March 2006 - Plumbing & HVAC

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RefrigerationCSI: Compressor Service InvestigationTechnician tackles refrigeration service mysteryBy John Carr, C.E.T.Fig 1: Allan finds thisalarm waiting on hiscomputer screen.MONDAY, 3:09 A.M.: Allan awakesto his cell phone ringing. He is on call, sohe knows there is a problem with one of the many systems heservices. He gets out of bed and walks to his computer in the next room. In the hallwayhe can hear the pinging sound of the alarm and as he enters the room he seesthe screen flashing “ALARM.” In moments he has hit the Enter key and is reading thealarm report.3:51 A.M.: Allan is in his service truck heading towards Velton Foods on MadisonStreet. He thinks about the refrigeration warehouse systems operated by Velton Foods.The information in the case beside indicates:Unit 28Type: FreezerOperating Temp: -22.2°C (-8.0°F)Compressor Rack: 4 – 40 Hp Screw Type,3500 RPM, Electrical rating 440/460-3-60.Rack Capacity: 190,325 KW (650 MBTU/Hr) with unloading down to 50%.Condenser: 225,000 KW (768 MBTU/Hr) 12 fans, divided into three stages.Refrigerant: R-22Refrigerant Oil: POE 100 (Rack has oil cooling)Evaporators: 4 – 48,000 KW (165 MBTU/Hr)Defrost Type: Hot Gas4:16 A.M.: Allan enters Mechanical Room 3. Every compressor rack is operatingwith the exception of Unit 28. He knows what the condition is, but he looks at thecontrol readout screen anyway.With confirmation complete, he punches in the key code to find out the conditionof the compressor at the moment of failure4:18 A.M.: Allan recognizes right away that oil pressure failure is the condition,but has to find out why oil pressure was lost. The system had worked for over twoyears without oil failure problems, so the basic piping design was sound. After a fewmore control module checks, Allan discovers that the oil level switch circuit is open.This indicates that there is a low oil condition.4:35 A.M.: After checking the rack thoroughly for oil leaks, Allan finds no indicationthat oil has left the system. Oil is not likely to pass through the oil separator, sohe considers the possibility of an oil-level switch failure. He removes the wire to theFig. 2: ControlModule read outconfirms alarm.Fig. 3: The controlmodule lets Allanknow the condition ofthe rack at midnight,prior to failure.Fig. 4: The place onthe compressor rackwhere field changesallowed the oil-levelswitch to be heated bythe discharge line.SNC-Lavalin ProFac Inc is the industry leader in Canada, providing a fullrange of integrated facility management services and solutions toClients in various sectors. Nationally, SNC-Lavalin ProFac providesintegrated management for over 110 million square feet of real estate.Within that portfolio, the Public Works and Government ServicesCanada (PWGSC) account is comprised of 319 buildings acrossCanada with a total area of over 31 million square feet.SNC-Lavalin ProFac Inc. conducts its procurement through bestpractices that honour both the spirit and the letter of openness andtransparency and is pleased to announce that the open procurementactivities for PWGSC service contracts across the country will betendered using the Private Tenders section of the MERX tenderingservice (www.merx.com - Private Tenders tab).For those who do not have Internet access, the open tenderingopportunities can be accessed by phone at 1-800-964-MERX (6379).Potential proponents can register with MERX online to access allProFac postings for the PWGSC contract. Potential proponents canset-up a user profile on MERX to receive automatic notification ofopportunity postings or visit the website regularly to view currentpostings. All questions about registering with MERX can be directedto merx@merx.com or 1-800-964-MERX (6379).Circle Number 129 for More Informationoil level switch at the base of the oil separator and checks it with his ohmmeter. Themeter reads 0 ohms, indicating that the switch is closed.4:36 A.M.: Extensive searches have led Allan to check for continuity between theoil-level switch and the control module. Here he finds an open circuit. But why, hethinks? This is a 220-volt control circuit, so if there was an electrical short at sometime there would have been a different alarm, and sooner.4:58 A.M.: Allan has just finished replacing the wiring from the control module tothe oil-level switch. He checks for continuity and all is normal. The next step is startup.5:12 A.M.: The rack is running and the control module reads that all is normal,with the readings similar to what was showing at midnight. The box temperature isbeginning to move down slowly.7:52 A.M.: Allan and two other refrigeration mechanics are inspecting the wirefrom Rack 28. They find a discolouration on the wire at the point where it wouldenter the panel just before its connection to the control module. Allan cuts the wireand peals back the discoloured insulation. He finds that the wire too, is discolouredand broken. Now Allan is concerned about the new wire and its location.12:02 P.M.: Back at the warehouse, Allan checks the wiring and finds that all isfine, but he does spot something that is not quite right. The back of the control panelis placed very close to the oil discharge line from the oil separator. This must havebeen a field change made by someone else. He insulates the wires, checks the controlmodule to see that all is normal and heads on out to his next call.Detective’ John Carr is the continuing education coordinator at SAIT Polytechnic inCalgary. He can be reached at john.carr@sait.ca.30 Plumbing & HVAC Product News – February/March 2006 www.plumbingandhvac.ca
