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Instalatii Frigorifice
Refrigeration Basics
An Introduction to the Refrigeration Trade
Forward
There are a great number of technical publications on refrigeration but few are written
from a mechanics perspective. This one is. It illustrates the mechanical refrigeration
process and related topics with straight forward explanations and graphics. It's intent is to
make it easy to understand important concepts and terminology. Traditional refrigeration
textbooks cover such a large scope of material and in such great detail that rudimentary
concepts often become lost in the process. Refrigeration Basics is an introduction to the
Refrigeration Trade and focus's on creating a solid foundation which can be built upon
readily. Learning about refrigeration is a never ending process and well understood
fundamentals make learning more advanced concepts much easier. This book is a
preparation for anyone interested in entering the refrigeration trade and is an introduction
to some of the immediate problems one will face in the field. It is designed for those who:
Electronic Media
This electronic book or "ebook" uses the HTML format for several reasons. (HTML
stands for Hyper Text Mark up Language and is the language that web pages are created
with) HTML is displayed in Internet Browsers and is generally platform independent.
Browsers support animated graphics, hyperlinks and JavaScript. Those capabilities are
used extensively to accomplish the goals outlined above. This is an introduction to
refrigeration in electronic form with interactive and animated graphics and interactive
objects. The first section is called Refrigeration Basics and is a very compact overview of
the refrigeration process. It is a slightly modified version of a web site that was online for
several years and received praises from folks from all over the world. Those compliments
are what inspired me to carry on from where The Refrigeration Basics web site left off.
Here are a few of those compliments:
writing is excellent. It's not easy explaining technical concepts in a way that is both clear
and interesting; you've succeeded on both accounts. In fact we intend to incorporate your
web site into our training regime. Keep up the good work.
Heating Contractor:
I am a heating contractor from the Boston area. I recently finished a basic HVAC course
that lasted 6 weeks. I have just absorbed more understanding in the last 30 minutes
viewing your Basic HVAC web pages than I did in the 6 week course. I have been in the
heating field for just over 22 years and I am just now willing to give A/C a try. I want to
thank you for taking the time to do what you have done in your web pages. Thanks again
and if your ever in the Boston area, let me take you out for a lobster dinner.
Misc:
This is simply an excellent web site, the best I've seen on this subject. Thanks for putting
this information out there for everyone to use.
Misc:
Great refrigeration site, another bulb is now on!
Installation Manager:
Great job. I have some employees (trainees) that need some basic knowledge of this field
and you have explained this more briefly and understandably than anything I have read,
without going into details that would distract from the basic concept. Have you written
anything else in this field with the simplicity of this? Again great job!!
Summary:
Thanks for all the many compliments I have received. And in answer to the question
posed above by the installation manager...now I have, this electronic book. The original
Refrigeration Basics web site was aimed at the lay person who was merely curious about
the refrigeration process. This book starts off with that original presentation and then
continues on with interactive training for the serious refrigeration apprentice or student or
otherwise interested person. It carries on with the straight forward and down to earth
approach that made the web site so popular. I hope this book is found to be useful and
informative.
Sincerely
Steve Kennedy
Readme
Contents
Version
System Requirements
JavaScript, this ebook uses it
Installation
Full screen mode & screen resolutions
Short Cut Icon
How to use this book
Technical Assistance
Site Licence
Hints
Warranty
Errors & Typo's
Disclaimer
Contact Seaside Computing
Version
This Refrigeration Basics CD-ROM is version III. The Version III release contains everything from the previous version as
well as an amazing 100 interactive troubleshooting boards. Learn the basics and then test your troubleshooting skills on
various types of refrigeration and air conditionong systems. All 100 boards utilize high and low side pressure gauges, a 9
point digital thermometer for measuring refrigerant, air, and water temperatures and of course an Amp/Ohm/Volt meter
which measures all test points on the electrical schematics.
System Requirements
● CD-ROM Drive
● Mouse
● Internet Browser (JavaScript enabled)
● screen resolutions supported:
640 x 480
800 x 600
1024 x 768 and higher
● Tested in Microsoft Internet Explorer 5.5, and 6.0, and Netscape Navigator 4.7 and 6.2 and 7.0
To take full advantage of this ebook you must have scripting turned on in your browser. Without it you will not be able to
use the temperature converter, the Causes-Effects trainer, the electrical troubleshooting sections, submit exam answers for
automatic marking, nor use the 100 troubleshooting boards. If using Internet Explorer, scripting can be enabled or disabled
by clicking in a check box. The scripting check box is located:
Internet Explorer:
Installation
There is no need to install anything. All files can be accessed directly from the CD-ROM.
