More and more commercial refrigeration systems
and air conditioning plants of a similar size are
built up around hermetic and semihermetic
compressors. These compressors, as compared
to the open type, are normally more vulnerable
to impurities in the refrigerant system and to
incorrect operating conditions.
Therefore, in modern refrigeration systems, there
are special demands on the quality of installation
work and commissioning.
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A well-dimensioned, correctly installed and
correctly commissioned refrigerant system is
fundamental to a reliable refrigeration system
with a long operating life.
An absolute requirement on the refrigerant
system is that it shall remain completely free of
foreign bodies (impurities).
Installation work must therefore be performed
with a high degree of cleanliness. This applies
especially to systems containing the new
refrigerants.
Particularly damaging
impurities
Problems caused by moisture in
the system
Moisture
Atmospheric air
Soldering ux
Rust, copper oxide, scale
Metal swarf
Unstable oils
Certain uorinated solutions (e.g. R11
or carbon tetrachloride)
Dirt or dust of any description.
Water separation and ice formation
(blockage) in the expansion valve
Acid formation
Ageing and breakdown of the oil
Corrosion
Copper precipitation (dissolved copper
from tubing deposited on bright steel
parts in the compressor)
Damage to the insulating lacquer on
motor windings.
Formation of organic and inorganic acids
Corrosion
Poor lubrication
Abnormal wear
Oil discolouration (darkening)
Sludge formation
Leaking discharge valves because of
oil carbon deposits
Increased discharge gas temperature
Compressor damage
Motor burnout
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Problems caused by other
impurities
Component and
material requirements
Components
The other impurities mentioned can cause:
Accelerated chemical processes
(breakdown)
Mechanical or electrical faults
High temperature accelerates the breakdown
processes, therefore abnormally high condensing
temperatures and, especially, abnormally high
discharge pipe temperatures must be avoided.
For the reasons just mentioned, a number of
requirements must be met. Some of these are
described in the next chapter.
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Compressors for refrigeration and heat pump
systems are put through a comprehensive cleaning process by the manufacturer so that, practically speaking, all traces of moisture and other
impurities are removed.
All other components in the system should be of
the same standard.
All components must full cleanliness requirements. In cases of doubt, components should be
checked.
Impurities that might appear if component
manufacturers are less thorough than they
should be:
Rust and scale (loose or embedded)
Old oil
Flux
Metal swarf
Moisture
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Moisture in smaller quantities in components
can be removed by simultaneous heating and
blowing through with dry nitrogen (N2).
It is almost pointless to try removing other
impurities. Components containing such impurities should not be used in systems with
halogenous refrigerants.
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Copper tubing
Refrigerant requirements
Special copper tubing must be used for refrigerant systems, tubing that is completely clean
and dry. In addition, the ends of tubes must be
hermetically sealed.
Tubing other than the type just described must
not be used in refrigerant systems, unless it fulls
the same cleanliness requirements.
All components must remain tightly sealed until
the moment they are installed in the system.
Refrigerants should only be purchased from
accredited distributors.
Refrigerants for hermetic systems must not
contain more than:
Fitters notes Practical Tips - The installation process
Installation process
Planning
Process:
Planning of component location and
tubing layout
Setting up of main components
Piping and component installation
Evacuation
Flushing
Pressure testing
Leak testing
Charging
Setting safety equipment
Testing safety equipment
Setting controls
Testing the complete system and
readjusting controls, etc.
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Installation must be planned so that
Damage to building sections, including
cold room insulation, is minimal.
Components are located functionally
correctly (e.g. adequate air ow to
compressor, condenser, evaporator).
Pipe runs are as short as feasibly possible.
Location of main components
Installation of refrigeration
system
Main components (compressor, condenser,
evaporator, etc.) must be mounted securely in
position, using the accompanying brackets and in
accordance with the manufacturer’s instructions.
The compressor must always be secured to
a horizontal base. If vibration dampers are
supplied, they must also be tted.
Installation must be as rapid as possible so that
signicant quantities of moisture, air or other
impurities have little chance of collecting in the
system.
Compressors and lter driers should therefore be
installed last, immediately before evacuating and
charging the system.
All openings into the refrigerant system - with
absolutely no exception - must be completely
sealed against air and water vapour for the
duration of any pauses that might occur in
installation work.
