Design & Assembly of Refrigeration Training System
(AR-026)
  • Installing and planning technically correct piping for a refrigeration system using copper pipes (bending, flanging, making to measure)
  • Handling refrigerant, filling, disposal and safety
  • Start-up, checking for leaks, leak testing and maintenance
  • Disassembly or shut-down
  • Vegetable cooling cabinet
  • Freezer compartment
  • Fridge compartment with power controlled by hot-gas by-pass
  • Refrigeration system with winter mode
  • 2 Fridge compartments at different temperatures via evaporator pressure regulating valve
  • Set-up and dismantling of piping and piping components
  • Pressure testing, pressure strength testing, electrical tests
  • Calibration of pressure switches
  • Start-up, checking for leaks, leak testing
  • Designing control systems
  • Filling with refrigerant
  • Siphoning of refrigerant to suitable disposal containers
  • Main Kit Code: (AR - 026.1)
    • Condensing unit
      • Frequency: 50 Hz (Standard)
      • Nominal Refrigerating Capacity: 1412 watts (Standard)
      • Current:
        • Rated current RLA: 4.2 A
        • Max current: 5.8 A
        • Start current LRA: 18 A
      • Compressor
      • Type: Reciprocating Compressors
      • Application: HBP/CBP - High/Commercial Back Pressure
      • Product Description: R-134a
      • Voltage/Frequency: 220-240V ~ 50Hz
    • Fan Motor
      • R.P.M: 1300 tr/min
      • Shaft power: 25 W
      • Fan blade dia.: Ø 250 mm
      • Protection: Overload
    • Receiver
      • Volume /Capacity: 0.75 L
      • PMS / Max. service pressure: 32 Bars

 

  • Refrigeration Tools Kit (Not Included) Code: (AR - 026.2)
    • Digital Refrigerant Manifold (AR - 026.2.1)
      • Display: LCD (5 inches diagonal)
      • Backlight: Blue (adjustable duration)
      • Low Battery Indication: is displayed when the battery voltage drops below the operating level.
      • Over Range Display: OL for pressure,
      • Auto Power Off: 30 minutes of inactivity (adjustable)
      • Maximum Manifold Pressure: 800 Psig (5500 kPa)
      • Battery Type: 6 x AA alkaline
      • Battery Life: 350 hours typical (without vacuum, backlight, and wireless)
      • Radio Frequency: 2.4 GHz
      • Wireless Range: 1000 feet (305 meters) line of sight – distance decreases through obstructions
      • Data Port: Micro USB (for extracting data logs or updating firmware)
      • Operating Environment: 32°F to 122°F (0°C to 50°C) at <75% RH
      • Storage Environment: -4°F to 140°F (-20°C to 60°C) at <80% RH (with battery removed)
      • Temperature Coefficient: 0.1 x (specified accuracy) per °C (0°C to 18°C, 28°C to 50°C), per 1.8°F (32°F to 64°F, 82°F to 122°F)
      • » Weight: 4.03 lbs (1.83 kg)
      • Water Resistant: Designed to IP54
    • Refrigerant Leak Detector (AR - 026.2.2)
      • Sensor Type: Infrared (IR)
      • Sensor Life: 10 years typical
      • Sensitivity Levels: High, medium, low, turbo (selectable)
      • Maximum Sensitivity: 0.03 oz/yr (1g/a), stationary; 0.1 oz/yr (3g/a), in motion
      • Detection Feedback: Red tip LED, LCD bar graph, LCD digits, beeper
      • Refrigerants: HFC, HCFC, CFC, HFOs, and blends
      • Response Time: <1 seconds typical
      • Recovery Time: <5 seconds typical
      • Battery Type: 3.7 VDC (nominal) 2550mAh, non-replaceable
      • Charge Time: 6 hours typical with included charger.
