Modern Refrigeration and Air Conditioning by Andrew D. Althouse, BS, (ME), MA Technical-Vocational Education Consultant Life Member, American Society of Heating, Refrigeration, and Air-Conditioning Engineers Carl H. Tumquist, BS, (ME), MA Technical-Vocational Education Consultant Associate Member, American Society of Heating, Refrigeration, and Air-Conditioning Engineers Member, Refrigeration Engineers and Technicians Association Alfred F. Technical Education Consultant Bracciano, BS, M.Ed., Ed. Sp. Member, Refrigeration Service Engineers Society Associate Member, American Society of Heating, Refrigeration, and Air-Conditioning Engineers Member, Association for Career and Technical Education Member, American Technical Education Association Daniel C. Bracciano, BSME Chief Product Engineer HVAC, Chrysler LLC Member, Interior Climate Control Steering Committee, SAE Member, Refrigeration Service Engineers Society Member, Mobile Air Conditioning Society Associate Member, American Society of Heating, Refrigeration, and Air-Conditioning Engineers Gloria M. Bracciano, BA, MA, Ed. Sp. Member, Refrigeration Service Engineers Society Associate Member, American Society of Heating, Refrigeration, and Air-Conditioning Engineers Member, Association for Career and Technical Educator Member, American Technical Education Association TECHNISCHE INFORMATIONSBIBLIOTHEK Publisher The Goodheart-Willcox Company, Inc. Tinley Park, IL www.g-w.com UNIVERSITATSBIBLIOTHEK HANNOVER
Modern Refrigeration and Air Conditioning XV Contents [Section 1 [Refrigeration System Fundamentals [Chapter 1 :undamentals of Refrigeration 2 1.1 Systems of Measurement 4 1.2 Matter and Energy 4 1.3 Force, Work, and Power 5 1.4 Heat 6 1.5 Volume 14 1.6 Pressure 15 1.7 Gas Laws 21 1.8 Saturated Vapor 22 1.9 Mass and Weight 22 1.10 Density 22 1.11 Basic Processes That Provide Cooling Effect 23 1.12 Measuring Refrigeration Effect 24 (Chapter 2 [Basic Refrigeration Systems 28 2.1 Compression Refrigeration Cycle 30 2.2 High Side and Low Side 31 2.3 Compression 32 2.4 Condensing 34 2.5 Metering Device 36 2.6 Evaporating 36 [Section 2 Service Basics Chapter 3 [Tools and Supplies 42 3.1 Hand Tools 44 3.2 Instruments 58 3.3 Standard Supplies 61 3.4 Employer-Provided Tools and ' si;"--^ -^'.-^JV--jrv«; Equipment 64 Chapter 4 Working with Tubing and Piping 68 4.1 Types of Refrigerant Tubing and Pipe 70 4.2 Non-Refrigerant Tubing and Pipe 71 4.3 Cutting Tubing 73 4.4 Bending Tubing 76 4.5 Connecting Tubing 77 4.6 Connecting Pipe 91 Chapter 5 Service Calls 96 5.1 Troubleshooting and Servicing 5.2 Customer Service 101 Section 3 Refrigerants Chapter 6 Introduction to Refrigerants 108 98 6.1 Refrigerants and the Ozone Layer 110 6.2 Classifying Refrigerants 111 6.3 Identifying Refrigerants 113 6.4 Refrigerant Properties 115 6.5 Refrigerant Applications 121 6.6 Inorganic Refrigerants 124 6.7 Refrigeration Lubricants 126 Chapter 7 Equipment and Instruments for Refrigerant Handling and Service 132 7.1 Refrigerant Cylinders 134 7.2 Pressure Gauges 136 7.3 Service Valves 140 7.4 Gauge Manifolds 147 7.5 Leak Detection Devices 151 7.6 Vacuum Pumps 154 7.7 Recovery, Recycling, and Reclaiming Equipment 156 Chapter 8 Working with Refrigerants 164 8.1 Checking Refrigerant Charge 166 8.2 Redistributing Refrigerant 167 8.3 Locating and Repairing Refrigerant Leaks 176 8.4 Evacuating a System 181 8.5 Charging a System 186
XVi Modern Refrigeration and Air Conditioning Section 4 Basic Electricity, Magnetism, and Electronics Chapter 9 Basic Electricity 198 9.1 Fundamental Principles of Electricity 200 9.2 Types of Electricity 204 9.3 Electrical Materials 205 9.4 Circuit Fundamentals 206 9.5 Magnetism 211 9.6 Electrical Generators 212 9.7 Transformer Basics 214 Chapter 10 Electrical Power 218 10.1 Electrical Power 220 10.2 Power Circuits 222 10.3 Electrical Problems 229 Chapter 11 Basic Electronics 234 11.1 Semiconductor Basics 236 11.2 Control Circuits and Electronic Devices 238 11.3 Circuit Boards and Microprocessors 242 11.4 Switches 242 11.5 Relays 243 11.6 Solenoids 243 11.7 Thermocouples 244 Section 5 Motors and Electric Control Systems Chapter 12 Electric Motors 250 12.1 The Elementary Electric Motor 252 12.2 AC Induction Motors 255 12.3 Electronically Commutated Motors 263 12.4 Standard Motor Data 264 12.5 Motor Applications in HVACR Systems 266 Chapter 13 Electrical Control Systems 272 13.1 Circuit Diagrams 274 13.2 Control System Fundamentals 275 13.3 Motor Controls 284 13.4 Motor Protection Devices 297 Chapter 14 Servicing Electric Motors and Controls 304 14.1 Electrical Test Equipment 306 14.2 Troubleshooting Electric Motors 313 14.3 Servicing Hermetic Compressor Motors 318 14.4 Servicing Fan Motors 321 14.5 Servicing External Motors 322 14.6 Servicing Motor Control Systems 328 Courtesy of Sporlan Division-Parker Hannifin Corporation
Modern Refrigeration and Air conditioning XVii (Section 6 [Compressors, Valves, and Metering Devices I Chapter 15 I Compressors 336 15.1 Compressor Drive Configurations 338 15.2 Types of Compressors 341 15.3 General Compressor Components and Systems 358 [Chapter 16 Valves and Metering Devices 366 16.1 Metering Device Basics 368 16.2 Capillary Tubes 368 16.3 Fixed-Orifice Metering Devices 371 16.4 Thermostatic Expansion Valves (TXVs) 373 16.5 Automatic Expansion Valves (AXVs) 389 16.6 Electronic Expansion Valves (EEVs) 392 16.7 Float-Operated Refrigerant Controls 397 16.8 Other Refrigerant Control Valves 400 Section 7 Domestic Refrigerators Chapter 17 and Freezers Overview of Domestic Refrigerators and Freezers 410 17.1 Domestic Refrigeration 412 17.2 Refrigerators and Freezers 413 17.3 Innovative Technologies 419 Chapter 18 Systems and Components of Domestic Refrigerators and Freezers 422 18.1 Basic Components of Refrigerators and Freezers 424 18.2 Specialized Systems 432 Chapter 19 Installation and Troubleshooting of Domestic Refrigerators and Freezers 450 19.1 Checking for Proper Installation 452 19.2 Diagnosing Symptoms 454 19.3 Checking External Circuits 462 19.4 Diagnosing Internal Troubles 465 Chapter 20 Service and Repair of Domestic Refrigerators and Freezers 480 20.1 External Service Operations 482 20.2 Internal Service Operations 483 20.3 Storing or Discarding a Section 8 Refrigerator-Freezer 494 Indoor Air Fundamentals Chapter 21 Air Movement and Measurement 498 21.1 Climate 500 21.2 Atmosphere and Air 500 21.3 Comfort Conditions 514 21.4 Air Movement 517 21.5 Factors Affecting Indoor Air Conditions 525 Chapter 22 Air Quality 530 22.1 Indoor Air Quality Standards and Guidelines 532 22.2 Air Pollutants 532 22.3 Indoor Air Quality 535 22.4 Air Cleaning 542 22.5 Indoor Air Quality Systems 551 Chapter 23 Air Distribution 556 23.1 Air Properties and Behavior 23.2 Air Circulation 559 23.3 Basic Ventilation Requirements 23.4 Air Ducts 563 23.5 Duct Sizing 573 23.6 Fans 579 23.7 Air Curtains 581 Chapter 24 Ventilation System Service 586 24.1 Airflow Measurement 588 24.2 Special Duct Problems and Duct Maintenance 591 24.3 Fan Service 597 24.4 Filter Service 598 558 560
XviH Modern Refrigeration and Air Conditioning Section 9 Air-Conditioning Systems Chapter 25 Ductless Air-Conditioning Systems 602 25.1 Principles of Cooling and Humidity Control 604 25.2 Remote Comfort Cooling Systems 605 25.3 Self-Contained Air-Conditioning Units 608 Chapter 26 Central Air-Conditioning Systems 620 26.1 Central Air Conditioning 622 26.2 Split Systems 624 26.3 Rooftop and Outdoor Units 627 26.4 Chilled Water Systems (Chillers) 630 26.5 Water-Cooled Condensers 642 26.6 Comfort Cooling Controls 646 Chapter 27 Absorption and Evaporative Cooling Systems 652 27.1 Absorption Refrigeration Systems 654 27.2 Absorption Cooling Systems 656 27.3 Evaporative Cooling 667 Chapter 28 Humidity Control 674 28.1 Humidity Levels and Comfort 676 28.2 Types of Humidifiers 678 28.3 Dehumidifying Equipment 683 Chapter 29 Thermostats 688 29.1 Thermostats for Heating and Air-Conditioning 690 29.2 Thermostat Operation 690 29.3 Types of Thermostats 695 Chapter 30 Heating and Cooling Loads 710 30.1 Heat Transfer 712 30.2 Heat Loads 712 30.3 Heat Leakage 713 30.4 Other Factors Affecting 30.5 Determining Total Heat Load 735 Chapter 31 Heat Loads 728 Air Conditioning Installation, Troubleshooting, and Service 742 31.1 Central Air Conditioning System Service 744 31.2 Ductless Air Conditioning Unit Service 753 31.3 Absorption System Service 760 31.4 Servicing and Installing Humidifiers 764 Section 10 Heating Systems Chapter 32 Forced-Air Heating Fundamentals 768 32.1 Basic Components 770 32.2 Furnace Types and Construction 773 32.3 Forced-Air Duct Arrangements 775 32.4 Makeup Air Units 775 32.5 Blower Controls 776 32.6 Unit Heaters 778 Carrier Corporation, Subsidiary of United Technologies Corp. Chapter 33 Hydronic Heating Fundamentals 782 33.1 Hydronic System Components 784 33.2 Hydronic System Designs 794 33.3 Hydronic System Controls 805 33.4 Hydronic System Installation 808
Modern Refrigeration and Air Conditioning Xix 33.5 Troubleshooting and Servicing Hydronic Systems 810 33.6 Preparing a Boiler for the Heating Season 819 Chapter 34 Heat Pumps 824 34.1 Heat Pump Basics 826 34.2 Types of Heat Pumps 827 34.3 Heat Pump Efficiency 830 34.4 Heat Pump System Components 832 34.5 Heat Pump Controls 844 34.6 Heat Pumps and Solar Heating Chapter 35 Systems 847 Gas-Fired Heating Systems 852 35.1 Combustion 855 35.2 Gas Valves 859 35.3 Gas Burners 860 35.4 Ignition Systems 862 35.5 Gas Furnace Controls 865 35.6 Gas Furnace Efficiency 869 35.7 Gas Furnace Venting Categories 871 35.8 Gas-Fired Radiant Heat 872 Chapter 36 Oil-Fired Heating Systems 876 36.1 Basic Oil Furnace Operation 878 36.2 Fuel Oil 878 36.3 Combustion Efficiency 880 36.4 Fuel Line Components 884 36.5 Oil Burners 888 36.6 Primary Control Units 895 36.7 Oil Furnace Exhaust 902 Chapter 37 Electric Heating Systems 906 37.1 Principles of Electric Resistance Heating 908 37.2 Electric Heating Elements 909 37.3 Electric Heating Systems 910 37.4 Electric Furnace and Duct Heater Controls 917 37.5 Electric Baseboard Heating Unit Controls 921 37.6 Electric Heat Construction Practices 922 Chapter 38 Heating System Installation and Service 926 38.1 Heat Pump System Service 928 38.2 Gas-Fired Heating System Service 932 38.3 Oil-Fired Heating System Service 939 38.4 Electric Heating System Service 947 38.5 Venting System Installation 949 Section 11 Energy Management Chapter 39 and Conservation Solar Power and Thermal Storage 956 39.1 The Nature of Solar Energy 958 39.2 Solar Collectors 959 39.3 Solar Heating Systems 962 39.4 Applications for Solar Heating Systems 963 39.5 Supplementary Heat 965 39.6 Solar Energy Cooling Systems 966 39.7 Converting Solar Energy to Electricity 967 39.8 Thermal Energy Storage 970 Chapter 40 Energy Management 978 40.1 Energy Consumption 980 40.2 Building Control Systems 980 40.3 Controllers for Building Control Systems 982 40.4 Building Control Protocols 984 40.5 Control System Diagnostics and Repair 987 Chapter 41 Energy Conservation 990 41.1 Building Efficiency 992 41.2 HVAC Equipment Efficiency 998 41.3 HVAC Alternatives for Energy Conservation 1000 41.4 The Role of the HVACR Technician 1002 kkays2/shutterstock.com
XX Modern Refrigeration and Air Conditioning Section 12 Commercial Refrigeration Systems Chapter 42 Overview of Commercial Refrigeration Systems 1006 42.1 Applications 1008 42.2 Commercial Refrigeration Systems 1010 42.3 Industrial Applications 1034 Chapter 43 Special Refrigeration Systems and Applications 1038 43.1 Transportation Refrigeration 1040 43.2 Alternative Refrigeration Methods 1046 Chapter 44 Commercial Refrigeration System Configurations 1058 44.1 Sophisticated Commercial Systems 1060 44.2 Multiple-Evaporator Systems 1065 44.3 Modulating Refrigeration Cycle 1066 44.4 Multistage Systems Cascade and Chapter 45 Compound 1070 Commercial Refrigeration Systems High-Side Components 1076 45.1 Compressors and Motors 1078 45.2 Commercial Condensers 1095 45.3 Cooling Towers 1113 45.4 Heat Recovery Systems 1119 45.5 Liquid Receivers 1120 45.6 Liquid Line Filter-Driers 1121 45.7 Secondary Loop Refrigeration Systems 1124 Chapter 46 Commercial Refrigeration Systems Low-Side Components 1130 46.1 Metering Devices 1132 46.2 Commercial Evaporators 1132 46.3 Accumulators 1156 46.4 Suction Line Filter-Driers 1157 46.5 Crankcase Pressure Regulators (CPRs) 1158 Chapter 47 Commercial Refrigeration Systems- Piping 1162 47.1 Refrigerant Lines 1164 47.2 Vibration Absorbers 1164 47.3 Heat Exchangers 1165 47.4 Check Valves 1166 47.5 Manual Valves 1167 47.6 Relief Valves 1169 47.7 Mufflers 1171 47.8 Sight Glasses 1172 Section 13 Designing Commercial Refrigeration Systems Chapter 48 Understanding Heat Loads and System Thermodynamics 1176 48.1 Heat Loads 1178 48.2 Thermodynamics of the Basic Refrigeration Cycle 1198 Chapter 49 Commercial Refrigeration Component Selection 1206 49.1 Sizing Compressors, Condensers, and Evaporators 1208 49.2 Calculating Theoretical Compressor Volume 1214 49.3 Designing Piping 1216
Modern Refrigeration and Air Conditioning ection 14 nstalling and Servicing Commercial ystems hapter 50 nstalling Commercial Systems 1226 50.1 Types of Commercial Installations 1228 50.2 Codes and Standards 1228 50.3 Installing Condensing Units 1229 50.4 Installing Expansion Valves 1231 50.5 Installing Evaporators 1233 50.6 Installing Refrigerant Lines 1235 50.7 Installing Electric Motors 1239 50.8 Testing Installations 1241 50.9 Charging Commercial Systems 1242 50.10 Starting a Commercial Refrigeration System 1246 hapter 51 roubleshooting Commercial Systems- System Diagnosis 1250 51.1 Commercial Refrigeration Troubleshooting 1252 51.2 Checking Refrigerant Charge 1257 51.3 Diagnosing Common Symptoms 1258 51.4 Troubleshooting Ice Machines 1279 hapter 52 roubleshooting Commercial Systems Component Diagnosis 1290 52.1 Checking Electrical Circuits 1292 52.2 Checking External Motors 1293 52.3 Checking Condensing Units 1293 52.4 Checking Liquid Lines 1306 52.5 Checking Thermostatic Expansion Valves (TXVs) 1306 52.6 Checking Electronic Expansion Valves (EEVs) 1307 52.7 Checking Evaporator Pressure Regulators (EPRs) 1309 52.8 Checking Hot-Gas Valves 1310 52.9 Checking Solenoid Valves 1310 52.10 Checking Evaporators 1311 52.11 Checking Suction Lines 1311 Chapter 53 Servicing Commercial Systems 1316 53.1 System Service Fundamentals 1318 53.2 Servicing Motors and Compressors 1 53.3 Servicing Condensers 1326 53.4 Servicing Liquid Lines 1333 53.5 Servicing Evaporators 1334 53.6 Servicing Valves 1335 53.7 Reconditioning Equipment after a Flood 1339 Section 15 Professional Development Chapter 54 Technician Certification 1342 54.1 EPA Certification 1344 54.2 EPA Service Requirements 1349 54.3 Service Organizations and Industry Associations 1351 Appendixes 1356 Appendix A: Service Information 1357 Appendix B: Troubleshooting Charts 1361 Appendix C: Refrigerants 1374 Appendix D: Electricity and Electronics 13i Appendix E: Heat, Temperature, and Pressure 1385 Appendix F: Equivalent Charts 1390 Glossary 1398 Index 1433