SECTION5

COMMERCIALREFRIGERATION
UNIT25
SPECIALREFRIGERATION
SYSTEMCOMPONENTS

UNITOBJECTIVES

Afterstudyingthisunit,thereadershouldbeableto

Distinguishbetweenmechanicalandelectricalcontrols
Describetheautomaticpumpdowncycle
Describevariouselectricalcontrolsthatapplytorefrigerationsystems
Explainthesimilaritiesanddifferencesamongplanned,random,
offcycleandtemperatureterminateddefrost
Describevariousaccessoriesfoundonrefrigerationsystems
Describethehighandlowpressuresiderefrigerationcomponents

THEFOURBASICCOMPONENTS
Compressionsystemsmusthaveacompressor,
condenser,expansiondevice,andevaporator
Othercomponentsenhancesystemoperation
Controlscanbeelectrical,mechanical,or
electromechanicaldevices
Mechanicalcontrolsstart,stopormodulatefluid
flowtoincreasesystemeffectiveness

TWOTEMPERATURECONTROLS
Twotemperatureoperationisutilizedwhenthere
aremultipleevaporatorsinthesystem
Theseevaporatorstypicallyoperateatdifferent
temperatures
Thepressuresintheseevaporatorsaretherefore
different
Twotemperatureoperationisnormally
accomplishedwithmechanicalvalves

18.4psig

20F

18.4psig

2temperaturedevice
26.1psig

30F

EVAPORATORPRESSURECONTROL
Evaporatorpressureregulator(EPR)
Preventsthepressureinanevaporatorfrom
droppingbelowapredeterminedpressure
Twopressurescontrolthevalve
Springpressurepushestoclosethevalve
Evaporatorpressurepushestoopenthevalve

Evaporatorsuperheatmaybehighwhenthe
EPRisclosed

THEEVAPORATORPRESSUREREGULATOR
Spring
Vaportocompressor
Seatdisc
Seat

Vaporfrom
evaporator

Schradervalve

MULTIPLEEVAPORATORS
AnEPRisneededinthesuctionlineofeach
evaporatorexceptthelowesttemperaturecoil
EPRvalvesareequippedwithSchradervalves
toreadevaporatorpressure
MultipleEPRscanbesetatdifferentpressures
soeachevaporatorcanbemaintainedata
differenttemperature

18.4psig
10psig
(Lowest
pressure
evaporator)
EPRValves

28psig

ELECTRICEVAPORATORPRESSURE
REGULATOR(EEPR)VALVES

Providemoreaccuratecontrol
Locatedattheevaporatoroutlet
Usedonsingleormultipleevaporatorsystems
Microprocessorsensescasedischargeair
temperature
Designedtomaintaindischargeairtemperaturein
therefrigeratedcase
Controlledbyabipolarstepmotor

CRANKCASEPRESSURE
REGULATOR(CPR)
Locatedclosetothecompressor
Preventscompressorfromoverloadingonstartup
Providesalimittothepressurethatcanenterthe
compressor
Referredtoasacloseonriseofoutlet(CRO)valve
ResemblesanEPRvalve

THECRANKCASEPRESSUREREGULATOR
Spring
Vaporfromevaporator
Seatdisc
Seat

Vaporto
compressor

Schradervalve

18psig
5psig

Evaporator
Crankcasepressureregulator

Liquidline

ADJUSTINGTHECPRVALVE
Valveisbestadjustedunderahighloadcondition
Anammetershouldbeusedwhensettingthevalve
Excessiveamperageindicatesthattoomuch
refrigerantisenteringthecompressor
Turningtheadjustingscrewintothevalvereduces
therefrigerantpressurereturningtothecompressor
Turningthescrewoutofthevalveincreasesthe
refrigerantpressurereturningtothecompressor

RELIEFVALVES
Releaserefrigerantfromasystemwhenahighpressure
conditionexists
Springloadedtype
Locatedinthevaporspace
Resetsafteropening

Onetimetype
Fittingsfilledwithlowtemperaturesolder
Usuallylocatedinthesuctionlinenearthecompressor

