Air conditioning and refrigeration miller

www.TheSolutionManual.com www.TheSolutionManual.com Air Conditioning and Refrigeration www.TheSolutionManual.com This page intentionally left blank www.TheSolutionManual.com Air Conditioning and Refrigeration REX MILLER Professor Emeritus State University College at Buffalo Buffalo, New York MARK R MILLER Professor, Industrial Technology The University of Texas at Tyler Tyler, Texas McGraw-Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto www.TheSolutionManual.com Copyright © 2006 by The McGraw-Hill Companies, Inc All rights reserved Manufactured in the United States of America Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher 0-07-148741-7 The material in this eBook also appears in the print version of this title: 0-07-146788-2 All trademarks are trademarks of their respective owners Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benefit of the trademark owner, with no intention of infringement of the trademark Where such designations appear in this book, they have been printed with initial caps McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs For more information, please contact George Hoare, Special Sales, at george_hoare@mcgraw-hill.com or (212) 904-4069 TERMS OF USE This is a copyrighted work and The McGraw-Hill Companies, Inc (“McGraw-Hill”) and its licensors reserve all rights in and to the work Use of this work is subject to these terms Except as permitted under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not decompile, disassemble, reverse engineer, reproduce, modify, create derivative works based upon, transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without McGraw-Hill’s prior consent You may use the work for your own noncommercial and personal use; any other use of the work is strictly prohibited Your right to use the work may be terminated if you fail to comply with these terms THE WORK IS PROVIDED “AS IS.” McGRAW-HILL AND ITS LICENSORS MAKE NO GUARANTEES OR WARRANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETENESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY INFORMATION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR OTHERWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE McGraw-Hill and its licensors not warrant or guarantee that the functions contained in the work will meet your requirements or that its operation will be uninterrupted or error free Neither McGraw-Hill nor its licensors shall be liable to you or anyone else for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting therefrom McGraw-Hill has no responsibility for the content of any information accessed through the work Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, consequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise DOI: 10.1036/0071467882 www.TheSolutionManual.com Professional Want to learn more? 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If you’d like more information about this book, its author, or related books and websites, please click here www.TheSolutionManual.com For more information about this title, click here Contents Preface xv Acknowledgments xvii and Air-Conditioning Refrigeration Tools and Instruments 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 Gages and Instruments Pressure Gages Gage Selection 10 Line Pressure 11 Effects of Temperature on Gage Performance 12 Care of Gages 12 Gage Recalibration 12 Thermometers 13 Pocket Thermometer 13 Bimetallic Thermometers 15 Thermocouple Thermometers 16 Resistance Thermometers 16 Superheat Thermometer 17 Superheat Measurement Instruments 17 Halide Leak Detectors 21 Setting Up 21 Lighting 22 Leak Testing the Setup 22 Adjusting the Flame 22 Detecting Leaks 22 Maintenance 22 Electrical Instruments 23 Ammeter 23 Voltmeter 25 Ohmmeter 26 Multimeter 26 Wattmeter 27 Other instruments 28 Air–Filter Efficiency Gages 28 Air-Measurement Instruments 28 Humidity-Measurement Instruments 29 Vibration and Sound Meters 29 Service Tools 30 Special Tools 31 Vacuum Pumps 32 Vacuum Pump Maintenance 34 Vacuum Pump Oil Problems 34 Operating Instructions 34 Evacuating a System 35 Charging Cylinder 35 Charging Oil 36 Changing Oil 37 Mobile Charging Stations 37 Tubing 37 Soft Copper Tubing 37 Hard-Drawn Copper Tubing 38 Cutting Copper Tubing 39 Flaring Copper Tubing 40 Constricting Tubing 41 Swaging Copper Tubing 41 Forming Refrigerant Tubing 42 Fitting Copper Tubing by Compression 43 Soldering 43 Soft Soldering 44 Silver Soldering or Brazing 46 Testing for leaks 47 Cleaning and Degreasing Solvents 47 Review Questions 47 Development of Refrigeration Performance Objectives 50 Historical Development 50 v www.TheSolutionManual.com Structure of Matter 50 Elements 51 Atom 51 Properties of Matter 51 Pressure 52 Pressure Indicating Devices 52 Pressure of Liquids and Gases 53 Atmospheric Pressure 53 Gage Pressure 53 Absolute Pressure 53 Compression Ratio 54 Temperature and Heat 54 Specific Heat 55 Heat Content 55 Sensible Heat 55 Latent Heat 55 Other Sources of Heat 56 Refrigeration Systems 56 Refrigeration from Vaporization (Open System) 56 Basic Refrigeration Cycle 56 Capacity 57 Refrigerants 57 Refrigerant Replacements and the Atmosphere 58 Review Questions 59 Current, and Voltage, Resistance Performance Objectives 62 Ohm’s Law 62 Series Circuits 62 Parallel Circuits 64 Current in a Parallel Circuit 64 Resistance in a Parallel Circuit 65 AC and DC Power 65 Phase 66 Power in DC Circuits 66 Power Rating of Equipment 67 Capacitors 67 How a Capacitor Works 68 Capacity of a Capacitor 69 Dielectric Failure 69 Basic Units of Capacitance 69 Working with Capacitive Values 69 Capacitor Types 70 Capacitor Tolerances 73 The AC Circuit and the Capacitor 73 Uses of Capacitors 75 Inductance 75 Four Methods of Changing Inductance 75 Self-Inductance 75 Mutual Inductance 76 Inductive Reactance 77 Uses of Inductive Reactances 77 Transformers 77 Transformer Construction 77 vi Contents Turns Ratio 78 Transformer Applications 78 Semiconductors 78 Diodes 78 Transistors 79 Silicon-controlled Rectifier (SCR) 80 Bridge circuits 80 Wheatstone Bridges 80 Variable Resistor 81 Sensors 81 Temperature Elements 82 Humidity Elements 82 Controllers 83 Single-Element Controllers 84 Dual-Element Controllers 86 Actuators 86 Electro-Hydraulic Actuators 86 Thermal Actuators 87 Auxiliary Devices 88 Electronic Compressor Motor Protection 88 Operation 88 Troubleshooting the Control 89 Restoring Service 91 Review Questions 91 Solenoids and Valves Performance Objectives 94 Industrial Solenoids 94 Tubular Solenoids 94 Frame Solenoids 94 Applications 97 Solenoids as Electromagnets 97 Solenoid Coils 97 Servicing Coils 97 Solenoid Valves in Circuits 98 Refrigeration Valve 99 Review Questions 100 Motors: Selection, Electric Operational Characteristics, and Problems Performance Objectives 102 Construction of an Induction Motor 102 Single-Phase Motors 103 Shaded-Pole Motor 103 Split-Phase Motor 103 Capacitor-Start Motor 104 Sizes of Motors 104 Cooling and Mounting Motors 105 Direction of Rotation 106 Synchronous Motor 107 Theory of Operation 107 Synchronous Motor Advantages 108 Properties of the Synchronous Motor 108 www.TheSolutionManual.com Electric Motors 109 Starting the Motor 109 Repulsion-Induction Motor 110 Capacitor-Start Motor 111 Permanent Split-Capacitor Motor 112 Shaded-Pole Motor 112 Split-Phase Motor 114 Polyphase-Motor Starters 115 Reduced-Voltage Starting Methods 116 Primary-Resistor Starting 116 Autotransformer Starting 119 Part-winding Starting 120 Wye-delta or Star-delta Starters 121 Multispeed Starters 123 Consequent-Pole Motor Controller 124 Full-Voltage Controllers 127 Starting Sequence 129 Protection Against Low Voltage 129 Time-Delay Protection 129 Electric Motors: Their Uses, Operation, and Characteristics 132 Motor Rotation 133 Variable-Speed Drives 133 Troubleshooting Electric Motors with a Volt-Ammeter 133 Split-Core AC Volt-Ammeter 134 Testing for Grounds 135 Testing for Opens 135 Checking for Shorts 136 Testing Squirrel-Cage Rotors 136 Testing the Centrifugal Switch in a Split-Phase Motor 136 Test for Short Circuit Between Run and StartWindings 136 Test for Capacitors 136 Using the Megohmmeter for Troubleshooting 138 Insulation-Resistance Testing 138 Measuring Insulation Resistance 139 Power Tools and Small Appliances 139 Hermetic Compressor Systems 140 Circuit Breakers and Switches 140 Coils and Relays 140 AC Motor Control 140 Motor Controller 141 AC Squirrel-Cage Motor 141 Enclosures 142 Code 142 Protection of the Motor 142 Contactors, Starters, and Relays 142 Motor-Overload Protector 142 Motor-Winding Relays 143 Solenoid Valves 143 Refrigeration Valve 144 Application 144 Operation 144 Installation 145 Temperature Controls 145 Bimetallic Thermostats 146 Thermostat Construction and Wiring 147 Defrost Controls 147 Defrost Timer Operation 147 Hot-Gas Defrosting 148 Motor Burnout Cleanup 148 Procedure for Small Tonnage Systems 148 Procedure for Large Tonnage Systems 150 Reading a Schematic 150 Review Questions 152 Refrigerants: New and Old Performance Objectives 156 Classification of Refrigerants 156 Common Refrigerants 156 Freon Refrigerants 158 Molecular Weights 158 Flammability 158 Toxicity 158 Skin Effects 158 Oral Toxicity 158 Central Nervous System (CNS) Effects 159 Cardiac Sensitization 161 Thermal Decomposition 162 Applications of Freon Refrigerants 162 Reaction of Freon to Various Materials Found in Refrigeration Systems 165 Metals 165 Plastics 165 Refrigerant Properties 166 Pressure 166 Temperature 166 Volume 166 Density 167 Enthalpy 167 Flammability 168 Capability of Mixing with Oil 168 Moisture and Refrigerants 168 Odor 168 Toxicity 169 Tendency to Leak 169 Detecting Leaks 169 Sulfur Dioxide 169 Carbon Dioxide 169 Ammonia 170 Methyl Chloride 170 Ban on Production and Imports of Ozone-Depleting Refrigerants 170 Phase-out Schedule for HCFCs, Including R-22 170 Availability of R-22 171 Cost of R-22 171 Alternatives to R-22 171 Servicing Existing Units 171 Installing New Units 171 Contents vii www.TheSolutionManual.com wet compression A system of refrigeration, in which some liquid refrigerant is mixed with vapor entering the compressor so as to cause discharge vapors from the compressor to tend to be saturated rather than superheated zero, absolute, of pressure The pressure existing in a vessel that is entirely empty The lowest possible pressure Perfect vacuum xylene A flammable solvent, similar to kerosene, used for dissolving or loosening sludges, and for cleaning compressors and lines zone, comfort (average) The range of effective temperature during which the majority of adults feel comfortable 590 Glossary zero, absolute, of temperature The temperature at which a body has no heat in it (–459.6°F or –273.1°C) www.TheSolutionManual.com Index A Absolute temperature, 398 zero, 55 Absorption air-conditioning systems, 459, 461 cold generator, 476 coling cycle, 470 refrigeration, 472 AC circuit, 73 and the capacitor, 73 motor control, 140, 141 power, 65 waveforms, 66 Accumulator, 183, 335 installation, 336 purpose, 335 Acids, 306 Acoustical treatment, 438 Actuator, 86 hydraulic, 87 operation of, 87 thermal, 87 Adding refrigerant, 354 Additional information, 529 Add-on cooling evaporators, 434, 435, 436 evaporators, 433 Adrenalin, 161 Air capacitors, 70 change load, 491 channel diffusers, 418 conditioning and refrigeration institute, 542 conditioning load, 490 conditioning mechanics, 526 cooled condensing unit, 366 doors, 492, 493 filter, 28 measurement, 409 gages, 28 motion, 419 movement, 404 noise, 414 properties, 401 systems, high velocity, 29 unsaturated, 403 volume, 413, 419, 421 lines, 408 Airflow distribution, 411 Air-stream pattern, 409 Alcohol, 309 Algae, slime, fungus, 264 Alternating current, Ambient temperature, 84 American National Standards Institute (ANSI), 10 Ammeter, 23, 25 Ammonia, 58, 157, 170 absorption system, 460 evaporators, controls, 275 refrigerant, gas-fired unit, 471 type evaporators, 288 Antifreeze, 472 Anti-smudge rings, 418 Appliances, small, 139 ASHRAE, 410 Aspiration, 408 Atmospheric pressure, 399 Atom, 51 Attic fans, 423 installation, 424 Automatic defrosting, 431 sequence accelerating relay, 124 sequence decelerating relay, 124 Automotive blends, 179 Autotransformer starting, 119, 120 Autotransformer type of magnetic starter, 121 starter, 122 advantages and disadvantages, 121, 122 operation of, 121, 122 Average value, 66 B Back-pressure regulator, 291, 292 thermal-compensating, 294, 295 Bacteria, 260, 264 Balanced diaphragm valve, 99 Bandwidths, 86 Barometer, 400 Basic refrigeration cycle, 56 Bellows, pressure sensing element, 53 Bender, tubing, 44 Bending tools, 43 Bimetallic thermostat, 146 Biological organisms, 264 Bleeder resistors, 360 Blower unit, 436 Blowers, 419 591 Copyright © 2006 by The McGraw-Hill Companies, Inc Click here for terms of use www.TheSolutionManual.com Bourdon tube, 11 spring tube type gage, 53 tube gages, 401 Brazing, 46 procedures, 321 Breakdown voltage, 79 Bridge circuits, 80, 81 British thermal unit, 28 Btu, 28, 55 Burnout, compressor motor, 347 Burnouts, 309 Bypass feeder, 268 Bypass installations, 309 C CAB-resistive element, 82 Calcium chloride, 157 Calculating product cooling load, 492 Can capacitor, 72 Capacitance, basic units of, 69 Capacitive reactance, 73, 74 Capacitive value conversions, 70 Capacitive values, working with, 69 Capacitor, 67 AC current in a, 74 capacity of a, 69 charge, 68 how it works, 68 parallel, 72 ratings, 359 start and run, 104, 206, 359 start motor, disassembled, 104 start-induction run, 206, 216, 217, 229 symbols, 69 test for, 135 types, 70 uses of, 75 Capacity capacitor, 137 control, 250 refrigeration machines, 57 of system machines, 490 Cap-check, 30, 31 Capillary tube, 389 Carbon composition resistors, 67 Carbon dioxide, 157, 169 Cardiac sensitization, 161 Casing radiated noise, 414, 415 Ceiling blower, 287, 288 Ceiling diffusers, 417 evaporator, 286 supply grilles, 416 Celsius, 398 Central nervous system, 159 592 Index Centrifugal fan, 424 switch, 136 Ceramic capacitors, 71 CFC, 179 Changeover, 472 Changing oil, 37 Characteristics of controllers, 125 Charge, checking refrigerant, 373 Charging by weight, 373 Charging cylinder, 35, 348 oil, 36 pump, 36, 37 station, 37 Check valves, 335 Checks, resistance, 364 Chest model freezer, 388 Chilled water systems, 268, 459, 462 Chiller, 246, 463, 465 components, 464 compressor, and cooler, 248 cutaway view, 249 heater, 472 reciprocating, 464 Chisels, Circuit breakers, 140 connections, 85 protection, 509 Circulated liquid, volume of, 178 Clamp-on volt-ammeter, 134 Cleaning and degreasing, 47 Cleaning system, 347 Cleanup, motor burnout, 148 Closed-system installations, 268 CNS effects, 159 Code limitations, wire size, 508 Coiled evaporator, 274 Coils, 140 servicing, 97 Cold-ban trim, 382 Comfort conditions, 406 Compression ratio, 54 Compressor, 182, 450, 192 applications, 200 centrifugal, 192 connected tubes, 231, 232 connections, 230 construction details, 213 crankcase, 374 cut-away view, 196 efficiency, 358 heat pump, 111, 207 hermetic, 194, 205 with internal thermostat, 226, 228 www.TheSolutionManual.com and motor, sealed, 342 motors, electrical systems, 212 reciprocating, 192 to replace, 346 replacing, 387 resistance start, 205 with run capacitor, 226 safety devices, 455 schematic, 202–204 scroll, 238 single-screw, 235, 237 with supplementary overload, 226 Tecumseh AE, 201 Tecumseh, 233, 234 terminals, 207 test stand, 362 troubleshooting, 343, 344, 345 and tubes, 230 twin screw, 237, 238 types, 194 Condenser, 183, 192, 342, 450 air cooled, 194, 242 configurations, 245, 247 evaporator, 196 flat, coil-type, 244 repairing, 387 replacing, 349 water cooled, 194, 243, 245, 246 Condensing unit, 368, 371 capacity, 491 installation, 365 pressure, 176 Conductors, heat generated by, 510 Connections external equalizer, 314 refrigerant, 368 star-delta, 123 various sequences, 128 wye-delta, 123 Consequent-pole motor controller, 124 Console air conditioner, 465, 466 Console, service, 467 Constant horsepower motors, 128 Constant liquid pressure control system, 286 Construction, 308 Contactors, 142 Control circuits, 187 Control modules, solid state, 90 Control system, 463 valves, 320 installation, 321 year-round automatic, 293 Control, 290 head pressure, 516 troubleshooting the, 89 wiring, 375 Controllers, 83 dual-element, 86 single element, 84 Controls, chiller, 249 Converting temperatures, 399 Cooling cycle, 277 chiller-heater, 475, 476 Cooling load, calculating, 490 tower, 195, 250 cleaning, 266 design of, 251 natural draft, 251, 253 new developments, 253 Copper losses, 78 Copper ACR tubing, 301 tubing, 38 fitting, 43 hard-drawn, 38 Copper wire size, 375 current carrying, 63 Cork insulation, 498 Corrosion, 263 Corrosive environment, 365 Crankcase heaters, 209 Crankcase, 315 CRO valve, 316 Crystals in drum or tank, 268 CSIR, 219, 222 CSR or PSC-type compressor motor, 220 Current in parallel circuit, 64 Current sensor, 519, 520 Cutters, tubing, 40 Cylinder handling, 340 storage, 185 D Data, rating, 336 DBV operation, 323 DC power, 65 Defrost controls, 147 cycle, 279 clock, 148 heat pump, 482 high temperature, 278 timer, 147 Defrosting, hot gas, 148 Defrost-timer termination, 359 Dehydrator cycle, 247 Designations and coding, 202 Detecting leaks, 22 Index 593 www.TheSolutionManual.com Detector, setting up, 21 Detectors, 21 halide leak, 21 Devices auxiliary, 88 metering, 300 pressure indicating, 52 test, Dew-point temperature, 402 Diagram, piping, chiller, 464 Dielectric failure, 69 Differential amplifiers, DC, 84 Diffusers, 409 Dimensional data, 367 Diode, 78 circuit, 79 symbol, 78 Direct drain, oil, 332 Direct expansion with top hot gas feed, 279 Direct multizone system, 456 Dirt, 306 Discharge lines, 496 Discharge-bypass valves, 327 Domestic refrigerator circuit, 143 schematic wiring diagram, 151 Drain system, 386 Drier coil, installing, 387 Driers, 304 Drilling equipment, Drills, masonry, Drop, 408, 409 DRV special considerations, 325 Dry-bulb temperature, 402, 406 Dual bridge, 86 Dual-pressure regulator, 287 DVD application, 323 E Eddy currents, 78 Effective, 66 Elbow, half-union, 42 Electric motors characteristics, 132 operation, 132 uses, 132 Electrical connections, 330 plugs, 429 safety, 341 Electrolytic capacitor, 71, 105 making an, 72 Electrolytics and AC, 72 Elementary diagrams, connections, 130 Elements, 51 Enclosures, 142 594 Index Enthalpy lines, 408 Enthalpy, 167 EPA, 172 Equipment, power rating of, 67 Error code for thermistors, 189 Ethyl chloride, 158 Evacuating a system, 35 Evacuation procedure, 371 Evaporating pressure, 176 Evaporation, latent heat of, 177 Evaporative condensers, 252 cooling system, 265, 458 Evaporator coil, 387 condenser, 196 direct expansion, 281, 282 finned-coil, 275 maintenance, 431 pressure-regulating valves, 317 temperatures, 336 Excess oil and the indicator, 309 Exhaust fans, 423 Expansion-valve kit, 450 system, 450 Extension cord, F Fahrenheit, 398 Fans, 419, 422 classifications, 421, 422 control mode, 446 operation, 423 Field service, 314 Field testing hermetic compressors, 361 water, 262 Filter drier, 149, 305, 342 replacement, 348 replacing, 347 suction-line, 306 Filters, 305 line, 306 Fire and smoke dampers, 416 Firestats, 437 Fitting flare, 301 and hardware, 301 losses, 444 Flammability, 158, 168, 175 Flares, double, 41 Float control system, 329 Float valve, interior construction, 328 Flooded ceiling blower, 283 evaporator, 280 www.TheSolutionManual.com Flooded floor-type blower, 283 gas leg shutoff, 283, 284 Flooded liquid systems, 279 Flooded re-circulator, 285, 291, 292 Floor blower, 289 Flow-check piston, 372 Flue effect, 425 Fluid cooler, 254, 257 operation of, 256 Fluorinated products, 163 Fluorocarbons, 161 potential hazards, 163 Foam insulation tape, 493 Forced and natural draft towers, 267 Fouling, scaling, and corrosion, 260 Frame solenoids, 94 Freezer compartment, 343 components, 382 installing, 381 portable, exploded view, 393 schematic, 381 troubleshooting, 390, 391, 392 types, 380 Freon-11, 162, 174 Freon-113, 164, 175 Freon-114, 164, 175 Freon-115, 175 Freon-12, 162, 174 Freon-13, 164, 174 Freon-13B1, 164 Freon-21, 174 Freon-22, 164, 175 Freon-500, 164 Freon-502, 164, 175 Freon-503, 164 Freon® products, applications of, 162 classifications, 174 properties of, 175 physical, 159–161, 175 refrigerants, 174 reaction of and to various materials, 165 Full load amperes, 506 Full voltage starters, 127 Furnace, blower, evaporator coil, 436 Fuse puller, Fuses, 509, 510 types of, 509 Future of a/c and refrigeration, 526 G Gage accuracy, 10 air filter efficiency, 28 ammonia, 11 classification, 10 effects of temperature, 12 electronic high-vacuum, 36 and instruments, liquid-filled, 11 performance, 12 pressure, 53, 399 recalibration, 12, 13 selection, 10 vacuum check, 35 Galvanic action, 263 Gas air conditioning, 470 Gases, pressure of, 53 Gas-fired air conditioning, 471, 474 chillers, 471 Glass quick-connect terminals, 219 terminals, 209 Glossary, 581–590 Grains of moisture, 407, 408 Graphs, 29 Grilles, 416 size, 416 Guide, cross reference, 514 Grommet, 206, 209 assembly, 220 Grounds, testing for, 135 H Hair-felt insulation, 499 Halon, 172 general information, 172 working with, 172 Hammers, Hand valves, 330 Hard start components, 374 Hardware and fittings, 309, 310 Harmonic distortions, 133 HCFCs, 171 phase out, 170 Head-pressure control valves, 322, 513 Heat content, 55 Heat exchanger, 343 balance point, 484 calculating, 489 defrost cycle, 484 installations, 484, 485 operation, 482 replacing, 349, 354 special requirements, 480, 485 Heat pumps, 480 Heat, other sources, 56 Heater, serpentine, 152 Henry, 75 Hermetic compressors, field testing, 361 Hermetic type centrifugal chiller, 462, 463 Index 595 www.TheSolutionManual.com HFCs, 176 High starting torque motors, 215 High torque motors, 221, 222, 223 High-pressure controls, 374 Hinges, 383 Home refrigerator, 50 Horsepower requirements, 421 Hot gas, 326 lines, 297 Humidity elements, 82 measurement instruments, 29 measuring, 28 Hydrofluorocarbons, 176 Hydrolysis rate, 168 Hydrolyzed humidity element, 83 Hygrometer, 401 Hysteresis, 78 I Ice-cream dispenser, 394 Impedance, 74 Indicator, installation, 309 Inductance, 74 changing, 75 Induction motor, construction of, 102 Inductive reactance, 77 uses of, 77 Industrial solenoids, 94 Inrush voltage drops, 507 Installation, console type, 466 Instantaneous value, 66 Instruments, electrical, 23 Insulation resistance measuring, 139 testing, 138 J Job qualifications, 525 K Kilopascal, 52 Knives, L Lamp continuity tester, 363 Large tonnage systems, 150 Latent heat, 55 Leak detection, envelope method, 356 Leak detector, 23, 309, 575, 576 Leak testing, 22, 370, 374 Leaks detecting, 169 refrigerators, 355 repair, 173 596 Index tendency to, 169 testing for, 47 Level-master control, 329, 333 installation, 330 Lid, freezer, 384, 385 Lifting, 341 Lighting, 22 Line, 302 monitors, single-phase, 513, 514 pressure, 11 strainers, 305 voltage, 358 head pressure controls, 514 Linear grilles, 419, 421 Line-break motor protector, 206 Liquid indicators, 307, 308 line sizing, 441 line, 331 pressure of, 53 pressure, charging by, 373 recovery, 183 refrigerant lines, 495 water, 309 Lithium-bromide system, 470, 478 Locating unit, 366 Location, valve, 312, 315, 318 Lock assembly, 383 Locked-rotor amperes, 506 Low temperature defrost cycle, 280 Low voltage operation, 430 protection against, 129 Low-pressure controls, 374 Low-temperature ceiling blower, 285 Lubricants, 178 Lubrication cycle, 249 Luminaire diffusers, 418 M Magnahelic manometer, 401 Magnetic starter, 118 Main element, 86 Maintenance, 22, 455 window units, 430 Malfunctions, 326 Manometer, 400 Manufacturers of compressors, 230 Markers, wire code, Maatter properties of, 51 structure, 50 Maximum value, 66 Mechanical ventilation, 419 Megohmmeter, 138 cable testing, 140 Meter movements, 24 www.TheSolutionManual.com Meters, sound, 29 vibration, 29 Methyl chloride, 157, 170 Mica capacitors, 70 Microfarad, 69 Milliampere, 23 Minimum wire size, 502 Miscellaneous loads, 491 Mixing with oil, 168 Mobile homes units, 444 Model numbers, 198 Modern thermostats, 147 Modules, solid-state, 89, 90 Moisture analyzers, 28, 29 content, 308 in hermetic compressor systems, 140 and refrigerants, 168 Molecular structure, 52 Molecular weight, 158, 169 Monitor, three-phase, wiring diagram, 520 Monitoring system, 577 Motor, 109 capacitor start, 111, 113 capacitor start, reversibility, 111 circuits, 117, 128 cooling cycle, 247 cooling, 105 direction of rotation, 106 manufacturers, 195 mounting, 105 mounts, 209 open, drip-proof, 132 permanent split-capacitor, 112 protection, 142 electronic compressor, 88 repulsion start, 110 reversibility, 110 rotation, 133 shaded pole, 103, 112 starting a, 109 theory of operation, 107 time delay protection, 129 totally enclosed fan cooled, 132 uses, 110 winding relays, 143 Motors, electric, 109 sizes of, 104 testing, 139 voltage variations, 109 Mounting, window units, 428–431 Multimeter, 26, 27 Multiple compressor unit installation, 497 Multispeed starter, 126 Multizone system, installation, 457 refrigerant piping, 457 Mutual inductance, 76 N National Electrical Code, 2, 142 National Electrical Manufacturer’s Association, 119 Natural ice, 50 Needle valves, 12 NEMA, 119, 128 New refrigerants, 179, 531–538 New systems, purchasing, 172 Newer models, 202 Noise, 346 Nomenclature explained, compressors, 198–200 Normal starting motors, 221 torque motors, 212 Nylon, 165 O Odor, 168 Ohm, 26 Ohm’s law, 62 Ohmmeter, 26 Oil and ammonia systems, 330 filled capacitors, 71 and halocarbon systems, 331 return draining, 333 return, 330 separator, 182 Open sensor, 91 Opens, testing for, 135 Operating pressure, 166 Operation, 317 of electronic motor protection, 88 Oral toxicity, 158 ORD, valve operation, 320 ORI operation, 319 Orlon-acrylic fiber, 165 ORO, valve operation, 320 ORO/ORD, system operation, 322 OSHA, 29 Outdoor thermostat, 482 Outlet velocity ratings, 412 location of, 410 Output circuit connections, 85 Overcharge, 389 refrigerant, 355 Overload protector, motor, 142 supplementary, location of, 214 Oxygen, corrosion by, 263 Ozone depleting, 170 P Packaged cooling units, 451 Paper capacitors, 70 Index 597 www.TheSolutionManual.com Parallel circuit, 64, 65 current in, 64 resistance in a, 65 Part-winding starter wiring diagram, 120, 123, 519 Pay and benefits, 527 People and moisture, 404 Percent run time, computing, 359 Performance, 376 Performance objectives, 2, 50, 62, 94, 102, 156, 192, 242, 260, 274, 300, 340, 380, 398, 428, 450, 470, 488, 502, 524 Perimeter system, 410 Perimeter tube, repairing, 350 Permanent split capacitor motor, 114, 206, 360 schematic, 210, 217, 224 Permissible relative humidity, 403 Phase, 66 Pilot light, 279 Pilot valve, 291 Pipe insulation, 494, 495, 498 Piston volume displacement, 175 Plastics, 165 Plate evaporator, 274 Pliers and clippers, Plugs, electrical, 431 Pointer, flutter, 11 Polychluorotrifluomethylene, 165 Poly-phase motor, 107 starters, 115 Portable freezers, 390 Potential type relay, 218 Power consumption, 177 in DC circuits, 66 tools, 139 wiring, 375 Pressure, 52, 166 absolute, 53 adjusting, 316 controls, 516 drop consideration, 495 drop, 312 equalization, 189 gage, 165 loss, 312 relief regulators, 296 requirement, 413 Pressures, 318 test and operating, 316 Pressurizing, 340 Primary resistor type of magnetic starter, 119, 120 starting, 116 Procedures, soldering, 45 Process tubes, 230 Product load, 489 598 Index Properties of matter, 50 Provision compartment, 357 PSC compressor motor, troubles, 362 motor diagram, 361 motor hookup, 211, 223, 225, 227, 228, 229 Psychrometers, stationary, 29 Psychrometric chart, 404, 405 Psychrometrics, 399 PTC start device, 215 P-traps, suction line, 302 Pulsating DC, 79 Pure water, 260 R R-11, 58 R-12, 180 R-123, 58 R-134a, 179, 180, 192 R-22, 170, 332 alternatives, 171 availability, 171 cost, 171 installing new units, 171 servicing existing units, 171 R-401B, 180 R-402A, 180 R-402B, 181 R-502, 332 Rapid start comparisons, 521 Recharge operations, 182, 187, 389 Recorder, voltage and current, Recovery, 184 mode, 184 system, 570 Rectifier circuit, 79 Recycle functional flow, 186 operations, 181, 185 Reduced-voltage starting methods, 116 Refrigerant and the atmosphere, 58 Refrigerant cycle, 460 Refrigerant cylinders handling, 178 storing, 178 Refrigerant characteristics, 176 circulated, 176 flow, 328 line size, 303, 369 pipe sizes, 441 piping, 439 properties, 166 R-12, 58 R-22, 58 www.TheSolutionManual.com R-40, 58 reclaiming, 181 replacement, 58 shortage, 358 Refrigerants, 57, 156 characteristics, 156 classification of, 156 common, 156 Freon, 158, 174 handling, 178 in order of boiling point, 167 new, 531–537 newer, 174 properties, physical, 535–537 property comparison, 532 recommendations, 532 thermodynamic properties, 533, 534 working with, 341 Refrigeration basic step, 57 blends, 179 cycle, 242, 246 installation, 100 load, 488 mechanics, 524 piping, 494, 495 process, 50 system, 342 multitemperature, 318 systems, 56,58 valve, 99 application, 144 installation of, 146 leads identification, 144 operation, 144 from vaporization, 56 Refrigerator cooling system, 278 Refrigerators, side-by-side, 349 Registers, 416 Relative humidity, 402 lines, 407 Relay, 140, 142 compressor motor, 207 current type, 207, 218 potential type, 207 Remote systems, 435 Replacement units, 368 compressor, 343 Repulsion-start motor, 110 Resistance checks, 364 in a parallel circuit, 65 Resistor ranges and properties, 119 Resistors, wire wound, 68 Restart function, 447 Restrictions, 359 Retrofit, relief from, 173 Return air systems, 438 Return grill grilles, 415 sound, 416 Returns, locating and sizing, 411 Rigid base mountings, 108 Rock-cork insulation, 498 Rooftop units, 437 heating and cooling, 452 installation, 453 Room air motion, 420 Rotary compressors, 230, 236, 447 Rotating blade rotary compressors, 233 Rotors, 238 RSIR compressor, 212 Ruler, Run capacitors, 210, 211, 360 S Safety, 270, 340 Saturated air, 403 vapor, 406 Scale formation, 265 Scale identification, 262 problem of, 265 Scaling, preventing, 261 Schematic, reading a, 150 SCR, 80 Screw compressors, 233, 234 Screwdriver, 2, Phillips head, Scroll compressors, 238, 240 models, 239 operation of, 238, 239 Sealed units, 334 Selecting a fan, 422 Selection of diffusers, 412 Self-inductance, 75 Self-leveling, 472 Semiconductors, 78 Sensible heat, 55 Sensors, 81 Sequence of operation, rooftop unit, 454 Serial plate information, 197 Series circuit, 62, 63 Serpentine heater, 152 Service, 317 operation, 187, 374 restoring, 91 tools, 30 valves, 319 Index 599 www.TheSolutionManual.com Servicing, 172 refrigerator, 341 Shade pole motor, shading, 103, 114, 115 Sheet insulation, 492 installing, 493 Shelf fronts, 383 Shell and tube chiller, 276, 277 Shell condensers, cleaning, 269 Short circuit, motor windings, 136 Short, testing for, 136, 137 Side diffusers, 418 Side-by-side models, refrigerators, 352–354 Silver soldering, 46 Single screw compressors, 235, 237 Single-phase current, 507 hookup for CL AC & Heat Pump, 212 induction motor, 109 line monitor, 514 motors, 103, 105, 116 Single-transistor amplifier stage, 85 Single-zone rooftop system, 439, 440, 441 Sizing procedure, 442 Skin effects, 158 Slide rules, 29 Sludge, 306 Slugs of insulation, 493 Small appliances, 139 Smoke dampers, 416 detectors, 437 Soft copper tubing, 37 Solar air conditioners, 476–481 Solar cooling, 477–480 Solder, soft, 44, 302 Soldering, 43 equipment, paste, procedures, 45 silver, 46 Solenoid, 94 applications, 97, 98 as electromagnets, 97 classes of, 98 coils, 97, 98 valves, 98, 99, 143 Solvents and detergents, 47, 270 Sound meters, 29 requirement, 414 Specific heat, 55, 177 Specific volumes, refrigerants, 167 Splicing power cord, 350, 351 Split-phase motor, 103, 113, 114 windings, 109 Spread, 409 600 Index Squirrel-cage motor, 141 Squirrel-cage rotors, 136 Standard rule, NEC, 509 Star-delta connections, 125 starters, 121 Start and run capacitors, 359 Start capacitor, location in compressor circuit, 113 Start capacitors, 216 Start kits, 512 Starter, 142 magnetic motor, 116 multispeed, 123 polyphase-motor, 115 wiring diagram, 126 Starting a motor, 109 method characteristics, 118 sequence, full voltage, 129 Start-up, 376 Stationary blade rotary compressors, 230 Storage cylinder cooling, 186 Strainer, 307, 316 line, 306 replacements, 307 Structure of matter, 50 Suction line sizes, 443 interconnection, 496 sizing, 442 Sulfur dioxide, 58, 156, 169 Sump, water in, 266 Superheat, 373 how it works, 20 measurement, 17 where and how to check, 20 Swaging tool, 43 Switches, 140 Symbol diode, 78 electrical, 540–547 electronic, 540–547 Synchronous motor, 107 advantages of, 108 properties, 108 System, 317 direct expansion, 277 liquid-recirculating, 284 mothballing, 174 small tonnage, 148 T Tape, Teaching as a career, 528 Teflon, 165 www.TheSolutionManual.com Temperature, 166, 398 controls, 145 conversion, 253 elements, 82 and heat, 54 Terminal box, 208 locating, 414 Terminals, built-up, 208 Terminology, 408 Terms, cooling tower systems, 251 Test operation, 187 pressures, 318 prods, Testing electrical components, 364 for leaks, 389 method, 363 and operating pressures, 325 TEV, 310 installation, 313, 314 Thermal actuator, operation of a, 87 Thermal decomposition, 162 Thermometer, 13, 14 analog, 14 bimetallic, 13, 15 care and repair, 18 dial-type, 16 electronic, 19 mercury, 15 pocket, 13 and pressure gage, 55 resistance, 13, 16 shielding, 13 split, 15 superheat, 14, 17 thermocouple, 13, 16 Thermostat, 510 construction 147 cut-out and cut-in, 357 freezer, 384, 385, 386 microprocessor, 511 modern, 147, Appendix IV programming, 550–568 service, 511 wiring diagram, 147 Three-phase compressors, 213 current, 507 line voltage monitor, 516 motor, cutaway, 106 Throw, 409 requirement, 413 Time delay, 513 control, 374 modules, 515 Time lag, 76 Tolerances, capacitor, 73 Tool kits, air-conditioning and refrigeration, swaging, 43 Tools bending, 43 and equipment, flaring, 40, 41 insulation stripping, masonry, metalworking, new, 579, 580 refrigeration and appliance, service, 30 special, 31 of the trade, 570–580 woodworking, Torque, 141 Totalclaim, 181, 182, 184, 187 operation of the unit, 183 Totaltest, 185 Towers cross flow, 254 types of, 254–256 Toxicity, 158, 169 oral, 158 Transformers, 77 applications, 78 construction, 77 Transistor amplifier, 80 Transistors, 79 Trigger rates, 173 Troubleshooting, 189, 376, 444–446, 450, 458, 467 add on units, 435, 436 approach, 189 console model, 451 hermetic compressor, 432, 433 a regulator, 297 with volt-ammeter, 133 voltage drop, 504 window units, 431 Tube adapter, 348 capillary, 342 capillary connection, 44 refrigeration service, 301 Tubes, capillary, 326 Tubing connections, 370 installation, 370 insulation, 492 Tubing, 37 capillary, 38, 301 constricting, 41 copper, 301 cutter, 42 Index 601 www.TheSolutionManual.com Tubing (Cont.): cutting, 39 diameters, 39 flaring copper, 40 forming refrigerant, 42 interconnecting, 368 soft copper, 37 swaging, copper, 41 Tubular ceramic capacitors, 71 Tubular solenoids, 94–96 Turns ratio, 78 Two-value capacitor motor, 106 Types of freezers, 380 U Undercharge of refrigerant, 355 Unit mounting, 366 Up flow evaporators, 435 Upright freezer, 389 Using the heat pump, 484 Utility room installation, 434 V Vacuum levels, 32, 33 Vacuum pump, 348, 572 maintenance, 34 oil problems, 34 operating instructions, 34 two stage, 34 Valve, 100, 289, 290 automatic expansion, 300 bypass, installation, 324 check, 334 compressor, 303, 304 and controls, 288 discharge bypass, 323 externally equalized bypass, 324 float, 301, 326 installation, 327 hand-expansion, 300 head pressure control, 319 level control, 326 line, 304 losses, 444 modulating, 311 operation, 311, 315 other types, 334 packless-line, 304 pressure-regulating, 315 receiver, 335 refrigeration, 144 service suggestions, 145 service, 321 sizing, 278, 281 thermostatic expansion, 300, 309 602 Index troubleshooting, 292 used in direct expansion system, 277 water, 334 Vane motor-crank angles, 249 Vapor recovery, 184 Variable resistor, 81 speed drives, 133 Various motor connections, 131 Varnish, 306 Vectrol, 412 Velocity, 406 pressure, 410 Ventilation methods, 425 Vertical lift, 312 VFDs, 133 Vibration meters, 29 Vinyl, 165 Voltage drop, calculations, 503 conductor, 504 unacceptable, 505 loss, limiting, 502 variations, 503 Volt-ammeter, clamp-on, 134 split core, 134 Voltmeter, 25, 26 Volume, 166 of air, 422 dampers, 439 Vortex shedding, 415 W Wall gain load, 489 mounted ductless air conditioners, 445 Warranty test procedure, 363 Water lines, 497 in tank, 266 valves, 496 volume, 266 Wattage, 358 rating, resistors, 67 Wattmeter, 27 Wet bulb temperature, 402, 407 Wheatstone bridges, 80 Window units, 428 Wire selection, 502 Wire size, 63, 361 choosing, 502, 505 wound resistors, 118 Wiring diagram, 455 for current sensors, 520 www.TheSolutionManual.com Totalclaim™, 188 two-speed motors, 129 constant horsepower motor, 127 Woodworking tools, Wool-felt insulation, 499 Working voltage, DC, 72 Wrapper condenser, 386 Wrenches, crescent, monkey, pipe, WVDC, 72 Wye-Delta, 121 starters, circuits, 123 X Xc, 74 Z Z (impedance), 74 Zener diode, 79 Index 603 www.TheSolutionManual.com www.digitalengineeringlibrary.com A Dynamic Online Source of WORLD-RENOWNED ENGINEERING TITLES Combined with Innovative Technology Digital Engineering Library Features: • A powerful online 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Contact Us: call 888-307-5984 (outside the U.S.: 1-614-759-3663) www.digitalengineeringlibrary.com ... since voltage and current changes can affect the operation of air- conditioning and refrigeration units It is impossible to install or service air- conditioning and refrigeration units and systems... Contents and 20 Air- Conditioning Refrigeration Careers Performance Objectives 524 Industries that Employ Air- Conditioning and Refrigeration Mechanics 524 Job Qualifications 525 The Future 526 Pay and. .. www.TheSolutionManual.com Air Conditioning and Refrigeration www.TheSolutionManual.com This page intentionally left blank www.TheSolutionManual.com CHAPTER Air- Conditioning and Refrigeration Tools and Instruments