4,~;._AA
~
TechnicalDirector
E-mail: sales@p-a-hilton.co.uk
(i)
POLICY STATEMENT
After Sales Service
We, P.A Hilton Ltd., attach considerable imJX)rtanCein being able to retain die confi(k;nce and goodwill
of our clients in offering an effective after sales service. Every effort is made to answer clients
COrIesponOODCC
promptly and to JXOvide a rapid follow up of spares and repi.:ement parts by
maintaining comprehensive stocks of COIDJXments
usually available ex-stock.
In the extreme~ a problem may arisein the operatiooof equipmentwbkh could seriouslydisrupt
a teachingor ~h
~hedule. In suchcircwnstancesrapid advicefrom the man~
is desirable
and we wish our clients to know that HiltoDs' will acceptfrom them a tlansfer chargetelephonecall
from anywherein the wcxld.
We ask our clients to treat d1is service as an emergerx:y service only and to use it sparingly and wisely.
INDEX
~
SCHEMATIC DIAGRAM
INTRODUCTION
The ValX>urCompressionCycle
6
10
Useful Data
10
Specification
11
Description
13
OPERATING PROCEDURE
IS
Nonnal Operation
IS
EvaporationPnx:ess
IS
CondensationProcess
16
16
17
Oil Return
11
Air Venting
18
MAINTENANCE:
19
High PressW'e
Cut Out
19
Thennometers
19
Minjanue Cin:uit B~
(MCB)
20
20
20
20
Checkingfor Leaks
20
21
23
1.
24
2.
The PressmeTemperatmeRelationship
27
3.
Demonstrationof PumpingOver
30
4.
Demonstrationof Charging
31
s.
32
6.
3S
7.
39
8.
43
9.
47
10.
Power Input 51
53
54
R141bP~SURE-ENTHALPY DIAGRAM
ss
S6
58
WIRING
DIAGRAM
- 11O-130V
Transformer
59
APPENDIX:
A. Optional R633A Digital Temper:ature
Indicator
- Fitting
Instructions
61
67
of-'
.c
:)
"Qj
~
"II
D
~
+-
~
4)
...
=
0)
it
NORMAL OPERATION
SHUTDOWN
3
SYMBOLS AND UNITS
Svrnool
Pc
kNm-2
P.
tNm-1
me
1i1.
it
oc
Tem~
oc
1,
f,.
ts
Evaporating Tempel8t1n"e
oc
..
Temperaturein Condenser
oc
t,
CompressorDischargeTemperature
oc
Is
CondensedLiquid TemperabJre
oc
W m-~K-1
Rate dU'OughCondenser
of WaterleavingEvaporator
10' pNm-1 .
150
This indicatesthat
or
alternatively
p = ISOkN m2.
. Absolute
pressure
4
INTRODUCTION
Tbe RefriaeratkD or Heat PumD Cycle:
A refrigerator is defined as a m~hine w~
prime function is to remove heat from a low temperature
region. Since energy cannot be deSU'OYed.
die heat Iaken in at a low temperature plus any other eneJ'gy
inJX1tm~t be dissipated to die SUn'()Undings.H the tempezabJreat which die heat is dissipated is high
enough ro be useful, e.g. for SpIM:;e
heating, the ~hine
is then called a heat pump.
By selectivedesignof the componentsthe cycle may be optimisedeidler for heat pump applications
or for refrigeration applications. Indeed unckr certain applicationsboth useful functions may be
performedby one machinewhere circumstancespenniL For example,in a dairy where refrigeration
is requiredfor milk cooling and storageand hot water is requiredfor OOuIeor tank washing.
The aausius Statementof the SecorKILaw of Thennodynamicsstatesthat heat will not passfrom a
cold to a ootter region without the aid of an "externalagency". Thus. a refrigerator will require an
"externalagency",i.e. an input of high gradeerergy, for it to operate.
This energy input may be in me foon of
w<X'k.
t
The Vapour Compression Cycle
The work input to the Vapom CcmpressionCycle drives a compressorwhich maintainsa k>wpressure
in an EVAPORATOR and a higher pressurein CONDENSER.
The temperatW'eat which a liquid will ev8lX>rate
(or a va[X)urwill coodense)is dependenton die
pressure,thus if a suitablefluid is introducedit will evaporateat a low temperatm'e
in the low pressure
evapora1Or
(taking in heat) and will condenseat a higher remperatW'e
in die high pressurecondenser
(rejectingheat).
The high IXeSStD'e
liquid fomted in the condenser must then be returned to the evaporator at a controlled
rate.
pressure
of die vapourbeingtransferred
to die condenser.
vapour.
Ald\Oughthe vapourcompressioncycle is simple to thosewho are familiar widt it many studentsfind
great difficulty in visualising and understandingdte eventsoccurring within the various components.
5
With dtis in mind P.A. Hilton Ltd., designeddie RefrigerationCycle DemoosuatiooUnit in which die
major pan of the cycle takesp~ inside glasschambersand can dlereforebe observed.
6
IN~ ALLA nON AND COMMISSIONING
Removeme unit from its p.:king caseand carefully examineit for damage.If any is foulKi. notify tile
insurersimmediately.
Standthe unit on a table at a convenientheight aM cl~
adlain.
Do not standthe unit in a positionwhere it will be in strongdirect sunlight for long periods.
This may result in high chamberpressureswith the subsequent
lossof the refrigerant charge
through the safetYvalves.
(i)
The tmit is fitted with two long life fluorescentlampswhich for shippingare ~
In orOOrto fit the lamps the rear panel of the m.:hine must be removed.
separately.
Ensuredlat die m&:hineIS NOT CONNEcrED 10 nIB MAINS ELEC1RICAL SUPPLY and
removedie hexagooalbolts and one Dut secmingdie rear panel Note that die bolts are 8mm
acrossflats and the COn'ectsize spanneris recommended.
The lamp socketsare locatedinternally and are under die two vertical slots in ~ unit panel.
Carefully remove me lamps from their packing ma1erialand imezt diem in me white plastic
socketson the left hand and right hand sidesof me panel. SUR>Ort
the socketsby handas tm
lamps are inserted.
While me rear panel is removed ensure mat die Residual C1DTCOt
CiIcuit Breaker switch situated
on DIN rail the right side of the panel is in die ON positioo. The unit will have been left in d1e
ON position when shipped but transit vibration or shock loading can ~
the switched to jwnp
to me OFF position.
(0)
Connectdie mainswater supply to die water inlet at the rear of die unit using the diagooainylon
reinforcedhose. When facing the rear of the machine the water ~
~ on the extreme left
or thepanel.
It ~ recommendedthat the water supply is red through an isolatingvalve that can be
turned ofTwhenthe unit is not in use.
In older to increasethe stability of the condenser water ftowmeter and evaporator water
flowmeter the conttol valveson thesedevicesare fitted to the dischargeside of the flowmeter.
Henceif externaldamageresultsin the flowmeter tubesbeing brokenan externalisolating valve
will be req~
to stop the flow of water from the unit
(ill)
Connectdie remainingwater coupling at the rear of the panelto a suitabledrain using the dear
plastic pipe provided.
(iv)
220/240V Units
Replacethe rear panel BEFORE connectingthe unit to the mains suWly.
The power supply cable will be foWld emergingfrom die rear panel. Connectdie cable to a
suitable fixed power supply via a fused outlet (for 5 Amps) which canplies with die ~
regulatioos.
Brown cable
LIVE or LINE
Bloocable
NEtn'RAL
EARTHor groond
to a low impedance
7
110/I20V Units
The unit hasan internally fitted transformerwhich is suitablefor input voltagesof between110
and 130 Volts (110 to 130V in 5 volt steps). The integral SUWlyl~ must be coonected10d1e
nearestsuitablevoltage tennina1sand mis can ooly be ~hieved by first removing tIx: rear panel
from the unit. The transfonneris locatedon the right handside of the unit when looking at the
rear of the machine.
Before connection to dte transf<l'D1eJ',die l()Cal mean voltage between Line aOONeulI8l should
be measured. by a competent person, widt a suitable meter. Until dte transfonner hu been
connec~ internally as described below die sUWly leOOSHOULD NOT BE CONNECTED TO
THE LOCAL ELECTRICAL
SUPPLY.
UVECR'LINE
NEU1RAL
EARm CR'ground
Note that for safe operation die GreenlYellow cable should be connectedto a low impedance
earthingpoint that complies with the local regulations.
(v)
The standard instrumentation kit includes five OOCto SOOCthermometers aOOtwo -lOOC U>llOOC
thennometers.
If theinSb'Umentation
upgradehasbeen~
in AppendixA in this manual.
8
If die djagramsare to be fitted to die panel then it will be ~-!!!-ry
to die ~ of d1epanel.
Auach the 4 spring cli~ to the ~ of 1be.-nel using the 8 self-tapping~WS povided. Note
that 8 small pre-drilled holesexist on the ~ of ~ panelto a:ceIXthe ~ws.
The clips shouldbe fitted wid! the OPEN end king toward the fratt of die panel.
The L shapedclear plastic schematicooldersare dIeDslid underthe spring clips.
In order to utilise the plastk COV~for the unit the L shapedschemabcholdezsmay be removed
and stored under the unit panel
Amendments
2 MAINS FL TER ADDED
10.9.97 JB
The ~ier
is req.jred to deliver goods strictly ~cordi-9 to
drowing. Componentinspection is the suppliers responsibiity
R8IIIDveoil sharp edges a~ burrs.
