Refrigeration Fundamentals & Sealed System Diagnosis

L2005-022PPT
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Refrigeration
Refrigeration is best defined as the movement of heat from a location where it is not wanted to a location where the added heat will not matter. Refrigeration works because there is a relationship between Heat and Pressure
Heat and pressure behave in a predictable ways By controlling pressure, we can control heat

Heat
Everything has heat Without heat, all molecular activity would stop (Absolute Zero) Heat is measured two ways
Heat Intensity (Thermometer) Heat Quantity (BTUs)

Heat

One BTU is equal to the heat generated by burning common wooden kitchen match

Heat Intensity (Temperature)

BTU (British Thermal Unit) Quantity

Heat Quantity
Heat Packet

Wood Table Top

Metal Leg

75 F Environment

Even though two items can be at the same temperature, some materials will contain more heat (heat packets) than others.
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Heat Transfer
BTU BTU

100 F
BTU

50 F

Heat travels from an area of higher heat concentration to an area of less heat. The great the temperature differential, the faster the heat transfer.

BTU

BTU

-5 F
BTU

-15 F

Even in temperatures that we consider cold, heat still moves.

Heat Movement
Con o uc t i d n
Heated air rises and is replaced with cooler air

Convection

Cooler air falls and repeats cycle.

Glass
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Radiation

BTU Transfer
Super heated vapor

Latent Heat of Vaporization Latent Heat of Fusion

(only under pressure)

One BTU is = to heat generated by burning a common kitchen stick match

Intensity and Quantity

212 F 212 F

Even though both the water and steam are at 212 F, the steam has 970 BTUs (per pound) more heat than the liquid (more heat packets)

Pressure Effect on Boiling points

Superheated vapor

212 F

Under pressure, the water and vapor temperatures will increase well beyond the normal 212 F boiling point at sea level. Heat quantity rises as well.

Adding heat to a liquid causes it to vaporize

Cooling the vapor causes it to condense back into a liquid

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Evaporation
Water wicks through the porous ceramic to the exterior of the vessel. There, the water evaporates (changes state).

Porous ceramic container

Water

Your body relies on this same principle to keep you cool. In a warm environment, your body sweats. The sweat evaporates and cools your skin.

As the water changes from a liquid to a vapor, heat is absorbed. This cools the walls of the vessel which, in turn, cools the water.

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Intensity and Quantity

The key take aways from the boiling water example is:
In order for a change of state to occur, heat must be added or taken away. With water, 970 BTUs of heat must be absorbed to effect a change of state from a liquid to a vapor. Conversely, the same 970 BTUs of heat must be removed from that vapor before that vapor can change back into a liquid. Boiling is just an exaggerated form of evaporation

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Pressure
Pressure is Relative
At sea level, pressure is 14.7 PSI Pressure drops with Altitude Pikes Peak
Altitude Pressure

Denver Boston Chicago LA

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212 F

75 F

To Vacuum Pump Reducing the pressure over a liquid lowers its boiling point
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Hg scale

Mercury (Hg) Tube

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Hg Scale
As pressure is increased over the open Mercury, the level of liquid within the mercury tube rises

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Hg Scale
Conversely, as pressure is reduced over the open Mercury, the level of liquid within the mercury tube falls

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Hg Scale
By measuring the number of inches of Hg in the tube, we can determine the pressure over the liquid. In weather reporting, atmospheric pressure is also known as barometric pressure. Changes in barometric pressure usually precedes a change in weather.

Normal Atmospheric pressure is 29.92 Hg

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PSI Scale
PSIA 96.7 92.2 PSIG 82 77.5

Normal Atmospheric Pressure

Absolute Pressure

Gauge Pressure
14.7 0

14.7 PSIA

0.0 PSIG

.5 0

28.9 29.2

At Sea Level

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PSI Scale
In refrigeration, pressure is relative. Since pressure is all around us, any measurements we make are referenced to normal atmospheric pressure. At sea level, the normal 14.7 PSIG pressure that surrounds us becomes the zero reference point for our refrigeration gauges.
PSIA
96.7 92.2

PSIG
82 77.5

14.7

.5 0

28.9 29.2

Compound Gauge Set

At Sea Level

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Positive and Negative Pressures

PSIA 96.7 92.2 PSIG 82 77.5

Pressure that are greater than normal atmospheric pressure are called positive pressures and are measured in P.S. I. Gauge. Pressures that are less than normal atmospheric are called partial vacuums and are measured in Inches of Mercury (Hg).

