P5731 Basic Refrigeration Build Bench

The P5731 basic build bench is the starting point for any tradesman
or engineer for whom making up or repairing refrigeration circuits
will be required. The bench provides a very simple circuit that would
be expected to take a student ten hours of lab time to build and test
as a working refrigeration circuit. The circuit comprises of a com-
pressor, condenser coil, capillary tube and condenser coil, with the
appropriate fans, driers filters and thermostat to make a working
circuit. Sufficient materials for 20 typical builds are provided.
The benches require the students to
Identify the components and set them up for assembly.
Pipe the components using flaring tools, pipe bending and
brazing tools.
Wire the components from the detail wiring diagrams.
Vacuum the bench and fill with refrigerant.
Detail instructions are provided for each step of the build process,
allowing students to progress at the appropriate pace for them. The
benches are ideal for students working either individually or in pairs.
REFRIGERATION AND AIR CONDITIONING
CUSSONS TECHNOLOGY LABORATORY RECOMMENDATION
Cussons Refrigeration laboratories are offered to provide teaching to a range of different skill levels. In all the
laboratories teaching the principle of the refrigeration cycle is a key element, from which further products are
offered to take students into commercial refrigeration and other areas.
The Assembly Range provides practical experience for students to build up their own working refrigeration circuits,
(with step by step instructions). The Vocational range provides a number of circuits for analysis and for practical
experience in fault finding. The Experimental range is designed for technical evaluation of all elements of the
refrigeration circuit through experiment and analysis. Additional ranges such as the modular range and stack units
provide a cost effective way to widen the variety of experiments. The Air Conditioning Range is increasingly
important and provides a variety of products from automotive through to industrial air conditioning.
Whilst each range is coordinated and can provide a complete laboratory, it is also a good idea to consider
purchasing a mix of products from each range if this suits your needs best. Each product is supplied as a stand alone
product with its own manual.
The experimental range can be supplied with or without Cussons CuDaq Data Acquisition
Please see www.cussons.co.uk for additional information on any product, or contact sales@cussons.co.uk
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The Assembly Range provides practical experience for students to build up their own working refrigeration circuits. Each bench
is provided with step by step instructions). The basic refrigeration bench provides an excellent introduction, whilst the commer-
cial bench introduces components used in commercial refrigeration. The beverage cooler and wiring skills benches are targeted at
those market segments.
Refrigeration Assembly Range
P5734 Beverage Cooler Build Bench

This bench is designed to provide practical experience to
those students who may work in the support of the bever-
age cooler industry
The bench mounted refrigeration system is equipped
with a facia mounting plate, on which a mimic of the
refrigerant circuit is provided showing the compressor,
condenser and evaporator within an insulated chamber.
An expansion valve, driers and filters are included in
the circuit, and a range of different. joint techniques are
required as part of the assembly process, such as brazing
and pipe flaring.
Pressure transducers and thermocouples can be installed
in the circuit.
Detail, step by step assembly instructions are provided.
Faults can be initiated by switches set in the control and
monitoring circuits
P5732 Commercial Refrigeration Build Bench

This build bench is also designed for student assembly. It is
designed to provide the next step after the basic build
bench. The pipe manufacture and assembly require greater
skills. Additionally the components on this bench are those
associated with commercial refrigeration (rather than do-
mestic refrigeration) practice.
The circuit is driven by a semi hermetic 1 HP unit
A receiver and isolation valves are included.
The expansion is through a thermostatic device
The evaporator includes an electric heating defrost
circuit
Control is provided by a more advanced program-
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P5735 Refrigeration Wiring Skills Bench

This bench is designed to provide practical experience to
those students who intend to work on the wiring of refrig-
eration circuits.
The unit is a bench top mounted unit, and with a
mimic of the refrigeration circuit on the front panel.
Junction boxes for mechanical components such as
compressors, condenser fans, thermostats and trans-
ducers are provided to which the wiring can be in-
stalled.
A range of different fuses, isolators and circuit
breakers are provided to teach the basics of circuit
protection. Detail, step by step assembly instructions
are provided.
Faults can be initiated by switches set in the control
and monitoring circuits
Step by step assembly instructions are provided.
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P5720 Domestic Refrigeration Trainer

This trainer is designed as an introduction to the range to
provide students with a clear understanding of the basic
refrigeration system and its safe operation.
The unit comprises a bench mounted refrigeration circuit.
A mimic of the refrigerant circuit is provided on the front
panel showing the circuit comprising of compressor, con-
denser and evaporator within an insulated chamber.
Expansion of the refrigerant is possible through a number of
different devices such as a regulating valves and capillary
tubes of various lengths. Pressure is displayed at two points
on the circuit.
Faults can be initiated by switches set in the control and
monitoring circuits
P5722 Multi Compressor Circuit Trainer

