Refrigeration and Air Conditioning Technology

1696 Pages·2012·1.7 MB·English

by  Bill Whitman

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SEVENTH EDITION
WILLIAM C. WHITMAN
WILLIAM M. JOHNSON
JOHN A. TOMCZYK
EUGENE SILBERSTEIN
Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States
Refrigeration and Air Conditioning © 2013, 2009 Delmar, Cengage Learning
Technology, Seventh Edition
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Printed in the United States of America
1 2 3 4 5 6 7 15 14 13 12
Brief Contents
SECTION 1: Theory of Heat Unit 28 Special Refrigeration Applications 733
Unit 29 Troubleshooting and Typical Operating
Introduction 1 Conditions for Commercial Refrigeration 752
Unit 1 Heat, Temperature, and Pressure 14
Unit 2 Matter and Energy 27 SECTION 6: Air-Conditioning
Unit 3 Refrigeration and Refrigerants 36
(Heating and Humidifi cation)
SECTION 2: Safety, Tools and Equipment, Unit 30 Electric Heat 798
Unit 31 Gas Heat 816
and Shop Practices
Unit 32 Oil Heat 889
Unit 33 Hydronic Heat 940
Unit 4 General Safety Practices 84
Unit 34 Indoor Air Quality 995
Unit 5 Tools and Equipment 102
Unit 6 Fasteners 135
Unit 7 Tubing and Piping 148 SECTION 7: Air-Conditioning (Cooling)
Unit 8 Leak Detection, System Evacuation,
and System Cleanup 178 Unit 35 Comfort and Psychrometrics 1016
Unit 9 Refrigerant and Oil Chemistry and Unit 36 Refrigeration Applied to Air-Conditioning 1040
Management—Recovery, Recycling, Unit 37 Air Distribution and Balance 1059
Reclaiming, and Retrofi tting 213 Unit 38 Installation 1107
Unit 10 System Charging 251 Unit 39 Residential Energy Audit 1130
Unit 11 Calibrating Instruments 269 Unit 40 Typical Operating Conditions 1181
Unit 41 Troubleshooting 1195
SECTION 3: Basic Automatic Controls
SECTION 8: All-Weather Systems
Unit 12 Basic Electricity and Magnetism 282
Unit 42 Heat Gains and Heat Losses in Structures 1226
Unit 13 Introduction to Automatic Controls 310
Unit 43 Air Source Heat Pumps 1245
Unit 14 Automatic Control Components
Unit 44 Geothermal Heat Pumps 1297
and Applications 322
Unit 15 Troubleshooting Basic Controls 552
SECTION 9: Domestic Appliances
Unit 16 Advanced Automatic Controls—Direct Digital
Controls (DDCs) and Pneumatics 376
Unit 45 Domestic Refrigerators and Freezers 1334
Unit 46 Room Air Conditioners 1408
SECTION 4: Electric Motors
SECTION 10: Commercial Air-Conditioning
Unit 17 Types of Electric Motors 398
and Chilled-Water Systems
Unit 18 Application of Motors 429
Unit 19 Motor Controls 447
Unit 47 High-Pressure, Low-Pressure, and Absorption
Unit 20 Troubleshooting Electric Motors 458
Chilled-Water Systems 1438
Unit 48 Cooling Towers and Pumps 1483
Unit 49 Operation, Maintenance, and Troubleshooting
SECTION 5: Commercial Refrigeration
of Chilled-Water Air-Conditioning Systems 1509
Unit 50 Commercial Packaged Rooftop, Variable
Unit 21 Evaporators and the Refrigeration System 476
Refrigerant Flow and Variable
Unit 22 Condensers 498
Air Volume Systems 1535
Unit 23 Compressors 532
Unit 24 Expansion Devices 566 Appendix A Alternative Heating
Unit 25 Special Refrigeration System Components 595 (Stoves and Fireplace Inserts) 1575
Unit 26 Applications of Refrigeration Systems 640
Unit 27 Commercial Ice Machines 684 Appendix B 1584
iii
Contents
Preface xiii 3.6 Refrigeration Components 45
3.7 The Evaporator 45
New in This Edition xiv
3.8 The Compressor 47
