EVAPORATORS

PRESENTED BY;

DOCTOR VARON P.
MARC ALPINE SANTOS
Performace objectives
 1. Be able to identify various types of evaporators.
 2. Know how a shell-and-tube chiller operates.
 3. Know how hot-gas defrost of ammonia evaporators
 controls operate.
 4. Know how various types of evaporators operate.

 5. Know the value of control valves in the proper oper-

 ation of evaporators.

 6. Know how to troubleshoot a differential pressure-

 relief regulator.

 7. Know how the differential pressure-relief regulator

 works.
The evaporator removes heat from the space being
cooled. As the air is cooled, it condenses water vapor.
This must be drained. If the water condensing on the
evaporator coil freezes when the temperature is below
32°F (0°C), the refrigerator or freezer must work
harder. Frozen water or ice acts as an insulator. It reduces
the efficiency of the evaporator. When evaporators are

operated below 32°F, they must be defrosted periodic-

ally. This eliminates frost buildup on the coils or the

evaporator plates.
There are several types of evaporators. The coiled
evaporator is used in warehouses for refrigerating large
areas. The fin evaporator is used in the air-conditioning
system that is part of the furnace in a house.
The finned evaporator has a fan that blows air over its
thin metal surfaces. Plate evaporators use flat surfaces

for their cooling surface. They are com-

monly used in freezers. If the object to be cooled or

frozen is placed directly in contact with the evaporator

plate, the cold is transferred more efficiently.
 COILED EVAPORATOR
Evaporator coils on air-conditioning units fall into two
categories:
• Finned-tube coil. The finned-tube coil is placed in the
air stream of the unit. Refrigerant vaporizes in it. The
refrigerant in the tubes and the air flowing around
the fins attached to the tubes draw heat from the air.
This is commonly referred to as a direct expansion
cooling system.
• Shell-and-tube chiller. Shell-and-tube units are used to
chill water for air-cooling purposes. Usually, the refrig-
erant is to tubes mounted inside a tank or shell contain-
ing the water or liquid to be cooled. The refrigerant in
the tubes draws the heat through the tube wall and from
the liquid as it flows around the tubes in the shell. This
system can be reversed
A thermal economizer in the bottom section of the

condenser brings warm condensed refrigerant into con-

tact with the inlet water tubes. These are the coldest

water tubes. They may hold water with a temperature

as low as 55°F (13°C). This subcools the refrigerant so

that when it moves on in the cycle, it has greater cool-

ing potential. This improves cycle efficiency and reduces

power per ton requirements. The liquefied refrigerant

leaves the condenser through a plate-type control. It
flows into the flash economizer or utility vessel. Here,
the normal flashing of part of the refrigerant into vapor
cools the remaining refrigerant. This flash vapor is
diverted directly to the second stage of the compressor.
Thus, it does not need to be pumped through the full

compression cycle. The net effect of the flash econo-

mizer is energy savings and lower operating costs. A

second plate-type control meters the flow of liquid

refrigerant from the utility vessel back to the cooler,
where the cycle begins again.
the first stage of the compressor at a rate controlled by
the size of the guide-vane opening. The first stage of the
compressor raises the temperature and pressure of the

vapor. This vapor, plus vapor from the flash econo-

mizer, flows into the second stage of the compressor.

There, the saturation temperature of the refrigerant is

raised above that of the condenser water.
This vapor mixture is discharged directly into the
condenser. There, relatively cool condenser water removes

heat from the vapor, causing it to condense again to liq-

uid. The heated water leaves the system, returning to a

cooling tower or other heat-rejection device.

