e’ll start this series from the

beginning where, unfortunate-

ly, the typical rink refrigeration

system training between experienced and

new operators goes something like this:

Through this series of articles, we are

hoping to help get this type of training to

progress a little further. While we do rec-

ommend that a bound book be used to

add credibility to the refrigeration logs, at

a very minimum create your own log that

is tailored to your equipment. There are

preprinted logbooks available from STAR

and some refrigeration manufacturers.

A logbook is good for risk management

and accountability. However, when it

comes to refrigeration logs, troubleshoot-

ing and maintenance are the main benefits

of keeping detailed information.

A good refrigeration service company

will check out the refrigeration logs

before performing any maintenance on

the system. During routine maintenance

visits, the information in the logs will let

the refrigeration mechanic see how the

system has been operating and alert

them to any abnormal conditions that

may exist.

Reading& Reacting

RINK REFRIGERATION 101

48 RINK MAGAZINE january/february 2010 STARrinks.com

How TO:

part 1 of 6This year RINK Magazine will discuss refrigeration in an educational 6-part series. This informationcan be shared with your staff to promote some good discussion and possibly even enhance the ability of your operationsstaff. We encourage you to share your comments, ideas and repairs related to rink refrigeration systems by sending themalong with pictures to davew@starrinks.com.

RINKPHOTOS

While reading andrecording the gaugesis part of the job,understanding thereadings is criticalto trouble shootingand maintenance.

“This is the refrigeration plant,DON’T TOUCH ANYTHING.

Just read these gauges and callme if something is wrong.”

by DAVE WESCOTT

W

48_How to JanFeb10:how to 12/22/09 12:31 PM Page 48

If the refrigeration mechanic is there

for an emergency call, such as the system

being down, the refrigeration logs can

help troubleshoot the problem and, in

most cases, save valuable time and effort

in getting the system running again.

Reviewing a sample logbook page

will give you a good idea of the items

that need to be recorded. The main suc-

tion and discharge pressures are indica-

tors of the heart of the system, and how

it is functioning. Brine/Glycol supply

and return temperatures let the opera-

tions staff know that the system is hold-

ing the temperatures needed for good

ice conditions.

Making sure the operators know and

understand what the gauges are reading,

and the proper limits for these readings,

is very important. There are many stories

from refrigeration mechanics who have

found refrigeration logs revealing

improper readings. However, because of

a lack of training, the operators taking

the readings never alerted anyone and

the refrigeration plant failed. Therefore,

it is very important to train the opera-

tors reading the gauges and make sure

they understand what they mean and

what the proper readings are.

Basic Refrigeration Courses are being

offered by STAR in many locations

across the country this year. This is great

training for staff that is responsible for

monitoring refrigeration equipment.

Graduates of the Basic Refrigeration

course have returned to their facilities

and have immediately been able to help

operate the plant more efficiently and

save some money on service calls, as they

themselves were able to troubleshoot and

solve minor problems. Many of them

saved much more money then was spent

to send them to the training! �

Making sure theoperators know andunderstand what thegauges are reading, andthe proper limits forthese readings, is veryimportant. There aremany stories fromrefrigeration mechanicswho have foundrefrigeration logsrevealing improperreadings.

january/february 2010 RINK MAGAZ INE 49STARrinks.com

get your logbook today!Order by contacting STAR atinfo@starrinks.com

48_How to JanFeb10:how to 12/22/09 12:32 PM Page 49

o you know exactly how yourrefrigeration plant is con-trolled? If not, you could be

missing out on an opportunity to operate

the plant more efficiently.

Most refrigeration plants built before

the 1980s relied on a thermostat in the

return brine line to control the operation

of the compressors. While this was a reli-

able way to control the compressors, it

was not the most efficient system because

of the delayed reaction time.

This design also requires the

brine/glycol pump to run continuously to

ensure that the thermostat receives the

current brine/glycol temperature.

Running the brine/glycol pump this way

can cost as much as $500 to $1,000 more

per month in energy costs.

When using the return brine/glycol

thermostat to operate the compressors,

any heat that is applied to the ice slab

(such as resurfacing) has to pass through

the ice, into the rink floor pipes. The heat

then must enter the secondary refrigerant

(brine/glycol) where it is carried back to

the compressor room so that the brine

return thermostat can sense the heat load

and activate the compressors.

This is a long lag time for the compres-

sors to react. The ice technician must rec-

ognize that the reverse needs to occur once

the ice surface is back down to the set

operating temperature. Note: The system

will not shut down until the brine/glycol has

reached a lower temperature than the ice

sheet, which may make the compressors run

more than required.