P5722 provides experience in the use of multiple compres-
sors, a common feature of commercial refrigeration, and vital
in industrial refrigeration circuits. Three compressors can be
run in parallel or individually. The load between the three
compressors is shared by a compound controller.
The trainer is provided on a wheeled, floor mounted frame
based and comprises a refrigeration system with three com-
pressors and a compound controller.
An air cooled condenser is provided, together with an electri-
cally heated evaporator built into a brine bath.
A mimic of the refrigerant circuit is provided on the front
panel showing the circuit .
Faults can be initiated by switches set in the control and
monitoring circuits
P5721 Domestic Refrigeration Trainer

Whilst the principles of refrigeration circuits are learnt on
the P5720 most students will work with commercial refrig-
eration circuits and the P5721 trainer provides the circuits
and components that reflect the additional complexity.
This commercial Refrigeration Trainer is similar to the
P5720, being a bench top mounted unit, and with a mimic
of the refrigeration circuit on the front panel.
However the circuit is considerably more complicated in-
cluding one chamber for chilling and one chamber for fro-
zen produce.
The circuits are arranged within the evaporators to allow
for hot gas defrosting.
Faults that can be simulated include blockage of pipes, fil-
ters, failure of expansion devices, thermostats etc.
P5723 Cold Room Refrigeration Trainer

P5723 provides practical experience in maintaining a cold
room at a set temperature.
The unit is also provided on a wheeled floor mounted
frame, and with a mimic of the refrigeration circuit on the
front panel.
The insulated chamber is provided with two air evaporators
focusing on opposite sides of the chamber.
A heat source can be moved within different areas of the
cold room, whilst thermostats provide control signals to
the expansion valves.
Faults that can be simulated include blockage of pipes, fil-
ters, failure of expansion devices, thermostats etc.
Cussons Vocational and Fault Finding Benches are designed for technicians and engineers for whom fault find-
ing in refrigeration circuits is an important part of their career prospects. However the benches also provide a
general introduction to fault finding techniques as well as a good understanding of refrigeration systems.
Vocational and Fault Finding
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P5724 Compressor Control Simulator

P5724 is a bench top mounted control simulator utilising
a programmable logic controller to simulate the operation
and consequences of problems in compressor safety, op-
eration and starting.
A mimic of the electric circuit is provided on the front
panel with a range of commercial products such as con-
trols and switching devices.
Faults can be initiated by side mounted switches so that
the lecturer can keep them hidden from students view.
Symptoms of the failure are indicated by the illumination
of LEDs and the students are required to relate these
symptoms to determine which fault had been initiated.
Twelve different faults can be initiated, such as loss of
power, fuse failure, motor coil failure etc.
Control Simulators P5724 and P5725

These two simulators are important for engineers and techni-
cians who may be responsible for plant where multi compres-
sors or motors are used, or where a large circuit means control
is maintained remotely.
These simulators provide operational and fault finding experi-
ence in this type of operation.
P5725 Refrigeration Control Simulator

The P5725 refrigeration control simulator provides a simulation
of a commercial refrigeration circuit such as that found in a
supermarket supply system. A range of failure scenarios are
available.
Cussons Experimental Benches are designed for engineers for an analytical understanding of refrigeration circuits is required as
part of their thermodynamics curriculum, or as part of the preparation for a career in refrigeration and air conditioning. All
products in the experimental range can be provided with Cussons CuDaq Data acquisition system as an extra price option.
P5750 Vapour Compression Refrigerator Unit

This comprehensive experiment allows the study of the thermo-
dynamics of a vapour compression cycle operating as either a
refrigerator or a heat pump.
Comprises vapour compression refrigerator and heat pump for
with two cylinder reciprocating compressor tapped for pressure
transducer. The unit is driven by a dynamometer instrumented to
determine the input load. The motor has a variable speed drive.
The refrigerant passes to an instrumented water cooled condenser
and through a manually controlled expansion valve.
The evaporator is within a water-glycol bath with electrical heat-
ing, again fully instrumented.
Instrumentation to include pressure gauges (3), multi-point direct
reading electronic thermometer for all temperatures under push
button control, variable area flowmeters for water flow and refrig-
erant flow, meter for heating element current, meter for torque
readout and tachometer.
Instrumentation is incorporated within a five colour instrument
panel with flow diagram.

