Refrigeration Experiment 1.1 v1

Chapter 1 – Basic Cooling and
Refrigeration Systems
EXPERIMENT 1.1 – INTRODUCTION TO COOLING AND REFRIGERATION
SYSTEMS
Name Class/Period Date
1. Objectives:
At the end of this experiment session, you will be able to:
 Explain the basic principles of refrigeration systems.

 Explain basic thermodynamics principles and terms.
 Perform basic calculations concerning a refrigeration system.
 Explain the basic operation of refrigeration systems.
 Explain the various components of the systems, their functions and methods of usage.
 Operate the refrigeration system at various operating conditions.
 Test the functions of the system components.
 Take measurements of the refrigeration system.
2. Equipment Required:
• Main Platform Unit
• Industrial Refrigeration Panel
3. Discussion: Basic principles of refrigeration

As a rule, the main function of the refrigeration system is to remove heat from air inside a closed place
and discharge the heat outside.
The two main principles for refrigeration operation are:
• Liquids absorb heat, when they transform from liquid into gas.
• Gases emit heat, when they transform from gas into liquid.
For instance, water absorbs heat from a flame as it boils and changes into gas or vapor. When that gas
or vapor condenses into a liquid, it radiates heat.
Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

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Experiment 1.1 – Introduction to Cooling and 1 All rights reserved
In a refrigeration system, a liquid refrigerant absorbs heat from the air, as it changes into gas.
The temperature is kept low by removing heat from the air faster than it is warmed up by the sun.
In a refrigeration system, heat is removed from the area to be cooled, to a required degree. This heat
must then be expelled to the outside air. This is done by utilizing the nature of heat movement.
Refrigerant is a liquid substance that flows through the refrigeration system. It absorbs heat from the
cooled down area, and emits it into the atmosphere. The refrigerant in a liquid state and under both low
pressure and temperature enters an Evaporator and absorbs heat, while changing its state into gas.
During compression, the refrigerant is under pressure and as a consequence its temperature rises.
The refrigerant in its gas state (high temperature and pressure) flows into a Condenser, where it
expands and emits heat while it changes back to a liquid state. After the expansion process, the
refrigerant returns to the Evaporator in a liquid state (low temperature and pressure) in order to absorb
the heat again and so on.
4. Discussion: Basic refrigeration cycle

To operate economically, refrigerant is recycled. For this reason, all refrigerators are based on the same
operation cycle, in a closed circuit, which is divided into four stages:
 Compression
 Condensation
 Expansion
 Evaporation
Those four stages are divided again into two parts:
 High side
 Low side
This refers to the pressures of the refrigerant in each side of the system.

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Energy Input
Low-Pressure High-Pressure
Compressor
Side Side
Heat moves Heat moves

Evaporator (4) Condenser (2)
from inside from
refrigerant to
Receiver
Expansion Valve (3)
Flow Cycle Heat Flow
Figure 1-1 Complete Four-part Cycle of Refrigeration
In order to understand the basic refrigeration cycle, it the first stage is at the Compressor (1). The
refrigerant enters into the compressor as a low-pressure gas, compresses, and moves out of the
compressor as a high-pressure and high temperature gas.
At the second stage, the refrigerant gas flows into the Condenser (2). Here the gas condenses into a
liquid, giving off its heat to the outside air.
The third stage is when the liquid then flows under high pressure, to the Expansion valve (3). This valve
restricts the flow of the liquid, thus lowering its pressure as it leaves the expansion valve.
The low-pressure liquid moves then to the fourth stage, the Evaporator (4), where heat from the inside
air is absorbed by the liquid changing its state from liquid into gas.
As a hot low-pressure gas, the refrigerant moves back to the compressor (1) where the entire cycle is
repeated.
5. Discussion: Basic operation of the system

As described above, all refrigeration systems must have four basic elements:

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 Compressor
 Condenser
 Expansion valve or restriction orifice
 Evaporator

These are all connected with pipes and connectors.
Figure 1-2
These four components determine the temperature, pressure and refrigerant output at each part of the
circuit.
In addition, the system is equipped with accessories and controls, which help the system to operate
efficiently and protects the main components from various problems. They are the following:
 Receiver-Drier (Accumulator)
 Sight Glass ("Eye")
 Pressure cut-off valves
 Temperature cut-off
 Electrical Blower
 Electrical Fan

