CONTENTS PART I - MECHANICAL EQUIPMENT y SECTION PAGE, 1 GENERAL INFORMATION 1,1 General Data .... 1.1.1 Introduction ... Overall Plant .. Compressor . Condenser Recelver Heat Interchanger Dryer .......- Condenser Water Regulating Valve King Solenoid Valve ......... Cooling Coil Solenoid Valve... Liquid Line Strainer .......... ‘Thermal Expansion Valve .... Evaporator Pressure Regulator High Pressure Control Switch . Low Pressure Control Switch . Water Pressure Failure Switch Oil Pressure Safety Switch... Room Thermostats «..« ional Description . . . General . . Compressor . Condenser Condenser Water Regulating Valve | | Receiver . orven eee eee ener Heat Interchanger .... King Solenoid Valve Cooling Coil Solenoid Valve . ‘Thermal Expansion Valve . . Evaporator Pressure Regulator High Pressure Control Switch . ‘Low Pressure Control Switch . Water Pressure Failure Switch Oil Pressure Safety Switch ... Room Thermostat Strainers .......eeseeeee Cut-out and Hand Expansion Valves . Automatic Control Sequence ... 2 3 4 6 7 8 9 1 Hi 1: 1: L i 1 Lv ui 0 ia} 2 3 4 5 6 7 8 BPP PEO ee AP} i 1 2 3 4 5 6 7 8 bee PPP PPP Pep pe peg WENNER EYNNNNNNHNNND SESSERSRES 1.3 Detai led Description . Compressor « Condenser Condenser Water Regulating Valve | | Receiver .SECTION CONTENTS Receiver-Condenser Equalizing Line Relief Valve. . Dryec eee tees Heat Interchanger King and Cooling Coil Solendid Valves | + ‘Thermal Expansion Valve ..... Evaporator Pressure Regulator . High Pressure Control Switch ........+ Low Pressure and Water Failure Switches . Ei Room Thermostats .......e++eeeeee 2 INSTALLATION we 2.1 General........ as . a 2.1.1 Space Requirements... a 20 2.1.2 Cleanliness .......4 - -- 2.1.3 Rigging ........0+06 : . 2,2 Compressor Drive .........- . +e 2.2.1 Lubricate Motor ...... ei Ee ; 212.2 Check Direction of Motor Rotation | || a 2.2.3 Reverse Oil Pump (if Necessary) ... goone 2.2.4 Install and Align Flexible Coupling... o 2.2.5 Secure Motor to Base .........06 seaee Siaea) Piping and) Wiring |... =|... 2-01 E eomis Mbintracuction mists snl eee peter 3.2 Refrigerant Piping... .se+eeeeeeee 3.3 Packless Valves .....eeseeereree Thermal Expansion Valves ........+ ‘Thermal Expansion Valve Remote Bulb . Solenoid Valve .....++esseeceees ‘Temporary Suction Filter ......++++ Condenser Water Piping . coerce WEES oo0g6an90500 Banner fay agepPreasureland Teak (lesths atest ler tet lalate alata 2.5 Evacuation and Dehydration 2.5.1 Preparation......+ 2.5.2 Dehydration Procedure . 2.6 Compressor Lubrication. ...+.++eseseseeessrecens 2.7 Initial Start-Up ....2.-2scsecsesccrscoreres 2.7.1 Preliminary System Inspection ...+-++..++ 2.7.2 Charging Refrigerant and Starting.......... 2.7.3 Control Switches . ae teercceee 2.7.4 Condenser Water Re; seeeeee 2.7.5 Compressor Capacity Control .ee++eeseeee 2.7.6 Change Compressor Oil .....+eeeeeeeeee 2.7.7 Final System Inspection . aeteaccoreeSECTION CONTENTS 3 OPERATION 4.3.1 3.1 Principles of Operation ..........5 3.1,1 Principles of Refrigeration . . . 3.1.2 Cycle of Operation......... 3.2 Characteristics of Refrigerant-12 ..........0ee006 3.3 Safety Precautions........2..2+-0-0+ ahael il Operating “eh ecn must tenis 3.3.2 Handling Refrigerant-12..... 3.4 Operating Procedures ....+++ee+eeeeee 3.4.1 Normal Operation ....... 0.005 3.4.2 Split Plant Operation .....+++.seeceeee Sedes ee startin ee eee eee erent een rr 3.4.4 Operating. ...... peer 3.4.5 Changeover from Split Plant to Normal Operation 3.4.6 Changeover to Standby Compressor ........+ 3.4.7 Changeover from Normal to Split Plant Operation 3.4.8 Securing Entire Plant....... Ee 3.4.9 Pumping Down ..........- a 3.4.1 i neers 3.5 Operator's Maintenance .........-02+-20-00+ 3.5.1 Charging Refrigerant ...........00605 3.5.2 Removing Refrigerant........+seeeeee 3.5.3 Refrigerant Undercharge........2.+.0+ 3.5.4 Refrigerant Overcharge ........2.+00+ 3.5.5 Refrigerant Flooding «.....2....00005 3.5.6 Compressor Lubrication......... 5 3.5.7 Compressor Capacity Control ..... - 3.5.8 Control Switches ........eeeeee . 3.5.9 Solenoid Valves...... 5 3.5.1 ° 4 TROUBLESHOOTING 4,1 Introduction .... wee 4.2 Abnormal Operating Pressures/Temperatures 3 4.2.1 High Head Pressure ...... 7 4.2.2 Low Head Pressure .. s s 4.2.3 High Suction Pressure... .. s 4.2.4 Low Suction Pressure ........0000005 4.2.5 Compressor Crankcase Cold . eee 4.2.6 High Crankcase Temperature ..... ae 4.3 Erratic Operation .... mage -eessee+ sees eee Compressor Will Not Start .........06 PAGE iiiCONTENTS SECTION 4.3.2 Compressor Short Cycles on High Pressure Cut-out . 5 4.3.3 Compressor Short Cycles on Low Pressure Cut-out . i 4.3.4 Compressor Runs Continuously « see caeeees . ¢hf\ fetinheitien tema 55 poop acon Goousosanos00eCDD z 4.4.1 Oil Leaves Compressor Crankcas¢.........0065 . 4.4.2 Oil Does Not Return to Crankcase ..+....seeeee . 4.4.3 Low Oil Pressure or No Oil Pressure......0++0+ : 4.4.4 Compressor Cuts Out on Low Oil Pressure ....... - 4,5 System Noises......... Beer 0 5 4.5.1 Compressor Noises coer z z 4.5.2 Pipe Rattles... peers é 3 4.5.3 Hissing .. sence : a 4.6 Capacity Control Troubles. . eee ere r 4.6.1 | Compressor Will Not Unload......+2.++06 : 4.6.2 Compressor Will Not Load ..essseseeesee . 4.6.3 Any One Cylinder Will Not Unload .......4+ . 4.6.4 Any One Cylinder Will Not Load.......2. 22 3 4,6,5 Compressor Noise Varying with Unloading... . . 4.6.6 Rapid Unloader Cycling... .ssseseceseree . Beng Cooling CotlUtroubles "leis risers leer rents cia . — 4.7.1 Loud Hissing at Thermal Expansion Valve ....... + . 4.7.2 Partial Frosting of Coil-Failure to Cool ...+++++ 5 4.1.3 No Frosting of Coil-Failure to Cool ..........05 6 4.7.4 Complete Frosting of Coil-Failure to Cool....... + - se Se oo Bt a bY Coo Ling eae yet eters . 5 MAINTENANCE bs Sor. ec rectd on eee todo eleted fetes eaTele tate estates eee tor 5.2 Preventive Maintenance Schedule ... . ao iv Hourly... Daily... Weekly, . . ‘Monthly . . Quarterly. Annually. . fOpetiin ge] Oystoti estar tse ete laa iat tete tata eteratet tetera erate totals Refrigerant Charge and Leaks ....... .1 Refrigerant Charge ........ 5.4.2 Testing for Piping Leaks. . 5.4.3 Testing for Condenser Leaks. .CONTENTS SECTION PAGE 5.5 General Compressor Maintenance. . . . Sane eetabr cavou ne ee eee tee eee er 2 ss B-4 5.5.2 Capacity Control System......... . ‘ 55 5.5.3 Operating Pressures and Temperatures. 0 . 5-5 5.5.4 Compressor Noises.....-.+.0++ eer 5-5 5.6 Disassembly, Inspection and Reassembly of Compressor . . . 5.6.1 Introduction..........+4+ eer BURA Uneiiseiten Seqosgaccoac a 5.6.8 Pumping Down........... a6 5.6.4 Draining Ol... 0.0.6. ae 5.6.5 Cylinder Heads 0 5.6.6 Valve Plate and Suction and Discharge Valve Dise. | ‘ 5.6.7 Cylinder and Unloader Sleeves.........- 5.6.8 Hand Hole Cover......... 3 5.6.9 Connecting Rods, Connecting Rod Bearing Inserts Pistons and Piston Pins ............ rs Boge) G5 5.6.10 Crankshaft Seal... ...+..