P5751 Data Acquisitionwhen factory fitted this CuDaq
data acquisition records data to a personal computer.
Experimental Benches
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P5755 Refrigeration Trainer Unit

The Refrigeration Trainer Unit is a bench top mounted
unit, designed for ease of understanding for engineering
students. It makes a low cost introduction to refrigeration,
as it does not have the level of control or instrumentation of
the P5750.
The unit comprises of a rear frame, fronted by a transparent
facia sheet, on which instruments are mounted.
A mimic of the refrigeration circuit is silk screened on the
facia so that students can follow both the cycle and relate
the cycle to the physical components.
The system comprises of a motor driven compressor, pump-
ing refrigerant into a condenser and through a manual ex-
pansion valve into the evaporator.
The condenser is cooled by a secondary water flow, whilst
the evaporator is prevented from icing over by water flow.
Temperatures are measured by thermocouple and displayed
by a digital display unit. Float type flow meters are pro-
vided to measure the water flow into the condenser and
into the evaporator.
A pressure gauge is used to show the pressure at the con-
denser and a second gauge shows the pressure at the evapo-
rator.
Alternative refrigeration systems

Whilst compression is the normal power source for most
refrigeration systems, engineers should be aware of two
other refrigeration systems; absorption and steam injec-
tion. Cussons offers two experimental rigs.


P5758 Absorption Refrigeration Apparatus

The absorption refrigeration apparatus is a desktop unit
able to provide students with a clear and effective under-
standing of absorption refrigeration.
The circuit contains a mixture of ammonia, hydrogen and
water and comprises of a boiler, condenser, evaporator
and the absorber.
The system is maintained at sufficient pressure so that the
ammonia is in a liquid state, until heat is applied to the
boiler.
The evaporator is fed with hydrogen, which causes the
ammonia to evaporate, chilling the chamber.
The product includes four pressure gauges and eight ther-
mocouples.
The evaporator is water cooled to allow an energy output
to be determined.
The boiler is electrically powered but propane gas is avail-
able as a costed option.
P5759 Steam Jet Refrigeration Apparatus

The apparatus is bench mounted and comprises of a small
propane powered steam boiler. The gas flow can be varied
to vary the steam supply.
The evaporator from which the water vapour is drawn by
the low pressure chills a small flow of water.
Thermocouples and a collecting jar allow the cooling effect
to be measured.
The steam drain is cooled by an air cooled condenser, and
returned to the evaporator in a batch process.
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Air conditioning has become an essential of life for an increasing proportion of the population. Cussons offer a range of train-
ing and experimental air conditioning units.
Compressors, comprising three modules, each with outlet pressure gauge and cut off,
1. Hermetic Type 2. Semi hermetic type or 3. Open type
Condensers, comprising two modules,
1. Air cooled type with fan, with thermocouples or
2. Liquid receiver, with water flow meter, water control and thermocouples
Refrigerant flow meter
(visual flow), drier and filter module
Thermostatic expansion valve
1. (capillary tube) with equaliser 2. Circuit with manual needle valve (without equaliser). Module includes pressure gauge and
thermocouple
Evaporators, comprising two modules,
1. Water evaporator with electrical heaterthe heater power is adjusted to balance cooling and a timer cut out is provided 2.
Finned air evaporator with fan
Electrical services module
displaying temperatures digitally and providing services to other modules. This module is permanently mounted on the support
frame.
Each module is connected to its appropriate services by quick connect plug in units.
The refrigerant circuit can be isolated at each module interface by shut off valves, and a short flexible hose unscrewed to mini-
mise refrigerant loss. The shut off valves can be used for fault simulation. Temperatures are measured by thermocouples, which
are connected via plugs to a digital display on the electrical services module.
P5801 Split System Domestic A/C Trainer

A bench top mounted trainer utilising a split system domestic air conditioning
package. The compressor and condenser are mounted within one unit at the
rear of the bench whilst the evaporator and thermostat are mounted on the front
of the bench.
Two pressure gauges show the pressure in the system. A mimic of the refrigerant
circuit is provided on the front panel together with a temperature display.
Faults can be initiated by side mounted switches so that the lecturer can keep
them hidden from students view. Symptoms of the failure are indicated by the
illumination of LEDs and the students are required to relate these symptoms to
determine which fault had been initiated.
Ten different faults can be initiated, such as loss of power, fuse failure, motor
coil failure etc.
P7540 Modular Refrigeration Range

The Cussons Modular Refrigeration System makes up a working refrigeration circuit through the selection
of the different modules. Available modules comprise of the following:
Air Conditioning Systems
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P5802 Car Air Conditioning Trainer

Cussons Automotive Air Conditioning Trainer unit is similar
to the P5801, being a bench top mounted unit, but with a
mimic of the refrigeration circuit on the front panel.
The components are typical of those used in production cars.
The compressor is driven from an electric motor. The control
and indication circuits all operate at 12V. Faults that can be
simulated include blockage of pipes, filters, failure of expan-
sion devices, thermostats etc.