Fractions * 1/6"
Decimals * 0.25 mm
130V TRANSFORMERWIRINGDlRGRAM
aAGRAH F~
[Drawnby
P. A. HL TON l TO
JB
IDimensions: mm
Checked
by:
@Q
Projection'
Issue: 2
KINGS SOMBORNEHAMPSHIRE
TERttNAL KEY
no/rig. 1
ENGLAND
633365
10
THE HD..TON REFRIGERAnON CYCLE DEMONSTRAnON UNrr
USEFUL DATA
Condenser:
E VSDOratOC
Refri~erant:
11
SPECIFICADON
Compreaor
aPJX"Oxirnately810 Watts.
The com~
is a single cylinder
Condenser
Vertical, dlick walled high suengtb glass cylinder widt f1arM ends to
give tension free connection to nickel plated brass end plates with
P.T.F.E. seals. Cooling surface - 9 coils of 6.3 mm dia ~
b1be
Evaporator
Aoo(k';d type
Expansion Valve
Charging Valve
Sight Glass
Instruments
(StandardUnit)
Pressure28U2eS
- Two
To indicateevaporatorand condenserpressures.
ThermometerS-Seven
Five, RangeOC to 50C x ISOmmlong, glass.
Two, Range-10 to 110Cx ISOmmlong, glass.
Fitted in masspocketsto iJxIicatewater inlet and outlet tem~wres 81
condenserand at evapora1.,evaJX>rabon
tem~b1re, condensation
temperatureand compressordischargetemperature.
Row meters. Two
Taperedglasstube type, widt stainlesssteel indicator float, ~h fitted
widt a conb'Olvalve. Range 0 to 50 gramme S.I, To indicate and
conttol water flow rate dtroUghevaporatorand condensercoils.
ODtiOnal UD2T8de Instrumentation:
(Not suppUed unless specifically ordered)
Temperature
Indicator
Wattmeter
12
of die StaDdaIdpanel and may easily be fined by the CUSfDm~.or if
purchased widt the standard unit can be a f~tory fitted 0IKia1.
SAFETY
No moving parts.
Intemally mounted relief val~ ~t to 2SOkN m"2 gauge fitted to
cOIxIen= aOOevaporator.
High ~ure
cut out fitted to stop compress<rif condenserpessme
exceOOs
220 kN m"2gauge.
Main switch is a combineddouble pole Ininjat1Jre~t
breakerand
overl<>lMi
cut out
3OmAimbalanceResidualCurrent Circuit Breakerfitted.
DIMENSIONS
Height
Width
Depth
Weight
7romm
7romm
43(knm
ro kg 22OVunits (+lOtg for 110V units)
CAUTION
This wnt ~ ~n specifically designedto opeJ'ateat low pressure00 R141band no other refrigerant
shouldbe chargedinto die systemas damageto the comples.D'<X'oda: ~~ts
will be die resulL
13
DESCRIYnON
(pleaserefer to me schematicdiagramon Page 1)
All COlDJX)nents
are mounted 00 an attractive durable glass reinf<XCedplastic panel.
The evaporatoris a v~
glasscylinder with pla1edmetal end plates. A helical coil of copperwbe
conveyswater mrough a pool of refrigerant in the cylinder. The compressordraws vapour from the
evaporatortherebyredocingpressurein the evaJXJrafnr
and this causesthe refrigerant to boil at a low
temperature. In order to boil, or changephasefroo1a liquid to a Vap)ur, heat is ~
and d1isis
extractedfrom the water passingmrough the coppercoil and to a lesserextent from the surroundings.
As heat bas been extta;ted froo1the water its temperabJre
is reduced.
The com~
is an hermetic type similar to those found in many domestic refrigemta'S. The
com~or
is inside the hermeticallysealedcasingand is directly coupledto an elecbic motor.
VaJX)Urfrom die evaJX)rat(X'is drawn into me compressor casing and then into the CODJK'es8(X'
itself
where its Jl'essure is raised before being discharged to the condenser. Having had work done on me
gas its tem~
is iocreased as well as its pressure.
The cooden.a- is also a vertical gJasscylinder fitted with plated metal end plates, the upper one
supportinga helical coil of tubethroughwhich cooling waterflows. The hot high pressurevapourfrom
the COrDpreSSt)f
cools and condensesas it ttansfersbeat to the cooling water inside the nickel plated
c~
coil As beat is transfenedto the cooling water itS temperatureis increased.
The cooled high pressureliquid collects in die tx>ttomof the con~nser and its level cootroIsa float
operatedex~on
valve. This valve reach~ an equilibrium position and discharg~ refrigerantliquid
back to die ev8iX>ratorat die samerate as it is fonned.
As the warm high pressureliquid passesthrough die valve seatingits presswe~
to that in die
evaporatOrand its temperaturemust fall to the saturationtempemwreat the lower pressure. The fall
of tempemnueis accompaniedby the f(X'Inationof vapour bubblesand thesemay be ~n througha
sight glass fitted in the pipe returning the liquid/vapour mixnIre to the evalX>rator.
On entering the evaJX)rat(X"
the low pressureliquid aOOvaJX}urseparate.the liquid passinginto the
"pool" for re-evaporation.while the vapour mixes with the vaJX}urproducedby the boiling ~tion of
the water coil. The vapour mixture then returns to the compressorto repeatthe cycle.
In the standardunit instrumentationis provided to measure:
(i)
The tem~rature and pressureof die refrigerant vapourin die evaporatorand condenser.
(ii)
The tem~rature of die water entering and leaving die coils in d1eevaporatorand condenser.
(ill)
(iv)
14
This ~hnique is imJX)rtantin onk:r to demOOSb'ate
how to pevcnt ~ escapeof refrig~t
maintermnce.
during
In common with all refrigeration and heat pump systemsthe unit containsa small amountof oil for
lutxication of ~ CaDpessa. During normaloperation~e oil. in die fOODof mist andoil/refrigerant
~Iution is carried from the compessor to the condenserand ultimately to die evap<J'atorwhere it
collects. In order to return this oil to the com~
casingin a controlledmannera valve at the base
of the evaporalorconnectsan oil return capillary to die suction side of the com~
via a ~nd
valve.
For ~rator safety the refrigerant used ~ a veIy low ~
for a given temperabue(V8IX>Uf
pressureat 2OOCis 0.81 Bar amolute). In addition die unit is fitted with a pres8\D'e
switch to nun off
the C<XDpressa'
if dIe condenser~
exceeds220 kN m-z.
For IMided safety and to allow operation by students, both the coodcosecand eVaJ)(Xatorare fitted with
IS
OPERATING PROCEDURE
(please refer to Figure 1 - SchematicDiagram, and Figme 2 R633 Valve Positionsdiagram)
To assiStin unOOrstanding
~ration. item namesand relevant items on the two scoomaticdiagrams
suppliedare refelTedto in bold type in the following sections.For example.Refrigerant Pump Down
on Figure 2 and Condenseror Evaporator etc on Figure 1.
The five baD valves shown on the two schematicdiagramshave beeninsIalled for ~
Figure 2 (Page2) diagramshowsthe four standardvalve combinations.
The vent valve on die condenseris namally only openedbriefly to vent air from the systemaId this
is referred to elsewhere.
Note mat when the mrlt is shut down the ball valves should AlL be in the closed positioo. This
preven~ the refrigerantmigrating to the lowest temperaturepart of the systemdue to vapourpressure
effects and in most ~s dtis would be the compressorcasing as this will respondmost rapidly to
variations in ambienttemperature.
Normal Ooeration
To start the unit first turn on the cooling water supply and the mains supply to the unit
11risallowsvapourto be<b'awn
from dIeevaporatorby thecompr~r
returnto theevaporator
from thecondenser.
andfor ~
liquid to
Twn on the watersupply to the unit and adjust the control valveson the evaporator water nowmeter
and condenser water nowmeter to give approximately20-30 gls flow rate.
Turnon themainswitchandthecom~
If the optional temperature indicator is fitted then the display on this will also illuminate.
Evaporation ~e&1
As dIe compressorruns dIe condenserpressurep. will rise and dIe evaporatorpressureP. will fall. If
dIe water supply temperawreis high (aPJK'Oximately
16Cor more) dIen the boiling oction shouldbe
reOOilyvisible from sev~ points on the submergedeV8p(X'a1or
coil. In order to promoteevalXJrabon
from the coil surfacethe coil has been specially treatedto provide many bubble nucleationsites.
If the water temperanue is low then the ev8lX>ratorpressure will need to reach a lower value and roiling
may occur from single sites on the coil, from me surface of me liquid adjacent to the coiJ/surface
interface or from the -.seplate of the evaporator.
To indoce further evaporationfrom odler sites open the ball valve at the baseof the ev8lX>r8tOf.00
NOT open the charging valve as this will allow air to enter the system.
Opening the ball valve at the baseof die evaporatCl'will causedie oil rewm capillary to becomepart
of the evaporatorand the resulting large increasein heat transfer surface area relative to die small
volwne of liquid in the capillary will result in vapour appearingfrom me baseof die chambec.
This techniqueis also usedwhen completing refrigerant pump down.
During normal opera&n oocenucleationhasbeenKtivaled from otha' sites within the chamberdlen
the ball valve at the baseof the chambermay be closed.
16
Unlessdie supply water temperatureis high men altera1ionof ~ evaIJ<nIOrwater flow rate will have
a relatively small eff~t on die ev8lXJrarDr
pressme.
