YMCA University of Science and Technology

Department of Mechanical Engineering

RAC WORKSHOP Lab Manual

EXPERIMENTNo.1
Aim: To find out the storage capacity of a refrigerator

Introduction: Refrigerator is an enclosed cabinet to provide 10 degree temperature. It is

used for pressuring perishable food stuffs and medicine. They are manufactured in different
sizes to meet the needs of various group of people. They are usually rated with internal gross
volume and the freezer volume. The freezer space is meant to preserve perishable product at
a temperature. Much below than 0 degree Celsius such as fish, meat, chicken, etc. and to
produce ice and ice cream as wellI. The refrigerators in India are available in different sizes of
various maximum volumes of 65, 90,140,200,250,300.liters of gross volume. The freezers
are usually provided at top portion of the refrigerator space occupying around 1/10 to 1/3rd
of the refrigerator volume. In some refrigerator freezers are provided at the bottom.

Construction: It consists of a small double door cabinet occupied with air tight doors. the
space between walls is filled with some heat insulation materials like glass wood,sock wood
,cork. puff, thermocol, etc .to minimize the heat loss ,the inner liner and outer surface of the
cabinet are kept highly polished with shining white paints .the inner lines made of steel is
divided into several slabs for storing the food stuffs . the refrigerators are equipped with an
automatic cabinet light controlled by the opening and closing of the door. For controlling the
temperature of the cabinet and making the working of the refrigerator automatic a thermostat
switch is provided on the top of the right hand side of inner liner. Rest regarding the cooling
system, the evaporator is fitting of the inner liner and condensing unit on the basis of
refrigerator.
Formula and Method: Actual volume of a refrigerator is found by subtracting the volume of
all accessories like egg tray, freezer ,cover ice trays, slabs , food box, etc. from gross volume
of inner surface of refrigerator ,i.e.,
Actual income = Gross volume-Accessories volume.
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

EXPERIMENT No. 2

Aim: To study different types of metering devices along with their dismantling and assemhlins
procedures and troubleshooting.

Theory: The expansion device is an important device that device the high pressure side and lou
pressure side of a refrigerating system .the expansion device performs the following functions

1. Reduces the high pressure liquid ref. to low pressure liquid refrigerant before being fed to the
evaporator.
2. It maintains the desired pressure difference between the high and low pressure sides of the
system, so that the liquid refrigerant vaporized at the designed pressure in the evaporator.
3. It controls the flow of refrigerant according to the load on the evaporator.

The types of expansion device:

1. Automatic or constant pressure expansion valve.

2 Thermostatic expansion valve.
3. Capillary tube.
4. Low side float valve.
5. High side float valve and,
6. Hand operated expansion valve.

.Automatic expansion valve: the automatic valve is also known as constant pressure valve
because it maintain constant pressure. Evaporator regardless of the load on the evaporator. The
main moving force is the evaporator
pressure.

The automatic expansion valve consists of a needle valve and a seat a metallic diaphragm o
bellows, spring and an adjusting screw. When the evaporator pressure rises the
upwards to reduce the opening of the valve.
diaphragm move

Adjusting screw
Spring-
Bellows of - Spring pressure
diaphragm
Needle and.
seat Evaporator pressure
Out
In

Strainer
 YMCA University of Science and
Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

Thermostat expansion valve: the thermostat

expansion valve is the most
PxDansion device is commercial and industrial commonly used
refrigerator system. This is also called a constant
SuDer heat valve because it maintains a constant.
Super
heat of the vapour refrigerator at the end
of the evaporator coil, by counting the flow of liquid refrigerant through the evaporator.
lts working depends upon the ditference of temperature of suction line
thus, a rise in evaporator
temperature will increase the temperature of the suction line and the thermal bulb of the
expansion valve. The higher temperature produce high pressure in the bulb , capillary and bellow
which causes the metal bellow to expend and force the needle to be away from its seats. Thus it
permit more liquid to enter in to evaporator to take care of increased heat load then a fall in
evaporator temperature will decrease temperature of suction line & thermal bulb of expansion
valve. Higher temperature produces higher pressure in bulb capillary & below which causes the
metal below to expand and force the needle to be away from its seats. Thus it permits move
liquid to enter into evaporator to take care of increased heat load then a fall of evaporator
temperature will decrease temperature of suction line and thermal bulb. Thus the needle comes
closer to its seat or orifice and admits uses refrigerant to the evaporator.

SENSINC BULB
AND CAPILLARY TUBE-

DAPHRAGM
SPRING-

INTERNAL EQUALZER POKTS-f

PIN
LOW PRESSURE LJQUID
VALVE AND SEAT-

VALVE BODY-

HIGH PRESsURE LIQUAD-

Fig. 15-13. Thermostatic eaxpansion valve.