Technical advancements in the 1980s

saw slab sensors become a more reliable

way to operate the compressors. When

using a slab sensor, the heat put onto the

ice surface only has to travel down

through the ice where the slab sensor

reacts to activate the compressors. This

occurs regardless of whether or not the

brine/glycol pump is running. Once the

RINK REFRIGERATION 101

48 RINK MAGAZINE march/april 2010 STARrinks.com

How TO:

part 2 of 6This year RINK Magazine will discuss refrigeration in an educational 6-part series. This informationcan be shared with your staff to promote some good discussion and possibly even enhance the ability of your operationsstaff. We encourage you to share your comments, ideas and repairs related to rink refrigeration systems by sending themalong with pictures to davew@starrinks.com.

RIN

KP

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Facilities that have multiple controls shouldoperate each independently to determine whichruns the system most efficiently.

Understanding What Controls RefrigerationPlant Temperature Settings by DAVE WESCOTT

D

Understandingthe controlsand makingadjustmentscan save youmoney.

48_How to MarApr10:how to 2/24/10 3:41 PM Page 48

slab reaches the proper temperature, the

system should control the compressors to

hold the temperature of the slab.

In the 1990s, infrared temperature sen-

sors became an option to operate the

refrigeration plant. The reality is the ice

surface temperature is the primary con-

cern of the ice technician. Infrared sensors

react quickly by sensing the heat load of

not only the ice resurfacer when it starts to

work, but also a large user load or a hot

day that warms up the ice surface. The

infrared sensor will work to keep the ice

surface at the set temperature.

The infrared sensor will also identify

when the surface is back down to the

set operational temperature, and will

shut down the compressors at the set

surface temperature. Infrared systems

will also help prevent the temperature

of the ice from getting too cold from

outside temperatures, offering energy

savings.

Facilities that have multiple controls

for their compressor system should con-

sider having the ice technician operate

each independently in order to deter-

mine which runs the system the most

efficiently.

It is worth stressing the importance

of always being careful not to operate

your compressors in a manner that

adversely affects ice quality. Learn your

system, operate it properly and save

energy in the process. �

march/april 2010 RINK MAGAZ INE 49STARrinks.com

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48_How to MarApr10:how to 2/25/10 9:55 AM Page 49

What type of refrigerationplant do you have?

This is the first question to ask as many

rink operators may not be sure what type

of refrigeration plant is in their building.

While it might seem like it’s OK not to

know your system because someone else

takes care of the maintenance, it is impor-

tant to understand how things works in

order to talk to service contractors intelli-

gently. If you don’t have a basic under-

standing of how things work, you are leav-

ing yourself exposed to potentially being

taken advantage of when it comes to serv-

ice and repairs.

Some of the basic information you need

to know about your system includes:

Is your ice plant a directsystem or an indirect system?

Direct systems only use primary refrig-

erant to cool the rink floor and have a large

amount of this refrigerant, somewhere

between 3,000-5,000 pounds per rink.

Freon would be the only refrigerant used

in this type of system.

Indirect systems use both a primary

and secondary refrigerant. The primary

refrigerant will remain in the ice plant and

condenser. The secondary refrigerant will

be circulated between the ice plant and the

rink floor. This is the most common sys-

tem used in the U.S.

What type of primary refrigerant doesyour system use?

The two main types of primary refrig-

erants used in ice arenas are fre-

ons and ammonia. The primary

refrigerant is the substance that

removes the heat and will be in

a liquid state. As it picks up

heat it boils and changes to a vapor/gas

which takes the heat and goes through the

compressor and ultimately out to the con-

denser that rejects the heat outside the

building. You should also know what type

of freon you have (R22 or R134A, etc.) if

that is your primary refrigerant.

What type of secondaryrefrigerant does your system use?

The two main types of secondary

refrigerant are salt brine (calcium chloride)

and glycol (ethylene or propylene). The

secondary refrigerant is the substance that

removes the heat by not changing state.

The secondary refrigerant will remain in a

liquid state as it is pumped through the

pipes in the rink floor and returns to the

chiller (evaporator) in the compressor

room. In rare cases you may find

methanol used as a secondary refrigerant.

What type of condenserdoes your system use?

Evaporative condensers are the most

common type used in ice arenas. This type

of condenser uses air and water to cool the

hot gas in the pipes running through the

condenser. This also requires that the sys-

tem have enough primary refrigerants to

be piped out of the building to the evapo-

rative condenser.