Positive Gauge Pressure

14.7

Negative Gauge Pressure (Partial Vacuums)

.5 0

28.9 29.2

At Sea Level

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Negative Pressure (Partial Vacuums)

A perfect vacuum is measured as Zero PSI on the absolute scale or negative 29.92 inches of mercury (Hg) on a refrigeration gauge

Measuring Pressure & Vacuums

Low side gauge High side gauge

Low Side Hose (Blue)

Compound Gauge Set

High Side Hose (Red)

Common Hose (Yellow)

Measuring Pressure

P r e s s u r e

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Gauge Markings
Low Side Gauge

Atmospheric Pressure

PSIG Pounds per Square Inch Gauge

R-134a

Negative Pressure (Vacuums)

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Gauge Markings
Low Side Gauge

This is read as 50 PSIG

Negative Pressure (Vacuums)

R-134a

This is read as a 20 Inch vacuum

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Partial Vacuums Can also be Measured in Microns

A micron is a thousandth of an inch. A total of 29,920 microns of pressure would have to be removed to achieve a perfect vacuum (zero microns).

Charles Law
At a constant temperature, the volume of a gas varies directly with pressure.

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Charles Law
At a constant volume, the pressure of a gas varies directly with temperature.

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Charles Law
At any given temperature, the contents of a cylinder will strike a balance between how much vapor and liquid exists within the tank

Vapor

Liquid Liquid

This is know as the Steady State of a liquid in a storage vessel

Charles Law

Temperature

Pressure

Charles Law

Temperature

Pressure

Charles Law
Just as increasing pressure increases the temperature, decreasing pressure decreases temperature

Pressure

Temperature

Charles Law
Because of the pressure/temperature relationship outlined in Charles law,
if we know the temperature of a liquid in a sealed container, we can determine the pressure the liquid is under
if we know the pressure, we can determine the temperature

lowering the pressure reduces the boiling point of a liquid increasing the pressure raises the condensation point of a vapor

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Pressure Affect on Boiling points

212 F

To Vacuum Pump 75 F

Under reduced pressure, water will boil at normal room temperatures or below

Pressure
Pressure Affect on Boiling Point of Water

Temperature

284 234 184 134 84 34

10 2 6

14

Atmospheric Pressure

334

18

22

26

30

At 0 PSIG, water boils at any temperature above 34 F and condenses at any temperature below 34 F
29.92 in Hg 19.74 in Hg

PSIG

11.6 in Hg

0
PSIG

1.4 PSIG

5 PSIG

10 PSIG

15 PSIG

34
20 PSIG

Refrigerants
Class of chemicals with extremely low boiling and condensing points

R-134a

R-22

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R-134a Boiling and Condensing Points

- At seal level, R134a boils at any temperature above -15 F

R-134a

75 F 212 F

-16 F

Because of its extremely low boiling point, R-134a boils normal room temperatures. The warmer the temperature, the more violently the refrigerant boils

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Finding Steady State Pressures and Temperatures

Refrigerant Temperature Refrigerant Temperature

PSIG

R-12

R-22 R-134a R-502 R-410A

PSIG

R-12

R-22 R-134a R-502 R-410A

0 2 4 6 8 10 12 14 16 18

-22 -16 -11 -7 -2 2 5 9 12 15

-41 -37 -32 -28 -24 -20 -17 -14 -11 -8

-15 -10 -5 -1 3 7 10 13 16 19

-50 -45 -40 -36 -32 -29 -25 -22 -19 -16

-60 -58 -54 -50 -46 -42 -39 -36 -33 -30

105 110 115 120 125 130 135 140 145 150

93 96 99 102 104 107 109 112 114 117

62 64 67 69 72 74 76 78 81 83

90 93 96 98 100 103 105 107 109 112

54 57 59 62 64 67 69 71 73 75

34 36 39 41 43 45 47 49 51 53

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T/P Gauge Markings

Low Side Gauge

Refrigerant Temperature Scales

R-134a

How refrigerants make refrigeration possible

Because refrigerants boil at very low pressure and temperatures, they absorb heat even in sub zero environments
Since R134a boils at any temperature above -15F (0PSIG), it can remove heat from a freezer compartment that is at 0F

Because of their pressure/temperature condensation points, they give up heat even in warm environments
Under normal sealed system operating conditions, R134a will condense at any temperature below 100F

