Part 4 SYSTEM DESIGN Section 17, BASIC APPLICATION Double Risers 18-22 RECOMMENDATIONS. Suction Piping for Multiplex Systems ...... 18-23 5 Piping Design for Horizontal and Fundamental Design Pri Elza a varied ieee 18.24 i Comptessor selection’ 17-1 Suction Line Piping Design ot the : System Balance 17-2 Evaporator oe 1825 Refrigerant 2 some V7 2 Receiver Location eenehe 18-25 Compressor Cooling wancicnwinenen 72 Vibration and Noise... . 18-27 Compressor Lubrication ~~ 17-3 Recommended Line Sizing Tables ......... 18-28 Oll Pressure Safety Controls «cnc 17> 4 Oil Separators 17-4 Suction Line Accumulators ... a We 5 | Pumpdown System Control 17-6 Section 19. LOW TEMPERATURE Crankeate Heaters... - 17-6 SYSTEMS | Crankease Pressure Regulating Valves .. 17-7 Single Stage Low Temperature Systems. 19-1 low Ambient Head Pressure Control .... 17- 7 Two Stage Low Temperature Systems... 19- 2 Liguid Line Filter-Driers 17-8 — Volumetric Efficiency eel 2 Sight Glass and Moisture Indicator 17-8 Two Stage Compression and i Liquid Line Solenoid Valves .. 17-8 Compressor Efficiency .cvccnenne 19° 4 i Heat Exchangers 17-9 Compressor Overheating at Excessive i Thermostatic Expansion Valves. 17- 9 Compression Ratios 19-6 Evaporators uni 1710 Basic Two Stage System 19-6 : Suction Line Filters . . 17-11 Two Stage System Components 19-7 High and Low Pressure Controls ......... 17-11 Piping on Two Stage Systems .. 19-9 Interconnected Systems .... 17-12 Cascade Refrigeration Systems «0. 19-13, Electrical Group Fusing ccneees W712 Section 20. TRANSPORT REFRIGERATION Section 18. REFRIGERATION PIPING. Compressor Cooling 20-1 i Basic Principles of Refrigeration Compressor Speed ... 20-1 Piping Design... 18-1 Compressor Operating Position .... 20- 2 Copper Tubing for Refrigerant «18 2 Compressor Drive 20-2 Fittings for Copper Tubing conse 18 2 Refrigerant Charge 20- 3 Equivalent Length of Pipe woe 18+ 5 Refrigerant Migration 20- 3 Pressure Drop Tables .. . 18-5 Oil Charge ...... 20-3 izing Hot Gas Discharge Lines ......... 18- 9 Oil Pressure Safety Control... 206 4 Sizing Liquid Lines = 18-14 Oil Separators... 20-4 Sizing Suction Lines — . 18-17 Crankcase Pressure Regulating Valve .... 20- 4Condenser 7 Receiver 7 Purging of Air From System ..... Liquid Line Filter-Drier - Heat Exchanger Liquid Line Solenoid Valve Suction Line Accumulator ...... 7 Crankcase Heaters Pumpdown Cycle even Forced Air Evaporator Coils ...cnrnnee Thermostatic Expansion Valves Defrost Systems - Thermostat High-Low Pressure Control ........ Eutectic Plate Applications Refrigerant Piping... - Vibration Electrical Precautions Installation : Field Troubleshooting on Transport Units Section 21. CAPACITY CONTROL Compressors with Unloaders Hot Gas Bypass Bypass Into Evaporator Inlet 7 Bypass Into Suction Line ... 7 Solenoid Valves for Positive Shut-off and Pumpdown Cycle .. a 20- a BOANNNNAonouas 20-12 20-12 20-13 20-13 20-14 2-1 21-3 21-3 21-5 21-5 Desuperheating Expansion Valve .. 21-5 Typical Multiple Evaporator Control System 21-6 Power Consumption with Hot Gas Bypass nn. -cocenee Section 22. LIQUID REFRIGERANT CONTROL IN REFRIGERATION AND AIR CONDITIONING SYSTEMS Refrigerant-Oil Relationship . 22. Refrigerant Migration 22- Liquid Refrigerant Flooding 22. Liquid Refrigerant Slugging .. 22. Tripping of Oil Pressure Safety Control .. 22- Recommended Corrective Action cece 22> Section 23. ELECTRICAL CONTROL CIRCUITS Typical Lockout Control Circuit... 23- Control Circuit for Compressor Protection Against Liquid Refrigerant Flooding 23 Control Circuits to Prevent Short Cycling 23- Control Circuits for Compressors with Copacity Control Valves ... - 23+Table Table Table Table Table Table Table Table Table Table Table Table Table Table Toble Table Table Table Table Table Table Toble Table Table Table Table Table Table 2 22 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 4 42 43 44 45 46 47 48 INDEX OF TABLES Recommended Minimum Low Pressure Control Setting .... woe WAV Dimensions and Properties of Copper Tube 18-3 Weight of Refrigerant in Copper Lines cncuecneennnen cece 184 Equivalent Length in Feet of Straight Pipe For Valves and Fittings 18 5 Pressure Drop Equivalent For 2° F. Change in Saturation Temperature at Various Evaporating Temperatures E 7 . 18-17 ‘Maximum Recommended Spacing Between Pipe Supports for Copper Tubing .... 18-28 Recommended Liquid line Sizes .. 7 18-29 Recommended Discharge Line Sizes ..... - coves 18-30 Recommended Suction Line Sizes, R-12, 40° F. ......- ee plea) Recommended Suction Line Sizes, R-12, 25° F. .... a 18-32 Recommended Suction Line Sizes, R-12, 15° F. ... . . 18-33 Recommended Suction Line Sizes, R-12, -20° F. _. 18-33 Recommended Suction Line Sizes, R-12, -40° F. .... ceveeeee 1884 Recommended Suction Line Sizes, R-22, 40° Fe seucscnrnn cevceceeeeeee 1BO4 Recommended Suction Line Sizes, R-22, 25° F. 7 7 18-35 Recommended Suction Line Sizes, R-22, 15° Fe... oe 18-36 Recommended Suction Line Sizes, R-22, -20° F. cece 18-37 Recommended Suction Line Sizes, R-502, 25° Fe ocscrcrsnenene . 18-37 Recommended Suction Line Sizes, R-502, 15° F. a 18-38 Recommended Suction Line Sizes, R-502, -20° F. ceceeenenenmereie 1889 Recommended Suction Line Sizes, R-502, -40° F. ... cece 18-40 Efficiency Comparison of Single Stage vs. Two Stage Compression Typical Air Cooled Application with Refrigerant R-502 a 1% 6 Recommended Discharge Line Sizes for Two Sluye Compressors 19-10 Recommended Liquid Line Sizes for Two Stage Compressors ... eels 19210 Recommended Suction Line Sizes for Two Stage Compressors, -60° Fe cvvccnee 19-11 Recommended Suction Line Sizes for Two Stage Compressors, -60° fr. - 19-11 Recommended Suction Line Sizes for Two Stage Compressors, -80° F. - 19-12 Recommended Suction Line Sizes for Two Stage Compressors, -80° F. 19-12Section 17 BASIC APPLICATION RECOMMENDATIONS FUNDAMENTAL DESIGN PRINCIPLES There are certain fundamental refrigeration design principles which are vital to the proper functioning of any system. 1. The system must be clean, dry, and free from all contaminants. 2. The compressor must be operated within safe temperature, pressure, and electrical limits. 3. The system must be designed and operated so that proper lubrication is maintained in the compressor at all times. 4, The system must be designed and oper- ated so that excessive liquid refrigerant does not enter the compressor. Refrige ation compressors are designed to pump refrigerant vapor, and will tolerate only @ limited quantity of liquid refrigerant. 5. Proper refrigerant feed to the evaporator must be maintained, and excessive pres- sure drop in the refrigerant piping must be avoided. If these five steps are accomplished, then operation of the system is reasonably certain to be trouble free. If any one is neglected, then eventual operating problems are almost certain to occur. These basic fundamentals are closely inter-related, and must always be kept in mind with regard to the application of any component, or whenever any change in system operation is contemplated. COMPRESSOR SELECTION The compressor must be selected for the capacity required at the desired operating con- ditions in accordance with the manufacturer's recommendations for the refrigerant to be used. Standard Copeland single stage compressors 7 are approved for operation with a given reftig- erant in one of the following operating ranges. Evaporating Temperature High Temperature 45° F.100° F. or 55°F. to 0° F. Medium Temperature 25° F.to-5° F. low Temperature 0° F. to -40° F, Extra Low Temperature -20° F. to -40° F. Operation at evaporating temperatures above the approved operating range may overload the compressor motor. Operation at evaporat- ing temperatures below the approved operating range is normally not a problem if the com- pressor motor can be adequately cooled, and discharge temperatures can be kept within allowable limits. Evaporating temperatures below -40° F. are normally beyond the prac- tical lower limit of single stage operation because of compressor inefficiencies and exces- sive discharge gos temperatures. Because of problems of motor cooling or overloading, some motor-compressors may have approval for op- eration at limited condensing or evaporating temperatures within @ given range, and if so, these limitations will be shown by limited per- formance curves on the specification sheet. A given compressor may be approved in two different operating ranges with different re- frigerants, for example, high temperature R-12 and low temperature R-502. Since the power requirements for a given displacement with both R-22 and R-502 are somewhat similar, in some cases a compressor may be approved in the same operating range for either of these refrigerants. Two stage compressors may be approved for evaporating temperatures as low as -80° F., but individual compressor specifications should be consulted for the approved operating range. Operation at temperatures below -80° F. is