ratio of about 1.5 to 2 parts liquid to 1 part gas. It should be
noted that the flow to each evaporator is regulated by a pressure reduction valve to ensure that the
evaporators are evenly balanced. While the discharge pressure at the pump is in the order of 2.5 bar
above suction gauge pressure this pressure advantage is lost as soon as the liquid begins to boil after it
passes the pressure reduction valve.
The liquid/gas mixture relies on pressure differential to return to the surge drum and this is likely to be
about .1 bar. As the liquid/gas mixture enters the surge drum from the wet return line the liquid falls to the
bottom of the surge drum to be taken up by the pump and the gas passes into the dry suction line to the
compressor.
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NORMAL OPERATION
Liquid line solenoid A is open along with wet return solenoid B to allow constant flow of refrigerant
through the evaporator causing boiling within the tubes and the cooling of the air that passes through the
coil matrix. The hot gas solenoid C is closed.
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DEFROSTING
At the start of defrost both solenoids A and B close thereby cutting off the evaporator from its supply of
refrigerant. After a rest period of approximately 2 minutes, hot gas solenoid C opens to provide high
pressure hot gas from the compressors. The pressure in the evaporator quickly rises and the cold
refrigerant is forced out through the defrost pressure relief valve D.' Until the pressure in the evaporator
rises sufficiently stop the hot gas condensing the evaporator tubes will not get hot enough to melt the ice.
When the tubes have reached a temperature when all the ice has disappeared (8 to 10) the hot gas
valve C will close and the evaporator will stand with all valves closed for about two minutes. At the end
of this driptime a small pilot solenoid around B will energise relieving the remaining pressure within the
evaporator into the wet return line.
If for any reason this pilot valve should not operate, when the main valve B opens two minutes later
there would be a slug of liquid returning under comparatively high pressure back to the surge drum. This
would dramatically increase the pressure in the drum (causing compressors to start unnecessarily) and
raise the level. (There could also be a noise like the clap of doom.)
About two minutes after the opening of main valve B when normal boiling is restored the pumped liquid
valve A opens to permit the normal flow of refrigerant to the now defrosted evaporator.
The hot gas defrost valve should only be open for about 10 to 15 minutes, any longer and there could be
a problem.
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