APPLICATION OF CONTROLS FOR HOT-
GAS DEFROST OF AMMONIA
EVAPORATORS
To defrost ammonia evaporators, it is sometimes neces-
sary to check the plumbing arrangement and the valves

used to accomplish the task. To enable hot-gas defrost

systems to operate successfully, several factors must be
considered. There must be an adequate supply of hot gas.
The gas should be at a minimum of 100 psig. The defrost
cycle should be accurately timed. Condensate removal
or storage must be provided. An automatic suctionaccumulator or heat reservoir should be used to protect
compressors from liquid-refrigerant slugs if surge drums
or other evaporators are not adequate to handle the excess
gas and condensates.
DIRECT EXPANSION SYSTEM
shows a high-temperature system [above32°F (0°C)]
with no drip-pan defrost. During the nor-
mal cooling cycle, controlled by a thermostat, the room
temperature may rise above the high setting of the ther-
mostat. This indicates a need for refrigeration. The liq-
uid solenoid (valve A), pilot solenoid (valve B), and the
dual-pressure regulator (valve D) open, allowing refrig-
erant to flow. When solenoid (valve D) is energized.
The low-pressure adjusting bonnet controls the regula-
tor. The regulator maintains the predetermined suction
pressure in the evaporator. When the room temperature reaches the low setting
on the thermostat, there is no longer a need for refriger-
ation. At this time, solenoid valve A and solenoid valve
D close and remain closed until further refrigeration is
required.
The hot-gas solenoid (valve C) remains closed dur-
ing the normal refrigeration cycle. When the three-
position selector switch is turned to DEFROST,
liquid-solenoid valve A and valve D with a built-in pilot
solenoid close. This allows valve D to operate as a
defrost pressure regulator on the high setting. The hot-
gas solenoid (valve C) opens to allow hot gas to enter
the evaporator. When the defrost is complete, the sys-
tem is switched back to the normal cooling cycle.
The system may be made completely automatic by
replacing the manual switch with an electric time clock.
Valves Used in Direct-Expansion Systems The pilot-
solenoid valve (B) is a 1/8 in. ported-solenoid valve that
is direct- operated and suitable as a liquid, suction, hot
gas, or pilot valve at pressures up to 300 lb.
Solenoid valve A is a one-piston, pilot-operated
valve suitable for suction, liquid, or gas lines at pressures
up to 300 lb. It is available with a
9/16 or 3/4 in. port.
Solenoid valve C is a rugged, pilot-operated, two-
piston valve with spring return for positive closing under
the most adverse conditions. It is used for compressor
unloader, and for liquid, and hot-gas applications.
The dual-pressure regulator valve (D) is designed
to operate at two predetermined pressures without reset-
ting or adjustment. By merely opening and closing a
pilot solenoid, it is capable of maintaining either the
low- or high-pressure setting.
COOLING CYCLE
During the normal cooling cycle, controlled by a ther-
mostat, as room temperature rises above the high setting
on the thermostate there is a need for refrigeration. Liq-
uid solenoid (A) and the built-in pilot valve (D) open, allowing refrigerant to flow. The opening of
the built-in
pilot allows the presure to bypass the sensing chamber of
valve D. This forces it to remain wide open with resultant
minimum pressure drop through the valve. When the room temperature drops to the low set-
ting on the thermostat, there is no longer a need for
referation. Solenoid valve A and pilot vlave D close.
They remain closed until refrigeration is again required.
Hot-gas valve C and defrost-water solenoid valve E
remain closed during the cooling cycle.
Defrost Cycle When the three-position selector

switch is turned to defrost, solenoid valve A and pilot-

solenoid valve D close as hot-gas valve C and evaporator-
pilot valve B open. This allows hot gas to enter the

evaporator. Valve D now acts as a back-pressure regu-

lator, maintaining a predetermined pressure above the

freezing point. After a regulated delay, preferably toward

the end of the defrost cycle, the time delay allows the
water solenoid to open. This causes water to spray over
the evaporator, melting ice that may be lodged between
coils and flushing the drWhen the evaporator is defrosted, the system

is returned to the cooling cycle by turning the three-

position selector switch. The hot-gas solenoid (valve C)

