3air Con03

LESSON
REFRIGERATION SYSTEMS
OPERATION
LECTURE
SUB-OBJECTIVE
At the end of this Lesson the Trainee will be able to:
1.0
1.
Identify the parts & functions different Refrigeration Systems.
2.
Trouble shoot for minor & major problems in the above.
3.
Correctly maintain the above systems.
CASCADE REFRIGERATING SYSTEMS

In a cascade refrigerating, two or more refrigerating systems are connected as
shown in Fig. 3-3-1. Both systems operate at the same time.
System A (on the right) has its evaporator, A, (heat absorbing part) arranged to
cool the condenser B for the system.
B. The evaporator for system B supplies the cooling effect desired. Each
system has a thermostatic expansion valve (TEV) for refrigerant control.
The low-pressure liquid of system A cools the high-pressure vapor of system
B.
Cascade systems are often used in industrial processes where objects must
be cooled to temperatures below - 50 F. (-46 C.)
One motor control is used for both motors. It is connected to a temperature
sensing bulb on evaporator B.
Motors used on cascade systems must be capable of starting under load.
With the use of thermostatic expansion valves, the pressure does not balance
on the off cycle. The condenser-evaporator is usually of the shell-and-tube
flooded evaporator type.
Since these systems operate at very low temperatures, the refrigerant must be
very dry. Otherwise, any moisture would condense at the needle-seat of the
TEV and stop the flow of refrigerant. System A must have special refrigerant
oil (wax free, moisture free and flows at extra low temperatures).
Oil separators should be installed in the compressor-to-condenser lines on
both of these condensing units to help keep the oil in the compressors.
MODULE 3
BASIC REFRIGERATION SYSTEM
AIR CONDITIONING & REFRIGERATION

LESSON 3 PAGE 1
Fig. 3-3-1. Cascade refrigerating system.

2.0
MODULATING REFRIGERATION CYCLE

In most refrigeration installations, the cooling or refrigerating capacity is
enough to maintain the desired temperature under the heaviest load. this
temperature is maintained by the motor control.
It starts the motor compressor when cooling (or heat removal) is required and
shuts it off as soon as the desired temperature is reached.
However, if the heat load is light, this single system may be over capacity for
the job.
The operating expense is greater than it would be if the machine capacity
more nearly matched the needed load.
The system also tends to cool too fast and it operates on and off too quickly.

LESSON 3 PAGE 2
MODULE 3
BASIC REFRIGERATION SYSTEMS
A modulating (varying capacity) system has been developed to fit the machine
capacity more closely to the needed heat load.
Using two or more compressors connected in parallel sometimes does this.
Each compressor is operated by a motor control.
During operation, if the heat load increases and the temperature starts to rise,
one compressor will continue to run.
But if the temperature keeps on rising, the second compressor will start to
operate. Additional compressor may cut in until enough capacity is obtained.
Fig. 1-9-2 illustrates a typical cycle diagram for a modulated installation.
This installation has three compressors. A pressure control connected to the
suction lines operates the motors.
The control contains a special switching device, which rotates the service of
the various compressors.
Thus, each compressor will be used about the same amount of time.
The modulating cycle maintains uniform temperatures and operates
economically.
Any conventional refrigerant control can be used. However, the thermostatic
expansion valve is most common.
All the compressors may use the same condenser and liquid receiver, or each
may have its own.
The same evaporator is connected to all the compressors.
A modulating system may use a multiple cylinder compressor, each cylinder
being equipped with an UN-loading device.
Variable speed motors are also used to provide a modulated refrigeration
capacity.
MODULE 3

LESSON 3 PAGE 3
Fig. 3-3-2. Modulating refrigeration cycle mechanism.

Which uses a three (3) motor compressor.
Pressure motor control is arranged to operate one or more compressors as need.
3.0
THERMOELECTRIC REFRIGERATION
Fig. 3-3-3 represents a simple thermoelectric couple.
The couple moves heat from the inside of an insulated space to a heat
exchanger on the outside.
Electrons, rather than refrigerants, carry away the heat.
Fins on the evaporator increase the heat flow. Fins on the outside of the heat
exchanger help give off the heat to the surrounding air.
The thermoelectric couple works because of the difference in the energy level
of the two semiconductors P and N. The P and N refer to the two different
semiconductor materials used (and their characteristics). This should not be
confused with positive and negative polarity of an electrical circuit.

LESSON 3 PAGE 4
MODULE 3
Semiconductors are metallic alloys and oxides. These vary greatly in energy
levels.
The electrical qualities of semiconductors lie between those of insulator and
conducts. They have properties of both, thus they do not carry electric current
as well as conductors and they do not stop flow of current as well as
insulators.
The choice of materials for the semiconductors P and N determines the
efficiency of the device.
Now a single couple can transfer much heat.
To increase the cooling effect, several couples may be connected in series.
This group of couples is called a module. Groups of modules may be
connected together in parallel, to increase the capacity still further.
A thermostat inside the refrigerated space controls the current flow through the
transformer rectifier, which supplies a controlled d.c. current to the modules.
In this way, the temperature inside the refrigerator is controlled.
There are no moving parts in this refrigerator. Aside from the construction of
the modules, it is quite simple.
Thermal efficiency is low. That is, the amount of refrigerating effect obtained
for the electrical energy spent is less than with a conventional compressor
type refrigeration system.
By reversing the direction of the flow of current through a thermoelectric
device, the hot and cold surfaces will be reversed.
Thus, the same device can be used for both heating and cooling an insulated
space.
One application of this thermoelectric device has been in the air conditioning
and heating of nuclear submarines.
It is also used extensively to control temperatures in electronic equipment
(computers, aerospace devices and so forth).
MODULE 3