How to Use the Text and Supplementary Materials xix 3.9 The Condenser 49
Support Materials xxii 3.10 The Refrigerant Metering Device 51
About the Authors xxiv 3.11 Matching Refrigeration Systems
and Components 53
Acknowledgments xxv
3.12 Refrigerants 55
3.13 Refrigerants Must Be Safe 56
3.14 Refrigerants Must Be Detectable 56
SECTION 1: Theory of Heat 3.15 The Boiling Point of the Refrigerant 58
3.16 Pumping Characteristics 58
3.17 Popular Refrigerants and Their Important
Introduction 1
Characteristics 58
History of Refrigeration and Air-Conditioning (Cooling) 2 3.18 Refrigerant Cylinder Color Codes 58
Green Awareness 5 3.19 Recovery, Recycling, or Reclaiming
History of Home and Commercial Heating 7 of Refrigerants 61
Career Opportunities 7 3.20 Plotting the Refrigerant Cycle 61
Technician Certifi cation Programs 8 3.21 Plotting the Refrigerant Cycle for Blends with
Programmatic Accreditation 9 Noticeable Temperature Glide (Zeotropic Blends) 77
National Skill Standards 10
Customer Relations and Technician Soft Skills 10
Unit 1 Heat, Temperature, and Pressure 14 SECTION 2: Safety, Tools and Equipment,
1.1 Heat, Temperature, and Pressure 14 and Shop Practices
1.2 Temperature 14
1.3 Introduction to Heat 16 Unit 4 General Safety Practices 84
1.4 Conduction 18
1.5 Convection 18 4.1 Pressure Vessels and Piping 84
1.6 Radiation 19 4.2 Electrical Hazards 88
1.7 Sensible Heat 20 4.3 Heat 93
1.8 Latent Heat 20 4.4 Cold 94
1.9 Specifi c Heat 22 4.5 Mechanical Equipment 94
1.10 Sizing Heating Equipment 22 4.6 Moving Heavy Objects 96
1.11 Pressure 22 4.7 Refrigerants in Your Breathing Space 96
1.12 Atmospheric Pressure 23 4.8 Using Chemicals 99
1.13 Pressure Gauges 24
Unit 5 Tools and Equipment 102
Unit 2 Matter and Energy 27 5.1 General Tools 102
2.1 Matter 27 5.2 Specialized Hand Tools 108
2.2 Mass and Weight 28 5.3 Tubing Tools 110
2.3 Density 28 5.4 Specialized Service and Installation Equipment 114
2.4 Specifi c Gravity 28 5.5 Refrigerant Leak Detectors 117
2.5 Specifi c Volume 28 5.6 Other Tools 118
2.6 Gas Laws 29 5.7 Miscellaneous Tools and Equipment
2.7 Energy 31 for Specialized Needs 126
2.8 Conservation of Energy 32
Unit 6 Fasteners 135
2.9 Energy Contained in Heat 32
2.10 Energy in Magnetism 32 6.1 Nails 135
2.11 Purchase of Energy 33 6.2 Staples and Rivets 136
2.12 Energy Used as Work 33 6.3 Threaded Fasteners 137
2.13 Power 33 6.4 Concrete Fasteners 142
2.14 Electrical Power—The Watt 33 6.5 Other Fasteners 143
Unit 3 Refrigeration and Refrigerants 36 Unit 7 Tubing and Piping 148
3.1 Introduction to Refrigeration 36 7.1 Purpose of Tubing and Piping 148
3.2 Refrigeration 37 7.2 Types and Sizes of Tubing 148
3.3 Rating Refrigeration Equipment 37 7.3 Tubing Insulation 149
3.4 The Refrigeration Process 38 7.4 Line Sets 151
3.5 Temperature and Pressure Relationship 40 7.5 Cutting Tubing 151
iv
Contents v
7.6 Bending Tubing 152 Unit 11 Calibrating Instruments 269
7.7 Soldering and Brazing Processes 154
11.1 Calibration 269
7.8 Heat Sources for Soldering and Brazing 155
11.2 Temperature-Measuring Instruments 270
7.9 Fluxing 160
11.3 Pressure Test Instruments 272
7.10 Soldering Techniques 161
11.4 Electrical Test Instruments 274
7.11 Brazing Techniques 163
11.5 Refrigerant Leak Detection Devices 276
7.12 Practical Soldering and Brazing Tips 164
11.6 Flue-Gas Analysis Instruments 277
7.13 Making Flare Joints 166
11.7 General Maintenance 278
7.14 Swaging Techniques 167