- oco0g0 5-16 5.6.11 Capacity Control Valve and Strainer en 5-18 5.6.12 Crankshaft. .......+.00+ os0cen 5-19 5.6.13 Main Bearings........... eee 5-20 la Eves] 4morleeninn Meee peer ners eee 5-22 _ 5.6.15 Unloader Power Element. ... ceerete 5-24 cs 5.6.16 Oil Return Check Valves... . aoe 5a24. 5.6.17 Oil Screen ..........-.. eer 5-255 5.6.18 Oil Pressure Regulator... .. eeeer 5-26 5.6.19 Pressure Relief Valve ..... aren 5-26 5.6.20 Suction Strainer.......... eee 5-26 Bil CHEESE oe vn op vougaaegegeaugoucocce a sees B87 ~ 5.7.1 Water Supply and Operating Pressures ... ss Sere 2 5.1.2 Purging. ..ssseeerereecrererecee 5 ooo | ail 5.7.3 Cleaning and Inspection...........++. 5 ee goa) 5.7.4 Tube Repairs .......-..sesereeee 5 30 5-28 G,8 ROceiver .......5.eseces sess seccesseecrercreecrers > 5-90) Sr De reser eee eet eta 7 5-30 6,10 Heat Intarchanger ........++-2++see-seeee-eee-------:- «BO 5.11 Liquid Line Strainer and Controls. . . er Bert se. 681 5.12 Controls, Instruments and Valves.........+++-+ 3 5-31 5.12.1 Packless Valves .....---+++-+eseeee : 5-31 5.12.2 Relief Valve . . a : - ss 5-31 5.12.8 Suction Line Thermometer . . eer 3 5-32 5.12.4 Thermal Expansion Valve... ere 3 5-32 5.12.5 Solenoid Valves... .. : eer B 5-32 5.12.6 Water Regulating Valve... .. ere ; 5-33CONTENTS SECTION 5.13 Repair Parts .......6. 5.13.1 Inspection 5.13.2 Ordering Parts . . 5.18.3 Returning Parts .... 6 DRAWINGS Refer to "List of Figures and Drawings". ...++++e+eeeeeeeees PART II - ELECTRICAL EQUIPMENT 1 COMPRESSOR MOTOR 2 COMPRESSOR MOTOR CONTROLLER vilPai LIST OF FIGURES AND DRAWINGS FIGURE PAGE 1.1 SME60 Compressor .........ee+eeee eee 7 % 1-11 1.2 Oil Pressure Regulator (Relief Valve) ....... > 1-12 1.3 Oil Return Check Valve eee eee a . 1-12 “ igi | AS ES gue gpeqqna9suGao0doosonae ” 1-12 1.5 Suction Valve Lifting Arrengement ......... 3 : 1-18, 1.6 Capacity Control System... ....... 0.0000 ° 5 1-15 Dismantled Coupling ..... Seribing a Line to Indicate Position of Motor Shaft, When Running . Preliminary Alignment . . Angular Misalignment. . . Parallel Misalignment ..... Dial Indicator Setup to Check Angular Alignment .. - Dial Indicator Setup to Check Parallel Alignment Packless Valve Stem Position ....... Packless Valve Installation - Preheating .. . . PY PPO NNONNDNNDN be bbb bearonneie Ap no no no no NO RO NSE A HRD BD ED ND pee Sob bad hh ; -10 Paekless Valve Installation - Heating . 10 -11 Packless Valve Installation - Brazing . ~10 12 Thermal Expansion Valve ......... LL 18 Thermal Bulb Installation ......... Berea) 14 Thermal Bulb Insulation .........- eee Bate 15 Temporary Suction Filter ......... pec eeaas 3.1 Compression Refrigeration Cycle vee 88 3.2 Gas Paths Through Compressor . +. 4 3.3 Charging or Drain Line....... ++. S-16ia Suction and Discharge Valve Seat Height Typical Compressor Assembly........ Typical Compressor Internal Parts .. Suction and Discharge Valve Assembly Valve Plate, Suction Valve and Clips . . Sleeve Puller .. Removing Sleeve Position of Cylinder Sleeves oe Testing Unloader Operation ... . Position of Piston Pin Retaining Clips . fg Eu eeeenee Menge ae anen ney nae Installation of Sleeve ‘Type Rotary Seal”! |)?! Compressor Hand Hole Cover and Capacity Control puller showlaar (0). Svetleiass cle ssaee Using Bearing Puller to Remove a Seal End Main Bearing Using Bearing Puller to Install a Seal End Main Bearing Pump End Main Bearing Position ......... Seal End Main Bearing Position Setting Oil Pump End Play (Typical Bearing Head)... Unloader Fork Height ...............- Unloader Power Element e 5 g EI ea é & g 5 = g £ 8 4 a é y 5 5 & a verges ggagaggaggGaGagaaa RRREEEL EERE EE Oakaameme SESSRSERERESES & Ree sar PEaaraaaagannagnnaaaaan &LIST OF FIGURES AND DRAWINGS FIGURE i PAGE a 6.1 Diagrammatic Piping Layout.....- : 6-1 6.2 Compressor Unit Assembly (Sheets 1. D 6-3 6.3 Compressor Sectional Assembly .. . . 6-5 aa 6.4 Condenser Assembly (Sheets 1-4) . . . 6-7 a 6.5 Receiver Assembly (Sheets 1-2)... : 6-9 6.6 Heat Interchanger Assembly... ... zs 6-11 6.7 Dryer Assembly......---..--- : 6-13 6.8 Condenser Water Regulating Valve. . 3 6-15 6.9 King Solenoid Valve.....-.....- 5 6-17 6.10 Cooling Coil Solenoid Valve ...... ' 6-19 6,11 Thermal Expansion Valve. . . 5 6-21 6.12 Evaporator Pressure Regulator. oe 6-23 6.13 High Pressure, Low Pressure, Control Switches. ......ssesersseene 0 meets 6-25 6.14 Oil Safety Differential Pressure Control Switch .... er 6-27 Gi GREER So osoccss90cce peancscuncccs po00 6-29 6.16 Certification Data Tables... . reer er 6-31 6.17 List of Equipment and Drawings (Sheets 1-2)...... 5 6-33 LIST OF TABLES TABLE PAGE «~~. 3.1 Physical Properties of Saturated Refrigerant-12 ....... see 3-5 a 3.2 Operating Pressures and Temperatures ........ een 3-21 5.1 Torque Values for Compressor Bolts.....- eee eCers 5-6 5.2 Compressor Wear Limits.........++.0+ a ° 5-6SECTION 1 3 GENERAL INFORMATION Ld. GENERAL DATA 1,1,1 Introduction This manual covers the description, installation, operation and maintenance of the 3.0 ton capacity ships stores refrigeration plant furnished by Carrier Air Conditioning Com- pany as specified on the approval and procurement record page. For a diagrammatic piping layout refer to figure 6.1. For a list of equipment refer to figure 6.17. 8 y Approved design data and characteristics of the main equipment are given in para- graphs 1.1, 2 through 1.1.18 below, Outline dimensions, weights, and other data are shown. | on the drawings included in section 6. A general, functional description of the equipment is given in paragraph 1.2. A detailed description is given in paragraph 1.3, ‘The compressor motor and motor controller are covered in part II. 1.1.2 Overall Plant No, of Ships Stores Refrigeration Plants/Ship a. No. of Compressor Units/Plant 2 Refrigerant Charge 199 Ib of Refrigerant-12 Applicable Iustrations Figures 6,1, 6,16 and 6,17 1.1.3 Compressor Assembly No, /Manufacturer 5MF60-219/Carrier * Capacity (Operating) 3,0 tons (Design: 11,61 tons) 6 Suction Temperature (Operating) -20°F (Design: 25°F) i Condensing Temperature 105° 40°C ; No. of Cylinders 6 v Bore 2-1/2" a Stroke ae Speed 1750 rpm ‘Type of Drive Direct Flexible Coupling \ Flexible Coupling Flange Spacing _-2-7/16" (Dimension E, Figure 2.3) \ Motor Horsepower 15 hp Electrical Characteristics 440 volts, 3 phase, 60 cycle $4 Initial Oil Charge 13 pints se Normal Operating Pressures: i High Side 126.6 psig : Low Side 0,58 psig ss Capacity Control: : Control Point > 2" Vacuum No. of Controlled Cylinders 4 Step 1 of Unloading: Uiiloads one cylinder - 83-1/3 Capacity Step 2 of Unloading: Uploads one cylinder - 6-2/8 Capacity Oc J} . GENERAL INFORMATION Step 3 of Unloading: Step 4 of Unloading: Applicable Iustration 1.1.4 Condenser Assembly No. /Manufacturer . ‘Tube Surface ‘Type of Surface No. of Tubes Tube Size Shell Diameter Overall Length No. of Passes No. of Renewable Zinc Rods Sea Water Quantity (Operating) Water Velocity Water Pressure Drop Water Inlet Temperature Water Outlet Temperature Capacity (feat Rejection Rate) ‘Materials: Shell ‘Tubes and Tube Sheets Tube Supports Water Heads Applicable Ilustration 1.1.5 Receiver Assembly No, /Manufacturer Type Shell Diameter > Overall Length = Refrigerant=12 Capacity Applicable Ilustration 1.1.6 Heat Interchanger Part No, /Manufacturer , Overall Length Shell Diameter . Comnections: Liquid Suction Applicable Tlustration Unloads one cylinder - 50% Capacity Unloads one cylinder - 33-1/3% Capacity Figures 6.2 and 6.3 9W70-179/Carrier 91.8 sq ft Fined "OD x . 