Product Manual EIE – CASCADE REFRIGERATION CYCLE TEST RIG

www.eieinstruments.com, www.eiepharmatest.com, www.eieceratest.com, www.eiepetrotest.com

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ORGANIZATION’S ISO 9001:2008 CERTIFICATE

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 FORWARD

Dear valued customer,

We just want to take a moment out to thank you for your keen interest in our company products. We
greatly appreciate your business and the opportunity you provided us to assist you. You have joined a
selected group of customers who have switched to the technologically superior and quality enhanced
laboratory testing product.

Time has changed, so do the technology. Your purchase lists you on the cutting edge of 21st century
technology. The attached test report is an excellent way of expressing and maintaining your trust in EIE’s -
superior quality testing products. Our continued efforts and commitment is to provide you efficient sales
after services, prompt attention and highest level of customer satisfaction. If for any reasons, you have
questions or comments, we are delighted to hear from you. Call us on 0091-79-660406013 or send us email
at info@eieinstruments.com/kunal@eieinstruments.com. You can expect us to respond to your email
within 24-48 working hours.

Once again, thank you for your trust and kind patronage. We look forward to serve you better in future.

Yours sincerely,
EIE Instruments

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 TABLE OF CONTENTS

ORGANIZATION’S ISO 9001:2008 CERTIFICATE ........................................................................ 2

FORWARD ............................................................................................................................. 3

TABLE OF CONTENTS .............................................................................................................. 4

1. INTRODUCTION .......................................................................................................... 5

2. TECHNICAL SPECIFICATIONS ........................................................................................ 7

3. OPERATION INSTRUCTION: ......................................................................................... 8

4. OBSERVATIONS........................................................................................................... 9

5. OBSERVATIONS TABLE ................................................................................................ 9

6. SAMPLE CALCULATIONS: ........................................................................................... 10

7. INSTALLATION INSTRUCTIONS................................................................................... 14

8. DIRECTION TO CLEAN THE INSTRUMENT ................................................................... 14

9. WARRANTY CERTIFICATE .......................................................................................... 15

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1. INTRODUCTION

A cascade refrigeration system can be considered to be equivalent to two independent vapor-compression

systems linked together in such a way that the evaporator of the high-temperature system becomes the
condenser of the low-temperature system. However, the working media of the two systems are separated
from each other.
This therefore, allows the use of different refrigerants working at different temperature ranges to achieve the
desired effect, which would otherwise, need to be achieved by a single refrigerant working at a bigger
operating pressure range. Thus, we can make use of suitable refrigerants at the higher and lower pressure
ranges to derive maximum benefit.

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➢ DIAGRAM

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2. TECHNICAL SPECIFICATIONS

SR NO. COMPONENT SPECIFICATIONS

1. COMPRESSOR Hermetically sealed type Emerson Copland Make

1/2 T. Capacity.-2 NO
2. AIR COOLED CONDENSOR Copper Coils with fins & cooling fan.
3. COPPER COILS WITH FINS & Capillary Tube
COOLING FAN. Expansion valve
4. EVAPORATOR Copper Coil immersed in air.
The evaporator is installed from outside to
prevent heat loss
5 REFRIGERANT R404a for high pressure system and R23 for low
pressure system
6. ROTAMETER 0-50 LPH for measuring flow of Refrigerant R23
(Maxon Make.)
7. ENERGY METER One each for power supply to the Measurement
of Compressor 1st and Compressor 2nd and
Heater
8. PID CONTROLLER To control power supply to heater.
9. PRESSURE GAUGE One each for the measurement of high & low
pressure of Compressor 1st and Compressor 2nd
11. ELECTRIC HEATER Immersion type 500 watt
13. DIGITAL TEMPERATURE Multispan MS-1208(8 channel) To Measure the
INDICATOR temperatures at various Points i. e. Evaporator
Inlet & Outlet Condenser Inlet & Outlet
temperatures of Refrigerant & Evaporator bath
Temperature.
14. HP & LP CUT OUT Safety device suitable for the low & high
pressure of compressor Danfoss make
15. SERVICE VALVE Needle type for charging gas.
16. FILTER DRYER 2 No.
17. SWITCHES For various controls

The refrigerant circuit is mounted on a board. The unit is supported on frame. Do not operate the changing
valve. See the sufficient water is filled in the evaporator container.