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Review:
High-pressure gas is sent from the Compressor to the Condenser, where the heat is dissipated and the
gas is condensed into liquid.
The high-pressure liquid flows to the Expansion valve, where it is metered and its pressure is reduced.
At the Evaporator, the liquid absorbs heat from the air and evaporates to gas. The cycle then repeated,
starting at the compressor.
6. Composition of the main system

6.1. The compressor:
Purposes of the compressor are, to:
• Circulate the refrigerant in the circuit.

• Compress the refrigerant that leaves the evaporator and thereby raising its temperature in
order to create a temperature difference that will enable heat transfer from the cooled area,
toward the outside.
The pressure build-up in the system can only be accomplished by having a restriction in the high-
pressure side of the system. This is a small valve located in the Expansion Valve. This metered orifice
serves that purpose in the system.
Typical compressor in a refrigeration system:
Figure 1-3 Hermetic Compressor
6.2. The condenser:

The purpose of the condenser is to receive the high-pressure and temperature gas from the compressor
and convert this gas into liquid, while emitting heat to the surroundings.

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The condenser consists of pipes, usually made of copper and cooling fins usually made of aluminum.
The refrigerant in its gas state flows through the condenser pipes, while air is forced (by the car
movement + cooling fan) around the fins.
Typical condenser in the air-conditioning system:
Figure 1-4
6.3. The expansion valve:

The expansion valve fulfills a triple function in the cooling circuit:
 It releases the pressure on the refrigerant which is in a liquid state on its way to the evaporator. This
enables the refrigerant's expansion while its temperature is reduced to the lowest value in the cooling
circuit, a degree that enables efficient temperature exchange with the air in the refrigerated area.
 It determines the refrigerant flow intensity through the cooling circuit, accommodating the
momentary cooling request for the refrigerated area.
 It enables the compressor to accomplish its compressing action by restricting the refrigerant flow.
While the air cools in the refrigerated area, the expansion valve is employed to reduce the cooling
output from the evaporator, to prevent ice formation on the evaporator pipes, negatively affecting the
efficient function of the refrigeration system. Because it controls the flow rate of the refrigerant through
the evaporator, it affects the output of the refrigeration system.
In refrigeration systems, there are two main expansion valve types:
1. Thermostatic expansion valve.

2. Capillary (orifice) tubes.

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Figure 1-5
Refrigeration circuit with an expansion valve:
Figure 1-6 Refrigeration Circuit with an Orifice Tube
The refrigerant fluid arrives to the expansion valve while it is very hot and under high pressure. The
refrigerant, when it exits the other side of expansion valve, will be at the lowest temperature in the
whole cooling circuit cycle.

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During the expansion process, the refrigerant starts to evaporate, such that when the refrigerant enters
the evaporator, it is already partly in a gas state.
Note:
The expansion valve size is normally characterized by the orifice diameter. The orifice size
determines the system performances. Therefore, it is very important to choose the right orifice for
the system requirements.
6.4. Capillary (orifice) tube:

The capillary tube is used as an “expansion” component in the refrigeration system. Its diameter and
length are determined by the system's size.
In contrast to the expansion valve where the capillary tube size may be adjusted, the capillary (orifice)
tube is non-adjustable. Like the expansion valve, it is located inside the inlet of the evaporator. The
refrigerant flow rate through the tube is determined only by the pressure differences between the high-
pressure side and the low-pressure side in the cooling circuit. The capillary tube cannot be serviced and
should be replaced when faulty.
The purpose of the expansion and capillary tube is to raise the pressure on the compression side and
lower the gas pressure from compression pressure to suction pressure.
6.5. The evaporator:

The function of the evaporator is the opposite of the condenser's function. In the evaporator, the
refrigerant turns into gas at low pressure, while absorbing heat. The cooling down is done by the
evaporator blower which sucks the air from the refrigerated area and blows it through the evaporator
fins. When the air has passed through the evaporator fins and has given up its heat, it returns to the
refrigerated area cooler and drier.
As the refrigerant evaporates, the vapor is returned to the suction side of the compressor via the suction
line.
Typical evaporator in the refrigeration system:

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Figure 1-7 Typical Evaporator
6.6. The fan:

The fan moves the air through the evaporator or the condenser. The heat exchange depends upon the
temperature difference between the air and the refrigerant. The greater the difference is, the greater
the amount of heat that is exchanged between the air and the refrigerant.
When the fan operates at its higher speed, it delivers its greatest volume of air across the fins and coils
for a rapid evaporation. As the area is cooled down, it soon reaches a temperature where little or no
extra cooling results if the fan continues at its high-volume flow. A reduction in the fan speed will
decrease the airflow volume but the lower volume rate will allow the air to remain in contact with the
fins and coils for a longer period of time and give up its heat to the refrigerant.
Typical evaporator fan in a refrigeration system:
Figure 1-8

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Note:
For the coldest air temperature from the evaporator, operate the fan at its Lowest speed possible, to
allow a greater heat absorption by the refrigerant from the air.
6.7. The receiver-drier:

Refrigeration systems normally do not operate continuously, but are off or on
according to the needs for cooling. Over time, the system's seals dry and allow
moisture penetration from the environment.
Moisture accumulates in the evaporator and turns into ice at low operating
temperatures. Ice restricts the refrigerant flow and decreases the cooling
action.
The refrigeration system is sealed but moisture may enter on filling refrigerant
or at service process. Receiver/Drier
In addition, the cooling output demand is not constant and varies depending Figure 1-9
upon the thermal load and the environment temperature. Surplus refrigerant
that does not take part in the cooling process must be stored in order to prevent over-floating the
system.
To compensate for those variables, the system is equipped with a small receiver tank. Here an additional
amount of refrigerant (about 0.5 liter) is stored until needed by the system.
To prevent moisture absorbance, the receiver/drier tank is equipped with a desiccant or drying agent,
which is sealed in during its manufacturing process. In addition, the receiver/drier is equipped with a
sight glass which enables checking the refrigerant condition.
6.8. The refrigerant:

The term refrigerant refers to the liquid used in a refrigeration system to produce "cold" by removing
heat from the air. The refrigerant that was used for the automobile industry until 1994 was the R12
refrigerant.
This sort of refrigerant was chosen because it was the safest liquid available that remains stable at both
high and low temperatures and still gives off or absorbs great quantities of heat. It is not toxic, not
flammable and does not harm plastic or metal components.
Over the years, it was found out that the R12 refrigerant is very harmful for the environment and in
particular for the Ozone layer. For that reason the R12 refrigerant was prohibited by law and
refrigeration systems were converted to operate with an environmentally friendly refrigerant, the
R134a.

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As such, the MAIN PLATFORM UNIT "Air-conditioning & Refrigeration System" too operates with
R134a refrigerant and should NEVER be refilled with R12 refrigerant or the like.
7. Basic thermodynamic principles and terms

Note: The content of this chapter serves only as a reference to and as a supplement for the given
subject. Detailed information about thermodynamic principles and terms should be taken from a
proper textbook about this subject.
Work: Work may be described as force applied to overcome a certain resistance

along a certain distance. The invested work is calculated by multiplying the
applied force (Kg) and the distance (m).
Energy: Energy may be described as the ability of a body to perform work. The main
feature of Energy is its ability to change forms such as:
 Heat Energy
 Light Energy
 Mechanical Energy
 Electric Energy
 Chemical Energy
 Nuclear Energy
For the air-conditioning system we are interested in the following Energy
forms:
Heat Energy, which deals with the thermal processes that occur in the cooling
circuit and in the air-conditioned area. Heat energy is usually measured with
Kcal units (1 Kcal = heat energy needed to raise the temperature of 1 Kg water
in 1ºC).
Mechanical Energy, which deals with the pressures, that occur in the cooling
circuit and with the power needed to operate the refrigeration compressor.
Mechanical energy is usually measured with kW or HP units (1 HP=746
W=0.746KW).
Electric Energy, which deals with electric and electronic systems in a vehicle.
Electrical energy is usually measured with kW units.
Pressure: Pressure is one form of Mechanical Energy which develops when a Fluid or a
Gas applies force within a pipe or against a reservoir wall. The units usually
used to measure pressure are (bars) 1 bar = 0.987 Atmosphere (a force of 1
Kg applied on an area of 1 cm2).

