2.02 The Cooling Machine Instructions

Heinen & Hopman Engineering bv
P.O. Box 9 - 3750 GA Bunschoten - Holland General Users Manual - HVAC

Tel.: +31 - (0)33 - 299 25 00
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Heat and specific heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Change of state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 The boiling process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Heat of evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Temperature-enthalpy diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Pressure-enthalpy diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.8 The condensing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Environmental problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Refrigerant alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.1 Refrigerant alternative R123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.2 Refrigerant alternatives R134a and R404a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Refrigerants - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 The Cooling cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.1 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.3 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 General cycle description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.1 Evaporator and condenser heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1.1 Finned heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1.2 Tube heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1.3 Plate heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Thermostatic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.1 Working of a thermostatic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.2 Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 How to use refrigerant charts, tables & diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.1 Refrigerant tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Guidelines for service and maintenance - the cooling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7.1 Standard service techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1.1 Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.1.1 Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.1.2 Purging non-condensables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.1.3 To de-air systems with purge valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.1.4 To ventilate systems without purge valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.2 Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.2.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.2.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.2.3 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.2.4 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.3 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.4 Gauge manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.4.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.4.2 Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.4.3 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.5 Leak testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.5.1 Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Part three Chapter 3 : The coolingsection - 1

Tel.: +31 - (0)33 - 299 25 00
7.1.5.2 Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.5.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.6 Evacuation and dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.6.2 Deep vacuum method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.7 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.7.2 Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.7 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1.8 Removing refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.8.1 Excess charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.8.2 Complete uncharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.9 Compressor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.9.2 Determining oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.9.3 Oil sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.9.4 To determine the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.9.5 Oil level plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.9.6 Adding oil to a compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.9.7 Removing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Before the first start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2.2 Compressorset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2.1 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2.3 Transmission of the compressorset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2.4 Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2.5 Thermostatic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2.6 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3 Starting and stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.2 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.1.1 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.1.2 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.2 Compressorset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.2.1 Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.2.2 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.2.3 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.3 Transmission of the compressorset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.3.1 V-belt driven type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4.3.2 Direct driven type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.4.4 Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4.4.1 Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4.4.2 Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4.5 Thermostatic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.4.6 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.4.6.1 Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.4.6.2 Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8 Guidelines for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.1 Frosted or sweating suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.2 Warm liquid line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.3 Frosted liquid line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.4 Back pressure lower than normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.5 No frost of the thermostatic expansion valve or cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.6 System operates too much or all time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.7 Storage compartment too cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1.8 Low operating head pressure on condensing unit
............................................................................................... 34
8.1.9 Head pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1.10 Frost on the thermostatic expansion valve only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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8.1.11 Storage compartment warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.1.12 Troubles with electric installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Complaints with a enumeration of possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.1 Compressor does not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.2 Compressor shortcycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.2 Condensing pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.4 Refrigerated product not cold enough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.5 Condensing unit runs too much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.6 Hot liquid line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.7 Frosted or sweating suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.8 Liquid line very cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2.9 Condensing unit noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2.10 Condensing pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2.11 Not cool enough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1.12 Noisy operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Summery Chapter 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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1 Introduction
In this chapter the cooling machine and its components of an air-conditioning installation will be explained. There will also be
looked at the maintance and troubleshooting of a cooling installation.
The dictionary defines refrigeration as a process of making something cold, and "cold" can be defined
as an absence of heat. So refrigeration, despite the means by which it is secured, is defined as the
process of eliminating heat. If heat is eliminated from the air contained in a given space, that space
becomes cooler, and its temperature lower.
Heat is a form of energy and can be transferred from one body to

another by virtue of a difference in temperature. A fundamental law
states that heat may only be transferred from the substance of the
higher temperature to that of the lower temperature. Therefore, figure 3-1
refrigeration becomes a process of providing a substance at a lower
temperature to which heat can flow from a substance at a higher temperature.A cooling machine
has the task to cool parts or substances to a temperature that is lower than the surrounding area
and keep it at this temperature.
The oldest most known refrigerants are ice, water and air. Initial the only purpose was the
figure 3-2 conservation of food for a longer time. The Chinese were the first who discovered that ice could
preserve and gave a better taste to drinks. The Eskimo's have for centuries preserved their food by
freezing it.
In the beginning of the last century bacteries, yeast, mould, enzymes, etc. were known. People discovered that the growth of
these micro organisms was dependable on the temperature. At lower temperatures the growth decreases and under 10EC
there is almost no growth anymore. This knowledge led to the application of cooling for preserving food. At first ice was used for
this purpose.
The first installation for production of artificial ice appeared around 1860. In America in the year 1880 they used the first
ammonia compressors and isolated cells. In the beginning of this century electricity became more important in our society,
because this was the power source for the many mechanical refrigerant installations that were used in breweries, abattoirs, the
fishing industry and the production of ice. After the second world war the development of small hermetic cooling compressors
was going very fast. Refrigerators and freezers started to take their place in for us now indispensable function in the household.
As said, they are considered nowadays as standard equipment in the household.
The applications of cooling installation are multiple. Examples are:

• conserving of provisions
• cooling of drinking water
• cool containers
• heat pumps
• freeze drying
• air drying (dismoisterizing of air)
• air handling
We can hardly imagine how our life would be without cooling and freezing. The influence on our existence is much greater than
people can realize. In this chapter first the basic principles of the cooling technique will be explained. After this the cooling
machine as application of air-conditioning installation is explained. There will also be looked at the components of the cooling
machine.
2 General principles
2.1 Heat and specific heat
Heat is an invisible form of energy that arise from the conversion of other forms of energy in energy of heat. For example; the
mechanical energy needed to rotate a wheel, causes friction that arise heat. Heat is often called a moving form of energy. This
is because heat is always moving from a warm object to a cold object. A tea-spoon placed in a glass of ice water loses its heat
to the water en becomes colder. However in a glass of hot water the tea-spoon absorbs the heat and becomes warmer. The
terms cold and warm are only usable in relation with each other. Only the effect of heat is perceptible and the measuring of it is
the way to define heat. The indication for heat is Q.

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The heat is the product of m x ? T x cp, in which m is the mass in kg, ? T is the change in temperature in EC and cp is the
specific heat. In the metric system the unit for heat is the calorie (cal), this means the quantity of heat needed to raise the
temperature of 1 g of water from 4EC to 5EC. In the cooling techniqic the kilocalorie (kcal) is generally used which is the same
as a 1000 calories. At the SI-system the unit for all the forms of energy (heat included) is joule (J). Conversion from metric to SI:
• 1 cal = 4,187 J
• 1 kcal= 4,187 kJ
There are big differences in the quantity of heat needed to raise the temperature of different
materials 1EC. For example; when we want to raise the temperature 1EC of 1 kg iron, there is
0,478 kJ of heat needed. 1 kg of air needs 1,00 kJ of heat. The specific heat (cp) is the amount of
heat needed to raise the temperature 1EC of 1 kg of a substance. The specific heat of a large
amount of substances is displayed in different charts as kJ/kgK (kcal/kgEC).
2.2 Change of state
Every substance can appear in three conditions (states): solid, liquid and gaseous. Water is the
most known example, in solid state as ice, in liquid state as water and in gaseous state as steam
figure 3-3 or vapour. For all the three states the water molecules does not change, the chemical formula is
always H2O. The temperature and pressure the substance is exposed to, define the state of the substance. When ice changes
into water the temperature during melting does not change. All the supplied energy is needed to change the substance from
solid form into liquid form. Only when the substance is entirely melted, the supply of heat will raise the temperature again.
The 'ice boxes' of the past were periodically charged with a cake of ice. The ice melted and the
pan of water below the box had to be 'emptied' on schedule to avoid overflow. In melting from a
solid to a liquid, the ice absorbed its latent heat of fusion. This is 334 kJ/kg ice, and the heat to
accomplish this was removed from the foodstuffs within the box. The water was discarded,
although it was cold because it had very limited refrigeration capacity. This is true because 4.18 kJ
raises the temperature of 1 kg of water one degree. Therefore, if 1 kg of water at 0 EC absorbs
41.8 kJ its temperature rises ten degrees to 10 EC. This defeats the cooling effect of ice.
The change-of-state process is important to the mechanical refrigeration cycle for two reasons.
First, the change absorbs a relatively large amount of heat per kg of substance; and second, this
change-of-state takes place at constant temperature.
figure 3-4
2.3 The boiling process
Since the properties of water are easily observed and since its behavior is similar too commonly used refrigerants, water is
used here to demonstrate the boiling process and to establish terminology.
If 1 kg of water is heated, its temperature increases 1 EC for each 4.18 kJ added. This process
continues until the water reaches its boiling point. The boiling point is determined by the pressure
over the water. In an open container the pressure over the water is atmospheric. In a closed
container the vapour pressure determines the boiling pressure. At a standard sea level pressure of
1.01 bar water boils at 100 EC.
SEA LEVEL
1,01 bar
If the pressure is higher than 1.01 bar, the temperature at which

100 EC
water boils also increases. For example, the boiling point for water in
figure 3-5
a pressure cooker operating at 0.34 bar above atmospheric pressure
figure 3-6 is 108 EC. At a pressure of 3.45 bar the temperature increases to 148 EC. Conversely, if the
pressure is less than 1.01 bar, as in vacuum, the temperature at which water boils is lower. For
instance, at a pressure corresponding to 0.67 bar the boiling temperature of water is 89 EC and at 0.33 bar, it is 72 EC. If the
pressure is lowered still further, water can be made to boil at temperatures sufficiently low to be used for air-conditioning
purposes.

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At any given pressure there is a corresponding boiling or saturation temperature:

1,35 bar 4,4 bar
Boiling temperature (E C) Pressure (bar)
148 4.54
108 1.35 108 EC 148 EC
89 0.67
72 0.33
10 0.01
At the boiling point either the pressure or the temperature establishes other \TEKENING\FIG2_7.ROB
properties of the liquid, such as heat content (enthalpy), density and volume. Water
figure 3-7
at the boiling temperature for a given pressure is called saturated liquid.
2.4 Heat of evaporation

SATURATED
After a fluid has been heated to the boiling point, further addition of heat results in VAPOR
evaporation of the fluid. The heat required to change the liquid to a vapour at the boiling 100 EC
point is called the heat of evaporation. At a standard barometric pressure of 1.01 bar
it takes 2260 kJ to complete the evaporation of 1 kg of water at 100 EC to steam at 100 LATENT HEAT
EC. OF
VAPORIZATION
At this point 1 kg of dry saturated vapour has been produced. The amount of fluid 100 EC 1 kg WATER
that evaporates depends on the amount of heat added and the heat of evaporation
of the particular fluid. If 226 kJ is added to water at its saturation temperature of 100 2260 kJ
EC, 1/10 kg of water will evaporate.
If 22,600 kJ is added, 10 kg of water will evaporate. If only part of the fluid

evaporates, the result is a mixture of saturated liquid and saturated vapour.
2.5 Superheat figure 3-8
SATURATED VAPOR
100 EC PRESSURE IS CONSTANT The point of saturated vapour is reached if there is added enough heat to a fluid.
If the fluid is completely evaporated and there is more heat added, we call this
additional heat "superheat." The change-of-state has been completed, so the
additional heat results in a rise in temperature of the vapour. In the superheat
region, the vapour expands slightly in volume as its temperature is raised.
WATER Moreover, the specific heat of the vapour is different from that of the liquid. For
100 EC
example: water, it takes only 2.0 kJ to raise 1 kg of vapour 1 EC in temperature. If
HEAT ADDED
SUPER HEATED VAPOR 1 kg of steam is superheated 30 EC, then 30 * 2 = 60 kJ is required.
figure 3-9
2.6 Temperature-enthalpy D
diagram
B C
The characteristics of a substance can be illustrated in a temperature-

enthalpy (t-H) diagram. On the horizontal axis the enthalpy is displayed and on
the vertical axis the temperature is displayed. Enthalpy is often indicated as
the heat content and is the sum of energy supplied to a medium. To further
simplify the demonstration, assume 1 kg of water at a standard atmospheric
pressure of 1,01 bar. Starting at point 'A', of figure 1.9, shows that 1 kg of
water at 0 EC has a heat content or enthalpy of 0 kJ/kg (figure 3-10).
A
figure 3-10