SPRINGLOADEDRELIEFVALVE

SEAL
VALVEINTHECLOSEDPOSITION

SPRINGLOADEDRELIEFVALVE

SEAL
VALVEINTHEOPENPOSITION

ONETIMERELIEFVALVE
Holeisfilled
withalow
temperature
solder

Holedrilled
throughthe
reliefvalve

LOWAMBIENTCONTROLS
Usedonrefrigerationsystemsthatareoperated
yearroundtomaintainheadpressure
Fancycling,fanspeedcontrol,airvolume
control,condenserflooding
Intendedtosimulatedesignoperatingconditions
Helptokeepthesystemsoperatingpressures
withindesiredranges

FANCYLINGHEADPRESSURE
CONTROL
Deviceopensonadropinheadpressure,turning
condenserfanoff
Deviceclosesonariseinheadpressure,turning
condenserfanon
Fancyclingcauseslargevariancesinthehead
pressure
Bestusedonsystemswithmultiplefans

FANSPEEDCONTROLFOR
CONTROLLINGPRESSURE
Astheoutsidetemperaturedrops,thefanslows
downtoreducetheamountofairflowthrough
thecondensercoil
Astheoutsidetemperaturerises,thefanspeeds
uptoincreaseairflowthroughthecondenser
Somecontrolsmonitortherefrigerants
condensingtemperature

AIRVOLUMECONTROLFOR
CONTROLLINGPRESSURE
Utilizespistoncontrolledshuttersand/or
dampers
Astheheadpressuredrops,theshuttersclose,
reducingairflowthroughthecondenser
Reducedairflowcausestheheadpressuretorise
Duringperiodsofwarmambienttemperatures,
thedampersarefullyopentomaximizeairflow
throughthecondensercoil

WARMAMBIENTTEMPERATURE
Condenser

Highpressure
sensedhere

Piston

Damperblades
intheopen
position

Hotgasfromcompressor

LOWAMBIENTTEMPERATURE
Condenser

Highpressure
sensedhere

Piston

Damperblades
intheclosed
position

Hotgasfromcompressor

CONDENSERFLOODINGFOR
CONTROLLINGHEADPRESSURE
Floodingvalvescauseliquidrefrigeranttomove
fromthereceivertothecondenser,reducingits
effectivesurfacearea,incoldweather
Systemswithfloodingvalveshaveoversized
receiverstoholdexcessrefrigerantchargeinwarm
weather
Thevalveisclosedwhenoutdoortemperatureis
high(allrefrigerantisdirectedtothecondenser)

Condenser
flooding
valve

CONDENSER

Duringwarm
ambient
temperatures,allof
therefrigerantis
directedtothe
condenser

COMPRESSORRECEIVER

Condenser
flooding
valve

CONDENSER

Duringlowambient
temperatures,the
refrigerantisdirectedto
thereceiver,bypassing
thecondenser

COMPRESSORRECEIVER

THESOLENOIDVALVE

Usedtostartorstoprefrigerantflow
Normallyopen(NO)ornormallyclosed(NC)
Snapactingvalves(openorclosed)
Valvesmustbeinstalledwiththearrowpointingin
thedirectionofflow
Oftenusedinconjunctionwithautomaticpump
downcycles
Valvepositioncontrolledbyasolenoidcoil

Solenoidcoil

Solenoidvalvebody

Directionofrefrigerantflow

NORMALLYCLOSEDVALVEWITHCOILDEENERGIZED

VALVEISINTHECLOSEDPOSITION

NORMALLYCLOSEDVALVEWITHCOILENERGIZED

VALVEISINTHEOPENPOSITION

NORMALLYOPENVALVEWITHCOILENERGIZED

VALVEISINTHECLOSEDPOSITION

NORMALLYOPENVALVEWITHCOILDEENERGIZED

VALVEISINTHEOPENPOSITION

PRESSURESWITCHES

Startandstopcurrentflowtocomponents
LowpressureswitchClosesonariseinpressure
HighpressureswitchOpensonariseinpressure
LowambientcontrolClosesonariseinpressure
OilsafetyswitchOpensonariseinpressure

