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14
Operational Checkout
After the system has been charged and has operated for at least 2 hours at normal operating conditions without any
indication of malfunction, it should be allowed to operate overnight on automatic controls. Then a thorough re-
check of the entire system operation should be made as follows:
(a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take
corrective action.
(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is
required, leak test all connections and system components and repair any leaks before adding refrigerant.
(c) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage
must be within 10% of that indicated on the condensing unit nameplate. If high or low voltage is indicated,
notify the power company. If amperage draw is excessive, immediately determine the cause and take
corrective action. On 3 phase motor compressors, check to see that a balanced load is drawn by each phase.
(d) The maximum approved settings for high pressure controls on Heatcraft air cooled condensing equipment is
425 psig. On air cooled systems, check as follows:
• Disconnect the fan motors or block the condenser inlet air.
• Watch high pressure gauge for cutout point.
• Re-check all safety & operating controls for proper operation and adjust if necessary.
(e) Check head pressure controls for pressure setting.
(f) Check crankcase heater operation if used.
(g) Install instruction card and control system diagram for use of building manager or owner.
System Balancing
IMPORTANT: In order to obtain the maximum capacity from a system, and to ensure
trouble-free operation, it is essential to balance each and every system.
The critical value to be checked here is suction superheat at the compressor:
1. Measure the suction pressure at the suction service valve of the compressor and determine the saturation
temperature corresponding to this pressure from a “Temperature-Pressure” chart.
2. Measure the suction temperature of the suction line about one foot back from the compressor using an accurate
thermometer.
3. Subtract the saturated temperature from the actual suction line temperature. The dierence is superheat.
Too low a suction superheat can result in liquid being returned to the compressor. This will cause dilution of the
oil and eventual failure of the bearings and rings or in the extreme case, valve failure or even “slugging” of the
compressor.
Too high a suction superheat will result in excessive discharge temperatures which causes a break down of the oil
and results in piston ring wear, piston and cylinder wall damage.
It should also be remembered that the system capacity decreases as the suction superheat increases. For maximum
system capacity, suction superheat should be kept as low as is practical. Copeland mandates a minimum superheat
of 20ºF and a maximum of 45ºF at the compressor. Heatcraft recommends a superheat of 30ºF.