      • Battery Life: 10 hours typical, backlight off
      • Auto Power Off: 10 minutes without detection or button press
      • Operating Environment: 32°F to 104°F (0°C to 40°C); < 75% RH (non-condensing)
      • Storage Temperature: -4°F to 140°F (-20°C to 60°C); < 80% RH
      • Water Resistance: Designed to IP54
    • Refrigerant Recovery Machine (AR - 026.2.3)
      • Display: 2 x 10000 count LCD with status messages
      • Backlight: Blue color
      • Measurement rate: 3.3 times per second, nominal
      • Input Port Pressure Sensor Range: -30” Hg to 600 psig
      • Output Port Pressure Sensor Range: -30” Hg to 600 psig
      • High Pressure Cutoff: 558 psig, nominal
      • Resolution and Units: 1 psig (1” Hg), 0.05 bar (2 cmHg), 0.01 Mpa (2 cmHg), 5 Kpa (2 cmHg)
      • Pressure Sensor Accuracy: ± 0.5 “ Hg (Vacuum) ± (0.6% of reading +2 psig)
      • Final Recovery Vacuum: 14.9” Hg
      • Compressor: Twin cylinder reciprocating (oil-less)
      • DC Motor: 1 HP (variable smart speed)
      • Max Current Draw: 12.0 AAC
      • Valve: Single dual-route ball valve
    • Vacuum Pump (AR - 026.2.4)
      • Nominal Flow Rate: 8 CFM (VP85), 5 CFM (VP55)
      • Oil Capacity: 8 oz (237 mL)
      • Oil Compatibility: Vacuum Pump Oil
      • Oil Backlight: Blue LED
      • Oil Drain: Ball valve
      • Port Sizes: (1) 1/4” (8 mm), (2) 3/8” (10 mm), (1) 1/2” (15 mm)
      • Compressor: Rotary vane, two stage
      • Motor: 3/4 HP brushless DC
      • RPM: 2500 (VP85)
      • Power Source: 207 to 253 VAC @ 50/60 Hz (VP85),)
      • Operating Environment: 30°F to 122°F (-1.1°C to 50°C)
    • Wireless Refrigerant Scale (AR - 026.2.5)
      • Over range: "OL" is displayed
      • Maximum load: 252 lbs (114 kg)
      • Auto power off: 30 minutes of inactivity (no change in weight or buttons pressed)
      • Backlight: Blue, turns off in 60 seconds if no buttons are pressed
      • Accuracy:
        • ±0.03%rdg + 0.25 oz (10 g), 0 to 66 lbs (0 to 30 kg)
        • ±0.05%rdg + 0.25 oz (10 g), 66 to 252 lbs (30 to 114 kg)
      • Resolution and Units:
        • lb oz (0.25 oz), lb (0.1 lb), oz (0.1 oz), kg g (10 g), kg (0.1 kg), g (10 g)
      • Temperature coefficient: 0.1 x (specified accuracy) per °F
      • Wireless Range: 100 feet (30 meters)
      • Radio Frequency: 2400 MHz
    • Digital clamp meters (AR - 026.2.6)
      • AC current (A):600A ±(2%+10)
      • DC current (A): 600A
      • AC voltage frequency(Hz):10Hz~10kHz±(1%+5)
      • Resistance (Ω): 60MΩ ±(0.8%+2)
      • Frequency (Hz):10Hz~10MHz ±(0.1%+4)
      • AC current frequency (Hz): 50Hz~100Hz±(1%+5)
      • AC voltage (V): 600V ±(0.8%+5)
      • DC voltage (A): 600V ±(0.5%+2)
      • Capacitance (F): 60mF ±(4%+5)
    • Nitrogen Cylinder (AR - 026.2.7)
      • Volume: 20 L
      • Pressure: 200 bar
    • Refrigerant Cylinder (AR - 026.2.8)
      • According to system refrigerant type
  • Design & Assembly of Refrigeration Training System (AR - 014)
    • Main Kit (AR - 025.1)
  • Hard Copy User manual.
  • Digital Content (BI-01)
  • Digital Refrigerant Manifold (AR - 026.2.1)
  • Refrigerant Leak Detector (AR - 026.2.2)
  • Refrigerant Recovery Machine (AR - 026.2.3)
  • Vacuum Pump (AR - 026.2.4)
  • Wireless Refrigerant Scale (AR - 026.2.5)
  • Digital clamp meters (AR - 026.2.6)
  • Nitrogen Cylinder (AR - 026.2.7)
  • Refrigerant Cylinder (AR - 026.2.8)

The design and assembly of refrigeration training system introduces trainees to a type of refrigerators used for storing fruits and vegetables. This trainer allows trainees to assemble this type of refrigerator starting from designing the refrigeration cycle till building the whole refrigeration system of the refrigerator and allows them to acquire hands-on skills such as pipe bending, flaring and soldering. The training system includes all refrigeration components, equipment and tools necessary for assemble the refrigerator such as a complete set of workshop tools and equipment needs for pipes bending, flaring and soldering

                                     
  • The training system demonstrates a commercial type of refrigerators that is used for storing fruits and vegetables to be fully assembled by trainees to gain practical skills of assembling and maintaining that type of refrigerators.
