Refrigeration Systems

Refrigeration Systems
Refrigeration Systems Student Resource Package No: NR 6/18/19/20/45/46

Nominal Student Hours: Delivery: 72 Hours.
Competence in this training program can be achieved through either a formal education setting or in the workplace environment.
Recognition of Prior Learning:
The student/candidate may be granted recognition of prior learning if the evidence presented is authentic and valid which covers the content as laid out in this package. This package provides the student with the underpinning knowledge to identify various types, of domestic refrigeration and commercial refrigeration systems together with their operational characteristics. Australian Refrigeration and Air Conditioning Vol 1&2. Various Manufacturers Service and Installation Manuals.
Package Purpose:
Suggested Resources:
Assessment Strategy:
The assessment of this package is holistic in nature and requires the demonstration of the knowledge and skills identified in the student package content summary. To be successful in this package the student must show evidence of achievement in accordance with the package
Competence:
This package should be supported by workplace exposure to the various applications under the guidance of a licensed mentor.
Compiled By: G Riach & R Baker
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Assessment:
Grade Code: 72 GRADE DISTINCTION CREDIT PASS CLASS MARK (%) >=83 >=70 >=50
Assessment Events:
1. 2. Theory Test Theory Test Domestic Refrigeration Coolrooms / Freezer Rooms Merchandising Cabinets Beverage Dispensing Equipment Total Marks: 30%
40% 30% 100%
3.
Theory Test
Theory Tests:
Short answer Questions / electrical drawings This assessment covers the contents of this student resource package.
Content Summary:
Domestic Refrigeration: Coolrooms & Freezer Room: Merchandising Cabinets: Beverage Dispensing Equipment: Beverage Cooler (Temprite) systems and associated equipment: Glycol Systems: Ice Making Machines: Postmix Refrigeration systems: 3 20 37 47 47 53 55 58
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Domestic Refrigeration Section No: 1
Purpose: the purpose of this section is to provide you with the underpinning knowledge and skills to identify the various types domestic refrigerators / freezers and their individual operational characteristics. Preamble: The majority of Australian homes have domestic refrigeration in the form of refrigerators and freezers that require 240 volts for their operation. It should be recognised that 240 volts can be deadly in the true sense of the word. It should be noted that domestic refrigeration appliances are referred to as white goods.
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Types of Refrigerant:
Service technicians can be exposed to two refrigerants when working on domestic refrigeration systems. These two refrigerants are R12 and R134a. Refrigerant R12 was phased out in 1996 and is classed as a controlled substance because of its harmful effect on the Ozone Layer. R134a is regarded as a greenhouse gas, however propane is used extensively overseas and may eventually be used in Australia. The Codes of Good Practice (HB40.3) and all legislative requirements must be followed when working on domestic systems.
Domestic Refrigerators:
Modern refrigerators can be classified into four headings: 1. 2. 3. 4. Cyclic Defrost Automatic Defrosting Frost Free. Manual Defrost
Cyclic Defrost: Reference (ARAC, page 7.3)

The cyclic defrost refrigerator defrosts when the compressor cycles off. This type of refrigerator usually has a plate heater fitted to the back of the evaporator mounted in the food compartment. Note: Fig.1. The freezer will not defrost each cycle as this section does not accumulate as much frost because its door is open less than the food compartment.
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Side view of cyclic defrost refrigerator
Freezer compartment
Spill over plate evaporator Condenser
Food compartment
Compressor
Operation: The operating temperature of the food compartment operates at approximately 3C and the freezer -18C. The refrigeration system operates on a critical refrigerant charge with a capillary tube as the refrigerant metering device. The refrigerant enters the low temperature evaporator first and excess liquid spills over to the food compartment plate evaporator which operates at a higher temperature than the freezer. Compressor operates when the thermostat is closed and the defrost heater is cycled off. When the compressor cycles off the defrost heater (usually located in the drain area under the fridge evaporator) is energised. The freezer compartment has to be manually defrosted when the frost builds up to approximately 8mm thick. Thermostat sensor is connected to the plate evaporator which has a constant cut-in temperature. CUT-IN = approximately 3C (evaporator completely defrosted at this point)
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CUT-OUT on evaporator plate temperature. This varies with the thermostat setting. For example cut out temperature could be from -8C down to -14C. Note: either a current coil, Potential or solid state relays are used in domestic refrigeration
Refrigeration Circuit Diagram
Freezer Evaporator
Condenser
Plate Evaporator
Comp
Drier Suction Accumulator Capillary Tube
Electrical Wiring Diagram
R C S OL
Defrost heater
Cyclic defrost refrigerator with current coil relay
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Automatic Defrosting Refrigerator Reference (ARAC, page 7.1)

The automatic defrosting refrigerator consists of a defrost timer that energises a three way solenoid valve and allows the hot discharge vapour from the compressor to enter the evaporator (note circuit below). The defrost timer only controls the three way solenoid valve because the compressor must be operating to supply the hot discharge refrigerant to the evaporator. (Note: the defrost timer is only energised when the compressor is operating and it is time initiated and temperature terminated). When used on a no frost refrigerator the evaporator fan must be switched off during the defrost cycle.
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Three way hot gas defrost solenoid valve
Evaporator
Condenser
Comp Suction accumulator collects liquid refrigerant on the off cycle and restricts liquid flood back during compressor start up. Drier Oil cooler
Capillary Tube
N
Current coil relay
R C S O/L
TM
Defrost timer with remote temp sensing bulb.
Three way solenoid valve coil
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Frost Free Refrigerator Reference (ARAC, page 7.5)

Frost free refrigerators have one cross finned coil evaporator with a fan circulating air over it. The majority of this air is diverted to the freezer section with only a small percentage diverted to the food compartment section. The amount of air diverted to the food compartment section is controlled by a baffle which opens and closes in response to the thermostat. (Note drawing below).
Operation:
Frost free refrigerators require approximately 3 defrost periods per day as the saturated evaporator refrigerant temperature can be as low as -25C causing ice build up on the evaporator coil which reduces air flow across the coil and lowers evaporator capacity. Thermostat cycles the compressor on freezer compartment temperature.
Supply Air from freezer compartment spills over to Food
Return air to evaporator coil Baffle Thermostat adjustment knob
Thermostat sensing bulb
Defrost timer is energised when the thermostat is in its closed position which initiates defrost cycle approximately every 6 hours of running time for a period of around 27 minutes + or 10%. After a period of time the evaporator fan delay thermostat closes which energises the evaporator fan motor. (Approximate settings for fan delay thermostat: close - 10C and opens at 0C). The fan delay prevents moisture and hot air entering the freezer compartment after the defrost cycle. Defrost and drain heaters are energised through the timer contacts and the high limit safety thermostat. After a period of time the high limit thermostat or timer will de-energise defrost and drain heaters which ever comes first. (Time or temperature). (Note: high limit thermostat: closes at -10C and opens at 6C approx).
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The food compartment temperature is maintained by the amount of air directed into this section of the refrigerator via the baffle which is operated by the thermostat. Note below:
It should be noted that the water gathered from the defrost cycle is drained to a defrost drain pan made of plastic and mounted on top of the motor compressor. Heat generated from the compressor evaporates the water. Note diagram below. Alternatively the hot gas from the compressors discharge line is diverted thru a drain pan, which dissipates the drain water.
Drain pipe Drain pan
Motor compressor
Note: to reduce moisture or any ice build up around the doors part of the condenser circuit is attached to the inner cabinet lining around the door jambs to act as an anti-sweat
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heater. Another method is to install electric mullion heaters around the door jambs that are low wattage and operate continuously.
Electrical Wiring Circuit Diagram No Frost Refrigerator

A M
N
Condenser Fan
TM
R C S O/L
Compressor
M
t
Evaporator Fan
Defrost/drain heaters
t
1 3 2
Butter conditioner
Butter conditioner: 1 = low
2 = medium
3 = cabinet temperature.
Note: both resistors are of different resistances. It should also be noted that modern refrigerators are fitted with ice making and chilled water supply facilities and even an internet connection. The vast majority of frost free refrigerators incorporate a condenser fan motor for the cooling of the compressor and the condenser which is housed in the bottom of the cabinet.
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Manual Defrost Refrigerator

The manual defrost refrigerator is much simpler in its construction in that it consists of a single evaporator which needs to be manually defrosted when the ice thickness reaches approximately 8mm. Defrosting is done by turning the refrigerator off and allowing the water to collect in the defrost drain pan immediately under the evaporator.
Push Button Manual Defrost

A push button is incorporated into the thermostat. Once depressed, it will not reset until the evaporator temperature reaches the pre-determined thermostat cut in point.
Domestic Deep Freezers Reference (ARAC, page 7.8)