LOWPRESSURESWITCH
Canbeusedaslowchargeprotectionandspace
temperaturecontrol
Lowchargeprotection

Cutoutpressuresetwellbelownormaloperating
pressure
Cutoutpressureshouldbesetaboveatmospheric
pressuretopreventatmospherefrombeingpulledinto
thesystem
Preventssystemfromoperatinginavacuum
Controlisnormallyresetautomatically

LOWPRESSURECONTROL
APPLIEDASATHERMOSTAT
Controlwillcutoffthecompressorwhen
thepressureequalsthesystempressurethat
correspondstoatemperatureabout15
coolerthandesiredboxtemperature
Controlisratedbypressurerangeand
currentdrawofthecontacts

L2 L1
Tstat
Overload
Lowpressurecontrol

CONTACTOR
MOTOR
START
RUN

AUTOMATICPUMPDOWNSYSTEMS
(SHUTDOWN)SEQUENCEOFOPERATION
Normallyclosedliquidlinesolenoidvalvecontrolledbya
thermostat
Thermostatopenswhendesiredboxtemperatureis
reached
Thesolenoidisdeenergizedandcloses
Compressorcontinuestopumprefrigerant
Thesuctionpressuredrops
Lowpressurecontrolopenswhensuctionpressuredrops
Lowpressurecontrolcontrolscompressoroperations

Lowpressurecontrol
closed

L2 L1

L2

L1

Thermostatclosed
Liquidlinesolenoidvalveopen
Compressorenergized

Lowpressurecontrol
closed

L2 L1

L2

L1

Thermostatopen
Liquidlinesolenoidvalveclosed
Compressorenergized

Lowpressurecontrol
open

L2 L1

L2

L1

Thermostatopen
Liquidlinesolenoidvalveclosed
Compressordeenergized

AUTOMATICPUMPDOWNSYSTEMS
(STARTUP)SEQUENCEOFOPERATION
Whentheboxtemperaturerises,thethermostat
closes
Theliquidlinesolenoidisenergized
Refrigerantflowstotheevaporator
Thecompressorisstilloff
Whenthelowsidepressureincreases,thelow
pressurecontrolcloses
Thecompressorisonceagainenergized

Lowpressurecontrol
open

L2 L1

L2

L1

Thermostatopen
Liquidlinesolenoidvalveclosed
Compressordeenergized

Lowpressurecontrol
open

L2 L1

L2

L1

Thermostatclosed
Liquidlinesolenoidvalveopen
Compressordeenergized

Lowpressurecontrol
closed

L2 L1

L2

L1

Thermostatclosed
Liquidlinesolenoidvalveopen
Compressordeenergized

Lowpressurecontrol
closed

L2 L1

L2

L1

Thermostatclosed
Liquidlinesolenoidvalveopen
Compressorenergized

HIGHPRESSURECONTROL
Preventscompressorfromoperatingathigh
headpressures
Controlopensonariseinpressure
Canbeautomaticallyormanuallyreset
Shouldbesetatapressurehigherthanthe
normaloperatingheadpressure
Manualresetcontrolsprovidebetterequipment
protection

LOWAMBIENTFANCONTROL
Startsandstopsthecondenserfanmotorin
responsetoheadpressure
Startsthecondenserfanmotorwhenthe
headpressurerises
Thissettingshouldbelowerthantheset
pointonthehighpressurecontrol

OILPRESSURESAFETYCONTROL
Largercompressorsareequippedwithoilpumps
Oilpumpisconnectedtothecompressor
crankshaft
Oilisforcedthroughholesinthecrankshaft
Measuresnetoilpressure
Netoilpressure=pumpoutletpressuresuction
pressure
Controlusesadoublebellows
Hasatimedelaybuiltintothecontroltoallowoil
pressuretobuildup

DEFROSTCYCLE(MEDIUM
TEMPERATUREREFRIGERATION
Typicalboxtemperaturerangesfrom34F
to45F
Coiltemperaturesarenormally10to15F
coolerthanthebox
Coilwillbeoperatingbelow32Fbutbox
willbeabove32F
Airinboxisusedtodefrostthecoilinthe
offcycle