Capillary tube: the capillary tube is used as an expansion device in small capacity hermetic
Sealed ref units such as in domestic refrigerators, water coolers, room air-conditioners and
freezers. It is a copper tube of small internal diameter of about 0.Smm to 2.25 mm and length
aries from 0.5 m to Smit is installed in liquid line between condenser and the evaporator. In its
offered
perator, liquid ref. from condenser enters the capillary tube. Due to frictional resistances
d small diameter tube., pressure drops. The greater pressure difference between condenser and
evaporator is needed for a given flow rate of refrigerant. The capillary tube has no moving
Parts and hence it has several advantages:-

NO wear occurs at any part.

OW starting torque motor can be used to drive compressor which is a great advantage.

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 YMCA University of Science and Technolog
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

Evaporator farn

Condenser Evaporator
Condenser tan

M
Fan motor

Drier iter
Capilary tube
Accumulator

Compressor
Schemetie layout of components

4. Low side float valve: A low side float valve is located in low
pressure side of refrigeration
system. It maintains a constants level of liquid ref. in evaporators and float chamber by opening
or closing a needle valve.

When the liquid refrigerant is evaporator vaporize, its level falls down. This causes the float to
drop& thus opens the needle valve and thereby allowing liquid line to float chamber and
then to
the evaporator to make up for the amount of
vaporization.

Low slde float valve Surpe drum

Flanged head

Foat b a Manua

Manual
o
shut
pin
Vave pirn

nahun Inlet connection

Vatvo soat
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

High Side Float Valve: It is located on high pressure side of refrigeration system. It is filled
vertically on condensing unit just after the condenser. When liquid level rise in float chamber
float balls rises up. pulling away the needle fromits seal % caused to open the outlet of float
ehamber, the float towards the evaporators through liquid line. Similarly as soon as liquid line
falls below the normal level in float chamber housing the float ball comes down, pushing the
needle to its seat, prevents further flow of the evaporators.

Body Float arm

High side float valve

Pvots

Valve pinn

Vahre seat

et
Dscharo ube
Foat bat Vont tube

6. Hand operated expansion simple expansion valve but it requires an

valve: it is the most
valve extends
operator to regulate flow of ref. to evaporator manually .the conical shaped needle on its
down into the valve part & restricts the flow area through port. When closed valve rests under
conical seats. The use of hand operated expansion valve is limited to systems. OperatingIt is not
nearly constants loads for long periods of time, such as in ice plants and cold storages.
to maintain a
Suitable for intermittently where load varies & compressor runs intermittently
Constant temperature.
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

EXPERIMENT No. 3

Aim: To identify leakage in a refrigeration system

flexible charging line, spanner set, brush, soap solktition
Tool usèd: Rotary vacuum pump.
detector.
pressure gauge.
halide torch and electronic leak

method to detect the leakage are as follows.

Theory: various testing
1. Water dip method
2. Electronic leak detector
3. Halide leak detector
4. Pressure test
5. No bubble test
6. Pipe evacuation

and shortest. Four detecting even minor

1. Water dip method: This method is very simple
co2 or n2 pressure in system &put a big water
leakages of refrigeration system, fill 60-70 pound
tank. Leakage can be detected with the help of bubble rising.

used in big refrigeration plants, ice plants etc. it is

2. Electronic leak detector: It is mainly an

electronic sensible device.

TUBE FILLED
WITH
REFRIGERANT
READOUT
POWER
AMPLIIER SUPPLY
LEAK

MALOGEN
PUMP SENSITIE
ELEMENT
PROBE
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP ILab Manual

detector: If there is change color in fhame coming out to be green are to from gas
3. Halideleak
leakage.

FLAME SHIE LD
REACTION
PLATE

MXER

-NEEDLE
VALVE

FUEL TANK

EXPLORING
HOSE

Figure 6-54-Halide leak detector,

& check the

the system through discharge or compound gauge
4. By pressure test: we pressure if leak is present in system.
solution and bubble solution will take place
system with sogp
vacuum pump, connect charging
line to discharge
bubble test: after creating vacuum by
5. No
end of charge line in oil. After sometime,
when we run the
line and dip the other
or part valve.
compressor, there should not be any bubbles when we open gauge
We make a
evacuation method: Evacuation
is done with the help of vacuum pump.
6. Pipe in we can not make vacuum.
vacuum of-29 inches .if there is any leakage system,

Gas charging
Refrigerator pressure= 5-10psi
Water cooler pressure= 24-35psi
Window a/c pressure= 60-75psi
For
recommended, then there will
be extra load on compressor.
pressure is more than this as
of service cylinder
of refrigerant is first filled in a service cylinder. Capacity
Cnarging refrigerant, now rub the ice on
service cylinder so that its temperature
2 to 5 kg. The method and
Irom
goes down.
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

EXPERIMENT No. 4
AIM: To perform electrical wiring of refrigerators, coolers, deep-freezers, multi-temperature
units and room air conditioners. ure

THEORY: In the refrigeration and air-conditioning system, the compressor is run with the heln
of a motor. The motor used has two windings, starting and running. At the time of
starting of
motor, both the windings-starting as well as running are in circuit. But after sometime the
starting winding has to be cut off from the circuit and the motor is run with running winding. The
device used to cut the starting winding from the circuit is called a relay.

