EBOOK - Refrigeration and Air Conditioning Technology - 7th Edition (Bill Whitman & Bill Johnson & John Tomczyk & Eugene Silberstein)

Đây là cuốn sách về chuyên ngành "Hệ thống lạnh & Điều hòa không khí" mà Ad thấy đầy đủ nhất bao gồm 1690 trang chia làm làm nhiều chuyên đề. Một tài liệu rất hay cho anh em chuyên ngành Nhiệt.

Refrigeration & Air Conditioning Technologyis designed and written for students in vocational-technical schools and colleges, community colleges, and apprenticeship programs. The content is in a format appropriate for students who are attending classes full-time while preparing for their fi rst job, for students attending classes part-time while preparing for a career change, or for those working in the fi eld who want to increase their knowledge and skills. Emphasis throughout the text is placed on the practical applications of the knowledge and skills technicians need to be productive in the refrigeration and air-conditioning industry.
The contents of this book can be used as a study guide to prepare for the Environmental Protection Agency (EPA) mandatory technician certification examinations. It can be used in the HVAC/R fi eld or closely related fi elds by students, technicians, installers, contractor employees, service personnel, and owners of businesses.
This text is also an excellent study guide for the Industry Competency Exam (ICE), the North American Technician Excellence (NATE), the HVAC Excellence, the Refrigeration Service Engineers Society (RSES), the United Association (UA) STAR certifi cation, and the Heating, Air Conditioning, and Refrigeration Distributors International (HARDI) voluntary HVAC/R technician certifi cation and home-study examinations.
The book is also written to correspond to the National Skill Standards for HVAC/R technicians. Previous editions of this text are often carried to the job site by technicians and used as a reference for service procedures. “Do-it-yourselfers” will find this text valuable for understanding and maintaining heating and cooling systems.
 As general technology has evolved, so has the refrigeration and air-conditioning industry. A greater emphasis is placed on digital electronic controls and system effi ciency. At the time of this writing, Every central split cooling system manufactured in the United States today must have a Seasonal Energy Effi ciency Ratio (SEER) rating of at least 13. This energy requirement was mandated by federal law as of January 23, 2006. SEER is calculated on the basis of the total amount of cooling (in Btus) the system will provide over the entire season, divided by the total number watt-hours it will consume. Higher SEER ratings refl ect a more efficient cooling system. Air-conditioning and refrigeration technicians are responsible for following procedures to protect our environment, particularly with regard to the handling of refrigerants. Technician certification has become increasingly important in the industry.
Global warming has become a major environmental issue. When HVAC/R systems are working correctly and effi ciently, they will greatly reduce energy consumption and greenhouse gases. Organizations like the Green Mechanical Council (GreenMech) are advocates for the HVAC/R industry and assist the industry in meeting with government, educational, industry, and labor interests to fi nd solutions to the world’s global-warming problem. GreenMech has created a scoring system designed to help engineers, contractors, and consumers know the “green value” of each mechanical installation. The “green value” encompasses the system’s energy effi ciency, pollution output, and sustainability. Realtors, building inspectors, builders, and planning and zoning offi cials will now have some knowledge about and guidance on how buildings and mechanical systems are performing. Green buildings and green mechanical systems are becoming increasingly popular in today’s world as a way to curb global warming.
 Energy audits have become an integral part of evaluating and assessing an existing building’s energy performance. Higher effi ciency standards for the energy performance of new buildings have been established. Higher levels of training and certifi cation have been developed for HVAC/R technicians to meet the needs of more sophisticated, energy-efficient buildings and HVAC/R equipment.


SECTION 1: Theory of Heat
Introduction  1
Unit 1   Heat, Temperature, and Pressure  14
Unit 2   Matter and Energy  27
Unit 3   Refrigeration and Refrigerants  36
SECTION 2: Safety, Tools and Equipment,
and Shop Practices
Unit 4   General Safety Practices  84
Unit 5   Tools and Equipment  102
Unit 6   Fasteners  135
Unit 7   Tubing and Piping  148
Unit 8   Leak Detection, System Evacuation,
and System Cleanup  178
Unit 9   Refrigerant and Oil Chemistry and
Management—Recovery, Recycling,
Reclaiming, and Retrofitting  213
Unit 10  System Charging  251
Unit 11  Calibrating Instruments  269
SECTION 3: Basic Automatic Controls
Unit 12 Basic Electricity and Magnetism  282
Unit 13 Introduction to Automatic Controls  310
Unit 14 Automatic Control Components
and Applications  322
Unit 15  Troubleshooting Basic Controls  552
Unit 16 Advanced Automatic Controls—Direct Digital
Controls (DDCs) and Pneumatics  376
SECTION 4: Electric Motors
Unit 17 Types of Electric Motors  398
Unit 18 Application of Motors  429
Unit 19 Motor Controls  447
Unit 20  Troubleshooting Electric Motors  458
SECTION 5: Commercial Refrigeration
Unit 21 Evaporators and the Refrigeration System  476
Unit 22 Condensers  498
Unit 23 Compressors  532
Unit 24 Expansion Devices  566
Unit 25 Special Refrigeration System Components  595
Unit 26 Applications of Refrigeration Systems  640
Unit 27 Commercial Ice Machines  684
Unit 28 Special Refrigeration Applications  733
Unit 29 Troubleshooting and Typical Operating
Conditions for Commercial Refrigeration  752
SECTION 6:  Air-Conditioning
(Heating and Humidification)
Unit 30 Electric Heat  798
Unit 31 Gas Heat  816
Unit 32 Oil Heat  889
Unit 33 Hydronic Heat  940
Unit 34  Indoor Air Quality  995
SECTION 7: Air-Conditioning (Cooling)
Unit 35 Comfort and Psychrometrics  1016
Unit 36 Refrigeration Applied to Air-Conditioning  1040
Unit 37 Air Distribution and Balance  1059
Unit 38 Installation  1107
Unit 39 Residential Energy Audit  1130
Unit 40 Typical Operating Conditions  1181
Unit 41 Troubleshooting  1195
SECTION 8: All-Weather Systems
Unit 42  Heat Gains and Heat Losses in Structures  1226
Unit 43 Air Source Heat Pumps  1245
Unit 44 Geothermal Heat Pumps  1297
SECTION 9: Domestic Appliances
Unit 45 Domestic Refrigerators and Freezers  1334
Unit 46 Room Air Conditioners  1408
SECTION 10:  Commercial Air-Conditioning
and Chilled-Water Systems
Unit 47 High-Pressure, Low-Pressure, and Absorption
Chilled-Water Systems  1438
Unit 48 Cooling Towers and Pumps  1483
Unit 49 Operation, Maintenance, and Troubleshooting
of Chilled-Water Air-Conditioning Systems  1509
Unit 50 Commercial Packaged Rooftop, Variable
Refrigerant Flow and Variable
Air Volume Systems  1535
Appendix A  Alternative Heating
(Stoves and Fireplace Inserts)  1575
Appendix B  1584
Preface  xiii
New in This Edition  xiv
How to Use the Text and Supplementary Materials   xix
Support Materials  xxii
About the Authors  xxiv
Acknowledgments  xxv
SECTION 1: Theory of Heat
Introduction 1
 History of Refrigeration and Air-Conditioning (Cooling)  2   Green Awareness  5
History of Home and Commercial Heating  7
Career Opportunities  7
 Technician Certifi cation Programs  8
Programmatic Accreditation  9
 National Skill Standards  10
 Customer Relations and Technician Soft Skills  10
Unit 1  Heat, Temperature, and Pressure  14
 1.1  Heat, Temperature, and Pressure  14
1.2 Temperature  14
 1.3  Introduction to Heat  16
1.4 Conduction  18
1.5 Convection  18
1.6 Radiation  19
1.7 Sensible Heat  20
1.8 Latent Heat  20
1.9 Specifi c Heat  22
 1.10  Sizing Heating Equipment  22
1.11 Pressure  22
1.12 Atmospheric Pressure  23
1.13 Pressure Gauges  24
Unit 2  Matter and Energy  27
2.1 Matter  27
 2.2  Mass and Weight  28
2.3 Density  28
2.4 Specifi c Gravity  28
2.5 Specifi c Volume  28
2.6 Gas Laws  29
2.7 Energy  31
 2.8  Conservation of Energy  32
 2.9  Energy Contained in Heat  32
 2.10  Energy in Magnetism  32
 2.11  Purchase of Energy  33
 2.12  Energy Used as Work  33
2.13 Power  33
 2.14  Electrical Power—The Watt  33
Unit 3  Refrigeration and Refrigerants  36
 3.1  Introduction to Refrigeration  36
3.2 Refrigeration  37
 3.3  Rating Refrigeration Equipment  37
 3.4  The Refrigeration Process  38
 3.5  Temperature and Pressure Relationship  40
3.6 Refrigeration Components  45
3.7 The Evaporator  45
3.8 The Compressor  47
3.9 The Condenser  49
 3.10  The Refrigerant Metering Device  51
 3.11  Matching Refrigeration Systems  and Components  53
3.12 Refrigerants  55
 3.13  Refrigerants Must Be Safe  56
 3.14  Refrigerants Must Be Detectable  56
 3.15  The Boiling Point of the Refrigerant  58
3.16 Pumping Characteristics  58
 3.17  Popular Refrigerants and Their Important  Characteristics 58
 3.18  Refrigerant Cylinder Color Codes  58
 3.19  Recovery, Recycling, or Reclaiming  of Refrigerants  61
 3.20  Plotting the Refrigerant Cycle  61
 3.21  Plotting the Refrigerant Cycle for Blends with  Noticeable Temperature Glide (Zeotropic Blends)  77
SECTION 2:  Safety, Tools and Equipment,
and Shop Practices
Unit 4  General Safety Practices  84
 4.1  Pressure Vessels and Piping  84
4.2 Electrical Hazards  88
4.3 Heat  93
4.4 Cold  94
4.5 Mechanical Equipment  94
 4.6  Moving Heavy Objects  96
 4.7  Refrigerants in Your Breathing Space  96
4.8 Using Chemicals  99
Unit 5  Tools and Equipment  102
5.1 General Tools  102
 5.2  Specialized Hand Tools  108
5.3 Tubing Tools  110
 5.4  Specialized Service and Installation Equipment  114  5.5  Refrigerant Leak Detectors  117
5.6 Other Tools  118
 5.7  Miscellaneous Tools and Equipment  for Specialized Needs  126
Unit 6  Fasteners  135
6.1 Nails  135
 6.2  Staples and Rivets  136
6.3 Threaded Fasteners  137
6.4 Concrete Fasteners  142
6.5 Other Fasteners  143
Unit 7  Tubing and Piping  148
 7.1  Purpose of Tubing and Piping  148
 7.2  Types and Sizes of Tubing  148
7.3 Tubing Insulation  149
7.4 Line Sets  151
7.5 Cutting Tubing  151
7.6 Bending Tubing  152
 7.7  Soldering and Brazing Processes  154
 7.8  Heat Sources for Soldering and Brazing  155 7.9 Fluxing  160
7.10 Soldering Techniques  161
7.11 Brazing Techniques  163
 7.12  Practical Soldering and Brazing Tips  164
 7.13  Making Flare Joints  166
7.14 Swaging Techniques  167
7.15 Compression Fittings  169
 7.16  Steel and Wrought Iron Pipe  170
 7.17  Installing Steel Pipe  173
7.18 Plastic Pipe  173
 7.19  Alternative Mechanical Piping Connections  174
Unit 8  Leak Detection, System Evacuation,
and System Cleanup  178
8.1 Leaks  178
 8.2  Basic Refrigerant Leak Detection  180
 8.3  Advanced Leak Detection  182
 8.4  Standing Pressure Test  184
 8.5  Leak Detection Tips  186
8.6 Repairing Leaks  189
8.7 System Evacuation  190
 8.8  General Evacuation Procedures  202
 8.9  Cleaning a Dirty System  208
Unit 9  Refrigeration and Oil Chemistry
and Management—Recovery, Recycling,
Reclaiming, and Retrofitting  213
 9.1  Refrigerants and the Environment  213
9.2 Ozone Depletion  214
9.3 Global Warming  215
9.4 Refrigerants  216
9.5 CFC Refrigerants  217
9.6 HCFC Refrigerants  217
9.7 HFC Refrigerants  218
9.8 HC Refrigerants  218
9.9 Naming Refrigerants  218
9.10 Refrigerant Blends  219
 9.11  Popular Refrigerants and Their  Compatible Oils  220
 9.12  Refrigerant Oils and Their Applications  225 9.13 Oil Groups  225
9.14 Regulations  227
 9.15  Recover, Recycle, or Reclaim  227
 9.16  Methods of Recovery  229
 9.17  Mechanical Recovery Systems  232
 9.18  Recovering Refrigerant from Small Appliances  239 9.19 Reclaiming Refrigerant  241
9.20 Refrigerant Retrofi tting  242
 9.21  Refrigerants and Tools in the Future  248
Unit 10  System Charging  251
 10.1  Charging a Refrigeration System  251
 10.2  Vapor Refrigerant Charging  251
 10.3  Liquid Refrigerant Charging  253
10.4 Weighing Refrigerant  256
 10.5  Using Charging Devices  257
 10.6  Using Charging Charts  258
 10.7  Subcooling Charging Method for TXV Systems  262  10.8  Charging Near-Azeotropic (Zeotropic)  Refrigerant Blends  263
Unit 11  Calibrating Instruments  269
11.1 Calibration  269
11.2 Temperature-Measuring Instruments  270
 11.3  Pressure Test Instruments  272
 11.4  Electrical Test Instruments  274
 11.5  Refrigerant Leak Detection Devices  276
 11.6  Flue-Gas Analysis Instruments  277
11.7 General Maintenance  278
SECTION 3: Basic Automatic Controls
Unit 12  Basic Electricity and Magnetism  282
 12.1  The Structure of Matter  282
 12.2  Movement of Electrons  283
12.3 Conductors  283
12.4 Insulators  283
 12.5  Electricity Produced from Magnetism  283
12.6 Current  284
 12.7  Units of Electrical Measurement  284
 12.8  The Electric Circuit  285
 12.9  Making Electrical Measurements  285
12.10 Ohm’s Law  288
 12.11  Characteristics of Series Circuits  289
 12.12  Characteristics of Parallel Circuits  289
12.13 Electrical Power  290
12.14 Magnetism  290
12.15 Inductance  292
12.16 Transformers  292
12.17 Capacitance  293
12.18 Impedance  294
 12.19  Electrical Measuring Instruments  294
12.20 Sine Waves  298
12.21 Wire Sizes  299
 12.22  Circuit Protection Devices  300
12.23 Semiconductors  303
Unit 13  Introduction to Automatic Controls  310
 13.1  Types of Automatic Controls  310
 13.2  Devices That Respond to Thermal Change  310  13.3  The Bimetal Device  311
 13.4  Control by Fluid Expansion  314
13.5 The Thermocouple  317
 13.6  Electronic Temperature-Sensing Devices  319
Unit 14  Automatic Control Components
and Applications  322
14.1 Temperature Controls  322
 14.2  Low-Voltage Space Temperature Controls  324  14.3  Line-Voltage Space Temperature Controls  328  14.4  Sensing the Temperature of Solids  330
 14.5  Measuring the Temperature of Fluids  333
14.6 Pressure-Sensing Devices  334
14.7 Pressure Transducers  338
14.8 High-Pressure Controls  340
14.9 Low-Pressure Controls  341
 14.10  Oil Pressure Safety Controls  341
 14.11  Air Pressure Controls  343
 14.12  Gas Pressure Switches  344
 14.13  Switchless Devices That Control Fluid Flow  344  14.14  Water Pressure Regulators  344
 14.15  Gas Pressure Regulators  345
 14.16  Mechanical and Electromechanical  Controls 346
 14.17  Maintenance of Mechanical Controls  347  14.18  Maintenance of Electromechanical Controls  347  14.19  Service Technician Calls  347
Unit 15  Troubleshooting Basic Controls  352
 15.1  Introduction to Troubleshooting  352
 15.2  Troubleshooting a Simple Circuit  353
 15.3  Troubleshooting a Complex Circuit  354
 15.4  Troubleshooting the Thermostat  357
 15.5  Troubleshooting Amperage in  the Low-Voltage Circuit  358
 15.6  Troubleshooting Voltage in  the Low-Voltage Circuit  359
 15.7  Troubleshooting Switches and Loads  360
 15.8  Pictorial and Line Diagrams  367
 15.9  Service Technician Calls  367
Unit 16  Advanced Automatic Controls—Direct
Digital Controls (DDCs) and Pneumatics  376
16.1 Control Applications  376
 16.2  Types of Control Systems  376
16.3 Pneumatic Controls  378
 16.4  Cleaning and Drying Control Air  379
16.5 Control Components  380
 16.6  Direct Digital Controls (DDCs)  385
 16.7  Residential Electronic Controls  393
SECTION 4: Electric Motors
Unit 17  Types of Electric Motors  398
 17.1  Uses of Electric Motors  398
17.2 Parts of an Electric Motor  398
 17.3  Electric Motors and Magnetism  399
 17.4  Determining a Motor’s Speed  400
17.5 Start Windings  401
 17.6  Starting and Running Characteristics  401
 17.7  Electrical Power Supplies  402
 17.8  Single-Phase Open Motors  403
17.9 Split-Phase Motors  404
 17.10  The Centrifugal Switch  405
 17.11  The Electronic Relay  405
17.12 Capacitor-Start Motors  405
 17.13  Capacitor-Start, Capacitor-Run Motors  406  17.14  Permanent Split-Capacitor Motors  407
17.15 Shaded-Pole Motors  408
17.16 Three-Phase Motors  409
 17.17  Single-Phase Hermetic Motors  410
 17.18  The Potential Relay  411
 17.19  The Current Relay  414
 17.20  Positive Temperature Coefficient Resistor (PTCR)  415
 17.21  Two-Speed Compressor Motors  416
 17.22  Special Application Motors  416
 17.23  Three-Phase Compressor Motors  417
17.24 Variable-Speed Motors  417
 17.25  DC Converters (Rectifi ers)  420
 17.26  Inverters and Variable Frequency Drives (VFDs)  421  17.27  Electronically Commutated Motors (ECMs)  425  17.28  Cooling Electric Motors  426
Unit 18  Application of Motors  429
18.1 Motor Applications  429
 18.2  The Power Supply  429
 18.3  Electric-Motor Working Conditions  436
 18.4  Insulation Type or Class  436
 18.5  Types of Bearings  437
 18.6  Motor Mounting Characteristics  439
18.7 Motor Drives  441
Unit 19  Motor Controls  447
 19.1  Introduction to Motor Control Devices  447  19.2  Run-Load and Locked-Rotor Amperage  448 19.3 The Relay  448
19.4 The Contactor  449
19.5 Motor Starters  451
19.6 Motor Protection  452
 19.7  Inherent Motor Protection  453  19.8  External Motor Protection  453  19.9  National Electrical
 19.11  Magnetic Overload Devices  456  19.12  Restarting the Motor  456
Unit 20  Troubleshooting Electric Motors  458
20.1 Motor Troubleshooting  458
 20.2  Mechanical Motor Problems  458
 20.3  Removing Drive Assemblies  459
20.4 Belt Tension  460
20.5 Pulley Alignment  461
20.6 Electrical Problems  461
20.7 Open Windings  461
 20.8  Shorted Motor Windings  462
 20.9  Short Circuit to Ground (Frame)  464
 20.10  Single-Phase Motor Starting Problems  466 20.11 Checking Capacitors  467
 20.12  Identifi cation of Capacitors  469
 20.13  Wiring and Connectors  470
 20.14  Troubleshooting Hermetic Motors  470
 20.15  Service Technician Calls  470
SECTION 5: Commercial Refrigeration
Unit 21  Evaporators and the Refrigeration System  476
21.1 Refrigeration  476
 21.2  Temperature Ranges of Refrigeration  477
21.3 The Evaporator  477
 21.4  Boiling and Condensing  478
 21.5  The Evaporator and Boiling Temperature  478 21.6 Removing Moisture  478
 21.7  Heat Exchange Characteristics  of the Evaporator  478
 21.8  Types of Evaporators  481
21.9 Evaporator Evaluation  487
 21.10  Latent Heat in the Evaporator  489
 21.11  The Flooded Evaporator  489
 21.12  Dry- Type  Evaporators  Performance  489
21.13 Evaporator Superheat  490
 21.14  Hot Pulldown (Excessively Loaded Evaporator)  490  21.15  Pressure Drop in Evaporators
 21.16  Liquid Cooling Evaporators (Chillers)  493
 21.17  Evaporators for Low- Temperature Applications  494  21.18  Defrost of Accumulated Moisture  495
Unit 22  Condensers  498
22.1 The Condenser  498
22.2 Water-Cooled Condensers  498
22.3 Tube-Within-a-Tube Condensers  499
22.4 Mineral Deposits  499
 22.5  Cleanable Tube-Within-a-Tube Condensers  500
vii Contents
22.6 Shell-and-Coil Condensers  501
22.7 Shell-and-Tube Condensers  502
22.8 Wastewater Systems  503
 22.9  Refrigerant-to-Water Temperature Relationship  for Wastewater Systems  505
 22.10  Recirculating Water Systems  507
22.11 Cooling Towers  507
22.12 Natural-Draft Towers  508
 22.13  Forced- or Induced-Draft Towers  509
22.14 Evaporative Condensers  511
22.15 Air-Cooled Condensers  511
22.16 High-Effi ciency Condensers  515
 22.17  The Condenser and Low Ambient Conditions  516  22.18  Head Pressure Controls  518
 22.19  Using the Condenser Superheat  528
22.20 Heat Reclaim  528
 22.21  Floating Head Pressures  528
22.22 Condenser Evaluation  529
 22.23  Service Technician Calls  529
Unit 23  Compressors  532
 23.1  The Function of the Compressor  532
 23.2  Types of Compressors  534
 23.3  Reciprocating Compressor Components  539  23.4  Belt-Drive Mechanism Characteristics  548
 23.5  Direct-Drive Compressor Characteristics  549  23.6  Reciprocating Compressor Efficiency  549
 23.7  Discus Valve Design  550
 23.8  New Technology in Compressors  551
 23.9  Liquid in the Compressor Cylinder  561
 23.10  System Maintenance and Compressor  Effi ciency  561
Unit 24  Expansion Devices  566
24.1 Expansion Devices  566
 24.2  Thermostatic Expansion Valve  567
24.3 TXV Components  568
 24.4  The Valve Body  568
24.5 The Diaphragm  568
 24.6  Needle and Seat  568
24.7 The Spring  572
 24.8  The Sensing Bulb and Transmission Tube  573  24.9  Types of Bulb Charge  573
 24.10  The Liquid Charge Bulb  573
 24.11  The Cross Liquid Charge Bulb  575
 24.12  The Vapor (Gas) Charge Bulb  575
 24.13  The Cross Vapor Charge Bulb  576
 24.14  Example of a TXV Functioning with an  Internal Equalizer  576
 24.15  TXV Functioning with External Equalizers  577  24.16  TXV Response to Load Changes  579
 24.17  Selection of TXV Valves  580
24.18 Balanced-Port TXV  581
24.19 Dual-Port TXV  582
24.20 The Pressure-Limiting TXV  582
24.21 Servicing the TXV  582
 24.22  Installing the Sensing Element  583
 24.23  The Solid-State-Controlled Expansion Valve  583  24.24  Step-Motor Expansion Valves  584
 24.25  Algorithms and PID Controllers  586
 24.26  The Automatic Expansion Valve  589
 24.27  Automatic Expansion Valve Response  to Load Changes  589
 24.28  Special Considerations for the TXV and AXV  589  24.29  The Capillary Tube Metering
 24.30  Operating Charge for the Capillary Tube System  592
Unit 25  Special Refrigeration System Components  595
 25.1  The Four Basic Components  595
25.2 Mechanical Controls  595
25.3 Two-Temperature Controls  595
 25.4  Evaporator Pressure Control  595
25.5 Multiple Evaporators  598
 25.6  Electric Evaporator Pressure-Regulating Valve  598  25.7  Crankcase Pressure Regulator  599
 25.8  Adjusting the CPR Valve  600
25.9 Relief Valves  600
 25.10  Fan-Cycling Head Pressure Controls  602
 25.11  Fan Speed Control for Controlling  Head Pressure  602
 25.12  Air Volume Control for Controlling  Head Pressure  603
 25.13  Condenser Flooding and Condenser Splitting  for Controlling Head Pressure
25.14 Electrical Controls  604
25.15 Pressure Switches  607
25.16 Low-Pressure Switch  607
 25.17  Low-Pressure Control Applied as a Thermostat  607  25.18  Automatic Pumpdown Systems
25.19 High-Pressure Control  612
 25.20  Low-Ambient Fan Control  613
 25.21  Oil Pressure Safety Control  613
 25.22  The Defrost Cycle  617
25.23 Medium-Temperature Refrigeration  618
 25.24  Random or Off-Cycle Defrost  618
25.25 Planned Defrost  618
 25.26  Low-Temperature Evaporator Defrost  619
 25.27  Internal Heat Defrost (Hot Gas and Cool  Gas Defrost)  619
 25.28  External Heat Defrost  620
 25.29  Defrost Termination and Fan Delay Control  621 25.30 Refrigeration Accessories  622
25.31 Receivers  622
 25.32  The King Valve on the Receiver  623
25.33 Filter Driers  623
 25.34  Refrigerant Check Valves  625
 25.35  Refrigerant Sight Glasses  625
 25.36  Liquid Refrigerant Distributors  625
25.37 Heat Exchangers  626
25.38 Suction-Line Accumulators  626
 25.39  Suction-Line Filter Driers  629
 25.40  Suction Service Valves  630
 25.41  Discharge Service Valves  630
 25.42  Refrigeration Line Service Valves  631
25.43 Diaphragm Valves  633
25.44 Ball Valves  633
25.45 Oil Separators  633
25.46 Vibration Eliminators  634
 25.47  Pressure Access Ports  635
25.48 Crankcase Heat  636
Unit 26  Applications of Refrigeration Systems  640
26.1 Application Decisions  640
26.2 Reach-in Refrigeration  640
 26.3  Self-Contained Reach-In Fixtures  641
 26.4  Individual Condensing Units  643
26.5 Single-Compressor Applications
and Multiple Evaporators  644
 26.6  Parallel Compressor Systems  647
 26.7  Secondary-Fluid Refrigeration Systems  655  26.8  Carbon Dioxide (R-744) Refrigeration Systems  657  26.9  Pressurized Liquid Systems  661
 26.10  Distributed Refrigeration Systems  663
 26.11  Evaporator Temperature Control  664
 26.12  Interconnecting Piping in Multiple-Evaporator  Installations 664
 26.13  Fixture Temperature Control  665
 26.14  The Evaporator and Merchandising  665
 26.15  Chest-Type Display Fixtures  666
26.16 Refrigerated Shelves  667
 26.17  Closed Chest Fixtures  667
 26.18  Controlling Sweating on Fixture Cabinets  667  26.19  Maintaining Store Ambient Conditions  668 26.20 Walk-in Refrigeration  669
 26.21  Knock-Down Walk-In Coolers  669
 26.22  Evaporators in a Walk-In Cooler  670
26.23 Condensate Removal  670
26.24 Refrigeration Piping  670
 26.25  Package Refrigeration for Walk-In Coolers  671  26.26  Vending Machine Refrigeration  671
26.27 Water Coolers  677
 26.28  Refrigerated Air Driers  679
Unit 27  Commercial Ice Machines  684
 27.1  Packaged-Type Ice-Making Equipment  684  27.2  Making Flake Ice  685  27.3  Making Cube Ice  693 27.4 Microprocessors  711
 27.5  Making Cylindrical Ice  716  27.6  Water and Ice Quality  717  27.7  Package Ice Machine Location  723  27.8  Troubleshooting Ice Makers  723  27.9  Service Technician Calls  727
Unit 28  Special Refrigeration Applications  733
 28.1  Special Refrigeration Applications  733
28.2 Transport Refrigeration  733
 28.3  Truck Refrigeration Systems  733
28.4 Railway Refrigeration  740
28.5 Extra-Low-Temperature Refrigeration  741
28.6 Cascade Systems  743
28.7 Quick-Freezing Methods  744
28.8 Marine Refrigeration  746
 28.9  Air Cargo Hauling  749
Unit 29  Troubleshooting and Typical Operating
Conditions for Commercial Refrigeration  752
29.1 Organized Troubleshooting  752
29.2 Troubleshooting High-Temperature
Applications 753
29.3 Troubleshooting Medium-Temperature
Applications 755
29.4 Troubleshooting Low-Temperature
Applications 755
 29.5  Typical Air-Cooled Condenser Operating  Conditions 756
 29.6  Calculating the Correct Head Pressure for  Air-Cooled Equipment  757
 29.7  Typical Operating Conditions for  Water-Cooled Equipment  758
 29.8  Typical Operating Conditions for Wastewater  Condenser Systems  758
 29.9  Typical Operating Conditions for Recirculated  Water Systems  759
 29.10  Six Typical Problems  759
 29.11  Low Refrigerant Charge  759
29.12 Refrigerant Overcharge  762
29.13 Ineffi cient Evaporator  764
29.14 Ineffi cient Condenser  766
 29.15  Refrigerant Flow Restrictions  768
29.16 Ineffi cient Compressor  771
 29.17  Compressor Vacuum Test  771
 29.18  Closed-Loop Compessor Running Bench Test  772  29.19  Closed-Loop Compressor Running Field Test  773  29.20  Compressor Running Test in the System  774  29.21  Service Technician Calls
SECTION 6:  Air-Conditioning
(Heating and Humidification)
Unit 30  Electric Heat  798
30.1 Introduction  798
 30.2  Portable Electric Heating Devices  798
 30.3  Radiant Heating Panels  799
 30.4  Electric Baseboard Heating  800
 30.5  Unit and Wall Heaters  800
 30.6  Electric Hydronic Boilers  800
 30.7  Central Forced-Air Electric Furnaces  801
 30.8  Automatic Controls for Forced-Air Electric  Furnaces 802
 30.9  The Low-Voltage Thermostat  802
 30.10  Controlling Multiple Stages  803
30.11 Wiring Diagrams  804
 30.12  Control Circuits for Forced-Air Electric  Furnaces 805
 30.13  Blower Motor Circuits  806
 30.14  Contactors for Controlling Electric Furnaces  807  30.15  Airfl ow in Electric Furnaces  807
 30.16  Service Technician Calls  811
Unit 31  Gas Heat  816
 31.1  Introduction to Gas-Fired,  Forced-Hot-Air Furnaces  817
 31.2  Types of Furnaces  817 31.3 Gas Fuels  820
31.4 Gas Combustion  822
31.5 Gas Regulators  824
31.6 Gas Valve  824
31.7 Solenoid Valve  825
31.8 Diaphragm Valve  825
 31.9  Heat Motor–Controlled Valve  826  31.10  Automatic Combination Gas Valve  827 31.11 Manifold  832
31.12 Orifi ce  832
31.13 Burners  832
31.14 Heat Exchangers  833
31.15 Fan Switch  836
31.16 Limit Switch  837
31.17 Pilots  839
 31.18  Safety Devices at the Standing Pilot  840 31.19 Ignition Systems  842
31.20 Flame Rectifi cation  844
31.21 High-Effi ciency Gas Furnaces  848
 31.22  Electronic Ignition Modules and Integrated  Furnace Controllers  853
 31.23  Two-Stage Gas Furnaces  859  31.24  Modulating Gas Furnaces  859 31.25 Venting  860
31.26 Gas Piping  864
 31.27  Gas Furnace Wiring Diagrams  and Troubleshooting Flowcharts  865
 31.28  Troubleshooting the Safety Pilot-Proving  Device—The Thermocouple  867
 31.29  Troubleshooting Spark Ignition and  Intermittent Pilot Systems  868
31.30 Combustion Effi ciency  877
 31.31  Service Technician Calls  882
Unit 32  Oil Heat  889
 32.1  Introduction to Oil-Fired, Forced-Warm-Air  Furnaces 889
32.2 Physical Characteristics  890
32.3 Fuel Oils  890
32.4 Oil Storage  893
 32.5  Fuel Oil Supply Systems  895 32.6 Combustion  900
 32.7  Preparation of Fuel Oil for Combustion  901  32.8  By-Products of Combustion  901  32.9  Gun-Type Oil Burners  901  32.10  Oil Furnace Wiring Diagrams  917  32.11  Wiring Diagram for the Stack Switch  Safety Control  917
 32.12  Wiring Diagram for Cad Cell Safety Control  917 32.13 Combustion Chamber  923
32.14 Heat Exchanger  924
 32.15  Condensing Oil Furnace  925 32.16 Service Procedures  926
32.17 Combustion Effi ciency  930
 32.18  Service Technician Calls  934
Unit 33  Hydronic Heat  940
 33.1  Introduction to Hydronic Heating  940
 33.2  The Heat Source  941
 33.3  The Basic Hydronic System  945
 33.4  The Point of No Pressure Change  950
 33.5  Other Hydronic System Components  952
 33.6  High-Temperature Hydronic Piping Systems  963  33.7  Radiant, Low-Temperature Hydronic  Piping Systems  974
 33.8  Combination (High- and Low-Temperature)  Piping Systems  980
 33.9  Tankless Domestic Hot Water Heaters  980
 33.10  Solar Heating as a Supplemental Heat Source  982  33.11  Service Technician Calls  991
Unit 34  Indoor Air Quality  995
34.1 Introduction  995
 34.2  Sources of Indoor Air Pollution  995
34.3 Common Pollutants  996
 34.4  Detecting and Eliminating the Source  of Contamination  1001
34.5 Ventilation  1002
34.6 Air Cleaning  1003
34.7 Duct Cleaning  1007
34.8 Air Humidifi cation  1008
34.9 Sizing Humidifi ers  1012
34.10 Installation  1012
34.11 Service, Troubleshooting, and Preventive
Maintenance 1012
SECTION 7: Air-Conditioning (Cooling)
Unit 35  Comfort and Psychrometrics  1016
35.1 Comfort  1016
 35.2  Food Energy and the Body  1016
 35.3  Heat Transfer to and from the Body  1017
 35.4  The Comfort Chart  1018
35.5 Psychrometrics  1018
 35.6  Moisture in Air  1018
 35.7  Absolute and Relative Humidity  1020
 35.8  Superheated Gases in Air  1022
 35.9  Dry-Bulb and Wet-Bulb Temperatures  1023  35.10  Dew Point Temperature  35.11 Enthalpy
 35.12  The Psychrometric Chart  1026
 35.13  Plotting on the Psychrometric Chart  1029
 35.14  Fresh Air, Infi ltration, and Ventilation  1029
Unit 36  Refrigeration Applied to Air-Conditioning  1040
36.1 Refrigeration  1040
 36.2  Structural Heat Gain  1040
36.3 Evaporative Cooling  1042
 36.4  Refrigerated Cooling or Air-Conditioning  1042 36.5 The Evaporator  1043
 36.6  The Function of the Evaporator  1044
36.7 Design Conditions  1045
36.8 Evaporator Application  1045
36.9 The Compressor  1045
 36.10  The Reciprocating Compressor  1047
 36.11  Compressor Speeds (RPM)  1048
 36.12  Cooling the Compressor and Motor  1048
36.13 Compressor Mountings  1049
 36.14  Rebuilding the Hermetic Compressor  1049  36.15  The Rotary Compressor  1049
 36.16  The Scroll Compressor  1050
36.17 The Condenser  1052
36.18 Expansion Devices  1054
36.19 Air-Side Components  1055
36.20 Installation Procedures  1055
Unit 37  Air Distribution and Balance  1059
37.1 Conditioning Equipment  1059
 37.2  Correct Air Quantity  1060
 37.3  The Forced-Air System  1060
37.4 The Blower  1060
37.5 System Pressures  1063
 37.6  Air-Measuring Instruments for Duct Systems  1064  37.7  Types of Fans and Blowers  1066
 37.8  Types of Drive Assemblies  1067
 37.9  The Supply Duct System  1068
 37.10  Duct System Standards  1072
37.11 Duct Materials  1073
 37.12  Duct Air Movement  1079
37.13 Balancing Dampers  1081
37.14 Zoning  1082
37.15 Duct Insulation  1086
 37.16  Blending the Conditioned Air with Room Air  1086  37.17  The Return-Air Duct System  1088
 37.18  Sizing Duct for Moving Air  1088
 37.19  Measuring Air Movement for Balancing  1092  37.20  The Air Friction Chart  1094
 37.21  Practical Troubleshooting Techniques  1101
Unit 38  Installation  1107
 38.1  Introduction to Equipment Installation  1107  38.2  Installing Square and Rectangular Duct  1107  38.3  Installing Round Metal Duct Systems  1109  38.4  Insulation and Acoustical Lining for Metal Duct  1110  38.5  Installing Ductboard Systems  1110  38.6  Installing Flexible Duct  1111 38.7 Electrical Installation  1112
 38.8  Installing the Refrigeration System  1114  38.9  Installing Split-System Air Conditioners  1118
 38.10  The Split-System Condensing Unit  1121
 38.11  Installing Refrigerant Piping on Split-Systems  1123 38.12 Equipment Start-Up  1126
Unit 39  Residential Energy Auditing  1130
39.1 Introduction  1130
 39.2  Residential (Home) Energy Auditing  1131
 39.3  Performing a Home Energy Audit  1132
39.4 Diagnostic Testing  1138
 39.5  Blower Door Testing  1138
 39.6  Infrared Scanning Using a Thermal  Imaging Camera  1141
 39.7  Sealing Air Leaks  1148
 39.8  Duct Leakage Testing  1152
 39.9  Duct Pressurization Test for Total  Air Leakage  1155
 39.10  Duct Leakage to the Outdoors  1156
39.11 Combustion Effi ciency and Safety Testing  1157
39.12 Furnace Effi ciency Testing  1159
39.13 Furnace Effi ciency Ratings  1161
39.14 Flame Color  1161
 39.15  Furnace Preventive Maintenance  1162
 39.16  Spillage and Backdrafting  1163
 39.17  Flame Safeguard Controls  1164
39.18 Excess Air  1166
39.19 Venting  1166
39.20 Draft  1169
39.21 High-Effi ciency Gas Furnace Anatomy  1171
 39.22  HVAC/R System Testing  1173
 39.23  Numerical Analysis and Reporting  1174
Unit 40  Typical Operating Conditions  1181
 40.1  Mechanical Operating Conditions  1181
 40.2  Relative Humidity and the Load  1182
 40.3  Relationships of System Component  Under Load Changes  1182
 40.4  Evaporator Operating Conditions  1182
 40.5  High Evaporator Load and a Cool Condenser  1182  40.6  Grades of Equipment  1185
 40.7  Documentation with the Unit  1186
 40.8  Establishing a Reference Point on  Unknown Equipment  1187
 40.9  System Pressures and Temperatures  for Diff  erent Operating Conditions  1188
40.10 Equipment Effi ciency Rating  1191
 40.11  Typical Electrical Operating Conditions  1192  40.12  Matching the Unit to the Correct Power Supply  1192  40.13  Starting the Equipment with the Correct Data  1192  40.14  Finding a Point of Reference for  an Unknown Motor Rating  1192
 40.15  Determining the Compressor  Running Amperage  1193
 40.16  Compressors Operating at Full-Load Current  1193  40.17  High Voltage, the Compressor,  and Current Draw  1193
 40.18  Current Draw and the Two-Speed Compressor  1193
Unit 41  Troubleshooting  1195
41.1 Introduction  1195
41.2 Mechanical Troubleshooting  1195
 41.3  Approach Temperature and Temperature  Difference  1197
 41.4  Gauge Manifold Usage  1197
 41.5  When to Connect the Gauges  1198
 41.6  Low-Side Gauge Readings  1201
 41.7  High-Side Gauge Readings  1201
41.8 Temperature Readings  1201
 41.9  Charging Procedures in the Field  1205
41.10 Electrical Troubleshooting  1207
 41.11  Compressor Overload Problems  1211
 41.12  Compressor Electrical Checkup  1212
 41.13  Troubleshooting the Circuit Electrical  Protectors—Fuses and Breakers  1215
 41.14  Service Technician Calls  1215
SECTION 8: All-Weather Systems
Unit 42  Heat Gains and Heat Losses
in Structures  1226
 42.1  Introduction to Heat Gain and Heat Loss  1226  42.2  Methods to Determine the Heat Gain  and Heat Loss of a Structure  1227
 42.3  Indoor and Outdoor Design Conditions  for Heating and Cooling  1228
 42.4  U-Values and R-Values  1229  42.5  Introduction to Heat Gain and Heat  Loss Calculations  42.6  Elements of Structural Heat Loss  (Heating Mode)  1231
 42.7  Elements of Structural Heat Gain  (Cooling Mode)  1238
Unit 43  Air Source Heat Pumps  1245
43.1 Reverse-Cycle Refrigeration  1245
 43.2  Heat Sources for Winter  1246  43.3  The Four-Way Reversing Valve  1246  43.4  The Air-to-Air Heat Pump  1251  43.5  Refrigerant Line Identifi cation  1252 43.6 Metering Devices  1253
 43.7  Thermostatic Expansion Valves  1253  43.8  The Capillary Tube  1254  43.9  Combinations of Metering Devices  1254  43.10  Electronic Expansion Valves  1255  43.11  Orifi ce Metering Devices  1256 43.12 Liquid-Line Accessories  1256
 43.13  Application of the Air-to-Air Heat Pump  1256 43.14 Auxiliary Heat  1258
43.15 Balance Point  1258
43.16 Coeffi cient of Performance  1258
 43.17  Split-System Air-to-Air Heat Pump  1260  43.18  The Indoor Unit  1260  43.19  Air Temperature of the Conditioned Air  1261  43.20  The Outdoor Unit Installation  1262  43.21  Package Air-to-Air Heat Pumps  1263  43.22  Controls for the Air-to-Air Heat Pump  1263  43.23  The Defrost Cycle  1271  43.24  Indoor Fan Motor Control  1275 43.25 Auxiliary Heat  1275
 43.26  Servicing the Air-to-Air Heat Pump  1276  43.27  Troubleshooting the Electrical System  1276  43.28  Troubleshooting Mechanical Problems  1277  43.29  Troubleshooting the Four-Way Valve  1278  43.30  Troubleshooting the Compressor  1280  43.31  Checking the Charge  1281  43.32  Special Applications for Heat Pumps  1283  43.33  Heat Pumps Using Scroll Compressors  1284  43.34  Heat Pump Systems with Variable-Speed Motors  1285  43.35  Service Technician Calls  1287
Unit 44  Geothermal Heat Pumps  1297
44.1 Reverse-Cycle Refrigeration  1297
 44.2  Geothermal Heat Pump Classifi cations  1297 44.3 Open-Loop Systems  1298
44.4 Water Quality  1299
44.5 Closed-Loop Systems  1301
 44.6  Ground-Loop Confi gurations and Flows  1304  44.7  System Materials and Heat Exchange Fluids  1307  44.8  Geothermal Wells and Water Sources  for Open-Loop Systems  1309
 44.9  Water-to-Water Heat Pumps  1311
44.10 Troubleshooting  1314
 44.11  Direct Geothermal Heat Pump Systems  1316  44.12  Service Technician Calls  1327
SECTION 9: Domestic Appliances
Unit 45  Domestic Refrigerators and Freezers  1334
45.1 Refrigeration  1334
 45.2  Capacity of Domestic Systems  1345
45.3 The Evaporator  1346
45.4 The Compressor  1350
45.5 The Condenser  1352
45.6 Metering Device  1357
 45.7  Typical Operating Conditions  1358
45.8 Ice-Maker Operation  1361
 45.9  Wiring and Controls  1361
 45.10  Servicing the Appliance  1371
 45.11  Service Technician Calls  1391
Unit 46  Room Air Conditioners  1408
 46.1  Air-Conditioning and Heating with  Room Units  1408
46.2 Room Air-Conditioning—Cooling  1409
 46.3  The Refrigeration Cycle—Cooling  1410  46.4  The Refrigeration Cycle—Heating  (Heat Pump)  1414
46.5 Installation  1416
 46.6  Controls for Room Units—Cooling  1422  46.7  Controls in Cooling and Heating Units  1423  46.8  Maintaining and Servicing Room Units  1424  46.9  Service Technician Calls  1431
SECTION 10:  Commercial Air-Conditioning
and Chilled-Water Systems
Unit 47  High-Pressure, Low-Pressure,
and Absorption Chilled-Water Systems  1438
47.1 Chillers  1439
 47.2  Compression Cycle in High-Pressure Chillers  1440  47.3  Reciprocating Compressors in High-Pressure  Chillers 1440
 47.4  Scroll Compressors in High-Pressure Chillers  1442  47.5  Rotary Screw Compressors in High-Pressure  Chillers 1443
 47.6  Centrifugal Compressors in High-Pressure  Chillers 1444
 47.7  Evaporators for High-Pressure Chillers  1447  47.8  Condensers for High-Pressure Chillers  1452  47.9  Metering Devices for High-Pressure  Chillers 1455
47.10 Low-Pressure Chillers  1458
 47.11  Compressors for Low-Pressure Chillers  1458  47.12  Condensers for Low-Pressure Chillers
 47.13  Metering Devices for Low-Pressure Chillers  1461 47.14 Purge Units  1461
 47.15  Absorption Air-Conditioning Chillers  1462
 47.16  Motors and Drives for Chillers  1472
Unit 48  Cooling Towers and Pumps  1483
 48.1  Cooling Tower Function  1483
 48.2  Types of Cooling Towers  1484
48.3 Fire Protection  1487
48.4 Fill Material  1488
48.5 Flow Patterns  1489
48.6 Tower Materials  1490
48.7 Fan Section  1490
48.8 Tower Access  1491
48.9 Tower Sump  1491
48.10 Makeup Water  1492
48.11 Blowdown  1492
 48.12  Balancing the Water Flow for a Tower  1494 48.13 Water Pumps  1495
 48.14  Chemical-Free Treatment of Cooling Tower Water 1503
Unit 49  Operation, Maintenance, and Troubleshooting
of Chilled-Water Air-Conditioning Systems  1509
49.1 Chiller Start-Up  1509
 49.2  Valves for Large Systems  1515
 49.3  Scroll and Reciprocating Chiller Operation  1517  49.4  Large Positive-Displacement Chiller Operation  1518  49.5  Centrifugal Chiller Operation  1518
 49.6  Air-Cooled Chiller Maintenance  1518
 49.7  Water-Cooled Chiller Maintenance  1520
 49.8  Absorption Chilled-Water System Start-Up  1523  49.9  Absorption Chiller Operation and Maintenance  1524  49.10  General Maintenance for All Chillers  1525
49.11 Low-Pressure Chillers  1525
49.12 High-Pressure Chillers  1526
49.13 Refrigerant Safety  1527
 49.14  Service Technician Calls  1528
Unit 50  Commercial Packaged Rooftop, Variable Refrigerant Flow and Variable Air Volume Systems
 50.1  Rooftop Package Units  1536
 50.2  Installation of Packaged Rooftop Units  1537 50.3 Economizers  1544
 50.4  Dual Enthalpy Sensor  1546
50.5  ASHRAE Standard 62  1549
 50.6  Demand Control Ventilation (DCV)  1549
50.7 Traditional Constant-Volume
Air Distribution Methods  1550
 50.8  Variable Air Volume (VAV) Systems  1551
 50.9  Blowers on VAV Systems  1551
 50.10  VAV Boxes and Terminal Units  1551
 50.11  Hot Water in the Reheat Coils  1553
50.12 Chilled-Water VAV Systems  1555
 50.13  Variable Refrigerant Flow (VRF) Systems  1562 Appendix A  Alternative Heating
 (Stoves and Fireplace Inserts)  1575
A.1 Wood-Burning Stoves  1575
 A.2  Organic Makeup and Characteristics of Wood  1575  A.3  Environmental Protection Agency  (EPA) Regulations  1576
A.4 Creosote  1576
 A.5  Design Characteristics of Wood-Burning Stoves  1576 A.6 Installation Procedures  1580
A.7 Smoke Detectors  1582
A.8 Gas Stoves  1582
A.9 Fireplace Inserts  1582
Appendix B  Temperature Conversion Chart  1584
Glossary 1586
Index 163

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Refrigeration & Air Conditioning Technologyis designed and written for students in vocational-technical schools and colleges, community colleges, and apprenticeship programs. The content is in a format appropriate for students who are attending classes full-time while preparing for their fi rst job, for students attending classes part-time while preparing for a career change, or for those working in the fi eld who want to increase their knowledge and skills. Emphasis throughout the text is placed on the practical applications of the knowledge and skills technicians need to be productive in the refrigeration and air-conditioning industry.
The contents of this book can be used as a study guide to prepare for the Environmental Protection Agency (EPA) mandatory technician certification examinations. It can be used in the HVAC/R fi eld or closely related fi elds by students, technicians, installers, contractor employees, service personnel, and owners of businesses.
This text is also an excellent study guide for the Industry Competency Exam (ICE), the North American Technician Excellence (NATE), the HVAC Excellence, the Refrigeration Service Engineers Society (RSES), the United Association (UA) STAR certifi cation, and the Heating, Air Conditioning, and Refrigeration Distributors International (HARDI) voluntary HVAC/R technician certifi cation and home-study examinations.
The book is also written to correspond to the National Skill Standards for HVAC/R technicians. Previous editions of this text are often carried to the job site by technicians and used as a reference for service procedures. “Do-it-yourselfers” will find this text valuable for understanding and maintaining heating and cooling systems.
 As general technology has evolved, so has the refrigeration and air-conditioning industry. A greater emphasis is placed on digital electronic controls and system effi ciency. At the time of this writing, Every central split cooling system manufactured in the United States today must have a Seasonal Energy Effi ciency Ratio (SEER) rating of at least 13. This energy requirement was mandated by federal law as of January 23, 2006. SEER is calculated on the basis of the total amount of cooling (in Btus) the system will provide over the entire season, divided by the total number watt-hours it will consume. Higher SEER ratings refl ect a more efficient cooling system. Air-conditioning and refrigeration technicians are responsible for following procedures to protect our environment, particularly with regard to the handling of refrigerants. Technician certification has become increasingly important in the industry.
Global warming has become a major environmental issue. When HVAC/R systems are working correctly and effi ciently, they will greatly reduce energy consumption and greenhouse gases. Organizations like the Green Mechanical Council (GreenMech) are advocates for the HVAC/R industry and assist the industry in meeting with government, educational, industry, and labor interests to fi nd solutions to the world’s global-warming problem. GreenMech has created a scoring system designed to help engineers, contractors, and consumers know the “green value” of each mechanical installation. The “green value” encompasses the system’s energy effi ciency, pollution output, and sustainability. Realtors, building inspectors, builders, and planning and zoning offi cials will now have some knowledge about and guidance on how buildings and mechanical systems are performing. Green buildings and green mechanical systems are becoming increasingly popular in today’s world as a way to curb global warming.
 Energy audits have become an integral part of evaluating and assessing an existing building’s energy performance. Higher effi ciency standards for the energy performance of new buildings have been established. Higher levels of training and certifi cation have been developed for HVAC/R technicians to meet the needs of more sophisticated, energy-efficient buildings and HVAC/R equipment.


SECTION 1: Theory of Heat
Introduction  1
Unit 1   Heat, Temperature, and Pressure  14
Unit 2   Matter and Energy  27
Unit 3   Refrigeration and Refrigerants  36
SECTION 2: Safety, Tools and Equipment,
and Shop Practices
Unit 4   General Safety Practices  84
Unit 5   Tools and Equipment  102
Unit 6   Fasteners  135
Unit 7   Tubing and Piping  148
Unit 8   Leak Detection, System Evacuation,
and System Cleanup  178
Unit 9   Refrigerant and Oil Chemistry and
Management—Recovery, Recycling,
Reclaiming, and Retrofitting  213
Unit 10  System Charging  251
Unit 11  Calibrating Instruments  269
SECTION 3: Basic Automatic Controls
Unit 12 Basic Electricity and Magnetism  282
Unit 13 Introduction to Automatic Controls  310
Unit 14 Automatic Control Components
and Applications  322
Unit 15  Troubleshooting Basic Controls  552
Unit 16 Advanced Automatic Controls—Direct Digital
Controls (DDCs) and Pneumatics  376
SECTION 4: Electric Motors
Unit 17 Types of Electric Motors  398
Unit 18 Application of Motors  429
Unit 19 Motor Controls  447
Unit 20  Troubleshooting Electric Motors  458
SECTION 5: Commercial Refrigeration
Unit 21 Evaporators and the Refrigeration System  476
Unit 22 Condensers  498
Unit 23 Compressors  532
Unit 24 Expansion Devices  566
Unit 25 Special Refrigeration System Components  595
Unit 26 Applications of Refrigeration Systems  640
Unit 27 Commercial Ice Machines  684
Unit 28 Special Refrigeration Applications  733
Unit 29 Troubleshooting and Typical Operating
Conditions for Commercial Refrigeration  752
SECTION 6:  Air-Conditioning
(Heating and Humidification)
Unit 30 Electric Heat  798
Unit 31 Gas Heat  816
Unit 32 Oil Heat  889
Unit 33 Hydronic Heat  940
Unit 34  Indoor Air Quality  995
SECTION 7: Air-Conditioning (Cooling)
Unit 35 Comfort and Psychrometrics  1016
Unit 36 Refrigeration Applied to Air-Conditioning  1040
Unit 37 Air Distribution and Balance  1059
Unit 38 Installation  1107
Unit 39 Residential Energy Audit  1130
Unit 40 Typical Operating Conditions  1181
Unit 41 Troubleshooting  1195
SECTION 8: All-Weather Systems
Unit 42  Heat Gains and Heat Losses in Structures  1226
Unit 43 Air Source Heat Pumps  1245
Unit 44 Geothermal Heat Pumps  1297
SECTION 9: Domestic Appliances
Unit 45 Domestic Refrigerators and Freezers  1334
Unit 46 Room Air Conditioners  1408
SECTION 10:  Commercial Air-Conditioning
and Chilled-Water Systems
Unit 47 High-Pressure, Low-Pressure, and Absorption
Chilled-Water Systems  1438
Unit 48 Cooling Towers and Pumps  1483
Unit 49 Operation, Maintenance, and Troubleshooting
of Chilled-Water Air-Conditioning Systems  1509
Unit 50 Commercial Packaged Rooftop, Variable
Refrigerant Flow and Variable
Air Volume Systems  1535
Appendix A  Alternative Heating
(Stoves and Fireplace Inserts)  1575
Appendix B  1584
Preface  xiii
New in This Edition  xiv
How to Use the Text and Supplementary Materials   xix
Support Materials  xxii
About the Authors  xxiv
Acknowledgments  xxv
SECTION 1: Theory of Heat
Introduction 1
 History of Refrigeration and Air-Conditioning (Cooling)  2   Green Awareness  5
History of Home and Commercial Heating  7
Career Opportunities  7
 Technician Certifi cation Programs  8
Programmatic Accreditation  9
 National Skill Standards  10
 Customer Relations and Technician Soft Skills  10
Unit 1  Heat, Temperature, and Pressure  14
 1.1  Heat, Temperature, and Pressure  14
1.2 Temperature  14
 1.3  Introduction to Heat  16
1.4 Conduction  18
1.5 Convection  18
1.6 Radiation  19
1.7 Sensible Heat  20
1.8 Latent Heat  20
1.9 Specifi c Heat  22
 1.10  Sizing Heating Equipment  22
1.11 Pressure  22
1.12 Atmospheric Pressure  23
1.13 Pressure Gauges  24
Unit 2  Matter and Energy  27
2.1 Matter  27
 2.2  Mass and Weight  28
2.3 Density  28
2.4 Specifi c Gravity  28
2.5 Specifi c Volume  28
2.6 Gas Laws  29
2.7 Energy  31
 2.8  Conservation of Energy  32
 2.9  Energy Contained in Heat  32
 2.10  Energy in Magnetism  32
 2.11  Purchase of Energy  33
 2.12  Energy Used as Work  33
2.13 Power  33
 2.14  Electrical Power—The Watt  33
Unit 3  Refrigeration and Refrigerants  36
 3.1  Introduction to Refrigeration  36
3.2 Refrigeration  37
 3.3  Rating Refrigeration Equipment  37
 3.4  The Refrigeration Process  38
 3.5  Temperature and Pressure Relationship  40
3.6 Refrigeration Components  45
3.7 The Evaporator  45
3.8 The Compressor  47
3.9 The Condenser  49
 3.10  The Refrigerant Metering Device  51
 3.11  Matching Refrigeration Systems  and Components  53
3.12 Refrigerants  55
 3.13  Refrigerants Must Be Safe  56
 3.14  Refrigerants Must Be Detectable  56
 3.15  The Boiling Point of the Refrigerant  58
3.16 Pumping Characteristics  58
 3.17  Popular Refrigerants and Their Important  Characteristics 58
 3.18  Refrigerant Cylinder Color Codes  58
 3.19  Recovery, Recycling, or Reclaiming  of Refrigerants  61
 3.20  Plotting the Refrigerant Cycle  61
 3.21  Plotting the Refrigerant Cycle for Blends with  Noticeable Temperature Glide (Zeotropic Blends)  77
SECTION 2:  Safety, Tools and Equipment,
and Shop Practices
Unit 4  General Safety Practices  84
 4.1  Pressure Vessels and Piping  84
4.2 Electrical Hazards  88
4.3 Heat  93
4.4 Cold  94
4.5 Mechanical Equipment  94
 4.6  Moving Heavy Objects  96
 4.7  Refrigerants in Your Breathing Space  96
4.8 Using Chemicals  99
Unit 5  Tools and Equipment  102
5.1 General Tools  102
 5.2  Specialized Hand Tools  108
5.3 Tubing Tools  110
 5.4  Specialized Service and Installation Equipment  114  5.5  Refrigerant Leak Detectors  117
5.6 Other Tools  118
 5.7  Miscellaneous Tools and Equipment  for Specialized Needs  126
Unit 6  Fasteners  135
6.1 Nails  135
 6.2  Staples and Rivets  136
6.3 Threaded Fasteners  137
6.4 Concrete Fasteners  142
6.5 Other Fasteners  143
Unit 7  Tubing and Piping  148
 7.1  Purpose of Tubing and Piping  148
 7.2  Types and Sizes of Tubing  148
7.3 Tubing Insulation  149
7.4 Line Sets  151
7.5 Cutting Tubing  151
7.6 Bending Tubing  152
 7.7  Soldering and Brazing Processes  154
 7.8  Heat Sources for Soldering and Brazing  155 7.9 Fluxing  160
7.10 Soldering Techniques  161
7.11 Brazing Techniques  163
 7.12  Practical Soldering and Brazing Tips  164
 7.13  Making Flare Joints  166
7.14 Swaging Techniques  167
7.15 Compression Fittings  169
 7.16  Steel and Wrought Iron Pipe  170
 7.17  Installing Steel Pipe  173
7.18 Plastic Pipe  173
 7.19  Alternative Mechanical Piping Connections  174
Unit 8  Leak Detection, System Evacuation,
and System Cleanup  178
8.1 Leaks  178
 8.2  Basic Refrigerant Leak Detection  180
 8.3  Advanced Leak Detection  182
 8.4  Standing Pressure Test  184
 8.5  Leak Detection Tips  186
8.6 Repairing Leaks  189
8.7 System Evacuation  190
 8.8  General Evacuation Procedures  202
 8.9  Cleaning a Dirty System  208
Unit 9  Refrigeration and Oil Chemistry
and Management—Recovery, Recycling,
Reclaiming, and Retrofitting  213
 9.1  Refrigerants and the Environment  213
9.2 Ozone Depletion  214
9.3 Global Warming  215
9.4 Refrigerants  216
9.5 CFC Refrigerants  217
9.6 HCFC Refrigerants  217
9.7 HFC Refrigerants  218
9.8 HC Refrigerants  218
9.9 Naming Refrigerants  218
9.10 Refrigerant Blends  219
 9.11  Popular Refrigerants and Their  Compatible Oils  220
 9.12  Refrigerant Oils and Their Applications  225 9.13 Oil Groups  225
9.14 Regulations  227
 9.15  Recover, Recycle, or Reclaim  227
 9.16  Methods of Recovery  229
 9.17  Mechanical Recovery Systems  232
 9.18  Recovering Refrigerant from Small Appliances  239 9.19 Reclaiming Refrigerant  241
9.20 Refrigerant Retrofi tting  242
 9.21  Refrigerants and Tools in the Future  248
Unit 10  System Charging  251
 10.1  Charging a Refrigeration System  251
 10.2  Vapor Refrigerant Charging  251
 10.3  Liquid Refrigerant Charging  253
10.4 Weighing Refrigerant  256
 10.5  Using Charging Devices  257
 10.6  Using Charging Charts  258
 10.7  Subcooling Charging Method for TXV Systems  262  10.8  Charging Near-Azeotropic (Zeotropic)  Refrigerant Blends  263
Unit 11  Calibrating Instruments  269
11.1 Calibration  269
11.2 Temperature-Measuring Instruments  270
 11.3  Pressure Test Instruments  272
 11.4  Electrical Test Instruments  274
 11.5  Refrigerant Leak Detection Devices  276
 11.6  Flue-Gas Analysis Instruments  277
11.7 General Maintenance  278
SECTION 3: Basic Automatic Controls
Unit 12  Basic Electricity and Magnetism  282
 12.1  The Structure of Matter  282
 12.2  Movement of Electrons  283
12.3 Conductors  283
12.4 Insulators  283
 12.5  Electricity Produced from Magnetism  283
12.6 Current  284
 12.7  Units of Electrical Measurement  284
 12.8  The Electric Circuit  285
 12.9  Making Electrical Measurements  285
12.10 Ohm’s Law  288
 12.11  Characteristics of Series Circuits  289
 12.12  Characteristics of Parallel Circuits  289
12.13 Electrical Power  290
12.14 Magnetism  290
12.15 Inductance  292
12.16 Transformers  292
12.17 Capacitance  293
12.18 Impedance  294
 12.19  Electrical Measuring Instruments  294
12.20 Sine Waves  298
12.21 Wire Sizes  299
 12.22  Circuit Protection Devices  300
12.23 Semiconductors  303
Unit 13  Introduction to Automatic Controls  310
 13.1  Types of Automatic Controls  310
 13.2  Devices That Respond to Thermal Change  310  13.3  The Bimetal Device  311
 13.4  Control by Fluid Expansion  314
13.5 The Thermocouple  317
 13.6  Electronic Temperature-Sensing Devices  319
Unit 14  Automatic Control Components
and Applications  322
14.1 Temperature Controls  322
 14.2  Low-Voltage Space Temperature Controls  324  14.3  Line-Voltage Space Temperature Controls  328  14.4  Sensing the Temperature of Solids  330
 14.5  Measuring the Temperature of Fluids  333
14.6 Pressure-Sensing Devices  334
14.7 Pressure Transducers  338
14.8 High-Pressure Controls  340
14.9 Low-Pressure Controls  341
 14.10  Oil Pressure Safety Controls  341
 14.11  Air Pressure Controls  343
 14.12  Gas Pressure Switches  344
 14.13  Switchless Devices That Control Fluid Flow  344  14.14  Water Pressure Regulators  344
 14.15  Gas Pressure Regulators  345
 14.16  Mechanical and Electromechanical  Controls 346
 14.17  Maintenance of Mechanical Controls  347  14.18  Maintenance of Electromechanical Controls  347  14.19  Service Technician Calls  347
Unit 15  Troubleshooting Basic Controls  352
 15.1  Introduction to Troubleshooting  352
 15.2  Troubleshooting a Simple Circuit  353
 15.3  Troubleshooting a Complex Circuit  354
 15.4  Troubleshooting the Thermostat  357
 15.5  Troubleshooting Amperage in  the Low-Voltage Circuit  358
 15.6  Troubleshooting Voltage in  the Low-Voltage Circuit  359
 15.7  Troubleshooting Switches and Loads  360
 15.8  Pictorial and Line Diagrams  367
 15.9  Service Technician Calls  367
Unit 16  Advanced Automatic Controls—Direct
Digital Controls (DDCs) and Pneumatics  376
16.1 Control Applications  376
 16.2  Types of Control Systems  376
16.3 Pneumatic Controls  378
 16.4  Cleaning and Drying Control Air  379
16.5 Control Components  380
 16.6  Direct Digital Controls (DDCs)  385
 16.7  Residential Electronic Controls  393
SECTION 4: Electric Motors
Unit 17  Types of Electric Motors  398
 17.1  Uses of Electric Motors  398
17.2 Parts of an Electric Motor  398
 17.3  Electric Motors and Magnetism  399
 17.4  Determining a Motor’s Speed  400
17.5 Start Windings  401
 17.6  Starting and Running Characteristics  401
 17.7  Electrical Power Supplies  402
 17.8  Single-Phase Open Motors  403
17.9 Split-Phase Motors  404
 17.10  The Centrifugal Switch  405
 17.11  The Electronic Relay  405
17.12 Capacitor-Start Motors  405
 17.13  Capacitor-Start, Capacitor-Run Motors  406  17.14  Permanent Split-Capacitor Motors  407
17.15 Shaded-Pole Motors  408
17.16 Three-Phase Motors  409
 17.17  Single-Phase Hermetic Motors  410
 17.18  The Potential Relay  411
 17.19  The Current Relay  414
 17.20  Positive Temperature Coefficient Resistor (PTCR)  415
 17.21  Two-Speed Compressor Motors  416
 17.22  Special Application Motors  416
 17.23  Three-Phase Compressor Motors  417
17.24 Variable-Speed Motors  417
 17.25  DC Converters (Rectifi ers)  420
 17.26  Inverters and Variable Frequency Drives (VFDs)  421  17.27  Electronically Commutated Motors (ECMs)  425  17.28  Cooling Electric Motors  426
Unit 18  Application of Motors  429
18.1 Motor Applications  429
 18.2  The Power Supply  429
 18.3  Electric-Motor Working Conditions  436
 18.4  Insulation Type or Class  436
 18.5  Types of Bearings  437
 18.6  Motor Mounting Characteristics  439
18.7 Motor Drives  441
Unit 19  Motor Controls  447
 19.1  Introduction to Motor Control Devices  447  19.2  Run-Load and Locked-Rotor Amperage  448 19.3 The Relay  448
19.4 The Contactor  449
19.5 Motor Starters  451
19.6 Motor Protection  452
 19.7  Inherent Motor Protection  453  19.8  External Motor Protection  453  19.9  National Electrical
 19.11  Magnetic Overload Devices  456  19.12  Restarting the Motor  456
Unit 20  Troubleshooting Electric Motors  458
20.1 Motor Troubleshooting  458
 20.2  Mechanical Motor Problems  458
 20.3  Removing Drive Assemblies  459
20.4 Belt Tension  460
20.5 Pulley Alignment  461
20.6 Electrical Problems  461
20.7 Open Windings  461
 20.8  Shorted Motor Windings  462
 20.9  Short Circuit to Ground (Frame)  464
 20.10  Single-Phase Motor Starting Problems  466 20.11 Checking Capacitors  467
 20.12  Identifi cation of Capacitors  469
 20.13  Wiring and Connectors  470
 20.14  Troubleshooting Hermetic Motors  470
 20.15  Service Technician Calls  470
SECTION 5: Commercial Refrigeration
Unit 21  Evaporators and the Refrigeration System  476
21.1 Refrigeration  476
 21.2  Temperature Ranges of Refrigeration  477
21.3 The Evaporator  477
 21.4  Boiling and Condensing  478
 21.5  The Evaporator and Boiling Temperature  478 21.6 Removing Moisture  478
 21.7  Heat Exchange Characteristics  of the Evaporator  478
 21.8  Types of Evaporators  481
21.9 Evaporator Evaluation  487
 21.10  Latent Heat in the Evaporator  489
 21.11  The Flooded Evaporator  489
 21.12  Dry- Type  Evaporators  Performance  489
21.13 Evaporator Superheat  490
 21.14  Hot Pulldown (Excessively Loaded Evaporator)  490  21.15  Pressure Drop in Evaporators
 21.16  Liquid Cooling Evaporators (Chillers)  493
 21.17  Evaporators for Low- Temperature Applications  494  21.18  Defrost of Accumulated Moisture  495
Unit 22  Condensers  498
22.1 The Condenser  498
22.2 Water-Cooled Condensers  498
22.3 Tube-Within-a-Tube Condensers  499
22.4 Mineral Deposits  499
 22.5  Cleanable Tube-Within-a-Tube Condensers  500
vii Contents
22.6 Shell-and-Coil Condensers  501
22.7 Shell-and-Tube Condensers  502
22.8 Wastewater Systems  503
 22.9  Refrigerant-to-Water Temperature Relationship  for Wastewater Systems  505
 22.10  Recirculating Water Systems  507
22.11 Cooling Towers  507
22.12 Natural-Draft Towers  508
 22.13  Forced- or Induced-Draft Towers  509
22.14 Evaporative Condensers  511
22.15 Air-Cooled Condensers  511
22.16 High-Effi ciency Condensers  515
 22.17  The Condenser and Low Ambient Conditions  516  22.18  Head Pressure Controls  518
 22.19  Using the Condenser Superheat  528
22.20 Heat Reclaim  528
 22.21  Floating Head Pressures  528
22.22 Condenser Evaluation  529
 22.23  Service Technician Calls  529
Unit 23  Compressors  532
 23.1  The Function of the Compressor  532
 23.2  Types of Compressors  534
 23.3  Reciprocating Compressor Components  539  23.4  Belt-Drive Mechanism Characteristics  548
 23.5  Direct-Drive Compressor Characteristics  549  23.6  Reciprocating Compressor Efficiency  549
 23.7  Discus Valve Design  550
 23.8  New Technology in Compressors  551
 23.9  Liquid in the Compressor Cylinder  561
 23.10  System Maintenance and Compressor  Effi ciency  561
Unit 24  Expansion Devices  566
24.1 Expansion Devices  566
 24.2  Thermostatic Expansion Valve  567
24.3 TXV Components  568
 24.4  The Valve Body  568
24.5 The Diaphragm  568
 24.6  Needle and Seat  568
24.7 The Spring  572
 24.8  The Sensing Bulb and Transmission Tube  573  24.9  Types of Bulb Charge  573
 24.10  The Liquid Charge Bulb  573
 24.11  The Cross Liquid Charge Bulb  575
 24.12  The Vapor (Gas) Charge Bulb  575
 24.13  The Cross Vapor Charge Bulb  576
 24.14  Example of a TXV Functioning with an  Internal Equalizer  576
 24.15  TXV Functioning with External Equalizers  577  24.16  TXV Response to Load Changes  579
 24.17  Selection of TXV Valves  580
24.18 Balanced-Port TXV  581
24.19 Dual-Port TXV  582
24.20 The Pressure-Limiting TXV  582
24.21 Servicing the TXV  582
 24.22  Installing the Sensing Element  583
 24.23  The Solid-State-Controlled Expansion Valve  583  24.24  Step-Motor Expansion Valves  584
 24.25  Algorithms and PID Controllers  586
 24.26  The Automatic Expansion Valve  589
 24.27  Automatic Expansion Valve Response  to Load Changes  589
 24.28  Special Considerations for the TXV and AXV  589  24.29  The Capillary Tube Metering
 24.30  Operating Charge for the Capillary Tube System  592
Unit 25  Special Refrigeration System Components  595
 25.1  The Four Basic Components  595
25.2 Mechanical Controls  595
25.3 Two-Temperature Controls  595
 25.4  Evaporator Pressure Control  595
25.5 Multiple Evaporators  598
 25.6  Electric Evaporator Pressure-Regulating Valve  598  25.7  Crankcase Pressure Regulator  599
 25.8  Adjusting the CPR Valve  600
25.9 Relief Valves  600
 25.10  Fan-Cycling Head Pressure Controls  602
 25.11  Fan Speed Control for Controlling  Head Pressure  602
 25.12  Air Volume Control for Controlling  Head Pressure  603
 25.13  Condenser Flooding and Condenser Splitting  for Controlling Head Pressure
25.14 Electrical Controls  604
25.15 Pressure Switches  607
25.16 Low-Pressure Switch  607
 25.17  Low-Pressure Control Applied as a Thermostat  607  25.18  Automatic Pumpdown Systems
25.19 High-Pressure Control  612
 25.20  Low-Ambient Fan Control  613
 25.21  Oil Pressure Safety Control  613
 25.22  The Defrost Cycle  617
25.23 Medium-Temperature Refrigeration  618
 25.24  Random or Off-Cycle Defrost  618
25.25 Planned Defrost  618
 25.26  Low-Temperature Evaporator Defrost  619
 25.27  Internal Heat Defrost (Hot Gas and Cool  Gas Defrost)  619
 25.28  External Heat Defrost  620
 25.29  Defrost Termination and Fan Delay Control  621 25.30 Refrigeration Accessories  622
25.31 Receivers  622
 25.32  The King Valve on the Receiver  623
25.33 Filter Driers  623
 25.34  Refrigerant Check Valves  625
 25.35  Refrigerant Sight Glasses  625
 25.36  Liquid Refrigerant Distributors  625
25.37 Heat Exchangers  626
25.38 Suction-Line Accumulators  626
 25.39  Suction-Line Filter Driers  629
 25.40  Suction Service Valves  630
 25.41  Discharge Service Valves  630
 25.42  Refrigeration Line Service Valves  631
25.43 Diaphragm Valves  633
25.44 Ball Valves  633
25.45 Oil Separators  633
25.46 Vibration Eliminators  634
 25.47  Pressure Access Ports  635
25.48 Crankcase Heat  636
Unit 26  Applications of Refrigeration Systems  640
26.1 Application Decisions  640
26.2 Reach-in Refrigeration  640
 26.3  Self-Contained Reach-In Fixtures  641
 26.4  Individual Condensing Units  643
26.5 Single-Compressor Applications
and Multiple Evaporators  644
 26.6  Parallel Compressor Systems  647
 26.7  Secondary-Fluid Refrigeration Systems  655  26.8  Carbon Dioxide (R-744) Refrigeration Systems  657  26.9  Pressurized Liquid Systems  661
 26.10  Distributed Refrigeration Systems  663
 26.11  Evaporator Temperature Control  664
 26.12  Interconnecting Piping in Multiple-Evaporator  Installations 664
 26.13  Fixture Temperature Control  665
 26.14  The Evaporator and Merchandising  665
 26.15  Chest-Type Display Fixtures  666
26.16 Refrigerated Shelves  667
 26.17  Closed Chest Fixtures  667
 26.18  Controlling Sweating on Fixture Cabinets  667  26.19  Maintaining Store Ambient Conditions  668 26.20 Walk-in Refrigeration  669
 26.21  Knock-Down Walk-In Coolers  669
 26.22  Evaporators in a Walk-In Cooler  670
26.23 Condensate Removal  670
26.24 Refrigeration Piping  670
 26.25  Package Refrigeration for Walk-In Coolers  671  26.26  Vending Machine Refrigeration  671
26.27 Water Coolers  677
 26.28  Refrigerated Air Driers  679
Unit 27  Commercial Ice Machines  684
 27.1  Packaged-Type Ice-Making Equipment  684  27.2  Making Flake Ice  685  27.3  Making Cube Ice  693 27.4 Microprocessors  711
 27.5  Making Cylindrical Ice  716  27.6  Water and Ice Quality  717  27.7  Package Ice Machine Location  723  27.8  Troubleshooting Ice Makers  723  27.9  Service Technician Calls  727
Unit 28  Special Refrigeration Applications  733
 28.1  Special Refrigeration Applications  733
28.2 Transport Refrigeration  733
 28.3  Truck Refrigeration Systems  733
28.4 Railway Refrigeration  740
28.5 Extra-Low-Temperature Refrigeration  741
28.6 Cascade Systems  743
28.7 Quick-Freezing Methods  744
28.8 Marine Refrigeration  746
 28.9  Air Cargo Hauling  749
Unit 29  Troubleshooting and Typical Operating
Conditions for Commercial Refrigeration  752
29.1 Organized Troubleshooting  752
29.2 Troubleshooting High-Temperature
Applications 753
29.3 Troubleshooting Medium-Temperature
Applications 755
29.4 Troubleshooting Low-Temperature
Applications 755
 29.5  Typical Air-Cooled Condenser Operating  Conditions 756
 29.6  Calculating the Correct Head Pressure for  Air-Cooled Equipment  757
 29.7  Typical Operating Conditions for  Water-Cooled Equipment  758
 29.8  Typical Operating Conditions for Wastewater  Condenser Systems  758
 29.9  Typical Operating Conditions for Recirculated  Water Systems  759
 29.10  Six Typical Problems  759
 29.11  Low Refrigerant Charge  759
29.12 Refrigerant Overcharge  762
29.13 Ineffi cient Evaporator  764
29.14 Ineffi cient Condenser  766
 29.15  Refrigerant Flow Restrictions  768
29.16 Ineffi cient Compressor  771
 29.17  Compressor Vacuum Test  771
 29.18  Closed-Loop Compessor Running Bench Test  772  29.19  Closed-Loop Compressor Running Field Test  773  29.20  Compressor Running Test in the System  774  29.21  Service Technician Calls
SECTION 6:  Air-Conditioning
(Heating and Humidification)
Unit 30  Electric Heat  798
30.1 Introduction  798
 30.2  Portable Electric Heating Devices  798
 30.3  Radiant Heating Panels  799
 30.4  Electric Baseboard Heating  800
 30.5  Unit and Wall Heaters  800
 30.6  Electric Hydronic Boilers  800
 30.7  Central Forced-Air Electric Furnaces  801
 30.8  Automatic Controls for Forced-Air Electric  Furnaces 802
 30.9  The Low-Voltage Thermostat  802
 30.10  Controlling Multiple Stages  803
30.11 Wiring Diagrams  804
 30.12  Control Circuits for Forced-Air Electric  Furnaces 805
 30.13  Blower Motor Circuits  806
 30.14  Contactors for Controlling Electric Furnaces  807  30.15  Airfl ow in Electric Furnaces  807
 30.16  Service Technician Calls  811
Unit 31  Gas Heat  816
 31.1  Introduction to Gas-Fired,  Forced-Hot-Air Furnaces  817
 31.2  Types of Furnaces  817 31.3 Gas Fuels  820
31.4 Gas Combustion  822
31.5 Gas Regulators  824
31.6 Gas Valve  824
31.7 Solenoid Valve  825
31.8 Diaphragm Valve  825
 31.9  Heat Motor–Controlled Valve  826  31.10  Automatic Combination Gas Valve  827 31.11 Manifold  832
31.12 Orifi ce  832
31.13 Burners  832
31.14 Heat Exchangers  833
31.15 Fan Switch  836
31.16 Limit Switch  837
31.17 Pilots  839
 31.18  Safety Devices at the Standing Pilot  840 31.19 Ignition Systems  842
31.20 Flame Rectifi cation  844
31.21 High-Effi ciency Gas Furnaces  848
 31.22  Electronic Ignition Modules and Integrated  Furnace Controllers  853
 31.23  Two-Stage Gas Furnaces  859  31.24  Modulating Gas Furnaces  859 31.25 Venting  860
31.26 Gas Piping  864
 31.27  Gas Furnace Wiring Diagrams  and Troubleshooting Flowcharts  865
 31.28  Troubleshooting the Safety Pilot-Proving  Device—The Thermocouple  867
 31.29  Troubleshooting Spark Ignition and  Intermittent Pilot Systems  868
31.30 Combustion Effi ciency  877
 31.31  Service Technician Calls  882
Unit 32  Oil Heat  889
 32.1  Introduction to Oil-Fired, Forced-Warm-Air  Furnaces 889
32.2 Physical Characteristics  890
32.3 Fuel Oils  890
32.4 Oil Storage  893
 32.5  Fuel Oil Supply Systems  895 32.6 Combustion  900
 32.7  Preparation of Fuel Oil for Combustion  901  32.8  By-Products of Combustion  901  32.9  Gun-Type Oil Burners  901  32.10  Oil Furnace Wiring Diagrams  917  32.11  Wiring Diagram for the Stack Switch  Safety Control  917
 32.12  Wiring Diagram for Cad Cell Safety Control  917 32.13 Combustion Chamber  923
32.14 Heat Exchanger  924
 32.15  Condensing Oil Furnace  925 32.16 Service Procedures  926
32.17 Combustion Effi ciency  930
 32.18  Service Technician Calls  934
Unit 33  Hydronic Heat  940
 33.1  Introduction to Hydronic Heating  940
 33.2  The Heat Source  941
 33.3  The Basic Hydronic System  945
 33.4  The Point of No Pressure Change  950
 33.5  Other Hydronic System Components  952
 33.6  High-Temperature Hydronic Piping Systems  963  33.7  Radiant, Low-Temperature Hydronic  Piping Systems  974
 33.8  Combination (High- and Low-Temperature)  Piping Systems  980
 33.9  Tankless Domestic Hot Water Heaters  980
 33.10  Solar Heating as a Supplemental Heat Source  982  33.11  Service Technician Calls  991
Unit 34  Indoor Air Quality  995
34.1 Introduction  995
 34.2  Sources of Indoor Air Pollution  995
34.3 Common Pollutants  996
 34.4  Detecting and Eliminating the Source  of Contamination  1001
34.5 Ventilation  1002
34.6 Air Cleaning  1003
34.7 Duct Cleaning  1007
34.8 Air Humidifi cation  1008
34.9 Sizing Humidifi ers  1012
34.10 Installation  1012
34.11 Service, Troubleshooting, and Preventive
Maintenance 1012
SECTION 7: Air-Conditioning (Cooling)
Unit 35  Comfort and Psychrometrics  1016
35.1 Comfort  1016
 35.2  Food Energy and the Body  1016
 35.3  Heat Transfer to and from the Body  1017
 35.4  The Comfort Chart  1018
35.5 Psychrometrics  1018
 35.6  Moisture in Air  1018
 35.7  Absolute and Relative Humidity  1020
 35.8  Superheated Gases in Air  1022
 35.9  Dry-Bulb and Wet-Bulb Temperatures  1023  35.10  Dew Point Temperature  35.11 Enthalpy
 35.12  The Psychrometric Chart  1026
 35.13  Plotting on the Psychrometric Chart  1029
 35.14  Fresh Air, Infi ltration, and Ventilation  1029
Unit 36  Refrigeration Applied to Air-Conditioning  1040
36.1 Refrigeration  1040
 36.2  Structural Heat Gain  1040
36.3 Evaporative Cooling  1042
 36.4  Refrigerated Cooling or Air-Conditioning  1042 36.5 The Evaporator  1043
 36.6  The Function of the Evaporator  1044
36.7 Design Conditions  1045
36.8 Evaporator Application  1045
36.9 The Compressor  1045
 36.10  The Reciprocating Compressor  1047
 36.11  Compressor Speeds (RPM)  1048
 36.12  Cooling the Compressor and Motor  1048
36.13 Compressor Mountings  1049
 36.14  Rebuilding the Hermetic Compressor  1049  36.15  The Rotary Compressor  1049
 36.16  The Scroll Compressor  1050
36.17 The Condenser  1052
36.18 Expansion Devices  1054
36.19 Air-Side Components  1055
36.20 Installation Procedures  1055
Unit 37  Air Distribution and Balance  1059
37.1 Conditioning Equipment  1059
 37.2  Correct Air Quantity  1060
 37.3  The Forced-Air System  1060
37.4 The Blower  1060
37.5 System Pressures  1063
 37.6  Air-Measuring Instruments for Duct Systems  1064  37.7  Types of Fans and Blowers  1066
 37.8  Types of Drive Assemblies  1067
 37.9  The Supply Duct System  1068
 37.10  Duct System Standards  1072
37.11 Duct Materials  1073
 37.12  Duct Air Movement  1079
37.13 Balancing Dampers  1081
37.14 Zoning  1082
37.15 Duct Insulation  1086
 37.16  Blending the Conditioned Air with Room Air  1086  37.17  The Return-Air Duct System  1088
 37.18  Sizing Duct for Moving Air  1088
 37.19  Measuring Air Movement for Balancing  1092  37.20  The Air Friction Chart  1094
 37.21  Practical Troubleshooting Techniques  1101
Unit 38  Installation  1107
 38.1  Introduction to Equipment Installation  1107  38.2  Installing Square and Rectangular Duct  1107  38.3  Installing Round Metal Duct Systems  1109  38.4  Insulation and Acoustical Lining for Metal Duct  1110  38.5  Installing Ductboard Systems  1110  38.6  Installing Flexible Duct  1111 38.7 Electrical Installation  1112
 38.8  Installing the Refrigeration System  1114  38.9  Installing Split-System Air Conditioners  1118
 38.10  The Split-System Condensing Unit  1121
 38.11  Installing Refrigerant Piping on Split-Systems  1123 38.12 Equipment Start-Up  1126
Unit 39  Residential Energy Auditing  1130
39.1 Introduction  1130
 39.2  Residential (Home) Energy Auditing  1131
 39.3  Performing a Home Energy Audit  1132
39.4 Diagnostic Testing  1138
 39.5  Blower Door Testing  1138
 39.6  Infrared Scanning Using a Thermal  Imaging Camera  1141
 39.7  Sealing Air Leaks  1148
 39.8  Duct Leakage Testing  1152
 39.9  Duct Pressurization Test for Total  Air Leakage  1155
 39.10  Duct Leakage to the Outdoors  1156
39.11 Combustion Effi ciency and Safety Testing  1157
39.12 Furnace Effi ciency Testing  1159
39.13 Furnace Effi ciency Ratings  1161
39.14 Flame Color  1161
 39.15  Furnace Preventive Maintenance  1162
 39.16  Spillage and Backdrafting  1163
 39.17  Flame Safeguard Controls  1164
39.18 Excess Air  1166
39.19 Venting  1166
39.20 Draft  1169
39.21 High-Effi ciency Gas Furnace Anatomy  1171
 39.22  HVAC/R System Testing  1173
 39.23  Numerical Analysis and Reporting  1174
Unit 40  Typical Operating Conditions  1181
 40.1  Mechanical Operating Conditions  1181
 40.2  Relative Humidity and the Load  1182
 40.3  Relationships of System Component  Under Load Changes  1182
 40.4  Evaporator Operating Conditions  1182
 40.5  High Evaporator Load and a Cool Condenser  1182  40.6  Grades of Equipment  1185
 40.7  Documentation with the Unit  1186
 40.8  Establishing a Reference Point on  Unknown Equipment  1187
 40.9  System Pressures and Temperatures  for Diff  erent Operating Conditions  1188
40.10 Equipment Effi ciency Rating  1191
 40.11  Typical Electrical Operating Conditions  1192  40.12  Matching the Unit to the Correct Power Supply  1192  40.13  Starting the Equipment with the Correct Data  1192  40.14  Finding a Point of Reference for  an Unknown Motor Rating  1192
 40.15  Determining the Compressor  Running Amperage  1193
 40.16  Compressors Operating at Full-Load Current  1193  40.17  High Voltage, the Compressor,  and Current Draw  1193
 40.18  Current Draw and the Two-Speed Compressor  1193
Unit 41  Troubleshooting  1195
41.1 Introduction  1195
41.2 Mechanical Troubleshooting  1195
 41.3  Approach Temperature and Temperature  Difference  1197
 41.4  Gauge Manifold Usage  1197
 41.5  When to Connect the Gauges  1198
 41.6  Low-Side Gauge Readings  1201
 41.7  High-Side Gauge Readings  1201
41.8 Temperature Readings  1201
 41.9  Charging Procedures in the Field  1205
41.10 Electrical Troubleshooting  1207
 41.11  Compressor Overload Problems  1211
 41.12  Compressor Electrical Checkup  1212
 41.13  Troubleshooting the Circuit Electrical  Protectors—Fuses and Breakers  1215
 41.14  Service Technician Calls  1215
SECTION 8: All-Weather Systems
Unit 42  Heat Gains and Heat Losses
in Structures  1226
 42.1  Introduction to Heat Gain and Heat Loss  1226  42.2  Methods to Determine the Heat Gain  and Heat Loss of a Structure  1227
 42.3  Indoor and Outdoor Design Conditions  for Heating and Cooling  1228
 42.4  U-Values and R-Values  1229  42.5  Introduction to Heat Gain and Heat  Loss Calculations  42.6  Elements of Structural Heat Loss  (Heating Mode)  1231
 42.7  Elements of Structural Heat Gain  (Cooling Mode)  1238
Unit 43  Air Source Heat Pumps  1245
43.1 Reverse-Cycle Refrigeration  1245
 43.2  Heat Sources for Winter  1246  43.3  The Four-Way Reversing Valve  1246  43.4  The Air-to-Air Heat Pump  1251  43.5  Refrigerant Line Identifi cation  1252 43.6 Metering Devices  1253
 43.7  Thermostatic Expansion Valves  1253  43.8  The Capillary Tube  1254  43.9  Combinations of Metering Devices  1254  43.10  Electronic Expansion Valves  1255  43.11  Orifi ce Metering Devices  1256 43.12 Liquid-Line Accessories  1256
 43.13  Application of the Air-to-Air Heat Pump  1256 43.14 Auxiliary Heat  1258
43.15 Balance Point  1258
43.16 Coeffi cient of Performance  1258
 43.17  Split-System Air-to-Air Heat Pump  1260  43.18  The Indoor Unit  1260  43.19  Air Temperature of the Conditioned Air  1261  43.20  The Outdoor Unit Installation  1262  43.21  Package Air-to-Air Heat Pumps  1263  43.22  Controls for the Air-to-Air Heat Pump  1263  43.23  The Defrost Cycle  1271  43.24  Indoor Fan Motor Control  1275 43.25 Auxiliary Heat  1275
 43.26  Servicing the Air-to-Air Heat Pump  1276  43.27  Troubleshooting the Electrical System  1276  43.28  Troubleshooting Mechanical Problems  1277  43.29  Troubleshooting the Four-Way Valve  1278  43.30  Troubleshooting the Compressor  1280  43.31  Checking the Charge  1281  43.32  Special Applications for Heat Pumps  1283  43.33  Heat Pumps Using Scroll Compressors  1284  43.34  Heat Pump Systems with Variable-Speed Motors  1285  43.35  Service Technician Calls  1287
Unit 44  Geothermal Heat Pumps  1297
44.1 Reverse-Cycle Refrigeration  1297
 44.2  Geothermal Heat Pump Classifi cations  1297 44.3 Open-Loop Systems  1298
44.4 Water Quality  1299
44.5 Closed-Loop Systems  1301
 44.6  Ground-Loop Confi gurations and Flows  1304  44.7  System Materials and Heat Exchange Fluids  1307  44.8  Geothermal Wells and Water Sources  for Open-Loop Systems  1309
 44.9  Water-to-Water Heat Pumps  1311
44.10 Troubleshooting  1314
 44.11  Direct Geothermal Heat Pump Systems  1316  44.12  Service Technician Calls  1327
SECTION 9: Domestic Appliances
Unit 45  Domestic Refrigerators and Freezers  1334
45.1 Refrigeration  1334
 45.2  Capacity of Domestic Systems  1345
45.3 The Evaporator  1346
45.4 The Compressor  1350
45.5 The Condenser  1352
45.6 Metering Device  1357
 45.7  Typical Operating Conditions  1358
45.8 Ice-Maker Operation  1361
 45.9  Wiring and Controls  1361
 45.10  Servicing the Appliance  1371
 45.11  Service Technician Calls  1391
Unit 46  Room Air Conditioners  1408
 46.1  Air-Conditioning and Heating with  Room Units  1408
46.2 Room Air-Conditioning—Cooling  1409
 46.3  The Refrigeration Cycle—Cooling  1410  46.4  The Refrigeration Cycle—Heating  (Heat Pump)  1414
46.5 Installation  1416
 46.6  Controls for Room Units—Cooling  1422  46.7  Controls in Cooling and Heating Units  1423  46.8  Maintaining and Servicing Room Units  1424  46.9  Service Technician Calls  1431
SECTION 10:  Commercial Air-Conditioning
and Chilled-Water Systems
Unit 47  High-Pressure, Low-Pressure,
and Absorption Chilled-Water Systems  1438
47.1 Chillers  1439
 47.2  Compression Cycle in High-Pressure Chillers  1440  47.3  Reciprocating Compressors in High-Pressure  Chillers 1440
 47.4  Scroll Compressors in High-Pressure Chillers  1442  47.5  Rotary Screw Compressors in High-Pressure  Chillers 1443
 47.6  Centrifugal Compressors in High-Pressure  Chillers 1444
 47.7  Evaporators for High-Pressure Chillers  1447  47.8  Condensers for High-Pressure Chillers  1452  47.9  Metering Devices for High-Pressure  Chillers 1455
47.10 Low-Pressure Chillers  1458
 47.11  Compressors for Low-Pressure Chillers  1458  47.12  Condensers for Low-Pressure Chillers
 47.13  Metering Devices for Low-Pressure Chillers  1461 47.14 Purge Units  1461
 47.15  Absorption Air-Conditioning Chillers  1462
 47.16  Motors and Drives for Chillers  1472
Unit 48  Cooling Towers and Pumps  1483
 48.1  Cooling Tower Function  1483
 48.2  Types of Cooling Towers  1484
48.3 Fire Protection  1487
48.4 Fill Material  1488
48.5 Flow Patterns  1489
48.6 Tower Materials  1490
48.7 Fan Section  1490
48.8 Tower Access  1491
48.9 Tower Sump  1491
48.10 Makeup Water  1492
48.11 Blowdown  1492
 48.12  Balancing the Water Flow for a Tower  1494 48.13 Water Pumps  1495
 48.14  Chemical-Free Treatment of Cooling Tower Water 1503
Unit 49  Operation, Maintenance, and Troubleshooting
of Chilled-Water Air-Conditioning Systems  1509
49.1 Chiller Start-Up  1509
 49.2  Valves for Large Systems  1515
 49.3  Scroll and Reciprocating Chiller Operation  1517  49.4  Large Positive-Displacement Chiller Operation  1518  49.5  Centrifugal Chiller Operation  1518
 49.6  Air-Cooled Chiller Maintenance  1518
 49.7  Water-Cooled Chiller Maintenance  1520
 49.8  Absorption Chilled-Water System Start-Up  1523  49.9  Absorption Chiller Operation and Maintenance  1524  49.10  General Maintenance for All Chillers  1525
49.11 Low-Pressure Chillers  1525
49.12 High-Pressure Chillers  1526
49.13 Refrigerant Safety  1527
 49.14  Service Technician Calls  1528
Unit 50  Commercial Packaged Rooftop, Variable Refrigerant Flow and Variable Air Volume Systems
 50.1  Rooftop Package Units  1536
 50.2  Installation of Packaged Rooftop Units  1537 50.3 Economizers  1544
 50.4  Dual Enthalpy Sensor  1546
50.5  ASHRAE Standard 62  1549
 50.6  Demand Control Ventilation (DCV)  1549
50.7 Traditional Constant-Volume
Air Distribution Methods  1550
 50.8  Variable Air Volume (VAV) Systems  1551
 50.9  Blowers on VAV Systems  1551
 50.10  VAV Boxes and Terminal Units  1551
 50.11  Hot Water in the Reheat Coils  1553
50.12 Chilled-Water VAV Systems  1555
 50.13  Variable Refrigerant Flow (VRF) Systems  1562 Appendix A  Alternative Heating
 (Stoves and Fireplace Inserts)  1575
A.1 Wood-Burning Stoves  1575
 A.2  Organic Makeup and Characteristics of Wood  1575  A.3  Environmental Protection Agency  (EPA) Regulations  1576
A.4 Creosote  1576
 A.5  Design Characteristics of Wood-Burning Stoves  1576 A.6 Installation Procedures  1580
A.7 Smoke Detectors  1582
A.8 Gas Stoves  1582
A.9 Fireplace Inserts  1582
Appendix B  Temperature Conversion Chart  1584
Glossary 1586
Index 163

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Chuyên mục: C. Bài giảng C. Bài giảng chuyên ngành Nhiệt Lạnh (Heat and Refrigeration) C. Bài giảng kỹ thuật