049" wall x 4! long 8-5/8" OD 57-9/16" 2 4 10 gpm (Design: 58 gpm) 92 ft/sec Design: 3.56 ft/sec) +1psi (Design: .8 psi) 85°F 96.8°F (Design: 91.3°F) 57, 000 biuh (Design: 176, 000 btuh) Steel 90-10 copper nickel Steel Gun Metal Figure 6.4 8M35-304/Carrier Horizontal 14" oD 44-3/8" 280 Ib Figure 6.5 CX-10NE/Precision 23" an 7/8" OD 2-1/8" OD Figure 6.6 se {Agila 1.1.8 1.1.9 1.1.10 ede 11,12 GENERAL INFORMATION Dryer Part No. /Manufacturer Dryer Cartridge Part No. Size of Connections Dessicant, Applicable Ilustration Condenser Water Regulating Valve Part No. /Manufacturer Size Capacity Water Pressure Drop Applicable Mlustration King Solenoid Valve Part No. /Manufacturer Size of Connections Voltage Applicable Tllustration Cooling Coil Solenoid Valve Part No, /Manufacturer Size Connections Voltage Applicable Hustration Liguid Line Strainer Part No. /Manufacturer Screen Cartridge Part No. Size of Connections Thermal Expansion Valve Part No./Manufacturer Type Equalizer Capacity O°F Room 33°F Room Superheat Setting Applicable Illustration 7415M/Henry Valve 757A, 3/8" OD. Activated alumina Figure 6.7 246NP16F/Penn Controls 2" PS 58 gpm 10 psi max, Figure 6.8 $2N25-1/Aleo Valve 5/8" OD. 440 Volts a-c Figure 6.9 NS120/Alco Valve 1/2" 0D 115 volts a-c Figure 6.10 8760A/tlenry Valve U201-5A 1/2" OD ‘TCLN100FW55/Alco Valve Internal - 69 tons @75 psi differential 1.2 tons @60 psi differential 8-10°F Figure 6,1111,13 11.14 1.4,15 1.1.16 eeae7, 1-4 GENERAL INFORMATION Evaporator Pressure Regulator Part No, /Manufacturer Size of Connections Regulator Settings: Chill Room at 33°F Chill Room at 0°F Applicable Hlustration High Pressure Control Switch ‘Manufacturer Model No. Nominal Voltage Cut-in Point (Close) Cut-out Point (Open) Range Differential Pressure Connection Applicable Illustration Low Pressure Control Switch Manufacturer Model No. Nominal Voltage Cut-in Point (Close) Cut-out Point (Open) Range Differential Pressure Connection Applicable Illustration Water Pressure Failure Switch ‘Manufacturer ‘Model No. Nominal Voltage Cut-in Point (Close) Cut-out Point (Open) Range Differential Pressure Connection Applicable Tllustration Oil Pressure Safety Switch Manufacturer Model No, 2255N/Alco Valve 7/8" OD 19.7 psig Bypass Regulator Figure 6.12 American Standard Controls Div. 220-10-NB7 440 volts a-c 140 psig 160 psig 60 to 350 psig 15 to 50 psi 7/16-20 UNF-2B Figure 6.13 American Standard Controls Div. 220-10-NB3 440 volts a-c 8 psig 5" vacuum 20" vacuum to 80 psig 9 to 30 psi 7/16-20 UNF-2B Figure 6.13 American Standard Controls Div. 222-10-NB3 440 volts ac 15 psig 5 psig 20" vacuum to 80 psig 9 to 30 psi 7/16-20 UNF-2B Figure 6.13 American Standard Controls Div. 222-10-NB201.1.18 2 bedi data on plant components is given in paragraphs 1.1.1 through 1.1.18. GENERAL INFORMATION Nominal Voltage Cut-in Point (Close) Cut-out Point (Open) Range Differential Pressure Connections Applicable Hlustration NOTE 1. Compressor stops when oil 440 volts a-c 18 psi differential 12 psi differential 7 to 70 psi 4 to 12 psi 1/4" SAE Figure 6.14 safety switch opens. 2. Oil safety switch time delay relay in compressor motor controller to permit 10 - 15 seconds opera- tion under low oil pressure at start-up. Room Thermostats Manufacturer Model No. Bulb Dimensions/Type Differential Range Capillary Tubing Length Voltage ‘Thermostat Settings for 0°F Operation: Cut-in Point (Close) Cut-out Point (Open) American Standard Controls Div. 222-10-NN 1-1/8" OD x 6-1/2"/NN & 5 to 2°F k 10 to 50°F 20" 115 volts a-c ar -3°F ‘Thermostat Settings for 33°F Operation: Cut-in (Close) Cut-out Point (Open) Applicable Ilustration FUNCTIONAL DESCRIPTION General 36°F 33°F Figure 6.15 The ships stores refrigeration plant has the capacity to maintain the freeze room at 0°F and the chill rooms at either 33°F or 0°F. The spaces are cooled by the evaporation of refrigerant-12 in the cooling coils mounted on the bulkheads. The plant (figure 6.1) consists of two interconnected condensing units which supply liquid refrigerant and a set of cooling coils for each refrigerated space. Each condensing unit includes compressor and driving motor, condenser, receiver, dryer, heat interchanger, valves, piping, and controls for automatic operation. Automatic controls are also provided to regulate refrigerant flow through the cooling coils in each refrigerated space. DetailedGENERAL INFORMATION Each condensing unit has a capacity of 3.0 tons of refrigeration, so that one unit is sufficient to maintain the refrigerated spaces at the desired temperatures during normal operation, For initial pulldown or other heavy load conditions both units must be in opera~ tion. Capacity variation for light loads is provided by a capacity control system integral = with the compressor. ‘That part of the plant (figure 6.1) extending from the compressor suction valve up to the thermal expansion valve is known as the high, or high pressure side. The high side includes the compressor, condenser, reociver, dryer, heat interchanger and #OTSEeTa Valves, ‘That part of the plant from the thermal expansion valve up to the compressor suction valve is known as the low, or low pressure side of the plant. The low side includes {he thermsl expansion valve, cooling colle, evaporuior pressure regulator, and compressgr suction valve. peetoniatve= 1,2.2 Compressor ‘The compressor (figures 6.2 and 6.3) withdraws the refrigerant suction gas from the cooling coils and delivers it to the condenser at such a pressure that its heat can be absorbed by sea water at ordinary temperatures. 1.2.8 Condenser ‘The condenser (figure 6,4) is a shell and tube heat exchanger. Sea water flowing through the condenser tubes serves to condense the compressed gaseous refrigerant flowing over the tubes by absorbing latent heat from it. At the same time, the refrigerant is also lowered in temperature. 1.2.4 Condenser Water Regulating Valve The water regulating valve (figure 6. 8) located in the condenser water outlet line is actuated by the refrigerant head pressure in the condenser and automatically regulates the water flow through the condenser. 1.2.5 Receiver ‘The receiver (figure 6.5) serves as a liquid refrigerant reservoir when there are surges due to load changes in the system; as a storage space when pumping down the system; and as a liquid seal against the entrance of refrigerant gas into the liquid line. ‘The receiver is equipped with a liquid level indicator. 