Howeverif die evaporatorwater flow is twned off completelythen the evaporatorpressurewill reduce
slowly until evaporation OCCID'S
from some other ~
smfa::e using beat tI3Dsfmed from die
sunuundings.
CondensadoaProcess
The vapouris dI3wn from the eVaJX)lata'
into the compressorand both ilS pressureand temperatureare
raised. The hot high pressurepassesdtroughthe insuJatedpipe to the condenser.
The temperanueof the p leaving the com~
may be measuredby d1ethermometerin pocket tr.
Note mat if the COOlpreSoD'
is run for long periods widl die coodenserJX'essutehigh then the
temperaturehere can reach SOOC.
As die gaspassesthrough the insulatedpipe therewill be someheat loss and after an initial warming
up period of operatioo this will result in the gas being partially de-supethcated
before it enters the
co~.
In fa:t just after starting,whenthe unit is cold. the gasenteringthe condenserchambermay
evenbe partially condensedand dropletsof liquid, will be seendrippingfrom the top plate.
The gas entering the condemer under n<X'D1al
opezatioowill be in a superheatedcondition and wiD
initially desuperbeatand then condenseon the water cooled coils.
Adjusunent
of thecontrol valveon thecondenser
water nowmeterwill allowthecondc~ ~
to be iocreased or decreased.
To increase the condenser pressure reduce the cooling water now rate.
To reduce the condenserpressure increasethe cooling water now rate.
The condenserpressurewill also be effectedby the inlet temperawreof the cooling water. F<X'the
samewater flow rate the condenserpressurewill be lower if the inlet cooling water temperawreis
lower. The inlet water temperaturewill thereforelimit the minimwn ~hievable coodenserpressure.
As me liquid ex~ds through the float controlledvalve at the baseof the condensersomeevalJ<Xation
of the liquid beginsto occur immediatelydownsueamof d1evalve.
The valve is physically ~hed
to the 00seplate of the condenserand dIereforesome of the heat
requiIedto bring aboutthis phasechangeis ex~ted from die liquid at dIe baseof die condenser.This
has the effect of sulx:oolingdie liquid below the saturationtemperatureassociatedwith the measured
pressureshown on the condenserpressure gauge.
If the optional temperature indicator is fitted then an additional thennocoupleIs is supplied to be
fitted in the baseof the condenserchamber.Heocethe subcooledliquid temperawremay be measured
and this togetherwith the otrer measuredtemperablreS
and p-essuresallows a completerefrigeration
cycle diagramto be plotted on the pressure-eothalpy
diagram ~lied.
The experimentalJl'()CeduIesdelailed elsewhereinvolve operation of the various 00ll valves and
variationof the condenserpressurein or~r to achievevariousoperatingconditions. Thesepl{x:edures
are detailedin the individual experimentalprocedures.
17
Normal running condition is widl aPJK'Oximately
2o-25mmof liquid in the bottom of the condenser
chamberand dle float valve maintainingthis level constanL
Oncenormal operatingconditionshavebeen~hieved menme main switch shouldbe turnedoff. The
compressorwill stop and me lights on the unit will be extinguished. If the optional temperature
indicator has been fitted the display on this too will be extinguished.
Turn off die cooling water suWly to die unit It is recommendeddlat die (water) control valves are
left open so that if die usersuppliedexternalisolating valve leakswater will be allowed to run to drain
and will be noticed more readily. In addition, if conditionsare suchthat the water supply is likely to
freeze dlen leaving die control valves on the flowmeterSopenmay not prevent die glasstubesbeing
broken but it will makebreakageless likely.
Oncethe unit b$ beenturnedoff then me ball valveson me unit shouldbe closedto mimic me
shutdowncondition. SeeFigure2 (page2).
This will prevent the large volume of refrigerant containedin the evaporcUormigrating into the
compressorcasingdue to vapourpressurechanges.The small volume of liquid in the condensermay
migrate to the compressorunder certain ambientconditionsbut this is no causefor concern.
18
cooling water aM evaJX)ratorwater flow rates are left as for normal nD1ningand me unit remaim
switched00. The only pam from me evapa-atorto the compressoris via the capillary tube.
The oil in the baseof the evaporatorwill start to flow mrough the capillary blK:t to the com~
casing.
The evaporator chamber may be at low JXeSSureand therefore the oil return process will be slow due
to the low differential pressure. This may be increased and the ~
speeded up if a small amount
of refrigerant liquid is OOmittedto the evalXJ[ator by briefly opening the ball valve at the base of the
condenser. However DO NOT leave this valve open.
Once the oil has beenreturnedto die CODlpresD'casingd1endie ball valves may be ~
position for normal operation as shown in Figm'e2 (page2).
to dx:;
Once die operating coOOiuons have rewrned to noonal and the liquid level in the conde~
is
apJX'Oximately2O-2Smm tOOntOOunit may be eithez shut oown as described ai)Ove or adjusted for
further experiment.
Air Ventin2
A vent valve is siwatedon dle top of the con<knseraIK1this allows air that bas beenadmittedto the
systemto be safely ventedinto the void inside the insb'Umentpanel
Air d1atenters me system usually from the charging valve as part of an experiment will be swept into
the com~
by d1eflow of vapoor from me evaporator and from here to the coodenser where it will
collect around the condenser coils. The air will remain in this area and effectively present an insulating
barrier to vapour ttamfer. condensation and hence heat transfer. The nett result will be a chamber
pressure that is far greater than should be the case for the condensing temperature ~ indicated.
Unl~ demonstratingd1eeffects of air in a coodenserit will be necessaryto vent the air from die
system. The oil utilised in die compresSa'is hygroscopicand air admittedto die systemis likely to
bring widt it water vapour. This should thereforebe ventedfrom die system.
To vent air from the condenser it is necessary 10increase the condenser pressure 10app-oximately 50kN
m-1aboveabnospheric
pressure.
With the unit nmning n<X'Dlally,
cl~ diecontrol valveon thecondenserwater nowmeter.Thiswill
cause die condenser pressure to rise. The time taken to rea;h 5c:k.Nm-1above abnospheric pressure will
depend upon die local ambient temperature and the amount of time that the unit has been running.
19
MAINTENANCE
The cut out hastwo adjustingscrewson its top surfacewhich may be coveredby a plastic cap secured
by a single screw. Removethe plastic top cover and to adjustthe cut out pressureturn the screwwith
the larger range. The cut out devicesare commercialdevicesand the pressureindicatedon the scale
may not matchthe cut out pressureindicatedby the pressuregaugewhich is of much higheraccmacy.
Only b1rnthe screw a small incrementat a time and then retest in order to obtain an estimateof its
effect.
By dlis methodthe cut out pressuremay be ~t to 22OkNm-2.
The smaller range scale usually labelled "DIFF" indicates tOOdifference between me cut out and restart
pressures. This should usually be set at aPIl"Oximately l2OkN m-z in order to ensure that me starting
l()1ki on me com~
is minimised
After adjustmentthe ~
Tbermometers
Due to the relatively small temperature differences between water inlet and outlet temperabJreS.it is
advisable to calIbrate the thermOOleten by pla:ing diem all in a container of watel'.
This should give a table of small differences from the "reference" thennometer.
20
Th~ differencesmay be added(B'subtlaCtedfrom dJe~
as awropriare.
The RCCB will be found on the right hand side of the unit WOOD
looting into the rear of the unit
Pressdie button malked 'Test' or 'T' on die RCCB, but 00 NOT TOUCH ANYTfnNG ELSE INSmE
THE UNIT. The largelever on the RCCB shouldh1IDfrOO1d1eON ('r) to OFF ('0') position
immediatelyand me unit isolatedfrom die supply. If dris ck>es
not OCCm',
die RCCB is faulty and~
to be repaired/repla:edby a qualified electrician.
Return die lever to die ON ('I') ~ition
This may be cleaned with a mild detergent and then JX}llshedwith a soft clodt. Abrasive cleaners must
not be used.
The pJasticdust cover provided shouJdbe kept in }X>sitionwhen the unit is not in use
21
Cbarg2 or Recharge
Under nonnal conditions me vapour press\U'eof die refrigerant does not reach abnospheric pressure Wltil
die liquid is at a temperatme of approximately 32C.
In order. merefore.to make charging me unit simpler. the one bip can supplied by P.A. Hilton LId
containsa small amolDltof Niuogen gas in order to raise me internal press\D'eartificially.
Before chargingit is recommendedthat me unit is set up in me following way:
Start die unit as detailed for normal operation in die operating procedure on Page 15 and operate
widl a moderatecooling water flow to bodl die condenserand evaporatoras detailed.
Allow the evaporatorpress1D'e
to reduceand then position the ball valvesfor shutdown condition (see
Figure 2 - Page2) and bJrn off the compressor. Note that if the unit is not chargedand containsair
then it may be necessaryto vent this from the condenservia the vent valve on the condensertop plate.
for charging.
The chargecan only be releasedfrom the can by using the brasschargingvalve (VCl7/2) suppliedin
the accessaieskiL
Unscrewdie small brasshexagonalnut from die chargingvalve and screwdiis onto die dtreadon die
top of the can. Screw die rest of the charging valve (VC27fl.) into the straight connector on die
refrigerant chargingline (C45/2), also suppliedin die accessorieskit
Removethe brasscap from the fixed charging valve at the baseof the evaporatoron the R633 uniL
Note that the angled end of the refrigerantchargingline hasa b~ pin in the.centreof the connector.
This end should be connectedto the fixed charging valve on the baseof the evaporatOr.When d1e
connectoris screwedtight the pin depressesthe centreof the fixed charging valve and allows access
to the evaporator.
