1. Purpose and application range
This manual is intended for the technical maintenance of refrigeration systems in industrial conditions. It covers the inspection and adjustment of the refrigerant, analysis of compressor oil and cleaning of the condenser. These procedures are performed upon detection of reduced efficiency, increased discharge air temperature, higher energy consumption or during planned maintenance every 6 months.
2. Safety and Protection
Energy Stop and Prevention of Accidental Start
When working with refrigeration systems, especially when working with liquid ammonia or freon, you must perform the lockout/tagout (LOTO) procedure to ensure safety. Use tools with special grounding.
Occupational Safety
Use personal protective equipment (PPE): work gloves, goggles, protective suit. When working with chemical substances (such as solvents for condenser cleaning), it is necessary to use breathing masks and special gloves.
3. Required Tools and Materials
| Tool Name | Specification | Quantity |
|---|---|---|
| Torque wrench with different sizes | Range 10-100 Nm | 1 |
| Multimeter | Range 0-500 V, 0-200 Ω | 1 |
| Temperature sensor | Range -40 to 120 °C | 1 |
| Ammeter | Range 0-10 A | 1 |
| Amplifier for range | Range 0-100 kPa | 1 |
| Condenser Cleaner | Acetate of ethyl solvent | 1 |
| Pressure Handbook | Range 0-10 bar | 1 |
4. Maintenance Check-off Sheet
| Item | Check | Acceptance/Rejection Criteria | Notes |
|---|---|---|---|
| 1 | Pressure presence in the system | Pressure ≥ 1 bar | Use the pressure manual |
| 2 | Outlet air temperature | Temperature ≤ 25 °C | Use thermometer |
| 3 | Level of liquid in the system | Level ≥ 60% of nominal | Use level or measuring instrument |
| 4 | Presence of leaks | No turns | Check all connections |
| 5 | Condenser condition | No dust accumulation | Use safety goggles |
5. Step-by-step procedure
- Preparation for Operation
Perform the lockout/tagout procedure for the electrical wiring and gas equipment. Use special gloves and goggles.
Дія: Вимкніть живлення та встановіть прапорець блокування.
Pressure: The pressure in the system must be ≤ 1 bar.
Visual inspection: Check all connections for leaks.
Error: Failure to perform lockout/tagout may result in accidental energization.
- Cold Carrier Level Check
Use a level or measuring system to determine the cold carrier level. The level must be ≥ 60% of nominal.
Дія: Відкрійте клапан для вимірювання рівня.
Pressure: The pressure in the system must be ≤ 2 bar.
Visual inspection: Check the level with measuring instrument.
Error: Incorrect measurement may lead to incorrect level of cold carrier.
- Oil Analysis of Compressor
Use a multimeter to measure the oil content in the compressor. The oil content should be ≥ 10% of nominal.
Дія: Відкрійте відвод для аналізу масла.
Pressure: The pressure in the system must be ≤ 3 bar.
Visual inspection: Check the oil content using a multimeter.
Error: Incorrect measurement may lead to incorrect oil content.
- Condenser Cleaning
Use an ethyl acetate based solvent to clean the condenser. Measure the temperature at the inlet and outlet.
Дія: Використовуйте розчинник для очищення конденсатора.
Pressure: The pressure in the system must be ≤ 5 bar.
Visual inspection: Check the capacitor for dust.
Error: Incorrect cleaning may lead to reduced efficiency.
- Electrical Circuit Disconnection
Perform the lockout/tagout procedure for the electrical circuit. Use special gloves and goggles.
Дія: Вимкніть живлення та встановіть прапорець блокування.
Pressure: The pressure in the system must be ≤ 1 bar.
Visual inspection: Check all connections for leaks.
Error: Failure to perform lockout/tagout may result in accidental energization.
6. After-sales inspection
| Test | Expected result | Actual | Pass/Fail |
|---|---|---|---|
| System pressure | ≥ 1 bar | ||
| Outlet air temperature | ≤ 25 °C | ||
| Cold carrier level | ≥ 60% of nominal | ||
| Oil content | ≥ 10% of nominal | ||
| Condenser condition | No dust accumulation |
7. Technical Help: Symptom-Cause-Action
| Symptom | Causes | Action |
|---|---|---|
| Reduction of efficiency | Insufficient level of cold carrier | Measure the level of the cold carrier and add if necessary |
| Increase in outlet air temperature | Condenser contamination | Clean the condenser |
| Higher energy consumption | Insufficient oil content | Measure the oil content and add if necessary |
| Turns | Incorrect connection | Check all connections |
| Reduction of compressor power | Compressor contamination | Clean the compressor |
8. Recommended Maintenance Schedule
| Task | Frequency | Continue time | Skill Level |
|---|---|---|---|
| Cold carrier level check | Every 6 months | 30 min | Average |
| Oil Analysis of the Compressor | Once every 12 months | 45 min | Average |
| Condenser Cleaning | Once every 12 months | 2 years | High |
| Preparation for operation | During servicing | 15 min | Average |
| Electrical circuit disconnection | During servicing | 15 min | Average |
9. Screening parts
| Part Description | Typical Specification | Category UNITEC-D |
|---|---|---|
| Cold carrier pump | Working pressure 10 bar, power 5 kW | Category 33 |
| Compact compressor | Working pressure 20 bar, power 10 kW | Category 35 |
| Cold carrier filter | Working pressure 15 bar, power 3 kW | Category 37 |
| Thermometer | Range -40 to 120 °C | Category 40 |
| Solvent for cleaning | Acetate of ethyl solvent | Category 50 |
Для отримання повної інформації про відсіювальні частини, відвідайте https://www.unitecd.com/e-catalog/.
10. References List
This manual complies with the standards DSTU 3037-95 (engineering calculations), EN 12952 (refrigeration systems), ISO 9001 (quality management) and the CE, UkrSEPRO standards. It also complies with the manufacturer's recommendations.
Additional information
This document is intended for the technical maintenance of refrigeration units. It is performed at the workplace and includes specific values of pressure, temperature, levels and checks. The manual is intended for operation of equipment used in industrial conditions.