Putting your browser in full screen mode will make some pages much easier to navigate. With MSIE (Microsoft Internet
Explorer) you can press F11 to toggle full screen mode. There are many sections with large and sometimes full screen
graphics which also have rows of buttons for user controlled sequential images. The screen shot below demonstrates how a
user controlled "slide show", as well as a related scrollable text area have been designed to fit on screen simultaneously. This
makes it easier to concentrate on the concepts at hand rather than scroll about looking for separate diagrams and text. The
text suggests appropriate moments to click on specific buttons that correlate to the concepts being discussed. Learning is fun
with interactive graphics. They make it easy to comprehend new concepts clearly, build a solid foundation and advance
quickly.
The CD-ROM has been designed to automatically detect your screen resolution settings. There are 3 resolution versions of
Refrigeration Basics on the CD-ROM and the contents.htm file in the appropriate folder will start automatically.
If your system does not automatically start CD-ROM's simply locate the appropriate folder for your screen resolution. The
folders are conveniently named:
● 640x480
● 800x600
● 1024x768
The start page is the contents.htm file. Locate that file and open it. All sections are linked to that page. You may wish to drag
a short cut of the contents.htm file to your desk top or anywhere you prefer on your system. This can be handy even if you
have an operational CD-ROM auto start because once you drag a short cut you will no longer have to open and close the CD-
ROM drive door to make Refrigeration Basics start. You can even assign the custom Refrigeration Basics icon to the short
cut. See the section below called Short Cut Icon for instructions how to do that.
The file called contents.htm is the start page of Refrigeration Basics. You can create a short cut of which ever contents.htm
start page suits your system settings. (see the section above on resolution versions) You can use a default short cut icon if
you wish, the custom icon graphic is just for fun. An image of the custom icon as shown in the title above. The custom
graphic is on the CD-ROM with the file name master icon.ico. If using Windows 95 or up, follow this procedure to assign
the custom icon graphic to your short cut:
1. Create a folder that can remain in place somewhere on your hard drive. You may name it icon or anything else you
like.
2. Find the icon file called master icon.ico and drag or COPY/PASTE a copy of it to the new folder you just made on
your computer.
3. Go back to the short cut that you created and right click on it. On the drop down list that appears, click on
Properties, Change Icon, Browse, and browse to the folder that you created containing the master icon.ico file.
4. Double click on the master icon.ico file and a new window called Change Icon will open. Click the OK button and
the Apply button and finally the Close button.
5. You can rename the short cut to anything you like, such as for example Refrigeration Basics.
The contents.htm page has button links to each section. The sections are presented in a purposeful order where subsequent
material is usually based on knowledge gained in the previous sections. If you do not go through the book in the order
presented you may find it difficult to comprehend. Most sections have a link to "Review Questions" for that section. Those
questions are hyperlinked to the exact spot in the book where the topic is discussed. Try to answer the questions and then
click the link to see if you knew the answer. At the end of the book is a 100 question multiple choice exam. The exam is an
opportunity for you to test yourself on how much of the material you have grasped from this book. A JavaScript routine
automatically checks your answers and displays your mark in percentage. You might find it amusing taking the test before
and after reading the book to see how your mark changes.
Technical Assistance
If you require technical assistance getting this CD-ROM to work contact Seaside Computing and we will do whatever we
can to assist you. (See our warranty section below)
Site Licence
Without a site licence the Refrigeration Basics CD-ROM is restricted to single point use on a single station. An unrestricted
site licence is available. See the ordering online page at:
www.refrigerationbasics.com
Hints
● Absolutely no side scrolling is required in this ebook. If horizontal scrollbars appear, you are viewing a version of
Refrigeration Basics that was created for a higher resolution than your current screen settings or system capabilities.
See the section on full screen mode & screen resolutions and utilize the version that matches your settings. (3
resolution versions are on the CD-ROM, use the one that's best for you)
● With one or two exceptions, no vertical scrolling is required to be able to see large full screen graphics. If you can't
see a large graphic without vertical scrolling you are using too much screen real estate for toolbars, status bars etc.