These can either be an upright or chest type style usually with plate evaporators. Some types of chest freezers have the inside liner of the cabinet utilised as a plate evaporator and the outer casing as a plate condenser. The advantage of a chest deep freezer is that air does not spill out when the lid is opened. However the contents are not readily accessible when they are stacked inside.
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Most upright freezers have plastic doors on each shelf to minimise air spillage, however a large amount of air still escapes. This is replaced by warm moist air which condenses to water and forms ice on the evaporator coils. The contents are much easier to access in comparison to the chest type. Many upright deep freezers now available are forced draught which are identical to the frost free refrigerators but without the food compartment. Domestic deep freezers are often equipped with a fast freeze switch. This simply overrides the thermostat by being connected in parallel with the thermostat.
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Domestic upright deep freezer
Evaporator coils and freezer shelfs
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Electrical circuit diagram (chest type / upright deep freezer)

A
R C S O/L t
Fast freeze switch
Refrigerant charging of domestic refrigerators / freezers:

Reference should be made to the current Codes of Good Practice On completion of evacuation domestic refrigerators should be charged with refrigerant to the manufactures specifications. This is usually done by using an accurate set of scales and charging by weight. Domestic refrigerators and freezers do not require much refrigerant which can be between 70 to 450 grams. If the manufacturers refrigerant charge is not known the refrigerant should be added to the system until the frost line from the evaporator ends just before coming out of the cabinet (when the fridge has reached the required temperature). Note: When evacuating a domestic refrigerator or deep freezer a vac stat should be used to determine vacuum and should be no more than 500 microns.
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Review Questions
Q.1 What is meant by a controlled substance?
Q.2
The two main refrigerants used in domestic refrigeration are:
Q.3
Explain how the defrost cycle of a cyclic defrost refrigerator is achieved:
Q.4
The defrosting of the freezer section of a cyclic defrost refrigerator should be done when and how:
Q.5
Construct an electrical circuit diagram for a cyclic defrost refrigerator using a current coil relay in the space provided below:
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Q.6
Describe how the defrost cycle operates on an automatic defrosting refrigerator:
Q.7
What is the main purpose of a suction line accumulator?
Q.8
What would be the expected saturated evaporator temperature for a frost free refrigerator?
Q.9
Describe the main purpose of the evaporator fan delay thermostat when used in a frost free refrigerator and what would be the expected cut in and out temperatures of this thermostat:
Q.10 How many defrost periods and the length of time for each period would a frost free refrigerator require?
Q.11
Describe how the temperature of the food compartment in a frost free refrigerator is controlled:
Q.12 How is the resultant water from the defrost cycle disposed of in a frost free refrigerator?
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Q.13 In the space provided draw a complete wiring circuit diagram for a frost free refrigerator. Include in your drawing a butter conditioner.
Q.14 When should a manual defrost refrigerator be defrosted and how?
Q.15 List the two main types of domestic freezers:
Q.16 What is the main advantage and disadvantage of a chest type deep freezer?
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Q.17 What are two disadvantages of an upright deep freezer?
Q.18
In the space provided draw a complete wiring circuit diagram for a chest type deep freezer. Include in your diagram a solid state relay and a fast freeze switch.
Q.19 Describe two ways in which you would charge a domestic refrigerator with refrigerant:
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Q.20 How much refrigerant would you expect a domestic refrigerator to hold and how could you find out?
Q.21 What is the Maximum reading required on a vac stat before charging a domestic refrigerator with refrigerant?
Q.22 List the additional components that a frost free refrigerator requires in comparison to a cycle defrost refrigerator:
Q.23 How is moisture, prevented from forming around the doors of a cyclic or frost free refrigerator?
Q.24 Name the three types of compressor start relays used in domestic refrigerators and freezers:
Q.25 What type of temperature control does a cyclic defrost refrigerator use?
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Coolroom & Freezer Rooms Section No: 2

Purpose: The purpose of this section is to provided you with the relevant knowledge and skills in regards to food preservation
Food Preservation: (ARAC, page 1.5) Refrigeration is the most widely used means of preserving food in its original fresh state. Refrigeration involves the use of low temperature as a means of preservation of perishables by eliminating or retarding the activity of spoilage agents. The degree of temperature required to adequately preserve various fruits, vegetables and meats varies with the length of time the product is to be stored. Note: Product storage data table 1.2 ARAC page 1.9 HACCP
HACCP stands for Hazard Analysis Critical Control Point (and its pronounced hass-up). HACCP emerged as a result of collaborative work between the Pillsbury Company, US Army Natick Laboratories and the National Aeronautic and Space Administration (NASA). A system for preventing food safety hazards was required for application to foods intended for the space program. (Think about vomiting in a space suit.) The only alternative was end product testing and, if certainty was to be assured, a 100% sampling rate would be required leaving little or no products for the astronauts to eat. Process control emerged as a solution. Since then, HACCP has been taken up by food companies around the world, to help control the food production process. It is usually part of a wider quality assurance program. Basically, a HACCP program means finding out where the really serious problems occur, monitoring these steps so you know if there are problems, and fixing any problems that arise. As for us, our responsibility is to ensure that our part of the process i.e. correct temperatures and humiditys are maintained at all times and that adequate monitoring and logging procedures are in place.
Note: Product storage data table 1.2 ARAC page 1.9
Coolroom / Freezer Room Construction:

Modern refrigerated coolrooms / freezer rooms are constructed of rigid self supporting Insulated panels. Both inner and outer skins are made form white powder coated steel sheeting (colorbond). The insulation sandwiched between the inner and outer skins can be either polystyrene foam (PSF) or polyurethane foam (PUF). The panels are designed so that each panel slips into each other without the need of extruded strips and are joined using a suitable sealant (mastic) and rivets. Kit type rooms are also available and the panels are locked together by a cam lock system, using a large Allen key.
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Self supporting coolroom / freezer rooms insulated panels

Insulation
Power coated steel sheet on both sides approx 0.7mm thick
Thermal Conductivity:
Thermal conductivity is known as the k Factor of a material and is a measurement of the rate at which heat will travel through a material that is 1 metre x 1 metre x 1 metre at a temperature difference of 1 Kelvin (1k). 15C
1m 1m 16C
1m
The K factor of a material = W/m.K (watts per metre Kelvin)
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Table 1 Material
Polyurethane Polystyrene (0C) Polystyrene (-18C) Fibreglass batt brick Concrete
Insulating Material k Factor
k Factor
0.025 W/m.K 0.032 W/m.K 0.030 W/m.K 0.035 W/m.K 0.81 W/m.K 1.44 W/m.K
U Factor:
The U factor is the overall coefficient of heat transmission in watts per square metre per Kelvin. To find the U factor of a material use: U= k factor of material Thickness of material (in metres)
k x
The U factor of a material is measured in W/m 2. K (Watts per square metre Kelvin). Example: 1 Determine the U factor of the following Construction of room 75mm polystyrene foam k factor 0.032 w/m.K 0.032 0.075 = 0.4267 W/m2. K.
Example: 2 Determine the U factor of the following Construction of room 100mm brick k factor 0.81 W/m.K 0.81 0.10 = 8.1 W/m2.K.
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Room Temperature Wall Thickness

Room Temperature
Recommended Wall
U Factor
Thickness
75 mm (PSF) + 2C 50mm (PUF)
0.426 W/m2.K 0.50 W/m2.K
150mm (PSF) - 20C 100mm (PUF)
0.20 W/m2.K
0.25 W/m2.K
Determining the U Factor of a Composite Material

Often the floor and walls of a coolroom / freezer room are made of more then one material. This is known as a composite wall or floor. When installing a coolroom on a raised concrete floor it is common practice for a panel of PSF to be placed in a recessed hole in the floor and a layer of concrete to be poured over it. Note: drawing below.
PSF Insulation
Concrete Floor
Vapour Barrier (Plastic sheet)
Recessed floor known as set down. Heated floor required if slab suspended.
Concrete Structure
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Calculating the U factor of a Composite Material:

The following details relate to the calculation required to determine the U Factor of a composite material:
X-Thickness of each material in metres K- Factor of each material. W/mK U= X1 K1 1 +
The following formula applies;
X2 .etc k2
Where:
U = total U Factor of the composite materials in W/m2.K X = thickness of each of the individual components in metres k = k factor of each individual component in W/m.K.
Example: Calculate the overall U factor for a coolroom floor consisting of 75mm polyurethane foam and 100mm of concrete. 1 0.075 + 0.10 0.025 1.44 1 3 + 0.069444 = 0.325 w/m2.K
Transmission Load:
Before obtaining plant and equipment for the installation of a coolroom or freezer room a thorough transmission load and product load should be determined to ensure correct refrigeration capacity and equipment selection. To determine the transmission load (heat leakage) of a coolroom the following applies: Formula: Q = U x A x td Where: Q = heat leakage in watts or kW U = overall U factor A = complete outside area in metres square Td = the temperature difference between the ambient and the room operating temperatures.
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Determining the transmission load for the attached coolroom
3.2m2
3C
Ambient 28C
4.2m2 2.5m2
Coolroom details: The coolroom is constructed from 75mm polyurethane foam rigid panels. Design operating temperatures of 3C with an ambient of 28C. Note: When determining the total transmission load you may have to do the floor separately due to the temperature difference. Step.1 Determine the outside surface area of the walls ane ceiling: 2 x 2.5 x 3.2 = 16m2 2 x 2.5 x 4.2 = 21m2 2 x 3.2 x 4.2 = 26.88m2 Total area = 63.88 m2 Step.2 Determine the U factor of polyurethane foam: Table 1 k factor = 0.25w/mK U factor = k factor of material 0.025 = 0.3333 w/m2.K Thickness of material 0.075 Step.3 Determine the temperature difference: 28C - 3C = 25K td = 25K
Step.4 Determine the total transmission load from the gathered information above: Q = U x A x td Q = 0.3333 x 63.88 x 25 Q = 532.33 watts.
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Total Capacity for a Medium Temperature Coolroom (3C)

Aim: To determine the refrigeration capacity for coolroom in accordance with the
following details: Transmission load as above in step 4. Product load Product pull down temperature time Air change load.
Determine the total refrigeration capacity for the above coolroom in accordance with the following details: Transmission load 532.33 watts 500 kg fresh beef entering at 34C and cooled down to 3C. 16 hours pull down time Specific heat capacity of fresh beef equals 3.22 kJ/kg/K above freezing. Temperature difference = 31K Method: Q = mass x specific heat x temperature difference
Q = 500 x 3.22 x 31 Q = 49910 kJ The heat removed in kilojoules must be converted to kilowatts kW (kJ/s) = kilojoules 3600(seconds/hr) x 16(hrs) = 49910 = 0.866 kJ/s or 0.866 kW Product load = 49910 3600 x 16 57600 Product load 0.866 kW + Transmission load 0.532 kW = 1.398 kW total load. Note: It should also be noted that there are other factors that may have to be included in the total heat load calculation for a particular coolroom or freezer room such as the air change, evaporator fans, light loads, glass door inserts, people, forklifts and heat of transpiration. If you require further details in the determination of transmission and product loads etc this will be covered in more detail in the HVAC & Refrigeration Diploma Course No:290.
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Medium temperature coolroom (3C)

Forced draught cooler or Induced draught cooler FDC or IDC
Metering device
Liquid line
Medium temperature coolroom with an average room temperature = 3C
Suction line
Liquid line filter drier Sight glass
Condensing unit
Typical Coolroom/ freezer construction of a kit room, these rooms are purchased in kit form and the polyurethane injected panels are locked together using a large Allen key.
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Electrical wiring diagram medium temperature coolroom

N
M K1- 4 M L1
K1-1 K1-2 K1-3
L2
L3
M 3~ K1
LP HP O/
L
L L S V
M
Evaporator Fan Motor
Medium temperature coolroom (3C) incorporating a pump down cycle.
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Note: The following two control circuit diagrams can also be used to control medium temperature coolrooms.
K1
LP HP O/L
M t
K1
LP
HP
O/L
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At this point you should be able to set all the controls on each of the above circuit to maintain an average room temperature of 3C. Example: In the space provided below determine the thermostat, low and high control settings for a medium temperature coolroom. The room is operating on R404A with an average room temperature of 3C, SST of -3C and an outside ambient temperature of 36.
SST = 457 kPa Room thermostat: Cut out = 2C Average room temperature = 3C Cut in = 4C Cut out = 100 kPa Cut in = 560 kPa = 3C
Low pressure control:
Please note that the above LP cut-in settings are designed to ensure that the evaporator is defrosted prior to compressor re-starting. Lower cut-ins may be set if an alternative form of defrosting i.e. timer is used. High pressure control Cut out = Ambient + 15 + 5 Safety factor 36 + 15 + 5 = 56C = 2525 kPa Automatic or manual reset.
Freezer Rooms:
Low temperature freezer rooms operate at a much lower saturated suction temperature (SST) than a medium temperature coolroom and for this reason they require regular defrosts. Freezer rooms can normally operate with a SST of between -15C down to -35C and therefore require the following additional components: Defrost timer Defrost heater Drain heater High limit safety thermostat Fan delay (low pressure control or thermostat) Anti sweat heater around door jamb and relief ports Suction line accumulator Oil Separator Crankcase pressure regulating valve. MOP TX valve
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Subject: Electromechanical Defrost Timer: The defrost timer activates the defrost cycle. This type of timer is driven by a synchronous motor, geared down to 24 hour function and allows for a set number of defrosts and duration. This can be adjusted by the technician to suit each individual application. Most low temperature freezers have four defrost periods per day with a duration set at approximately 25 minutes. The termination of the defrost cycle can either be from time, temperature or pressure. Types of Defrost Timers: Time initiated time termination Time initiated time or pressure termination Time initiated time or temperature termination Electronic Timers.(are replacing electromechanical defrost timers) Defrost Heaters: The defrost heaters are energised by the defrost timer and are required to remove the ice that has accumulated on the evaporator. This is done by heating the evaporator coil and at the same time raising refrigerant temperature. Note: all the ice on the coil should be removed at approximately 8C. Drain Heater As the ice melts on the evaporator the drain heater keeps the water warm allowing it to flow freely to the outside drain. High Limit Safety Thermostat The high limit safety thermostat is designed to de-energise the defrost and drain heaters if the evaporator temperature rises above a predetermined thermostat setting Usually set to close at approximately -10C and open at around 14C. Note this thermostat opens on rise (OOR) and closes on fall (COF).
Fan Delay Thermostat (Reverse Acting Low Pressure Control) The reverse acting thermostat or low pressure control fan delay controls are designed to delay the period before the evaporator fans start up and usually close at a SST of around -10C and open at 0C. This type of control removes the possibility of hot air and water from being blown onto the product on the completion of the defrost cycle. Anti -Sweat Heaters Small wattage heater fixed to the inside of the door jamb to prevent any moisture or ice forming around the door. The floor at the door will have a threshold heater fitted if the concrete floor is set down. Suction Line Accumulator Designed to collect excess liquid refrigerant and allows the compressor to draw vapour and oil back.
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Crankcase Pressure Regulating Valve (CPRV) At the completion of a defrost cycle the evaporator pressure can exceed 600 kPa and for this reason a CPRV is installed in the suction just before the compressor and can be adjusted to control the pressure of the vapour entering the compressor regardless of the evaporator and suction line pressure. Installing the valve to close to the compressor may cause hunting. CPRV adjustment is accomplished by fitting service gauges and a clamp on ampere meter around one of the active wires at the compressor. The valve is adjusted by increasing or decreasing the spring pressure until the full load amperes of the compressor is between 90 & 100 % FLA. This must be done during compressor start up following defrost.
Types of refrigerant: The preferred refrigerants used for low temperature applications within the industry are R404A / R507 A. However some systems may still have R502, R12 or R22. Relief Ports Some times referred to as explosion or implosion ports. These devices are inserted in the freezer wall and used to balance the external and internal air pressures as to save the room from being structurally damaged. They have hinged flaps internally and are heated. The number and size increase proportionally with room volume.
Typical Cold room installation Showing IDC and weather proof lighting.
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Low Temperature Freezer Room