7.15 Compression Fittings 169
7.16 Steel and Wrought Iron Pipe 170
7.17 Installing Steel Pipe 173
SECTION 3: Basic Automatic Controls
7.18 Plastic Pipe 173
7.19 Alternative Mechanical Piping Connections 174
Unit 12 Basic Electricity and Magnetism 282
Unit 8 Leak Detection, System Evacuation,
12.1 The Structure of Matter 282
and System Cleanup 178
12.2 Movement of Electrons 283
8.1 Leaks 178 12.3 Conductors 283
8.2 Basic Refrigerant Leak Detection 180 12.4 Insulators 283
8.3 Advanced Leak Detection 182 12.5 Electricity Produced from Magnetism 283
8.4 Standing Pressure Test 184 12.6 Current 284
8.5 Leak Detection Tips 186 12.7 Units of Electrical Measurement 284
8.6 Repairing Leaks 189 12.8 The Electric Circuit 285
8.7 System Evacuation 190 12.9 Making Electrical Measurements 285
8.8 General Evacuation Procedures 202 12.10 Ohm’s Law 288
8.9 Cleaning a Dirty System 208 12.11 Characteristics of Series Circuits 289
12.12 Characteristics of Parallel Circuits 289
Unit 9 Refrigeration and Oil Chemistry 12.13 Electrical Power 290
12.14 Magnetism 290
and Management—Recovery, Recycling,
12.15 Inductance 292
Reclaiming, and Retrofi tting 213
12.16 Transformers 292
9.1 Refrigerants and the Environment 213 12.17 Capacitance 293
9.2 Ozone Depletion 214 12.18 Impedance 294
9.3 Global Warming 215 12.19 Electrical Measuring Instruments 294
9.4 Refrigerants 216 12.20 Sine Waves 298
9.5 CFC Refrigerants 217 12.21 Wire Sizes 299
9.6 HCFC Refrigerants 217 12.22 Circuit Protection Devices 300
9.7 HFC Refrigerants 218 12.23 Semiconductors 303
9.8 HC Refrigerants 218
Unit 13 Introduction to Automatic Controls 310
9.9 Naming Refrigerants 218
9.10 Refrigerant Blends 219 13.1 Types of Automatic Controls 310
9.11 Popular Refrigerants and Their 13.2 Devices That Respond to Thermal Change 310
Compatible Oils 220 13.3 The Bimetal Device 311
9.12 Refrigerant Oils and Their Applications 225 13.4 Control by Fluid Expansion 314
9.13 Oil Groups 225 13.5 The Thermocouple 317
9.14 Regulations 227 13.6 Electronic Temperature-Sensing Devices 319
9.15 Recover, Recycle, or Reclaim 227
9.16 Methods of Recovery 229 Unit 14 Automatic Control Components
9.17 Mechanical Recovery Systems 232 and Applications 322
9.18 Recovering Refrigerant from Small Appliances 239
14.1 Temperature Controls 322
9.19 Reclaiming Refrigerant 241
14.2 Low-Voltage Space Temperature Controls 324
9.20 Refrigerant Retrofi tting 242
14.3 Line-Voltage Space Temperature Controls 328
9.21 Refrigerants and Tools in the Future 248
14.4 Sensing the Temperature of Solids 330
14.5 Measuring the Temperature of Fluids 333
Unit 10 System Charging 251
14.6 Pressure-Sensing Devices 334
10.1 Charging a Refrigeration System 251 14.7 Pressure Transducers 338
10.2 Vapor Refrigerant Charging 251 14.8 High-Pressure Controls 340
10.3 Liquid Refrigerant Charging 253 14.9 Low-Pressure Controls 341
10.4 Weighing Refrigerant 256 14.10 Oil Pressure Safety Controls 341
10.5 Using Charging Devices 257 14.11 Air Pressure Controls 343
10.6 Using Charging Charts 258 14.12 Gas Pressure Switches 344
10.7 Subcooling Charging Method for TXV Systems 262 14.13 Switchless Devices That Control Fluid Flow 344
10.8 Charging Near-Azeotropic (Zeotropic) 14.14 Water Pressure Regulators 344
Refrigerant Blends 263 14.15 Gas Pressure Regulators 345
vi Contents
14.16 Mechanical and Electromechanical 18.4 Insulation Type or Class 436
Controls 346 18.5 Types of Bearings 437