Different electrical motor circuits are:

1. Split Phase Motor.

2. Capacitor start and Run motor (CSR).
3. Permanent Capacitor Run motor (PSC)
4. Capacitor Start Induction motor (CSIR).

REFRIGERATOR

Construction: It consists of small double wall cabinet occupied with air tight doors. The space
between walls is filled with some heat insulated materials like glasswool, rockwool, put-cork,
etc. to minimize heat loss. Inner liner and outer surface are kept highly polished and shining. The
inner liner made of steel is divided into several slabs for storing food stuffs. The refrigerators are
occupied with an automatic controlling light with opening and closing of door. For controlling
the temperature of cabinet and making working of refrigerator automatic, a thermostat switch is
provided on top of right hand side of inner surface. Rest
regarding cooling system, evaporator is
filled on top of inner liner and condensing unit on basis of refrigerator.

r kad restain

Concr
Refrigerator Wiring Diagram
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

DOMESTIC REFRIGERATOR WIRING TYPE-1

(DEFROST TIMER MOTOR CONNECTED TO TERMINAL 1-3)

THERMOSTAT

DEFROST
DEFROST THERMO
TMER

PLATE
HEATER

DOOR
SWITCH
-o- o-
DEFROST
HEATER
LO

N
EVAPORATOR
FAN MOTOR

THERMALL
WTERIoR OVERLOAD
EO
LIGHT PROTECTOR

cOMPRESsOR
THERMO MOTOR
FUSE
(72C)

PTC
STARTER

drawn by

hermawan http://hvactutorial.wordpress.com

10
 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual
RYAN

COOLERS
that increase of area
Principle: It is based on the principle that evaporation causes cooling. Also
increases rate of evaporation. We continuously give out water through our skin in the form of
This
sweat. The air surrounding our skin absorbs this water by changing it into vapours.
then fresh
evaporation does reduce the body temperature and produces cooling. If air is moving
air will come to collect water from our skin. If air has high humidity it will not be able to absorb
water from our skin.

of a
COOLER: It is a device to cool down or lower the temperature of a closed room. It consists
Water is
cuboidal metallic body having a fan on one side and pads on all three remaining sides.
filled in it and circulated through the pads with the pump. The air entering intro it gets cooled by

circulating water and blown out by fans.

DESERT COOLER: Its capacity is more and placed in windows. Use fresh air for blowing in
and produces low humidity.

room air
ROOM COOLER: Its capacity is low and is kept inside the rooms. It circulates the
is
and increases humidity. A running capacitor is used to provide high torque and starting supply
to common and any of the remaining terminals except
the common will run immediately.
given

Phase
Thermostat Fan
motor
R

Capacitor
Neutral oLP

Over load protactor

Compressor

Water Cooler Wiring Diagram

 YMCA University of Science and Technology
Department of Mechanical Engineering
RAC WORKSHOP Lab Manual

Room Air Cooler Wiring Diagram # 2 iO

With Capacitor marking and Installation)
gy.orr
nol Moving
HIGH FAN OFF OFF
OFF
1 LOW ON coolling
htto/01e
ON ON
3 3
Selector Switch

2
//eler
eler

Design By
Moving Motor Wasim Kharn
Bulb Indicator

Power
ogy.or
Supply P

tec C2
ricaN

2.2MF 5%
400W, VAC 85% ttp://e
600uFor 6MFt 5%
400Watts VAC 85C Water Pump Motor
Exhaust FAN
Copyright @ http://electricaltechnology.org/

12
 Technology
and
University ofScience E n g i n e e r i n g
YMCA Mechanical

Department
of Manual
WORKSHOP
Lab
RAC

end.
AIR CONDITIONER:
condenser on
the opposite
tube and s u c t i o n line
steel in which fin and evaporator
of tube,
C o n s t r u c t i o n : It has
casing made filter, capillary (R-22)
condenser, gas with Freon
discharge line, is charge shaf
All the parts
like refrigeration system one side
of the motor
complete fitted on
are c o n n e c t e d
in series. This double shaft
motor is
sealed unit, a
refrigerant by the side of other side of
a fan.
and the
evaporator
a blower is fitted behind

B a an

fhwrtat

wnderce fur