The can should be inverted and me two componentsof the brasscharging valve should be screwed
togetherby rotating me can. SeeFigure 4, Page22. When the componentsof the chargingvalve are
screwedtogemerme refrigerantwill flow into me chargingline dueto me nittOgenpressurein d1ecan.
Open me ball valve at me baseof me evaJX>rator
and me refrigerantwill flow into the evaporator.
Switchon die writ and d1iswill againreducedie evaporatorpressureand assistdie flow of die
refrigerant into die evaJX)rator.
When the liquid level in the evaporatOris abovethe level of the tOpcoil close the ball valve at the base
of the evaporatOr.
Allow die unit to run under nonna! operatingconditions until die liquid level in die condenserhas
stabilised. Ensurethe liquid level is still abovedie top coil of die evapomtol. If this is not die case
then open the ball valve at die 00seof die evaporatorbriefly until d1erequired level is ~hieved.
Unscrewthe charging line from the can and this will close the valve in the can. The ball valve at die
baseof the evaporatorcan be briefly openedto draw in any liquid remaining in die chargingline.
The chargingprocedureis likely to result in someair enteringthe system. To removethe air follow
the procedurefor Air Venting describedon Page 18.
22
0,. Tr~Can
RMX74/1
Figure 4
rn
Bras.C~gi'1g
Valva VC27/2
Refrigerant Charging
Line CI.5/2
IN c~~
Valw With Centre
Pin
Angled Comector
With Central Pn
23
CAPABILmESOF THE REFRIGERATION CYCLE DEMONSTRATION UNIT
Demonstration of vaJX)m'compressioo refrigeration or heat pump cycle widt visual observation of
the important ~.
2.
3.
4.
Demonstrationof charging.
5.
9.
With the addition of the optionalwattmeter:10. Measurementof me eff~t of condensingtemperatureon compressorpower input.
24
1. DEMONSTRA nON OF VAPOUR COMPRESSION REFRIGERA nON OR REA T PUMP
CYCLE
The ex~cnt
shouldbegin wid! the unit at rest.havingbeenleft in die shutdown (SeeFigure2, Page
2) condition for sometime in order for all of the compo~nu to be at a similar ambienttempelabD'e.
Open the ball valveson the cylinders as for normal operation (SeeFigure 2, Page2) but do oot bIrD
on die unit and do not bIrD on die water supply to the evaporatorand condensercoils.
The stu<kntsshouldnOtCthat all of die systemremperaUJreS
and pressmesare "awroximately similar"
(assumingmat d!e unit has DOtbeen left standingin mght swilight and that d!ere is liquid visible in
bod! the conde~ and evaporator).
00 Page15.
(i)
(ii)
25
addition, dependingupon me local ambient conditions,water vapour will also condenseon die
outside surfaceof me glasscylinder and baseplate. The changein phaseof me water vapourto
a liquid will in itself IX'Oviooheat to causeevaporationof die refrigerant in me chamber.
In addition, if the evaporatorcooling water flow is stoppedthen the rate of condensationfonning
on the condensercoils will also reducedue to me reducedvapourgenerationrate in the evaporataand me reducedvolumettic efficiency of the compressorand increasein specific volume of me
vapour generatedin the evaporatorchamberat low pressure.
(ill) With the evaporatorand condenserwater again flowing as describedin the normal operation
conditions on Page 15 the condenserpressureshouldbe observed.
The condenserpressmewill be seento be higher than that of the evaporator. This is obviously
due to the compressor. The ratio of condenserpressureto evaporatorpressure.PJP.. is known
as the compressorPressureRatio. This will vary ID1derdifferent operating conditions and may
be investigated.
After the W1ithas been nmning for several minutes under nonna! conditions the condenser cooling
water inlet temperabD'eand the discharge temperawre should be compared.
26
As soonas the liquid passesthroughthe expansionvalve iU pressuredropsto awroximately the
pressIU'e
inside the eV8lXX8fOr.This ~
me liquid to immediaIelystart to changephasefrom
liquid to V81XXJr.As in the evaporatm'cragy is requiredto bring about me phasechangeand
someof this is taken from the baseplate of the condensera the expansionvalve is ~hcd to
the hue plate.
ExtrlK:tingbeatfrom me baseplateredIx:esits te~
and this in bIrDreducesthe tem~nue
of the condenserliquid at me baseof the condenser.This resultsin ~ liquid being "sub cooled"
below its satUIationtempelatm'e.
If the optional temperature indicator is fitled ~
an IKiditional thennocouple r. is supplied to
be fitled in the base of the colxleDSQ"chamber. Hence the sub cooled liquid tem~
may be
measured and this together with the other measured remperattlreSand pressures allows a complete
refrigeration cycle diagram to be plotted on the pfeSSW'C-enthalpydiagram supplied.
si,ht ,-
27
2.. PRESSURE TEMPERATURE RELATIONSHIP
The relationshipbetweensanuationpressureand temperaturemay be observedin both me evaporator
and condenser. However as variation in the evaporatingtemperat1D'e
is small for aU but extreme
changesin cooling water flow me condenserIX"Ovides
a moregraphicillustration.
As the conoonser contains refrigeJ'ant in all stages from superheatedvapour through to sub cooled liquid
the dlermometer pocket ~ only records temperatures close to saturation when die pocket is showing
signs of condensed liquid Therefore it is recommended that die pressure temperature relationship in
the condenser is investigated as the condenser pressure increases.
Procedure:
(i)
Start the unit for normal operation as shown on Page 15 but iocrease the condenser cooling water
flow to the flowmeter maximum (50 g S.l). The pressure at which the condenser stabilises will
depend upon the water inlet temperawre.
(ii)
Allow die unit to run for approximately IS minutes in order to reach a uniform operating
temperature. Then record die condenserpressmePc, evaporatorpressurePe' die condensing
temperature~ and die evaporatingtemperaturer,.
(ill) ReducedIe cooling water flow by a small incrementso that dIe condenserpressureincreaseby
approximately10-2CBcN
m-z. This amountwill vary depending
upon dIe coolingwaterinlet
temperature.
Allow the unit to stabilisefor a few minutesand againrecord the aboveparameters.
(iv) Re~ the procedureup to the maximumcondenserJX'eSSure
requiredor to the high pressurecut
out value of 22OkNm4
Typical resultsare shown in the table below.
Local Aunospheric~:
lOlkN mol
Condenser
Pressure
Pc I kN m-1 gauge
CondenserPressure
Pc I kN m-1-absolute
Condensing
temperature
E vaporatol' Pressure
E vaporata Pressure
Evaporating
temperature
../~
P.I kN
m7.
gauge
PG I kN m4 absolute
.,/OC
-41
-31
-21
-11
+4
+49
70
80
90
105
150
15.0 19.5
24.0
27.0
31.0
41.0
-68
-69
-69
-69
-69
-69
33
32
32
32
32
32
6.S
4.0
4~
4.0
4.0
4.0
28
Note that tem~
have been estimatedto d1enearestO.soC~ing die SIaOOard
1benDOIDC1m
SUWIied. Whezcthe opdoul temperature indicator is fitted ~~
may be ~
to d1e
nearestO.loC.
The resultsare ploUCdin graphicalfonn on Page29.
Note that the standardJD'eSSUIe
gauge~y
of tl % of gaugefull ..::a)ehasbeat shown as 00Ued
lines abouta mean. The absolute.:curacy of the dlermometers(m-~(XIa} tem~
iDd-k.J1O!'
and
thmnocouples)plus readingerrorswill also .sd to any disc~ies.
8
(f)
0
0
ffit
r~
~
N
_f3
III
.1.~
0
0
.l.,~T
UO!:J8.1D.:J8S
0
Ll)
f5
0
to..
0
~
tV)
0
N
0
~
29
30
3.
Duringmaintenance
of refrigemOOopJaob.partkularly when repl-=ementof com~nb
is involved.
it is convenient to transf~ the ~gerant to me conck.nser.This ba the ~vantage of saving me
refrigerantfor f1D1heruse and also may avoid the needof ev~ua1ionprior to rechargink.
In addition.for ecologicalreasons
followingme guidelinesof d1eMontreal~l.
refrigerantis in manycountriesoowa criminaloffence.
~ ventingof
Fig1De 2
of the conoonSel:
is ~
- Page2), me
and liquid
As liquid ttansfecsfrom the evapcnror, the level will fall and lessof the evaporaur coil surf~ will
be effective in evaporalingthe liquid. The evaporatioorate will reduceand die processwill become
slower. This effect may be offset as the liquid level becomesvery low by opening(ONLY) the baD
valve at the baseof the evaporaU>r.
This will have the effect of utilising die capillary surface area and ambient air temperawre to eVa(X)rate
additiona1liquid.
If, beforepumping down, the unit basbeenoperatedfor a prolmged period, die liquid collectedat d1e
baseof the evaporaUX'may appearthicker and less viscoos. It may also appearslightly yellow in
colour. The liquid remaining in die eva!X)ratoris primarily the oil d1athas been carried over in die
form of mist and refrigerantoil mixture from the com~.
The oil will not evaporateat die pessures .:hieved by d1ecanpressor and tOOreforeit must be
physically rewmed to die compressorcasing.
Note that the unit should ~
SHUT DOWN when the refrigerant charge is in the PUMP DOWN
condition as under certain ambient conditions it is possible for die charge to migrate to the compreS&:Jr
casing.