RefrigerationDigital analyzerDigi-Cool introduced its new digitalrefrigeration system analyzer DRSA-1200 at AHR Expo in Chicago inJanuary. It measures superheat andsubcooling with minimum-maximumpressure logging. Bar graphs show systempressure fluctuations with 22+standard refrigerant profiles.Digi-Cool Industries Circle no. 340Reduces condensationThe Emerson Control Link anti-condensatecontroller for anti-condensateheaters, commonly used in refrigeratordoors, features improved algorithms.Greater energy savings (up to50 percent) are achieved by maintaininga specific differential between arefrigerated case’s dew point and itsframe temperature. Part of Emerson’sIntelligent Store control architecture,it keeps condensation from buildingand activates the heaters only whennecessary.Emerson Climate Control Circle no. 341Product ProfileNew HFC refrigerants mineral oil compatibleDuPont introduced its five new ISCEON 9 Serieshydrofluorocarbon refrigerant blends for airconditioning and supermarket conversions to theNorth American market at the AHR Expo in Chicagoin January.“With this new line, DuPont can meet the needsof end-users and contractors for easy-to-use,cost effective, mineral oil compatible retrofitrefrigerants,” reported Jim Bachman, national salesand marketing manager.Acquired from Rhodia last August, these HFCrefrigerants are mineral oil compatible and have a 20-40 percent lower global warming potential than HFCoptions R-404A and R-507, reports DuPont.Isceon 79 or R-422A offers capacity and efficiencycomparable to R-404A and can replace R-22, R-502,HP80, R-404A and R507.Isceon 59 or R-417A provides the lowestoperating pressures for supermarkets with excessR-22 system capacity.Isceon 29, initially called R-422D, allows for conversionswithout major equipment changes in systemswith excess R-22 capacity.Isceon 49 or R-413A is an R-12 replacement instationary refrigeration and mobile air conditioning.Isceon 69 is an HCFC refrigerant replacement forR-403B and R-502 in stationary refrigeration.More information is available on the company’snewly enhanced web site athttp://refrigerants.dupont.com.DuPont Canada Circle no. 347CompressorsBristol showed its latest Benchmarkcompressors at AHR Expo in Chicagoin January. New features include amuch lower sound level on 1.5 to 3.5-ton models, a unique cylindrical shelland improved internal suction muffleron the H21J scroll which is designed forapplications below 3.5 tons.Bristol Compressors Circle no. 345Analog controllerThe Industrial Scientific 820 Controllerfor fixed-point gas monitoring installationsfeatures two channels and acceptsone or two 4-20 mA input signals.There is a user interface for configurationand control of every parameter, fiveprogrammable analog relays for alarmand fault conditions along with a realtimeclock.Industrial Scientific Circle no. 342reciprocating recovery compressor. It isR-410A ready. Features include a uniquesuction port design, very large dischargeport, automatic low-pressure shut-offand 550 psi high pressure shut-off. Itweighs 16-lbs/16.2 kg, is CSA listed, andis available in 115 and 230 volt models.CPS Canada Circle no. 344Air-cooled condensersBohn Monarch Series condensers withEC motors offer variable speed withoutcomplexity, optimizing fan speeds forload requirements, maximizing energyefficiency and minimizing sound. TheAmbassador Series features QuietEdgeswept fan blades, including four-bladefans on 540 rpm motors and five-bladeon 830 rpm motors.Heatcraft Refrigeration Circle no. 346Evaporator controllerKeepRite Refrigeration’s SmartVaptwo-pipe, two-wire evaporator controlleris designed to control box temperature,time clock and fan delay. Italso replaces the defrost initiation andtermination thermostat, room thermostat,defrost heater contactor andheater fusing. It is designed for electricdefrost single-phase evaporatorsup to 25 amp maximum over-currentprotection.National Refrigeration Circle no. 343Refrigerant recoveryThe Pro-Set Cyclone refrigerant recoveryunit by CPS features a 1-hp oil-lessNew CM-12:10,500 Btu/H of cooling foreasy installation above astandard drop ceiling.· Focus cool air exactly where needed· Capacities up to 60,000 BTU/h· Mobile, reliable and affordable· Customizable to any requirementApplications:· Backup / Emergency /Off-Hours Cooling· Computers /Telecommunication /Data Processing Rooms· ManufacturingProduction LinesNew PAC12:12 Ton PortableSpot Cooler· Offices / Schools / Labs /Warehouses· Humidity Control· Special EventsCost Effective Solutions for all your Ventilation and Air Conditioning NeedsPortable Spot Coolers · Package Terminal Air Conditioners · Water Source Heat Pumps · Fan CoilsPhone (905) 820-1400 · Toll Free 888-209-0999anna@williamshvac.com · www.williamshvac.com3350 Ridgeway Drive, Unit #2 Mississauga, Ontario L5L 5Z9 Fax: (905) 820-1435Visit us at CMXBooth #2414/18Circle Number 130 for More Informationwww.plumbingandhvac.ca February/March 2006 – Plumbing & HVAC Product News 31
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March 2006 - Plumbing & HVAC

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