Air Conditioning and Refrigeration · 2nd Edition by Miller, Rex -- Read -- Imperial Library of Trantor

Index

Preface Acknowledgments 1 Tools, Instruments, and Specialized Equipment Performance Objectives Tools and Equipment

Pliers and Clippers Fuse Puller Screwdrivers Wrenches Soldering Equipment Drilling Equipment Knives and Other Insulation-Stripping Tools Meters and Test Prods Tool Kits

Gauges and Instruments

Pressure Gauges Gauge Selection Line Pressure Effects of Temperature on Gauge Performance Care of Gauges Gauge Recalibration

Thermometers

Pocket Thermometer Bimetallic Thermometers Thermocouple Thermometers Resistance Thermometers Digital Thermometers

What Is Superheat?

How Does It Work? Operation Subcooling Target Superheat and Subcooling

Superheat Measurement Instruments Halide Leak Detectors

Setting Up Lighting Leak Testing the Setup Adjusting the Flame Detecting Leaks Digital Leak Detectors

Electrical Instruments

Ammeter Voltmeter Ohmmeters Multimeter Digital Multimeter Wattmeter

Other Instruments

Air Filter Efficiency Gauges Air Measurement Instruments Newer Measurement Instruments Humidity Measurement Instruments Relative Humidity Measurements by Digital Meter Vibration and Sound Meters

Service Tools Special Tools Vacuum Pumps

Vacuum Pump Maintenance Vacuum Pump Oil Problems Operating Instructions Evacuating a System

Charging Cylinder Charging Oil Changing Oil Mobile Charging Stations

Standalone Vacuum Gauge

Tubing

Soft Copper Tubing Hard-Drawn Copper Tubing Cutting Copper Tubing Flaring Copper Tubing Constricting Tubing Swaging Copper Tubing Forming Refrigerant Tubing Fitting Copper Tubing by Compression

Soldering

Soft Soldering Silver Soldering or Brazing

Testing for Leaks Cleaning and Degreasing Solvents Review Questions 2 Development of Refrigeration Performance Objectives Historical Development Structure of Matter

Elements Atom

Properties of Matter Pressure

Pressure Indicating Devices Pressure of Liquids and Gases Atmospheric Pressure Gauge Pressure Absolute Pressure Compression Ratio

Temperature and Heat

Specific Heat Heat Content Sensible Heat Latent Heat Other Sources of Heat

Refrigeration Systems

Refrigeration from Vaporization (Open System) Basic Refrigeration Cycle Capacity Refrigerants Refrigerant Replacements and the Atmosphere

Review Questions 3 Voltage, Current, and Resistance Performance Objectives Ohm's Law Series Circuits Parallel Circuits

Current in a Parallel Circuit Resistance in a Parallel Circuit

AC and DC Power

Phase Power in DC Circuits

Power Rating of Equipment Capacitors

How a Capacitor Works Capacity of a Capacitor Dielectric Failure Basic Units of Capacitance Working With Capacitive Values Capacitor Types Capacitor Tolerances

The AC Circuit and the Capacitor

Uses of Capacitors

Inductance

Four Methods of Changing Inductance Self-Inductance Mutual Inductance Inductive Reactance Uses of Inductive Reactances

Transformers

Transformer Construction Turns Ratio Transformer Applications

Semiconductors

Diodes Transistors Silicon-Controlled Rectifier

Bridge Circuits

Wheatstone Bridges Variable Resistor

Sensors

Temperature Elements Humidity Elements

Controllers

Single-Element Controllers Dual-Element Controllers

Actuators

Electro-Hydraulic Actuators Thermal Actuators

Auxiliary Devices Electronic Compressor Motor Protection

Operation Troubleshooting the Control Restoring Service

Review Questions 4 Solenoids and Valves Performance Objectives Industrial Solenoids