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Line A-B represents the sensible heat needed to raise the water to its boiling point temperature or saturated liquid temperature at
100 EC. As stated previously, for every degree rise 4.18 kJ must be absorbed by the liquid. Therefore, the heat content at 100 EC
is 100 × 4.18 = 418 kJ.
Line B-C represents the latent heat of evaporation needed to completely change 1 kg of saturated liquid at point 'B' to dry saturated
vapour at point 'C'. The heat of evaporation for water at standard atmospheric pressure is 2260 kJ/kg. Therefore, the enthalpy of the
dry saturated vapour at point 'C' is 418 + 2260 = 2678 kJ. As shown in the diagram the change-of-state from point 'B' to 'C'
represents no change in temperature. Therefore, we call this latent.
Line C-D illustrates the effect of adding sensible heat to saturated vapour. This process is called superheating. For every degree
of superheat 2 kJ must be added. For example, if 30 degrees of superheat is required, the temperature at point 'D' is 100 + 30 = 130
EC and to accomplish this 30 * 2.0 = 60 kJ must be added.
The enthalpy of the superheated vapour at point 'D' becomes 2678 + 60 = 2738 kJ.
2.7 Pressure-enthalpy diagram
Since the t-H diagram is restricted to a particular pressure, the pressure- p-H DIAGRAM FOR H2O
enthalpy (p-H) diagram is more commonly used because of its greater flexibility. CRITICAL POINT
The temperature can readily be related to the pressure as was indicated earlier 221.5
(see figure SUBCOOLED SUPERHEAT

3-11). REGION REGION
MIXTURE OF
WATER & VAPOR
Similar diagrams are available for the commonly used refrigerants. By drawing
a horizontal line at a given pressure, it is possible to determine the heat content SATURATED
LIQUID LINE
SATURATED
VAPOR LINE
of the saturated liquid. This is done by reading the enthalpy scale corresponding
to point 'A' on the saturated liquid line. A HEAT OF B
VAPORIZATION
The heat content at point 'B' for saturated vapour can be determined in a similar
manner. The difference in enthalpy between points 'A' and 'B' is the heat of
evaporation.
2117 2791
ENTHALPY (kJ/kg)
2.8 The condensing process figure 3-11
The change-of-state from liquid to vapour is reversible; that is, the fluid can be changed from a vapour back to liquid. This
process is called 'condensing'. Just as heat must be added to affect evaporation, heat must be taken away to change a vapour
back into a liquid, and in the same amount. Just as pressure establishes the temperature at which a fluid boils, pressure also
fixes the temperature at which condensation takes place.
3 Refrigerants
3.1 Introduction
We already saw that if we want to make sure that the crew members feel comfortable during the working and resting period, we
have to regulate the temperature of the different spaces in the ship. Therefore the temperature of the air must be lowered or
raised to an optimum level. In case of raising the temperature we use a heater in the air-conditioning installation. When we want
to lower the temperature of the air, we use a cooler.
In every refrigeration installation there is a quantity of refrigerant. The refrigerant is a liquid or a gas with fixed properties.
Because the boilingpoint of refrigerants lays far below 0EC, the refrigerants only exist in gaseous state at surrounding pressure
(1 bar). When we raise the pressure with a compressor but we keep the same temperature, the gaseous refrigerant will at
some point change-of-state and becomes liquid.
The refrigeration effect of a cooling installation is based on the evaporation of liquid refrigerant at low temperature. The
refrigerant absorbs surrounding heat during evaporation. Because of this process, the surrounding temperature is lowered. In
case of an air-conditioning installation the air is cooled, transported and blown into different spaces in the ship.

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The first practical use of piston-compressors was during the years 1870 - 1880. At this time there was the disposal of the
refrigerant ammonia. For a good practical use of a substance as a refrigerant the following properties are needed:
• A large evaporation and condensation heat

The larger the heattransfer for a determined refrigerant (from liquid to vapour and reversed), the less refrigerant has to flow
through a cooling machine. Therefore, the compressor can be chosen much smaller in capacity.
• Low evaporating pressure (0 - 5 bar) and condensation pressure (1 - 15 bar).

The higher the pressure, the thicker the compressor- and evaporator material. Also a good quality of lubrication oil is needed
to make sure that cilinderwalls will be well lubricated at this continuing cooling process.
Although ammonia as a refrigerant satisfies this need and is much applied for industrial cooling machines, it is not much applied
for the air handling units because it is too dangerous. This is because ammonia is poisonous, very inflammable at temperatures
above 650EC and very explosive at a concentration of 1,5% ammonia in the air. Until 1940 CO2 (carbonic dioxide) was used as
a refrigerant but there was a high condensation pressure needed. Also SO2 or sulphur dioxide was used but this is also very
poisonous.
Water as a refrigerant possesses, just like ammonia, very good qualities: it is cheap and has a large evaporation heat.
Unfortunately the evaporating pressure needed for the cooling of the air is very low (vacuum) and is very difficult to reach with a
mechanical cooling compressor (tightening).
3.2 Refrigerants
In the beginning of this century, people discovered the dangers of the then known refrigerants used for air handling (poisonous,
explosion- and burning danger). The American company Dupont has done a lot of research between 1928 and 1935 and has
produced some new types of refrigerants that were named "Freon." The first refrigerant was R12 (Freon 12) and satisfied the
then needed requirements, including safety. In the fifties some practical refrigerants were developed for the different application
in the cooling technic. These refrigerants could apparently be used without any danger.
3.3 Environmental problems
During the years 1989 and 1990 international environmental experts attended humanity on a new environmental danger, the
depletion of the ozone layer which was caused by CFK's used in cooling installations. Because of this, a high ultraviolet
radiation-level can reach the earth which can cause skin-cancer. Also showed accurate measurements that different waste
gases such as CO2 form an isolation layer around the earth (green-house-effect). Because of this the solar radiation that
provides life on earth can be much harder radiated back into the universe. Therefore the atmosphere around the earth is heated
stronger then normal with the danger of extra meltingwater of the North- and Southpole and therefore the raise of the sealevel.
During the environmental conference in Copenhagen in 1995 there was decided that delivery, application and the use of CFK-
refrigerants become forbidden to ensure a fast CFK-reduction.
3.4 Refrigerant alternatives
The manufacturers of refrigerants developed in the years 1988 and 1990 two replacing refrigerants. These are R123 and
R134a.
3.4.1 Refrigerant alternative R123
The refrigerant R123 is a replacement for the low pressure refrigerant R11. R123 has a less damaging effect on the ozone layer
then R11. It also has almost the same thermodynamic characteristics as R11 and can even be mixed without problems with
R11. Existing installations can be refilled in a short time with R123. The short term testing results have shown that R123 is a
safe but in some degree poisonous refrigerant. The long term testing results will become available within the following years.

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3.4.2 Refrigerant alternatives R134a and R404a
The refrigerants R134a and R404a are replacements for the high pressure refrigerants R12 and R500 and possible even R22.
Not so long ago there were still problems with R134a. This refrigerant cannot be combined with the till now used synthetic oil
and refrigerants.
3.5 Refrigerants - general
Heinen & Hopman normally uses R-22 or R-134A for their installations. Both are clear to water, practically odorless, non-
irritating, non-toxic (except in open flame), non-explosive and non-combustible. They are supplying chemically pure and dry in
sealed containers ranging from small cans to cylinders or drums over a 1000 kg.
There is no universal refrigerant for every application. Each has unique characteristics considered by the equipment
manufacturer. Additional factors to consider include the relationship with oil, controllability, stability, availability and cost.
Because of the different characteristics, refrigerants should never be mixed or substituted in a system. Check the refrigerant
specification on the compressor nameplate or refer to the manufacturer documents.
The refrigerants used by Heinen & Hopman are very suitable for use in refrigeration machines because :
• The working pressures are not high so that the machinery does not have to be unduly heavy in construction, and leakage
through glands etc., is minimized.
• It has no chemical action on most metals.
• It will condensate at relatively high temperatures, which makes it suitable for most conditions.
• They are non-inflammable and non-explosive, but when any quantity of refrigerant gas is being blown into the atmosphere,
naked lights should be extinguished. This is because it has been found that refrigerant gas is liable to decompose in the
presence of a naked flame and the products of decomposition are unpleasant to inhale.
Since the used refrigerants are odorless, small leaks may remain undetected until they adversely affect the functioning of the
plant. The presence of oil at a joint or gland is a good early indication of leakage. It is therefore advisable to keep the plant, and
all joints particularly, externally clean and free from oil. Other methods of leak detection are explained in the chapter "Guidelines
for service and maintenance."
4 The Cooling cycle
4.1 Introduction
In this chapter the principle of the cooling machine will be explained. First the different fases of the working of the cooling
machine will be explained. After this the general cycle description will be explained.
The principle of the cooling machine is based on the following four functions:
• Expansion
• Evaporation
• Compression THERMOSTATIC
EXPANSION VALVE
• Condensation B
HOT GAS LINE
These four functions are obtained by the following three main components of A C
D
the cooling machine: EVAPORATOR
SUCTION LINE
CONDENSOR
• Evaporator
• Compressor LIQUID LINE COMPRESSOR
• Condenser RECEIVER
figure 3-12
4.2 Main components
4.2.1 Evaporator
A refrigerant in liquid form will take on heat during evaporation. This change of state leads to the cooling in the cooling process. If
a refrigerant of surrounding temperature is expanded to surrounding pressure through a tube, heat is withdrawn from the
surrounding area. In this case evaporation will take place that corresponds with the surrounding pressure.

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The part of the cooling process in which this process takes place is called the evaporator. The task of the evaporator is to
withdraw heat from the surrounding area, in other words the cooling.
4.2.2 Compressor
Because of the environment it is not allowed to expand the refrigerant into the free
atmosphere. Because of this, the cooling process must take place in a closed circuit.
If the refrigerant which leaves the evaporator is lead to a receiver, the pressure in the
receiver will be the same as the pressure in the evaporator. The result will be that the
circulation of refrigerant will stop and the temperature in the evaporator will become the
same as the surrounding temperature. To maintain a lower pressure and therefore a
lower temperature, it is necessary to remove vapour/gas. This is done by a
compressor that sucks in the refrigerant gas from the evaporator. (figure 3-13) A
compressor can be compared with a pump that moves the refrigerant gas through the
cooling circuit. In a closed system there will be always a balance. For example: if the
compressor sucks in the refrigerant gas much faster then it can be formed in the
evaporator, the pressure and therefore the temperature will lower. Or reversed, if the
load of the evaporator is increased and the refrigerant will evaporate faster, the
pressure and temperature in the evaporator will increase. figure 3-13
4.2.3 Condenser
The refrigerant transfers its heat to the condenser and this heat is transferred to a medium with a lower temperature. The heat
transferring (heat receiving) medium can be air or water. The only condition of this medium is that the temperature is lower than the
temperature in the condenser, which corresponds to the condensation pressure. The process in the condenser is comparable to
the process in the evaporator, only in opposite direction. In this case a change in phase is from vapour to liquid.
4.3 General cycle description
A continues cooling process can be obtained by several ways. The most applied is the compression system. The compression
system is characterized by two pressures:
• The low pressure or evaporating side
• The high pressure or compression side
As said before the refrigerant transports the heat that is collected in the evaporator to the condenser where it is transferred to air
or water. A change of state for the refrigerant from liquid to vapour and back again to liquid makes it possible to take on or give off
large quantities of heat in an efficient way.
THERMOSTATIC
EXPANSION VALVE
Next the principle of the coolingprocess is described (figure 3-14). B
HOT GAS LINE
Liquid refrigerant entering the evaporator is controlled by an automatic throttling A C

