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Volume II, Issue 1

February 1998

TECHNI-BRIEFS

Pump Guardian P rotect Your Pumps

he Hansen Technologies Pump Guardian is


the first integrated pump controller designed
specifically for use with liquid refrigerant
pumps. This easy-to-understand controller is
designed to protect pumps from improper or
harmful operating conditions and to alert plant
operators as these conditions occur. The Pump
Guardian avoids nuisance pump shutdowns
while still protecting the pump from excess
cavitation. It can be used with Hansen-Hermetic
and other sealless or open-type pumps.

Frost Master
Improvements

Pump Guardian

The Pump Guardian provides a centralized point to monitor a


pumps operation. The pump status, such as running, cavitating
(potentially running dry), off due to low liquid level, motor overtemperature, and excessive on/off cycling is indicated by bright LEDs.
The easy-to-view display on the Pump Guardian allows the current
status of the pump to be quickly identified. In situations of sustained
cavitation, repeated cavitation, low liquid level, and motor overtemperature, the Pump Guardian shuts the pump down and initiates
an alarm until the situation is corrected. An internal memory keeps
track of pump history, alarms, and shutdowns. The RS232 port on the
Pump Guardian allows access to this information using a computer.

s a result of engineering
testing and field experience,
Hansen Technologies Frost
Master and Frost Master Plus
defrost controllers have
undergone several product
improvements. These changes are
designed to ensure that these
controllers perform more reliably
and last longer in the
environments where they are
typically installed.
The quartz time clock
component now incorporates
heavier-duty gears for longer life
and to withstand the cold
temperatures of some Frost
Master installations. The Frost
Master can be installed in
locations with ambient temperature as low as 20F (29C).
(continued on page 2)

When was Your Pressure-Relief


Valve Installed?

ansen Technologies Corporations


line of high-quality pressure-relief valves
now feature an installation date tag to help
quickly and easily identify how long the valve
has been installed. Refrigeration industry
safety practices recommend that pressurerelief valves be replaced at an interval of
no longer than five years of service. The
installation date tag makes it easy to
identify just how long the valve has been
installed. Most pressure-relief valves are
only stamped with the date of manufacture.
This date may be a year or more before the
actual installation date of the valve.
Hansens pressure-relief valve

Product Improvement:
Vari-Level ............................... 2
Hot Gas Defrost
Basics for Ammonia ................ 2
Field Report:
Filter System Findings ............ 3
New Literature ............................ 4
Service Tip:
Removing Seat Rings .............. 4

with installation date tag.

(continued on page 3)

Volume 2 Issue 1.p65

Inside

2/28/00, 9:07 AM

Product Improvement: Vari-Level

GREEN

BLACK

RED

Probe Inside Detail


Control Cable
BLACK

RED

WHITE

PROBE
WIRING

GREEN

Vari-Levels produced before 1997 without the


shielded control cable can be easily retrofitted in
the field, if desired. Simply replace the existing
control cable with 22 AWG four-conductor shielded
cable having a separate shield grounding wire.
This type of cable can be purchased from Hansen.
Connect the four conductors (red, white, green, and
black) to the corresponding color-coded terminals
on both the probe and control unit ends. Connect
the shield grounding wire to the white terminal at
the probe end. Engineering and field testing have
shown that grounding the shield, at the probe end
only, provides the most effective protection. At the
control unit end, insulate the shield grounding
wire, as shown in the illustration to the right.

WHITE

Shield Grounding
Wire (Bare)

n January of 1997, Hansen Technologies


began using shielded control cable on the
Vari-Level adjustable level controls in order to
help meet CE requirements for Europe. This change
also improves resistance to electrical noise, such as
radio frequency interference (RFI).

15 14 13 12

Control Unit
Inside Detail

3A
11 10

Electrical Tape
or Shrink Tubing
(Shield Grounding Wire
Enclosed Underneath)

Hot Gas Defrost Basics for Ammonia


The hot gas supply entering the evaporator
must be free of condensate to avoid slugs
of liquid.
Approximately 100 psig (6.8 bar) minimum
of hot gas pressure should be available for
ammonia refrigeration system rapid defrost.
Pressure inside the evaporator must be above
60 psig (4.1 bar) during defrost.
The defrost controller should sequence
control valves in a manner which minimizes
stress to evaporators, piping, and compressors.

No more than 1/3 of a plants evaporators


should be in defrost at one time.
A smaller soft gas solenoid valve should be
used to gradually increase pressure inside
the evaporator if the hot gas solenoid valve
is 1 1/2" or larger or if the evaporator temperature is below 0F (18C).
A post-hot-gas equalizer valve is recommended for evaporators having a capacity of
15 tons (53 kW) or greater, or a 2 1/2" and
larger suction line, to slowly reduce pressure
in the evaporator to about 5 psid (.3 bar)
before opening the suction shut-off valve.

Frost Master
(continued from page 1)

The controller electronics now run cooler,


draw less power, and can carry a higher amperage
switching load. In addition, slide potentiometers
for timing are now more resistant to corrosion,
providing Frost Master units with much more
protection in high-humidity and slightly-caustic
environments.
Also, a desiccant module is incorporated into
the controller enclosure. This removes moisture

trapped inside the


enclosure, minimizing
condensation and the
potential for deterioration of
the circuit board and other
components.
The Frost Master and Frost Master Plus
feature many improvements.

Note: All diagrams, schematics, and installation drawings in this newsletter are representations for
illustration purposes only and should not be used for actual engineering or installation.