and built-in pilot valve E) close as the liquid solenoid

(valve A) opens.
This system can be made completely automatic by
replacing the manual selector with an electric time
clock.
DIRECT EXPANSION WITH TOP HOT GAS FEED
In the evaporator shown in Fig. 10-10, when the defrost
cycle is initiated, the hot gas is introduced hot-gas solenoid valve to the manifold.
It then passes
through the balancing-glove valve and the pan coil to a
check valve that prevents liquid crossover. From the
check valve, hot gas is directed to the top of the evapo-
rator. Here, it forces the refrigerant and accumulated
oil from the relief regulator (valve A). This regulator
has been deenergized to convert it to a relief regulator
set at about 70 psig. It meters defrost condensate to the
suction line and acculmulator.
 DIRECT EXPANSION WITH BOTTOM HOT GAS FEED
Compare the systems shown in Figs. 10-10 and 10-11.
In the system shown in Fig. 10-11, the defrost hot gas
is introduced into the bottom of the evaporator through
the drain pan. The system operates similarly to that

shown in Fig. 10-10. However, most of the liquid refrig-

erant is retained in the evaporators as defrost proceeds

from the bottom to the top.

 FLOODED LIQUID SYSTEM
A flood-gas and liquid-leg shutoff
(top hot-gas feed) system. Here, the gas-powered valve is used in both ends of the
evaporator. It is a gas-powered check valve. At defrost, the normally closed type-A pilot
solenoid is energized. Hot-gas pressure
closes the gas-powered check valves. Hot gas flows
through the solenoid, globe valves, pan coil, and in-line
check valve into the top of the evaporator. Here, it
purges the evaporator of fluids. The evaporator is dis-
charged at the metered rate through valve B that has
been deenergized and acts as a regulator during defrost.
At the end of the defrost cycle, excess pressure will
bleed from the relief line at a safe rate through the
energized valve B. The gas-powered valves will not
open the evaporator to the surge drum until the gas
pressure is nearly down to the system pressure.
FLOODED GAS LEG SHUTOFF (BOTTOM HOT GAS FEED)
The liquid leg of the evaporator
dumps directly into the surge drum without a relief
valve. In this system, valve C is a defrost regulator. It is
placed in the suction line, where it is normally open.
During defrost, valve C is deenergized, converting to a
defrost regulator. In such a system, it is recommended
that a large-capacity surge drum or valve A be used as a
bypass valve. This will bleed defrost pressure gradually
around valve C into the suction line. Note how the in-line
check valve is used to prevent cross flow.
FLOODED CEILING EVAPORATOR LIQUID LEG SHUTOFF
(BOTTOM HOT GAS FEED )
A flooded-ceiling evaporator.
Upon initiation of the defrost sequence, the hot-gas
solenoid (Number 1) is opened. Gas flows to gas-
powered check valve, isolating the bottom of the surge
tank from the evaporator. The hot gas flows through the
pan coil and the in-line check valve into the evaporator.
Excess gas pressure is dumped into the surge tank. It
will bleed through valve A. During defrost, this valve
has been deenergized to perform as a relief regulator

set at approximately 70 psig.

FLOODED CEILING EVAPORATOR LIQUID LEG SHUTOFF (TOP HOT GAS FEED)

A multiple flooded-evaporator sys-

tem using input and output headers to connect the various
evaporators and the surge drum. Note that, upon defrost, the fluid and condensate, are purged
from the evaporatorand surge drum into the remote accumulator through the
regulator, which is a reseating safety valve. This is usu-
ally set at about 70 psig. The accumulator must be sized
to accept the refrigerant, plus hot-gas condensate.
FLOODED CEILING BLOWER (TOP HOT GAS FEED
Top-fed hot-defrost gas forces the evaporator fluid directly to the
bottom of the large surge drum. The defrost regulator
(valve A), which is normally open, is deenergized during
the defrost to act as a relief regulator.
To minimize heating of the ammonia that accumu-
lates in the surge drum during defrost, a thermostat bulb
should be used to sense the temperature rise in the bottom
header. This thermostat can be used to terminate the
defrost cycle. Once again, the gas-powered check valve
isolates the evaporator from the surge drum until the gas
pressure is shut off.
FLOODED FLOOR TYPE BLOWER (GAS AND LIQUID LEG SHUTOFF