D
device called the thermostatic expansion valve. This valve allows the high EVAPORATOR
SUCTION LINE
CONDENSOR
pressure liquid refrigerant to expand; thus, reducing it from condenser to
evaporator pressure. The expansion valve is one of the division points between LIQUID LINE COMPRESSOR
the 'high pressure' and the 'low pressure' side of the system. RECEIVER
Because of the reduction of pressure (to atmospheric pressure) the refrigerant figure 3-14
begins to boil and evaporates at a low temperature (with R22 this is -41EC). It immediately begins to absorb heat from the air that
is flowing across the evaporator surface. The refrigerant continues to absorb heat in the evaporating coil until it is completely
evaporated.
Due to the 'sucking' action of the compressor, the gas thus produced is drawn through the
suction line into the compressor cylinder. The down stroke of the piston admits a cylinder full
of gas through the suction valve. On the upstroke of the cylinder the gas is compressed,
thereby raising temperature and pressure of the gas (figure 3-15). The compressed gas is kept
from re-entering the cylinder on its next down stroke by the compressor discharge valve. The
pressure thus produced causes the hot gas to flow to the condenser. EFFECT OF COMPRESSION ON
BOTH TEMPERATURE AND PRESSURE RISE
figure 3-15

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The compressor discharge valve, like the thermostatic expansion valve, marks a division between the 'high pressure' and 'low
pressure' side. After the compressed gas has passed the discharge valve and enters the condenser, heat flows from the hot gas
into the condensing medium. This action cools the compressed gas and changes it back into a liquid.
This liquid under pressure is collected in the receiver and then forced through the liquid line to the thermostatic expansion valve, and
the cycle repeats itself.
5 Refrigerant circuit components
In this part the different circuit components of a cooling installation will be explained.
5.1 Evaporator and condenser heat exchanger
In a heat exchanger (evaporator (figure 3-16) or condenser (figure 3-17)) heat is transferred through a wall between media with
different temperatures. In the evaporator and condensing heat exchanger the heat transfer on one side of the wall is characterized
by the change of state. In the evaporator this is a change of state from liquid to vapour, in the condenser from vapour to liquid. As
said before in this process a large quantity of heat is transferred. The cooling media can be air or water.
figure 3-16 figure 3-17
The heat exchange of the condenser and evaporator depends on different factors which are:
• the cooling surface
• the temperature between the cooling medium and the refrigerant
• the speed of the refrigerant flow along the pipes
• condenser material
• the cleanness of the heat exchanging surface
Dirt and lime tarnish on the waterside will influence the heat exchange in a bad way.
If we use an air cooled evaporator or condenser we can use the following types:
• Finned pipe heat exchanger
• Tube heat exchanger
• Plate heat exchanger
5.1.1 Finned heat exchanger
These are heat exchangers where the evaporating or condensing refrigerant flows through U-formed copper tubes. On the outside
of the tubes aluminium finns are mounted which transfers the heat. The air flows along the finned tubes on the outside. Sometimes
the copper tubes are foreseen from spiral formed inside grooves to improve the heattransfering process (almost 30%) without extra
refrigerant resistant.
5.1.2 Tube heat exchanger
These heat exchangers are used for cooling of liquids or condensing of the refrigerant by means of water. In case of a cooled water
evaporator the evaporating refrigerant flows through tubes (except for centrifugal cooling machines) and the cooling water through
a pressure vessel (shell). In a watercooled condenser the cooling water flows through tubes and the refrigerant condenses on the
outside of the tubes in the pressurevessel. The outside of the tubes is often covered with finns to increase the condensing surface.
The tubes are constructed from copper and are used in installations on land with non corrosive water. For use on ships and
corrosive water the tubes are constructed from cupro/nickel.

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5.1.3 Plate heat exchanger
This type of heat exchanger is constructed from plates varying in shape from flat and crosswise waved stainless steel. In this way
the heat exchange through the plates from evaporating or condensation heat takes place between the liquid and the evaporating
or condensing refrigerant. The direction of the cooling liquid and refrigerant flow is generally opposite. This type of heat exchanger
is sensitive for obstruction and therefore there is often a waterfilter used in the water supply tube.
5.2 Thermostatic expansion valve
The most important task of an expansion device is to ensure sufficient pressure difference between the high- pressure and low-
pressure side of the system. The most simple way is to place a conduct-tube, with a small diameter, between the condenser and
evaporator. This is called a capillary tube. The expansion capillar is only used in small, simple cooling machines such as
refrigerators. This is because of the fact that this device cannot control the quantity of refrigerant which is injected in the evaporator.
For this process be a metering device must be used. The most common device is a thermostatic expansion valve.
A thermostatic expansion valve is a precision device designed to meter the flow of refrigerant into the evaporator. The flow of
refrigerant is in exact proportion to the rate of evaporation of the refrigerant in the evaporator. It is by that preventing the return of liquid
refrigerant to the compressor. Figure 3-18 shows a picture of a thermostatic expansion valve. By being responsive to the
temperature of the refrigerant gas leaving the evaporator and the pressure in the evaporator, the thermostatic expansion valve can
control the refrigerant gas leaving the evaporator at a predetermined superheat. The valve is built up around a thermostatic element
(1) separated from the valve body by a diaphragm. A capillary tube connects the element to a bulb (2) and a valve body with valve
seat (3) and a spring (4).In a part of the bulb there is a small amount of fluid. In the rest of the bulb, capillary tube and the space
above the diaphragm there is saturated vapour with a pressure that correspond with the temperature of the bulb.
5.2.1 Working of a thermostatic expansion valve
The function of a thermostatic expansion valve is determined by three fundamental pressures:

P1: Bulb pressure that acts on the upper surface of the diaphragm, in the valve opening direction.
P2: Evaporating pressure that acts on the underside of the diaphragm, in the valve closing
direction.
P3: Spring pressure that also acts on the underside of the diaphragm, in the valve closing
direction. (figure 3-18)
The bulb of the thermostatic expansion valve placed immediately after the evaporator, opens on
rising superheat. Pressure on the diaphragm increases when bulb temperature increases. The
pressure under the diaphragm increases when the evaporating temperature increases. The
pressure differential, which correspond to the refrigerant superheat, manifests itself as a force that
tries to open the valve against the opposite force of the spring. If the differential in superheat,
exceeds the spring force the valve will open. When the expansion valve regulates, balance is
created between bulb pressure on one side of the diaphragm and evaporating pressure plus spring
force on the other side.
As the refrigerant is injected into the evaporator and moves along, the liquid boils off into a vapour.
Because of this, the amount of fluid decreases until all of the liquid has evaporated due to the
absorption of a quantity of heat from the surrounding atmosphere. By the time refrigerant gas
reaches the end of the evaporator the refrigerant gas is now superheated. The degree to which the
refrigerant gas is superheated depends on the amount of refrigerant being fed to the evaporator and
the load to which the evaporator is exposed. figure 3-18
The factory superheat setting of the thermostatic expansion valves is made with the valve pin just starting to move away from the
seat. Thermostatic expansion valves are so designed that an increase in superheat of the refrigerant gas leaving the evaporator,
is necessary for the valve pin to open to its rated position.
5.2.2 Superheat
Superheat is measured at the point where the bulb is located on the suction line. This is the difference between the temperature at
the bulb and the evaporating pressure/ evaporating temperature at the same point. Superheat is measured in Kelvin (K) or EC and
is used as a signal to regulate liquid injection through the expansion valve.

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6 How to use refrigerant charts, tables & diagrams
6.1 Refrigerant tables
To design equipment for use with a particular refrigerant, the designer must have access to its thermodynamic properties. These
are published by the refrigerant manufacturer, for example for the refrigerant R22:
t P V1 Vv hl hv t P Vl Vv hl hv
-90 0.05 0.65 3580.66 105.49 364.40 -10 3.54 0.76 65.34 188.43 401.56
-80 0.11 0.66 1763.19 115.06 369.31 -5 4.21 0.77 55.34 194.18 403.50
-70 0.21 0.67 940.94 124.81 374.23 0 4.98 0.78 47.14 200.00 205.36
-60 0.38 0.68 537.15 134.76 379.11 5 5.84 0.79 40.36 205.90 407.14
-55 0.50 0.69 414.83 139.83 381.53 10 6.81 0.80 34.71 211.88 408.84
-50 0.64 0.70 324.56 144.96 383.92 15 7.89 0.81 29.99 217.94 410.43
-45 0.83 0.70 256.99 150.15 386.28 20 9.10 0.82 26.00 224.08 411.92
-40 1.05 0.71 205.75 155.41 388.61 25 10.44 0.84 22.62 230.32 413.29
-35 1.32 0.72 166.40 160.74 390.90 30 11.92 0.85 19.74 236.66 414.53
-30 1.64 0.73 135.84 166.14 393.14 35 13.55 0.87 17.27 243.11 415.63
-25 2.01 0.73 111.86 171.61 395.33 40 15.34 0.88 15.14 249.69 416.56
-20 2.45 0.74 92.84 177.14 397.47 45 17.29 0.90 13.28 250.40 417.31
Table 3-19. : Table for R22
t = Temperature of the saturated refrigerant in (EC)

P = Vapour pressure of the saturated refrigerant in (bar).
Vl = Specific volume of the liquid in (dm 3/kg).
Vv = Specific volume of the saturated vapour in (*103 dm 3/kg).
hl = Enthalpy of the liquid in (kJ/kg).
hv = Enthalpy of the saturated vapour in (kJ/kg).
Pressure = Bar exerted at a given temperature. Determines equipment strength and, therefore, affects equipment cost, high
pressure usually results in high equipment cost.
Specific volume = Cubic meters of space required when one kg of refrigerant liquid evaporates. Influences the equipment size.
Enthalpy = Heat content of refrigerant. This is a measure for liquid heat and vapour heat. The latent heat is a measure of
the refrigeration or cooling effect. The difference in enthalpy between the liquid and the saturated vapour is the
latent heat of evaporation at the given temperature.
Table 3-19 shows that one kg of R-22 in liquid state, at 5 EC has an enthalpy of 205.9 kJ/kg. It also shows that at saturated
conditions, the pressure increases with the temperature. In the superheat region, however, pressure and temperature no longer
corresponds, and this introduces another variable in defining the condition of the refrigerant. Therefore, superheat tables are much
more extensive. For every refrigerant, superheat tables are available.
7 Guidelines for service and maintenance - the cooling machine
In the former chapters we looked at the different parts of the cooling section. Because a cooling machine is just like other mechanical
equipment not free of maintenance, it is important to know what to do when maintenance is needed. Because of that we look in this
chapter at several service and maintenance techniques.
7.1 Standard service techniques
A cooling machine contains a harmful refrigerant under pressure. LEAK DANGER! Keep room well ventilated. In the
presence of an open flame, freon is liable to decompose in toxic gases. Always put the main- and/or workswitch off during
activities at the machine. Only qualified personal is authorized to execute the following activities at the cooling machine

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7.1.1 Contaminants
7.1.1.1 Effect
The serviceman shall always keep the refrigerant system as clean and dry as possible. Otherwise, contaminants may enter or
develop and cause poor operation or failure. Some contaminants are : air, moisture, antifreeze agents, soldering flux, solvent, metal
chips and dirt. Some of their harmful effects are: sludging, corrosion, copperplating, freezing-up and restrictions.
The chemical breakdown of oil under high temperature in the presence of air or a non-condensable may cause sludging. Corrosion
is caused by air or an oxidizer in a high temperature. Also, soldering flux or acid may cause rust or corrosion. Copperplating can
be traced to contaminated oil that dissolves copper in the system. It then will transfer to a high temperature area such as bearings,
seals or valve plates. Here it is precipitated out by another contaminant such as water, alcohol or air. Freezing-up occurs when a
wet system is placed into operation or a leak develops in a refrigerant to water system operating below 0 EC. A freeze-up can be
significant to the serviceman because it alerts him or her to the presence of a contaminant in the system.
7.1.1.2 Purging non-condensables
A leak in the suction side of a system operating in a vacuum or an improper installation will
PURGE VALVE
allow air and other non-condensables to enter the system. Their presence is indicated by
excessive head pressure and/or reduced system capacity. The non-condensables tend to
accumulate in the high pressure side of the system. They also tend to accumulate at the
top of the condenser or receiver because they are lighter than refrigerant vapour. Many
systems have purge valves to allow non-condensable venting (figure 3-20).
figure 3-20
7.1.1.3 To de-air systems with purge valves.
• Shut down the system by turning the main- and/or work-switch off and allow it to reach ambient temperature.
• Compare the system pressure to the corresponding refrigerant pressure for ambient temperature.
• A higher system pressure indicates the presence of non-condensables. Give non-condensables time to rise to the system
high point.
• Slowly open the purge valve until gas can be heard venting from the port. Limit the opening because liquid refrigerant will boil
and remix non-condensables into refrigerant.
• Ventilate for about ten seconds and close the valve.
Some V-shaped condensers have two purge valves. Open them alternately.
• Restart the system if reduction in discharge pressure occurs. Run the system normally for several hours.
• If the discharge pressure is still high repeat steps 1 to 4.
7.1.1.4 To ventilate systems without purge valves
• Remove and salvage the refrigerant. Ventilate off any remaining.