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Temperature: Temperature may be defined as the heat energy of a certain body. Two
reference points are determined for temperature measurements:
 The heat energy in water at its freezing point.
 The heat energy in water at its boiling point.
For temperature measurements, two systems are employed:

1. The Anglo-Saxon system which measures on the Fahrenheit scale (oF).
2. The Metric system which measures on the Celsius scale (oC).
Note: For the calculations in this chapter we will solely use the metric system.
Water freezing point = 0ºC, water boiling point = 100ºC.
Latent Heat: Causes changes in the accumulation state of a certain substance, without
changing the given substance temperature. Every substance can change its
accumulation state from a solid state into a liquid state or from a liquid state
into a gas state and vise versa.
These procedures are performed without any changes in the substance

temperature, but are accompanied with the emission or absorption of Latent
Heat.
The absorption of heat during evaporation and emission of heat during

condensation maintains a steady base temperature because Latent Heat
enables the cooling cycle.
Enthalpy: Enthalpy is a figure which indicates the energy quantity preserved in a given
substance (potential internal energy in the form of heat; potential internal
energy in the form of pressure.)
The Enthalpy figure is determinate by the temperature and the pressure at

which the substance exist.
Specific Is a figure which indicates the energy quantity preserved in a weight unit of a
Enthalpy: given substance?
The specific Enthalpy is determined in the following way:
H = Cp(T – Tr)
When:
1. H – Enthalpy

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2. Cp – Specific heat
3. T – Substance temperature (absolute)
4. Tr – Related temperature (absolute)
Entropy: The entropy is the energy quantity preserved in the substance at a

certain state of form, for a given absolute pressure T (measured with Kelvin degrees).
The Entropy is determinate as the following:
h
S=
T
When:
S – Entropy
h – Enthalpy
t – Substance temperature (absolute)
Thermal load: The thermal load of a refrigeration system is the heat quantity that the
system has to remove from the air-conditioned area. This is one of the main parameters
that are taken in consideration while designing a refrigeration system and its
components.
8. Coefficient Of Performance (COP):

Coefficient of performance of a cooling system is described as the relation between the discharged
cooling output and the power needed to drive the compressor for the compression process (or the
power input).
The mathematical relations look like:
Discharges cooling output [kW]

COP =
Power input [kW]
9. p-h diagram:
p-h diagram gives the refrigerant pressure as a function of its Enthalpy.
The diagram gives additional parameters as well such as: Refrigerant temperature, its Entropy and its
form of state.

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The theoretical cooling process as The real cooling process as shown on a
shown on a p-h diagram p-h diagram
Figure 1-10
A real process of a cooling cycle is described on the right fig. as it appears on a p-h diagram. There are
pressures lost at the condenser and at the evaporator, which cause a certain temperature drop of the
refrigerant while flowing through them, although the heat transfer is performed without changing the
refrigerant temperature. In addition, an over cooling process occurs at the condenser at the end of the
condensing cycle and an overheating process occurs at the evaporator at the end of the evaporation
cycle.
10. Structure and operation of the system:

As explained above and as seen in the basic cooling system, all refrigeration systems must have four
basic elements:
1. A compressor.
2. A condenser with a fan.
3. An orifice element as a Thermostatic Expansion Valve (TEV) or capillary tube.
4. An evaporator with a fan.
These components determine the temperature, pressure and refrigerant output at each part of the
circuit.
The professional cooling system is composed of MAIN PLATFORM UNIT and INDUSTRIAL
REFRIGERATION PANEL as described in the following circuit:

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INDUSTRIAL
EVR
V8 REFRIGERATION PANEL
CV3
V7
L2 L1
TEV2
TS7 E2 TS8 V6 E1
TS5 TS6
Evapora Evapora
Room 2 Room 1
Air Air
Quick Quick Quick
TEV1
V5
MAIN
RV OF
TS3 TS4 PLATFORM V4
UNIT
Capillary
Conden
PS1 PS2
Air Receiver CV2
TS1 TS2
Sight
Compressor
V1 V2
CV1
Filter
FD
V3
The system includes two cooling chambers intended to have two different temperatures. The right
chamber is for low temperature and the left one is for higher temperature.
Every chamber includes an evaporator, a fan, temperature sensors and an electric valve controlling the
gas supply to the evaporator.