Water-cooled

condensers will

work in combi-

nation with a

cooling tower to

allow water to

run between the tower and condenser. This

system keeps the primary refrigerant in the

compressor room where a smaller amount

of primary refrigerant is needed. Only

water is piped out of the building and cir-

culated between the water-cooled condens-

er and the cooling tower.

Air-cooled condensers are primarily

used in northern U.S. locations and also

with seasonal rinks, due to their limited

capacity to cool in hot temperatures.

These condensers are located outside and

will have the hot gas primary refrigerant

piped out to them. These look like large,

flat aluminum beds with lots of fans run-

ning on top of them.

What type of compressors do you have?The most common type of compressor

used in ice rinks is the reciprocating com-

pressor. This compressor works much like

a car engine with pistons and valves doing

the work.Like a car engine, it requires reg-

ular maintenance to operate efficiently.

We are seeing more screw compressors

being used in the rink industry lately and,

since they are more efficient and require

less regular maintenance, this trend

should continue.

With geo-thermal systems, scroll com-

pressors are being used for rink refrigera-

RINK REFRIGERATION 101

52 RINK MAGAZINE may/june 2010 STARrinks.com

How TO:

part 3 of 6This year RINK Magazine will discuss refrigeration in an educational 6-part series written by DaveWescott. This information can be shared with your staff to promote some good discussion and possibly even enhance theability of your operations staff. We encourage you to share your comments, ideas and repairs related to rink refrigerationsystems by sending them along with pictures to davew@starrinks.com.

52_How to MayJune10:how to 4/23/10 1:32 PM Page 52

tion. Scroll compressors are used in home

refrigerators and are sealed, requiring no

regular maintenance. However, when they

do fail, they have to be completely

replaced.

Knowing the manufacturer, size of your

compressors and the electric motors that

drive them is essential for rink operators.

And lastly, what type of chiller(evaporator) does your system use?

For facilities with direct systems, this

does not apply as direct systems use the

rink floor as the chiller (evaporator) to

remove the heat and turn the liquid pri-

mary refrigerant into a vapor/gas.

The chiller is a very important part of

the indirect refrigeration system because it

is in the chiller that the heat from the sec-

ondary refrigerant (brine/glycol) is trans-

ferred to the primary refrigerant

(Ammonia/Freon). This heat transfer has

to take place without the two substances

mixing with each other.

The main type of chiller used in ice

rinks is the flooded chiller. This type of

chiller floods the tubes full of secondary

refrigerant inside of a shell with the pri-

mary refrigerant.

The second most common type of

chiller used in ice rinks is the dry chiller

(also called direct expansion chiller). This

type of chiller floods the tubes full of pri-

mary refrigerant inside of a shell with the

secondary refrigerant.

The use of plate and frame chillers in

ice rink applications is becoming more

prevalent. These chillers are much small-

er in size and are more efficient for trans-

ferring the heat from the primary to the

secondary refrigerant. Plates are used

instead of tubes and a shell for larger sur-

face area, creating more heat transfer for

the size of the unit.

Any and all rink operators should

know which of these systems and pieces of

equipment are used in their rink. If they

don’t, the Basic Refrigeration course

offered by STAR would be able to bring

anyone up to speed on these systems. �

may/june 2010 RINK MAGAZ INE 53STARrinks.com

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52_How to MayJune10:how to 4/23/10 1:33 PM Page 53

In this installment we discuss

the start-up of the refrigera-

tion plant and the importance

of spare parts for your refrig-

eration plant.

First off, we recommend

that seasonal start-ups be per-

formed by your refrigeration

service professional. However, we also rec-

ommend that rink staff assist in the start-

up and learn how the procedure works, as

well as learning as much as possible about

the refrigeration system at your facility

from your service company. Add this

knowledge with the information your

employees can receive from a Basic

Refrigeration class and your facility will

benefit greatly.

Seasonal start-ups give you a chance to

make sure your plant is operating efficient-

ly. During the shutdown period you have

the opportunity to clean, inspect and eval-

uate your refrigeration equipment. It’s a

good idea to check out the refrigeration

room a couple of weeks before the sched-

uled start-up and complete a list of pre-

start-up procedures.

This list of prestart-up operations

should be developed with your service

company and will be specific to your sys-

tem. There will be items like inspecting

drive belts and couplings and checking

valves for leaks and proper operation along

with the refrigerant and oil levels.

If you wait until it’s too

close to start-up time to

perform the pre-startup

checks and find out you

need something replaced

or repaired, you may not

have the time to get the

parts and complete the

repairs before start-up.

The last start-up item

is to schedule plenty of

time to make the ice.

Planning one extra day

for any unexpected delay

is always a good idea.