• Allow the refrigerant container to set undisturbed for several hours.
• Crack the container valve and ventilate off non-condensables.
• Leak test and evacuate the system.
• Charge the system.
7.1.2 Driers
After disconnecting the cooling machine some parts may be cold (pipes).
FREEZING DANGER!
7.1.2.1 Use
Regardless of the degree of caution, workmanship and ability an installer or serviceman exercises, a small amount of residual
moisture and solid particles is nearly always left in the field built-up system. Therefore, every field-piped system must contain
some type of refrigerant drier.

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7.1.2.2 Construction
A drier is a container with inlet and outlet connections (figure 3-21). Inside is a chemical
compound called a desiccant.
The desiccant either physically holds (adsorbs) or chemically reacts with the residual
moisture and prevent it from circulating throughout the system. Most desiccants have
some degree of acid removal ability. They have some form of filtering screen or pad to
prevent the desiccant from entering into the system and also to remove solid particles
already in circulation. Some desiccants are cast or molded into the form of a cylinder to figure 3-21
improve their filtering ability. These are called filterdriers. Some desiccants are field
removable and replaceable.
7.1.2.3 Selection
A good general rule is always to use the drier type and size recommended by the unit manufacturer. Where no recommendation
is available, the drier should be selected according to the following factors :
• Water capacity - How much will it pick up and hold?

• Refrigerant flow rate - What flow rate of refrigerant can it sustain without excessive pressure drop?
• Safety - Will it be able to mechanically withstand the pressures encountered within the system?
• Acid removal ability - Will it pick up and hold acids?
• Filtration ability - How small a solid particle will it retain and how much before it plugs up?
• Size - Will it fit in the unit?
The unit manufacturer can more closely control the entrance of moisture and contaminants than the average installer or
serviceman. When replacing a factory-installed drier, always use the next larger size.
7.1.2.4 Precautions
• Never accept or install a drier or replacement desiccant that is not factory sealed.
• Never abuse or mishandle the drier.
• Once the seals have been removed from the drier or desiccant, install it immediately.
figure 3-22
7.1.3 Handling
To avoid the entrance of contaminants into a system via the refrigerant container only factory filled
and sealed containers should be used. Facts to remember :
• Fusible metal plugs (figure 3-23) are designed to protect the cylinder in case of fire. They may
not protect the cylinder from gradual and uniform overheating.
• The interstate commerce commission prescribes that a liquefied compressed gas container
shall not be liquid full below 55 EC. Above 55 EC, liquid refrigerant will completely fill a container figure 3-23
and the hydrostatic pressure will build up rapidly with each degree of temperature
• Fusible metal plugs begin to soften at 71 EC and melt completely at 74 EC. The hydrostatic pressure developed at 74 EC is far
more than the cylinder test pressure.
• Never apply a direct flame to a refrigerant cylinder.
• To provide some margin of safety, never heat a cylinder above 52 EC.
• Never place an electric resistance heater in direct contact with a refrigerant cylinder.
• Never transfer refrigerant from one cylinder to another without a refrigerant transfer pump.
• Do not drop, dent or otherwise abuse refrigerant cylinders.
• Always replace valve and hood cap when a cylinder is not in use or empty.
• Use the proper valve wrench for opening or closing the valve. Loosen the valve packing nut before turning the valve on;
retighten after closing.
• Secure all cylinders in an upright position with a chain or strap when they are not mounted in a suitable stand.
• Never exceed the weight marked on the container (figure 3-24).

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7.1.4 Gauge manifold
7.1.4.1 Use
LOW HIGH
One of the most useful tools for the serviceman is a gauge manifold. It is an instrument and
should be treated as such. Figure 3-25 shows a typical gauge manifold. It contains two shut-off
valves and three external connections. When both valves are closed (front seated) the center or
utility port is isolated. The ports above and below each valve are interconnected so the gauges
will register always when connected to a system.
VALVE VALVE
The left-hand gauge is a compound or suction pressure gauge. The right-hand gauge is the
figure 3-25
high or discharge pressure gauge. Flexible charging lines or hoses connect the manifold to the
system. To determine system operation, add charge, purge, equalize or evacuate (figure 3-27).
Services gauges should have the best degree of accuracy that is commercially available.
7.1.4.2 Care
• Never drop or abuse the gauge manifold.

• Have the gauges checked and adjusted regularly.
• Keep the ports or charging lines capped when not in use.
• Be sure the hoses meet the high-pressure requirements.
• Never use with any fluid other than clean oil and refrigerant.
• Prevent the hoses from being chafed, crushed or stretched.
• Never subject gauges to pressures higher than the scale face maximum or a high-pressure gauge to vacuum.
7.1.4.3 Connection
low high low high
Most systems have a high- and low-pressure service tap point for checking
pressures and charging. They may be located on the compressor shut-off close open open close
valves, liquid valves or as independent points (ex. Schrader valve). Note that
Schrader service valve ports require an adapter fitting or a core remover CHARGING OR
between the service valve and the hose. See figure 3-28. These ports should PURGING
ADDING OIL
always be leaktight and capped or plugged when not in use. low high
low high
The procedure is the same for all type of service ports if the system is
pressurized : open open close close
GAUGE
• Locate the usable high- and low-pressure service ports. BY-PASSING READING
• Backseat shut-off valves to isolate the ports from the system.
• Slowly remove plug or cap. Vent residual pressure to the atmosphere. figure 3-27
Install an adapter in the plug hole for a male flare fitting.
• Be sure both manifold valves are closed (front seated).
a - Connect the low-pressure manifold hose to the low-pressure service port.
b - Connect the high-pressure manifold hose to the high-pressure service port.
c - If the utility hose is used for charging or evacuating, connect it to the refrigerant cylinder or vacuum line. Otherwise, leave
it plugged.
• a - Crack open the low-pressure service port for five seconds then close. Repeat on the
high-pressure service port.
b - Watch both gauges for thirty seconds. If either gauge pressure falls, a leak exists. Find it
and seal it.
c - Loosen the utility port cap and crack open the low-pressure manifold valve. Purge air
entrained in the hose. Close the valve. Repeat on high-pressure side of the manifold.
• The gauge manifold is ready for use. Crack open both the high- and low-pressure ports. The
system pressure will register on gauges.
figure 3-28
If the utility port is used, a third valve should be installed in the utility hose. All venting or
purging is done with the third valve.
7.1.5 Leak testing

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7.1.5.1 Methods
Leak testing by pressure or by vacuum are two common field methods. Either one performed properly
and in sequence will ensure a leaktight system. The pressure method consists of admitting a
refrigerant into the system, or part of the system, and checking for leakage to the outside. The vacuum
method consists of pumping a vacuum in the closed system and watching for a rise in pressure on an
indicator. Here a leak is indicated but is difficult to locate. Therefore, only the pressure method is
treated further.
figure 3-29
7.1.5.2 Detection
The following are three popular detectors listed in order of their sensitivity :
• Electronic halogen detector:

a guntype detector or probe connected to a control unit. An airpump draws a sample of air
through the detector tip and over a halogen sensitive element. When the probe passes near a
leak, escaping halogen gas actuates the halogen sensitive element and creates an electric
signal. The signal is amplified and alerts the serviceman either audibly or visibly.
• Halide torch:
consists of a propane or LP gas tank, hose and a special burner that contains a copper
element (figure 3-29). A 'sniffer' hose is used as the probe. As gas is burned, a slight vacuum is
pulled on the probe. When the probe is passed near a halogen leak, the halogen is drawn into
the hose and injected into the burner below the copper element. A small amount of halogen
burning in the presence of copper has a brightgreen to bluegreen flame. A larger amount of
halogen will
burn with a violet colored flame.
• Soap bubbles:
this is a common type of leak detection. Swab a suspected leak area with liquid soap or figure 3-30
detergent and watch for bubbles to appear (figure 3-30).
7.1.5.3 Procedure
(Assume that no part of the system contains a refrigerant vapor under pressure and that the entire system is to be leak tested.)
• All flare, flange, solder, braze, weld or thread fittings must be mechanically tight. Also, seals, packing glands and service valve
packing nuts.
a - Where two wrench flats are available (unions, quick-connects), use two properly sized wrenches to avoid twisting or
distorting tubes or fittings. Do not overtighten.
b - All service, safety and charging valves must be closed to the atmosphere.
c - Wirebrush and wipe flux and oxides from all heated joints.
• Open all interconnecting manual system valves, solenoid and expansion valves to ensure complete system volume.
• Connect a cylinder of refrigerant (used in operating system) to a convenient point such as the liquid, suction, discharge or
charging port service valve.
• Pressurize the entire system with refrigerant vapour.
Do not exceed the safe test pressure limits established by the unit manufacturer. Remember that some
systems are running under vacuum; so be sure that the seal or pressure relief device blow-off pressures will
not exceeded.
• When the selected leak test pressure is attained.

a - Leak test the entire system, including factory-made joints, seals, and insulated lines with one of the halogen leak detecti-
on devices mentioned previously.
S Follow the detector manufacturer instructions. Usually a two-cm-per-second movement of any halide detector probe is
sufficient to pick up leaks.
S If liquid soap is used, allow at least one minute before looking for bubbles.
S Check pressure relief devices for leaks.
S On water-cooled or chilled water equipment check the tower slumps, drains or storage tank for traces of refrigerant.
b - Mark or identify any located leaks and proceed on, unless the leak is severe.
S If a threaded gasket or flange joint leaks, try tightening it before proceeding.
• When the leak testing is completed and all leaks are identified, the system must be vented. The venting must be done to the
outside to prevent contaminating the equipment area with refrigerant vapour.

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• Repair all detected leaks.

a - When open flame heating of a joint is required, do not breath the products of combustion if refrigerant vapour is present.
Ventilate the area.
S On a leaking flare fitting, disassemble the fitting and check for dents, distortion or cracks.
S On leaking pipe fittings, disassemble and inspect. Reassemble using a refrigerant grade sealant.
S Gaskets or O-rings can sometimes be made to seal by loosening the flange or holding bolts slightly and giving the casting
or flange plate a sharp rap with a soft mallet.
S Do not 'overfill' a heated joint with solder or brazing alloy. Clean the leak area and attemp to draw the alloy into the leak
area. If necessary, completely unsweat the fitting and start over.
• Retest all detected and repaired leaks by repeating the procedure.
7.1.6 Evacuation and dehydration
7.1.6.1 General
Evacuate and dehydrate only after pressure leak testing. Proper evacuation and dehydration prove system tightness, expel non-
condensables, and assure a dry system before charging.
Essential tools to properly evacuate and dehydrate any system are a good vacuum pump and a good evacuation indicator.
Never use the system compressor to evacuate the system. A good evacuation indicator can be a mercury manometer, wet-
bulb indicator or thermocouple vacuum indicator. A compound gauge should not be used because of its internal friction and
inherent inaccuracy. Follow the manufacturer's instructions for the pump suction line sizing, oil, indicator location and
calibration.
7.1.6.2 Deep vacuum method
When a low absolute pressure or high vacuum is established in a closed system, the remaining noncondensables become
negligible. As the pressure is reduced, the boiling point of water is also reduced. This is the principle of the deep vacuum
method of dehydration. As long as the ambient temperature surrounding the system is higher than the boiling point of the internal
moisture, it will boil of and can be expelled. To properly employ this method, a good vacuum indicator must be used. In the
following procedure a wet-bulb vacuum indicator is used.
A good vacuum reading without a wet-bulb reading may indicate a tight system but not always a dry one.
If free water enters the compressor crankcase (ruptured chiller or condenser), the oil must be drained from the crankcase,
because the oil will float on the water and will not allow the water to evaporate. Dehydrate without oil in the compressor. After the
system has dried, add the proper oil charge and dehydrate again.
Table 3-31: Water boiling point

Boiling point Absolute pressure Boiling Absolute pressure
point
EC psia bara EC psia bara
100 14.7 1.013 12.7 0.21 0.014

93 11.5 0.792 10 0.17 0.012
82 7.4 0.510 7.2 0.14 0.010
46 1.4 0.097 4.4 0.12 0.008
26 0.49 0.034 1.6 0.10 0.007
21.1 0.36 0.025 0 0.08 0.005
15.5 0.25 0.017
F
• Ventilate all system pressures.