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How refrigerants make refrigeration possible

By controlling pressure, we can control the boiling (evaporation) and condensation points of a refrigerant
Lowering pressure reduces the boiling point Increasing pressure raises the condensation point

By setting up pressure differentials within a Sealed System, we can control the temperatures at which the refrigerant will boil (evaporate) and condense
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Tying it all together

In ANY refrigeration system, refrigerant is alternately evaporated, absorbing heat) and condensed (giving up the heat)
Evaporation occurs in low pressure side of the system Condensation occurs in high pressure side of the system Compressor and capillary set up pressure differentials
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Components of a Typical Sealed System

Condenser Filter Drier Capillary Tube Evaporator
Heat Exchanger

Suction line Compressor

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How Compressor Increases Pressure

To Cond To Cond

On the intake stroke, vapor refrigerant from the low side of the system is pulled into the compression chamber

On the exhaust stroke, the refrigerant is pushed out of the compression chamber and into the high side of the system

How Compressor Increases Pressure

To Cond

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How the Drier Creates a Restriction

porato To Eva

From C on d e nser or larger

As the liquid droplets enter the drier, the smaller cap tube restricts their flow into the condenser

Cap Tube .030 or smaller

Refrigerant Flow
Condenser Filter Drier Capillary Tube
Heat Exchanger

Low Pressure Evaporator

Suction line Compressor

High Pressure

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How Refrigerant Absorbs Heat

Evaporator
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How Refrigerant Absorbs Heat

High pressure liquid travels from the condenser, through the capillary tube and enters the evaporator
High pressure liquid from cap tube

The lower pressure of the evaporator drops the boiling point of the liquid and the refrigerant begins to evaporate (boil)

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How Refrigerant Absorbs Heat

As the refrigerant boils, it pulls heat from the coil and the vapor becomes Superheated (contains trapped heat)
High pressure liquid from cap tube

When the coil in that area drops to -15F, the refrigerant can no longer exist as a vapor and condenses back into a -15F Liquid The latent heat that the refrigerant absorbed during evaporation is now trapped in the -15F liquid

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How Refrigerant Absorbs Heat

As each section of the coil drops to -15F, the superheated vapor condenses back into a liquid
High pressure liquid from cap tube

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How Refrigerant Absorbs Heat

This process continues until the entire coil is down to -15F and the evaporator is completely filled with liquid This condition is referred to as a Flooded Evaporator The -15F can now continue to absorb heat without any further evaporation taking place

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How Refrigerant Absorbs Heat

Eventually, the only place where evaporation is taking place is the the very end of the coil (Evaporator outlet) The super heated vapor now travels through the heat exchanger back to compressor

S
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Heat Exchanger
This cools the liquid refrigerant before it enters the evaporator.
er ns de n Co

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T ap C t ea H

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t ea H

t ea H

t ea H

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OR P VA

As the vapor travels through the suction line, it continues to absorb heat.

Heat Exchanger

or ess r mp Co To

It also warms the vapor and insures that no liquid enters the compressor.

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How Refrigerant Releases Heat

Static Condenser Drier

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How Refrigerant Releases Heat

The combination of the higher condensing temperature and the cooler air moving across the coil causes the refrigerant to condense. In the process, the refrigerant gives up its latent heat. Liquid droplets travel to the drier

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How the Drier Creates a Restriction

porato To Eva

From C on d e nser or larger

As the liquid droplets enter the drier, the smaller cap tube restricts their flow into the condenser

Cap Tube .030 or smaller

How Refrigerant Releases Heat

Liquid begins to pool and backs up into the condenser.

How Refrigerant Releases Heat

Once the drier fills with liquid, the liquid begins to pool back into the condenser

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How Refrigerant Releases Heat

The condenser begins to fill with liquid Eventually, the last few passes of the condenser are liquid filled. This reservoir of liquid insures that there is enough refrigerant in the system to maintain a flooded evaporator

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Condensers
Forced Air

Warm Wall

Static

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Evaporators
Tube an Fin

Shelf

Roll Bond

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Gas Loops (Yoder lines)

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Condenser Loop Refrigerant Flow

Post Condenser Loop

General Refrigeration Rules

Under normal conditions, low side and high side pressures follow one another.
If high side pressure goes up, low side pressure follows If low side pressure goes up, high side pressure follows

