energy efficiency

applied to RAC

4
best practices

UNDP Nigeria project

before commissioning or intervention
on a refrigeration system, the engineer
in charge must be aware of the operating
conditions foreseen in the project
and the type of refrigerant used
 it would be good if the operating conditions
calculated by the designer are part of the
equipment
documentation

failing this, we can

take in consideration values that common sense and
experience suggests
AIR COOLED CONDENSER

outdoor air temperature +35 C

condensing temperaure +50 C

Δt = 15K

Δt air = 8 / 10K
 SUBCOOLING
tc CONDENSING TEMPERATURE

tu AIR - OUTLET TEMPERATURE

tE AIR - INLET TEMPERATURE

VENTILATED EVAPORATOR

indoor air temperature +27 C

evaporating temperature +5 C

Δt = 22K

Δt air = 13 / 15K
tE AIR - INLET TEMPERATURE tU AIR - OUTLET TEMPERATURE

SUPERHEATING

to EVAPORATING TEMPERATURE
• check of safety devices
• starting pumps of chilled water circuit
• starting of condenser water pumps
• starting of cooling tower
• check of oil temperature
• starting of the compressor
• check of pressures and temperatures
compressor start-up must be preceded by a series
of static checks tare carried out with the main
switch turned off

the main checks concern the oil level, the electrical

characteristics of the power supply line, the correct
power supply of the oil heater
a preliminary check
of the calibration
of the main safety
and control devices
can be carried out
even before starting
the compressor, simply
by observing the position
of the calibration indices
on the reference scales
high pressure switch is normally set at a pressure
significantly higher than the condensing pressure
foreseen by the equipment design

at the same time it must be below both the maximum

operating pressure of the components installed
on the compression line and of the compressor
low pressure switch must be set to cut-off pressure
corresponding to a saturation temperature
about 10K lower than normal evaporating temperature

if properly calibrated, the pressure switch can also

operate as anti-frost safety device
the calibration of the oil differential pressure switch,
(only for compressors with oil pump) depends on the
manufacturer's prescriptions
the latest generation compressors are equipped with
electronic oil differential pressure switch
this, state of the art control, doesn't need setting
 the preliminary calibration of the motor protector
of the compressor must correspond to a value
higher than the operating input current

MRA (maximum input current)

± 10% max
tolerance

operating input current

then, the voltage is checked, considering
that a tolerance of 10% more or less than the nominal
value is allowed
the main switch on, allows the power supply
of the oil heater of the compressor and the
compressor contactors
any abnormal noise of the compressor forces
the immediate stop of the
compressor and to repeat
the start-up after identifying
the source of the problem
 in the first seconds of compressor operation
check the correct rotation of the three-phase
condenser fans

use the digital clamp meter

to measure the starting current
of the compressor and compare
the read value with that
declared by the manufacturer
once the operations have been completed and the oil
level in the compressor has been checked once again,
the system can operate without special assistance for
as long as it takes to make it fully operational

this time can be

extended even
for several days
we now simulate a logical sequence of measurements
of the operating parameters whose results reveal
any anomalies and / or refrigerant leaks
(indirect method – regulation EU 1516/2007, art.7, 1)
subcooling - condenser outlet

subcooling - metering device inlet

superheating - evaporator outlet

superheating - compressor inlet

compressor head temperature

compressor input current

 R134a

EVAPORATOR

14 bar

55,4 C
saturation temperature

CONDENSER
 R134a
subcooling:
55,4 – 50 = 5,4K

EVAPORATOR

55,4 C

liquid temperature

50 C

CONDENSER
 R134a

EVAPORATOR

14 bar

55,4 C
saturation temperature

CONDENSER
 R134a
subcooling:
55,4 – 49 = 6,4K

EVAPORATOR

55,4 C 49 C

CONDENSER 50 C
 R134a

EVAPORATOR

3 bar

8,9 C
saturation temperature

CONDENSER
 R134a
superheating:
14 – 8,9 = 5,1K

8,9 C EVAPORATOR
saturation
tempetature

14 C

CONDENSER
 R134a

EVAPORATOR

3 bar

8,9 C
saturation temperature

CONDENSER
 R134a
superheating:
16 – 8,9 = 7,1K
16 C

EVAPORATOR
14 C

8,9 C

CONDENSER
 R134a

EVAPORATOR

max suction temperature

20 C
CONDENSER
the constructive characteristics of the split circuit require
a different superheating verification method based on the
relationship between indoor wet bulb temperature (WB)
and outdoor dry bulb temperature (DB)
indoor
wet bulb

outdoor
dry bulb
outdoor dry bulb temperature C

indoor wet bulb temperature C

besides to the requirements of the legislation in force, it is
also necessary to check other situations which, if out of
control, could lead to future irreversible damages:

• compressor oil level

3/4 maximum level

1/4 minimum level

when the system is in operation, the operator must
provide all the necessary procedures to keep the
system under control in order to:

- keep it efficient

- keep records of the operating status

in absence of design data, the evaluation of the
performance of a cooling system is a procedure
lacking in reliability

this means that the result of comments,

measurements should be regularly
carried out and recorded
 the initial efficiency of the refrigeration system tends
to decrease over time; wear and dirt are the main
factors in reducing efficiency

a well-structured and regularly applied maintenance

program allows decay to be slowed down
the program must include all the parameters
to be monitored regularly and if compared with
the reference values they allow to check the status

repairs must also be recorded; the register

represents a very useful tool for a more valid
troubleshooting
very important are the suggestions made
by the manufacturer of the equipment;
for example:
each manufacture suggests a maintenance plan basically
consisting in:

pressure and temperature monitoring

MONTHLY
each manufacture suggests a maintenance plan basically
consisting in:

oil level and temperature

MONTHLY
each manufacture suggests a maintenance plan basically
consisting in:

control and safety devices (pressure switch, solenoid

valves)

QUARTERLY
each manufacture suggests a maintenance plan basically
consisting in:

refrigerant charge and leak detection

ACCORDING TO THE LAW

IN FORCE
each manufacture suggests a maintenance plan basically
consisting in:

lubricant and lubricant filter

AFTER THE FIRST 100 HOURS OF OPERATION

THEN EVERY 10000 HOURS OF OPERATION
each manufacture suggests a maintenance plan basically
consisting in:

filter drier

AFTER THE FIRST 100 HOURS OF OPERATION

THEN EVERY 10000 HOURS OF OPERATION
sometime particular troubles can be identified without
metering and control instruments

it is enough a minimum of experience to locate and

evaluate most frequent troubles also by means sight,
hearing, touch and sense of smell
with water cooled condenser,
controls and maintenance
criteria SHOULD ALSO
be applied to the water circuit
in order to remove limescale
deposits and other pollutants
water cooled condenser
cooling tower