~:
In an industrial plant, isolating valves are usually fitted between all major components. As ~
as the refrigerant has been b'ansferred to the condenser (or liquid receiver) the valves may be
closed. trapping the liquid. The defective comlX>nentcan dIeDbe serviced or repJ.lK:edwid>Ut
losing the refrigerant charge.
At me end of the demonsb'8tionthe opportunitymay be takento reblrn the oil collectedin the baseof
me evaporatorto die condenser.The procedurefor this is given underOil Return on Page 17.
However,if oil is not to be returnedto the compressorat this stage,~ mIl valves should be set for
normal operation (SeeFigwe 2, Page2) and me refrigerantallowed to rewrn to the evaporator.
31
4.
DEMONSTRATION OF CHARGING
Due to die restrictionsof die Montreal Protocol it is not recommendedd1atthe refrigerant chargeis
removed from the machinefor any ~n
other than essentialrepair.
If chargeremoval is necessaryd1enrechargingmay be "demonstrated"if convenientto 00 so.
Chargingfrom a Hilton suppliedone nip can should follow the Chargingor RechargingjX'OCedure
on
Page21.
Note that any refrigerantremovedfrom the machineshouldbe storedin a screw topped metal can to
preventevaporationand to stop moistme being absorbedby the oil in solution.
Any refrigerantstoredin sucha can may be drawn ~k into the evaporatorby connectingthe charging
line to the charging valve in a similar way to the standardchargingprocedurebut then immersingthe
open end in the liquid inside the container. If the unit is turned on for normal operation then the
pressuredrop in the evaporatorwill causethe refrigerant to flow into the evaporator. Note that air is
likely to needventing from the condenser.
32
s.
When air is presentin a refrig~oo plant. it will O(X'Inallybe sweptfrom the evaporata by me flow
of refrigerant vapourand will becomettappedin the con(k;D.W'.
For a combinationof reasons.the air will ~
the com~
delivery IX'CSSIJre
to rise. reducingdie
coefficient of peifonnance.arxl increasingthe power input for a given duty.
The ilx:reaseof pressureis due to
(i)
The total pressure in the coodensu is approximately equal to die sum of the refrigeJ'aDtsatumtion
pressure~ the pressure of die air Jl'CseDt(Dalton's Law of partial pressures).
and
(ii) The air tendsto be swept towards die heat transfersurfaces.fonning an insuJatinglayer which
reduces~ heat b'ansfercoefficient. This in Ulm drives up die temperaturedifferencerequjred
for a given heat transferrate and this results in a higher refrigerant sabJratiootemperatureand
pressure.
The effect of air in the systemmay be demonsttatedas follows:
Procedure:
(i)
Start the unit for normal operation and adjust the evaJX)ratorcooling water flow rate so dlat the
evaporator pressure is below abnospheric pressure. Unless the cooling water temperablre is vy
high this is likely to be the case in all conditions.
Ensure that the unit is free of air and if o.essary follow the air vendng procedtDe shown 00 Page
18.
(ii)
33
Local AtmosphericPressure:lOlkN m-1
TestNo.
1 Air Free
1.With Air
Evaporala GaugePressure
p ~ I kN mo2
-69
-66
Absolute EvaporatorPressure
p ~ I kN mo2
32
35'
t,/OC
400
5.5
EvaporatorwateJ'flow
m.1 g S.l
20.0
20.0
~/OC
11.0
11.0
Evapora1(X'water outlet
~/OC
9.5
10.0
Evaporatingtemperature
Po 1kN
m-2
-21
59
Pol kN m-2
80
160
25.5
30.5
4.0
4.0
CondensingTemperature
Condenserwater flow
r./OC
IDa 1 g
S.l
Condenserwater inlet
t./OC
12.0
12.0
Condenserwater outlet
t,/OC
22.0
20.3
:-.
=
=:
2'
.,
00
2'
.,
tD
~
tD
a
"=
tD
.,
~
34
0
m-2
CN
..,
Q)
CD
:AJ
CD
Q)
~
(Q
~
0
~
-.
0W
W..,
(") :AJ
Q) ..
-~
CD ..
-n"C
c
-n
=0
I
~
..(J)
~ o~ -.
~O'.
+ 0
'<
..,
>-,
(")
c:
(")
(Q"C
CD CD
<
G)-I
Q) CD
c: 3
CD
c:
..,
CD
(J)
(J)
""D
35
6.
ON THE
The effect of evaporatingtemperatmeon die refrigeration rate can be investigated.but due to d1e
limited effect on evaporatingtemperatureof all but very largechangesin cooling waterflow it is more
graphic to investigatecondensingtemperaturefirst.
If time pennits. the correspondingeffects of evaporatingtemperaturemay then be investigated.
The effect of increasingme condensingtemperatureon many refrigeration systemsand heatpwnps is
a reduction in me heat dischargedfrom me condenserand in many casesa smaller reduction in the
refrigerating effect at the evaporator.
Similar reductionswill be observedif the evaporatingtemperatureis lowered
The effocts are due pimarily to the reduction in volwnetric efficiency of the compressorat high
pressureratios (PJPJ and the reduction in specific volume of the refrigerant gas as the evaporating
temperaturereduces.
An investigationof die effectsof pressureratio are given in the following experiment
A simple explanationfor this is that for eachsuctionstrokeof die compressora lower massof gas(for
the samevolume) is drawn in to the cylinder to be compressed.
The effect of increasingcondenserpressuremay be investigatedin the following manner.
Once air free increasethe condensercooling water flow to the flowmeter maximum (50 g S.l).
The pressureat which the condenserstabiliseswill dependupon the water inlet temperature.
(ii)
Set die evaporator water flow to approximately 20-30 g S'l and allow the unit to run for
approx,irnately15-20 minutes. The time taken to stabilisewill dependupon the local ambient
conditions and the cooling water inlet temperature.
36
OBSERVA nONS
Local AtmosphericPresswe:lOlkN m-2
Test No.
:t
Evaporaux'GaugePressure
Pel kN m-2
-68
-69
-69
-69
-69
AbsoluteEvaporalOr Pressme
Pel kN m-2
33
32
32
32
32
6.5
4.0
4.0
4.0
4.0
20
20
20
20
20
IJ.,O
11.0
11.0
E V8IXX8UX' Temperature
t,/OC
di./ gin S.l
Evapor8tcrWater InJetTemp.
it/OC
11.0
11.0
ft/1IC
10
10
It)
IG
10
CondensedLiquid Temp.
../IIC
4
P./ tN m-2-
-41
.31
-21
-II
AbsoluteCondenser Pressure
P./ tN m-2-
60
70
80
90
105
CompressorDischarge
- - Temp.
- -
t,/1IC
Condenser Temperawre
r./OC
15.0
J9.5
24,0
27.0
31.0
50.0
10.0
4.0
2.0
1.0
r./ac
11.0
11.0
11,0
11.0
11.0
r,/1:C
12.0
16.5
22.0
26.5
31.5
CompressorPowerInput
W/Waus
Note d1a1the temperaturesrecorded have been estimatedto the nearest0.5C using die standard
thennometerS
supplied. If the optional temperature indicator is fitted with the thermocouplesensors
then the temperaturesmay be recordedto the nearestO.lC.
37
SPECIMEN CALCULA nONS FOR TFST NO.2
EVAPORATOR
Rate of Heat Transfer to Water in EvaJX)rator:
<J.
<J.
m. C, (t1 - tz)
20.0 x 10-3x 4.18 x 10' x (11.0 - 10.0)W
Q. =83.6W
-
CONDENSER
Rate of Heat Transferto Water in Condenser:
Qc
= mcc, (" - tJ
DERIVED RESULTS
EvaporatingTemperature
t,/OC
6.5
4.0
4.0
4.0
4.0
CondensingTemperature
~/OC
15.0
19.5
1A.O
27.0
31.0
Q./W
83.6
83.6
83.6
83.6
83.6
Oc/W
229.9
183.9
129.6
85.7
39
7. ~GA
nON OFTHE EFFECTOF COMPRESSOR
PRESSURE
RAno ON SYSTEM
PERFORMANCE
Once air free increase the condenser cooling water flow to the flowmeter maximum (50 g S.l). The
pressure at which the condenser stabilises will depend ulX>nthe water inlet temperature.
(ii)
Setthe evaporatorwater flow to approximately30 g S.land allow the unit to run for approximately
15-20minutes. The time takento stabilisewill dependupon the local ambientconditionsand the
cooling water inlet temperature.
40
OBSERVA nONS
Local Atmospheric Preaure: 101 kN m4
Test No.
1.
EvapoI31a'GaugePressID'e
Pel tN m-2
-68
-69
-69
-69
-69
PeI tN m-2
33
32
32
32
32
6-"'
4.0
4.0
4.0
4.0
20
20
20
20
20
11.0
11.0
EvaponI(X'Tem~
Evapora1aWater Row Rate
t,/OC
Ih. I gin S.l
it/OC
11.0
11.0
ta/-C
10
10
10
10
10
CondensedLiquid Temp.
re/OC
11,0
p.1 tN m-2
-41
-31
-21
-11
AbsoluteCondensez
~sure
p.1 tN m-2
60
70
8C
90
IOS
15.0
19.5
24.0
27.0
31.0
50.0
10.0
4.0
2.0
1.0
Cu.u~~
Discharge
Temp
CondenserTmnpelabJre
Condenser Watel' Row Rate
r.,/OC
../OC
di./ lID Sol
r./OC
11,0
11.0
11.0
11.0
11.0
's/OC
12.0
16.5
22.0
26.5
31.5
CompressorPower Input
W I Watts
Note that the temperaturesrecorded have been estimatedto the nearestO.5C using the standard
thermometerssupplied. If the optional temperature indicator is fitted with the thermocouplesensors
then the tempe~
may be recordedto the nearestO.IC.