1.2.6 Dryer i i‘ ‘The dryer (figure 6.7) is installed in the main liquid line to keep the system free of moisture. The dryer is a cylinder containing a cartridge filled with activated alumina, ~ ‘The dryer is equipped with an indicator which shows the moisture content of the refrigerant, 1-6GENERAL INFORMATION 1.2.7 Heat Interchanger ‘The heat interchanger or exchanger (figure 6.6) is located in the refrigerant liquid~ suction lines to improve plant performance by subcooling the liquid refrigerant and super- heating the suction gas. The heat interchanger also eliminates liquid refrigerant return to the compressor. 1.2.8 King Solenoid Valve ‘The king solenoid valve (figure 6.9) in the main liquid line from the receiver stops the flow of refrigerant to the cooling coils when the compressor is stopped by the motor con~ froller stop button, overload or low voltage relay, high pressure control switch, or oil pres~ sure safety switch, 1.2.9 Cooling Coil Solenoid Valve ‘The cooling coil solenoid valves (figure 6. 10) are located in the liquid lines to the refrigerated spaces ahead of the thermal expansion valves (see figure 6.1). ‘The solenoid valves are actuated by the room thermostats opening or closing in response to the action the thermostats.. Refer to paragraph 1.2.16. 1.2.10 ‘Thermal Expansion Valve A thermal expansion valve (figure 6.11) controls the quantity of liquid refrigerant that passes through each cooling coil circuit. The valve is designed to maintain a constant degree of superheat of the refrigerant gas leaving the cooling coil circuit regardless of suction pressure, The expansion valve provides automatic expansion control and prevention of liquid refrigerant return to compressor. 1,2.11 Evaporator Pressure Regulator © An evaporator pressure regulator (figure 6.12) is installed in the suction line from a refrigerated space (kept at a temperature higher than 0°F) to prevent excessive tempera- ture difference between the space and the refrigerant in the cooling coils. 1,2,12 High Pressure Control Switch ‘The high pressure control switch (figure 6,13) stops the compressor in the event of excessive discharge pressure. The compressor may be started again by pressing the motor controller start button when the discharge pressure drops to the cut~in setting of the high pressure control switch and the cause of excessive discharge pressure has been elimi- nated. 1.2.18 Low Pressure Control Switch ‘The low pressure control switch (figure 6.13) starts and stops the compressor at the proper predetermined suction pressures. 1-7GENERAL INFORMATION 1.2.14 Water Pressure Failure Switch ‘The water pressure failure switch (figure 6.13) stops the compressor in the event of failure of water pressure to the condenser. The compressor will start again when water pressure is restored to the level of the cut-in point of the water pressure failure switch, S 1.2.15 Oil Pressure Safety Switch The oil pressure safety switch (figure 6.14) is a differential pressure control which stops the compressor if compressor lubricating oil pressure drops below a minimum of 12 psi above crankcase pressure during operation, The switch is interlocked with a time delay relay in the compressor motor controller to permit an operating period of 10 - 15 seconds under low ofl pressure at start up and allow oil pressure to build up to a minimum of ‘ 18 psi above crankcase pressure, When the compressor is stopped by this switch, it may be restarted by pressing the motor controller start button after the cause of low oil pressure has been eliminated, 1,2,16 Room Thermostat Tre room thermostats (figure 6.16) control the flow of refrigerant to the cooling coils by opening or closing the cooling coil solenoid valves. The thermostat completes the electrical circuit to the solenoid valve, thus energizing and opening the valve, when the space temperature rises above the thermostat cut-in setting. The thermostat opens, de-energizing and closing the solenoid valve, when the desired space temperature (thermostat cut-out setting) is obtained. Each solenoid (figure 6. 1) is provided with a thermostat, Where a space is provided with two solenoid valves, the thermostats are wired so that either one will actuate both solenoid valves (see figure 6.1). 1:2.17 Strainers Since the refrigerant is capable of removing particles of dirt and scale from sur- faces, refrigerant strainers are provided in the compressor suction manifold and an oil strainer is provided in the crankcase. A liquid line strainer is also installed ahead of each cooling coil solenoid valve. 1.2.18 Cut-out and Hand Expansion Valves Cut-out valves (12, figure 6,1) permit the automatic refrigerant controls at the cooling coils to be isolated for service while plant operation can be continued by using hand 4 expansion valves (13). 1.2.19 Automatic Control Sequence \ Each refrigerated space is fitted with a solenoid valve (10 figure 6,1) and a thermal expansion valve (11) for each cooling coil circuit, The solenoid valve (10) is actuated by the a room thermostat which has its thermal control bulb in the refrigerated space. 1-8ae GENERAL INFORMATION ‘The thermal expansion valve (11) is actuated by its control bulb located on the re~ frigerant suction line from the coil circuit. (Note that the freeze room and chill room No.2 each use two thermostats in parallel to control the two solenoid valves.) ‘The thermal expansion valve regulates the flow and expansion of the refrigerant in the cooling coils and is factory set to remain open as long as the temperature of the refriger- ant gas at the point of bulb attachment is 8° - 10°F or more above the refrigerant saturation temperature. In this way, the cooling coils are provided with a maximum amount of refrig- erant while liquid refrigerant is prevented from surging back to the compressor. As the refrigerated space is cooled to the desired temperature, the room thermo- stat(s) open, closing the solenoid valve(s) (10) and cutting off refrigerant to the thermal expansion valve(s) (11) and cooling coils. (An open solenoid valve can be detected by observing the contacts in the thermostat, which should be closed, or by a humming sound when the ear is pressed against the valve casing.) After the last solenoid valve closes and the supply of liquid refrigerant is cut off to all coil circuits, the compressor continues to operate for a short time until the suction pressure drops to the cut-out setting of the low pressure control switch opening the switch contacts and stopping the compressor motor. As soon as refrigerated space temperature rises to or above the cut-in sotting of = a room thermostat, the solenoid valve(s) (10) open allowing liquid refrigerant to flow to the thermal expansion valve(s) (11). Liquid refrigerant is thus allowed to flow to the cooling — coils, The refrigerant expands in the coils and the suction pressure rises. When the suction pressure rises above the cut-in setting of the low pressure control switch, the switch contacts close and the compressor motor starts. 