RANDOMOROFFCYCLE
DEFROST
Coildefrostsusingboxtemperatureair
compressorcyclesoffonthethermostat
Evaporatorfanwillcontinuetorunwhilethe
compressorisoff
Airinboxdefrostcoil
Coildefrostswhenevercompressorcyclesoff

PLANNEDDEFROST
Defrostiscontrolledbyatimer
Systemgoesintodefrostatpredetermined
times
Defrostcycleisinitiatedduringlowload
periods
Systemsinretailestablishmentsoftengo
intodefrostwhenthestoreisclosed

LOWTEMPERATURE
EVAPORATORDESIGN
Boxandcoiltemperaturesarebothbelow32F
Coilisdefrostedusinginternalorexternalheat
Airintheboxcannotbeusedtodefrostthe
evaporatorcoil
InternalheatHotgasfromthecompressor
ExternalheatElectricstripheaters

DEFROSTUSINGINTERNALHEAT
(HOTGASDEFROST)
Useshotgasfromthecompressorsdischarge
Dischargegasisdirectedintotheevaporator
Utilizesahotgassolenoiddefrostisinitiatedbya
timer
Defrostisterminatedbyeithertimeorcoiltemperature
Evaporatorfanisdeenergizedduringdefrost
Compressorrunsduringdefrost
Refrigerantcondensesintheevaporator

Suctionlineto
compressor

Evaporator

Solenoidvalve

Dischargelinetothecondenser
Liquidlinefromcondenser

Suctionlineto
compressor

Evaporator

Solenoidvalve
closed

Liquidlinefromcondenser
Dischargelinetothecondenser
Refrigerationmodeofoperation

Suctionlineto
compressor

Evaporator

Solenoidvalve
open

Liquidlinefromcondenser
Dischargelinetothecondenser
Defrostmodeofoperation

EXTERNALHEATTYPEOF
DEFROST
Usuallyaccomplishedwithelectricheaters
mountedtotheevaporatorcoil
Defrostisinitiatedbyatimer
Defrostisterminatedbyeithertimeorcoil
temperature
Evaporatorfanisdeenergizedduringdefrost
Compressorisdeenergizedduringdefrost

DEFROSTTERMINATIONANDFAN
DELAYCONTROL

Singlepole,doublethrowswitch
Terminatesdefrostwhenfrosthasallbeenremoved
Delaysevaporatorfanstartuntilcoiltemperaturedrops
Whenicehasbeenremoved,theevaporatorsurface
temperatureincreases
Thecontrolsensesthisincreaseintemperatureandthe
systemisputbackintorefrigerationmodemechanically
Whenthecoiltemperaturedropstothesetpoint
temperature,thefanisenergized

DEFROSTTERMINATIONANDFAN
DELAYCONTROL
Singlepole,doublethrowswitch

RECEIVERS

Locatedintheliquidline
Thedevicestoresliquidrefrigerant
Refrigerantleavesthereceiveras100%liquid
Adiptubeisusedtoremovetheliquidfromthebottom
Mustbeusedonsystemswithcondenserfloodingvalves
Foundonsystemswithautomaticorthermostatic
expansionvalves
Notfoundoncriticallycharged(capillarytube)systems

Receivershell

Liquidline
servicevalve
Servicevalve

Liquidlinefromcondenser

Diptubeensuresthatonly100%
liquidflowstothemeteringdevice
Liquidlinetothemeteringdevice

THEKINGVALVEONTHERECEIVER
Locatedintheliquidlinebetweenthereceiver
andexpansiondevice
Undernormaloperatingconditions,thevalveis
backseated
Valvecanbefrontseatedinordertopump
systemdown
Hasaserviceporttoenablethetechnicianto
takepressurereadings
Valvemustbecrackedoffthebackseattotake
pressurereadings