41
iii. C, (11- ~
Q. . 20.0X 10-3X 4.18X 10'X (11.0- 10.0)W
Q. = -I3..6W
Q.
CONDENSER
Rate of Heat Transfer to Water in Condenser:
Qc
= "c C, (r, - tJ
COMP~_SDR
Note that dIe pressmemtio shouldbe derived using Absolutepres8W'e
not GaugePressures.
Delivered PressureRatio
=Pc/P.
32/80
=-2.5
DERIVED RESULTS
CompressorPressmeRatio
p./p.
1.82
2.19
2.5
2.81
3.28
Q./W
83.6
83.6
83.6
83.6
83.6
Q./W
200
229.9
183.9
129.6
85.7
43
8.
DE~ATlON
OF OVERALL HEAT TRANSFER BETWEEN R141b AND WATER
IN mE EV APORA TOR AND CONDENSER
The Overall Heat TransferCoefficient (U) is die heatttansferrateper unit areaof heatttansfersurface
when a temperaturedifferenceof ooe degreeexists betweendie hot and cold fluids.
In die evaporator,die refrigeranttemperatureis sensiblyconstant,but die water temperaturefalls as it
passesthrough the coils. In die condensersomedegreeof superheating~
be presentwhen the gas
entersthe condenserglasschamber. However the quantity of heat delivered due to the superheating
will be small relative to that attributableto the condensingphasechange. Examination of the high
pressureline of the cycle diagramgeneratedin ExperimentNo.9 on Page47 will confirm this.
In oroor to analysethe overall heatb'aIlSfercoefficient a representativetemperaturedifferencemust be
determinedthat representsthe driving force for heat transferbetweenthe refrigerant and the water.
The temperaturedifferenceto be usedin this caseis the "Logarithmic Mean" which is given by
where9... = Temperawre
differencebetweendie two fluids at inlet,
9..-1ot
= Temperature
differencebetweendie two fluidsat outlet.
and
Once air free increasedie condensercooling water flow to a mid range value. The pressureat
which the condenserstabiliseswill dependupon the water inlet temperature.
(ii)
Set the evaporatorwater flow to a mid range value and allow the unit to run for approximately
15-20minutes. The time takento stabilisewill dependupon the local ambientconditionsand the
cooling water inlet temperature.
44
OBSERVATIONS
Local AUDOspheric
~:
lOlkN m.~
Test No.
Evaporata GaugePressure
Pel tN mea
-68
AbsoluteEvaporatorPressure
p.1 kN mea
33
Evaporata'Temperature
EvaporaI Waf Flow Rate
t,/OC
die I gin S.l
11.0
'a/OC
10
CondensedLiquid Temp.
"lac
CondenserGaugePressW'e
p.1
tN
m-2
-41
AbsoluteCondenser
~
p.1
tN
m-2
ro
Condenser Tempelature
Condenser Water Flow Rate
t,IOC
r-/OC
Ib./ gin 8"1
15.0
so.o
~/ac
11.0
r,/OC
12.0
20
rs/OC
Discharge
Temp.
-
6.5
Compreso
2.
W I WatU
Note that the tem~rabJres recordedhave been estimatedto me nearest0.5C using me standard
mennometerssupplied. If the optional temperature indicator is fitted with the themtocouple~nsors
then the temperaturesmay be recordedto the nearestO.IC.
45
For the Evaoorator
RaICof Heat Transferto Wata' in EvaJX)rator:
Q.
Q.
- t,)
IN. C, (t1
Q. :.83.6W
e~
- 11.0- 6.5
e~
= 10.0 - 6.5 =
4.5- 3.5
8- .
In~
3.5
~K
Q
U=A&:
83.6'--, W.-2
~~
u =~
For
-
the
g-l
w..-2c'
Condenser
= *~ c, ("
Q~
- tJ
Q~ = .
8~ . 15.0- 12.0
8--
. 15.0- 12.0 .
8-
4.0
3.0
ID~
3.0
~K
3.0K
46
Heat Transfer Rate
u=~
A8.
u.
u = ~
Wm-2K-l
47
9. GENERATION OF A REFRIGERATION CYCLE DIAGRAM ON A PRFSSUREENTHALPY CHART
Note this procedure can ONLY be undertaken by the following detailed method with the optional
temperature indicator fitted to the R633 unit as the temperature of the refrigerant liquid in the
condenseris required for one state point on the cycle diagram. However the procedure may be
modified for use with the standard thermometer set. SeePage48.
The fitting JX'OCedUIe
for the optional temperatureIndicator kit, if not already fitted. is given in
Appendix A. Details of the kit are availablefrom P.A. Hilton Ltd. or their local representative.
The vapour compressionrefrigeration cycle is of paramountimportancein tentls of food and drug
preservation,air conditioning, and heatpumps. In order to analysethe systemperformancein tentlS
of die diermodynamiccycle it is common for engineersto record systempressW'eS
and temperawres
and dien to plot the various statepoints on a pressure-enthalpy
chart of the wm'king fluid.
The working fluid in me Hilton RefrigerationCycle DemonstrationUnit SeriesR633 is R141b. This
has me chemicalname 1.1.-Dichloro-l-fluoroed1ane.
A pressure-enthalpy
chart for this substanceis shownon Page55.
A detaileddescriptionof die variousparametersdisplayedand obtainablefrom pressure-endtalpy
charts
will be found in most text books on thermodynamicsand thereforewill not be expandedupon in this
manual.
In order to plot a cycle diagramfor the unit the following procedureshould be adopted.
Procedure:
(i) Start me unit fOf normal operation as shownon Page 15 and ensuredtat me unit is air free by
venting air from the condenseras describedunder air venting on Page 18.
Once air free increasethe condensercooling water flow to a mid range value. The pressureat
which the condenserstabiliseswill dependupon the water inlet temperature.
(ii)
Set the evaporatorwater flow to a mid range value and allow the unit to run for approximately
15-20minutes. The time takento stabilisewill dependupon the local ambientconditionsand the
cooling water inlet temperature.
Pointa is at theintersection
of theevaporator
chamber pIeSSm-eP. = 32 kN mozabsolute
andthe
evaporating
temperature Is= 4.0OC.
(ii)
m2.absolute
and the
48
(ill) Point c is at the inte~tion
condensedliquid tem~
and d1e
At JX)inta die v8lX>urfrtm die evaporBtis drawn into the compe.-,r and me pressureis raised
from P. to Pc. It is evident from die line of constantentropyintersectingwith JX)inta (1.9 kJ kg-I
K-1) that die compession is not isentropic as die pressurerise is completedat an entropy of
aPJXQximately1.92 kJ kg-l K-1. If required the isentropic efficiency of compressionmay be
evaluated.
Note that mough me experimentmay only be carried out in the aOOvedetail utilising the optional
temperatureindicator. statepoints a and b may be determired using the standardthermometerS.
The temperatureof dIe conOOnsed
liquid may. however.be estimatedfrom dIe saturationpressurein
the condenserif it is assumeddlere is no sub-<:ooling.In dIe aboveexampler.. dIe condensedliquid
tem~.
is measuredas 19.5oC.but dIe saturationtemperawreat 70 kN m-zpressureis 21.7OC.
Cearly somesub-coolinghasoccurred.
49
OBSERVAnONS
Local AttnospbericPressure:lOlkN m-2
Test No.
Evaporala GaugePressure
p. I kN m4
-69
P. I kN m4
32
Eva{X)ratCKTemperature
ts/OC
Ib.I gill S-l
4.0
20
it/OC
11.2
~/OC
9.7
CondensedLiquid Temp.
../OC
19.5
Condenser
Gauge~
PcI tN m-l
-31
PcI tN m-l
70
t.,/OC
41.7
CondenserTemperablre
../OC
19.5
10.0
r,./OC
11.6
~/OC
16.7
CompressorPower Input
W I Watts
2.
!~
Q)
'0
n
=-
CD
13
so
I.A
0
w
0
0
t-.)
\.It
0
t-..)
0
0
~v.
=0
=-
.
-6"
;O ~
_0
~o
=
c..
=.
-6"
'<~
_v.
~o
~~
Vt
0
0
VI
VI
0
0\
0
0
0\
""
0
.,..J
0
0
-.0
i
~
~
0
:...
0
""
;;'f
'j~
G'
~r"i:t
~
~
~
0
""
0
"0\
0
c.
-V ~:
..~
- ~~
-.J
;i
N
..
w
~.:;
::r~P
:~
-
m
",,~'
'c
'8
i;:~
9~
..~
~E
1-.8
~
!
1 ~~
fij-
-t.,)
loA
000
A; ..,..
l~11
rl"r1
,~
1\
{
~,r\
Oa
Co
'oc
INI
~~I.09
00
i.I- ~
.ft
I~
"
"v-
f\
't~J
-N
""-0
~t
-N
V-O
~~
"
\.
i::1:'
~:'.
-
", 1
1~
'
,\
:~
,\
.. ,
-,
,"
1\
w . V\O\~-0
r:
~-:::
.~
'.~
~
I.~
A\
\"
\\.:..\
I" \
'i~
0
~
~=-,~,
;If:::to:tt1- ~
0
'w
w~
00
1I
'-0
---
w
~
0000
~I
\'1
V\O\
~
0
0
N
v0
~
0
0
~
v.
