Flooded System Charging - Data Aire DAMA-01 Installation, Operation And Maintenance Manual

NOTE: Charging to a full liquid line sight-glass should never be the sole means of de-
termining the correct refrigerant charge. Other parameters such as superheat, suction
pressure, head pressure, sub-cooling and ambient temperature are also important. A
system charged to a clear sight-glass is often overcharged.

5.2.4 Flooded System Charging

Flooded systems include an optional liquid receiver and head pressure control valve for use primar-
ily in colder climates. When the ambient temperature falls during cold weather, the head pressure
control valve will regulate the fl ow of refrigerant to ensure nearly constant receiver pressure. The
receiver is partially fl ooded with liquid refrigerant in cold weather. In warm weather the extra refrig-
erant is stored in the receiver.
Flooded systems require more refrigerant than units with fan speed control. Connect the pressure
gauge manifold set to the high and low ports near the compressor. Connect the charging line to
the refrigerant tank and set it for liquid feed. Open the refrigerant tank valve and purge the line at
the manifold. Open the high side valve on the manifold only and allow the refrigerant to fl ow until
the system pressure equalizes. At this point the system will have 75 to 85% of the total refrigerant
charge. Start the evaporator blower. Start the compressor and check the operating pressures and
temperatures.
For units with either the Mini DAP-III or DAP-III, a quick and easy way to run the blower and com-
pressor is by using the manual switches provided with the microprocessor (located in the control
module). Switch the blower and compressor manual switches to the ON position. All automatic
control is disabled but safety switches will remain functional.
WARNING: Before starting a compressor, the crankcase heater should be energized
for a minimum of 12 hours to reduce the possibility of liquid slugging on start-up. Fail-
ure to energize the crankcase heater could result in compressor damage. If the system
is charged from a vacuum, the pre-heating of the compressor is not necessary.
Start the evaporator fan and verify the fan rotation. Start the compressor. Check the liquid line
sight-glass to get a feel for the approximate charge. Bubbles in the sight-glass are not unusual at
this point and can be caused by fl ashing from liquid pressure drop, low sub-cooling or low charge.
It is likely more refrigerant will be required to complete the charging procedure.
If the receiver (head) pressure is below 230 PSIG, block part of the condenser coil surface until the
pressures rises to 230 PSIG or greater. During extremely cold weather all the condenser fans may
have to be de-energized to maintain 230 PSIG.
Observe the sight-glass on the receiver. Add refrigerant through the suction line until the level of
liquid in the receiver is approximately 1/3 from the bottom of the sight-glass (the leveling ball in the
receiver will start to fl oat). At this point the receiver is 80% full. Observing the receiver sight-glass
becomes diffi cult when they are remotely mounted near the condenser. The unit should be allowed
to stabilize for several minutes before meaningful measurements can be taken.
After the system is allowed to stabilize, the superheat at the compressor suction line (reading from at
least 6 inches from the compressor) should be 8 to 15°F. Units with remote condensing units (DRCU),
the superheat should be 20 to 25°F at the compressor. The sub-cooling will be the same 8 to 10°F
as a standard unit (with condenser – DARC). Remove any block that may have been used on the
condenser coil. If the ambient temperature while charging is below 60°F, some of the refrigerant will
be backed up into the condenser coil causing the liquid level in the receiver to drop (this is normal).
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