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The two chambers are located in the INDUSTRIAL REFRIGERATION PANEL professional refrigeration
panel and are connected to MAIN PLATFORM UNIT by quick fasteners.
The experiments in chapter one are experiments with the right chamber only. Valves 6 and 7 are always
closed in these experiments. The INDUSTRIAL REFRIGERATION PANEL panel acts as DAR-3311 panel. The
drawings in chapter one experiments show only the right chamber.
Identify these components in the following drawing of the basic refrigeration system including MAIN
PLATFORM UNIT and INDUSTRIAL REFRIGERATION PANEL.
V8
L1
INDUSTRIAL REFRIGERATION PANEL TS5 E1 TS6
Evapora
Air
Quick Quick
TEV1
V5
MAIN
RV OF
PLATFORM
TS3 TS4
UNIT V4
Capillary
Conden
PS1 PS2
Air Receiver CV2
TS1 TS2
Sight
Compressor
V1 V2
CV1
Filter
FD
V3
Figure 1-11

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In addition, the system is equipped with accessories and controls, which help the system operate
efficiently and protect the main components from various problems. They are the following:
 Receiver-Drier – A container equipped with desiccant to remove moisture and is utilized to store and
filter liquid refrigerant. The receiver-drier is located in the liquid line between the condenser outlet
and the expansion valve inlet.
 Sight Glass ("Eye") found on the liquid line. This unit checks whether the cooling liquid level is
satisfactory. Bubbles usually signal lack of cooling liquid in the system.
 Receiver – A container for storing gas.
The MAIN PLATFORM UNIT has two modes of operations: TEV mode and Capillary mode. Valves are
installed in the system in order to enable these two modes.
These valves direct the refrigerant according to the chosen refrigeration circuit. The valves are operated
by the system monitor.
The basic refrigeration system is composed of MAIN PLATFORM UNIT (general air-conditioning and
refrigeration system) and DAR-3311 (basic refrigeration panel).
Because MAIN PLATFORM UNIT is also geared for air-conditioning, it includes a 4-way valve (the RV).
This valve enables changing the system from a cooling system to a heating system.
In a refrigeration system, the RV stage is always at its normal position, which forms a cooling system
only. The compressor sucks gas from the evaporator and compresses it to the condenser.
The system also includes Temperature Sensors (TS1-TS6), and Pressure Sensors (PS1 and PS2).
The evaporator includes a heater which acts as a thermal load or as a defrost device.

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The system is operated by the switches, keys and LCD display on the monitor controller as follows:
LCD
 Suction pressure too low

 Room temperature is high
 Discharge pressure too high
Fault  Ice on the evaporator
 Suction & discharge pressure are equal
Description  Room temperature is not cold enough
 System is not working
 Air-conditioning cools instead of heating
MONITOR
1 2 3
4 5 6
7 8 9
* 0 #
STATE FAULT
ENTER
POWER
ON
OFF
PROGRAM
ON Auto
OFF Manual

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11. Procedure:
Step 1: Check that the INDUSTRIAL REFRIGERATION PANEL panel is properly installed on the
refrigeration and air-conditioning general system MAIN PLATFORM UNIT according to the
instructions described in the book's preface.
Step 2: Check that the MAIN PLATFORM UNIT MONITOR and PROGRAM switches are at OFF
position.
A ground leakage relay, a semi-automatic switch, and a main power switch are installed in a
main power box located on the rear panel.
Step 3: Connect the MAIN PLATFORM UNIT power supply cable to the Mains.
Step 4: Check that the high voltage ground leakage relay and the semi-automatic switch are ON.
Step 5: Set the Auto/Manual switch (located on the bottom left of the simulator) to the Manual
position.
Step 6: Turn ON the main POWER switch located on the main power box on the rear panel.
Step 7: Turn ON the monitor power switch.
Step 8: The FAULT display should display the number 00. If not, use the keys above the FAULT
display to display the number 00 (no fault condition) on the FAULT 7-SEG. display and press
the ENTER key beneath this display.

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Step 9: The STATE display should display the number 00 (no operation program).
The refrigeration devices (with the INDUSTRIAL REFRIGERATION PANEL for basic
refrigeration) are as follows:
No. Symbol Description
1. V1 Receiver's input valve (for TEV mode)
2. V2 Receiver's output valve (for TEV mode)
3. V3 Receiver's by-pass valve (for capillary mode)
4. V4 Transfers gas to the capillary unit
5. V5 Transfers gas to the TEV unit
6. V8 Transfers gas from the evaporator to the compressor
7. CM Compressor
8. OF Out fan (the base condenser fan)
9. E1 Evaporator fan (the panel evaporator fan)
10. L1 Evaporator thermal load
These components are controlled by the system's controller.

