Experiment No.

6: Study of Installation and Maintenance Practices

for Refrigeration Systems

A. Safety Notices:
1. Installation and maintenance/servicing are to be performed only by trained and
qualified personnel familiar with commercial refrigeration systems.
2. Ensure that all field wiring conforms to the equipment requirements and all applicable
local and national codes.
3. Disconnect all power sources before servicing the refrigeration equipment.
4. Sheet metal and coil surfaces have sharp edges. Use appropriate protective gloves to
prevent injury.
5. Use appropriate eye protection during installation and servicing.

B. Pre-Start Checks:
1. Verify that all service valves are fully open.
2. Ensure that all refrigerant and electrical connections are tight.
3. Verify that the wiring and piping is properly routed and secured.
4. The compressor mounting bolts are properly adjusted .
5. All fan motors and mounting brackets are tight.
6. The condensing unit base and evaporator coil are properly secured

C. Installation:
At the time of installation, following points should be noted to ensure proper installation

1. Air Handling Unit:

a. Check AHU is as per the requirement/ order
b. The package should be installed in the AHU room on rubber pads to reduce vibrations due
to fan
c. Supply air duct should be connected to fan outlet by flexible connection. This will prevent
transmission of vibrations of fan to the ducts
d. Fresh air openings should be provided with manual or automatic dampers. This enables
increased fresh air intake during intermediate seasons etc.

2. Ducting
a. Joints for ducts are made as per Indian Standard specifications
b. To give rigidity to ducting , angle iron frames should be fitted from outside at regular
intervals
c. Care should be taken of aesthetics while ducts pass through occupied spaces
d. Insulation should be fire proof. Glass wool pads are safer and easy to install. However
these are covered by wire mesh and plastered with cement for longer life etc.

3. Refrigeration Plant
a. If more than one AHU is to be served by a plant , then chilled water system is used.
Therefore a chillers of adequate capacity is installed in a plant room.
b. The chilled water pipes should be properly insulated and protected against physical
damage. If these are located underground wherever possible , the damage can be avoided.
c. The condenser should be located below or above a compressor to reduce piping and make
installation more compact.
d. The piping should be supported from ceiling or from sides to prevent vibrations. Excessive
vibrations may lead to opening of joints.
e. Cooling tower if natural should have adequate open space for natural wind
f. A water softening plant should be used if the source of water is hard water.
g. Adequate ventilation should be maintained in plant room etc.

D. Checks before Testing

An air conditioning plant needs to be tested before commissioning it in regular service.
Following important checks are carried out before conducting the performance tests
a. Check all rotating parts for free movements
b. Check the lubrication in the bearings of the motor / pump and change the same if
required before starting the equipments
c. Remove dust accumulated on the windings and ventilation openings of the motor
d. Run motor on ‘No Load’ condition
e. Electrical connections , starters and controls must be properly tightened
f. Check alignments of motor to compressor, motor to pumps etc.
g. Check refrigerant is charged etc.

E. Performance Tests
a. Phase I Tests: This is carried out before acceptance of the plant and before formal
Completion. Such test is carried out to test the system rigorously and in diligent manner. If
this test is carried out correctly
b. Phase II Tests: Plant is again tested in next one year during seasons other than the seasons
of Phase I Test.

F. Troubleshooting of Refrigeration Systems

(Write about any 8 points out of 16 points given below)