Tubular Solenoids Frame Solenoids

Applications

Solenoids as Electromagnets Solenoid Coils Servicing Coils

Solenoid Valves in Circuits

Refrigeration Valve

Review Questions 5 Electric Motors: Selection, Characteristics, and Problems Performance Objectives Construction of an Induction Motor

Single-Phase Motors Shaded-Pole Motor Split-Phase Motor Capacitor-Start Motor

Motors Sizes Cooling and Mounting Motors Direction of Rotation Synchronous Motor

Theory of Operation Synchronous Motor Advantages Properties of the Synchronous Motor

Electric Motors

Starting the Motor

Repulsion-Induction Motor Capacitor-Start Motor Permanent Split-Capacitor Motor Shaded-Pole Motor Split-Phase Motor Polyphase-Motor Starters Reduced-Voltage Starting Methods

Primary-Resistor Starting Autotransformer Starting Part-Winding Starting Wye-Delta or Star-Delta Starters Multispeed Starters

Consequent-Pole Motor Controller Full-Voltage Controllers

Starting Sequence Protection Against Low Voltage Time-Delay Protection

Electric Motors: Their Uses, Operation, and Characteristics

Motor Rotation Variable-Speed Drives

Troubleshooting Electric Motors With a Volt-Ammeter Split-Core AC Volt-Ammeter

Testing for Grounds Testing for Opens Checking for Shorts Testing Squirrel-Cage Rotors Testing the Centrifugal Switch in a Split-Phase Motor Test for Short Circuit Between Run and Start Windings Test for Capacitors

Using the Megohmmeter for Troubleshooting Insulation-Resistance Testing

Measuring Insulation Resistance Power Tools and Small Appliances

Hermetic Compressor Systems

Circuit Breakers and Switches Coils and Relays

AC Motor Control

Motor Controller

AC Squirrel-Cage Motor

Enclosures Code Protection of the Motor

Contactors, Starters, and Relays

Motor-Overload Protector Motor-Winding Relays

Solenoid Valves Refrigeration Valve

Application Operation Installation Temperature Controls

Bimetallic Thermostats

Thermostat Construction and Wiring

Defrost Controls

Defrost Timer Operation Hot-Gas Defrosting

Motor Burnout Cleanup

Procedure for Small Tonnage Systems Procedure for Large Tonnage Systems

Reading a Schematic Review Questions 6 Refrigerants: New and Old Performance Objectives Refrigerants Classification of Refrigerants

Common Refrigerants

Freon Refrigerants

Molecular Weights Flammability Toxicity Skin Effects Oral Toxicity Central Nervous System (CNS) Effects Cardiac Sensitization Thermal Decomposition

Applications of Freon Refrigerants Reaction of Freon to Various Materials Found in Refrigeration Systems

Metals Plastics Substitutes for Freon Used in Industrial Processes

Refrigerant Properties

Pressure Temperature Volume Density Enthalpy Flammability Capability of Mixing With Oil Moisture and Refrigerants Odor Toxicity Tendency to Leak

Detecting Leaks

Sulfur Dioxide Carbon Dioxide Ammonia Methyl Chloride

Ban on Production and Imports of Ozone-Depleting Refrigerants

Phase-Out Schedule for HCFCs, Including R-22 Availability of R-22 Cost of R-22

Alternatives to R-22

Servicing Existing Units Installing New Units Servicing Your System Purchasing New Systems

Air Conditioning and Working With Halon

General Information

Leak Repair

Trigger Rates When Additional Time Is Necessary Relief from Retrofit/Retirement System Mothballing

Epa-Certified Refrigerant Reclaimers Newer Refrigerants Freon Refrigerants

Classifications Properties of Freons Physical Properties

Refrigerant Characteristics

Critical Temperature Latent Heat of Evaporation Specific Heat Power Consumption Volume of Liquid Circulated

Handling Refrigerants

Storing and Handling Refrigerant Cylinders

Lubricants R-134a Refrigerant

R-134a Applications

R-12 Systems—General Considerations

R-12 Medium/High Temperature Refrigeration (>0°F evap) R-12 Low Temperature Refrigeration (<20°F evap) R-401B R-402A R-402B

Reclaiming Refrigerant

Description Compressor Oil Separator Condenser Filter Drier Accumulator/Oil Trap

Operation of the Unit

Recovery Plus/Recovery Operations Storage Cylinder Cooling Recycle Operation Recharge Operation Service Operation Test Operation Control Circuits

Troubleshooting

Troubleshooting Approach

Questions and Answers on Alternative Refrigerants (EPA)

General Questions

Questions from Manufacturers Review Questions 7 Refrigeration Compressors Performance Objectives Compressors Condensers

Air-Cooled Condensers Water-Cooled Condensers Hermetic Compressors Compressor Types Newer Models Designations and Coding

Hermetic Compressor Motor Types

Resistance Start-Induction Run Capacitor Start-Induction Run Capacitor Start and Run Permanent Split Capacitor

Compressor Motor Relays

Current-Type Relay Potential-Type Relay

Compressor Terminals

Built-Up Terminals Glass Quick-Connect Terminals

Motor Mounts Crankcase Heaters Electrical Systems for Compressor Motors

Normal Starting Torque Motors (RSIR) With a Current-Type Relay High-Starting Torque Motors (CSIR) With a Current-Type Relay High-Starting Torque Motors (CSIR) With a Two-Terminal External Overload and a Remote-Mounted Potential Relay High-Starting Torque Motors (CSR) With Three-Terminal Overloads and Remote-Mounted Relays PSC Motor With a Two-Terminal External Overload and Run Capacitor PSC Motor With an Internal Overload (Line Breaker) CSR or PSC Motor With the Start Components and an Internal Overload or Line Breaker Compressors With Internal Thermostat, Run Capacitor, and Supplementary Overload CSR or PSC Motor With Start Components, Internal Thermostat, and Supplementary External Overload

Compressor Connections and Tubes

Process Tubes Other Manufacturers of Compressors

Rotary Compressors

Stationary Blade Rotary Compressors Rotating Blade Rotary Compressors

Screw Compressors

Single Screw Twin-Screw Making the Rotors Scroll Compressors Scroll Compression Process Operation Scroll Compressor Models

Review Questions 8 Condensers, Chillers, and Cooling Towers Performance Objectives Radiant Cooling Condensers

Air-Cooled Condensers Water-Cooled Condensers

Chillers

Refrigeration Cycle Motor Cooling Cycle Dehydrator Cycle Lubrication Cycle

Controls

Solid-State Capacity Control

Cooling Towers

Cooling Systems Terms Design of Cooling Towers

Evaporative Condensers New Developments Temperature Conversion Types of Towers Crossflow Towers

Fluid Cooler

Review Questions 9 Working With Water-Cooling Problems Performance Objectives Water as a Coolant Pure Water Cooling Towers Fouling, Scaling, and Corrosion

Scaling Prevention Scale Identification Field Testing Corrosion

Control of Algae, Slime, and Fungi Bacteria The Scale Problem

Evaporative Systems Scale Formation

How to Clean Cooling Towers and Evaporative Condensers

Determining the Amount of Water in the Sump Determining the Amount of Water in the Tank Total Water Volume Chilled Water Systems

How to Clean Shell (Tube or Coil) Condensers Safety Solvents and Detergents Review Questions 10 Evaporators Performance Objectives The Evaporator

Coiled Evaporator

Application of Controls for Hot-Gas Defrost of Ammonia Evaporators

Direct-Expansion Systems Cooling Cycle

Direct Expansion With Top Hot-Gas Feed Direct Expansion With Bottom Hot-Gas Feed Flooded Liquid Systems

Flooded-Gas Leg Shutoff (Bottom Hot-Gas Feed) Flooded Ceiling Evaporator-Liquid Leg Shutoff (Bottom Hot-Gas Feed) Flooded Ceiling Evaporator—Liquid-Leg Shutoff (Top Hot-Gas Feed) Flooded Ceiling Blower (Top Hot-Gas Feed) Flooded Ceiling Blower (Hot-Gas Feed Through Surge Drum) Flooded Floor-Type Blower (Gas- and Liquid-Leg Shutoff) Flooded Floor-Type Blower (Gas-Leg Shutoff)

Liquid Recirculating Systems

Flooded Recirculator (Bottom Hot-Gas Feed) Flooded Recirculator (Top-Gas Feed) Low-Temperature Ceiling Blower

Year-Round-Automatic Constant Liquid Pressure Control System Dual-Pressure Regulator Valves and Controls for Hot-Gas Defrost of Ammonia-Type Evaporators Back-Pressure Regulator Applications of Controls

Refrigerant-Powered Compensating-Type Pilot Valve Air-Compensating Back-Pressure Regulator Electric-Compensating Back-Pressure Regulator

Valve Troubleshooting

Noise in Hot-Gas Lines

Review Questions 11 Refrigerant: Flow Control Performance Objectives Metering Devices

Hand-Expansion Valve Automatic-Expansion Valve Thermostatic-Expansion Valve Capillary Tubing Float Valve

Fittings and Hardware

Copper Tubing Line Solder Suction Line P-Traps Compressor Valves Line Valves

Driers, Line Strainers, and Filters

Driers Line Strainers and Filters

Liquid Indicators

Construction Installation Bypass Installations Excess Oil and the Indicator Alcohol Leak Detectors Liquid Water Hermetic-Motor Burnouts Hardware and Fittings

Thermostatic-Expansion Valve

Valve Location Bulb Location External Equalizer Field Service

Crankcase Pressure-Regulating Valves

Operation of the Valve Valve Location Strainer Brazing Procedures Test and Operating Pressures Adjusting the Pressure Service

Evaporator Pressure-Regulating Valves

Operation Type of System Valve Location Test and Operating Pressures Service

Head-Pressure Control Valves

Operation ORO Valve Operation ORD Valve Operation Installation Brazing Procedures Test and Operating Pressures Service Nonadjustable ORO/ORD System Operation Discharge Bypass Valves Operation Application Malfunctions

Level-Control Valves

Capillary Tubes Float Valve

Level-Master Control

Installation Electrical Connections Hand Valves Oil Return Oil and Ammonia Systems Oil and Halocarbon Systems Conclusions

Other Types of Valves

Service Valves on Sealed Units Water Valves Check Valves Receiver Valves

Accumulators

Purpose

Rating Data

Refrigerant Holding Capacity Minimum Evaporator Temperature and Minimum Temperature of Suction Gas at the Accumulator

Installation of the Accumulator Review Questions 12 Servicing and Safety Performance Objectives Safety

Handling Cylinders Pressurizing Working With Refrigerants Lifting Electrical Safety

Servicing the Refrigerator Section

Sealed Compressor and Motor Condenser Filter Drier Capillary Tube Heat Exchanger Freezer Compartment and Provision Compartment Assembly

Compressor Replacement Troubleshooting Compressors Troubleshooting Refrigerator Components

Compressor Will Not Run Compressor Runs, but There Is No Refrigeration Compressor Short Cycles Compressor Runs Too Much or 100 Percent Noise To Replace the Compressor

Compressor Motor Burnout Cleaning System After Burnout Replacing the Filter Drier Replacing the Condenser Replacing the Heat Exchanger Repairing the Perimeter Tube (Fiberglass Insulated)

Top-Freezer and Side-by-Side Models Foam-Insulated 12 and 14 ft3, Top-Freezer Models Foam-Insulated 19 ft3 Side-by-Side Models

Replacing the Evaporator-Heat Exchanger Assembly

Top-Freezer, No-Frost Models Side-by-Side Models

Adding Refrigerant

Low-Side Leak or Slight Undercharge High-Side Leak or Slight Undercharge Overcharge of Refrigerant

Testing for Refrigerant Leaks Service Diagnosis

Thermostat Cut-Out and Cut-In Temperatures Freezer and Provision Compartment Air Temperatures Line Voltage Wattage Compressor Efficiency Refrigerant Shortage Restrictions Defrost Timer Termination Computing Percent Run Time

Start and Run Capacitors

Capacitor Ratings Start Capacitor and Bleeder Resistors Run Capacitors

Permanent Split-Capacitor (PSC) Compressor Motors Field Testing Hermetic Compressors

Warranty Test Procedure

Method of Testing

Resistance Checks Testing Electrical Components

Installing an Air-Cooled Condensing Unit

General Information Checking Product Received Corrosive Environment Locating Unit Unit Mounting Refrigerant Connections Replacement Units Evaporator Coil

Interconnecting Tubing

Suction and Liquid Lines Maximum Length of Interconnecting Tubing Condensing Unit Installed Below Evaporator Condensing Unit Installed Above Evaporator

Tubing Installation Tubing Connections Leak Testing Flow Check Piston Evacuation Procedure Checking Refrigerant Charge

Charging by Superheat Charging by Liquid Pressure Charging by Weight

Final Leak Testing Service

Operation Single-Pole Compressor Contactor (CC) Compressor Crankcase Heat (CCH) Hard Start Components (SC and SR) Time Delay Control (TDC) Low Ambient Control (LAC) High- and Low-Pressure Controls (HPC or LPC)

Electrical Wiring

Power Wiring Control Wiring

Start-up and Performance Troubleshooting

Leaks in Copper Tubing Household Sources of Acetic Acid or Acetate

Review Questions 13 Freezers Performance Objectives Types of Freezers Installing a Freezer Freezer Components

Wrapped Condenser Cold-Ban Trim Shelf Fronts Vacuum Release Lock Assembly Hinges Lid Thermostats Drain System Wrapper Condenser Evaporator Coil

Replacing the Compressor Repairing the Condenser Installing the Drier Coil Complete Recharge of Refrigerant Overcharge of Refrigerant

Restricted Capillary Tube

Testing for Refrigerant Leaks Troubleshooting Freezers

Portable Freezers

Review Questions 14 Temperature, Psychrometrics, and Air Control Performance Objectives Temperature

Degrees Fahrenheit Degrees Celsius Absolute Temperature

Converting Temperatures Psychrometrics Pressures

Gauge Pressure Atmospheric Pressure

Pressure Measuring Devices Hygrometer

Properties of Air People and Moisture

Psychrometric Chart Air Movement

Convection, Conduction, and Radiation

Comfort Conditions

Velocity

Terminology Designing a Perimeter System

Locating and Sizing Returns Airflow Distribution

Selection of Diffusers and Grilles

Air-Volume Requirement Throw Requirement Pressure Requirement Sound Requirement

Casing Radiated Noise

Locating Terminal Boxes Controlling Casing Noise Vortex Shedding

Return Grilles

Performance Return Grille Sound Requirement

Types of Registers and Grilles Fire and Smoke Dampers

Smoke Dampers for High-Rise Buildings

Ceiling Supply Grilles and Registers Ceiling Diffusers

Antismudge Rings Air-Channel Diffusers Luminaire Diffusers Room-Air Motion

Linear Grilles Fans and Mechanical Ventilation

Air Volume Fans and Blowers Air Volume Horsepower Requirements Fan-Driving Methods Selecting a Fan Applications for Fans Operation of Fans Installation of Attic Fans Routine Fan Operation

Ventilation Methods Review Questions 15 Comfort Air Conditioning Performance Objectives Window Units

Mounting Electrical Plugs Maintenance Low-Voltage Operation Troubleshooting Evaporator Maintenance Automatic Defrosting

Evaporators for Add-on Residential Use

Troubleshooting

Remote Systems Single-Package Rooftop Units

Smoke Detectors Firestats Return-Air Systems Acoustical Treatment Volume Dampers Refrigerant Piping Troubleshooting

Refrigerant Pipe Sizes

Liquid-Line Sizing Suction-Line Sizing

Mobile Homes

Troubleshooting

Wall-Mounted Ductless Air Conditioners

Fan Control Mode Restart Function Rotary Compressor

Review Questions 16 Commercial Air-Conditioning Systems Performance Objectives Expansion-Valve Air-Conditioning System

Compressor Condenser

Expansion-Valve Kit

Troubleshooting

Packaged Cooling Units Rooftop Heating and Cooling Units

Electrical Sequence of Operation Compressor Safety Devices Maintenance Troubleshooting

Direct Multizone System

Troubleshooting

Evaporative Cooling System Absorption-Type Air-Conditioning Systems Chilled Water Air Conditioning

Refrigerant Cycle Control System

Chillers

Reciprocating Chillers Components Used With Chillers

Console-Type Air-Conditioning Systems

Installation Service Troubleshooting

Review Questions 17 Various Types of Air Conditioners and Heat Pumps Performance Objectives Air-Conditioning Types

Absorption Cooling Cycle Ammonia Refrigerant in a Gas-Fired System

Gas-Fired Chillers Chiller-Heater

Changeover Sequence for Chilled Water Operation Changeover Sequence for Hot Water Operation Self-Leveling Feature

Absorption Refrigeration Machine

Absorption Operation Cycle

Solar Air Conditioners

History of Solar Cooling Systems of Solar Cooling Lithium-Bromide Water Absorption Cycle Solar Cooling Research Centers

Heat Pumps

Operation Defrost Outdoor Thermostat Special Requirements of Heat Pump Systems Sizing Equipment Defrost Cycle Balance Point Using the Heat Pump

Review Questions 18 Estimating Load and Insulating Pipes Performance Objectives Refrigeration and Air-Conditioning Load Running Time Calculating Cooling Load

Wall Gain Load Air Change Load Product Load Miscellaneous Loads

Calculating Heat Leakage Calculating Product Cooling Load

Capacity of the Machines Used in the System

Air Doors Insulation

Sheet Insulation Tubing Insulation Pipe Insulation

Refrigeration Piping Pressure-Drop Considerations Liquid Refrigerant Lines Interconnection of Suction Lines Discharge Lines Water Valves Multiple-Unit Installation

Piping Insulation Cork Insulation Rock-Cork Insulation Wool-Felt Insulation Hair-Felt Insulation

Review Questions 19 Electrical Power for Air Conditioners Performance Objectives Choosing Wire Size

Limiting Voltage Loss Minimum Wire Size Wire Selection

Wire Size and Low Voltage

Voltage Drop Calculations

The Effects of Voltage Variations on AC Motors Selecting Proper Wire Size Unacceptable Motor Voltages Calculating Starting Current Values and Inrush Voltage Drops

Single-Phase Current Three-Phase Circuits Inrush Voltage Drop

Code Limitations on Amperes per Conductor Heat Generated Within Conductors Circuit Protection

Standard Rule Circuit Breakers

Thermostats

Thermostat as a Control Switch Service Start Kits

Single-Phase Line Monitors Time Delays Head Pressure Control Pressure Controls

Line-Voltage Head Pressure Controls Three-Phase Line-Voltage Monitor Current Sensing

Indoor Air Quality

Types of Air Cleaning Systems

Electronic Air Cleaners Ultraviolet Air Cleaners Review Questions 20 Air-Conditioning and Refrigeration Careers Performance Objectives Industries that Employ Air-Conditioning and Refrigeration Technicians

Job Qualifications The Future Pay and Benefits

Teaching as a Career Sources of Additional Information Professional Organizations and Certification

ASHRAE ACCA

Review Questions Appendices A. Some New Refrigerants B. Electrical and Electronic Symbols Used in Schematics C. Programming Thermostats D. Tools of the Trade (Plus Frequently Asked Questions With Answers) E. Generic Substitute Names Used in SNAP Listings Glossary Index

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