The gas–pressure powered valve used in this circuit

has a solenoid pilot operator. This provides positive
action with gas or liquid loads at high or low tem-
peratures and pressures.
To defrost a group of evaporators without affecting
the temperatures of the common surge drum, the gas-
powered valve is used in each end of the evaporator. A
reseating safety valve is a relief regulator. It controls
the defrost pressure to the relief-line accumulator. A
check valve prevents back flow into the relief line. The
in-line check valve prevents crossover between adja-
cent evaporators.
At high temperatures [above −25°F (−31°C)], use
of the gas-powered check valve in place of the gas-
powered solenoid valve is recommended.
FLOODED FLOOR TYPE BLOWER GAS LEG SHUTOFF
a single gas-type, pressure powered valve is used. Overpressure at the surge drum is
relieved by valve
B, a defrost-relief regulator. This is normally wide
open. It becomes a regulating valve when its solenoid
is deenergized during defrost.
Defrost gas flows through the hot-gas solenoid
when energized. It then flows through the glove valve
and the in-line check valve to force the evaporator fluid
into the surge drum.
An optional hot-gas thermostat bulb may be used
to sense heating of the bottom of the evaporator. Thus,
it can act as a backup for the timed defrost cycle.
 LIQUID RECIRCULATING SYSTEM

Liquid–refrigerant recirculating systems are frequently

fed by liquid flow upward through their evaporators.
These systems are called bottom fed. This is accomplished by either mechanical
or gas displacement recirculators during the refrigerant cycle. In some systems,
more than a single evaporator is fed from the same recirculator, a proper
distribution of liquid between evaporators must be maintained to achieve
efficient operation of each evaporator. This balance is usually accomplished by
the insertion of adjustable globe valves or orifices into the liquid-feeder line.
Similarly, adjustment of the globe valves or insertion of orifices is also often used
properly to distribute hot gas during the defrost cycle. Equalizing orifices or globe
valves are not used if the hot gas used for defrosting is fed to the bottom of the
evaporators In such cases, most of the hot gas could flow through the circuits
nearest the hot-gas supply line. The same would also happen in circuits where
both vertical and horizontal headers are used.
FLOODED RECIRCULATOR (BOTTOM HOT GAS FEED)
The multiple system shown in Fig. 10-20 shows the
check valve mounted in each of the liquid-refrigerant
branch lines. A single solenoid valve is used in the
main refrigerant line. The defrost gas is bottom fed.
FLOODED RECIRCULATOR (TOP GAS FEED)
Check valve mounted directly at the outlet of each of the liquid-
solenoid valves. The defrost gas is top fed. This system
permits selective defrosting of each evaporator. A
single accumulator is used to protect the compressor
during defrost, as well as to accumulate both liquid
refrigerant and defrost condensate. This protection is
accomplished by using a differential pressure-regulator
valve in an evaporator bypass circuit.
The differential pressure-regulator valve will open
ufficiently to relieve excess pressure across the com-
pressor inlet. The pressure will discharge as this excess
pressure differential occurs. When the pressure differ-
ential is less than the regulator valve setting, the regu-
lator will be tightly closed.
LOW TEMPERATURE CEILING BLOWER
The low-temperature liquid recirculating system ,During the
cooling cycle, No. 1 pilot valve is opened and No. 2
pilot valve is closed, holding the gas-powered solenoid
valve wide open. This allows flow of liquid through the
energized liquid-solenoid valve from the recirculator
and then through the circuit of the unit. The in-line
check valve installed between the drain pan coil header and suction line prevents drainage
of liquid into the drain pan coil. For defrost, the liquid-solenoid valve is closed. The
No. 1 pilot solenoid is deenergized. The No. 2 solenoid is
opened, closing the gas-powered solenoid valve tightly. The hot gas, solenoid is energized.
This allows distribution of the hot gas through the drain pan coils, the in-line check valve,
the top of the suction header, and the coiLThe gas comes out the bottom of the liquid
header.
Check valve A prevents the, flow of the high-pressure
gas in the liquid line. Therefore, the gas is relieved through the safety-valve relief
regulator (B). This is set to maintain pressure in the evaporator to promote rapid, or
efficient defrost.
YEAR ROUND AUTOMATIC CONSTANT LIQUID
PRESSURE CONTROL SYSTEM