14.17 Maintenance of Mechanical Controls 347 18.6 Motor Mounting Characteristics 439
14.18 Maintenance of Electromechanical Controls 347 18.7 Motor Drives 441
14.19 Service Technician Calls 347
Unit 19 Motor Controls 447
Unit 15 Troubleshooting Basic Controls 352
19.1 Introduction to Motor Control Devices 447
15.1 Introduction to Troubleshooting 352 19.2 Run-Load and Locked-Rotor Amperage 448
15.2 Troubleshooting a Simple Circuit 353 19.3 The Relay 448
15.3 Troubleshooting a Complex Circuit 354 19.4 The Contactor 449
15.4 Troubleshooting the Thermostat 357 19.5 Motor Starters 451
15.5 Troubleshooting Amperage in 19.6 Motor Protection 452
the Low-Voltage Circuit 358 19.7 Inherent Motor Protection 453
15.6 Troubleshooting Voltage in 19.8 External Motor Protection 453
the Low-Voltage Circuit 359 19.9 National Electrical Code® Standards 455
15.7 Troubleshooting Switches and Loads 360 19.10 Temperature-Sensing Devices 455
15.8 Pictorial and Line Diagrams 367 19.11 Magnetic Overload Devices 456
15.9 Service Technician Calls 367 19.12 Restarting the Motor 456
Unit 16 Advanced Automatic Controls—Direct Unit 20 Troubleshooting Electric Motors 458
Digital Controls (DDCs) and Pneumatics 376 20.1 Motor Troubleshooting 458
16.1 Control Applications 376 20.2 Mechanical Motor Problems 458
16.2 Types of Control Systems 376 20.3 Removing Drive Assemblies 459
16.3 Pneumatic Controls 378 20.4 Belt Tension 460
16.4 Cleaning and Drying Control Air 379 20.5 Pulley Alignment 461
16.5 Control Components 380 20.6 Electrical Problems 461
16.6 Direct Digital Controls (DDCs) 385 20.7 Open Windings 461
16.7 Residential Electronic Controls 393 20.8 Shorted Motor Windings 462
20.9 Short Circuit to Ground (Frame) 464
20.10 Single-Phase Motor Starting Problems 466
SECTION 4: Electric Motors
20.11 Checking Capacitors 467
20.12 Identifi cation of Capacitors 469
Unit 17 Types of Electric Motors 398 20.13 Wiring and Connectors 470
20.14 Troubleshooting Hermetic Motors 470
17.1 Uses of Electric Motors 398
20.15 Service Technician Calls 470
17.2 Parts of an Electric Motor 398
17.3 Electric Motors and Magnetism 399
17.4 Determining a Motor’s Speed 400 SECTION 5: Commercial Refrigeration
17.5 Start Windings 401
17.6 Starting and Running Characteristics 401
Unit 21 Evaporators and the Refrigeration System 476
17.7 Electrical Power Supplies 402
17.8 Single-Phase Open Motors 403 21.1 Refrigeration 476
17.9 Split-Phase Motors 404 21.2 Temperature Ranges of Refrigeration 477
17.10 The Centrifugal Switch 405 21.3 The Evaporator 477
17.11 The Electronic Relay 405 21.4 Boiling and Condensing 478
17.12 Capacitor-Start Motors 405 21.5 The Evaporator and Boiling Temperature 478
17.13 Capacitor-Start, Capacitor-Run Motors 406 21.6 Removing Moisture 478
17.14 Permanent Split-Capacitor Motors 407 21.7 Heat Exchange Characteristics
17.15 Shaded-Pole Motors 408 of the Evaporator 478
17.16 Three-Phase Motors 409 21.8 Types of Evaporators 481
17.17 Single-Phase Hermetic Motors 410 21.9 Evaporator Evaluation 487
17.18 The Potential Relay 411 21.10 Latent Heat in the Evaporator 489
17.19 The Current Relay 414 21.11 The Flooded Evaporator 489
17.20 Positive Temperature Coeffi cient Resistor (PTCR) 415 21.12 Dry- Type Evaporators Performance 489
17.21 Two-Speed Compressor Motors 416 21.13 Evaporator Superheat 490
17.22 Special Application Motors 416 21.14 Hot Pulldown (Excessively Loaded Evaporator) 490