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General Refrigeration Rules

Heat load has greatest effect on low side pressure
As heat load increases, both low and high side pressures go up As heat load is decreased, pressures go down

Ambient conditions has a greatest effect on high side pressures

As ambient temperature rises, condenser temperatures increase Higher condenser temperatures mean higher low side temperatures and pressures and reduced ability to absorb heat
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General Refrigeration Rules

Compressor running wattage reflects how much work the compressor is performing How much work the compressor is doing is dependent on heat load and ambient conditions

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Sealed System Diagnosis

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Constant State

Condenser

Evaporator

Normal Conditions
High Side (Condenser) Pressure: About 120 to130 PSIG

Running Amperage Approximatel y 1 amp (Ranges from .6 to 1.4 Amps depending on Compressor BTU rating)

Liquid level varies but normally last couple of passes of condenser is filled with liquid when running Evaporator frosted from top to bottom

Low Side (Evaporator) Pressure: About 0 PSIG (Ranges between 10 and 5-7 lb PSIG)

Charging
(Cooling Capacity) 1000 950 900 850 800 750 700 650 600
75 80 85 90 95 100 105 110 115

BTUs

Amp Draw
1.4 1.3 1.2 1.0 .9 .8 .7 .6 .5

Percent Correct Charge

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Refrigeration Diagnosis Dos and Donts

Do
Check internal and external air flow Check refrigerator and freezer temperatures Check for unusual heat sources
Light staying on Air leaks into freezer or refrigerator sections

Dont
Assume a system problem unless youve eliminated all other possible causes
Air flow Heat load Customer usage

Check that defrost system is working properly Check current draw Feel compressor, condenser for proper temperatures

Tap into system unless you are absolutely sure that the problem is with the sealed system

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Low Side Leak- Refrigerant still left in the system

HS pressure: Depends on Air/Refrigerant ratio* Cond Temp: Depends on Air/Refrigerant ratio* LS Pressure: Lower than normal Evap Temp: Warmer than normal

Condenser

Low Current Draw

Low liquid level Evaporator Ice ball on first pass (passes) of evaporator

* Condenser pressure and temperature will depend on volume of non-condensables absorbed into the system

Low Side Leak- Air in system

HS pressure: Very high Cond Temp: Very hot
Condenser

LS Pressure: Atmospheric Evap Temp: Warm

High Current Draw

No liquid

Evaporator No frost on evaporator

High Side Leak

HS pressure: Lower than normal* Cond Temp: Cooler than normal*
Condenser

LS Pressure: Lower than normal Evap Temp: Warmer than normal

Current Draw ** Low Watts

Liquid Level

Evaporator

Frost ***

* Liquid level will depend on how much refrigerant still left in system
**Compressor run wattage, pressures and temperatures of Evaporator and Condenser dependent on how much refrigerant is left in system. ***Frost on Evaporator and liquid level in condenser depends on how much refrigerant left in the system

Restriction
HS pressure: Ambient Cond Temp: Ambient LS Pressure: Vacuum Evap Temp: Warmer than normal

Condenser

Low Current Draw

Condenser full of liquid

Evaporator

No Frost on evaporator

Inefficient Compressor
HS pressure: Lower than normal Cond Temp: Cooler than normal LS Pressure: Higher than normal Evap Temp: Warmer than normal

Condenser

Low Current Draw

Liquid level low or non existent

Evaporator

Little or o Frost on evaporator

Inefficient compressor (defective exhaust valve)

To Cond

Because the condenser is under higher pressure than the dome of the compressor, most of the refrigerant is pulled back from the condenser on the down stroke

Inefficient compressor (defective intake valve)

To Cond

Because the condenser is under higher pressure than the dome of the compressor, most of the refrigerant is pushed back into the dome rather than the condenser

Undercharge
HS pressure: Lower than normal Cond Temp: Cooler than normal
Condenser

LS Pressure: Lower than normal Evap Temp: Warmer than normal

Low Current Draw

Low liquid level Evaporator

No frost on last pass (or passes) of evaporator

Overcharge
HS pressure: Higher than normal Cond Temp: Hotter than normal LS Pressure: Higher than normal Evap Temp: Slightly Warmer than normal

Condenser

High Current Draw

High liquid level

Evaporator

Frosted suction line all the way back to compressor

Conditions When Pressure/Temp/Watts Dont Follow One Another

Low Side Leak- Non-Condensables in high side
High side pressureLow Side pressureWatts High side pressureLow Side pressureWatts