0
~
0
0
~
v.
0
u0
0
"'"
"'"
0
0\
\oft
0
51
10. MEASUREMENT OF mE EFFECT OF CONDENSING TEMPERATURE ON
COMPRFSSOR POWER INPUT
Notethis procedurecan~
be undertakenby the followingmethodwith the ootionaldi2ital
wattmeterfitted to the R633unit.
The fitting procedurefor the optional wattmeter kit. if not alreadyfitted, is given in Appendix B.
Details of the kit are availablefrom P.A. Hilton Ltd. or meir local re~tative.
The vapourcompressionrefrigerationcycle is utilised in both refrigerationand heatpump awlications.
In a refrigeration situation the eff~t of high ambienttemperaturewill be to both ~rease the loan on
the refrigeration system(due to heat leakagejntq the cold spacethrough thennal insulation) and to
increasethe condensingtemperaturein order to reject heat from the system.
In a heatpump applicationthe useful heatfrom the condenserwill be more easily utilised for heating
applicationsif rejectedat a high temperature.
Procedure:
(i) Start the unit as for normal operation as shown on Page15 and ensurethat the unit is air free
by venting air from me condenseras describedunder air venting on Page 18.
Once air free increasethe condensercooling water flow to maximum (50 g/s). The pressureat
which the condenserstabiliseswill dependupon the water inlet temperatm'e.
(ii)
Set the evaporatorwater flow to a mid range value and allow me unit to run for awroximately
15-20minutes. The time takento stabilisewill dependuponthe local ambientconditionsand me
cooling water inlet temperature.
(ill) RecorddJecompressorpower input shown OIl the digital wattmeterand the condensingpressure
Pcas illustrated in dJetable on Page52.
(For referenceit is recommendedthat studentscarefully touchthecompressorcasingto experience
the heat loss from die compressordue to electrical heating effects. This representselectrical
energy wasted by the system. Care should be exerc~ed as the comoressor casioa will be
!!QI.)
(iv) Adjust the condensercooling water flow to a lower valueand againallow the systemto stabilise.
Re~
d1eaboveobservations.
(v) The proceduremay be repeatedup to the maximum condensingpressureif local cooling water
conditionspermit
S2
OBSERVAnONS
Local AtmosphericPressure:
kNmo2
Test No.
Evaporala GaugePre~
Pel tN mol
Pel tN mol
Evaporata T~penIuIC
E Vaporatm'
Watrl'
Row
Rate
~/OC
CondensedLiquid Temp.
"/OC
CondenserGaugePreaure
p./tN
m4
p./tN
m4
Temp.
-
Condenser T emperahlre
Condenser Water Flow Rate
190
274
302
",/OC
,,/oc
Ib./ gin S'1
~/OC
r,/OC
Compressor
15
Discharge
"/OC
Compressor
-
Power Input
W I Watts
Note that the val~ observedwill dependupon the local conditions,the p-essuresset and the local
supply voltage and frequerx:y.
As indicatedabove,the power required to drive the com~
is increased.
increasesas ~ condensingpressme
S3
OBSERVAnONS
Local Atmospheric~:
kNm-7.
TestNo.
Evaporata' GaugePressure
Pel kN m-2
Absolute EvaporatorPressme
p.1 kN m-2
Evaporat(X'Temperature
.,/OC
m. I gin S-1
"/OC
t,/OC
CondensedLiquid Temp-
r./OC
p~I kN m-2
p~I kN m-2
Compres~ DischargeTemp.
t.,/OC
Condenser
Temperawre
~/OC
r./OC
t,/OC
CompressorPower Input
W / Watts
54
rn
~
2'
.,
~
C'.
=
=
--3
tD
a
~
.,
~
2'
~
0
~
0
(.a)
tn
0
m
0
...,
0
U1
0
~
0
0
Saturation
r-m
~
(11
0
1-'.'
m-2
~
n-{+~
Tl
t1.
n-111
LL
ti
TI
~
a
f1
++i
~
~
=
z
t
<
=
0
V\
\0
0
'1"\
'1"\
0
0
\I")
0
In
'o:t'
0
0
~
0
~
~
0
0
M
<:>
It"\
N
0
0
N
-In
0000
\CV\
000
\O\t'\
~
0\;
"#'
0\;
0';
(f'I
N-
o~
\,
011'\
N-
~~
..1
~~
-I
""
...a
l i
I~ !
ill~
~tl
X
'S.J
~
I~
- i
-0 ~ \OV\.qoM
~!
\,
I '.
m
l'
0
~
(.l8q) 3.1ns~.ld
~t
- 0 00 0 0
-~~~-
-tv / 3RlosQU'UO!St3Jd
N00
'"
. J~
~;
N-::00
0 '55
0
r---
0
V\
\0
0
0
10
0
V\
V\
0
0
'1"\
OJ)
o~
VI~~
c.
";
.c
=
O~
0~~ .c.
";
.c
-
0=
VI~
~
0
0
('f')
0
V\
N
g
N
0
Ir)
S6
SPECIFIC RISKS
. Contact with liquid will causeseverefrost bite
. Decomposesin a fire to give toxic and corrosive fumes
. Containen may bunt if overheated
. Risk of asphyxiation at high concentration
IDENI1F1Ct770N
1.
LI
1.1
SYDOBymS
l,l,-Dichloru-l-O=roethaDe. R-141b
Uses
2.
COMPOSmON
Substance
Impurida
3.
PHYSIC4LPROPERTIES
At2G-C
liquid
3.1
PbysicalSUte
colo1U': colourless
0d01U': slightly etherial
Tempentura
3.2
~tiOD
~.1Ure:
CAS
EINCS
1717-00-6
404-080-1
SOO-C
3.J
pH
DCutr81
3.4
Solubility
in ~
at20.C: 0.54%by weight
in solvCDts:
misciblewith aliphatichydrocarbons.
aromatlcs,ketoaes.chkwiDated
derivatives
a1i~
3.5
Vapour pressure
at SO.C:
3.6
Deasity
(liquid) at 2S.C:
(vlpOur) at 32.C:
5.011
kIfm)
3.7
Other data
criticalpressure: 43.4bar
4.
4.1
4.%
PacklDgmaterials
4.3
DecompolltioD prvducu
Stableat ambienttemperabl1'e,
but willlDfcrlo thermal
decompositionat elevatedtemper8tures
to give off
hydrochloricand hydrofllWric acidsaDdpossiblypbol8~
4.4
DaQcroas reacdODS
4.5
lDdJvtduaJpmeDdoD
and pAtecd"e measures
Gloya-
4.6
Sped" protecdve
mcuara
4.7
If in m ~loscd
.83bIr
1.24.,cm)
loula r=ommeaded
AvoidliquidcoDtKt
withskiD
- eyes
aDd
theiDh8Iati~
of~.
No aaked
bratbiDI ~
(risk or -.hyxi8lioa/llK)xia).Allow
to eT8pOrIIcor pump into salecoatIiIICr. Prevalt.!rom
mtailla ~
bucmCUISetc.
In caseof emergencytelephone"
01443 842255
57
SPECIFIC RISKS
. Contact with liquid will causeseverefrost bite
. Decomposesin a fire to give toxic and corrosive fumes
. Containers may burst if overheated
. Risk of asphyxiation at high concentration
DestnacttoD of
coDtamiDated coDwDer
...8
4.9
Ret\un to supplia-.
5.
5.1
5.1
S.J
area,
5.4
Extinction
Not applicable
5.5
Particularmeasura
during OR-fighting
5.,
Other recommendations
6.
TOXlCOLOGICtLINFORMATION
CAS
EINCS
1717-00-6
404-080-1
7.
Vapour
Uquid
8.
01443 842255
S9
'3
4
Amendments
2 MAINS FILTER ADDED
10.9.97 JB
()
r---
..
LINE t )1
-0
HA~
-.
IFLTER
~~IPA~
LOCAl ~PL Y V~ TAGE A~
CON~CT BROWNWIRETO ~AREST
va. TAGE TAPP~ PaNT.
SET TO 130V ~
r-
~I
~I
~
HAt-IJFACTURE
1
.
1
i:
~:1
m
r-
Q ~o~~~1
<@
(2}1
IllJ--,m
@}
1111
@
IW
~I
...1
10
1m
@I
-<I
~.
r-1
i.
.
.
..
1
.
..
~~.~:..
."J.
c
OR~L
3 CORE POWERCABLE
DSC~CT
FROM HAINS FL TER LINE IN
RE ROOTE TO PRt1ARY SIDE
CF TRANSFORMER
~PLY
to -mY
5O/~
SEE MAN WlRNG CMAGRAHFOR TERMNAL KEY
110
130V
TRANSFORMER
--
MTL:
FINISH:
DrcwnbY: ..B
Checked
iDimensions mm I Y
@c::J
Fractions .t 1/6'.
Decimals .t 0.25 mm
Projection:
Issue: 2
WIRING
DIRGRAM
Scale.-
no/rig. 1
---
HA~SHIRE ENGLAND
P. A. HLTON LTD KINGSSOMBORNE
633385
61
APPENDIXA
IfI-I"iNG
INSTRUcnONS
62
-- --
VjQllK
mQJCator
~l
The addition of the digilal temJ'eraLureindicator not only increases die resolutioo of tem})el3ture
measuremenmfrom to.soC to O.IOC but a thennocouple sensor is provided to record the temlJeJ'a1Ures
refrigerant
additiOnal
teJnj)elatures
R141b
allow
PCessure-enthaIpy
complete
vapour
re.
comPlession
cycle
diagram
to
be
nrn.i..~_..
diagram.