Fitters notes Practical Tips - The installation process
Piping installation
As far as possible, piping must be horizontal or
vertical. The exceptions are:
Suction lines, which can be given a slight fall
towards the compressor.
Discharge lines, which can have a slight fall
away from the compressor.
Pipe xing brackets, clips, etc. must be pitched
to suit the pipe diameter and load from components mounted in the lines.
If vibration dampers are tted to the compressor,
then suitable vibration eliminators should be
tted to suction and discharge piping.
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Oil locks must be mounted in vertical suction
lines at a pitch of 1.5 to 5 m depending on
running time per cycle. In systems with
large load variations it can be necessary to
introduce double risers.
Suction lines must also be installed to take
account of oil return to the compressor.
In systems with varying loads, the demands
are particularly critical at low loads.
Location of other components
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All components should be installed so that they
are easily accessible for service and possible
repair.
Controls and safety equipment must be located
so that testing and adjustment can easily be
performed using ordinary tools.
Fitters notes Practical Tips - The installation process
Compressors in parallel
installation
Compressors in parallel must be installed with
oil equalization between compressor crankcases,
otherwise whichever compressor(s) run most
will „steal“ oil from the other compressor(s). Oil
equalization can be introduced by installing an
equalizing tube between oil sumps. In systems
with one equalizing tube, the tube must be
installed between compressor oil sumps and
must be of such a diameter that both oil and
refrigerant vapour are able to ow through it
unhindered.
With two equalizing tubes (g. 1)
One tube must be installed between compressor
oil sumps, the other between compressor vapour
chambers (crankcases). When installing oil
equalization in either of the forms described, the
compressors must be set up in exactly the same
horizontal plane.
Oil level controls (g. 2)
Oil equalization is also possible using oil level
regulators.
If these are used, the compressors can be
installed at dierent levels. However, level
controls are much more expensive than
equalizing pipes.
The following components are necessary with oil
level regulation:
Oil separator (1)
Pressure equalizing valve (2)
Oil reservoir (3)
Oil lter (4)
Oil level regulator (5)
Remember that each compressor must be
protected with a high-pressure control, e.g. KP7.
Important installation processes
Component storage
The processes that might give rise to
contamination of refrigerant systems
are:
Component storage
Pipe cutting
Cleaning pipe ends
Soldering
Flare connections
All components must have a temperature not
lower than that of their surroundings - before
they are opened. This prevents condensation in
the components.
For example, components must not be installed
immediately after they have been brought from a
cold service van into a warm room.
Fitters notes Practical Tips - The installation process
Phosphor solder
Use of inert gas when soldering
Phosphor solder consists of 2-15% silver with
copper and phosphor. The melting range is about
640°C to 740°C.
Flux must not be used when making phosphor
solder connections.
Phosphor solder can only be used to join copper
to copper.
At the high temperatures used in soldering,
oxidation products (scale) form immediately if
the pipe comes into contact with atmospheric air
while soldering is taking place.
An inert gas must therefore be blown through
the system during soldering. Send a slight ow of
dry nitrogen or another kind of inert gas through
the tubing.
Do not begin soldering until there is no more air
in the component(s) concerned.
Start the operation with a strong ow of inert
gas.
Closely observe that no air ow goes into the
pipe with inert gas ow.
Reduce the ow to a minimum when soldering is
started.
Maintain this slight ow of shielding gas during
the whole soldering process.
Soldering must be performed with oxygen and
gas, with a slight oxygen decit and a relatively
large burner jet.
The solder must not be applied until the melting
temperature is reached on the parts being
connected.
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Economic soldering
Never use more solder than necessary, otherwise
there is a risk of blocking the pipe partially or
completely.
Solder quickly so that the oxygen absorption
property of the ux is not impaired, i.e. for no
longer than about 15 seconds.
Fitters notes Practical Tips - The installation process
Be careful with the temperature
Flare connections
(copper piping)
The temperature must not be higher than
necessary.
Therefore draw the ame back slowly when the
melting temperature is reached.
External ux residue must be removed by
brushing with hot water.
Alloys based on tin or lead are not recommended
as solders for refrigerant systems.
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Use only approved refrigeration copper piping.
Cut ends at right angles to the piping.
Remove all internal and external burrs.
Make the are the right size, neither too small nor
too large.
Do not compress the are so severely that it
becomes hard.
Leave nal tightening up until actual installation.