  • • The trainer consists of a refrigerator cabinet, a condensing unit, a trolly of refrigeration cycle components and another trolly for tools and equipment necessary for assembling the refrigeration system.
    • The refrigerator cabinet has a door to isolate the low temperature resulted by the evaporator coil inside the refrigerator and contains two evaporators, each evaporator has a heater to prevent ice formation at the evaporator fan and two sensors, one of them to sense the evaporator temperature and the other to sense the defrost heater temperature.
  • • The refrigerator unit also contains a humidifier to adjust humidification needed to store food in the refrigerator and a thermostat
    • The condensing unit consists of a compressor, condenser and a liquid receiver in addition to the main power panel of the trainer that includes main ON/OFF with of the trainer, emergency switch, three selector switches, digital displays to display refrigerator cabinet temperature, evaporator temperatures and evaporator defrost heater temperature and a 24h timer to operate the defrost heaters inside the refrigerator unit round the clock.
    • The refrigerator unit is provided with a panel that includes data transfer sockets and two lines of refrigerant hoses connections to connect the refrigerator unit components mechanically and electrically to the condensing unit.
  • The trolly of the refrigeration components is divided into drawers that contains:
    • Set of Thermostatic expansion valves
    • Interchangeable nozzle set
    • Start-up regulator: 0.2 bars-6.0 bars
    • Evaporator pressure regulator: 5-17.5 bars
    • Power regulator: 0.2 bars-6.0 bars
    • Collector pressure regulator with manometer nozzle: 3-20 bars
    • Evaporator pressure regulator with manometer nozzle: 0-5.5 bars
    • Low-pressure switch and Low-pressure limiter
    • Thermostat, switch, changeover switch
    • Thermostat fan, switch, changeover switch
    • Thermostat fan, switch, changeover switch
    • Defrosting thermostat, switch, changeover switch
    • Set of Solenoid valves
    • Inspection window
    • High-pressure monitor
    • Low-pressure monitor
    • Filter dryer
    • Check valve 0.56m³/h
    • Check valve: 1.43m³/h
    • 4-way manometer array with storage case
    • Nitrogen cylinder, 5 l with regulator
    • Pressurized cylinder 12.5L
    • Workbench with punched hole panel
    • Set of cables
    • Set of copper pipes.
    • Refrigeration copper fittings
    • Reducing Coupling
    • Coupling with rolled tube stop
    • 90° elbow – close rough
    • 90° Elbow – Long Radius
    • Tee
    • DWV 90° Elbow
    • DWV Return Bend
    • Heat exchanger
    • Liquid trap
    • Oil trap with Connectors
    • 4-way valve
    • Expansion valve
    • Cold-chamber regulator
    • Heating regulator
    • Carel pressure regulator
    • Expansion valve
    • Air sensor, Pipe sensor, Defrost sensor
    • Danfoss sensor sleeve
    • Display unit
    • Assembled and soldered
    • Set of Jet nozzles
    • Screw terminals, Coil
    • Pressure transmitter
    • Cap nut, Sealing cap
    • Connector terminal set
    • Copper piped 16 mm
    • Cold room regulator
    • Refrigeration and heating regulator
    • Defrosting in regular cycles or in real time, remote start
  • The trolly of assembly tools and equipment is divided into drawers that contains:
    • Set of pliers
    • Set of screwdrivers.