Forced draught cooler FDC or Induced draught cooler Metering device Reverse acting LP fan delay
Defrost timer
DT
LP
Low temperature freezer room with an average room temperature = -18C, operating on R404A.
Suction line accumulator CPR valve
Heated drain must be Trapped and Insulated.
Note:
A relief port is installed in one of the walls of the freezer room to balance any air pressure differences.
Cross-section of freezer room relief port
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Low Temperature Freezer Room Insulation Thicknesses (Australia)
Room Temperature
Polystyrene
Polyurethane
-10C to -20C
100-150 mm
75-100 mm
-20C to -35C
150-200 mm
100 mm to 150 mm
Note: If unsure about the type of panel thickness required for the application, consult the manufactures.
Factors to consider when selecting panel thickness: Ambient temperature. Is room exposed to direct sunlight? Relative humidity. Span (distance between walls). Height of walls. Load bearing.
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Low Temperature Freezer Wiring Diagram
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Review Questions Section No: 2
Q.1
Name two types of insulation material used in the construction of coolrooms and freezer rooms:
Q.2
What is meant by the terms transmission and product load:
Q.3
List four factors that determine the refrigeration capacity of a coolroom or freezer room plant
Q.4
List four additional components that are required for a freezer room in comparison to a medium temperature coolroom:
Q.5
List three types of defrost timers and their operation methods:
Q.6
What is the purpose of the drain heater on a freezer room?
Q.7
Describe the operation of a reverse acting low pressure control:
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Q.8
Why and where is an anti-sweat heater used?
Q.9
What is the purpose of a suction line accumulator?
Q.10 Describe how you would adjust a crankcase pressure regulator:
Q.11 A medium temperature coolroom operates on R134a at an average room temperature of 3C with an evaporator TD of 6K and an outside ambient of 36C. In the space provided indicate the following control settings: (Note show all working).
Room thermostat
Low pressure control
High Pressure control
Q.12
A low temperature freezer room operates on R404A at a room temperature of -20C
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With an outside ambient of 35C. In the space provided indicate the following control settings: Room thermostat
Fan delay thermostat
High limit safety heater thermostat
Defrost timer (Time initiated time or pressure terminated)
Low pressure safety control
High pressure safety control.
Q.13 Describe the construction and operation of a relief port. __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
Merchandising Cabinets
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Section No: 3
Purpose: The purpose of this section is to provide you with the underpinning knowledge to identify the various types of merchandising cabinets their application, construction and operational characteristics.
Supermarket Merchandisers: (ARAC, page 7.10)

Supermarket merchandising cabinets have been constructed over the years to provide customers with the opportunity of self service and the type of cabinets are as follows: Multi-deck open display cases Single deck, well type cases Reach in cabinets
Multi Deck Display Cases

The multi-deck display cases are used to refrigerate and display dairy produce, cheese and cooked meats at a temperature of around 3C. The evaporator coil is usually installed in the bottom of the cabinet with fans forcing air up and over the product. Note: evaporator fans operate continuously. A well directed air curtain is designed to keep cold air in the cabinet and reduce air spillage to a minimum. These cases loose approx 60% of air circulated. Most multi-deck display cases are designed with removable ends so as they can be connected end to end to increase the length to meet the customers requirements.
Low front Type Multi-Deck dairy
Single Deck Well Type Cases
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The single deck case is designed as a meat, fruit or vegetable merchandiser and can also be redesigned as a freezer in a single width or double. These cabinets have much less air spillage than up right merchandisers because the cold air circulating is heavy and falls down over the product. Anti-sweat heaters are installed under the cabinets stainless steel rub rail to prevent water from condensing on the rub rail and dropping onto the floor.
Denotes Air flow Evaporator
Light
ine l d Loa
Defrost heater
Drain
Evaporator fan
Single deck case
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L1
K1-1 K1-2 K1-3
L2
M
N
L3
K 1
HP
LP
O/ LL
Defrost heater, if fitted
M
Most cabinets have a number of evaporator fan motors.
Cabinet ant-sweat heater element
Note:
Defrost timer time initiated time or pressure termination.
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Multi-Deck Display Case Piping Circuit Diagram
EPRV
LP/HP
Defrost timer
DT
Suction line accumulator
Denotes Air flow Evaporator
Light
e d lin a o L
Defrost heater
Drain
Evaporator fan
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Low Temperature Merchandising Cabinet
Wide island freezer

Air delivery Defrost heater Air return Evaporator
RACEWAY
Drain
Fan
It should be noted that the evaporator fans on these cabinets operate continuously even through the defrost cycle. The reason for this is to ensure that the supply and return air ducts do not accumulate any ice which may restrict air flow and reduce capacity.
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Electrical Wiring Circuit Low Temperature Case

L1
K1-1 K1-2 K1-3
L2
M
N
L3
K 1
HP
LP
O/
Defrost heater
t Drain heater High limit safety thermostat close at approximately - 10C Open at 8C
M
Isolator
Isolator Cabinet ant-sweat heater element

Note: Defrost timer time initiated time and or pressure termination. Compressor has a belt driven drive motor.
Diagram
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Low Temperature Merchandising Cabinet Piping Circuit Diagram
EPRV
CPRV
LP/HP
Defrost timer
DT
Oil separator
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Multi Deck Display Case Electrical wiring Diagram

L1
K1-1 K1-2 K1-3
L2
M
N
L3
K 1
HP
LP
O/ LL
Defrost heater, if fitted
M
Cabinet ant-sweat heater element
Note:
Defrost timer time initiated time or pressure termination.
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Piping Circuit Diagram
EPRV
LP/HP
Defrost timer
DT
Cabinet Capacities: Freezers

The following details approximate cabinet ratings per length: Length of Cabinet Type of Cabinet Saturated Evaporator Temp Store Conditions Store Conditions A/C 24C Non / Air 60 % RH 32C 60% RH Cabinet capacity Cabinet capacity
2448 mm (8 ft) 3870 mm (12 ft) 2448 mm (8 ft) 3870 mm (12 ft)
Single Island Single Island Rear wall Rear wall
- 35C - 35C - 35C - 35C
1190 watts 1780 watts 1190 watts 1780 watts
1320 watts 1980 watts 1320 watts 1980 watts
Recommended Control Settings:

Type of cabinet
Frozen food Ice cream Frozen food Ice cream
Refrigerant
R22 R22 R404A R404A
LP cut / cut out

62kPa /158 kPa 36 kPa / 140 kPa 90 kPa / 185 kPa 70 kPa / 165 kPa
EPR valve
62 kPa NA 110 kPa NA
Thermostat Cut in / cut out -26C / -22C -29C / -25C -26C / -22C -29C / -25C
Note: Defrost timer has a maximum of 4 defrosts / 24 hours Defrost duration of approximately 40 minutes. Temperature over ride: 8C. Pressure over ride: 668 kPa for R404A and 540 kPa for R22.
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Reach in Merchandiser cabinets

Reach in merchandisers are available in self contained or remote units in a variety of temperature ranges from medium temperature to low temperature applications. With the majority using forced draught evaporators the location of the evaporator can either be at the top or the bottom of the cabinet. Low temperature freezer cabinets are automatic in operation and require a number of defrosts per day to keep the evaporator clear of ice.
Reach in Merchandiser cabinet
3 degree Celsius to 25 degree Celsius

Adjustable shelves Force draught evaporator
Glass doors, may be heated
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Problems associated with self service reach-in cabinets are as follows: Placing stock above the load limit line Drain blockage due to poor house keeping (product spillage and unattached labels). Overloading cabinet with warm product. Cost of operation. Poor thermal hold over.
Cabinet temperatures, saturated evaporator temperatures and types of refrigerant for various cabinets
Application
Cabinet Temp 0C
Refrigerant R134a R22 R404A R407A R507 R134a R22 R404A R404A R507 R404A R507
Suction Temp (SST) -10C
Meat merchandising
Dairy multi-deck
3 to 5C
-4 to -10C
Freezer double width
-20C
-32C to -36C
Reach in frozen food
-20C
-25C-32C
Reach in ice cream
-25C
-36C
Installation:
To ensure the correct installation procedures are implemented you should check with the manufacturers requirements and site conditions in regards to the following factors, Refrigeration capacity for each cabinet Installation and location of each cabinet Refrigeration components required Supply and electrical control circuits Correct adjustment of all controls. Type of refrigerant. Drainage requirements. Site Access. Weight of stocked cabinets.
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Control Circuits (Systems)

The majority of supermarket merchandising and display cabinets utilise computer-operated systems where all the parameters are programmed in to provide automatic control and feedback through an alarm system. Typical systems in use are: CPC, Phasefale and Danfoss.
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Q.1 List three different types of supermarket merchandising cabinets:
Q.2
Where is the evaporator normally located in a multi-deck display cabinet?
Q.3
Why do most multi-deck display cases have removable ends?
Q.4
Why do single well deck cases have less air spillage than upright merchandising cases?
Q.5
Anti sweat heaters are installed under the cabinets rub rail for what reason?
Q.6
List three problems associated with self service cabinets:
Q.7
Explain why the evaporator fans in a low temperature island freezer cabinet operate continuously:
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Q.8
What is the purpose of the air curtain on a Multi deck open Cabinet?
Q.9
List three common refrigerants that are used in dairy multi deck cabinets:
Q.10 Give five factors that should be taken into account prior to installing supermarket equipment:
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Beverage Dispensing Equipment Section No: 4

Purpose: the purpose of this section is to provide with the relevant knowledge and skills in the application and operation of various beverage cooling systems and ice making systems that are used in the presentation of beverages in the hotel, club and restaurant industries.
Beverage Coolers (Temprite) Reference (ARAC, pages 5.4 & 7.20)