Receivershell

Liquidline
servicevalve
Servicevalve

Liquidlinefromcondenser

Diptubeensuresthatonly100%
liquidflowstothemeteringdevice
Liquidlinetothemeteringdevice

SERVICEVALVES
Serviceport
Lineport

Valvestem

Packinggland

Deviceport

SERVICEVALVES

BackseatedPosition
Serviceportissealed,lineportisopentothedeviceport
Normaloperatingposition

SERVICEVALVES

CrackedofftheBackseatPosition
Serviceportisopentothelineportanddeviceport
Positionusedfortakingsystempressurereadings
Positionusedforaddingorremovingsystemrefrigerant

SERVICEVALVES

MidseatedPosition
Serviceportisopentothelineportanddeviceport
Positionusedforsystemevacuationandleakchecking

SERVICEVALVES

FrontseatedPosition
Serviceportisopentothedeviceport
Lineportissealedoff
Positionusedforpumpingthesystemdown

FILTERDRIERS
Locatedintheliquidline
Removesdirt,moisture,andacidfromtherefrigeration
system
DesiccantActivatedalumina,molecularsieve,silica
gel
Canbepermanentorreplaceablecoretype
Connectedtosystemwitheithersolderjointsorflare
connections

REFRIGERANTCHECKVALVES
Allowsrefrigeranttoflowinonlyone
direction
Canbeeithertheballtypeormagnetictype
Mustbeinstalledwiththearrowpointingin
thedirectionofrefrigerantflow
Installedattheoutletofthelowest
temperaturecoilonmultievaporatorsystems

REFRIGERANTSIGHTGLASSES
Installedintheliquidline
Enablesthetechniciantodetermineifasolid
columnofliquidisreachingtheexpansion
device
Canalsobesuppliedwithamoistureindicator
Usuallyinstalledafterthefilterdrier

LIQUIDREFRIGERANT
DISTRIBUTORS
Usedonmulticircuitevaporators
Locatedattheoutletoftheexpansiondevice
Designedtoallowequalrefrigerantflowtoall
evaporatorcircuits
Somedistributorsaremadewithsideinletsused
forhotgasdefrost

HEATEXCHANGERS
Inthesuctionlineleavingtheevaporator
Suctionandliquidlinesareconnectedto
allowheattotransferbetweenthem
Increasestheamountofsubcoolinginthe
liquidenteringtheexpansiondevice
Preventsliquidfrommovingthroughthe
suctionlineintothecompressor

SuctionLine

Capillarytubeconnected
tothesuctionline

Capillarytuberuninsidethe
suctionline

CapillaryTube

CapillaryTube

SuctionLine

HighTemperature,High
PressureRefrigerant
Heatistransferredfromthe
refrigerantinthecapillary
tubetotherefrigerantinthe
suctionline

SuctionGas

SUCTIONLINEACCUMULATORS
Locatedinthesuctionline,closetothe
compressor
Preventsliquidrefrigerantfromenteringthe
compressor
Givesliquidaplacetoboiloffbeforeentering
compressor
Sometimes,theliquidlineisroutedthroughthe
accumulatortohelpboilawayanyliquidandalso
increaseliquidsubcooling

Suctiongasfrom
evaporator

Suctiongastothe
compressor

Accumulatorshell
Holeforoilreturn

Suctiongasfrom
evaporator

Suctiongastothe
compressor

Liquidto
expansionvalve

Accumulatorshell
Liquidfrom
condenser
Holeforoilreturn

CAUSESOFLIQUIDFLOODBACK

ImproperTXVsetting
OversizedTXV
LooseTXVthermalbulb
Systemovercharge
Reducedairflowthroughevaporatorcoil
Lowsystemload
Defrostproblems

SUCTIONLINEFILTERDRIERS
Locatedinthesuctionline
Goodcompressorprotection
Mustbeinstalledwhensystemhasbecome
contaminated
Usuallyhavetwopressureportstoreadthe
pressuredropacrossthedevice