• Connect a center tapped 'jumper line' between point A and B, the high and low
sides of the system (figure 3-32). Use at least a 1/2“ OD line. Both points must E G
be closed when the system is evacuated. VACUUM
PUMP A
• Systems having Schrader type service points may require the use of a core B
depressor or remover (figure 3-28). VACUUM

C
• Connect the pump suction line, indicator and manifold suction hose to the INDICATOR
D
'jumper line' as shown. Valves C and D must be closed leaktight.
• Connect a container of dry system refrigerant to the manifold utility hose. Do
not allow the indicator line till below the pump suction line as oil may enter it Figure 3-32

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and cause a false reading. Use only distilled water in the wet-bulb indicator.
• Open valves A,B,C and E. Start the pump. Evacuation has started.
• Occasionally open valve D to check system evacuation. Allow valve D to remain open at least three minutes.
• Use table 3-31 to convert the wet-bulb reading to absolute pressure or vacuum based on water boiling point.
• When the system is evacuated to 0.1 bara close valves C and E. Stop the pump.
• Open valve D. Watch the indicator for a loss of system evacuation over a fifteen-minute period. A steady loss indicates a
system leak. Double check all field connections from A and B. If the leak cannot be stopped, stop the evacuation and
pressure leak test the system. Before admitting refrigerant vapour be sure valve D has closed.
• If no leaks are present close valve D, open valves C and E and restart the pump.
• Continue evacuating until the indicator shows a reading of 2 EC that corresponds to an absolute pressure of 0.01 bar.
• Close valves C and D. Open valve F allowing dry refrigerant to raise the system pressure to 0.7 bara.
• Allow the system to remain pressurized for about thirty minutes.
• Vent all system pressure by opening valve G.
• Close valve G, open valves C and D and restart the pump.
• Re-evacuate the system to 0.01 bara or lower, if possible.
• Close valves C and D, open valve F, pressurize and isolate the system by closing valves A and B.
• The system is ready for charging. Any remaining moisture will be picked up by refrigerant drier.
7.1.7 Charging
7.1.7.1 General
Despite the system size, the operating charge of refrigerant determines how efficient
and economic the system will run. An overcharged system can lead to high
temperatures, pressures and operating costs with the possibility of component failure.
An undercharged system leads to insufficient cooling, high operating costs and, on
hermetic systems, the possibility of compressormotor tipoff or failure. Therefore, proper VAPOR
refrigerant charging is one of the most important responsibilities in installing or servicing LIQUID
any system.
VAPOR AND LIQUID

7.1.7.2 Methods
CHARGING
Refrigerant may be added to a system in either a vapour or liquid state. This is figure 3-34
depending on the availability of charging points in the high and low pressure sides of the
system.
Vapour charging
Vapour charging (see figure 3-34) is done by transferring refrigerant vapour from the top of the liquid level
in the refrigerant container to either the high or the low (usually low) pressure side of the system. A
complete charge addition on systems containing 7 kg or less of the refrigerant is usually done by vapour
method. Although vapour charging is slow it allows a very close control. As vapour is expelled from the
refrigerant container, the system and container pressures tend to equalize and
the flow of vapour slows or even stops. When this occurs, the serviceman must either warm the container
by placing it in warm water (see precautions on handling refrigerants) or use the system compressor to
draw vapour from the container (figure 3-35). When using the system compressor, be aware first to check
the compressor oil level before starting.
Liquid charging
figure 3-35 Liquid charging is accomplished by adding or 'pouring' liquid directly from the refrigerant container into the
high-pressure side of the system. When liquid charging, remember :
• Never add liquid into the low-pressure side of the system.
• Never add liquid into the compressor discharge service valve port. Both can cause compressor damage.
• When liquid charging, always install a filter in the refrigerant feed line to prevent any solid particles in the container from
entering the system.
7.1.7 Procedures

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The following are three common charging procedures with a brief description how each should be done.
Follow the unit installation instructions for the method and charge procedure selection.
Charging by weight
This method (see (figure 3-36) is used if a complete charge is to be added and the amount of charge is
known. On systems short of charge of 4.5 kg or less it is sometimes faster and more economical to
remove all of the remaining system charge and add a complete new charge.
• Check the unit nameplate or the manufacturer documents for both charge weight and refrigerant type. figure 3-36
• Obtain the correct amount and type of refrigerant, charging manifold, hoses, and an accurate weight
scale in the correct range of refrigerant, container weight and charge reduction.
• Connect the manifold and container to the system with hoses, purge the hoses.
• Weigh the refrigerant container, be sure that the connecting hoses do not cause a false weight indication. Write down the
container weight, then subtract the system charge weight and mark the scale face for the correct charge reduction.
• Add refrigerant to the system by vapour or liquid method until the correct charge has been added to the system. Stop adding
charge by closing the refrigerant container valve.
Charging by sight glass
The sight glass (see figure 3-37) should be located in the system liquid line. This must be as
near as possible to the refrigerant feed device inlet. When the system is properly charged, only
a clear flow of liquid refrigerant passes through the sight glass. Some have refraction indicators
to help in determining the flow. Bubbles or flashing usually indicates a shortage in refrigerant.
Also a clear sightglass of liquid may be present but the system may not be charged at a higher
load condition. Always check and charge at the maximum load and the temperature conditions
expected.
When looking into a sight glass, always be sure that the clear sight glass is liquid and not
vapour.
figure 3-37
• Check the unit nameplate or manufacturer documents for the proper refrigerant type.
• Obtain the correct type and estimated amount of refrigerant and a charging manifold with
hoses.
• Connect the manifold and container to the system with hoses, purge the hoses.
• If a complete charge is to be added, add some refrigerant to the system by vapour or liquid method.
• Start the compressor and allow the system to run about ten minutes.
• Add refrigerant by vapour or liquid method.
• Allow the system to run on full load for ten minutes or until no fluctuations appear on the manifold gauges.
• Raise the compressor discharge or liquid pressure and hold it to a level equivalent to 43 EC (this may vary depending on
manufacturer recommendations) by throttling the condenser intake water or air.
• Observe the sight glass, add more refrigerant vapour if necessary.
• Allow the system to return to the initial running condition, the system should now be charged properly.
Charging by pressure-temperature relation
This method (see figure 3-38) of charging or checking charge is based on certain
assumptions listed at the end of the procedure. T
• Check the unit nameplate or manufacturer documents for the proper refrigerant
type.
• Obtain the correct type and estimated amount of refrigerant, a charging manifold
with hoses and an accurate temperature measuring instrument (thermocouple or
thermometer). Connect the manifold and container to the system with hoses,
purge the hoses. Attach the temperature indicator probe to the exterior of the
system liquid line as close as possible to the refrigerant feed device inlet. Insulate
it to prevent stray air currents or radiation from causing inaccurate readings.
• Add enough refrigerant to the system (vapour or liquid method) to enable the figure 3-38
compressor to run without a safety trip. Allow the system to run until the manifold gauges do not fluctuate.
• a - Measure the liquid line temperature.
b - Measure the discharge pressure and convert it to temperature. This becomes the system liquid condensing temperature.
c - Compare temperature (a) with (b). If the liquid line temperature is above the condensing temperature, add charge
because hot gas is mixed with the liquid.
d - Continue adding vapour to the system until the liquid line temperature (a) is equal to the system condensing temperature

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(b). The system is now charged for the condensing pressure present. Full load and raise the system discharge pressure
to the maximum expected conditions. Repeat these steps. The system is now properly charged.
The following assumptions have been made :
• The discharge pressure gauge is accurate within ± 0.15 bar.

• The temperature indicator is accurate within 1/2 EC and the probe contact is a true indication of the liquid line temperature.
• No pressure drop will take place between the point of pressure reading and the point where the temperature readings are
taken. On normal systems a 0.07 bar drop for discharge lines, 0.2 to 0.35 bar drop for liquid lines and 0.15 to 0.3 bar drop for
condensers is allowed.
7.1.8 Removing refrigerants
7.1.8.1 Excess charge
If a system has been overcharged, it is necessary to remove the excess. The excess will be removed PROTECT HANDS AND EYES !
by venting to the atmosphere (outdoors if possible) as a vapour. Proceed as follows:
• Connect a gauge manifold to the system and start it.

• Check the system charge using a procedure in 3-27.
• If there is an overcharge, crack open the manifold high-pressure valve. Allow vapour to vent from
the utility hose.
figure 3-39
On water-cooled condensers or chillers (unless water is circulating or is completely drained) do not release
the refrigerant pressure rapidly. A freeze-up may result.
• Secure the utility hose to prevent whipping. If the high-pressure hose is connected to the liquid line or receiver, vent all vapour
from the low-pressure side of the system.
• Vent vapour for ten seconds, reclose the valve. Allow the system pressures to settle out then re-check the charge.
• Alternately vent and check until the system is properly charged.
On systems having a liquid petcock excess charge can be removed by cracking open the petcock port.
7.1.8.2 Complete uncharge
On systems having a chiller and/or a water-cooled condenser, either drain

completely or circulate the water at all times to prevent a freeze-up.
Occasionally the serviceman must remove the system charge to make repairs or
modifications. Some methods of charge removal are: ICE
S Use the system compressor (see figure 3-40)

S Use a scavenging pump system (see figure 3-42)
S By the charge migration
Pump-out method - Using system compressor
Use containers marked for the system refrigerant. figure 3-40
• Isolate the compressor service ports and connect the gauge manifold. Connect the manifold utility hose to
the refrigerant container. Purge all hoses with system vapour.
• Place the refrigerant container in ice water and allow it to chill.
• Obtain weight scales and a sufficient number of empty, clean, dry refrigerant containers.
• Start the system - Open the service valves allowing the system pressure to register on the manifold
gauges.
• Fully open the refrigerant container valve.
• Open the manifold high-pressure valve. Hot discharge gas or liquid should now enter the cold container
and condense.
• Attempt to hold the compressor discharge pressure equivalent to a 90 % condensing pressure.
• Continue bypassing discharge gas or liquid into the refrigerant container until it is filled to its weight Figure 3-41