1.8 DETAILED DESCRIPTION “1.3,1 Compressor ‘The compressor (figure 1.1) is a reciprocating, single acting unit, The compressor unit (figure 6.3) is equipped with a capacity control system, a pressure relief valve, and an oil pressure safety switch, 1, Crankshaft, The alloy steel crankshaft (16, figure 6.3) is rifle drilled and grooved externally for oil passage. Its bearing surfaces are hardened and polished, It is mounted in insert type main bearings, babbitt lined, and between bronze thrust bearings (36, 37) with the addition of a hardened steel thrust washer (88) at the seal end. 2, Cylinders, Replaceable cylinder sleeves (24, 25, figure 6,3) in the cylinder block and replaceable valve plates (6) located between the cylinder block and the cylinder heads (13) form the cylinder walls. The discharge valve assembly (4) mounted over the opening in the valve plate (5) forms the cylinder head. The cylinder block, which is inte~ grally cast with the crankcase, valve plates, and cylinder heads are grey iron castings. The cylinder sleeves are nickel alloy iron castings. 3. Piston Assembly. Automotive type pistons (22, figure 6. 3) of alloy iron fitted with two compression and two oil control rings are used in conjunction with H-section con- 1-9GENERAL INFORMATION necting rods of high carbon steel. Connecting rods are provided with split insert bearings (23), babbitt lined, and bronze bushings drilled and grooved for oil passage to piston pins, Piston pins are of nickel steel, push-fitted, and held in place by spring wire lock rings. 4, Valves. Valving is accomplished by non-flexing ring type suction (6, figure 6.3) and discharge (4) valves of Swedish "flapper valve" steel. These valves are actuated by changes in cylinder pressure. Ports in the cylinder sleeve (24, 25) are closed by the suction valve which seats on the sleeve and lifts against conical springs (7) in a recess on the underside of the valve plate (5). Mounted atop the valve plate, directly over the cylinder opening, is the discharge valve assembly which consists of the valve guide, inner seat and valve. The annular space between the valve plate and the discharge valve assembly is closed by the discharge valve, which seats both on top of the valve plate and its inner seat and lifts against conical springs in the discharge valve guide. Figure 3.2 illustrates operation of valves. . 5. Refrigerant Gas Flow. Compressed gas discharged into the cylinder head (13, figure 6.3) passes into the discharge manifold and from there into the discharge line through a stop valve (70) located atop the machine. Suction gas enters through a stop valve (69) located at the pump end of the compressor and passes through suction strainer (15) in the suction manifold before being drawn into the eylinders, Figure 3.2 shows gas paths through ‘the compressor. ; 6. Relief Valve. ‘The compressor is provided with an internal relief valve (71, figure 6.3) set at 350 psi. If for any reason a pressure of 350 psi greater than the low side pressure should develop in the high pressure side of the compressor, the relief valve will open and permit the refrigerant gas to discharge from the high to the low pressure side, 7. Lubrication, The seal end and pump end main bearings, and connecting rod bearings (23, figure 6.3) are lubricated by forced feed through passages in the crankshaft, (16) by a direct driven oil pump (21). The cylinder walls and piston pins are splash lubri- cated, Oil from the seal end bearing is fed directly through a cartridge type oil pressure relief valve (9) to the shaft seal compartment, At normal operating oil pressures, the oil pressure relief valve (9) opens partially and meters sufficient oil to keep the shaft seal (27) constantly immersed. At ex- cessive oil pressures this valve opens fully and relieves the oil pressure in the shaft seal compartment by allowing oil to return to the crankcase (1) through an overflow passage. Oil level is indicated by a bull's-eye sight glass in the side of the compressor hand hole cover @). The lubrication system is protected against foreign matter by permanent mag- nets in the oil drain and pump intake plugs and by a fine mesh screen 20A) in the lower part of the crankcase (1) through which screen oil is drawn by the pump. 8, Oil Pump, The oil pump (figure 5.20) located in the pump end bearing head (21, figure 6.8) is of the positive displacement gear type and is manually reversible, The pump will deliver oil under pressure only when its rotation coincides with the direction of rotation shown by the arrow on the ofl pump cover. 9. Oil Pressure Regulator (Relief Valve). Correct oil pressure is vital in main- taining adequate lubrication and satisfactory unloader operation, The compressor is designed 1-10a GENERAL INFORMATION grr vauve oiscHaRe ye ~~. swut oni VALVE HA OOF a 1% tow pressure ontnou. cow, ? . capaory c va" ips. \ WN CONTROL VALVE eam ou pnessvne DOWEL WOLE oe j. _~, on_puuP reskin : i Bio! = ® crease) Figure 1,1 - 5MF60 Compressor ~~ NOTE “)% Oil pump pressure gauge is located on condensing unit gauge board, Install a control oil pressure gauge where shown above when checking or adjusting capacity control system, a se gO Sa leneGENERAL INFORMATION to operate with an oil pressure 45 to 55 psi above suction pressure. An oil pressure regula- tor (relief) valve (9, figure 6.3) is located on the side of the crankcase (1) adjacent to the shaft seal housing. ‘This valve is a non-adjustable, cartridge type pressure relief valve (figure 1.2), % A iL RETURN Shed ite ES ~e fe i J i coast : a woe ree / fee ¥ » oadker Ps LEAF TYPE } Figure 1,2 - Oil Pressure Figure 1.3 - Oil Return Regulator (Relief Valve) Check Valve 10, Oil Return Check Valves. The oil return check valves (figure 1.3) prevent loss ~ of oil which may be caused by foaming upon compressor start-up, and allow oil return from the suction manifold to the crankcase. These are normally open valves which will close when A crankcase pressure becomes higher than suction pressure. These leaf type oil return check valves are located at the top center of the hand hole cover openings. ‘They are easily removed when the hand hole covers are off, mum \o = Figure 1.4 - Shaft Seal Oil Seal (Shaft Seal), The shaft seal (27, figure 6.) is of the rotary type, rensrtn immersed in oll. See figure 1,4, The seal is precision built and capable of ~ automatically adjusting for wear and movements (radial and axial) of the shaft, The rotating A "seal head!" is factory assembled as a single unit, ‘The rotating seal nose mates with a ‘; stationary seat on the cover plate. Both faces are precision lapped to prevent leakage. The seal can be quickly