CRES Study Guide
CRES Study Guide
Table of Contents
Introduction to the CRES Study Guide 2
Using RETA References on Screen 2
Calculations and Refrigeration System Screens 4
Sample System Screen 5
Formulas 7
CRES References Sheet 8
Ammonia Safety Data Sheet (SDS) 10
CRES Screens 1 to 24 19
Ammonia Saturated Properties Table 41
Halocarbon Refrigerant Properties Table 49
Lighting 57
This CRES Examination Study Guide is designed to help you prepare to demonstrate what
you know and can do in this RETA certification test. You will improve your chances of
earning your CRES credential by treating this CRES Study Guide as you would the technical
manuals in a refrigeration facility where you work. Your chances of earning the CRES
credential improve if you are familiar with the details in the CRES Study Guide. Just as
your job requires that you know what is in operating manuals and when to refer to them to
understand or resolve a problem, the CRES test requires that you know what is in the
References document and when to use it. You will not be told when to use the references
for this test.
Using RETA References On-Screen
References for each RETA test are in a PDF that appears on the screen next to test
questions. You will have the following tools for using the PDF.
• Move the red vertical line separating the two sections from side to side to assign
more screen space to the References or to questions.
• Zoom in or out to make pages in the References PDF larger or smaller by clicking on
the plus (+) or minus (-) symbols at the top of the screen. This tool bar disappears after a
few seconds. The toolbar reappears when you move the mouse over the References
document.
• Scroll from page to page to find the location in the References that has the table,
formulas or other information you want to use.
Do not use the CTRL + F keys for searching in the PDF as this will cause
the testing system to think a security violation is happening and will
automatically log the test taker out and the login screen will appear.
The following screens show how this will work during the test.
Screen 1 The sample question asks about controlling an ammonia fire. The
References document title page appears on the right side of the screen.
Zoom in or out to make pages in the References larger or smaller by holding down the Control key and
using the scroll wheel on the mouse. You cannot use the save or print functions in the toolbar during the
test. If you click on those icons, you need to click “Cancel” in the menu that appears for either function to
return to References.
Screen 2 Information to help answer the question appears in the Ammonia SDS.
Scroll to the opening page of the SDS.
Screen 3 The answer to the question appears in the first paragraph of Section 5,
Fire Fighting Measures, in the ammonia SDS. In this screen the vertical
red line has been moved
to the left to increase the screen space assigned to the References document.
All calculations required in this test can be completed with a simple calculator. A scientific
calculator is NOT required to perform well on this examination. The screens that appear in
the CRES examination provide information about operating conditions in a refrigeration
system. Some screens include information about both “NORMAL” and “ABNORMAL”
operating conditions. The screens do not specify how much time has passed between these
two sets of data. Several months may have passed between the time when the “NORMAL”
and “ABNORMAL” readings were recorded.
The CRES examination requires you to demonstrate that you can use these screens to:
• Determine the condition of the refrigerant at any place in the system by knowing
how to use the information provided.
• Analyze the findings of the conditions and apply your knowledge to adjust
system components to resolve a problem and/or achieve a better running
condition.
• Determine the cost of operating under the conditions indicated in the screens. In
both dollars per hour and in power demand or consumption over time.
• Use refrigerant properties tables in the CRES References and in this CRES Study
Guide to interpret information and/or solve a problem in the system’s operating
conditions. CRES references in this Study Guide will be available on screen
during the examination.
A = side1•side2
A = Radius • Radius • 3.1416
BHP =
Amps • Volts • PowerFactor • Efficiency • 1.73
746
Cost($) = ($ price per kiloWatt hour • kiloWatt hours metered ) Hours operated
Pictograms:
Hazard Statements
Flammable Gas
Contains gas under pressure; may
explode if heated Toxic if inhaled
Causes severe skin burns and eye damage
Very toxic to aquatic life with long lasting effects
Precautionary Statements
Wear protective gloves: >8 hours (breakthrough time): Use chemical-resistant,
impervious gloves. Wear eye or face protection (Recommended: Chemical Splash
Proof Goggles, Face shield). Wear protective clothing (Recommended: Chemical-
resistant apron).
Keep away from heat, sparks, open flames and hot surfaces. – No
Smoking. Use only outdoors or in a well-ventilated area.
Avoid release to the environment.
Avoid breathing gas.
Wash hands thoroughly after handling.
Collect spillage.
Remove victim to fresh air and keep at rest in a position comfortable for
breathing. Immediately call a POISON CENTER or physician.
IF SWALLOWED: Immediately call a POISON CENTER of physician. Rinse mouth.