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capacity. Check with the scales (figure 3-41). Do not overfill. Change to another container if necessary.
• Reduce the system charge until the suction pressure falls to 1.3 bar. Stop the compressor.
• Close the refrigerant container valve and manifold high-pressure valve. Remove the utility hose from the container.
• Allow the system to set idle. Ventilate any overpressure pressure above 1.3 bar by cracking open the manifold valve.
• Before making repairs vent all system pressures.
• Tag all the containers having system liquid refrigerant in them as used.
• Evacuate the system before recharging.
Pump out - using scavenging pump system
A small air-cooled condenser with safety controls may be used.
• Obtain weight scales, a scavenging pump system and a sufficient number of empty, SCAVENGING
PUMP
clean, dry refrigerant containers capable of holding the system charge. SYSTEM
• Isolate the compressor service ports and connect the gauge manifold. figure 3-42
• Connect the manifold utility hose to the suction side of the scavenging system.
• Loosely connect another hose from the scavenging system liquid outlet valve to the
refrigerant container. Open the scavenge outlet.
• Midseat both the compressor service valves.
• Crack open the manifold low pressure-valve and allow the system pressure to flow into the scavenging system. Start the
scavenging pump.
• Allow vapour to be taken from the system until all lines have been purged with air.
• Tighten the hose at the refrigerant container. Open the refrigerant container valve.
• Allow the scavenging system to run with a 90 % condensing pressure and a 40 % suction pressure by modulating the hand
valves on the manifold and scavenge outlet valve. Do not overfill or overheat the refrigerant container. Check the cylinder
weight with scales. Remove and replace it when necessary.
• When the system pressure to the scavenging pump can no longer be held at a 40 % suction pressure, open the manifold
high-pressure valve.
• Continue removing refrigerant from the system until all internal pressure decreases to 1.3 bar. Turn off the scavenging pump.
• Close the refrigerant container valve and manifold valves. Vent the scavenging system pressure by loosening both the suction
and discharge hoses. Remove the refrigerant container. Tag all containers containing refrigerant as used.
• Before making any repairs or modifications to the system, vent all remaining pressure.
• Re-evacuate the system before recharging.
Charge migration method.
• Obtain weight scales and a sufficient number of empty, clean and dry refrigerant containers. Only use containers marked for
the system refrigerant. Evacuate the containers if possible.
• Connect a gauge manifold to the system. If the system has a liquid charging valve, connect the high-pressure manifold hose
to that valve. Connect the manifold utility hose to the refrigerant container. Purge all hoses. Close both manifold valves.
• Chill the refrigerant container to the lowest possible temperature. Isolate in ice if possible. Add as required during the transfer.
• a - If the high-pressure manifold hose is connected to the liquid valve, open the high-pressure manifold valve and refrigerant
container.
b - If no liquid service valve is available, open the manifold suction valve.
If the container was evacuated some refrigerant transferring to the container will flash and further chill the container. This
will fasten the refrigeration transfer.
• Allow the system refrigerant to migrate to the chilled containers until the system pressure is equivalent to the container
temperature. For example : If the container is at 3.3 EC and the system contains R-22. No further transfer will take place
when the system pressure reaches 5.5 bar.
• Once the condition in previous step occurs, either reduce the container temperature or increase the system temperature. If
neither can be done, discontinue removing the charge.
• Vent all remaining system pressure to the atmosphere before making repairs or modifications.
• Tag all containers having refrigerant as used.
• Re-evacuate the system before recharging.
7.1.9 Compressor oil
Start the compressorset only if all shields are mounted. After disconnecting the compressorset will run out for
some time and some parts will be hot. BURNING DANGER!

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7.1.9.1 General
Lubricating oils prevent friction and minimize wear. Refrigeration grade oils also have special characteristics which enable them
to work efficiently under various load and temperature conditions. Specifications and oil type are usually established by the
compressor or unit manufacturer based on extensive laboratory and performance tests.
The oil refiners meet or exceed the manufacturer's specifications and supply their oil in clean, dry, sealed containers ranging in
size from 1 liter cans to 200 liter drums. All are clearly identified. The serviceman has to recognize two things when choosing a
refrigeration oil :
• Specify only oil types recommended by the unit or compressor manufacturer.

• Purchase only the quantity of oil necessary for current needs to prevent leftover oil from becoming contaminated by air and
moisture.
7.1.9.2 Determining oil level
All Heinen & Hopman compressors are factory shipped with a normal charge of the correct type
of refrigeration grade oil and should rarely require additional oil. The serviceman must be sure that
the proper oil level is maintained in the compressor when it is installed and running.
7.1.9.3 Oil sight glass

figure 3-43
Most open, semi-hermetic and large full hermetic compressors have an oil sight glass or bulls-eye
located in their crankcase or shell (figure 3-43). This enables the serviceman to observe the oil
level.
When two compressors are connected in parallel the oil sight glass is usually located in the oil
equalizer line ( figure 3-44). Normally the compressor oil level is one-half way up the sight glass.
However it may vary slightly. When running, the oil level may surge-up and down due to the
sloshing of the oil by moving parts. When idle, the oil level may be higher due to absorption of
refrigerant by oil. A crankcase heater (figure 3-45) helps to prevent this condition and should always figure 3-44
be used when available.
When restarting an idle compressor the oil level may initially decrease below normal in the sight glass but should return to near
normal in less than one minute. Excessive foaming or a cloudy appearance may indicate a floodback condition and could be harmful
to the compressor. An oil level should always be observed in an oil sight glass, whether running or idle.
7.1.9.4 To determine the oil level
• Check to see that an oil level exists.

• Start the system on full load to ensure against the possibility of oil being trapped in the system.
figure 3-45
Allow the system to run full loaded for about twenty minutes.
• Stop the compressor and allow it to set idle for about five minutes
• Observe the level in the oil sight glass.
a - If the level is low, either a permanent trap or leak exists. Determine which, correct, and add oil to the compressor.
b - Too high level may cause high power consumption and/or possible compressor damage. Remove the excess charge to
obtain one-half sight glass level but first be sure the extra oil not absorbed refrigerant.
Beware of false oil levels caused by the capillary attraction of oil to glass.
7.1.9.5 Oil level plugs
Some compressors contain an oil level plug or valve which helps to determine the compressor oil level
(figure 3-46). It consists of a small hole at the exact normal oil level. A small threaded plug or valve
seals the drilled hole.
To determine the oil level :
• Run the compressor on full load for about twenty minutes. figure 3-46
• Stop the compressor and allow it to set idle for about five minutes.

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• Isolate the compressor from the system by closing the shut-off valves.
• Ventilate the internal compressor pressure by opening the suction shut-off valve service port.
• Slowly remove the oil level plug (if a valve is used, open the valve).
• Check the oil level by observation and/or a probe wire. A correct level should be at opening level.
Some small full hermetic compressors have no method of determining the oil level. Since these compressors are always
installed in factory designed, assembled and pipe systems there is rarely any problem with the oil level, except in the case of a
leak. If the amount of lost oil can be calculated, this amount should be added to the compressor. If the amount of lost oil cannot
be calculated, the serviceman must remove the compressor and drain all remaining oil from the suction line stub. Add a
measured normal oil charge by either the suction stub or by cutting the oil process tube and re-sealing it.
7.1.9.6 Adding oil to a compressor
There are many methods of adding oil to a compressor. Two of the most practical are :
Open system method OIL IN
• Run the compressor on full load, close the suction shut-off valve and reduce the crankcase pressure to 0.14
bar. figure 3-47
• Stop and isolate the compressor from the system by closing the discharge shut-off valve.
On non-operable compressors close suction and discharge shut-off valves. Reduce crankcase-pressure by
bleeding excess pressure through valve service ports.
• Slowly remove the oil fill plug.

• Add the required amount of oil. Be sure no dirt enters the oil fill hole (figure 3-47). Do not leave the compressor open any
longer than necessary.
• Replace the oil fill plug.
• Open the shut-off valves and restart the compressor, then run twenty minutes fully loaded and re-check the oil level.
In this procedure it is assumed that when venting or pumping the compressor crankcase to 0.14 bar, a small quantity of
refrigerant remains in the oil. As oil is added, refrigerant vapour is escaping to the atmosphere and no air enters the
compressor. If no refrigerant vapour is present in the oil, it will be necessary to either evacuate the compressor via the service
ports or sweep the air from the compressor. Crack open the discharge shut-off valve, pressurize the crankcase and vent the air
and some refrigerant vapour to the atmos-phere via the suction shut-off valve service port.
Closed system method

B A
Build an oil charging arrangement like shown in figure 3-48. Put the amount of oil
PLUG
necessary in the compressor into the oil charging reservoir via the oil fill plug.
Replace and seal plug. RESERVOIR
• Connect the oil feed line flare A to the compressor suction shutoff valve
SYSTEM FEED LINE
service port. REFRIGERANT VALVE
• Open the feed line valve.
• Loosely connect the pressure line flare B to the refrigerant cylinder. figure 3-48
• Crack open the serviceport on the suction shut-off valve. Allow refrigerant
vapour under system pressure to bubble through the reservoir oil and vent to the atmosphere via flare B.
• Tighten flair B and close the feed line control valve.
• Close the compressor suction shut-off valve, start the compressor and allow the crankcase pressure to reduce to 0.7 bar (10
psia).
• Stop the compressor and isolate by closing the discharge shut-off valve.
• Open the refrigerant cylinder valve.
• Slowly open the oil feed line valve and add the required amount of oil.
• Allow sufficient time for the oil to drain into the crankcase. Don not overfeed additional oil.
• Close the oil feed and refrigerant cylinder valves.
• Open the compressor shut-off valves and restart the compressor, then allow it to run for twenty minutes,
recheck the oil level.
This method of oil addition can be used on any system where a pressure tap is available in the suction
side of the compressor and the refrigerant cylinder pressure can be maintained higher than the
compressor suction pressure. An alternative to this method is to partially evacuate the isolated
compressor and draw oil into the compressor crankcase from an open container, see figure 3-49.
figure 3-49

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7.1.9.7 Removing oil
If oil must be removed from a compressor, use one of the following methods.
By drain or level plug
• Run the compressor on full load, close the suction shut-off valve and reduce the crankcase pressure to 0.14 bar
• Stop the compressor and isolate it by closing the discharge shut-off valve .
On non-coperable compressors close shut-off valves and reduce crankcase pressure by bleeding from the shut-off valve
service ports.
• a- If a compressor has an oil drain plug, carefully open it until oil seeps around the plug threads.
Do not remove the oil plug, than the full oil charge will be lost.
b- If an oil level plug is available, carefully loosen and remove it.

• Drain oil to the described level. Discard used oil.
• Re-tighten the plug, open the shut-off valves, start and re-check the oil level.
figure 3-50
By fill plug
• Follow the first two steps above. Then carefully remove the oil fill plug.
• Insert a syphon line into the compressor oil via the fill hole.
• Seal the line in place by using a neoprene stopper or modified oil plug (figure 3-50).
• Crack open the suction shut-off valve and pressurize the crankcase to 0.36 bar and reclose.
• Slowly open the syphon line valve and drain the required amount of oil from the compressor. Remove the used oil.
• Purge the excess crankcase pressure via the service port and remove the syphon line. Re-install the fill plug, open the shut-
off valves, start the compressor and recheck the oil level.
7.2 Before the first start-up
A cooling machine contains a harmful refrigerant under pressure. LEAK DANGER! Keep room well
ventilated. In the precense of an open flame, freon is liable to decompose in toxic gasses. Before checking
the following points put the main- and/or workswitch off. Only qualified personal is authorized to execute
the following activities at the cooling machine.
7.2.1 General
Check :
• Whether all parts and securities are mounted correctly (drawing).

• Whether all valves are in the right position.
7.2.2 Compressorset
7.2.2.1 Electric motor
The motor can be used for either direction of rotation. The sense of rotation can be changed by interchanging any two feeders of
the electrical wire.
Check :
• Whether the motor is connected correctly.

• Whether the air inlet is free.
• Set the thermostatic protection 5% above the current indicated on the nameplate.
• Whether the motor is turning easy and in balance.
7.2.2.2 Compressor

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• For information about the compressor is referred to the manufacturer documents.
7.2.2.3 Transmission of the compressorset
Check :
• Whether the transmission is mounted correctly.

• When the transmission is accomplished by a V-belt; pay attention to the following points :
a- Alignment of the V-belt (look at maintenance).
b- Tension of the V-belt (look at maintenance).
• Check, in case of a direct driven compressorset, the alignment of the transmission (look at maintenance).
• Whether the shields are mounted correctly.
7.2.2.4 Drier
Check :
• Whether the drier core is placed.

• Through the sight glass whether the filling is still active, green is active and yellow indicates saturation.
7.2.2.5 Thermostatic expansion valve
• Check whether the bulb is connected just after the evaporator.

• For further information is referred to the manufacturer documents.
7.2.2.6 Condenser
Water-cooled condenser
• Start the cooling water pump.

• Check whether the cooling water flow is sufficient.
Air cooled condenser
• Start the fan(s).