Instantaneous beverage coolers (IBC) were one of the most familiar evaporators encountered in hotels and clubs. Although single IBC are encountered large hotels or clubs may connect as many as six IBC to the one condensing unit. In this situation two, three or more condensing units may share the load of ten, fifteen or more IBC distributed throughout the hotel or club so that the failure of one unit would not adversely effect the total number of IBCs and thus trading would continue virtually uninterrupted. IBCs are fully flooded evaporators. The liquid level is controlled by a low side float and needle and seat (cartridge).
Installation requirements of IBCs:

Surge Tank: This tank or vessel should be installed above the suction line so that the excess suction pressure but not oil can be contained in this component. The vessel is sized in such a way that for every one kilowatt motor power it should accommodate at least 50 litres (0.05m3). Its purpose is that by increasing the volume of the suction line it absorbs suction line pressure line fluctuations and prevents the condensing unit from short cycling.
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Constant Pressure Valve (750 valve): This valve is fitted to each IBC to maintain a constant SET above the freezing point of the beverage. The constant pressure valve is similar to an EPR valve but far more accurate. Example: Standard strength beer freezes at approximately -2C. Refrigerant 134a SET = 202 kPa = 1C Refrigerant R22 SET = 413 kPa = 1C
The adjustment is done by fitting a set of gauges to the inlet side of the EPRV and adjusted to the selected minimum pressure / temperature required. The valve bellows can be lubricated by the removal of an 1/8th BSP plug and the insertion of refrigerant oil. Oil Separator: An oil separator must be fitted to any refrigeration system that has an IBC so that the possibility of oil entering the evaporator of an IBC is reduced. Accumulated oil in the evaporator of an IBC reduces the amount of refrigerant and thus capacity. The oil separator is installed between discharge line and condenser as close to the compressor as possible and should be charged with the recommended oil before installation. The oil return line from the separator and compressor should be as short as possible.
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LP / HP Control Settings: Low Pressure Control Setting: Cut out: Should be a reasonable low pressure to ensure a long off cycle Example = 21 kPa (134a) 100kPa (R22) High gh Pressure Control Setting: Cut out: Example = Ambient + TD + 5K safety factor Ambient temperature = 35C Saturated Condensing Temperature = 40C Temperature difference = 15K Cut out = Cut in = 35 + 15 + 5 = 50C = 1220 kPa for 134a Can either be manual or automatic reset with a fixed differential. Electrical wiring diagram beverage cooling system
Condenser fans M K1- 4 M L1
K1-1 K1-2 K1-3
L2
L3
M 3~
Compressor
K1
LP HP O/
L
L L S V
Coolroom or bottle Cabinet circuit

t
M
Evaporator Fan Motor
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Refrigeration circuit diagram beverage cooling system
EPRV Coolroom Evaporator Pressure relief IBC 1 IBC 2
Note: addition hand line valves can be installed in the suction and liquid line manifolds for additional bottle cabinets if required.
Surge tank
Beverage flows from the coolroom to the IBC at 4C. The temperature is further reduced in the IBC to 2C where it is transferred via the beer tap into a glass for consumption. Note: CO2 is used as the pressure to force the beer from the kegs to the glass.
CO2 gas cylinder and regulator Coolroom used to store package beer and beer kegs at around 7C. Heater
IBC
Beer Kegs
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Bottle Cabinets (Hotels / Clubs)

The following details a range of bottle cabinets that are used in clubs, hotels and restaurants
Low pressure control Liquid line LP Forced draught evaporator (FDC) Usually two or three fan motor.
Suction line solenoid valve
Under bar bottle cabinet
Control circuit diagram A

S L S V LP
M
Evaporator fan motors
M
Cabinet light circuit
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Operation of under bar cabinet:

The under bar bottle cabinet is usually part of the complete beverage cooling system. This is obtained by the addition of further suction and liquid line hand line valve connections on each of the manifolds. The cabinet temperature is controlled by the low pressure control which cycles the suction line solenoid valve on the evaporators saturated refrigerant pressure temperature. Note: evaporator fans operate continuously. Temperature control: (Refrigerant R134a) Place a compound pressure gauge on the evaporator side of the suction line solenoid valve. Set the cabinet low pressure control to cut in at 3C (225 kPa) With the main condensing unit in operation place a thermometer in the return air steam of the cabinet. Adjust the low pressure control to cut out at approximately 2C. With an evaporator temperature difference of around 6 K the cut out pressure would equal 161 kPa (SET = -3C.
Liquid line solenoid valve
Forced draught evaporator (FDC) Usually two of three fan motors.
Suction line
Under bar bottle cabinet
Temperature controlled by cycling a liquid line solenoid valve by a cabinet thermostat which senses the return air or evaporator coil temperatures.
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Under Bar Bottle Cabinet

N
L L S V
t
Evaporator fan motors
M
Cabinet light circuit
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Glycol Systems
Glycol systems have become the most popular system and have been designed to replace beverage cooling systems and are manufactured to fit into a standard glass rack. The chiller plate is basically a plate heat exchanger has no moving parts and can chill two, four or six beverages. Each chiller plate is individually controlled by a digital thermostat which is adjustable to suit the required application. The DX evaporator is mounted within a glycol bath which includes a small agitator motor to ensure an even glycol temperature. The temperature of the glycol bath is controlled by a thermostat in series with a liquid line solenoid valve which feeds refrigerant to the TX valve (this type of control relies on a pump down cycle).
Mix ratio of around 30% glycol and 70 % water and should be regularly checked with a refractometer. Note: To become competent with current glycol systems it may be necessary for you to under take on the job workplace training under the guidance of a licensed mentor, attend manufacturers and or suppliers training program on their product range.
Water Duct Systems:

This system is used for large hotel installations. It uses a simple refrigeration system that combines the chilling of beer in the keg room by IDCs as well as continuously cooling the beer as it flows through the dispensing tap, by using a chilled water heat exchanger. The water duct is a simple heat exchanger that has the beer in a centre tube and chilled water in the outer tube. Beer Water
Water Duct
One condensing unit is used for both the coolroom and chilled water. The chilled water tank is simply a TX valve fed coil in an insulated tank filled with the circulating water. The circulating pump must have the capacity to maintain water flow in all circuits during peak loads. It runs continuously during trading hours. The coolroom contains the kegs as well as the water tank and circulating pump.
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Typical Piping Diagram for Glycol Chiller Plate System
Beer font The glycol and beer lines are enclosed in 25mm of insulation called a python.
Glycol lines
Chiller plate heat exchanger
Circulating glycol pump Beer line
DX evaporator in glycol bath Beer gas cylinder and regulator
Beer kegs stored in coolroom at 7C
The above circuit represents a glycol system using one plate heat exchanger and beer line. In the majority of hotels and clubs there are a number of different beers available and for that reason the number of plate heat exchangers and fonts may have to be increased to meet the consumers; needs. Note: one chiller plate can have six different beer circuits
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Ice Making Machines

Reference (ARAC, page 4.18) Self contained ice making machines can be split into two categories and they are as follows: 1. Ice FLAKE machines 2. Ice CUBE machines. Each category has many sub-groups as many of these machines are grouped mainly by the shape of the ice cube they dispense. It must also be noted that the machines are controlled electronically, electro-mechanically or a combination of both 1. Ice Flake Machines: These machines continuously deliver an irregularly shaped ice flake and are often referred as crushersor flakers. This type of system relies on specially designed tubular evaporators into which a slowly revolving auger with minimal wall clearance is fitted. The auger motor power is around 300watts and the gearbox driving the auger may require heavy duty gear box oil during routine service. The auger bearings should be replaced approx every two years.
FLAKERS
OPERATING PRINCIPLES - REFRIGERANT
ACCUMULATOR EVAPORATOR CAPILLARY TUBE COMPRESSOR
AIR COOLED CONDENSER DRIER
Figure .1.
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Flakers
OPERATING PRINCIPLES - WATER
PLASTIC SPOUT
FLOAT VALVE
WATER SEAL
Figure .2.
FLAKERS
OPERATING PRINCIPLES - MECHANIC
TOP BEARING PLASTIC SPOUT ICE BREAKER
AUGER
WATER SEAL
BOTTOM BEARING COUPLING DRIVE MOTOR
GEAR REDUCER
Figure .3.
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Ice Being Forced Thru Breaker by Auger

After two-three minutes the first pieces of flakes ice are discharged through the spout of the freezer dropping down into the storage bin.
FLAKERS
Figure .4.
COMPONENTS - MECHANICAL SYSTEM
FLAKERS
WATER SEAL AUGER
ICE BREAKER
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Figure .5.
2.
Ice Cube Machines:

Ice cube machines are often given particular names based on the cube shape they produce. This shape is determined by the design of the evaporator, water circulation and harvesting methods. The most common types of ice makers produce cubes by running or spraying water over an evaporator which is manufactured to the shape of the cube required (see figure .9.). The evaporator temperature, typically ranges from -6 degrees at the beginning of the freezing cycle to -12 degree prior to harvest (defrost). Ice Cubers consist of two main circuits the first being the refrigeration circuit and the second being the water circuit.
Operation Refrigeration Cycle (refer to figure 6)

During the refrigeration cycle and with the assistance of a compressor the warm refrigerant vapour is remove from the evaporator and pumped to the condenser under high pressure where it is transformed into a liquid. From the condenser the refrigerant passes thru a filter drier and then onto the expansion device. The expansion device will either be a thermostatic expansion valve or a capillary tube. The liquid refrigerant the passes thru the expansion device and into the evaporator. On entering the low pressure evaporator the high pressure liquid vaporizes and absorbs the water travelling over the evaporator. This process continues until sufficient ice has formed on the evaporator. For the machine to know when the ice thickness is correct (and to initiate a defrost) several methods are used.
Defrost initiation methods

Time and temperature. With this method a thermostat is attached to the evaporator. Once the evaporator has reached a pre determine temperature it supplies power to a defrost timer. The timer then times out for approx 15 minutes and then commences a defrost. Water level. With this method an electronic control module look at the level of the water in the water reservoir, it does this buy sensing earth leakage thru probes positioned at different levels in the tank. Once the level has dropped to the desired level the machine assumes that the water has now been converted to ice and initiates a defrost. Ice thickness sensors. There sensor are position on a bracket at a pre determine distance, once the ice builds up on the evaporator and touches the sensor the defrost is initiated. These sensors take the form of either a mechanical thermostat type or an electronic type were to probes allow a small current to pass between them once the ice hits them. An electronic module senses the current and initiate a defrost.
Defrost Cycle (refer to figure 7)

Once the defrost cycle has been initiated a solenoid valve is energized. This solenoid valve passes hot gas form the compressor directly into the evaporator. This causes the evaporator to heat up, and any ice that has formed to fall away from the evaporator and into a storage bin.
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Defrost termination
Defrost termination is either accomplished by the following methods, Thermostatically. This method employs a thermostat which is attached the evaporator. Once the evaporator reached the desired temperature and the ice has left the evaporator plate. The thermostat breaks the supply of power to the hot gas solenoid and forces the system back into refrigeration mode. Magnetic and Micro switches. (refer to figure 10) With the gravity cascade type machines a hinged door covers the water cascade. During the defrost cycle the ice falls of the plate and forces the hinged door open as it falls into the bin. As the door opens it actives a micro switch or magnetic switch which sends a signal to the electronic controller to terminate the defrost and restart the refrigeration cycle.
Maintenance
All Machine require regular maintenance. Most manufacturers supply recommended maintenance shedules. However water and air quality does have a large bearing on the frequency of maintenance. Therefore each installation should be evaluated seperately. With regardes to filtration, water filter not more than 5 micron rating should be used.
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OPERATING PRINCIPLES - FREEZE
Evaporator
Hot gas valve
Air cooled condenser
Compressor
Figure .6.
OPERATING PRINCIPLES - HARVEST
Evaporator
Hot gas valve
Air cooled condenser
Compressor
Figure .7.
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MODULAR SERIES
FREEZING CYCLE
.
Figure .8.
MODULAR SERIES
FREEZING CYCLE
The machine remains in the freezing cycle with the ice that become thicker .
Figure .9.
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OPERATING PRINCIPLES
In this picture the ice can be seen forcing the hinged door open. A micro switch is attached to the door. The switch sends a signal to stop the defrost. If the door stays open i.e the bin is full the machine will stop.
Figure .10.
MAINTENANCE
The most important program on the maintenance of the cuber machines is the cleaning/sanitizing to be done on regular base as detailed here below:
Sanitizing: Cleaning:
Every month Every six
On next slides will be shown the procedure for sanitizing and cleaning.
Figure .11.
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Postmix Refrigeration Systems

(Reference to manufacturers catalogues)
Counter top refrigeration systems can be broken down into two categories. These are: Mechanical Ice-Cooled.
Mechanical Refrigeration: The dispenser is mounted on the counter serve top and contains the refrigeration unit within the dispenser. Inside this unit the refrigeration system develops an ice block inside a water bath area it also contains stainless steel cooling coils for water, soda water and syrup. A small agitator motor runs continuously and assists in the efficient removal of heat from the product coils and carbonator tank.
To carbonate the soda water a carbonator is installed inside the water bath to maintain maximum carbonation. Note with exception to the ice bin type where the carbonator is positioned outside the storage bin area either in the base of the unit or directly Under the counter. The syrup is supplied to the dispenser by stainless steel CO2 driven diaphragm pumps and a bag in box package. The water filter should be positioned as close to the unit as possible and accessible at all times.
The syrup ratio or brix: The taste of the finished product is dependent on the correct ratio of soda water to syrup. This can be checked by using a syrup separator to separate the syrup from the soda water or plain water at the dispensing valve. Or commonly a refractometer is used.
A ratio cup is used to measure the two products and has two chambers calibrated in mls or ccs. Adjustment of the syrup ratio is done by adjusting the soda water first. The soda water adjustment screw is on the left hand side of the faucet and should be adjusted for a nominal flow of 5 ounces of water in three seconds. Once the soda flow rate is set the syrup can be adjusted as per the correct ratio that is found on the Bag in Box.
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Typical Countertop Dispensing Refrigeration System
Coola Cola
Water Filter
Syrup Boxes
10Kg CO2 Bottle
1000mm
Ice Cooled This type of dispenser consists of a stainless steel storage bin with an aluminium plate that has stainless steel cooling coils, the soda water, clean water and syrup cooling cast into it. Ice fills the storage bin and acts as a refrigeration medium to cool the product passing through the coils. This ice can be supplied by an ice maker fitted to the dispenser or from an outside source.
The carbonator is positioned outside the storage bin either in the base of the unit or directly under the counter.
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Typical Ice-Cooled Dispensing System
Coola Cola
Ice bin
Water Filter
Water Pump & Carbonator
10Kg CO2 Bottle
1000mm
Syrup Boxes
Remote Syrup boxes
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Q.1 Describe the purpose of the surge drum when used within a beverage cooling system:
Q.2
State the main purpose of a constant pressure valve (750 valve) and why is it used in preference to an EPR valve:
Q.3
Why must an oil separator be installed in an instantaneous beverage cooler (IBC)?
Q.4
Name two methods of controlling the cabinet temperature of under bar bottle cabinets:
Q.5
Describe in your own words the main advantage of a glycol system in comparison to a beverage cooling system (IBC).
Q.6
State the major disadvantage of a Temprite (IBC) system?
Q.7
List two types of ice making machines and their major differences:
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Q.8
Describe two types of postmix refrigeration systems and their operational characteristics:
Q.9
What does the term brix mean?
Q.10 In an ice-cooled counter top refrigeration system the ice can be provided by what two means?
Q.11 Describe how you would adjust a beverage cooler (Temprite) to maintain a saturated evaporator temperature of -1C:
Q.12 What drives the diaphragm pumps on a post mix refrigeration system?
Q.13 Why is it necessary for the compressor to operate during the harvest cycle on icecube machine?
Q.14 What type of evaporator is an IBC?
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Q.14 When adjusting the syrup ratio on a postmix dispenser what should be adjusted first?
Q.15
State the main purpose of the agitator motor in a postmix mechanical refrigeration system:
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Saturated Pressure / Temperature Chart for Common Refrigerants

O
R12 kPa
-89 -85 -81 -76 -69 -62 -54 -43 -32 -18 -1 5 11 21 32 44 56 70 85 103 116 131 150 165 184 207 224 248 270 292 323 344 372 402 432 465 497 531 571 605 644 683 724 765 824 860 912 962 1010 1060 1118 1172 1236 1300 1362 1428
R134a kPa
R409a kPa
R22 kPa
-81 -75 -68 -60 -48
R502 kPa
-74 -67 -57 -46 -34 -19 -2 16 41 70 98 115 132 151 171 191 214 235 260 284 313 340 369 400 435 470 508 547 586 620 668 718 767 810 860 910 967 1020 1080 1145 1207 1270 1340 1410 1482 1558 1644 1725 1807 1887 1977 2070 2165 2265 2378 2475
R408a kPa
R404a kPa
R500 kPa
-87 -83 -78 -71 -64
R717 kPa
-90 -87 -82 -76 -69 -60 -50 -37 -22 -4 18 30 46 60 76 89 105 124 145 165 190 215 241 269 299 328 362 397 433 473 513 555 605 654 704 755 811 868 930 995 1065 1130 1203 1277 1369 1449 1543 1630 1722 1820 1914 2005 2110 2229 2366 2515
-70 -66 -62 -58 -54 -50 -46 -42 -38 -34 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
-71 -64 -55 -45 -32 -17 -9 0.3 10 20 31 43 56 69 84 99 115 133 151 171 191 213 236 260 286 313 341 371 402 434 469 505 543 582 623 666 711 758 807 858 911 966 1024 1063 1145 1210 1277 1347 1419 1494 1571 -63 -54 -43 -31 -16 -7 2 11 21 33 44 57 71 85 100 117 134 152 172 192 214 237 262 287 314 342 372 404 437 471 507 545 585 626 670 715 762 811 863 920 970 1030 1090 1150 1220 1290 1360 1430 1500 1580
-37 -22 -6 10 32 63 80 91 106 126 145 165 185 207 231 254 284 310 334 361 396 430 465 504 542 584 622 668 716 769 814 866 917 975 1040 1107 1165 1230 1300 1378 1448 1525 1610 1688 1770 1855 1950 2050 2140 2245 2345
-23 -8 11 34 60 89 105 123 141 161 181 203 227 251 277 305 334 364 396 430 465 502 541 582 625 670 716 765 816 869 920 980 1040 1100 1170 1240 1310 1380 1460 1530 1610 1700 1790 1880 1970 2060 2160 2270 2370 2480 2590
-23 -6 15 39 66 97 114 133 152 173 195 219 243 270 297 326 357 390 424 460 496 537 579 623 669 716 766 819 873 929 989 1049 1119 1179 1249 1329 1399 1479 1559 1639 1729 1819 1909 2009 2109 2209 2319 2429 2549 2659 2789
-55 -44 -33 -18 -3 16 35 45 54 65 76 87 100 118 134 156 174 193 215 239 262 285 314 340 367 398 422 454 490 530 569 610 651 695 740 785 832 875 925 980 1038 1098 1155 1215 1278 1348 1420 1489 1560 1635 1714
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Answers to Review Questions: Section No: 1

Q.1 It has a harmful effect on the Ozone Layer and cannot be released into the atmosphere. R12, and R134a Defrosts when the compressor is on its off cycle a plate heater assists the process. The thermostat has a constant cut in temperature of around 3C. Manually by turning the refrigerator off and should be defrosted when the ice thickness reaches approx 8mm.
Q.2 Q.3
Q.4
Q.5 A N
R C S OL
Defrost heater
Cyclic defrost refrigerator with current coil relay
Q.6
The defrost timer energises a three way solenoid valve and injects hot discharge refrigerant vapour from the compressor into the start of evaporator. The compressor must be operating. Collects liquid refrigerant on the off cycle and restricts liquid flood back during compressor start up. -25C The fan delay thermostat prevents moisture and hot air entering the freezer from compartment after the defrost cycle.
Compiled By: G Riach & R Baker Ultimo 2005
Q.7
Q.8 Q.9
78
10. 11.
4 defrosts / day at approximately 27 minutes duration. Air directed into the section from the freezer compartment and controlled by a baffle which is operated by a thermostat. The defrost water enters a plastic pan mounted on top of the compressor. Heat generated by the compressor evaporates the water.
12.
13.
A M
N
Condenser Fan
TM
R C S O/L
Compressor
M
t
Evaporator Fan
Defrost/drain heaters
t
1 3 2
Butter conditioner
14. 15. 16.
When the thickness of the ice reaches approximately 8mm. Chest and upright. Advantage does not spill air out when the lid is open. Disadvantage contents not readily accessible.
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17.
Advantage contents much easier to access. Disadvantage air spills out when the door is opened.
18.
Electrical circuit diagram (chest type / upright deep freezer)
A
R C S O/L t
Fast freeze switch
19.
By measuring the amount of refrigerant required using a dial a charge and dumping refrigerant in the system as a liquid. In accordance with the manufacturers listed charge, If the manufacturers refrigerant charge is not known the refrigerant should be added to the system until the frost line from the evaporator ends just before coming out of the cabinet.
20. 21. 22.
70 450 grams 500 microns Evaporator fan, Defrost timer, Defrost & Drain Heaters, High Limit Thermostat, Thermostat Baffle Plate and Evaporator Fan Delay Thermostat. Mullion heaters or part of the condenser circuit attached to the inner cabinet. Current Coil & Solid State. Constant cut in thermostat.
23. 24. 25.
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Q1. Q.2 Q.3

Polystyrene & Polyurethane. Heat leakage into the room & Heat removed from the product.
Transmission load Product Load Product pull down temperature time. Air change load.
Q.4
Defrost timer, Defrost timer, Drain heater, High limit safety thermostat, Fan delay, Suction line accumulator, Oil separator, CPR Valve, Anti-sweat heater around door jam and implosion port.

Q.5 Time initiated time termination Time initiated time or pressure termination Time initiated time or temperature termination Electronic timers. To allow defrost water to drain freely and prevent it from freezing. The reverse acting low pressure fan delay control is designed to delay the evaporator fan on start up to prevent the possibility of hot air and water blowing onto the product on completion of the defrost cycle. Ant-sweat heaters are used to prevent moisture or ice forming around the door. Suction line accumulator collects excessive liquid refrigerant and allows the compressor to draw it back as a vapour. CPR Valve adjustment is accomplished by fitting service gauges and a clamp on ampere meter around one of the active wires at the compressor. The valve is adjusted `by increasing or decreasing the spring pressure until the FLA amperes of the compressor is between 90 and 100% FLA.
Q.6 Q.7
Q.8 Q.9
Q.10
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Q.11

SET = 167 kPa Room thermostat: Cut out = 2C Average room temperature = 3C Cut in = 4C Cut out = 100kPa Cut in = 226 kPa = 3C Cut out = Ambient + 15 + 5 Safety factor 36 + 15 + 5 = 56C = 1352 kPa Automatic or manual reset.
Low pressure control:
High pressure control
Q.12. SET = -30C = 97 kPa.
Room thermostat:
Cut out = -21C Average room temperature = - 20C Cut in = -22C Cut in = -10C Cut out = 0C
High limit safety thermostat Cut out = 8C Cut in = -10C Defrost timer 4 defrosts per day each approx 40 minutes. Pressure override 623kPa = 6C Cut out = 20 kPa Cut in = 100 kPa Cut out = Ambient + 15 + 5 Safety factor 35 + 15 + 5 = 55C = 2489 kPa Automatic or manual reset.
High pressure control

Q.1

Multi deck display cases Single deck well type cases Reach in cabinets.
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Q.2
In the bottom of the cabinet
Q.3
So that they can be connected end to end
Q.4
Because the cold air circulating is heavy and falls down over the product.
Q.5
To prevent water from condensing on the rub rail and dropping onto the floor.
Q.6

Placing stock above the load limit line Drain blockage due to poor house keeping Overloading cabinet with warm product.
Q.7
So that supply and return air ducts do not accumulate any ice.
Q.8
To keep cold air in the cabinet and reduce air spillage to a minimum.
Q.9
R407A, R507, R134a.
Q.10

Refrigeration capacity of each cabinet Installation and location of each cabinet Refrigeration components required Supply and electrical control circuits Correct adjustment of all controls Type of refrigerant.
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Q.1 By increasing the volume of the suction line the surge drum absorbs suction line pressure fluctuations and prevents the condensing unit from short cycling Constant pressure valve is fitted to each IBC to maintain a constant SET above the freezing point of the beverage. Constant pressure valve is similar to an EPR valve but far more accurate. To reduce the possibility of oil entering the evaporator of an IBC.

Q.2
Q.3 Q.4
Low pressure control to cycle a suction line solenoid valve Thermostat to cycle a liquid line solenoid valve.
Q.5
Uses much less refrigerant than an IBC and is manufactured to fit into a standard glass rack Amount of refrigerant contained in the temprite.

Q.6 Q.7
Ice flake machine, delivers irregularly shaped ice flake Ice cube machine, delivers ice cubes.
Q.8

Mechanical: contains a refrigeration unit within the dispenser. Ice cooled: ice is contained in a storage bin and acts as the refrigeration medium.
Q.9 Q.10 Q.11
The syrup ration. By an ice maker fitted to the dispenser or from an outside source. Adjustment is done by fitting a set of gauges to the inlet side of the EPRvalve and adjusted to the selected minimum pressure / temperature required. CO2 or Beer gas. Because the hot gas injected into the plate evaporator allows the ice slab to slide down onto the cutting grid. Soda water flow rate has to be adjusted first. To assist in the efficient removal of heat from the product coils and carbonator tank.
Q.12 Q.13
Q.14 Q.15
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SURNAME: _____________________________
OTHER NAMES: _________________________
CLASS: ________________________________ _
HVAC - REFRIGERATION
Course No. 9189 Domestic Refrigerators & Freezers Package No: 6
Time allowed 2 Hours

All questions to be attempted
SECTION
CONTENT
POSSIBLE MARK
ACTUAL MARK
Short Answer Electrical
60
2 Drawings TOTAL
40
100
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Domestic Refrigerators & Freezers Section No: 1

Short answer questions Total marks 60 Q.1 The two main refrigerants used in domestic refrigeration are:
Q.2
Explain how the defrost cycle of a cyclic defrost refrigerator is achieved:
Q.3
The defrosting of the freezer section of a cyclic defrost refrigerator should be done when and how:
Q.4
Describe how the defrost cycle operates on an automatic defrosting refrigerator:
Q.5
What is the main purpose of a suction line accumulator?
Q.6
What would be the expected saturated evaporator temperature for a frost free refrigerator?
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Q.7
Describe the main purpose of the evaporator fan delay thermostat when used in a frost free refrigerator and what would be the expected cut in and out temperatures of this thermostat:
Q.8
Describe how the temperature of the food compartment in a frost free refrigerator is controlled:
Q.9
How is the water from the defrost cycle disposed of in a frost free refrigerator?
Q.10 When should a manual defrost refrigerator be defrosted and how?
Q.11 List the two main types of domestic freezers:
Q.12 What is the main advantage and disadvantage of a chest type deep freezer:
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Q.13 What is the major disadvantage of an upright deep freezer?
Q.14 Describe two ways in which you would charge a domestic refrigerator with refrigerant:
Q.15 How much refrigerant would you expect a domestic refrigerator to hold and how could you find out?
Q.16 What is the minimum reading required on a vac stat before charging a domestic refrigerator with refrigerant?
Q.17 List the additional components that a frost free refrigerator requires in comparison to a cycle defrost refrigerator:
Q.18 How is moisture, prevented from forming around the doors of a cyclic or frost free refrigerator?
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Q.19 Name the two types of compressor start relays used in domestic refrigerators and freezers:
Q.20 What type of temperature control does a cyclic defrost refrigerator use?
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Section No: 2 Electrical Drawings

Total marks 40 Q.1 Construct an electrical circuit diagram for a cyclic defrost refrigerator using a current coil relay in the space provided below: Marks: 10
Q.2
In the space provided draw a complete wiring circuit diagram for a chest type deep freezer. Include in your diagram a current coil relay and a fast freeze switch. Marks: 10
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Q.3
In the space provided draw a complete wiring circuit diagram for a frost free refrigerator. Include in your drawing a butter conditioner. Marks: 20
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SURNAME: _____________________________
OTHER NAMES: _________________________
CLASS: ________________________________ _
HVAC - REFRIGERATION
Course No. 9189
Package No: 18/19/20/45/46
Time allowed 2 Hours

All questions to be attempted
SECTION
CONTENT
POSSIBLE MARK
ACTUAL MARK
1 2 3
Short Answer Calculations Drawings TOTAL
50 25 25 100
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Section No: 1
Short answer Total marks 50 Q.1 Describe the purpose of the surge drum when used within a beverage cooling system:
Q.2
Why do single well deck cases have less air spillage than upright merchandising cases?
Q.2
Why must an oil separator be installed in an instantaneous beverage cooler (IBC)?
Q.3
What is meant by the terms transmission and product load:
Q.4
Name two methods of controlling the cabinet temperature of under bar bottle cabinets:
Q.5
Describe in your own words the main advantage of a glycol system in comparison to a beverage cooling system (IBC).
Q.6
List two types of ice making machines and their major differences:
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Q.7
Name two types of insulation material used in the construction of coolrooms and freezer rooms:
Q.8
Why do most multi-deck display cases have removable ends?
Q.9
Describe two types of postmix refrigeration systems and their operational characteristics:
Q.10 What does the term brix mean?
Q.11 Describe how you would adjust a beverage cooler (Temprite) to maintain a saturated evaporator temperature of -1C:
Q.12 List four additional components that are required for a freezer room in comparison to a medium temperature coolroom:
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Q.13 In an ice-cooled counter top refrigeration system the ice can be provided by what two means?
Q.14 What drives the diaphragm pumps on a post mix refrigeration system?
Q.15 Why is it necessary for the compressor to operate during the harvest cycle on icecube machine?
Q.16 Anti sweat heaters are installed under the cabinets rub rail for what reason?
Q.17
List three different types of supermarket merchandising cabinets:
Q.18
State the main purpose of the agitator motor in a postmix mechanical refrigeration system:
Q.19 Describe how you would adjust a crankcase pressure regulator on a low temperature freezer room:
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Q.20 List three types of defrost timers and their operation methods:
Q.21 Explain why the evaporator fans in a low temperature island freezer cabinet operate continuously:
Q.22 What is meant by the term air curtain?
Q.23 Give five installation procedures that should be implemented when installing supermarket equipment:
Q.24 List four factors that determine the refrigeration capacity of a coolroom or freezer room:
Q.25 List three common refrigerants that are used in dairy multi deck cabinets:
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Section No: 2 Calculations

Total marks 25
Q.1
A medium temperature coolroom operates on R134a at an average room temperature of 3C with an evaporator TD of 6K and an outside ambient of 36C. In the space provided indicate the following control settings: (Note show all working). 10 marks.
Room thermostat
High Pressure control
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Q.2
A low temperature freezer room operates on R404A at a room temperature of -20C with an outside ambient of 35C. In the space provided indicate the following control settings: 15 marks.
Room thermostat
High limit safety heater thermostat
Defrost timer (Time initiated time or pressure terminated)
Low pressure safety control
High pressure safety control.
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Section No: 3 Drawings

Total marks 25 Note: Free hand drawings will not be marked. Q.1 Construct a control circuit diagram for under bar bottle cabinet using the correct symbols and colour coding in the space provided. 10marks.
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Q.2
Construct the complete wiring circuit diagram for a medium temperature coolroom in the space in accordance with the following details: 15 marks.

Three phase motor compressor. Two single phase condenser fan motors. Single phase evaporator fan motor. Thermostat to cycle LLSV on room temperature. Include and the necessary cycling and safety controls. Condensing unit to operate on a pump down cycle.
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Refrigeration Systems Student Resource Package No: NR 6/18/19/20/45/46

Recognition of Prior Learning:

Compiled By: G Riach & R Baker

40% 30% 100%

Compiled By: G Riach & R Baker

Domestic Refrigeration Section No: 1

Compiled By: G Riach & R Baker

Cyclic Defrost: Reference (ARAC, page 7.3)

Compiled By: G Riach & R Baker

Side view of cyclic defrost refrigerator

Spill over plate evaporator Condenser

Compiled By: G Riach & R Baker

Refrigeration Circuit Diagram

Drier Suction Accumulator Capillary Tube

Electrical Wiring Diagram

Cyclic defrost refrigerator with current coil relay

Compiled By: G Riach & R Baker

Automatic Defrosting Refrigerator Reference (ARAC, page 7.1)

Compiled By: G Riach & R Baker

Three way hot gas defrost solenoid valve

Defrost timer with remote temp sensing bulb.

Three way solenoid valve coil

Compiled By: G Riach & R Baker

Frost Free Refrigerator Reference (ARAC, page 7.5)

Supply Air from freezer compartment spills over to Food

Return air to evaporator coil Baffle Thermostat adjustment knob

Thermostat sensing bulb

Compiled By: G Riach & R Baker

Drain pipe Drain pan

Compiled By: G Riach & R Baker

Electrical Wiring Circuit Diagram No Frost Refrigerator

Butter conditioner: 1 = low

Compiled By: G Riach & R Baker

Manual Defrost Refrigerator

Push Button Manual Defrost

Domestic Deep Freezers Reference (ARAC, page 7.8)

Compiled By: G Riach & R Baker

Compiled By: G Riach & R Baker

Domestic upright deep freezer

Evaporator coils and freezer shelfs

Compiled By: G Riach & R Baker

Electrical circuit diagram (chest type / upright deep freezer)

Fast freeze switch

Refrigerant charging of domestic refrigerators / freezers:

Compiled By: G Riach & R Baker

The two main refrigerants used in domestic refrigeration are:

Explain how the defrost cycle of a cyclic defrost refrigerator is achieved:

Compiled By: G Riach & R Baker

Describe how the defrost cycle operates on an automatic defrosting refrigerator:

What is the main purpose of a suction line accumulator?

Compiled By: G Riach & R Baker

Q.14 When should a manual defrost refrigerator be defrosted and how?

Q.15 List the two main types of domestic freezers:

Compiled By: G Riach & R Baker

Q.17 What are two disadvantages of an upright deep freezer?

Compiled By: G Riach & R Baker

Compiled By: G Riach & R Baker

Coolroom & Freezer Rooms Section No: 2