Do NOT induce vomiting.
IF ON SKIN (or hair): Take off immediately all contaminated clothing. Rinse skin
with water or shower. Wash contaminated clothing before reuse. Immediately
call a POISON CENTER or physician.
IF IN EYES: Rinse cautiously with water for several minutes. Remove contact
lenses, if present and easy to do so. Continue rinsing. Immediately call a
POISON CENTER or physician.
Leaking gas fire: Do not extinguish, unless can be stopped
safely. Eliminate all ignition sources if safe to do so.
Store locked up.
Protect from
sunlight.
Store in a well-ventilated place.
Dispose of contents and container in accordance with all local, regional, national and
international regulations.
Contact eye lenses should never be worn while handling anhydrous ammonia.
Ingestion: If this gas is swallowed in liquid form, keep victim warm and OBTAIN
IMMEDIATE MEDICAL ATTENTION. If signs of respiratory obstruction develop,
immediately transport to medical facility. Do not induce vomiting. Never give fluids or
induce vomiting if patient is unconscious or having convulsions.
Inhalation: Remove victim to fresh air. Give oxygen if breathing is difficult.
If breathing has stopped, start artificial respiration. OBTAIN IMMEDIATE
MEDICAL ATTENTION.
Skin: Apply water immediately to exposed areas of skin and continue for at least
30 minutes. Remove contaminated clothing, shoes, and constrictive clothing while
continuing to apply water, being careful not to tear the skin. If skin surface is
damaged, apply a clean dressing. If skin surface is not damaged, cleanse the
affected area(s) thoroughly with mild soap and water. Do not apply salves or
ointments to affected areas. OBTAIN IMMEDIATE MEDICAL ATTENTION.
Eyes: Remove victim to fresh air. Immediately flush with plenty of water for at least
30 minutes with the eyelids held apart. OBTAIN IMMEDIATE MEDICAL ATTENTION.
Medical Conditions Generally Aggravated by Exposure: Ammonia is a
respiratory irritant. Persons with impaired pulmonary function may be at an
increased risk from exposure. Also pre-existing skin disorders may be aggravated by
exposure.
Summary of Acute Health Hazards
Ingestion: This material is a gas under normal atmospheric conditions and ingestion
is unlikely. Ingestion of liquid ammonia may result in severe irritation or ulceration of
the mouth, throat and digestive tract which may be displayed by nausea, vomiting,
diarrhea and, in severe cases, collapse, shock and death.
Inhalation: Irritation to the mucous membranes of the nose, throat and lungs is
noticeable at 100 ppm. Concentrations above 400 ppm will cause throat irritation
and may destroy mucous surfaces upon prolonged contact. High concentrations can
cause pulmonary edema. Breathing air containing concentrations greater than
5,000 ppm may cause sudden death from spasm or inflammation of the larynx.
Skin: Liquid Ammonia produces severe skin burns on contact. Ammonia gas may
cause skin irritation, especially if skin is moist. The liquid can cause skin damage
resulting from combined freezing and corrosive action on the skin. Atmospheric
concentrations above 30,000 ppm will burn and blister skin after a few seconds of
exposure.
Eyes: Exposure to high gas concentrations may cause temporary blindness and
severe eye damage. Direct contact of the eyes with liquid ammonia will produce
serious eye burns.
Extinguishing Media: Use Water Spray or Water Fog, Carbon Dioxide, Polar or
Alcohol Foam, Dry Chemical. Halon may decompose into toxic materials. Carbon
dioxide can displace oxygen. Use caution when applying halon or carbon dioxide in
confined spaces.
Unusual Fire and Explosion Hazards: Gas may ignite at vapor concentrations
between 16% and 25% in air. However, ammonia-air mixtures are difficult to
ignite and burn with little vigor. In the absence of oxygen enrichment, the risk of
initiating an accidental fire or explosion is low. Do not allow ammonia vapors to
accumulate in confined areas where ignition may occur. Intense heating
particularly in contact with hot metallic surfaces may cause decomposition of
ammonia generating hydrogen, a flammable gas.
Special Protective Equipment for Firefighters: Stop flow of gas. Use water fog to
keep fire-exposed containers cool and to protect personnel effecting the shut-off.
Wear self-contained breathing apparatus (SCBA) and encapsulating chemical
protective clothing. Approach fire upwind and evacuate area downwind. Emergency
responders in the danger area should wear bunker gear and self-contained breathing
apparatus for fires beyond the incipient stage (29CFR 1910.156). In addition, wear
other appropriate protective equipment as conditions warrant (See Section VIII).