• Check whether the air in- and outlet are free.
7.3 Starting and stopping
7.3.1 Starting
If the compressorset is provided with carterheating, the carterheating must be active 24 hours before the first
start up. Start the compressorset only if all shields, doors etc. are mounted.
• Open the solenoid valve manually by means of the spindle, so that there can be sufficient pressure build-up.
• Start the system by turning the main switch on.
• Turn on: - Evaporator fan switch
- Compressor switch
- Coolwaterpump switch (watercooled condensor) or the condensor fan switch (aircooled condensor)
• Measure (during the first start) the current consumption in every phase.
• Set the thermostatic protection to 5% above the highest measured current.
• Watch the pressure gauges closely, until the machine has reached its normal operation condition.
• The evaporator temperature is about 10 EC lower than the room temperature.
• The temperature of the freon in the condensing unit is about 5 - 9 EC above the cooling water temperature.

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7.3.2 Stopping
After disconnecting, the compressorset will run-out for some time and some parts will be hot (e.g.
compressor) and others will be cold (e.g. tubes). BURNING AND FREEZING DANGER!
• Close the solenoid valve of the condenser.

• All of the freon is pumped into the condenser (this is called the evacuating of the system).
• The low pressure control will switch the compressor off when the setting is attained.
• Close all the valves of the installation.
• Stop the evaporator fan(s).
• Stop the cooling water pump or close the inlet valve, in case of a watercooled condenser.
• Stop the condenser fan(s) in case of an aircooled condenser.
After the machine has been in operation for ten hours the pulleys must be re-tightent to ensure that they
are still fixed.
7.4 Maintenance
A cooling machine contains a harmful refrigerant overpressure. LEAK DANGER! Keep room
well vented. In the presence of an open flame freon is liable to decompose in toxic gasses.
Always1 put the main- and/or workswitch off during activities at the installation. Start the
installation only if all shields, doors etc. are mounted. After disconnecting the compressorset
will run out for some time, and some parts will be hot (e.g. compressor) and others will be cold
(e.g. tubes). BURNING AND FREEZING DANGER! Only qualified personal is authorized to
execute the maintenance of the cooling machine.
1 = Excluding the commissioning of the cooling machine
7.4.1 General
7.4.1.1 Daily
• Check by sight glass whether the freon is clear and no bubbles are present (replenish).

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7.4.1.2 Monthly
• Check all connections for leakage.
The presence of oil on the tubes indicates a leakage.
7.4.2 Compressorset
7.4.2.1 Weekly
• Clean the compressorset.
7.4.2.2 Electric motor
• Ensure that the motor is clean and the air inlet is free.
• Check regularly whether the motor is noisy, when this occurs, the bearings may be worn and the electric motor or bearings
must be replaced.
Removal of the electric motor
• Disconnect the motor from the supply.

• Remove the shields over the transmission.
• Disconnect the transmission between motor and compressor.
• Dismount the motor and remove it.
Never place or move the motor by the shaft.
7.4.2.3 Compressor
• When the compressor is opened, all parts must be cleaned before they will be replaced.
Daily
• Check the suction and discharge pressure.

• Check the oilpressure.
• Check the oil level (sight glass), a correct oil level is halfway the sight glass.
Yearly
• Replace the compressor oil yearly.
7.4.3 Transmission of the compressorset
7.4.3.1 V-belt driven type

RULER
Removing of the V-belt
• Remove the front part of the shield over the transmission.

• The electric motor is placed on a cradle, that is secured with nuts.
• Loosen the nuts and move the cradle to loosen the V-belt. ALIGNMENT
• Remove the V-belt. V-BELT PULLEY'S
figure 3-51

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Mounting of the V-belt
Never force the V-belts on the sheaves, as this may damage the belt core, so that the belt will break after a short time of
operation.
• Shorten the distance between the centers, by moving the electric motor, until the belts can be fitted easily without the use of
tools.
• Then increase the distance until the V-belt is tensed.
• Align the V-belt with a ruler or something like that (figure 3-51).
• Give the V-belt the pre-discribed tension and secure the cradle.
• Replace the front part of the shield. After about 15 minutes of loaded operation the V-belt should be tightened (see tightening
of the V-belt).
• During the continued operation the tension should be checked after about 50 working hours, and there upon it should be
checked occasionally.
Tightening of the V-belt
• Measure the center distance.

• Deflect the V-belt in the middle. PUSH DOWN
• Measure the deflection and check according the table.
Profile diameter of smallest pulley (mm) Deflection (mm)

CENTRE DISTANCE (cm)
SPZ-ALPHA 67 - 95 1.0 - 1.5
DEFLECTION (mm)
100 - 200 1.5 - 2.0
SPB-BETA 160 - 224 3.6 - 5.1

250 - 400 5.1 - 6.6
Always ascertain that the V-belt is aligned correctly and at the right tension. Replace a figure 3-52
V-belt that shows signs of wear immediately.
V-belt pulley's
The V-belt pulley's are provided with a taper-lock bush and can be removed easily without the use of blow- or pull-tools.
Removing of the pulley’s
• loosen the screws and place one screw in the pressure hole of the pulley.
• Turn the screw in until the pulley is released.
• Remove the pulley from the shaft.
Mounting of the pulley’s
• Place the taper-lock bush and pulley together, so that the holes in the pulley and taper-lock bush are corresponding.
• Turn the screws in the holes and fasten them slightly.
• Align the pulley's.
• Tighten the screws equally until they are fixed.
7.4.3.2 Direct driven type
Removal of the coupling.
• The coupling can be disassembled by removing the screws.

• Clean the compressor and motor shafts and the coupling flanges. Remove all burrs.
Tighten the compressor hold down bolts.
figure 3-53

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Mounting of the coupling
• Fit the compressor flange to the compressor crankshaft. The flange has a tapered bore and
a keyway. Be sure the key fits in the keyway before placing the flange on the shaft.
• After the flange is in place, install the bolt and washer provided with the compressor. Tighten
the bold securely
Do not use the bolt and washer to force the flange in place.
• Fit the motor flange to the motor shaft, be sure that the key fits in the keyway. All parts
should fit snugly but easily. Do not force them into place.
• Start the motor and scribe a line adjacent to the motor bearing housing to locate the running
position of the armature. figure 3-54
• If the motor cannot be started, measure the amount of end play in the motor shaft. Set the
motor shaft at half this measurement and mark the position.
• The coupling is to be aligned with the motor shaft in this running position.
• Re-assemble the coupling and make a preliminary adjustment of dimension “E” (distance between flanges), shown in figure
3-53.
For the correct dimension of “E” is referred to the manufacturers documents.
• Tighten the motor flange screws.
Alignment of the coupling
• Move and shim the motor until dimension “E” is correct when measured at four positions at 90E
apart, and until the edges of the flanges are in line when tested with a straight edge (figure 3-53).
• Tighten the motor hold-down bolts.

• Check dimensions A, B, C and D. See figure 3-54 and 3-55. If the dimensions are all equal the
coupling is correctly aligned.
A convenient way to compare the dimensions is to set an inside capilar at the smaller
dimension and measure the extra width at the larger dimension with the capilar and a feeler
gauge.
figure 3-55
• If A and B are larger than C and D (figure 3-54) the coupling is in angular misalignment.
Move and shim the motor until the dimensions are within tolerances.
• If A and D are larger than B and C (fig. 3-55) the coupling is in parallel misalignment. Move and shim the motor until the
dimensions are in tolerances.
• Run the compressor until it warms up and re-check the alignment.
7.4.4 Drier
7.4.4.1 Normally
• Check regularly whether the drier filling is not saturated. Green is active and yellow indicates saturation.
• Before the drier is opened all freon must be pumped in the condenser.
• Always replace the drier filling in case of reparations at the cooling machine.
• When a new installation is taken into operation the drier filling must be regularly checked to determine the replacement
interval.
7.4.4.2 Yearly
• Replace the drier filling.
It is possible that the drier filling has to be changed more than once a year

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7.4.5 Thermostatic expansion valve
The cooling machine must be in operation several hours before the thermostatic expansion valve can be adjusted.
The thermostatic expansion valve is usually set to 10 EC superheating. The value can be set by the adjusting screw, by turning it
in the freon supply is enlarged (less superheating) and by turning it out the supply is reduced (more superheating).
When the thermostatic expansion valve is not set correctly, the adjusting screw must be turned slightly. Thereupon let the
installation operate for at least 15 minutes before another adjustment is made.
In case of freeze-up of the suction line the adjusting screw must be turned out slightly.
For further information is referred to the manufacturer documents.
7.4.6 Condenser
7.4.6.1 Weekly
• Check the freon level weekly.
7.4.6.2 Yearly
• Checking and possible cleaning of the condensor tubes must be performed yearly. This may only be performed by skilful
personnel.
8 Guidelines for troubleshooting
8.1 Troubleshooting
Once a source of trouble in a refrigeration system is located, it may be an easy matter to correct it. The main difficult in
servicing work generally being the location of the trouble. It is important that a systematic method of analyzing will be followed. It
would be considerably better for the serviceman to take the first half-hour to observe the arrangement and operation of the
machine. This is better than to make a hasty decision as to the cause of the trouble and make any adjustment in the hope that it
will solve the trouble. Such a procedure often adds trouble because the adjustment was not necessary or proper. When the
serviceman is following a systematic method of fault locating, he should first listen to the complaint of the owner or operator of
the equipment. This will give him his first impression as to the cause of the trouble. He should then carefully check the complaint
to look that it is justified.
In some instances, the cause of the trouble will be immediately apparent, but in the large majority of cases, some measuring of
pressures, temperatures and running time will have to be made. In this case, it will be necessary to determine the type of
machine since the method of locating the trouble will depend upon the type of refrigerating machine and the method of control.
The following table is put in as a guide for locating and correcting those troubles found more frequently within refrigeration
plants.
8.1.1 Frosted or sweating suction line
Cause Remedy
Thermostatic expansion valve adjusted so that refrigerant is Adjust the thermostatic expansion valve.
admitted to the expansion coil faster then it can be
evaporated.
The control adjustment is set for too low temperature and Adjust the control for a higher temperature of the cooling
does not correspond with the adjustment of the thermostatic unit.
expansion valve.

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In weather conditions where the relative humidity is very high This is not serious but may be avoided by insulating the
there may be some condensation on the suction line tubing. suction line by a vapour barrier material.
8.1.2 Warm liquid line
Cause Remedy
The system contains less than the required amount of Recharge with refrigerant.
refrigerant and warm vapour is passing through the liquid
line.
The thermostatic expansion valve is opened too far. Adjust the thermostatic expansion valve for correct back-
pressure.
8.1.3 Frosted liquid line
Cause Remedy
The liquid receiver shut-up valve is partly closed or Make sure the liquid line valve is wide open and if the liquid
obstructed with foreign matter, causing it to act as an receiver valve is partially obstructed it will be necessary to
expansion valve. either remove it and repair it or replace it by a new one.
8.1.4 Back pressure lower than normal
Cause Remedy
Thermostatic expansion valve adjusted so that too little liquid Re-adjust the thermostatic expansion valve for the correct
passes through the expansion coil. suction pressure setting.
Little or no refrigerant in the system. Locate the leak, repair it and recharge the system.
Thermostatic expansion valve blocked with ice from moisture Change or clear the thermostatic expansion valve and if
in the system or accumulation of dirt. moisture is the source of the trouble install a system drier.
8.1.5 No frost of the thermostatic expansion valve or cooling unit
Cause Remedy
Liquid line valve closed. Open the valve.
Liquid line completely blocked. Clear the line or replace the tubing.
Strainer completely stopped up with dirt. Clear the strainer.
The suction line closed. Open the suction line.
No refrigerant in the system. Locate the leak and recharge the system with refrigerant.
Inefficient compressor. Check compressor for efficiency. Make the necessary

repairs.
Motor operates but the compressor is idle. Tighten or replace the V-belt.
The operation cycle is short. Adjust the control.
8.1.6 System operates too much or all time