Oncethe level has beenmeasuredor marked,position the ball valves for shutdown (SeeFigure 2
R633 Valve Positions)and hJm the unit off. Turn off and disconnectthe unit from the water supply.
Isolate the unit from its electrical supply and then remove the bolts and one nut securing the rear
panel.
Storethe bolts, nut and washersin a containeras thesewill be requiredfor refitting the panel.
63
Ensuremat the liquid level is below the level of the blanking rod and that the condenserpressureis
either at or below atmospheric pressure.
Using a close fitting spannerremovethe nut securingdIe blanking rod.
Take the 0 3mm x 8Smm long diennocouple (!MIS/IO) and using a 0 3mm compressionolive
(PF4/67)and die original nut. insert the diennocouplein die chamberto a depdi JUST BELOW that
of the measuredliquid level.
Rewm me unit to an upright position. Thosewim accessto a vacuumpump may eXb'actany air from
the systemby connectingto me internal pipe leading from me vent valve on top of the condenser
chamber.
Note that the oil in the unit is hygroscopic(absorbswater vapourfrom the air) and the unit shouldDOt
be left open to atmospherefor long periods.
Fit the 7 shon rod type thermocouples(IMlS/l6) in placeof the original thermometers.For the present
time the thermocoupleconnectingleadscan be left ttailing at the front of the panel.
Remove die 92mm x 92mm blank insttument case from the panel by releasing die retaining screws from
inside die machine panel and withdrawing die case from die front of the unit.
The digital temperatw'eindicator and multi way selecta-switch are two separateitems. A separate2
coretbennocouple
cableis suppliedto makemelink betweenmemo
FirSt install the 10 way selector(]MIS/50) at the bottom of the 92mm x 92mm panel orifice. This is
Electrical Installation
The 3 core IX>wersupply lead for die optional ternperattJre
indicator and separateoptional wawneter
is factory fitted to the following tenninalson the DIN rail connectorson the right handsideof die unit
adjacentto the input IX>werlead. Their free endsare identified ~ follows:
~
units already fitted widt a wattmeter (R633B) will use the ~k. of loose JinkssuWlied to tap
into the wattmeterIK>wersupply. Refer to the wiring diagramon Page71.
Unitsnot fitted wim mewattmeterwill useme free wireslabelled47 (Line - Cololn' Red) and 48
(Neub'al- Colour Black) directly.
64
The free end of d1elead will havebeenprotectedwith tenninal covers. Theseshooldbe removedand
the 3 wires given 1 turn throughme ferrite ring suppliedand ~1Ued ooarto the indicator. The red and
b1a;kcablesshooldbe connectedto the following terDlinalson the digital temperatW'e
indicator. Note
that as ~ digital temper8bJre
indicator is double insulated.the green/yellowearth wire is not usedin
this application.
18 L Line renninal securesRed wire 47
17 N Neuttal terminal securesB1a:k wire 48
The themtocoupleleadsmay now be ~red
to the thennocoupletenninalson the multi way switch
oox. Note fran the wiring diagramon Page71 that ~h of the 10 switcOOdchannelcoonectiooson
the rear of the oox has4 terminals. However.in eachcaseonly the left baOO
pair of eachgroup of four
areutilised.
Note that due to a new EuropeanStandard,sometype K d1ennocoupie
w~
insulation and od1ersgreenand white to identify the polarity.
NOTE that if local regulations require, or any doubt exists concerning correct connection of the
instrument, the unit should be inspectedby a competent electrician before supplying power to the
unit.
Refit die unit back paneland restoredie elecbical supply and water supply.
Start the unit as for normal operation following the procedureon Page IS and verify that when the
main switch is turnedon the digital temperahlreindicator lights.
The rotary selectorswitch connectsthe indicated thermocouplenumrer to the digital display.
Note that the unconnecteddtennocouplechannelswill give readingsthat have no meaning(full scale
negativeor full scalepositive) unlessa dtennocoupleis flued by dte user.
The digital temperat1D'eindicator has five fmtCtiODkeys on its front fascia. These are used only during
manufocbJre to configure the instrument Pressing me keys may disturb d1e displayed value. The
display will revert to normal after a 60 second delay.
to the recommendedlJ:()COOures.
6S
PA~L
FIGURE A
~
USE A SUITABLE FLAT
SCREWDRIVERTO PUSH AND
ROTATE THE ClP ONTO THE
TWO BRASS STUDS ON THE
SlOE OF THE SWITCH CASE.
66
67
APPENDIX B
ttrl-rING INSTRUcnONS
68
--ESCRIPfION
INST
ALLA
of a blackDIN ~,
nON
;
A 3 core power supply lead for dIe optional wattmeter and separateoptional digital temperature
indicator is factory fitted to dIe following terminals00 dIe DIN rail connectionson die right handside
of dIe unit adj~ent to dIe power input lead. Their free endsare identifIed as follows:
links supplied to tap into the IX>wersupply. Refer to the wiring diagram on Page 71. H the tempezanue
indiCa1CK
gets in me way, unclip and push forward.
Units not fined with the digital temperature indicator will usethe threeunusedwires within the loom
identified as follows:
69
49 (Earth
ColourGreen+ Yellow stripe)
47 (Line
Colour Red)
48 (Neuttal- Colour BJack)
Before connecting to me watbneter,pass mese3 wires 1 turn through the ferrite ring supplied and
securenear to me watbneter.
The lOOmmred link from watuneterTenninall L to 3 AC V is usedin all cases.
The baseboardis pre-drilled with 4 off pilot holes 2mm dia. to receive the 2Ommlong self-tapping
screws(SFl/118). Theseshouldbe usedto securethe currenttransformer(E3/108) in position. Refer
to diagramon Page70.
Remove the compressorelectrical connectionscover. Detach the red line wire 31 and cut enough
adjacentcable ties to enablethis wire to passthrough the centreof the current transformerand back
to the compressor.Reconnectthe red line wire 31 to its original terminal on the compress<l'and refit
the cover.
Connect the 1200mm long red wires from the current transformer 51 and 52 terminals to the
conespondingterminalson the wattmeter. Twist thesetogetherto form a twisted pair of wires. Route
them throughthe releasablecableties securingthe loom to the fascia,and passthe pair 2 bJIDSthrough
the ferrite ring.
Tidy the loom using the cable ties IX"Ovided.
NOTE that if local regulations require, or any doubt exists concerning correct connection of the
instrument, the unit should be inspectedby a competentelectrician before supplying power to the
unit.
Refit d1erear paneL
Restoreelectricalpower.
Switch on the main switch and verify the wattmeteris indicating. Minus valueswill appearif S1 and
S2 are reversed.i.e. S1 on the cWTenttransfonneris connectedto S2 on the wattmeter,and vice versa.
Or alternativelyif the direction of the compressorpower supplythrough the core of me transfonneris
reversed,the samenegativevalues will be seen.
70
..
!!
I
i~i~
5~"'1
~'
,
,
"i"
I
I
Ii.;.-n
CIJ:D~
:11
!: I'";
- J.I i
..I
I'!
: i~
8p
~
~p
~
-Iu.-W"aiW--'
Ila~~III!
"
..
I ~
1t\.!1
~
0(
~
@
~oO
I-W
cl- e @ iii
~t:
~~
WW
..1~~
~~
,~
i
~i
:
IL,% :
I!
1
I
~~
\ I
i",
~.
I!!i
!!
~"AZ
~"~
SJ.~
S1J.YM
AG"
ZI.
AG,
$"AS ScIIY 8
AGJ.
{"
UIoH W8 ~S S
~c
Qw
1-1~~
~)I~
~'t
IIIi
11
~~
ii
...1
~~
Oil
t
t
t
..
t
1
I
I
I
I
I
I
I
I
I
I
I
,
I
I
- ... - EJ...J
8_lI
i~
~i
~ yo
.."~
- aE
-I~
- i~
@~
'-
~!
Ii
i~
.~
~
~
\11;1
~I
'\
~
'"
!*.;;..
!~..
t-
.~~...
,I&.
In
il
~@.il..
~~
3~iij,a.@.@
-'~a~~aaa~
-'
ffidlm~I~~
t-u
~
I
~
71
~~
I-~
:~i
~~
1&1
i
I
I
,
t-'
~
~
c
a:
"
~I
:i ~
~ ~
~
~
~
~
~
~
~
t)(
W
~
~
i
I
I
i
j I I 5
I .. ~ III
1:8m18Itll
Ii..
~8.
5 5
im~..~
~~
~.~!I.
~5
i~!!~!!~
/-0
..
_O-
I
,..
@~'t' I
i.. Ii
..~ Ie
~~
Wi
. II
;~
72
-1
4
Amendments
A
Sl,PPLY
TO WATTMETER
ANDOR
TEMPERATURE
INDICATOR
SIGNAL TO S1 AND S2
ON WATTMETER
'\
r~~#
...#...
~,
."
, ##
, ,##
I , '"
I ."
, :
B
ONCE THROUGH
, ;
,
, .
I: .
TWICE THROUGH
.
...
~'
.'
"'.
,-'
~ .
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~---
\Dimensions:
mm \ by:
suppiiersresponsibility.
---
!Drawnby: JB IChecked
to
Fractions
Decimals
:Projec:tion
-
t 1/6'.
t 0.25 mm
!Issue:
TITLE:
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HTL:
KINGS SOMBORNE
P.
A.
HI..
TON
LTC
HAMPSHIRE
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1.
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~-~