Isolate damage area, keep unauthorized personnel out. Stop spill/release if it can
be done with minimal risk. If this cannot be done, allow fire to burn. Move
undamaged containers from danger area if it can be done with minimal risk. Stay
away from ends of container. Water spray may be useful in minimizing or
dispersing vapors.
Cool equipment exposed to fire with water, if it can be done with minimal risk.
Additional Description Requirement: Inhalation
Hazard NFPA Rating: Health - 3; Flammability - 1;
Instability - 0 0=Insignificant 1=Slight 2=Moderate
3=High 4=Extreme
According to the (UFC) Uniform Fire Code Standard 79-3 (2000), the degree of
Hazard is 3-3-0 in a confined space.
Personal Precautions: Note that although ammonia gas is lighter than air,
sudden release may generate an aerosol of liquefied ammonia which may cling to
the ground for long distances. May ignite in the presence of open flames and
sparks. Narrow lower to upper combustion range (16-25%) makes ignition difficult.
Keep all sources of ignition away from spill/release. Do not apply water onto
leaking tank. Stop the flow of gas or liquid. Use water to protect personnel
effecting the shut-off. Approach from upwind. Evacuate the area immediately.
Eliminate all open flames in vicinity of indoor spills or released vapor. Water fog
can be used to cleanse atmosphere of ammonia vapor. Downwind areas can be
protected by water fog nozzles positioned downwind.
Protective Equipment: Wear full protective clothing and self-contained breathing
apparatus.
Emergency Procedures: Do not enter a visible cloud of ammonia. Isolate and
evacuate the leak or spill area immediately for at least 150 feet in all directions. For
larger spills, isolate at least 300 feet in all directions and then evacuate area
downwind at least 0.4 miles in width and at least 0.8 miles in length. Keep area
isolated until gas has dispersed.
Methods of Containment and Clean-Up: Dike liquid spills to contain liquid.
UN#: UN1005
UN/DOT Proper Shipping Name: Anhydrous Ammonia
Transport Hazard Class: 2.2 (Domestic), 2.3, (8)
International Packing Group: N/A
Marine Pollutant: Yes
Transport in Bulk: N/A
Special Precautions: N/A
CRES SCREEN 5
RECIPROCATING COMPRESSOR – NH3 ABNORMAL CONDITIONS
SUCTION PRESSURE 33 PSIGCOMPRESSOR MOTOR AMPS 145 AMPS
DISCHARGE PRESSURE 154 PSIG
COMPRESSOR MOTOR VOLTAGE 480 VAC
OIL PRESSURE 45 PSID COMPRESSOR LOADING 100%
SUCTION TEMP 60°F
CONDENSER WATER SUMP 72°F
TEMP
DISCHARGE TEMP 269°F CONDENSER LIQUID TEMP 85°F
MOTOR POWER FACTOR 0.82 CONDENSER OUTLET PRESSURE 151 PSIG
NOTES: MOTOR TYPE IS 3 PHASE MOTOR EFFICIENCY IS 92%
CONDENSER TYPE IS EVAPORATIVE COMPRESSOR WATER COOLED
CONDENSER OUTLET NOT SUBCOOLED
CRES SCREEN 9
TWO -STAGE PACKAGE – NH3 NORMAL CONDITIONS
LOW STAGE COMPRESSOR HIGH STAGE COMPRESSOR READINGS
SUCTION PRESSURE 9” HG SUCTION PRESSURE 31 PSIG
DISCHARGE PRESSURE 31 PSIG DISCHARGE PRESSURE 154 PSIG
OIL PRESSURE 45 PSID OIL PRESSURE 45 PSID