Inefficient Compressor

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Sealed System Analysis

Indicators
Conditions
Watts Condenser Temp Condenser Liquid Frost Line Level Capillary Tube Low Side Sound Pressure High Side Pressure Pressure Equalization Rate

Overcharge

Undercharge Low-Side Leak -Refrigerant in System Low-Side Leak- NO Refrigerant in System High Side Leak Low Capacity Compressor Restrictions Capillary Tube (Complete) Capillary Tube (Floating)

Sealed System Analysis

Indicators
Conditions
Watts Condenser Temp Condenser Liquid Level Frost Line Capillary Tube Low Side Sound Pressure High Side Pressure Pressure Equalization Rate Normal to slightly longer Quicker than Normal

Overcharge

High

Higher than Normal Higher than Normal Lower than Normal Lower than Normal Normal to Slightly Higher * Lower than Normal

All the way back Louder than to suction line Normal Partial Intermittent

Higher than Normal Lower than Normal

Higher than Normal Lower than Normal

Undercharge

Low

High* Low-Side Leak -Refrigerant in System

Partial to Non Intermittent to existent (possible non existent frost ball) Non existent
None

Normal to slightly Normal to Normal higher* slightly higher than Normal * Atmospheric Higher than Normal Normal

Low-Side Leak- NO Refrigerant in System High Side Leak Low Capacity Compressor Restrictions Capillary Tube (Complete) Capillary Tube (Floating)

High

High

None

Low Low

Low Low

Low to non existent Low

None Partial to Non existent

None Intermittent to non existent

Vacuum Higher than normal

Low Lower than Normal

Quicker than Normal Quicker than Normal

Low Low

Low Low

Higher than normal Higher than Normal

None Intermittent

None Intermittent

Vacuum

Ambient

No equalization Intermittent

Intermittent Partial Intermittent Vacuum lower than normal

*Compressor run wattage and the pressures and temperatures of Evaporator and Condenser dependent on how much refrigerant is left in system.

Restricted Evaporator Air flow

HS pressure: Lower than normal Cond Temp: Cooler than normal LS Pressure: Higher than normal Evap Temp: Slightly Warmer than normal

Condenser Condenser

Low Current Draw

Low liquid level

Evaporator

May be frosted all the way back to compressor

Restricted Condenser Air Flow

HS pressure: Higher than normal Cond Temp: Warmer than normal LS Pressure: Higher than normal Evap Temp: Slightly Warmer than normal

Condenser

High Current Draw

Normal liquid level

Evaporator

Normal Frost Pattern

Conditions that Mimic Sealed System Failures

Indicators
Conditions
Watts Condenser Temp Frost Line Capillary Tube Sound Low Side Pressure High Side Pressure Fresh Food Temp Freezer Temp

Plugged condenser Blocked Cond. Fan Blocked Evap Fan Evap Iced up (defrost failure) High heat load High ambients Damper failed closed Damper failed open

Conditions that Mimic Sealed System Failures

Indicators
Conditions
Watts Condenser Temp Frost Line Capillary Tube Sound Low Side Pressure High Side Pressure Fresh Food Temp Freezer Temp

Plugged condenser Blocked Cond. Fan Blocked Evap Fan Evap Iced up (defrost failure) High heat load High ambients Damper failed closed Damper failed open

High High Low Low

Higher than Normal Higher than Normal Lower than Normal Lower than Normal Higher than Normal Higher than Normal Lower than Normal

Full Full Frost back to compressor Frost back to compressor Full Full Full

Normal Normal Normal Normal

Higher than Normal Higher than Normal Lower than normal Lower than normal Higher than normal Higher than normal Lower than normal Lightly higher than normal

Higher than Normal Higher than Normal Lower than Normal Lower than Normal Higher than normal Higher than normal

Warmer than Normal Warmer than Normal Warmer than Normal Warmer than Normal Warmer than Normal Warmer than Normal

Warmer than Normal Warmer than Normal Warmer than Normal Warmer than Normal Warmer than Normal Warmer than Normal Cooler than Normal Warmer than Normal

High High Low

Normal Normal Normal

Lower than normal Warmer than Normal Slightly higher than normal Cooler than Normal

Slightly higher Slightly higher than Normal

Full

Norma;

Be Aware, Be Alert Always work safely. On the Job, On the Road, In the Home Every Time, All the Time
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