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Step 10: On the LCD display you should find the following table:
V1 V2 V3 V4 V5 V6 V7 V8 CM OF
TEV mode:
The TEV (Thermostatic Expansion Valves) are used to gauge and restrict the liquid
refrigerant's flow entering the evaporator, to a rate equivalent to the amount of refrigerant
being evaporated in the evaporator. The valve causes a pressure drop in the system,
separating the high-pressure side of the system from the low-pressure side of the system,
allowing the low-pressure refrigerant to absorb heat onto itself.
Use the keys above the STATE display to display the number 11 (Basic Refrigeration TEV
Experiment Program) on the STATE 7-segment display and press the ENTER key beneath
this display.
Operating this program, the refrigeration system is set to TEV mode.
Step 11: Changing the STATE number does not start the operating program (even after pressing the
ENTER key).
The STATE number after pressing the ENTER key, only displays the required operating
program and state.
Step 12: Lower the PROGRAM switch and raise it.
The message 'Program 11' should appear on the LCD.
The TEV mode states are 11-16.
Note:
You can move from one TEV state to another without lowering and raising the PROGRAM
switch. If you lower and raise the PROGRAM switch, the system acts as a relax device for
safe operation.

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The TEV programs are:
State 11 – TEV operation with oC display.
State 12 – TEV operation with oF display.
State 13 – TEV operation with graphic display.
State 14 – TEV operation with oC display and thermal load.
State 15 – TEV operation with oF display and thermal load.
State 16 – TEV operation with graphic display and thermal load.
ON ON ON ON ON ON
If "on" (lowercase) appears on the CM and OF columns, it means that the compressor is in a
3 minutes delay state before it starts to work. This delay protects the compressor.

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Step 14: Copy the following circuit to your notebook and mark the refrigerant path on it.
V8
L1
Evapora
Air
Quick Quick
TEV1
MAIN V5
PLATFORM
RV OF
TS3 TS4 UNIT V4
Capillary
Conden
PS1 PS2
Air Receiver CV2
TS1 TS2
Sight
Compressor
V1 V2
CV1
Filter
FD
V3

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Step 15: The LCD also displays the system pressures and temperature as follows:
LP – Low Pressure (the suction pressure measured by PS1)
HP – High Pressure (the compression pressure measured by PS2)
T1 – The compressor inlet temperature (measured by TS1)
T2 – The compressor outlet temperature (measured by TS2)
T3 – The condenser inlet air temperature (measured by TS3)
T4 – The condenser outlet air temperature (measured by TS4)
T5 – The evaporator outlet air temperature (measured by TS5)
T6 – The evaporator inlet air temperature (the cooling chamber temperature measured
by TS6)
T7 – Not relevant
T8 – Not relevant
The values are displayed in a table as follows:
LP HP T1 T2 T3 T4 T5 T6 T7 T8
Identify the sensors in the drawing and in the system.
Step 16: Another table that appears on the LCD display is the control parameters:
S1 – Room temperature setup
D1 – Room temperature difference

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S1 D1 S2 D2 SP PD E1 L1 E2 RT
20oC 5o C LO
The setup temperature is the required temperature. When the cooling chamber
temperature goes below this temperature, the refrigeration system should stop cooling and
this is done by stopping the compressor.
The compressor turns ON when the cooling chamber temperature reaches S1 + D1. D1 is
determined in order to avoid the system oscillating.
There is a linear relationship between the temperature and pressure. This is why the
cooling chamber temperature can be controlled according to the system low pressure or
the system high pressure. This subject will be described later.
Identify the system's default values of S1 and D1.

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Step 17: Immediately after operating the refrigeration, the suction pressure should be high and go
down while the system is cooling according to the following graph.
LP
The Stabilization Point
At the stabilization point the suction pressure (LP) is almost unchanged.
The stabilization point, which is the operation point, is where the pressures in the system
are the right ones for cooling and are appropriate for the system's devices, the refrigerant,
the fan speed and the environment.
The system includes a sight glass (an "eye") enabling observation on the refrigerant.
The refrigerant at that point should be liquid without bubbles.
If there are bubbles after a long period of operation, it indicates faulty refrigeration system.
Observe this sight glass and check that there are no bubbles.
At the stabilization point there should not be bubbles at all.
Inside the cooling chamber there is a partition plate dividing the chamber
It is possible to move the partition back and forth in order to change the volume of the
cooling chamber. The cooling chamber may be made smaller in order to reach very low
temperatures.
Move the partition according to the distances showed in the following table, and fill the
table with your results (wait 5-10 minutes between measurements).
Temperature/Distance X=0 X=10 X=20 X=30
[cm] [cm] [cm] [cm]
T5 [c]