Cause Symptoms Remedy

1.Compressor will not Start
High Head Pressure Starter overload cuts out Reset starter overload and
determine cause of high head
pressure
Defective Pressure switch Pressure switch contacts Repair or replace pressure
remain “open” regardless of switch
pressure
Loss of refrigerant charge Pressure switch contacts Check the system for leaks,
“Open” repair and recharge the
system
2. Compressor Short-Cycle
Incorrect setting of low Compressor cycling on low Reset low pressure switch
pressure side of pressure pressure switch differential
switch
Defective over load Compressor cycling on over Replace overload
load
Dirty or iced evaporator Compressor cycling on low Clean or defrost evaporator
pressure switch
3. Compressor runs continuously
Excessive load High dry bulb or not bulb Check the excessive outside
temperature in connectional air infiltration and excessive
area source of moisture
Dirty condenser Higher than normal head Clean condenser
pressure
Overcharge of refrigerant Higher than normal head Purge and remove excess
pressure refrigerant
Leaking System is turned off Hermetic compressor
4. System short of capacity
Low refrigerant charge Lower than normal head and Check system for leaks,
suction pressures repair and add refrigerant
Condenser blower and motor Higher than normal head Tighten or replace belts
belts slipping pressure
Expansion valve or strainer Lower than normal suction Clean expansion valve or
plugged pressure strainer
5.Head pressure too high
Dirty condenser Higher than normal head Clean condenser
pressure
Condenser air short circuiting Higher than normal head Remove abstraction or
pressure causes of short circuiting air
Air or non-condensable gases Higher than normal head Purge system
in the system pressure
6. Head pressure too low
Low refrigerant charge Sight glass indicates bubbles Check the system for leaks,
or liquid level valve on repair and added refrigerant
receiver indicates shortages
of refrigerant
Compressor valve leaking Lower than normal head Replace valve plates
pressure and pressures assembly or the complete
equalize rapidly when system hermetic compressor
is turned off
7. Suction pressure too high
Excessive load on system Compressor runs Remove conditions causing
continuously and capacity is excessive load
low
Expansion valve is struck in Lower than normal head Repair or replace expansion
“open” position pressure valve
Incorrect setting of expansion Lower than normal suction Adjust superheat setting 5o to
valve pressure 6oC
8. Suction pressure too low
Incorrect setting of expansion Suction line warm and Adjust superheat setting 5o to
valve system capacity low 6oC
Evaporator air volume low Abnormally cold suction line Increase air over the
and low suction pressure evaporator
Stratification of cool air in System capacity low and Increase air velocity through
conditional area temperature of return air low supply grilles
9. Compressor is noisy
Worn or scored compressor Noticeable knock in Replace the compressor
bearings compressor
Expansion valve is struck in Abnormally cold suction line Repair or replace expansion
“open” position or defective and high suction pressure and valve
lower than normal pressure
Overcharge of oil Oil sight glass in compressor Remove excess oil
completely filled during
operation
Hold down bolts loosening or Noticeable transmission of Loosen compressor hold
removed vibration from compressor to down bolts so compressor is
rest of unit and compressor freely floating in mountings
held firmly in mounting
10. Compressor loses oil
Leaks in system Presence of oil at piping Repair leaks and add
joints or connections refrigerant and oil as required
Expansion valve or strainer Lower than normal suction Adjust superheat setting 5o to
plugged pressure 6oC
11. Compressor and condenser fan motor will not start
Power failure Test lamp or voltmeter Call power company
indicates no voltage at
disconnect switch
Faulty wiring Compressor contactor or Check wiring and make
starter and fan relay do not necessary repairs
become energized
Low voltage Starter overload tripped Reset and check for cause of
tripping
12. Compressor will not start, but condenser fan runs
Defective compressor motor Voltage available at Replace the compressor
compressor but an open
winding, ground or stuck
compressor prevents
operation
Defective compressor Overload contacts remain in Replace overload
overload “open” position
Defective starting capacitor Starting capacitor does not Replace capacitor
indicate rated capacitance
13. Compressor fan motor will not start, but compressor runs
Defective fan relay Relay contacts do not “make” Repair or replace relay
when coil is energized
Defective fan motor Test lamp or voltmeter Replace fan motor
indicates no voltage available
at motor
14. Condenser fan motor runs, but compressor hums and will not start
Low voltage Test lamp or voltmeter Check line voltage.
indicates inadequate voltage Determine the location of the
at compressor voltage drop
Failure of one phase
Defective potential relay
15. Compressor starts, but cycles on overload
Low voltage
Defective running capacitor
Unbalanced line
16. Evaporator fan motor will not start
Fuse blown
Faulty wiring
Defective fan motor
Test lamp or voltmeter Check fuses and wiring
indicates no voltage from one
phase to ground
Potential relay contacts do Replace potential relay
not close for starting
Test lamp or voltmeter Check line voltage.
indicates inadequate voltage Determine the location of the
at compressor voltage drop
Running capacitor is Replace the capacitor
completely dead
Test lamp or voltmeter Check wiring, call power
indicates unequal phase company
voltages
Test lamp or voltmeter shows Replace blown or defective
voltage on line side of fuse
disconnect switch but not on
unit side
Evaporator fan relay do not Check the wiring and make
become energized necessary repairs
Test lamp or voltmeter Replace fan motor
indicates voltage available at
motor