SUCTION TEMP -38°F SUCTION TEMP 24°F
DISCHARGE TEMP 135°F DISCHARGE TEMP 156°F
CONDENSED LIQUID TEMP 85°F
CONDENSER OUTLET PRESSURE 151 PSIG
OIL TEMPERATURE 125°F OIL TEMPERATURE 125°F
OIL COOLER – OIL INLET 135°F OIL COOLER – OIL INLET TEMP 145°F
TEMP
OIL COOLER – 85°F OIL COOLER – REFRIGERANT 85°F
REFRIGERANT OUTLET OUTLET TEMP
TEMP
BOOSTER COMPRESSOR 48 AMPS HIGH STAGE COMPRESSOR MOTOR 49 AMPS
MOTOR AMPS AMPS
BOOSTER COMPRESSOR 100% HIGH STAGE COMPRESSOR SLIDE 100%
SLIDE VALVE POSITION VALVE POSITION
MOTOR POWER FACTOR 0.82 MOTOR POWER FACTOR 0.82
NOTES: THERMO SIPHON OIL COOLING MOTOR EFFICIENCY IS 92%
MOTOR TYPE IS 3 PHASE MOTOR VOLTAGE(S) IS 480 VAC
CRES SCREEN 13
MEDIUM TEMPERATURE ROOM – NH3 NORMAL CONDITIONS
COIL SUCTION HEADER 33 PSIG AIR LEAVING TEMPERATURE 31°F
PRESSURE
COIL SUCTION HEADER 20°F ROOM AIR TEMPERATURE 33°F
TEMPERATURE
LIQUID LEVEL 29% MODE: REFRIGERATING
FEED STATUS SATISFIED
EVAPORATOR FAN 7.2 AMPS
MOTOR AMPS
COMPRESSOR INLET 30 PSIG PARAMETERS:
PRESSURE ROOM TEMP: 33°F
COMPRESSOR 154 PSIG ROOM HIGH TEMP: 38°F
DISCHARGE PRESSURE ROOM LOW TEMP: 32°F
COMPRESSOR INLET 23°F LIQUID LEVEL CALL: 25%
TEMP LIQUID LEVEL SATISFIED: 31%
COMPRESSOR 212°F LIQUID HIGH LEVEL: 40%
DISCHARGE TEMP
DEFROST PUMP DOWN: 20 MIN
DEFROST HOT GAS REG: 90 PSIG
FAN DELAY: 2 MIN
NOTES:
- UNIT IS A FLOODED EVAPORATOR WITH A SOLENOID ACTIVATED BACK PRESSURE
REGULATOR FOR EVAPORATOR PRESSURE CONTROL.
- HOT GAS DEFROST METHOD USED.
- LIQUID FEED IS AN ELECTRIC SOLENOID VALVE IN SERIES WITH A HAND EXPANSION
VALVE.
- ENGINE ROOM USES MULTIPLE RECIPROCATING COMPRESSORS.
CRES SCREEN 15
MEDIUM TEMPERATURE ROOM – NH3 NORMAL CONDITIONS
COIL SUCTION HEADER 33 PSIG COMPRESSOR DISCHARGE TEMP 212°F
PRESSURE
COIL SUCTION HEADER 20°F AIR LEAVING TEMPERATURE 31°F
TEMPERATURE
LIQUID LEVEL 29% ROOM AIR TEMPERATURE 33°F
FEED STATUS SATISFIED
EVAPORATOR FAN MOTOR 7.2 AMPS MODE: REFRIGERATING
AMPS
COMPRESSOR INLET 30 PSIG PARAMETERS:
PRESSURE ROOM TEMP: 33°F LIQUID HIGH LEVEL: 40%
COMPRESSOR DISCHARGE 154 PSIG ROOM HIGH TEMP: 38°F DEFROST PUMP DOWN: 20 MIN
PRESSURE ROOM LOW TEMP: 32°F DEFROST HOT GAS REG: 90 PSIG
COMPRESSOR INLET TEMP 23°F LIQUID LEVEL CALL: 25% FAN DELAY: 2 MIN
LIQUID LEVEL SATISFIED: 31%
MEDIUM TEMPERATURE ROOM – NH3 ABNORMAL CONDITIONS
COIL SUCTION HEADER 90 PSIG COMPRESSOR DISCHARGE TEMP 224°F
PRESSURE
COIL SUCTION HEADER 60°F AIR LEAVING TEMPERATURE 34°F
TEMPERATURE
LIQUID LEVEL 95% ROOM AIR TEMPERATURE 33°F
FEED STATUS HIGH
EVAPORATOR FAN MOTOR 0.0 AMPS MODE: DEFROST – HG “ON”
AMPS
COMPRESSOR INLET 30 PSIG PARAMETERS:
PRESSURE ROOM TEMP: 33°F LIQUID HIGH LEVEL: 40%
COMPRESSOR DISCHARGE 154 PSIG ROOM HIGH TEMP: 38°F DEFROST PUMP DOWN: 20 MIN
PRESSURE ROOM LOW TEMP: 32°F DEFROST HOT GAS REG: 90 PSIG
COMPRESSOR INLET TEMP 65°F LIQUID LEVEL CALL: 25% FAN DELAY: 2 MIN
LIQUID LEVEL SATISFIED: 31%
NOTES:
- UNIT IS A FLOODED EVAPORATOR WITH A SOLENOID ACTIVATED BACK PRESSURE REGULATOR
FOR EVAPORATOR PRESSURE CONTROL.