Another topic that goes

hand in hand with the start-up is having a

good inventory of spare parts. There have

been many plant start-ups that have been

interrupted by a lack of spare parts. Some

facilities are fortunate to be located in

major cities that have parts within a day or

two of the facility. However,

for facilities located in more

remote places it can take

longer to receive parts, so

having spare parts on hand

is invaluable.

It’s a good idea to create

a spare parts inventory

with both your manufac-

turer and service company.

Things to consider: batter-

ies for your computer con-

trols, back-up software or

discs, fuses, motorstarter

contacts, relays and coils.

Also consider belts for the

compressors and condenser

and drive couplings for

compressors and pumps. If

not locally available, a spare

condenser motor should be

considered since there is no redundancy

for it and ice could be lost without it.

Preparation is the most important part

of the start-up process — the turning of

valves and flipping of switches is the easy

part. So, make sure you are prepared! �

RINK REFRIGERATION 101

42 RINK MAGAZINE july/august 2010 STARrinks.com

How TO:

part 4 of 6This year RINK Magazine will discuss refrigeration in an educational 6-part series written by DaveWescott. We encourage you to share your comments, ideas and repairs related to rink refrigeration systems by sendingthem along with pictures to davew@starrinks.com.

Start-Up andSpare Parts

The Chicago Blackhawkswill sure be looking for-ward to Start-Up of thisplant next year.

Sample pre-startProcedures• Check seal on water pumpfor leaks• Check spray nozzles oncondenser – make sure theyare not plugged

• Check all water and brinevalve stems

• Check all v-belts forwear/cracking

• Grease all bearings

• Check brine headers forcorrosion – wire brush &paint if necessary

• Conduct an internal inspec-tion of compressors (to man-ufacturer’s specifications)

• Check brine/glycol level andstrength (specific gravity)

• Drain the chiller of oil –ammonia systems

• Replace oil in compressors– check lines\filters

• Check seal on brine\glycolpump for leaks

• Drain/clean condenserwater tank

Drive Belts are a very impor-tant part to have on hand.

42_How to JulyAug10:how to 6/23/10 2:29 PM Page 42

For those of us fortunate enough to

have opened a new facility, we can

all remember how nice it was to go

into a nice, clean refrigeration room, with

a dry floor.

Now fast forward five years and see if

this sounds familiar: the floor is wet in a

lot of spots, oil is under the compressors,

ice has built up where repairs have been

made, insulation hasn’t been replaced, the

oil drums are stacked up and the room

has become a storage area for everything

from plywood to motor oil!

If in addition to the disorder already

described, your refrigeration room has

become the operations storage shed, it’s

definitely time to clean it up.

The refrigeration room is the heart of

your facility and should be treated as

such. Access to this area should be

restricted to trained personnel only and

the doors should be locked at all times.

These are dangerous areas with moving

parts and hazardous chemicals that

demand respect. All of our facilities have

children in them, and keeping kids out of

areas like the refrigeration room is very

important.

If your room has already deteriorated,

the first step is just getting the access to

the room under control. Once this is

accomplished, a thorough inspection of

the room should be done with staff and

the service company. Identify all items

that need to be addressed and try to pri-

oritize them, with safety-related items

being first on the list. It’s best to create

two lists, one that the staff can work on

and another that the service company can

work on.

Each week assign the staff an area of

the room that is safe to work in to

accomplish cleaning and painting tasks,

and keep the work in process going until

the room is back in shape and looking

good.

So why should keeping things clean be

a priority in an already busy facility? As

with most mechanical equipment, the

cleaner it is the better it runs. Electric

motors, for example, will last longer and

run cooler if they are not covered in dust

and grime. The most important and cost-

saving reason to have a clean refrigeration

room is for the discovery and trouble

shooting of equipment problems.

RINK REFRIGERATION 101

32 RINK MAGAZINE September/October 2010 STARrinks.com

How TO:

part 5 of 6This year RINK Magazine will discuss refrigeration in an educational 6-part series written by DaveWescott. We encourage you to share your comments, ideas and repairs related to rink refrigeration systems by sendingthem along with pictures to davew@starrinks.com.

KeepIt Clean!

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32_How to SeptOct10:how to 8/24/10 5:13 PM Page 32

Imagine going into a room day after

day and seeing water and oil on the floor

and dirt on the pipes, compressors and

motors. Eventually you will not be look-

ing for things out of the ordinary because

it looks bad all the time. If a new leak

develops it could be days before it’s dis-

covered.