The constant liquid control system is a means of increasing the efficiency of a refrigeration
system that utilizes air-cooled, atmospheric, or evaporative condensers. To compensate for
a decrease in liquid measure, it is
necessary automatically to throttle the discharge to a predetermined point and regulate
the flow of discharge pressure to the liquid line coming from the condenser and going to
the receiver. Thus, predetermined pressure is applied to the top of the liquid in the
receiver. The con-
stant liquid pressure control does this. In addition, when
the compressor “start and stop” is controlled by pressure-
stats, the pressure-operated hot-gas flow control valve is a tight closing stop valve during
stop periods. This per-
mits efficient “start and stop” operation of the compres-
sor by pressure control of the low side.
DUAL PRESSURE REGULATOR
A dual-pressure regulator It is used on a shell-and-tube cooler. The dual-pressure regulator
is particularly adaptable for the control of shell and tube brine, or water coolers, which at
intervals may be subjected to increased loads. In this case, a thermostat affects the
transfer between low and high pressure. The remote bulb of the thermostat is located in
the water or brine line leaving the cooler. A temperature increase at this bulb, indicating
an increase in load, will cause the thermostat to open the electric pilot and transfer
control of the cooler to the low-temperature diaphragm. Upon removal of the excess load,
the thermostat will cause the electric pilot to close the low-pressure port. The cooler is
thenautomatically transferred to the normal pressure for
which the high-pressure diaphragm is set. The diaphragms
may be set at any two evaporator pressures at which it
is desirable to operate. Any electric switching device
responsive to load change may be used to change from
one evaporator pressure to the other.
VAVLVE AND CONTROLS FOR HOT GAS DEFROST OF
AMMONIA TYPE EVAPORATORS
The following valves and controls are used in the hot-
gas defrost systems of ammonia-type evaporators Hot-gas or pilot solenoid valve. The valve
is a 1/8 in. ported-solenoid valve. It is a direct-operated valve suitable as a liquid, suction,
hot gas, or pilot valve at pressures up to 300 lb. Suction, liquid, or gas-solenoid valve. The
suction solenoid valve is a one-piston, pilot-operated valve suitable for suction, liquid, or
gas lines at pressures up to 300 lb. It is available with a 9/16 or 3/4in. port.
Pilot-operated solenoid valve. The valve is a one-piston, pilot-operated solenoid valve used
as a positive stop valve for applications above −30°F (−34°C) on gas or liquid. Pilot-
operated two-piston valve. The solenoid valve is a rugged, pilot-operated, two-piston valve
with spring return for positive closing under the most adverse conditions. It is used for
compressor unloader, suction, liquid, and hot-gas applications. Gas-powered solenoid
valve. The gas-powered sole-
noid valve is a power-piston type of valve that uses high pressure to force the valve open
through the control of pilot valves. Because of the high power available to open these
valves, heavy springs may be used to close the valves positively at temperatures
down to −90°F (−68°C).
Dual-pressure regulator valve. The dual-pressure regulator valve is designed to operate at
two predeter mined pressures without resetting or adjustment. By merely opening and
closing a pilot solenoid, either the low- or high-pressure setting is maintained.
Reseating safety valve. The reseating safety valve is generally used as a relief regulator to
maintain a predetermined system pressure. The pressure maintained by the valve is
adjustable manually.
Back-pressure regulator arranged for full capacity.The back-pressure regulator is normally
used where pressure control of the evaporator is not required, as in a direct expansion
system. A pilot solenoid is energized, allowing pressure to bypass the sensing chamber of
the regulator holding the valve wide
open. Deenergizing the pilot valve allows the valve to revert to its function as a back-
pressure regulator maintaining a preset pressure upstream of the valve. The valve perform
both as a suction solenoid and as a relief regulator.
Differential relief valve. The differential relief valve is a modulating regulator for liquid or
gas use. It will maintain a constant preset pressure differential between
Reverse-acting pressure regulator. The reverse-acting pressure regulator is used to
maintain a constant predetermined pressure downstream of the valve. When
complete shutoff of the regulator is required, a pilot valve is installed in the upstream
feeder line. When the solenoid valve is closed, the regulator closes tightly. When the
solenoid valve is open, the regulator is free to operate as the pressure demands.
Gas-powered check valve. The gas-powered check valve is held in a normally open position
by a strong spring. Gas pressure applied at the top of the valve closes the valve positively
against the high-system pressures. A manual opening stem is standard.
Check valve. The check valve is a spring-loaded positive check valve with manual opening
stem. It is used to prevent backup of relatively high pressure into lower pressure lines.
In-line check valve. The in-line check valve is used in multiple-branch liquid lines fed by a
single solenoid valve. This check valve prevents circulation between
evaporators during refrigeration. The in-line check valve is also used between drain pans
and evaporators to prevent frosting of the drain pan during refrigeration.
 BACK PRESSURE REGULATOR APPLICATION OF
CONTROLS