P5803 Open Duct Air Conditioning Trainer

P5803 provides a realistic introduction to the theory and
practice of typical commercial air conditioning.
This trolley mounted trainer utilises an open duct air condi-
tioning system cooled by a compact refrigeration plant. The
compressor and condenser are mounted within one unit at
the base of the trolley, whilst the evaporator and thermostat
are mounted within the open duct. The unit has eight ther-
mocouples and two pressure gauges.
Airflow in the duct is controlled by a variable speed motor,
and the flow is measured by differential pressure trans-
ducer. A mimic of the refrigerant circuit is provided on the
front panel, together with a temperature display. Faults can
be initiated by side mounted switches so that the lecturer
can keep them hidden from students view. Symptoms of
the failure are indicated by the illumination of LEDs and
the students are required to relate these symptoms to deter-
mine which fault had been initiated. Ten different faults can
be initiated, such as loss of power, fuse failure, and motor
coil failure etc.
P5804 Air Conditioning with Climate Chamber

The air Conditioning Trainer with climate chamber is similar
to the P5803, but comprises of a closed air circuit, routed
through a modest climate chamber. This is an advanced vo-
cational and experimental system.
The air conditioning unit therefore includes a humidity con-
trol and steam injector system. The climate chamber includes
an electric heater, and a water tray can be introduced to vary
the demand from the chamber. Humidity sensors and addi-
tional thermocouples are provided for different points in the
system. A flap drive is used to regulate the mix of fresh to re-
circulated air. A PLC controls the unit.

P5810 Domestic A/C Simulator

Cussons offer two PLC driven simulators to provide operat-
ing experience for air conditioning systems.
A bench top mounted control simulator utilising a program-
mable logic controller to simulate the operation and conse-
quences of problems in a domestic air conditioning system.
A mimic is provided on the front panel showing the circuit
flow. It includes a range of commercial products such as
thermostats and switching devices. Faults can be initiated
by side mounted switches so that the lecturer can keep them
hidden from students view. Symptoms of the failures are
indicated by the illumination of LEDs, and the students are
required to relate these symptoms to determine which fault
had been initiated. Twelve different faults can be initiated,
such as loss of refrigerant, failure of evaporator fan etc.
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The Company may alter detail specifications at its discretion and without notice, in line with its policy of continuous development.
102 Great Clowes Street, Manchester M7 1RH, England
Tel. +(44)161 833 0036 Fax. +(44)161 834 4688
E-mail: sales@cussons.co.uk Web: www.cussons.co.uk
Cussons Technology Ltd.
Issue 1
P5811 Commercial A/C Control Simulator

The unit is similar to the P5810, being a bench top mounted
unit, but with additional controls such as humidity meas-
urement devices and controls for the proportion of air to be
re-circulated and to be admitted. It can be set to operate in
a warm climate or cold climate mode.
P5780 Thermodynamic Trainer Unit

To complement an understanding of refrigeration, training in
heat exchangers and heating systems can also be useful to
trainees.
P5780 comprises of a range of different heat exchangers
through which a hot water circuit and a coldwater circuit can
be pumped.
Hot water is provided by an thermostatically controlled, elec-
tric water heater. Heat can be lost from the cold water system
by diverting the water through the water and air radiator. The
unit incorporates suitable flow rate, temperature and pressure
measurement required for each experiment. P5780e includes
a data acquisition system incorporating a computer with
mimic display showing readings of temperature and pressure
in real time.

P5670 Air to Water Heat Pump

This trolley mounted apparatus comprises semi-hermetic,
twin-cylinder, air-cooled, reciprocating compressor. A shell
and tube type condenser with water on the tube side; an air
handling unit with 3 speed fan provided with measurement
points for wet and dry bulb temperatures at inlet and outlet.
Fitted with air flow measurement orifice on a removable inlet
duct.
The exhaust duct is fitted with silencer and unit housing di-
rect expansion evaporator for the working fluid. Instrumen-
tation consists of
Eight thermocouples around the circuit; cooling water tem-
perature into and out of condenser, and wet and dry bulb air
temperature at inlet and outlet of air handling unit,
Four pressure measurements of the working fluid
Flow rates of water and refrigerant, measurement of air ori-
fice depression and compressor electrical power input.