- HOT GAS DEFROST METHOD USED.
- EVAPORATOR IS ONE OF SEVERAL IN THE SYSTEM.
- LIQUID FEED IS AN ELECTRIC SOLENOID VALVE IN SERIES WITH A HAND EXPANSION VALVE.
- ENGINE ROOM USES MULTIPLE RECIPROCATING COMPRESSORS.
CRES SCREEN 16
LOW TEMPERATURE ROOM – NH3 NORMAL CONDITIONS
COIL SUCTION HEADER 8” HG AIR LEAVING TEMPERATURE -28°F
PRESSURE
COIL SUCTION HEADER -39°F ROOM AIR TEMPERATURE -25°F
TEMPERATURE
RECIRCULATOR LIQUID LEVEL 29% MODE: REFRIGERATING
FEED STATUS SATISFIED
EVAPORATOR FAN MOTOR 13.6 AMPS
AMPS
COMPRESSOR INLET PRESSURE 12” HG PARAMETERS:
COMPRESSOR DISCHARGE 154 PSIG ROOM TEMP: -25°F
PRESSURE ROOM HIGH TEMP: -20°F
COMPRESSOR INLET TEMP -40°F ROOM LOW TEMP: -30°F
COMPRESSOR DISCHARGE TEMP 153°F LIQUID LEVEL CALL: 25%
LIQUID LEVEL SATISFIED: 31%
LIQUID HIGH LEVEL: 40%
CRES SCREEN 17
LOW TEMPERATURE ROOM – NH3 NORMAL CONDITIONS
COIL SUCTION HEADER 8” HG AIR LEAVING TEMPERATURE -28°F
PRESSURE
COIL SUCTION HEADER -39°F ROOM AIR TEMPERATURE -25°F
TEMPERATURE
RECIRCULATOR LIQUID 29% MODE: REFRIGERATING
LEVEL FEED STATUS SATISFIED
EVAPORATOR FAN 13.6 AMPS
MOTOR AMPS
COMPRESSOR INLET 12” HG PARAMETERS:
PRESSURE ROOM TEMP: -25°F
COMPRESSOR DISCHARGE 154 PSIG ROOM HIGH TEMP: -20°F
PRESSURE ROOM LOW TEMP: -30°F
LIQUID LEVEL CALL: 25%
COMPRESSOR INLET -40°F
LIQUID LEVEL SATISFIED: 31%
TEMP 40%
LIQUID HIGH LEVEL:
COMPRESSOR DISCHARGE 153°F DEFROST PUMP DOWN: 20 MIN
TEMP DEFROST HOT GAS REG: 90 PSIG
FAN DELAY: 2 MIN
LOW TEMPERATURE ROOM – NH3 ABNORMAL CONDITIONS
COIL SUCTION HEADER 10” HG AIR LEAVING TEMPERATURE -18°F
PRESSURE
COIL SUCTION HEADER -42°F ROOM AIR TEMPERATURE -18°F
TEMPERATURE
RECIRCULATOR LIQUID 26% MODE: REFRIGERATING
LEVEL FEED STATUS SATISFIED
EVAPORATOR FAN 14.9 AMPS
MOTOR AMPS
COMPRESSOR INLET 12” HG PARAMETERS:
PRESSURE ROOM TEMP: -25°F
COMPRESSOR DISCHARGE 154 PSIG ROOM HIGH TEMP: -20°F
PRESSURE ROOM LOW TEMP: -30°F
LIQUID LEVEL CALL: 25%
COMPRESSOR INLET -46°F
LIQUID LEVEL SATISFIED: 31%
TEMP LIQUID HIGH LEVEL: 40%
COMPRESSOR DISCHARGE 151°F DEFROST PUMP DOWN: 20 MIN
TEMP DEFROST HOT GAS REG: 90 PSIG
FAN DELAY: 2 MIN
NOTES:
- ROOM IS A SMALL BOX WITH A SINGLE UNIT.
- UNIT IS A PUMPED LIQUID EVAPORATOR USING AXIAL PROPELLER FANS AND A GAS
POWERED SUCTION OUTLET CONTROL VALVE.
- HOT GAS DEFROST METHOD USED.
- LIQUID FEED IS AN ELECTRIC SOLENOID VALVE IN SERIES WITH A HAND EXPANSION
VALVE.