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3. OPERATION INSTRUCTION:

Connect the plugs to mains supply. Before ON the supply, conform that all the switches on panel are off
position. . Then put ON the heater switch & give power to heater. This will heat the AIR in evaporator & this
can be seen on PID controller.
Now ON the D.P. switches. Put ON the condenser fan switch & wait for 2 - 3 minutes. Now switch ON the
compressor switch. The refrigeration flow will start. This can be confirmed on the Rota meter. Note down
the time for 10 impulse of energy meter for compression.
After some time we will see that the Temperature of AIR in the evaporator slowly goes down & reaches
steady state. (Adjust this temp. at 28 to 30 C.)
After the steady state note down the readings as follows:

1. HP1 = Condenser pressure of First Compressor in Kg/cm2.

2. LP1 = Evaporator Pressure of First Compressor in Kg/Cm2
3. HP2= Condenser pressure of second compressor in Kg/cm2.
4. LP2 = Evaporator Pressure of second compressor in Kg/Cm2
5. Q = Rota meter in Reading LPH = LPH (for R404a)
6. Tci1 = T1 = 1st Compressor Condenser Inlet Temperature in 0C
7. Tco1 = T2 =1st Compressor Condenser Outlet Temperature in 0C
8. Tei1 = T3 = 1st Compressor Evaporator Inlet Temperature in 0C
9. Teo1 = T4 = 1st Compressor Evaporator Outlet Temperature in 0C
10. Tci2 = T5 = 2nd Compressor Condenser Inlet Temperature in 0C
11. Tco2 = T6 = 2nd Compressor Condenser Outlet Temperature in 0C
12. Tei2 = T7 = 2nd Compressor Evaporator Inlet Temperature in 0C
13. Teo2 = T8 = 2nd Compressor Evaporator Outlet Temperature in 0C
14.T c1 = Time for 10 Pulses of first compressor energy meter = in sec
15.T c2 = Time for 10 Pulses of second compressor energy meter = in sec.
16. T h = Time for 10 Pulses of heater in evaporator bath = in sec.
17. T9 = Evaporator Bath Temp in 0C = 0
C. (PID CONTROLLER)

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4. OBSERVATIONS

• Energy meter Constant of First Compressor ( E M C)com = 3200 Pulses/kwatt hr

• Energy meter Constant of Second Compressor ( E M C)com = 3200 Pulses/kwatt hr
• Heater Energy meter Constant ( E M C) h = 3200 Pulses/kwatt hr

5. OBSERVATIONS TABLE

High pressure (R404 a) Gauge pressure Atmospheric pressure Absolute pressure

HP1 PSI 5 14.7 24.7 psi
HP2 PSI 240 14.7 224.7 psi
Tci2 83 80 c as per p-h chart
Tco2 38
Tei2 -33.3 -30 c as per p-h chart
Teo2 29.4
Low pressure (R23)

HP2 (kg/cm2) 6 0.1 0.19 mpa

LP2 (kg/cm2) 135 0.1 2.84 mpa
Tci2 79
Tco2 44
Tei2 -17 -70 c as per p-h chart
Teo2 36.2 15 c as per p-h chart

Tc1(10 impulse) 26
Tc2(10 impulse) 28
Th 24

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6. SAMPLE CALCULATIONS:

1. Power of First Compressor ( Wact1 )

Nc x 3600
=
tc x Emc1 comp

10 x 3600
=
26 x 3200

= 0.432 Kwatt.

2. Power of second Compressor ( Wact2 )

Nc x 3600
=
tc x Emc1 comp

10 x 3600
=
28 x 3200

= 0.401 Kwatt.