and easily replaced. The seal assembly should be replaced and no attempt made to repair or replace components of the seal. 12, Oil Pressure Safety Switch, The oil pressure safety switch (figure 6.14) pro- - tects the compressor in case of insufficient oil pressure. This switch is a differential ee : . *‘g GENERAL INFORMATION pressure control which measures net oil pressure (difference between oil pump discharge —~ pressure and crankcase pressure). The switch is wired to the compressor motor controller so as to stop the compressor if: (@) lubricating oil pressure drops below a safe minimum during operation, i.e., less than 12 psi above crankcase pressure; or (b) oil pressure fails - to build up to a satisfactory minimum at start up, i.e., at least 18 psi above crankcase pres- sure. The oil safety switch Is interlocked with a time delay relay in the motor controller to permit a short operating period (10 to 15 seconds) at start up under low oil pressure to allow oil pressure to develop. ‘The switch is wired so that when the compressor is stopped by switch action, it may be restarted at the motor controller after the cause of low oil pressure has been eliminated. 13. Capacity Control System, The compressor is equipped with a capacity control system operated by oil pressure from the lubrication system. The capacity control system unloads cylinders (that is, cuts cylinders out of operation) in response to decreases in the refrigeration load imposed on the compressor. Unloading of a controlled cylinder is accom- plished by holding the cylinder suction valve off its seat (open) so that no gas can be com pressed. The suction valve lifting arrangement is shown in figure 1.5. The capacity control system operates in steps, each step on a givenycompressor unloading one or more of the controlled cylinders, The number of controlled cylinderstand steps of unloading for this compressor are given in paragraph 1.1.3. Since oil pressure is required to load or put cylinders into operation, the som= r™, pressor will start with all controlled cylinders unloaded, But, as soon as the compressor comes up to speed and full oil pressure is developed, all cylinders become operative. After” _ the temperature pulldown period, the refrigeration load imposed on the compressor will d crease and the capacity control system will unload cylinders accordingly. The unloading will result in reduced power consumption. On those applications where numerous evaporators 3 are supplied by one compressor, the capacity control system will delay the suction pressure from dropping to the low pressure cut-out setting and prevent stopping the compressor before all the solenoid valves are closed. ‘The capacity control system consists of a power element and its linkage for each controlled cylinder, a step control hydraulic relay, and a capacity control valve. See figure oe sucTiON vaLvE DISC (OPER) susrion va Sar CaN ~SBRING Ligter PIN uETING FORK. = «| uNtoaper < Sy power’ ae 4 onuyger® Figure 1.5 - Suction Valve Lifting Arrangement nia EN, f \ untoaos 4 SLEEVE —_ aeGENERAL INFORMATION In operation, compressor ofl is pumped through the control ofl strainer into the hydraulic relay where the oil flow to the unloader power elements is controlled in steps by the movement of the hydraulic relay piston. As soon as pump oil pressure reaches a power element the piston rises, the lifting fork pivots and the unloader sleeve is lowered, permitting the suction valve to seat. The system is governed by suction pressure which actuates the capacity control valve. The capacity control valve controls the movement of the hydraulic relay piston by metering the oil bleed from the control oil side of the hydraulic relay back to the crankease. Suction pressure increases or decreases according to increases or decreases in the refrigeration load requirements of the plant. With a decrease! ion pressure the capacity control valve moves to increase the control ofl bleed to the crt 7m the hydraulic relay. The resulting decrease in control oil pressure within the hydraulic relay allows the piston to bé moved by spring action, successively closing oil ports and preventing compressor oi] pump pressure from reaching the unloader power elements. As oil pressure leaves a power element, the suction valve rises and that cylinder unloads. With an increase in suction pressure, the above process is reversed and the controlled cylinders will load in succession. 1.3.2 Condenser ‘The condenser (figure 6, 4) is of the multipass shell and finned tube type with cir- culating water flowing through the tubes. The refrigerant vapor is admitted to the shell on the outer surface of the tubes. The cylindrical shell (1, figure 6.4) contains finned copper nickel tubes (7) expanded into copper nickel tube sheets (2) and supported by a steel tube “ support sheet (8). The tube sheets (2) and water heads (3, 4) are separated by gaskets (, 6). Water heads are constructed so that cooling water makes two passes from head to head. The heads are provided with renewable zine protector rods (14) in each wate¥ compartment to minimize the electrolytic corrosion of the condenser parts in contact with sea water. Hot refrigerant gas under pressure is pumped by the compressor to the condenser inlet (9). The hot gas passes down over the condenser tubes (7) and is cooled by the water passing through the tubes, When the gas had been cooled to the saturation point it condenses to a liquid and leaves by the outlets (10) at bottom of the condenser, ‘The water enters and leaves by the connections provided in the condenser front head (3). Condenser water is circulated by means of a centrifugal pump or is taken from the fire and flushing system,via a pressure reducing valve. On passing through the condenser the water is discharged over- board, A water regulating valve automatically regulates the flow of condenser water, 1,3,3 Condenser Water Regulating Valve The water.regulating valve (figure 6. 