- ENGINE ROOM USES MULTIPLE SCREW COMPRESSORS ARRANGED AS A TWO STAGE
SYSTEM
CRES SCREEN 23
DIRECT EXPANSION DOCK UNITS – NH3 NORMAL CONDITIONS
COIL SUCTION HEADER 30 PSIG AIR LEAVING TEMPERATURE 33°F
PRESSURE
COIL SUCTION HEADER 30°F ROOM AIR TEMPERATURE 35°F
TEMPERATURE
EVAPORATOR FAN 8.4 AMPS MODE: REFRIGERATING
MOTOR AMPS
COMPRESSOR INLET 28 PSIG PARAMETERS:
PRESSURE ROOM TEMP: 34°F
COMPRESSOR DISCHARGE 154 PSIG ROOM HIGH TEMP: 40°F
PRESSURE ROOM LOW TEMP: 32°F
COMPRESSOR INLET 34°F
TEMP DEFROST PUMP DOWN: 20 MIN
COMPRESSOR DISCHARGE 235°F DEFROST HOT GAS REG: 90 PSIG
TEMP FAN DELAY: 2 MIN
CRES SCREEN 24
DIRECT EXPANSION DOCK UNITS – NH3 ABNORMAL CONDITIONS
COIL SUCTION HEADER 30 PSIG AIR LEAVING TEMPERATURE 30°F
PRESSURE
COIL SUCTION HEADER 17°F ROOM AIR TEMPERATURE 33°F
TEMPERATURE
EVAPORATOR FAN 8.4 AMPS MODE: REFRIGERATING
MOTOR AMPS
COMPRESSOR INLET 29 PSIG PARAMETERS:
PRESSURE ROOM TEMP: 34°F
COMPRESSOR 154 PSIG R OOM HIGH TEMP : 40°F
DISCHARGE PRESSURE ROOM LOW TEMP: 32°F
COMPRESSOR INLET 17°F
TEMP DEFROST PUMP DOWN: 20 MIN
COMPRESSOR 140°F DEFROST HOT GAS REG: 90 PSIG
DISCHARGE TEMP FAN DELAY: 2 MIN
NOTES:
- UNIT IS A DIRECT EXPANSION EVAPORATOR WITH A SOLENOID ACTIVATED BACK
PRESSURE REGULATOR FOR EVAPORATOR PRESSURE CONTROL.
- HOT GAS DEFROST METHOD USED WHICH IS SUPPLIED FROM A COMMON
CONDENSER.
- LIQUID FEED IS AN ELECTRIC SOLENOID VALVE IN SERIES WITH A THERMOSTATIC
EXPANSION VALVE.
- ENGINE ROOM USES A SINGLE RECIPROCATING COMPRESSOR FOR THIS LOAD.
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
Refrigerant HCFC-22
Temp in Gauge Absolute Specific Specific Density Density
Degrees Pressure Pressure Volume Volume Liquid Vapor
Fahrenheit liquid Vapor
An Integrated Approach to
Efficient Industrial Refrigeration Systems Lighting
Lamp There are several useful measures of lamp performance that can be used to
Performance compare the products offered by different manufacturers. Some are:
Criteria
• Light output and power input
• Lumen depreciation
Light Output One measure of lamp performance is light output. For most lamps, output is
measured in total lumens or overall light output. Lumens is defined as the
amount of light generated by a light source. For directional light sources
(such as reflector lamps) light output (or the luminous intensity) is measured
in candlepower or candelas (cd). This is the directional intensity of light from
a point source.
Lamp efficacy is defined as the ratio of lumens of light output to total watts of
input power (efficacy = lumens/watts) and is the best way to measure a lamp’s
energy efficiency. Efficacy is a term that also can be used to assess the energy
efficiency of an entire lighting system. The higher the efficacy the better,
because that means we are getting more light (lumens) per watt.
Energy Consumption
Different lamps are rated for lumen output and lamp life under strict standards set by the
American National Standards Institute (ANSI). The ratings are based on specific combinations
of voltage, mounting orientation, ballast, and ambient air temperature. Differences in any of
these conditions can affect both input power requirements and light output, which in turn will
affect efficacy.
lumens/watt
umens/watt
lumens/watt
umens/watt
lumens/watt
Daylight fluorescent
6000 -
Clear mercury
5500 - Summer sunlight
5000 -
4500 - Metal halide
4000 - Cool white
3500 - White
Tungsten 3000 - Warm white; Metal halide
halogen 40-watt 2500 -
incandescent lamp 2000 - High pressure sodium lamps
Low pressure sodium lamps
Candle 1500 -
Reduced Heat
Gain Whenever a lower wattage lamp is retrofit in a refrigerated space, energy is not
only saved from the lighting itself but also from the reduced heat gain.