SUCTIONSERVICEVALVES
Normallyattachedtothecompressor
Valvepositions

BackseatedNormaloperatingposition
Frontseatedusedforpumpdownandservice

MidseatedUsedforsystemevacuation
CrackedoffthebackseatUsedfortaking
pressurereadings,chargingrefrigerantinto
thesystem,orremovingrefrigerantfrom
thesystem

SERVICEVALVES
Serviceport
Lineport

Valvestem

Packinggland

Deviceport

DISCHARGESERVICEVALVES
Locatedinthedischargeline
Normallyattachedtothecompressor
Usedasagageportandtovalveoffthe
compressorforservice
Samepositionsasthesuctionservicevalve
Thisvalveshouldnotbefrontseatedwhen
thecompressorisrunningexceptduring
closedloopcapacitytests

OILSEPARATORS
Installedinthedischargeline
Separatesoilfromtherefrigerantandreturns
theoiltothecompressor
Oildropsfalltothebottomoftheseparator
Oillevelraisesafloatandopensavalve
Differencebetweenhighandlowside
pressurespushoilbacktothecompressor
Deviceneedstobekeptwarm

Dischargelineto
condenser

Discharge
from
compressor

Oilseparator

Oilreturnline
tocompressor
Floatvalve

Oil

PRESSUREACCESSPORTS
Installedtotakepressurereadingsatvarious
pointsinthesystem
Linepiercingvalvescanbeinstalledwhilethe
systemisrunning
Canbesaddletypeorsoldertype
CaneitherhaveaSchraderpinorasmallvalve

CRANKCASEHEAT
Preventsrefrigerantfrommigratingtotheoilin
theoffcycle
Preventsoilfromfoamingandbeingpumpedout
ofthecompressor
Externaltypeheaters
Insertiontype
Crankcaseheatisneededduringtheoffcycleand
issometimescontrolledbyasetofnormally
closedcontactsthatopenwhenthecompressoris
energized

UNITSUMMARY1
Additionalcomponentsenhancesystemoperation
TheEPRisusedonmultipleevaporatorsystemsto
maintaindifferentpressuresineachevaporator
EPRvalvesarelocatedinallevaporatorsexceptthe
lowestpressureevaporator
TheCPRprovidesalimittothepressurethatcanenterthe
compressor
Reliefvalvesreleaserefrigerantfromasystemwhena
highpressureconditionexists
Lowambientcontrolsareusedonrefrigerationsystems
thatoperateyearround

UNITSUMMARY2
Commonlowambientcontrolsincludefancycling,
shutters,dampersandcondenserflooding
Solenoidvalvesareusedtostartandstoptheflowof
refrigerant(Snapactingvalve)
Liquidlinesolenoidsareusedaspartoftheautomatic
pumpdowncycle
Pressurewitchesopenandcloseinresponsetosensed
pressures
Pressureswitchescanbeoperationalorsafetydevices

UNITSUMMARY3
Theoilpressuresafetycontrolensuresthat
compressorsoperatewithsufficientoilpressure
Defrostingmediumtemperaturerefrigeration
systemscanbeaccomplishedwithplanned,
randomoroffcycledefrost
Defrostinglowtemperaturerefrigeration
systemsisaccomplishedwithhotdischargegas
(internal)orelectricstripheaters(external)

UNITSUMMARY4
Receiversarerefrigerantstoragetankslocatedatthe
outletofthecondenser
Receiversareequippedwithservicevalvesthatcanbe
beackseated,crackedoffthebackseat,midseatedor
frontseated
Filterdriersremovedirt,moisture,andacidfromthe
refrigerationsystem
Checkvalvesensurethatrefrigerantflowsthroughthe
circuitinonlyonedirection
Refrigerantdistributorallowequalamountsofrefrigerant
flowtoallevaporatorcircuits

UNITSUMMARY5
Suctionline/liquidlineheatexchangersincrease
subcoolingandhelpensurethat100%vaporenters
thecompressor
Accumulatorshelpliquidrefrigerantboilbeforeit
entersthecompressor
Oilseparatorshelpremoveoilfromthehotvapor
thatisdischargedfromthecompressor
Crankcaseheathelpsboilrefrigerantfromtheoil
inthecompressorcrankcase