17.23 Three-Phase Compressor Motors 417 21.15 Pressure Drop in Evaporators 491
17.24 Variable-Speed Motors 417 21.16 Liquid Cooling Evaporators (Chillers) 493
17.25 DC Converters (Rectifi ers) 420 21.17 Evaporators for Low- Temperature Applications 494
17.26 Inverters and Variable Frequency Drives (VFDs) 421 21.18 Defrost of Accumulated Moisture 495
17.27 Electronically Commutated Motors (ECMs) 425
17.28 Cooling Electric Motors 426 Unit 22 Condensers 498
22.1 The Condenser 498
Unit 18 Application of Motors 429
22.2 Water-Cooled Condensers 498
18.1 Motor Applications 429 22.3 Tube-Within-a-Tube Condensers 499
18.2 The Power Supply 429 22.4 Mineral Deposits 499
18.3 Electric-Motor Working Conditions 436 22.5 Cleanable Tube-Within-a-Tube Condensers 500
Contents vii
22.6 Shell-and-Coil Condensers 501 Unit 25 Special Refrigeration System Components 595
22.7 Shell-and-Tube Condensers 502
25.1 The Four Basic Components 595
22.8 Wastewater Systems 503
25.2 Mechanical Controls 595
22.9 Refrigerant-to-Water Temperature Relationship
25.3 Two-Temperature Controls 595
for Wastewater Systems 505
25.4 Evaporator Pressure Control 595
22.10 Recirculating Water Systems 507
25.5 Multiple Evaporators 598
22.11 Cooling Towers 507
25.6 Electric Evaporator Pressure-Regulating Valve 598
22.12 Natural-Draft Towers 508
25.7 Crankcase Pressure Regulator 599
22.13 Forced- or Induced-Draft Towers 509
25.8 Adjusting the CPR Valve 600
22.14 Evaporative Condensers 511
25.9 Relief Valves 600
22.15 Air-Cooled Condensers 511
25.10 Fan-Cycling Head Pressure Controls 602
22.16 High-Effi ciency Condensers 515
25.11 Fan Speed Control for Controlling
22.17 The Condenser and Low Ambient Conditions 516
Head Pressure 602
22.18 Head Pressure Controls 518
25.12 Air Volume Control for Controlling
22.19 Using the Condenser Superheat 528
Head Pressure 603
22.20 Heat Reclaim 528
25.13 Condenser Flooding and Condenser Splitting
22.21 Floating Head Pressures 528
for Controlling Head Pressure 603
22.22 Condenser Evaluation 529
25.14 Electrical Controls 604
22.23 Service Technician Calls 529
25.15 Pressure Switches 607
25.16 Low-Pressure Switch 607
Unit 23 Compressors 532
25.17 Low-Pressure Control Applied as a Thermostat 607
23.1 The Function of the Compressor 532 25.18 Automatic Pumpdown Systems 609
23.2 Types of Compressors 534 25.19 High-Pressure Control 612
23.3 Reciprocating Compressor Components 539 25.20 Low-Ambient Fan Control 613
23.4 Belt-Drive Mechanism Characteristics 548 25.21 Oil Pressure Safety Control 613
23.5 Direct-Drive Compressor Characteristics 549 25.22 The Defrost Cycle 617
23.6 Reciprocating Compressor Effi ciency 549 25.23 Medium-Temperature Refrigeration 618
23.7 Discus Valve Design 550 25.24 Random or Off -Cycle Defrost 618
23.8 New Technology in Compressors 551 25.25 Planned Defrost 618
23.9 Liquid in the Compressor Cylinder 561 25.26 Low-Temperature Evaporator Defrost 619
23.10 System Maintenance and Compressor 25.27 Internal Heat Defrost (Hot Gas and Cool
Effi ciency 561 Gas Defrost) 619
25.28 External Heat Defrost 620
Unit 24 Expansion Devices 566 25.29 Defrost Termination and Fan Delay Control 621
25.30 Refrigeration Accessories 622
24.1 Expansion Devices 566
25.31 Receivers 622
24.2 Thermostatic Expansion Valve 567
25.32 The King Valve on the Receiver 623
24.3 TXV Components 568
25.33 Filter Driers 623
24.4 The Valve Body 568
25.34 Refrigerant Check Valves 625
24.5 The Diaphragm 568
25.35 Refrigerant Sight Glasses 625
24.6 Needle and Seat 568
25.36 Liquid Refrigerant Distributors 625
24.7 The Spring 572
25.37 Heat Exchangers 626
24.8 The Sensing Bulb and Transmission Tube 573
25.38 Suction-Line Accumulators 626
24.9 Types of Bulb Charge 573
25.39 Suction-Line Filter Driers 629
24.10 The Liquid Charge Bulb 573
25.40 Suction Service Valves 630
24.11 The Cross Liquid Charge Bulb 575
25.41 Discharge Service Valves 630
24.12 The Vapor (Gas) Charge Bulb 575
25.42 Refrigeration Line Service Valves 631
24.13 The Cross Vapor Charge Bulb 576
25.43 Diaphragm Valves 633
24.14 Example of a TXV Functioning with an
25.44 Ball Valves 633
Internal Equalizer 576
25.45 Oil Separators 633
24.15 TXV Functioning with External Equalizers 577
25.46 Vibration Eliminators 634
24.16 TXV Response to Load Changes 579
25.47 Pressure Access Ports 635
24.17 Selection of TXV Valves 580
25.48 Crankcase Heat 636
24.18 Balanced-Port TXV 581
24.19 Dual-Port TXV 582
Unit 26 Applications of Refrigeration Systems 640
24.20 The Pressure-Limiting TXV 582
24.21 Servicing the TXV 582 26.1 Application Decisions 640
24.22 Installing the Sensing Element 583 26.2 Reach-in Refrigeration 640
24.23 The Solid-State-Controlled Expansion Valve 583 26.3 Self-Contained Reach-In Fixtures 641
24.24 Step-Motor Expansion Valves 584 26.4 Individual Condensing Units 643
24.25 Algorithms and PID Controllers 586 26.5 Single-Compressor Applications
24.26 The Automatic Expansion Valve 589 and Multiple Evaporators 644
24.27 Automatic Expansion Valve Response 26.6 Parallel Compressor Systems 647
to Load Changes 589 26.7 Secondary-Fluid Refrigeration Systems 655
24.28 Special Considerations for the TXV and AXV 589 26.8 Carbon Dioxide (R-744) Refrigeration Systems 657
24.29 The Capillary Tube Metering Device 590 26.9 Pressurized Liquid Systems 661
24.30 Operating Charge for the Capillary Tube System 592 26.10 Distributed Refrigeration Systems 663
viii Contents
26.11 Evaporator Temperature Control 664 29.15 Refrigerant Flow Restrictions 768
26.12 Interconnecting Piping in Multiple-Evaporator 29.16 Ineffi cient Compressor 771
Installations 664 29.17 Compressor Vacuum Test 771
26.13 Fixture Temperature Control 665 29.18 Closed-Loop Compessor Running Bench Test 772
26.14 The Evaporator and Merchandising 665 29.19 Closed-Loop Compressor Running Field Test 773
26.15 Chest-Type Display Fixtures 666 29.20 Compressor Running Test in the System 774
26.16 Refrigerated Shelves 667 29.21 Service Technician Calls 776
26.17 Closed Chest Fixtures 667
26.18 Controlling Sweating on Fixture Cabinets 667
26.19 Maintaining Store Ambient Conditions 668
SECTION 6: Air-Conditioning
26.20 Walk-in Refrigeration 669
26.21 Knock-Down Walk-In Coolers 669 (Heating and Humidifi cation)
26.22 Evaporators in a Walk-In Cooler 670
26.23 Condensate Removal 670
Unit 30 Electric Heat 798
26.24 Refrigeration Piping 670
26.25 Package Refrigeration for Walk-In Coolers 671 30.1 Introduction 798
26.26 Vending Machine Refrigeration 671 30.2 Portable Electric Heating Devices 798
26.27 Water Coolers 677 30.3 Radiant Heating Panels 799
26.28 Refrigerated Air Driers 679 30.4 Electric Baseboard Heating 800
30.5 Unit and Wall Heaters 800
Unit 27 Commercial Ice Machines 684 30.6 Electric Hydronic Boilers 800
30.7 Central Forced-Air Electric Furnaces 801
27.1 Packaged-Type Ice-Making Equipment 684
30.8 Automatic Controls for Forced-Air Electric
27.2 Making Flake Ice 685
Furnaces 802
27.3 Making Cube Ice 693
30.9 The Low-Voltage Thermostat 802
27.4 Microprocessors 711
30.10 Controlling Multiple Stages 803
27.5 Making Cylindrical Ice 716
30.11 Wiring Diagrams 804
27.6 Water and Ice Quality 717
30.12 Control Circuits for Forced-Air Electric
27.7 Package Ice Machine Location 723
Furnaces 805
27.8 Troubleshooting Ice Makers 723
30.13 Blower Motor Circuits 806
27.9 Service Technician Calls 727
30.14 Contactors for Controlling Electric Furnaces 807
30.15 Airfl ow in Electric Furnaces 807
Unit 28 Special Refrigeration Applications 733
30.16 Service Technician Calls 811
28.1 Special Refrigeration Applications 733
28.2 Transport Refrigeration 733 Unit 31 Gas Heat 816
28.3 Truck Refrigeration Systems 733
31.1 Introduction to Gas-Fired,
28.4 Railway Refrigeration 740
Forced-Hot-Air Furnaces 817
28.5 Extra-Low-Temperature Refrigeration 741
31.2 Types of Furnaces 817
28.6 Cascade Systems 743
31.3 Gas Fuels 820
28.7 Quick-Freezing Methods 744
31.4 Gas Combustion 822
28.8 Marine Refrigeration 746
31.5 Gas Regulators 824
28.9 Air Cargo Hauling 749
31.6 Gas Valve 824
31.7 Solenoid Valve 825
Unit 29 Troubleshooting and Typical Operating
31.8 Diaphragm Valve 825
Conditions for Commercial Refrigeration 752
31.9 Heat Motor–Controlled Valve 826
29.1 Organized Troubleshooting 752 31.10 Automatic Combination Gas Valve 827
29.2 Troubleshooting High-Temperature 31.11 Manifold 832
Applications 753 31.12 Orifi ce 832
29.3 Troubleshooting Medium-Temperature 31.13 Burners 832
Applications 755 31.14 Heat Exchangers 833
29.4 Troubleshooting Low-Temperature 31.15 Fan Switch 836
Applications 755 31.16 Limit Switch 837
29.5 Typical Air-Cooled Condenser Operating 31.17 Pilots 839
Conditions 756 31.18 Safety Devices at the Standing Pilot 840
29.6 Calculating the Correct Head Pressure for 31.19 Ignition Systems 842
Air-Cooled Equipment 757 31.20 Flame Rectifi cation 844
29.7 Typical Operating Conditions for 31.21 High-Effi ciency Gas Furnaces 848
Water-Cooled Equipment 758 31.22 Electronic Ignition Modules and Integrated
29.8 Typical Operating Conditions for Wastewater Furnace Controllers 853
Condenser Systems 758 31.23 Two-Stage Gas Furnaces 859
29.9 Typical Operating Conditions for Recirculated 31.24 Modulating Gas Furnaces 859
Water Systems 759 31.25 Venting 860
29.10 Six Typical Problems 759 31.26 Gas Piping 864
29.11 Low Refrigerant Charge 759 31.27 Gas Furnace Wiring Diagrams
29.12 Refrigerant Overcharge 762 and Troubleshooting Flowcharts 865
29.13 Ineffi cient Evaporator 764 31.28 Troubleshooting the Safety Pilot-Proving
29.14 Ineffi cient Condenser 766 Device—The Thermocouple 867
Contents ix
31.29 Troubleshooting Spark Ignition and 35.5 Psychrometrics 1018
Intermittent Pilot Systems 868 35.6 Moisture in Air 1018
31.30 Combustion Effi ciency 877 35.7 Absolute and Relative Humidity 1020
31.31 Service Technician Calls 882 35.8 Superheated Gases in Air 1022
35.9 Dry-Bulb and Wet-Bulb Temperatures 1023
Unit 32 Oil Heat 889 35.10 Dew Point Temperature 1025
32.1 Introduction to Oil-Fired, Forced-Warm-Air 35.11 Enthalpy 1025
Furnaces 889 35.12 The Psychrometric Chart 1026
32.2 Physical Characteristics 890 35.13 Plotting on the Psychrometric Chart 1029
32.3 Fuel Oils 890 35.14 Fresh Air, Infi ltration, and Ventilation 1029
32.4 Oil Storage 893
Unit 36 Refrigeration Applied to Air-Conditioning 1040
32.5 Fuel Oil Supply Systems 895
32.6 Combustion 900 36.1 Refrigeration 1040
32.7 Preparation of Fuel Oil for Combustion 901 36.2 Structural Heat Gain 1040
32.8 By-Products of Combustion 901 36.3 Evaporative Cooling 1042
32.9 Gun-Type Oil Burners 901 36.4 Refrigerated Cooling or Air-Conditioning 1042
32.10 Oil Furnace Wiring Diagrams 917 36.5 The Evaporator 1043
32.11 Wiring Diagram for the Stack Switch 36.6 The Function of the Evaporator 1044
Safety Control 917 36.7 Design Conditions 1045
32.12 Wiring Diagram for Cad Cell Safety Control 917 36.8 Evaporator Application 1045
32.13 Combustion Chamber 923 36.9 The Compressor 1045
32.14 Heat Exchanger 924 36.10 The Reciprocating Compressor 1047
32.15 Condensing Oil Furnace 925 36.11 Compressor Speeds (RPM) 1048
32.16 Service Procedures 926 36.12 Cooling the Compressor and Motor 1048
32.17 Combustion Effi ciency 930 36.13 Compressor Mountings 1049
32.18 Service Technician Calls 934 36.14 Rebuilding the Hermetic Compressor 1049
36.15 The Rotary Compressor 1049
Unit 33 Hydronic Heat 940 36.16 The Scroll Compressor 1050
36.17 The Condenser 1052
33.1 Introduction to Hydronic Heating 940
36.18 Expansion Devices 1054
33.2 The Heat Source 941
36.19 Air-Side Components 1055
33.3 The Basic Hydronic System 945
36.20 Installation Procedures 1055
33.4 The Point of No Pressure Change 950
33.5 Other Hydronic System Components 952
33.6 High-Temperature Hydronic Piping Systems 963 Unit 37 Air Distribution and Balance 1059
33.7 Radiant, Low-Temperature Hydronic 37.1 Conditioning Equipment 1059
Piping Systems 974 37.2 Correct Air Quantity 1060
33.8 Combination (High- and Low-Temperature) 37.3 The Forced-Air System 1060
Piping Systems 980 37.4 The Blower 1060
33.9 Tankless Domestic Hot Water Heaters 980 37.5 System Pressures 1063
33.10 Solar Heating as a Supplemental Heat Source 982 37.6 Air-Measuring Instruments for Duct Systems 1064
33.11 Service Technician Calls 991 37.7 Types of Fans and Blowers 1066
37.8 Types of Drive Assemblies 1067
Unit 34 Indoor Air Quality 995
37.9 The Supply Duct System 1068
34.1 Introduction 995 37.10 Duct System Standards 1072
34.2 Sources of Indoor Air Pollution 995 37.11 Duct Materials 1073
34.3 Common Pollutants 996 37.12 Duct Air Movement 1079
34.4 Detecting and Eliminating the Source 37.13 Balancing Dampers 1081
of Contamination 1001 37.14 Zoning 1082
34.5 Ventilation 1002 37.15 Duct Insulation 1086
34.6 Air Cleaning 1003 37.16 Blending the Conditioned Air with Room Air 1086
34.7 Duct Cleaning 1007 37.17 The Return-Air Duct System 1088
34.8 Air Humidifi cation 1008 37.18 Sizing Duct for Moving Air 1088
34.9 Sizing Humidifi ers 1012 37.19 Measuring Air Movement for Balancing 1092
34.10 Installation 1012 37.20 The Air Friction Chart 1094
34.11 Service, Troubleshooting, and Preventive 37.21 Practical Troubleshooting Techniques 1101
Maintenance 1012
Unit 38 Installation 1107
38.1 Introduction to Equipment Installation 1107
SECTION 7: Air-Conditioning (Cooling) 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
Unit 35 Comfort and Psychrometrics 1016
38.5 Installing Ductboard Systems 1110
35.1 Comfort 1016 38.6 Installing Flexible Duct 1111
35.2 Food Energy and the Body 1016 38.7 Electrical Installation 1112
35.3 Heat Transfer to and from the Body 1017 38.8 Installing the Refrigeration System 1114
35.4 The Comfort Chart 1018 38.9 Installing Split-System Air Conditioners 1118