Each kWh of lighting savings is 3,413 fewer BTUs of heat in the refrigerated
space, and thus creates additional savings at the compressor.
The great advantages of a fluorescent light are its high light output per watt and
Fluorescent its long life.
Lamps
How Fluorescent A fluorescent light uses a fluorescent phosphor coating inside its tube. An
electric current is applied to electrodes that are positioned at each end of the
Lamps Work lamp which causes an arc to jump from one end of the lamp to the other. In the
process, ultraviolet radiation is emitted. When the radiation strikes the
phosphor coating, the phosphors begin to fluoresce (emit visible light).
Since the resistance of the arc decreases as current increases, the current
would destroy the lamp if not controlled. Also, in a fluorescent light circuit, a
relatively high voltage (one to three hundred volts) is required to initiate the arc,
and a much lower voltage is needed to maintain the arc and keep the lamp
lighted.
Comparing Next, we will describe a few fluorescent alternatives and discuss some of their
Fluorescent features and relative benefits. First, let’s look at the full length fluorescent
options. T-8 fluorescent lamps are full-size lamps. They were introduced in
Alternatives the United States in 1982, and are now made by all major U.S. lamp
manufacturers. T-8 lamps are available in several straight-tube and U-bent
configurations.
Like standard F40T12 (T-12) lamps, T-8 lamps are rated at 20,000 hours for
60 Hz rapid start. For highest effectiveness, they are often matched with
electronic ballasts. These operate the lamps in an instant start mode and at
25,000 Hz. (Electronic ballasts for rapid start operation are also available.)
T-8 lamps offer several advantages over the standard T-12 lamps:
• All T-8 lamps contain rare earth phosphors which means better color
rendering and lamp lumen maintenance when compared to T-12
halophosphor lamps— phosphors “love” high frequency. (Lumen
maintenance is a measure of how well a lamp maintains its lamp
output as it ages and is usually expressed as a curve.)
• Unlike T-12 lamps which have a tendency to trap light, T-8 lamps
allow more light to escape from the lamp.
/ inch
T-5
5 8
1 inch
1 inch
T-8
Diameter
1 ¼ inch
T-10
1 ½ inch
1 ½ inch
1 ½ inch
T-12
Ballasts A type of inductor known as a ballast serves both needs for high and low
voltage. It limits the current; and, for most sizes, it increases the voltage
for reliable starting and stable operation. Lamps of different sizes require
different ballasts.
ies the correct voltage that is needed to start an arc between the
two electrodes.
• Controls the electric current needed to maintain light output.
Magnetic vs. There are two fundamental ballast designs. Traditionally, fluorescent lamps
Electronic used electromagnetic (or simply “magnetic”) ballasts. The relatively recent
electronic (or simply “electric”) ballasts can help save energy. The specific
Ballasts ballast used has a significant impact on a fluorescent lamp’s energy efficiency.
T-5 lamps, which are 5/8” in diameter, have improved phosphors and are part
T-5 Lamps of a new generation of lamps that offer improved efficacy and optical control
when compared to T-12 and T-8 lamps.
T-5 lamps can be up to 18% more efficient than T-8 systems, have lumen
maintenance as high as 97%, and provide a high optimal operating
temperature that improves performance in enclosed fixtures. Also, T-5 lamps
and ballasts are much thinner than T-12’s and T-8’s and present sleeker and
more contemporary fixtures. T-5 lamps are used with specially designed, high
frequency electronic ballasts for optimum performance.
T-5’s originated in Europe and have metric lengths—they are about two inches
shorter than comparable T-8 and T-12 bi-pin U.S. lamps. A typical 1,150 mm
T-5 has a lifetime of 16,000 hours and generates 2,900 initial lumens. One
example lamp provides system efficacy over 100 lumens per watt, a CRI of 85,
and is available in color temperatures of 3,000, 3,500, and 4,000 K.
Other T-5 lamps have a rated life of 20,000 hours and come in standard sizes
of 14, 21, 28, and 35 watts. HO (High Output) sizes are 24, 39, and 54 watts.
• Wall washing
Key features
• Lens assembly features closed cell
neoprene gasketing and cam-lock latches;
the sealed housing retains the heat
produced by the lamps and ballasts
• Can be used down to -20° F
• Available in 4-lamp through 6-lamp 2 x 4
versions
• Peak light output at -10° F
T-5 Industrial For warehouse and interior lighting, the recent trend in lighting systems is
Fixtures and away from HPS (high pressure sodium) and toward industrial T-5 lighting.
Older warehouse and interior lighting are being converted to linear
Applications fluorescent.