LESSON 3 PAGE 5
Fig. 3-3-3. Diagram of simple thermoelectric couple, used for refrigerating an

insulated space.
Heat absorbed by thermoelectric couple is released to outside by fins
attached to heat radiating surface (heat sink).
4.0
ELECTRIC DEFROST
Electric heating elements placed alongside the evaporator surfaces heat up to
melt the frost and ice buildup from the evaporator.
A timer or control mechanism operates the heater during the time that the
refrigerating mechanism is on the off cycle.
Fig. 3-3-3A shows the
refrigerating cycle; Fig. 3-4-3B shows the defrost cycle.
In 3-3-3A, the electric heating mechanism is in the refrigerating part of the
cycle. Liquid refrigerating is vaporized in the evaporator. It absorbs heat and
becomes a vapor.
While in the evaporator, it flows through an accumulator, passes on to the
suction line back to the compressor.
In the compressor, it is compressed to a high-pressure high temperature and

flows into the condenser. Here the heat of vaporization is removed and the

LESSON 3 PAGE 6
MODULE 3
refrigerant returns to a liquid flowing into the liquid receiver. From here the
cycle is repeated.
In Fig. 3-4-3b the same system is in the defrost cycle.
The compressor is stopped and, then defrosts the control mechanism and, lets
electric current flow through the resistance heating elements alongside the
evaporator surface.
Heat warms the evaporator surfaces until the frost and ice are melted and the
moisture empties into a drain pan.
The operation of the resistance units is usually timed to control both the
frequency and the duration of the electric heating.
This timing provides for adequate frost removal and the system is helped to
operate efficiently with little or no frost on the evaporator surfaces.
MODULE 3

LESSON 3 PAGE 7
Fig. 3-3-4A. An electric defrost system during the refrigerating cycle.

LESSON 3 PAGE 8
MODULE 3
Fig. 3-3-4B. An electric defrost system during the defrost cycle.
MODULE 3

LESSON 3 PAGE 9
7.0
TEST YOUR KNOWLEDGE

1.
What are some of the advantages of the capillary tube type refrigerant
control?
2.
What causes the needle valve to open in an automatic expansion valve

with refrigerant control?
3.
What causes the needle valve to open in the thermostatically controlled

expansion valve?
4.
What controls the cabinet temperature in a system which uses a

thermostatically controlled expansion valve?
5.
What is the chief advantage of a compound system?
6.
What is the chief advantage of a cascade system?
7.
In a thermoelectric refrigeration system, how is heat carried out of the

space to be refrigerated?
8.
How is modulation (varying capacity) in refrigeration accomplished?
9.
Why is it sometimes necessary to use a multiple evaporator system?
10.
What is the chief disadvantage of thermoelectric refrigeration?
11.
In what kind of refrigerating mechanism are semi-conductors used?
12.
In "cascade" systems, are the refrigerating temperatures usually above

or below 0 F. (-18 C.)?
13.
What is another name for an "open" refrigerating system?

LESSON 3 PAGE 10
MODULE 3

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LESSON

Identify the parts & functions different Refrigeration Systems.

Trouble shoot for minor & major problems in the above.

Correctly maintain the above systems.

CASCADE REFRIGERATING SYSTEMS

AIR CONDITIONING & REFRIGERATION

Fig. 3-3-1. Cascade refrigerating system.

MODULATING REFRIGERATION CYCLE

AIR CONDITIONING & REFRIGERATION

AIR CONDITIONING & REFRIGERATION

Fig. 3-3-2. Modulating refrigeration cycle mechanism.

AIR CONDITIONING & REFRIGERATION

AIR CONDITIONING & REFRIGERATION

Fig. 3-3-3. Diagram of simple thermoelectric couple, used for refrigerating an

In the compressor, it is compressed to a high-pressure high temperature and

AIR CONDITIONING & REFRIGERATION

AIR CONDITIONING & REFRIGERATION

Fig. 3-3-4A. An electric defrost system during the refrigerating cycle.

AIR CONDITIONING & REFRIGERATION

Fig. 3-3-4B. An electric defrost system during the defrost cycle.

AIR CONDITIONING & REFRIGERATION

TEST YOUR KNOWLEDGE

What causes the needle valve to open in an automatic expansion valve

What causes the needle valve to open in the thermostatically controlled

What controls the cabinet temperature in a system which uses a

What is the chief advantage of a compound system?

What is the chief advantage of a cascade system?

In a thermoelectric refrigeration system, how is heat carried out of the

How is modulation (varying capacity) in refrigeration accomplished?

Why is it sometimes necessary to use a multiple evaporator system?

What is the chief disadvantage of thermoelectric refrigeration?

In what kind of refrigerating mechanism are semi-conductors used?

In "cascade" systems, are the refrigerating temperatures usually above

What is another name for an "open" refrigerating system?

AIR CONDITIONING & REFRIGERATION

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