8) is located in the condenser water outlet line. This is a modulating valve which automatically regulates the flow of cooling water through the condenser andalso, therefore, the refrigerant head pressure. The valve is actuated by the S refrigerant head pressure in the condenser. The valve serves to reduce the quantity of water used to a minimum and to maintain a relatively constant condensing pressure and tem- perature, q —~ ‘The valve opening point is adjustable. The closing point is about 3 to 7 psi below the opening point and is non-adjustable. To increase operating head pressure or decrease water 1-14GENERAL INFORMATION 1-15GENERAL INFORMATION — flow, turn adjusting stem (81, figure 6.8) counterclockwise. To reduce operating head pres- sure, or increase water flow, turn adjusting stem clockwise. Allow sufficient time for the system to balance itself after a change in adjustment, Set the valve to maintain approxi- mately 125 psig head pressure, As shown on figure 6,8, sea water enters the valve from the right or under the seat. The actuating line from the condenser is connected to bellows assembly (1, 38) and supplies refrigerant head pressure to bellows. ‘The valve opens on an increase and closes on a de- crease in head pressure. As refrigerant head pressure acting upon bellows increases above valve setting, bellows plate (2) is compressed forcing bellows push rod (3) upward, overcoming force of vange spring (18), unseating valve dise (11), and allowing water to flow through. . ‘As the valve unseats, pressure is exerted upward through valve dise (11), valve ‘disc holder (12), guide post (16), and valve assembly screw (17) to compress range spring (8). As refrigerant head pressure decreases, range spring (18) expands, seating valve seat _ (10) and cutting off the flow of water. « ‘The.valve modulates in proportion té condenser head pressure, opening or closing ~ only a8 necessary to maintain head pressure at the valve setting. To flush the valve without affecting head pressure setting, insert screwdrivers into openings at opposite sides of spring housing (22) and lift upper guide plate (14). 1.3.4 Receiver The receiver is provided with refrigerant connections (6, 9) and a liquid level indicator (4). ‘The liquid level indicator (4) is a magnetic action, float type gauge. The float ball is geared to the center shaft of the gauge. As the liquid level moves up or down, the float follows and the center shaft rotates turning the magnet in the gauge head, The lines of force of the mag- net pass through the non-magnetic gauge head and turn the pointer to its relative position on the dial showing the liquid level in the receiver. ‘ ‘The receiver is a cylindrical shell (1, figure 6.5) with dished heads (2) at both ends. * The receiver collects excess liquid refrigerant leaving the condenser during normal operation, During pump down the receiver is used as storage space for the refrigerant charge of the system. Stop valves m tne lines leading to and from the receiver permit the charge to be confined. ‘The location of the receiver in the system is shown in figure 6,1. 1.3.5 Receiver-Condenser Equalizing Line Relief Valve A pressure relief valve (see figure 6, 1) installed in the receiver to condenser equal- izing line protects the receiver against any excessive hydraulic pressure should the receiver ever be completely full when shut down. If the pressure in the receiver should rise above 225 psi, the relief valve will open and allow refrigerant to flow back into the condenser. 1-16 \Para GENERAL INFORMATION 1.3.6 Dryer The dryer is a brass shell (1, figure 6.7) with inlet and outlet comections and a removable cover plate (16) at the outlet end. The shell encloses the replaceable cartridge 27) using either silica gel or activated alumina as the dryer agent, a safety cap (12), and a spring (11). The safety cap prevents any particles of dryer agent from entering the system should they pass through the cartridge screen. The spring keeps the dryer cartridge firmly seated against the safety cap and end cap @) assuring filtration and prevention of liquid by- pass. The dryer is located in the main liquid line (see figure 6.1). ‘The dryer cover plate (16, figure 6.7) includes a "dry eye". Sight glass (22) in the cover plate permits observation of paper dise (26), or moisture indicator. The moisture indicator changes in color from blue to pink, A blue tinge indicates an acceptable level of moisture in the refrigerant. A pink color indicates excessive moisture and the need for re~ placement of dryer cartridge. 1.3.7 Heat Interchanger ‘The heat interchanger (figure 6.6) is a brass shell (1) containing several copper tubes (4) roller expanded and silver brazed to copper silicon tube sheets (3). Liquid refrig- erant flowing over tubes (4) superheats suction gas circulating through annular spaces formed by plugs (6) within the tubes (4). At the same time liquid refrigerant is subcooled. Fins (6) increase tube surface. The heat interchanger increases system efficiency and pre- vents liquid refrigerant return to compressor. The heat interchanger is located in the main suction and liquid lines (see figure 6.1). 1,3,8 King and Cooling Coil Solenoid Valves The king and cooling coil solenoid valves (figures 6.9 and 6,10) are pilot operated, piston type valves,operated by the magnetic action of an electric coil on a movable steel core or plunger. ‘The solenoid valves perform the same action as hand shutoff valves except that since they are electrically actuated their operation is automatic. ‘The solenoid valves are open when the current is "on" and closed when the current is "off". The king solenoid valve (7A, figure 6.1) is located in the main liquid line to prevent flooding of coils with liquid refrigerant when the compressor is stopped by the compressor motor controller stop button, or safeties such as overload or low voltage relay, high pressure control switch, or oil pressure safety switch, After the cause of shutdown on any safety has been determined and corrected, the compressor can be restarted and the king solenoid valve opened by momentarily pressing the motor controller start button, The king solenoid valve will remain open when the compressor is stopped by the low pressure control switch or water pressure failure switch. A cooling coil solencid valve (10, figure 6. 1) is located in the liquid line to each refrigerant circuit upstream of the thermal expansion valve (11). The cooling coil solenoid valve opens or closes in response to the room thermostat(s). The valve closes when the refrigerated space reaches the minimum desired temperature and the thermostat cuts-out breaking the electrical circuit. The valve opens when the refrigerated space rises above the maximum desired temperature and the thermostat cuts-in completing the electrical circuit. 1-17GENERAL INFORMATION When the valve opens, liquid refrigerant flows to the thermal expansion valve which regu- ate its admission to the cooling coil circuit. As the cooling coil solenoid valves open or close, the compressor starts and stops automatically througa the action of the low pressure Saal control switch (refer to paragraph 1.2.19). 