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Field Report: Filter System Findings

ecently, two Hansen Filter Systems were


installed on a new refrigeration system in a
beef processing facility located in suburban
Chicago. One Filter System was installed in a lowtemperature pump recirculator. The other was
installed in a high-temperature pump recirculator.
Both Filter Systems are appropriately located on
pump discharge lines.
On initial start-up, the refrigeration system
was operated at reduced capacity. During this time,
the differential pressure gauge consistently
indicated less than 1 psi pressure differential.
However, after about a week of operating at
reduced capacity, the pressure drop across one of
the Filter Systems increased until the needle on the
pressure differential gauge was above the
recommended maximum of 7 psid. This indicated
that the filter element had captured a large amount
of dirt and contaminants.
The built-in pump-out feature allowed easy
access to the filter element for inspection and
cleaning. When the filter element was removed, a
large amount of very fine iron oxide and some
organic material had accumulated on the metal
screen surface of the filter element.
Once the filter element was cleaned and
reinstalled, and the Filter System returned to
service, the pressure differential returned to
normal. The refrigeration system has continued to
operate normally since that time, about 3 months,
with the refrigeration system at full capacity. The
pressure drop continues to be monitored.

The 120 mesh filter element of the Hansen Filter System


protects refrigeration systems by capturing very fine
particles of dirt and other solid contaminants.

This example demonstrates the importance of


having a Filter System or strainer in place on
system start-up. Had the Filter Systems not been in
place in this beef processing facility, the fine
contaminants trapped in the filter element would
continue to be recirculated throughout the system.
This could have resulted in premature wear or
failure of pump bearings, shaft seals, and control
valves. Filter Systems are also desirable for
installation on existing systems to provide the
same superior protection of recirculating or main
liquid lines.

Pressure-Relief
(continued from page 1)

When installing the pressure-relief valve,


punch-out the tabs corresponding appropriate
month and year on the tag. The tag is made of a
highly-durable plastic that will not tear or break.
This minimizes the possibility that the tag becomes
accidentally separated from the valve. The tag is
factory installed on the valves tamper-resistant
stainless steel seal wire.
Hansens line of pressure relief valves helps
meet the requirements of ANSI/ASHRAE 15-1994
Safety Code for Mechanical Refrigeration, as well
as other worldwide codes. They are built in strict
conformance to ASME Boiler and Pressure Vessel
Code requirements for safety relief devices and
each valve bears the ASME Code symbol of

certification (UV). The capacities


of these pressure-relief valves are
rated by the National Board of
Boiler and Pressure Vessel
Inspectors. They also
dimensionally replace Henry
pressure-relief valves. Hansen
Bulletin K109 covers the range of
pressure-relief valves, their
selection and sizing, and more.
When installing a Hansen
pressure-relief valve,
punch-out the tabs
corresponding to the
installation date.

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New Literature Now Available From Hansen


Over the past few months, Hansen
Technologies has published some new technical
bulletins. A brief description of each appears
below. For a copy of any of these bulletins or
information on any Hansen product, contact us
at 1-800-426-7368 or 630-325-1565.

Bulletin T782a: Liquid Refrigerant Filter


System. This bulletin includes both a single and
dual filter system application and service
information. Also included is adjustment
instructions for the integral pressure differential
gauge switch.

Bulletin NEAP-001: Non-Electrical


AUTO-PURGER. This bulletin covers the newest
addition to the Hansen line of noncondensible
(air) refrigerant purgers, the Non-Electrical
AUTO-PURGER (NEAP). Included is installation
instructions, an explanation of purger operation,
and service information.

Bulletin R549a: HA2A and HA2B Series Small


Pressure Regulators. This bulletin has been
updated to include the new high-flow HA2A
pressure regulator. Included are available
variations for these regulators and typical
applications.

Service Tip: Removing Stainless Steel


Seat Rings for Inspection

ansen Technologies pressure regulators and


solenoid valvesport sizes 1" through
6"have removable seat rings. These seat rings are
made of corrosion-resistant stainless steel and
normally do not need replacement. However, the
seat ring must be removed to allow access to the
V-port/seat and closing spring. This is also
required when inspecting these items.

Commonly-found service tools can be used for


this procedure. In addition, a specially-designed
tool is available from Hansen to make seat ring
removal easier. This tool requires a " drive ratchet
and extension. The extension needs to be long
enough to reach down into the valve,
approximately 10" to 15" depending on the valve
being serviced.

Removing the seat ring is a simple process.


Sales Drawing 7501-58 details four acceptable
methods of removing the seat ring. These methods
were developed to allow proper removal and
reinstallation of the seat ring without damaging it
or the valve. Before attempting any service on the
valve, be sure to read and understand the Safety
Precautions in Hansens current list price sheet and
the Safety Precautions sheet originally supplied
with the valve.
Refer to the technical bulletin for the specific
valve being serviced for general disassembly
instructions. Then, use the procedure detailed in
Hansen Sales Drawing 7501-58. A copy of this
drawing can be obtained directly from Hansen.

Seat Ring
The seat ring on the Hansen pressure regulators and
solenoid valves can be easily removed when
servicing the V-port, seat, or closing spring.

TECHNI-BRIEFS
c/o Hansen Technologies Corporation
6827 High Grove Boulevard
Burr Ridge, Illinois 60521 USA
1-800-426-7368 or 630-325-1565
FAX: 630-325-1572

IARW
International Association
of Refrigerated Warehouses

ISO 9002
1998 Hansen Technologies Corporation

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