In a refrigeration system designed to maintain a predetermined temperature at full load,

any decrease in load would tend to lower below full-load temperature the temperature of the
medium being cooled. To maintain constant temperatures in applications having varying
loads, means must be provided to change refrigerant temperature to meet varying load
requirements. Refrigerant temperature is a function of evaporator pressure. Thus, the most
direct means of changing refrigerant temperature to meet varying load requirements is to
vary the system pressure. This variation of system pressure is accomplished by adjusting the
setting of a back-pressure regulator.
REFRIGERANT POWERED COMPENSATING TYPE PILOT
VALVE

The upper portion of the valve head is similar to a stan-

dard pressure-regulating head. On the lower portion of
the head another diaphragm is connected to the main
diaphragm by a push rod. As the thermal bulb warms,
the liquid in it expands, pushing up on the rod and
opening the regulator. Because this is accomplished by
an outside power source, the pressure drop through the
head is reduced considerably. The valve head will
function in connection with the regulator on a 1/2- to
3/4-lb overall pressure drop.
AIR COMPENSATING BACK PRESSURE REGULATOR

A standard regulator is reset by manually turning the

adjusting stem, which increases the spring pressure on
top of the diaphragm. In an air-compensated regula-
tor, a change of pressure on top of the diaphragm is
accomplished by introducing air pressure into the air-
tight bonnet over the diaphragm. As this air pressure
is increased, the setting of the regulator will be increased.
This will produce like changes of evaporator pressure
and refrigerant temperature. The variations in air pres-
sure are produced by the temperature changes of the
thermostatic remote bulb placed in the stream of the
medium being cooled as it leaves the evaporator.
ELECTRIC COMPENSATING BACK PRESSURE
REGULATOR

A standard regulator is reset manually by turning the adjusting stem, usually

found at the top of the regulator. In an electrically compensated regulator,
turning the stem to obtain different refrigerant pressures and temperatures in
the evaporator is accomplished by a small electric motor. This motor rotates the
adjusting stem in accordance with temperature variations in a thermostatic bulb
placed in the medium being cooled as it leaves the evaporator. The adjusting
stem, spring and controlling diaphragm have been separated from their positions
at the top of the regulator.
VALVE TROUBLESHOOTING
Most of the problems in an evaporator system occur in the valves that make the defrost
system operate properly.