    • Set of ball Head L Allen Key
    • 9 Piece Foldup Hexagon Key Set
    • 1/4” Drive 6-Point Sockets (12 pieces)
    • 1/4” Drive 6-Point Deep Sockets (11 pieces)
    • 1/4” Drive Slotted Socket Bits (3 pieces)
    • 1/4” Drive Phillips Socket Bits (2 pieces)
    • 1/4” Drive Socket Bits (2 pieces)
    • 1/4” Drive Socket Bits (2 pieces)
    • 1/4” Drive TORX Socket Bits (8 pieces)
    • 1/4” Drive Hexagon Socket Bits (5 pieces)
    • 1/4” Drive Quick Release Reversible Ratchet
    • 1/4” Drive Spinner Handles
    • 1/4” Drive Sliding T-Handle
    • 1/4” Drive Extension Bars
    • 1/4” Drive Flexible Extension Bar
    • 1/4’’ Drive Universal Joint
    • 1/4’’ Drive Socket Adaptor
    • 1/4” Drive Bit Holder Socket
    • TORX Tamper Resistant Bits (7 pieces)
    • 1/2” Drive 6-Point Sockets (18 pieces)
    • 1/2" Drive 6-Point Deep Sockets
    • 1/2" Drive Quick Release Reversible Ratchet
    • 1/2’’ Drive Sliding T-Handles
    • 1/2’’ Drive Extension Bars
    • 1/2’’ Drive Universal Joint
    • 1/2’’ Drive Socket Adaptor - F:1/2” M:3/8”
    • 1/2’’ Drive Socket Adaptor - F:1/2” M:3/4”
    • 1/2” Series 1/2” Bit Holder Sockets
    • Slotted Bits (Impact Grade)
    • Series Phillips Bits (Impact Grade)
    • TORX Bits (Impact Grade)
    • Hexagon Bits (Impact Grade)
    • 16 Piece Combination Key Set (with EVA)
    • 12 Piece Double Open-End Wrench Set
    • 11 Piece Saw and Watchmaker File Set
    • Torque Wrenches (2 pieces)
    • Drive Insert Reversible Ratchet (2 pieces)
    • Drive Insert Reversible Ratchet (18 pieces)
    • Ball Pein Hammer
    • Soft Face Hammer
    • Spare Plastic Head - Ø 40 mm (Single)
    • 3 PC: Ø3x110, Ø4x120, Ø5x150 mm Centre Punch
    • 2 PC: Ø (2, 5) x150 mm Parallel Pin Punch
    • C-Pro Tape Measure (Inch/Metric) 5M-16 FT x 25 mm
    • Stainless Steel Rule- 30 cm
    • Vernier Caliper - 150 mmv
    • Torque Wrench
    • LCD Digital Voltage Continuity Tester
    • Professional LED Flashlight
    • Magnetic Pick-Up Tool
    • Magnetic Pick-Up and Claw Tool
    • Telescoping Inspection Mirror
    • Engineer’s Double End Scriber
    • Foldable Trimming Knife
    • Torque Wrench
    • LCD Digital Voltage Continuity Tester
    • Flare Punch Cutter
    • Stainless Steel Rule- 30 cm
    • L Type wrench with hole
    • Steel pipe cutter
    • Wooden folding rule
    • Step drill
    • Cable stripper knife
    • 180 Degree 3-in-1 Tube Bender
    • Handle adjustable saw arm
    • Copper tube bender
    • Mini Copper Pipe Cutter
    • Leveler hammer
    • Protective goggles
    • Plastic Handle Wire Brush
    • L-shaped ruler 90-degree curved ruler.
    • Automatic Cable Stripper with Handle
    • Tubing cutter
    • Flaring tool
    • Lubricator
    • Aluminum Spirit Level
    • 2x120mm Conical Pin Punch
    • 8 Blades Control Cabinet Switch
  • The trainer is also supplied with a refrigerant cylinder with its manifold to teach trainees how to charge and discharge refrigerant to refrigeration circuits.
  • The trainer allows trainees to learn the sequence of refrigeration cycles creation and maintenance as they are performed in real life and digital manifold The trainee should first perform mechanical setup of the refrigeration components needed for the required refrigeration cycle.
  • Then, trainees should perform the pipe connections and check them, then evacuate moisture in the pipes using the nitrogen cylinder and the digital manifold, then vacuum the system using the vacuum pump and digital manifold.
  • Then, trainees have to charge the refrigeration cycle with refrigerant from the refrigerant cylinder using the recovery machine, a wireless scale to identify the amount of refrigerant taken from the refrigerant cylinder to the cycle, a clamp ampere device is used also to check charging the refrigerant and a sight glass to visual passing the refrigerant through pipes and assure there is no bubbles through the refrigerant in the cycle.
  • The trainees have to perform the leakage test using the leakage detector and perform the electrical setup of the refrigeration components.
  • After performing the experiment, the trainee should learn how to discharge the cycle from the refrigerant.
  • The educational unit allows trainees to gain these skills and much more by safe experimentation.