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Cause Remedy
Control will not cut out. Adjust, repair or replace the control.
Little or no refrigerant in the system. Locate the leak and recharge as necessary.
Incorrect adjustment of the thermostatic expansion valve. Adjust as necessary.
Inefficient compressor. Check the compressor and make the necessary repairs.
Compressor operating at too low a speed. See that the motor specifications correspond with the supply
voltage. See that the V-belt is not slipping and has the
correct tension.
Presence of air in the system. Purge air from the system as outlined under 'Purging the
system'.
Restricted circulation over the coolingcoils. See that there is unrestricted air flow around the coils.
8.1.7 Storage compartment too cold
Cause Remedy
Control set too low. Adjust to the desired temperature.
Control will not cut out. Repair and replace control.
8.1.8 Low operating head pressure on condensing unit
Cause Remedy
Insufficient refrigerant. Locate and repair the leak and recharge with correct amount
of refrigerant.
Inefficient compressor. Test the compressor for efficiency and make the necessary
repairs.
Thermostatic expansion valve clogged with ice or dirt Replace or clear the thermostatic expansion valve and
replace the system drier if moisture is the cause of the
trouble.
8.1.9 Head pressure too high
Cause Remedy
Presence of air in the system Remove the air from the system as outlined under 'Purging
the system'.
Too much refrigerant in the system. Blow of the refrigerant as necessary.
Dirty condensortubes or insufficient water supply to a Action as necessary.

watercooled condensing unit
Too much oil in the system which would tend to retard the Remove the oil charge from the compressor during the
removal of heat in the condenser. normal cycle and recharge the compressor with the correct
oil charge.
8.1.10 Frost on the thermostatic expansion valve only

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Cause Remedy
Thermostatic expansion valve clogged with ice or dirt. Replace or clear the thermostatic expansion valve and
dehydrate the system if moisture is the cause of the trouble.
8.1.11 Storage compartment warm
Cause Remedy
Control set too high. Adjust control for correct temperature.
Control will not cut out. Re-adjust or replace with a new or repaired control.
Insufficient refrigerant in the system. Locate the leak and recharge the system.
Too much frost on the cooling coil or evaporator. Defrost as necessary.
Insufficient compressor. Check the compressor and repair as necessary.
Fuses burned out and the motor idle. Replace fuses and check current supply line from the
switches.
8.1.12 Troubles with electric installation
Motor troubles usually develop during hot weather when the maximum load is put on the unit. Especially dangerous in hot
weather, are :
a. High head pressure due to air being present in the system.
b. Dirty condenser restricting the flow of heat.
c. Overcharged plants.
d. Cold room doors left open.
The following causes are some of the more usual complaints (applying to electric motors in general), of which the service
engineer will be confronted with.
Cause Remedy
Fuses blown. Fit the recommended size of fuses.
Low voltage. See that the supply voltage is within 10 % of the nameplate
volt.
Incorrect wiring up. Check with the wiring diagram supplied with the plant.
Break in the motor circuit. Check the circuit for continuity including also the starter
circuit.
Excessive load. Larger size of motor required.
Worn brushes making poor contact (where applicable). Replace and clean as necessary.
8.2 Complaints with a enumeration of possible causes
8.2.1 Compressor does not run
Check for following causes:
Electric line to motor open Head pressure too high
Fuse blown Loose flywheel

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Tripped overload V-belt(s) slipping
Cord not plugged in V-belt(s) broken
Control off-cold location Piston stuck
Control stuck open Stuck compressor or motor
8.2.2 Compressor shortcycles
Compressor capacity too great for evaporator Shortage of refrigerant
Control differential set too close Leaky thermostatic expansion valve
Discharge valve leak Overcharge of refrigerant
Motor overload relay cutting out Cycling on high pressure switch
8.2.2 Condensing pressure too high
Refrigerant overcharge Supply water too warm
Air in the system Water shut off or restricted water-cooled condenser
Dirty condenser Restricted water or drain lines
Too hot unit location Poor air circulation around unit
8.2.4 Refrigerated product not cold enough
Shortage of refrigerant Evaporator too small
Control set too high Compressor too small
Expansion valve, strainer or drier plugged Not enough circulation of cooled air
Leaking discharge or suction valve Restricted or too small refrigerant lines
Expansion valve not opening wide enough Service load too great
Iced or dirty coil
8.2.5 Condensing unit runs too much
Shortage of refrigerant Leaking discharge or suction valve
Unit too small or service load too great Iced or plugged coil
Control contacts stuck or closed Defective insulation

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Dirty condenser Air in system
Location too warm Inadequate air circulation around unit assembly
8.2.6 Hot liquid line
Shortage of refrigerant Condensing temperature too high
8.2.7 Frosted or sweating suction line
Thermostatic expansion valve adjusted to pass to much Therm. expansion valve bulb too warm or in wrong location
refrigerant
Capillary tube units-overcharge Refrigerant or condenser pressure too high
8.2.8 Liquid line very cold
Receiver shut-off valve partially closed or restricted Evaporator too high above condenser
Restricted drier or strainer
8.2.9 Condensing unit noisy
Insufficient compressor oil Mounting loose
V-belts defective or loose Motor brushes riding on commutator
Tubing rattle Oil sludging or refrigerant flooding back
Compressor flywheel or motorpully loose Condensing pressure too high
Worn motor or compressor bearings
8.2.10 Condensing pressure too low
Shortage of refrigerant Cold room
Compressor suction or discharge valves leaking Cold water, and water valve stuck open
8.2.11 Not cool enough
General

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Insufficient airmovenment in conditioned spaces User expecting results not designed fop
High wet bulb outside Unequal distribution
Too much make-up air Insufficient capacity of equipment
Excessive smoke or odors Dampers incorrectly set or position moved
Unusual loads, e.g. extra lights, appliance or population Ducts too small or badly laid out
Insufficient capacity of evaporator
Originally chosen too small Excessive static pressure of ducts
Not enough air over coil-belts slipping Coil not fully active; insufficient refrigerant
Blower motor underspeed (low voltage) Thermostatic expansion valve misadjusted, dirty defective
Coil dirty Coil oil-logged
Filters dirty
Insufficient capacity of condensing unit
Originally chosen too small Underspeed, belts, slipping, motor pulley too small
Under-size suction lines Suction valves leaking (dirty, broken or corroded)
Not enough water through condenser Discharge valves leaking (dirty, broken or corroded)
Stoppage in condenser, water or drain lines, water control Discharge or suction valve springs broken, rings worn or
valve, strainers or water pressure regulating valves broken
High head in drain lines Pistons worn
Misadjusted or defective water control valve Cylinder walls worn or scored : gasket leak between cylinder
Low or fluctuating water pressure heads Not enough lift of discharge or suction valves
Stoppage in suction or discharge shutoff valves or strainers Compressor not delivering full capacity
Stoppage in gas passages in condenser
8.1.12 Noisy operation
Vibrating sounds
Motor, pulley, belts out of line Piping connections too rigid
Belts loose Loose or insecure parts rattling
Inadequate foundation-insecure mounting Sheet metal panels inadequately braced

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High side or low side units not level Pulleys out of balance
Weight of units unequally supported at corners Ducts connected rigidly to low side
Knocking or pounding sounds
Excessive end-play of motor or fan shaft Seal squeaking-not being lubricated
Pulley loose on shaft, motor or compressor Oil grooves in bearings stopped
Motor or compressor not bolded tightly to base Oil pumping-liquid refrigerant returned to compressor
Water hammer-dirt in water control valve Broken suction or discharge valves
Too much refrigerant in system Solder or other foreign matter in cylinders
Too much make or too little oil in compressor Excessive lift of suction or discharge valves
Air noise
Excessive air velocities Bad design of supply grilles
Supply grilles too small

9 Summery Chapter 3
The dictionary defines refrigeration as a process of making something cold, and "cold" can be defined as an absence of heat.
A cooling machine has the task to cool parts or substances to a temperature that is lower than the surrounding area and keep it
at this temperature.
The applications of cooling installations are multiple. Examples are:
• conserving of provisions
• cooling of drinkingwater
• cool containers
• heat pumps
• freeze drying
• air drying (dismoisterizing of air)
• air handling
Heat is an invisible form of energy that arise from the conversion of other forms of energy in energy of heat. Only the effect of
heat is perceptible and the measuring of it is the way to define heat. The indication for heat is Q. The specific heat (cp) is the
amount of heat needed to raise the temperature 1EC of 1 kg of a substance.
Every substance can appear in three conditions (states): solid, liquid and gaseous. Water is the most known example, in solid
state as ice, in liquid state as water and in gaseous state as steam or vapour. When ice changes into water the temperature
during melting does not change. All the supplied energy is needed to change the substance from solid form into liquid form. Only
if the substance is entirely melted, the supply of heat will raise the temperature again. The change-of-state process is important
to the mechanical refrigeration cycle for two reasons. First, the change absorbs a relatively large amount of heat per kg of
substance; and second, this change-of-state takes place at constant temperature.
The point of saturated vapour is reached if there is added enough heat to a fluid. If the fluid is completely evaporated and there is
more heat added, we call this additional heat 'superheat'.
In every refrigeration installation there is a quantity of refrigerant. The refrigerant is a liquid or a gas with fixed properties.
Because the boilingpoint of refrigerants lays far below 0EC, the refrigerants only exist in gaseous state at surrounding pressure
(1 bar). When we raise the pressure with a compressor the gaseous refrigerant will at some point change of state and
becomes liquid. The refrigeration effect of a cooling installation is based on the evaporation of liquid refrigerant at low
temperature.

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The principle of the cooling machine is based on the following four functions:
• Expansion
• Evaporation
• Compression
• Condensation
These four functions are obtained by the following three main-components of the cooling machine:
• Evaporator
• Compressor
• Condenser
Refrigerant circuit components of a cooling machine are:

• Evaporator and condenser heat exchanger
- Finned heat exchanger
- Tube heat exchanger
- Plate heat exchanger
• Thermostatic expansion valve

2.02 The Cooling Machine Instructions

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Heinen & Hopman Engineering bv

P.O. Box 9 - 3750 GA Bunschoten - Holland General Users Manual - HVAC

4 The Cooling cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 How to use refrigerant charts, tables & diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Guidelines for service and maintenance - the cooling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Part three Chapter 3 : The coolingsection - 1

8 Guidelines for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Part three Chapter 3 : The coolingsection - 2

8.1.11 Storage compartment warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Part three Chapter 3 : The coolingsection - 3

Part three Chapter 3 : The coolingsection - 4

Heat is a form of energy and can be transferred from one body to

The applications of cooling installation are multiple. Examples are:

2.1 Heat and specific heat

Part three Chapter 3 : The coolingsection - 5

2.2 Change of state

2.3 The boiling process

If the pressure is higher than 1.01 bar, the temperature at which

Part three Chapter 3 : The coolingsection - 6

At any given pressure there is a corresponding boiling or saturation temperature:

Boiling temperature (E C) Pressure (bar)

2.4 Heat of evaporation

If 22,600 kJ is added, 10 kg of water will evaporate. If only part of the fluid

2.5 Superheat figure 3-8

SUPER HEATED VAPOR 1 kg of steam is superheated 30 EC, then 30 * 2 = 60 kJ is required.

The characteristics of a substance can be illustrated in a temperature-

Part three Chapter 3 : The coolingsection - 7

2.7 Pressure-enthalpy diagram

(see figure SUBCOOLED SUPERHEAT

2.8 The condensing process figure 3-11

Part three Chapter 3 : The coolingsection - 8

• A large evaporation and condensation heat

• Low evaporating pressure (0 - 5 bar) and condensation pressure (1 - 15 bar).

3.3 Environmental problems

3.4 Refrigerant alternatives

3.4.1 Refrigerant alternative R123

Part three Chapter 3 : The coolingsection - 9

3.4.2 Refrigerant alternatives R134a and R404a

3.5 Refrigerants - general

4 The Cooling cycle

HOT GAS LINE

Part three Chapter 3 : The coolingsection - 10

4.3 General cycle description

Next the principle of the coolingprocess is described (figure 3-14). B

HOT GAS LINE

Liquid refrigerant entering the evaporator is controlled by an automatic throttling A C

Part three Chapter 3 : The coolingsection - 11

5 Refrigerant circuit components

5.1 Evaporator and condenser heat exchanger

figure 3-16 figure 3-17

5.1.1 Finned heat exchanger

5.1.2 Tube heat exchanger

Part three Chapter 3 : The coolingsection - 12

5.1.3 Plate heat exchanger

5.2 Thermostatic expansion valve

5.2.1 Working of a thermostatic expansion valve

The function of a thermostatic expansion valve is determined by three fundamental pressures: