energy efficiency

applied to RAC

6
best practices

UNDP Nigeria project

due to the sound problem, I suggest this procedure

You have my e-mail address, use it to communicate me

an e-mail address to use for replying to your questions

You send me your questions, I read them a reply will be

sent to your e-mail

In such a way you can ask me answer to your question,

communicate to me your complain, request of
documentation

Do you agree with this emergency procedure ?

the different design criteria, fundamental for the
proper working of each type of application, are:

optimized selection of components

correct installation and start-up procedures

correct regular maintenance

these last two considerations involve

the execution of vacuum and refrigerant charge
once completed any maintenance intervention with
circuit opening and before starting of cooling system,
following procedures must be carried out:

✔ PRESSURE TEST
✔ VACUUM
✔ REFRIGERANT CHARGE
before vacuum and charge owing to assembling,
maintenance, repairing, it is essential to test the
sealing of the cooling circuit
the only suitable operation is the pressure test
wear suitable P.P.E
couple directly to the system (not via a manifold)
sequence the process
cordon off the area where the testing is to take place
keep the cylinder upright and secure
isolate supply if leaving the area
discharge the gas in a well ventilated area
only dry nitrogen (or similar inert gas) must be used
for pressure test taking in consideration the maximum
working pressure (PS) of the equipment declared
by the manufacturer
pressure test is able to point out large leakages
only

leak detection by means pressure can be done

with soap foam or suitable pressure gauge
this method allows the large leaks to be identified

after nitrogen charge, pressure gauge will show

the leakage by means a decreasing in pressure
this kit is suitable for:

• leak detection in pressure

• circuit flushing
• fluxing during soldering
• pressure switch setting
• gauge calibration
from 1.0 to 1.43 PS
≥ 1.0 ≤ 1.43 PS
the word “vacuum” means the condition of a closed
volume containing air or other gases with a pressure
considerably lower than atmospheric pressure

metering the vacuum level means to measure the

residual pressure existing inside the defined volume

vacuum is essential to remove from inside of the

circuit the residual gases resulting from welding,
atmospheric air and contained vapour
vacuum is an extremely beneficial procedure that
grants the bases to a long working life and long
lasting efficiency the only equipment suitable for
that purpose is

vacuum pump
very low residual pressure achieved with good quality
vacuum pump, allows the non condensable gases to
be removed as well as little amount of water by
means its vaporization
fundamental concept of vacuum is:

fall in inner pressure, lower than water saturation

point due to its temperature (ambient temperature)

7,251 mm
Hg
0,0227 atm
0,033 PSI
vacuum level is gauged with vacuum
gauge, the instrument suitable to
measure the absolute pressure

measuring absolute
pressure 0 reading
is equal to vacuum
while atmospheric
is 1 bar (or 1000 mbar)
a frequent question is about which is the vacuum level
to get at the inlet connection of the vacuum pump (that
is the conventional point where vacuum is measured)
to certainly have a very few amount of remaining
pollutants inside the circuit

50µ assembling line of refrigerating equipments

(0,065 mbar)

300 350µ installation site

(0,39 0,46 mbar)
humidity easily accumulates in two crucial
points where the removal represents a very
demanding commitment
• electric motor winding
• compressor lubricant charge
humidity is very hard to be removed but
operation can be accelerated through power
supply of electric oil heater (if present)
once achieved the expected vacuum level, keep on running
the vacuum pump for a period suitable to evacuate properly
the cooling circuit
how long the vacuum pump must work ?
no method, no mathematical formula, no
manual can identify the period of time to
evacuate completely the cooling circuit

it depends on the experience, quality of

instruments and the suitability with the
volume of circuit

but ………
I FOUND IT !!!!
 t = V / q ln(p0 / p1)

t = evacuation time (s)

V = enclosed evacuated volume (m3, cu.ft)
q = volume flow rate capacity of the vacuum pump (m3/s,
cu.ft/s)
p0 = initialization pressure - normal atmospheric pressure
(mbar, mmHg)
p1 = end vacuum pressure (mbar, mmHg)
Bourdon tube
LO low pressure
VAC vacuum

REF refrigerant

HI high pressure
Vacuometro meccanico
 EVOLUTION

analogic manifold electronic analizer

gauges
 heavy duty

standard
 secondary seal
-

primary seal
this is a commonly used
three position service valve

all caps are secondary seals

and should be present and
undamaged
primary seal
same instruments are
suitable to vacuum and
charge processes
without disconnect or
modify hoses positioning

LP
HP
VAC - REF
before to operate any
vacuum/charge procedure,
every valve must be
tightly closed and,
subsequently, open only
the one necessary to the
required operation

LP
HP
VAC - REF
 manifold gauges

LO closed
X X
VAC closed

REF closed

HI closed
X XX X

X
 manifold gauges

FI closed
X X
P; = closed

L ?@ closed

BC closed
X XX X

X
 manifold gauges

FI closed
X X
P; = open

L ?@ closed

BC closed
X X X

X
 manifold gauges

FI closed
X X
P; = open

L ?@ open

BC closed
X X

X
 manifold gauges

FI open
X X
P; = open

L ?@ open

BC closed
X

X
 manifold gauges

FI open
X X
P; = open

L ?@ open

BC open

X
 manifold gauges

FI open
X
P; = open

L ?@ open

BC open

X
 manifold gauges

FI open

P; = open

L ?@ open

BC open

X
 manifold gauges

FI closed

P; = closed

L ?@ closed

BC closed
X XX X

X
 manifold gauges

FI closed

P; = closed

L ?@ closed

BC closed
X XX X

X
excessive duration of period to reach a
vacuum level of about 10 millibar, shows
a large leakage not pointed out during
previous pressure test
the same leakage could turn to yellow (WET)
the coloured indicator of the sight-glass
previously green (DRY) at the end of evacuation

LEAKAGE

VAC U U M
observing the needle of vacuum gauge it is possible
to check the tighteness of the circuit or the quality of
the vacuum

the rise of the needle means a leakage of the circuit

or further humidity is coming out of the lubricant mass
DON’T run the compressor in vacuum condition
before the switching off of vacuum pump (once achieved
the expected vacuum level) connecting flexible hoses
must be closed

this procedure must applied even if the vacuum pump

equipment is with solenoid valve and check valve, a very
small amount of air is able to flow back into the circuit
after vacuum finishing carry out the “vacuum breakage”

it consists in introduction of liquid refrigerant straight into the

high pressure side of cooling system

this avoid the liquid to arrive to the compressor carter

polluting the lubricant
knowing the exact amount of
refrigerante, this can be entirely
introduced into the high pressure side;
the whole charge in liquid state can be
metered with the bottle placed on a scale
not knowing the amount of refrigerant fixed by
the manufacturer or designer, the same cannot
be calculated

there are various procedures for charging

and ensure subsequent acceptable operation

this that follows is a suggestible one

 manifold gauges

LO closed
X X
VAC closed

REF closed

HI closed
XXX X

X
 manifold gauges

LO closed
X X
VAC closed

REF open

HI closed
X X X

X
 manifold gauges

LO closed
X X
VAC closed

REF open

HI open
X X

X
 manifold gauges

LO closed
X
VAC closed

REF open

HI open
X X

6 7 bar
it is suggestable to cut liquid introduction off when
high pressure gauge shows

6 ÷7 bar
(approximate values referred to continental
climate)

refrigerant charge will be completed with running

compressor
 manifold gauges

LO closed
X X
VAC closed

REF open

HI closed
X X X

X
 manifold gauges

LO closed
X
VAC closed

REF open

HI closed
X X X

X
 manifold gauges

LO open
X VAC closed

REF open

HI closed

X X

X
 manifold gauges

LO open
X VAC closed

REF open

HI open

X
before the advent of zeotropic refrigerants it was a common
procedure to adjust the refrigerant charge after breaking
the vacuum by introducing refrigerant in the gas phase
the characteristic glide of the new zeotropic (and even near
azeotropic) refrigerants makes the adjustment procedure of
the charge with liquid refrigerant on the suction side of the
circuit obligatory but… .

...... with the necessary precautions !!!!!

it is advisable to adopt this procedure even for refrigerants

without glide (pure and azeotropic) so as to avoid operating
errors
 manifold gauges

LO open
X VAC closed

REF open

HI open

0,5 bar
 0,5 bar

X
 0,5 bar

X
 0,5 bar

X…X…X…X…
the correct balance of the system, which depends
on the choice of the fundamental components and
the metering of the refrigerant charge, can be verified
by measuring the superheating of the refrigerant
at the evaporator outlet

a correct superheating value, between 4 and 6K,

shows that the refrigerant supplied to the evaporator
is completely evaporated and there is no liquid
in the suction line

it also shows that the system is loaded with refrigerant

in the right quantity
excessively low superheating indicates incomplete
vaporization of the refrigerant fluid in the evaporator,
with the consequent return of liquid to the compressor

too low superheating can be caused by an excessive

charge of refrigerant, by the thermostatic valve too
open or oversized, but also, more simply, by the valve
bulb not well fixed to the suction line or affected by an
air current
considering that the density of the refrigerant changes
with its temperature variation, it is advisable to check
its superheating and subcooling when with the change of
season the temperature also changes environment