1,3.9 Thermal Expansion Valve The thermal expansion valve (figure 6.11) controls the quantity of liquid refrigerant - that passes through a cooling coil circuit. ‘The valve operates from the pressure and temperature of the suction gas leaving the coils at the point of bulb attachment, opening or closing in response to changes in suction = pas superheat, ‘When the superheat in the suction gas increases, indicating need for greater refrig- evant flow, the valve thermal bulb senses this and the valve moves in an opening direction to provide greater refrigerant flow. Conversely, when suction gas superheat decreases, in- dicating need for a reduction in refrigerant flow, the valve moves in a closing direction to 3 reduce refrigerant flow. In operation, the valve assumes intermediate or throttling positions ~ depending on the load. ‘The thermal expansion valve is factory set to maintain the suction gas leaving the cooling coils at 8° - 10°F superheat. It is seldom necessary to adjust the superheat setting. To change the superheat setting, remove the seal cap (1V, figure 6,11) on the side of the valve and turn the adjusting stem (1S). ‘Turning the stem to the right increases the superheat and reduces refrigerant flow to the coils. Turning the stem to the left lowers the superheat and increases refrigerant flow. Four complete turns of the adjusting stem will change the actuating superheat approximately 2°F, Wait between adjustments to observe results. Tighten any loose connections and replace seal cap. 1.3.10 Evaporator Pressure Regulator ‘The evaporator pressure regulator (figure 6.12) is a self-controlled, constant pressure valve installed between the cooling coil outlet and the compressor suction, The function of the regulator (19, figure 6.1) is to maintain a predetermined pressure in the cooling coil when two or more coils, operating at widely different temperatures, are con- nected to a common suction line,i.e., a freeze room (0°F) coil and a chill room (83°F) coi To operate’ the valve, the pressure on the inlet side of the valve must be higher than =~ the pressure on the outlet side by a predetermined amount. Until this state exists, the valve remains closed, To adjust the valve, remove seal cap (1A, figure 6,12) and gasket (1B) and turn adjusting nut (IE). Turning the nut to the right increases spring tension on the valve, causing it to unload at a higher pressure. During initial temperature pulldown or when a refrigerated space is being maintained at 0°F, the regulator should be bypassed. When a space is being maintained at a temperature 1-18GENERAL INFORMATION higher than 0°F, the regulator should be set to maintain a refrigerant temperature in the coils 15°F below space temperature, Refer to paragraph 1,1, 13 for recommended regu- lator setting when the chill room is maintained at 33°F, 1.3.11 High Pressure Control Switch The high pressure control switch (figure 6,13) opens the circuit with increasing pressure and has an operating range of 60 to 350 psig and an adjustable differential. The switch should be set to cut-out at 160 psig and cut-in at 140 psig. Turning the range ad- Justing screw to the right raises both the cut-in and cut-out points and turning it to the left lowers these points. The differential adjustment affects only the cut-out point. Turning this adjustment to the right (wider), raises the cut-out point, increasing the differential be- tween cut-in and cut-out pressure. Turning it to the left lowers the cut-out point, decreasing the differential. The cut-in point must be set first with the range screw and the cut-out point then set with the differential adjustment. To set the high pressure control switch, first start the compressor. Control the compressor discharge pressure by throtiling the amount of water circulated through the condenser. Turn the differential adjustment to its minimum position (left) and turn range serew to high limit (right), Raise compressor discharge pressure to about 150 psig. Turn range screw to left until the switch contactor opens stopping the compressor. When the dis~ charge pressure drops to 140 psig, turn the range screw to the right until the contactor closes, The cut-in point is now set. With the compressor running, turn the differential ad- justing screw to its widest limit (to right) and raise the discharge pressure to 160 psig. Then turn the differential adjustment to the left until the contactor opens, stopping the compressor. The cut-out point is now set, 1.8.12 Low Pressure and Water Failure Switches Both the low pressure and water failure switches (figure 6.13) open the circuit with decreasing pressure, Their operating ranges and differentials are given in paragraphs 1,1,15 and 1,1,16, Turning the range adjustment screw to the right raises both the cut-in and cut-out points. ‘Turning it to the left lowers these points, The range adjustment screw fixes the cut-in point and the differential adjustment fixes the cut-out point. The water failure switch should be set to cut-in at 15 psig and cut-out at 5 psig. To set the water pressure failure switch, turn the differential adjusting screw to the left limit for minimum differential. ‘Throttle water valves until a pressure of 15 psig is maintained at the condenser water inlet. Turn range screw clockwise until contacts of switch open then turn counterclockwise slowly until contacts close. Slowly shut off water supply decreasing pressure, The switch contacts should open at 5 psig. ‘The low pressure control switch should be set to cut-in at 8 psig and cut-out at 5" vacuum. To set the switch, first start the compressor. Control the suction pressure by throttling the compressor suction stop valve. Turn the differential adjustment to the mini- mum position (to left), and turn range screw to low limit (to left). Lower the suetion pres- sure to about 4" vacuum and turn the range screw to the right until contactor opens, stopping compressor, Allow pressure to rise to 8 psig and close suction valve to hold it there. Now turn the range screw to left until contactor closes starting compressor. The cut-in point is now set. Lower the suction pressure to 5" vacuum and turn the differential adjustment to right until the coniacts open. This fixes the cut-out point. 1-19GENERAL INFORMATION 1.3.13 Room Thermostats ‘The room thermostats (figure 6.15) are directly actuated by a seamless metallic bellows element controlled by the pressure exerted by a volatile liquid charge in its remote bulb. The bellows operates the switch mechanism to close and open the electrical circuit. A permanent magnet imparts a snap-action to the contacts to prevent excessive arcing and prolong contact life. The temperature at which the thermostat opens and closes the circuit is adjustable within the operating range. The range adjustment always sets the point at which the circuit closes. The differential adjustment governs the point at which the circuit opens. Refer to paragraph 1.1.18 for recommended thermostat settings and other data, To set a thermostat, first tun differential adjusting screw clockwise to wide limit and turn range screw counterclockwise to low limit, Bring the refrigerated space tempera- ture to the cut-in setting and turn range screw clockwise until contacts open; then turn range screw slowly counterclockwise until contacts just close. This fixes the cut-in point. Lower the space temperature to the cut-out setting, then turn differential screw counterclockwise until contacts open, This fixes the cut-out point. Allow system to stabilize and observe thermostat settings during an operating cycle. 1-20