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Step 18: Change the STATE no. to 12 and press ENTER.
This state does not change the system's operation; it only changes the display from oC to oF.
Observe that.
Step 19: When the LP is stable at the stabilized point, record the temperature and pressure values of
the stabilization point in the table at step 44.
The cooling chamber temperature should continue to go down.
This state does not change the system's operation; it only changes the display to the
graphic display.
The monitor samples and displays the LP and T6 every 2 seconds and displays them
graphically on the screen.
Observe that.
Step 21: The chamber temperature T6 goes down as long as the system is cooling (the compressor
works).
On the 11-16 experiment states the refrigeration's control is according to the temperature.
The compressor should turn OFF when the chamber temperature goes below S1 and should
turn ON when the chamber temperature reaches S1+ D1.
The default value of S1 is 20oC (68oF) and the default value of D1 is 5oC (9oF).
Check that.
Step 22: See what happens when the cooling chamber temperature reaches the S1 point.
Step 23: Wait until the compressor turns ON again.
Step 24: The evaporator speed can be changed by the '*' key.
Press the '*' key and check that the evaporator fan (E1) changes to HI.
Step 25: Wait until the system reaches the stabilized point.
Record the stabilization values.
Step 26: Press the '*' key again and check that E1 is changed into 'LO'.

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Step 27: Now we will use the thermal load (heat source).
Change the STATE no. to 16 and press ENTER.
You should put a heat source inside the cooling chamber. Use any heat source available.
The suction pressure should go up slowly.
Step 28: Wait until the system is stable.
Identify the new stabilized point.
Step 29: Change the E1 speed to high and record the new stabilized point values.
Step 30: Change the E1 speed back to low.
Step 31: Change the STATE no. to 14 (oC) and press ENTER.
Step 32: Change the STATE no. to 15 (oF) and press ENTER.
States 14, 15 and 16 operate a heating body in the evaporator for two minutes (ON) and
one minute (OFF) alternately.
Step 33: The system at 11-16 states allows you to change the S1 value in a certain range.
Step 34: Key in the number 18 (if you are in oC) or 65 (if you are in oF) and key '#'.
Step 35: Change the state no. to 11 or 12 accordingly.
Step 36: Wait until the compressor stops working.
Step 37: Record the pressures and temperatures.
Step 38: Open the cooling chamber window.
Step 39: Wait until the compressor turns ON.
Lower the PROGRAM switch and raise it.

Systems
All the devices should shut OFF.
Step 42: Open the cooling chamber window and let the environment air to enter inside.
Step 43: Wait about 5 minutes.
Step 44: Fill in the following table with the stabilization point's values you have recorded.
No. Comp. Load E1 LP HP T1 T2 T3 T4 T5 T6
1. ON OFF LO
2. ON OFF HI
3. OFF OFF LO
4. OFF OFF HI
5. ON ON LO
6. ON ON HI
7. OFF ON LO
8. OFF ON HI
Capillary mode:
The capillary tube is designed to lower the cooling liquid pressure at the same measure the
compressor raised it during the compression process.
The pressure drop on the tube depends on:
 The internal diameter of the tube.

 The tube length.
 The flow speed.
 The cooling material specific weight.
 The friction coefficient between the cooling material and the tube.
This is a fix control element, which depends on its dimensions and material.

Systems
Step 46: Lower the PROGRAM switch and raise it.
The capillary mode states are 21-26.
You can move from one capillary state to another without lowering and raising the
PROGRAM switch. If you lower and raise the PROGRAM switch, the system acts as a relaxed
device for safety operation.
The capillary programs are:
State 21 – capillary operation with oC display.
State 22 – capillary operation with oF display.
State 23 – capillary operation with graphic display.
State 24 – capillary operation with oC display and thermal load.
State 25 – capillary operation with oF display and thermal load.
State 26 – capillary operation with graphic display.
ON ON ON ON ON
If "on" (lowercase) appears on the CM and OF columns, it means that the compressor is in a
3 minutes delay state before it starts to work. This delay protects the compressor.