Evacuation, ushing and
charging
Necessary equipment
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Steps to follow:
On completing installation work, the next steps
are:
Evacuation and refrigerant charging
Leak testing
Starting up and adjustment.
Faults, which occur after the system has been
started, can necessitate:
Repair of the system.
Vacuum pump
Vacuum gauge
Charging bottle (or service cylinder
containing refrigerant)
(Vacuum pump, vacuum gauge and
charging bottle can be obtained
assembled as an evacuation and
charging board.)
Charging hoses
Leak detector
Remove moisture, atmospheric air and inert gas
from the system when evacuating.
Fitters notes Practical Tips - The installation process
Vacuum pump
Vacuum hoses
The vacuum pump should be capable of quickly
bringing the system pressure down to about 0.05
mbar.
Pump capacity, e.g. 20 l/minute. Eective
evacuation requires large pipe diameters.
Therefore evacuation through “Schraeder”
valves is not advisable. Use a “Quick Connector”
for compressors with process tube or use the
process connectors on the compressor suction
and perhaps the discharge stop valve.
The valve spindle must be in its mid position.
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Vacuum hoses and tubes must be as short as
possible and the diameter suciently large.
Normally, an ordinary 1/4" charging hose not
more than 1 m in length can be used.
Evacuate in two stages with refrigerant ushing
between.
The process of evacuation, ushing and charging
is described below.
Checking the vacuum pump and hoses
a) Mount the charging hoses between charging board and compressor. Shut o the
connections between charging hoses and
compressor.
b) Start the pump and allow it to suck the
pressure down as far as possible.
c) Shut o the pump from the rest of the system.
d) Stop the pump.
e) Read o and register the pressure on the
vacuum gauge. The pressure must not be
more than 0.05 mbar.
f) Check to ensure that the vacuum can be
maintained. If not, replace charging hoses
and/or leaking valves and/or vacuum oil in the
vacuum pump.
Fitters notes Practical Tips - The installation process
Provisional setting of safety
equipment
Checking the electrics
Check and set high-pressure control and any
other safety equipment, incl. motor protector
(setting in accordance with scale values).
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Check all wiring.
Test the control system with compressor
motor disconnected.
Check the direction of rotation of the motor.
Swap two phases if necessary.
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Refrigerant charging
After nal evacuation, the system can be charged
with refrigerant.
A charging board can be used for the purpose
and will, with sucient accuracy, dose the correct
quantity of refrigerant for the system. High
accuracy is needed in systems without receiver.
If the system has a charging valve, refrigerant
can be supplied in the form of liquid to the liquid
line. Otherwise the refrigerant can be supplied as
vapour to the compressor suction stop valve with
the compressor running.
Caution:
Too little superheating during the charging
process can cause liquid hammer in the
compressor.
Charging must be continued until no vapour
formation appears in the sight glass - unless
vapour formation is due to other faults, see the
section “Trouble shooting - Fault location”.
If the necessary quantity of refrigerant is not
known, use the method last described.
Here however, it is necessary the whole time
to check that the condensing pressure and
suction pressure remain normal and that the
Thermostatic expansion valve superheat is not
too low.
Fitters notes Practical Tips - The installation process
Condensing pressure too high
Setting and testing safety
equipment
Conditions
Too high a condensing pressure during the
charging process can mean that the system has
been overcharged with refrigerant and must be
partly drained.
Always use the recycling unit if it becomes
necessary to drain o refrigerant.
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Final setting and testing of safety equipment
must be performed with all mechanical and
electrical equipment installed and the system
running.
The functions must be checked with accurate
instruments. See also the chapter “Trouble
Shooting” , section “Measuring Instruments“
with reference to the instructions for the equipment concerned.
Setting and testing
regulation equipment
Procedure
Setting the high-pressure control
Setting the low-pressure control
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If a constant-pressure valve is installed, make a
coarse setting.
Set the expansion valve superheat.
Using a pressure gauge, set the constant
pressure valve.
Set the capacity regulator, if installed.
Set the thermostats (using a thermometer).
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Increase the condensing pressure to
permissible maximum and use a pressure
gauge to set the high-pressure control.
Reduce the suction pressure to the
permissible minimum and use a pressure
gauge to set the low-pressure control.
Attention:When making the above settings,
constantly check whether the system
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is operating normally (pressure, etc.).
Finally - ensure that correct refrigerant identi-
cation labels are axed to the system in order
that correct future servicing is ensured.