The old rule of thumb in the lighting industry says that for indoor settings,
fluorescent lighting made the most sense for low ceilings below about 15 or
20 feet and high-intensity discharge (HID) lighting was the best choice for
higher ceilings (high-bay applications). This is no longer the case.
Today’s high-output T-5 fluorescent lamps and specially designed high-
bay fluorescent fixtures can now work well in the high-bay applications.
There are now at least a dozen fixture manufacturers who are producing high-
bay fixtures for long twin-tube or straight-tube T-5 lamps. These fixtures
typically come with four to eight of the very bright T-5 lamps in a relatively
small luminaire with high-efficiency reflectors that deliver almost all of the light
output downward.
Replacing metal halide HID high-bays with T-5 high-bays can provide energy
savings of 50% or more. The savings are a result of the features of the newer
T-5 fixtures:
HID lighting has been around for over 100 years. HID lamps produce light with
an electric arc through a tube that contains gases. Like fluorescent lamps, HID
lamps require a ballast for starting and operating the lamp. HID lamps generally
have a good to excellent CRI and are available in sizes from 39 W to 1500 W.
Included in this lighting group are Mercury Vapor (MV), Metal Halides (MH),
Low Pressure Sodium (LPS), and High Pressure Sodium (HPS).
• Mercury vapor is the oldest type of HID lighting. It is mostly used for
street lighting. Most indoor mercury vapor lighting has been replaced
with metal halide lighting, which has better color rendering and
efficiency.
• Metal halide lamps are similar to mercury vapor lamps and are used in
large indoor areas such as gymnasiums and sports arenas, and for
outdoor areas. Compared with mercury vapor lamps, metal halide
lamps have higher light output, more lumens per watt, and better color
rendition. The first metal halide lamp was developed about 1960.
• Their high intensity limits the range of application for metal halide
lamps and requires the use of sophisticated fixtures.
Although HID lighting is popular, most HID lamps take several minutes to
HID Lamp Warm-up reach full light output. This makes them less amenable to automatic control,
and they cannot be efficiently switched off and on without creating
Time inconvenience for occupants. (Some lamps over 400 watts are available with
instant restrike capability, but they require special ballasts.)
Depending on the type of lamp, HID lamps may need from one minute to as
much as 15 minutes for a “restrike.” (Restrike refers to turning the light back
on after it has been turned off.) For example, a typical low pressure sodium
lamp requires 7 to 15 minutes for a “cold” restrike but less than one minute for
a “hot” restrike.
During the warm-up period the gases used to create the lighting arc rise to
the necessary temperatures.
• Discrete LEDs
• Chip LEDs
The discrete package, also called the “through-hole” LED, is the most common.
Its packaging includes a reflector to gather and focus the light and a plastic
dome envelope, which determines the beam-spread and protects the LED.
The surface mount chip packaging consists of only a flat plastic lens. Chip
LEDs are micro-soldered to a circuit board and, because they have no
reflector or dome envelope, provide a wider beam spread at lower intensity
than discrete LEDs.
Significant technology developments during the past few years have reduced
LED Exit Signs the cost and improved the practicality of LED exit signs. Second-generation
LEDs have been developed that are up to 30 times as bright as earlier ones.
The higher light output allows the LEDs to be used in exit sign boxes in the
same way as incandescent and fluorescent lamps, instead of using the LEDs
in direct view to spell “EXIT.” The use of strips of LEDs or LED lamps makes
them feasible for retrofit applications. LED Exit Sign Retrofit Kit are designed
for retrofitting either incandescent or compact fluorescent exit signs and can
consume as little as 1.5 watts.
Manufacturer’s estimates of the life of LED lamps generally range from 30,000 to 100,000 hours depending
on the type and the color. For example, red LEDs have a rated life up to 10 times longer than white LEDs.
(100,000 hours is a little over 34 years at 8 hours per day.) It is possible that the actual life is longer. One
manufacturer claims that 80 to 100 years is a reasonable expectation.
Typical fluorescent or incandescent lamps are given a “rated lamp life” which is based on standard tests that
document the number of lamps that fail. On the other hand, LEDs don’t really fail; instead they begin to
“fade away,” but continue to operate. This means new test methods will need to be developed to measure the
useful life of LEDs. The latest generation of LEDs have a longer life and operate at about 85% of their
original output after about 20,000 hours.
The optical control is a distinct advantage for this type of LED, in that the array of lenses can be customized
to control the beam of light to point it at desired areas and avoid illuminating areas that are not desired.
LED’s also function well under cold temperatures and restrike instantly from an off state.