Systems
Step 48: Copy the following circuit to your notebook and mark the refrigerant path on it.
V8
L1
Evapora
Air
Quick Quick
TEV1
V5
MAIN
PLATFORM
RV OF
TS3 TS4 UNIT V4
Capillary
Conden
PS1 PS2
Air Receiver CV2
TS1 TS2
Sight
Compressor
V1 V2
CV1
Filter
FD
V3
Step 49: The sensor table is the same as the TEV experiment.
LP HP T1 T2 T3 T4 T5 T6 T7 T8

Systems
Step 50: The control table is a little different. At this experiment the control is made according to
the low pressure.
The table is as follows:
S1 D1 S2 D2 SP PD E1 L1 E2 RT
33 17 LO
SP – setting low pressure.
PD – low pressure difference.
This state does not change the system's operation; it only changes the display from oC to oF.
Observe that.
Step 52: Observe the temperature and pressure values and wait for the system to stabilize.
Step 53: When LP is at a stable point, record the temperature and pressure values at the
stabilization point in the table at step 72.
The cooling chamber temperature should continue to go down.
This state does not change the system's operation; it only changes the display to graphic
display.
The monitor samples and displays the LP and T6 every 2 seconds and displays them
graphically on the screen.
Observe that.
This state operates the thermal load to the evaporator.
Here you should put a heat source inside the cooling chamber. You can use any heat source
available.

Systems
The suction pressure should go up slowly.
Step 56: Change the E1 speed (by keying '*') to high and record the new stabilization point values.
Step 58: Wait until the system is stable.
Identify the new stabilization point.
Step 59: Change the STATE no. to 24 (oC) and press ENTER.
Step 60: Change the E1 speed to high and record the new stabilization point values.
Step 62: Change the STATE no. to 25 (oF) and press ENTER.
Step 63: The system at 21-26 states allows you to change the SP value in a certain range.
Step 64: Key in the number 20 and key '#'.
Step 65: Change the state no. to 21 or 22.
Step 66: Wait until the compressor stops working.
Step 68: Open the cooling chamber window.
Step 69: Wait until the compressor turns ON.
Lower the PROGRAM switch and raise it.
All the devices should shut OFF.

Systems
Step 72: Fill in the following table with the stabilization point's values.
No. Comp. Load E1 LP HP T1 T2 T3 T4 T5 T6
1. ON OFF LO
2. ON OFF HI
3. OFF OFF LO
4. OFF OFF HI
5. ON ON LO
6. ON ON HI
7. OFF ON LO
8. OFF ON HI

Systems

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Chapter 1 – Basic Cooling and

Name Class/Period Date

 Explain the basic principles of refrigeration systems.

3. Discussion: Basic principles of refrigeration

The two main principles for refrigeration operation are:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

4. Discussion: Basic refrigeration cycle

Those four stages are divided again into two parts:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Heat moves Heat moves

Expansion Valve (3)

Flow Cycle Heat Flow

Figure 1-1 Complete Four-part Cycle of Refrigeration

5. Discussion: Basic operation of the system

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

6. Composition of the main system

• Circulate the refrigerant in the circuit.

Typical compressor in a refrigeration system:

Figure 1-3 Hermetic Compressor

6.2. The condenser:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Typical condenser in the air-conditioning system:

6.3. The expansion valve:

In refrigeration systems, there are two main expansion valve types:

1. Thermostatic expansion valve.

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Refrigeration circuit with an expansion valve:

Figure 1-6 Refrigeration Circuit with an Orifice Tube

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

6.4. Capillary (orifice) tube:

6.5. The evaporator:

Typical evaporator in the refrigeration system:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

6.6. The fan:

Typical evaporator fan in a refrigeration system:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

6.7. The receiver-drier:

6.8. The refrigerant:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

7. Basic thermodynamic principles and terms

Work: Work may be described as force applied to overcome a certain resistance

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

For temperature measurements, two systems are employed:

These procedures are performed without any changes in the substance

The absorption of heat during evaporation and emission of heat during

The Enthalpy figure is determinate by the temperature and the pressure at

The specific Enthalpy is determined in the following way:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Entropy: The entropy is the energy quantity preserved in the substance at a

8. Coefficient Of Performance (COP):

The mathematical relations look like:

Discharges cooling output [kW]

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

10. Structure and operation of the system:

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Quick Quick Quick

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.

Chapter 1 – Basic Cooling and Refrigeration © 2018 Intelitek Inc.