3. Heater Power ( Nact 1)

N h x 3600
=
TC x 3200

10 x 3600
=
29 x 3200

= 0.387 Kwatt.

4. Cooling capacity of lower temperature cabinet:

= Nact 1/Wact2

=0.387/0.401

= 0.965 kw

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For 1st compressor
From p-h chart
H1=86 btu/lb=200 kj/kg
H2=108 btu/lb=251 kj/kg
H4= btu/lb=97.69 kj/kg

5. C. O. P. of First System(R404a )

H1 – H4
=
H2 -H1

200-97.69
=
251-200

= 2.006
For 2st compressor
From p-h chart
H1=340 kj/kg
H2=390 kj/kg
H4=200 kj/kg

6. C. O. P. of Second System(R23)

H1 – H4
=
H2 -H1

340-200
=
390-340

= 2.8

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7. INSTALLATION INSTRUCTIONS

1) Remove packing strip the machine and transit it to a suitable safe place, where it is intended to
install. Caution: Heavy weight, protect yourself first. Handle with care.
2) Do not install the equipment in a draft, sunlight or near a place of equipment, which emits heat as
well as electromagnetic conduction emission.
3) Do not install unit in a corrosive environment. A corrosive environment may lead to poor
performance and deterioration of unit.
4) Allow a minimum 4” clearance on all sides of the instrument for maintenance work.
5) Do not stack any items on top of the unit.
6) Check the electrical specifications requirement of the instrument and make it available.
7) Plug the power cord into a properly grounded outlet.
8) Read this instruction manual carefully and abide to its requisites.
9) Recycle the packing material.

8. DIRECTION TO CLEAN THE INSTRUMENT

1) Disconnect from power supply prior to cleaning.
2) The wheel assembly and lower clamp of the unit should be periodically wiped out with soft cloth.
3) Exterior body of the instrument should be cleaned periodically with mint cream to maintain its finish
& shine.
4) Wear gloves while cleaning the equipment, so no finger prints can spoil the body of the equipment.
5) Never use benzene or paint thinner for cleaning.
6) Do not use an abrasive or alkaline solution.

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9. WARRANTY CERTIFICATE

Your EIE product is guaranteed to be free from defects in materials and workmanship for one ( 1 ) year
under normal use from the date of purchase. This WARRNATY does not apply to any product damaged
by accident, misuse, mishandling, abuse, negligence, transit, improper line voltage, drop, fire, flood or if
the products were altered or repaired by anyone other than the qualified service personnel.

The liability of EIE Instruments is limited to repair or replacement and under no circumstances shall EIE
be liable for any collateral consequential damages or loss. This guarantee specifically excludes the
expendables and consumables. All warranty claims must be directed to your corresponding purchase
organization that is responsible for the sale of this equipment. The users are responsible for shipping
expense. The warranty cards which are not signed and stamped by the actual user will be treated as
void. The warranty card should accompany the defective products sent for repair, without which no
claims would be entertained. Please detach the below warranty card from following cut-line.

…………………………………………………………………………………………………………………………

Name of the company : _______________________________________________________________

Address :________________________________________________________________
________________________________________________________________
Telephone no :________________________________________________________________
Mobile no :________________________________________________________________
Email address :________________________________________________________________
Date of purchase :________________________________________________________________
Product model :________________________________________________________________
Serial no :________________________________________________________________
Bill or cash memo no :________________________________________________________________

This card should be detached, filled in properly and posted within 15 days from the date of purchase
otherwise the warranty becomes invalid.

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EIE Instruments (Factory Address) Email : service@eieinstruments.com
B-14, 15, 16, Zaveri Industrial Estate, Phone : 0091-79-66040613
Opp. Shyam Villa Society, Near Sarswati Vidhyalaya, Fax : 0091-79-66040600
Kathawada GIDC Road, Off National Highway,
Kathawada, Ahmedabad 382430

Testing Equipment For Packaging Industries

EIE Instruments Pvt Ltd

www.eieinstruments.com

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