Now imagine going into that same

room and it’s clean and dry. As soon as a

leak of any type develops it will be noticed

right away, possibly saving time and

money on repairs.

Personal pride should be another fac-

tor in maintaining a clean equipment

room. After showing pictures of the

Chicago Blackhawks’ refrigeration room

to other NHL building operators at one of

their meetings, many other rink opera-

torss worked at getting their rooms as nice

as Chicago’s, including adding team logos.

When your staff keeps the equipment

room clean it will keep the pressure on

your service company to do the same. If

they are led to believe that you don’t care

how the room looks, they will not care

either and just add to the mess. So

remember, “Clean is Keen!” �

34 RINK MAGAZINE September/October 2010 STARrinks.com

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The Chicago Blackhawks added team logos to their refrigeration room as a nice touch.

32_How to SeptOct10:how to 8/24/10 2:21 PM Page 34

As any STAR Basic Refrigeration class graduate can tell you,

the definition of refrigeration is the “removal and transfer

of heat under controlled conditions.” The refrigeration

system in your rink is not making the ice sheet cold; it is actually

removing heat from the ice sheet. The resulting temperature is

then below the other areas of the building and below the freezing

point of water.

The condenser, the single most important piece of equipment

in the refrigeration system, removes heat and controls operating

pressures. There are three types of condensers: water-cooled, air-

cooled and evaporative (combination of water and air). Hot

refrigerant gas (ammonia or freon) is moved through the con-

denser by the compressor or compressors. The gas is cooled in

the condenser, causing it to condense back into a liquid before it

goes back into the evaporator (chiller). When the refrigerant gas

is cooled to the condensing point, latent heat of

vaporization occurs and the heat in the gas is

released, allowing the gas to condense back to a

liquid. In most refrigeration systems the con-

densing point is usually about 90 degrees

Fahrenheit.

If a condenser gets a build up of dirt or miner-

al deposits on its coil of tubes, or has poor air

and/or water flow it will make it harder for the

gas to condense to a liquid. Also, if the outside

air temperature is close to the condensing point

of the system (summertime), the condenser will

be less efficient at condensing the gas. Both of

these conditions will cause the pressure to rise in

the high side of the system. When the high side

pressure rises, the compressors must work harder

to move the gas, using more electricity.

Unfortunately, some facilities have undersized

condensers and therefore run consistently high

pressures, causing higher utility bills and extra

RINK REFRIGERATION 101How TO:

part 6 of 6This year RINK Magazine will discuss refrigeration in an educational 6-part series written by DaveWescott. We encourage you to share your comments, ideas and repairs related to rink refrigeration systems by sendingthem along with pictures to davew@starrinks.com.

Efficiently RemovingHeat and Energy

Water treatment is very important for evaporative and water-cooled condensers.

The classic evaporative condenser.

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34 RINK MAGAZINE november/december 2010 STARrinks.com

34_How to condensors NovDec10:how to 10/26/10 10:49 AM Page 34

STARrinks.com november/December 2010 RINK MAGAZ INE 35

wear and tear on the compressors.

Getting your condenser to work properly will take some rou-

tine maintenance. Most ice rinks operate with an evaporative

condenser because they are the most efficient type. These con-

densers use air and water circulated over tubes in the unit to cool

off the hot gas. Just 1/16 inch of mineral scale build up on the

tubes will cut the heat removal efficiency dramatically. Chemical

water treatment of the condenser cooling water is critical to limit

this mineral build up. However, even with chemical water treat-

ment, it is important to manually clean the outside of the tubes

and water nozzles regularly.

Water-cooled condensers use water circulated through tubes

that are surrounded by the hot refrigerant gas. This type of con-

denser will also get mineral build up inside the tubes, making

chemical water treatment very important. Manually cleaning the

tubes must be done regularly to maintain proper water flow

through the tubes. This cleaning process usually includes run-

ning a rod with a brush on the end to clean out the tubes.

Air-cooled condensers are the least efficient of the three types

of condensers, but also require the least amount of maintenance.

The only regular maintenance needed to keep these condensers

running efficiently is pressure washing dirt and debris off the

coils. However, in warm weather air-cooled condensers can

struggle to condense the gas completely.

If you start to notice your high side pressure increasing gradu-

ally over a period of time or experience sudden rise in pressure,

take a look at your condenser. Dirty coils, clogged water spray

nozzles, faulty water pumps, broken fan belts and faulty fan

motors are the major culprits of high pressure. Remember that

when high side pressure goes above its normal operating range,

you can be sure your electric meter is going up too! �

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34_How to condensors NovDec10:how to 10/26/10 10:50 AM Page 35