Refrigeration Basics is designed to be viewed in full screen mode. See the section on full screen mode & screen
resolutions.
Warranty
This product is warranted to be free from defects for a period of 90 days from date of purchase. All CD-ROM's are tested
before shipping. Any CD-ROM that fails to work within the 90 day warranty period will be replaced under warranty.
(Shipping Extra) Contact Seaside Computing for shipping instructions.
If you find any mistakes in this production please do inform us of what you found so that we can correct the error. We are
interested in any suggestions that you may have to improve this ebook and appreciate your input. Suggestions about topics to
include in subsequent versions are also very welcome.
Disclaimer
Attempts have been made to keep all information as accurate as possible and many mentions of safety precautions are made
throughout this e-book. It is however not a substitute for hands on training through an indentured apprenticeship nor live
technical school training. Refrigeration Basics is a great introduction to the refrigeration trade and would put anyone at an
advantage prior to entering a trade school or apprenticeship. It is also contains material that is quick and easy to locate and
reference and you will want to have permanently available. However, Seaside Computing Services takes no responsibility
for any mistakes, omissions or errors that happen to reside in any copy or version of Refrigeration Basics.
Contact Seaside
seaside@refrigerationbasics.com
Part 1
This section explains in basic terms the principals that are used to
create the refrigeration effect. Graphics and animation's are used in
an attempt to make it easy to understand the concepts involved.
First of all, did you know that there is no such thing as cold? You can describe something as cold and everyone will know
what you mean, but cold really only means that something contains less heat than something else. All there really is, is
greater and lesser amounts of heat. The definition of refrigeration is The Removal and Relocation of Heat. So if something is
to be refrigerated, it is to have heat removed from it. If you have a warm can of pop at say 80 degrees Fahrenheit and you
would prefer to drink it at 40 degrees, you could place it in your fridge for a while, heat would somehow be removed from it,
and you could eventually enjoy a less warm pop. (oh, all right, a cold pop.) But lets say you placed that 40 degree pop in the
freezer for a while and when you removed it, it was at 35 degrees. See what I mean, even "cold" objects have heat content
that can be reduced to a state of "less heat content". The limit to this process would be to remove all heat from an object. This
would occur if an object was cooled to Absolute Zero which is -273º C or -460º F. They come close to creating this
temperature under laboratory conditions and strange things like electrical superconductivity occur.
The latter two are used extensively in the design of refrigeration equipment. If you place two objects together so that they
remain touching, and one is hot and one is cold, heat will flow from the hot object into the cold object. This is called
conduction. This is an easy concept to grasp and is rather like gravitational potential, where a ball will try to roll down an
inclined plane. If you were to fan a hot plate of food it would cool somewhat. Some of the heat from the food would be
carried away by the air molecules. When heat is transferred by a substance in the gaseous state the process is called
convection. And if you kicked a glowing hot ember away from a bonfire, and you watched it glowing dimmer and dimmer, it
is cooling itself by radiating heat away. Note that an object doesn’t have to be glowing in order to radiate heat, all things use
combinations of these methods to come to equilibrium with their surroundings. So you can see that in order to refrigerate
something, we must find a way to expose our object to something that is colder than itself and nature will take over from
there. We are getting closer to talking about the actual mechanics of a refrigerating system, but there are some other
important concepts to discuss first.
They are of course; solid, liquid and gas. It is important to note that heat must be added to a substance to make it change state
from solid to liquid and from liquid to a gas. It is just as important to note that heat must be removed from a substance to
make it change state from a gas to a liquid and from a liquid to a solid.
Long ago it was found that we needed a way to quantify heat. Something more precise
than "less heat" or "more heat" or "a great deal of heat" was required. This was a fairly
easy task to accomplish. They took 1 Lb. of water and heated it 1 degree Fahrenheit. The
amount of heat that was required to do this was called 1 BTU (British Thermal Unit). The
refrigeration industry has long since utilized this definition. You can for example purchase
a 6000 BTUH window air conditioner. This would be a unit that is capable of relocating
6000 BTU's of heat per hour. A larger unit capable of 12,000 BTUH could also be called a
one Ton unit. There are 12,000 BTU's in 1 Ton.
To raise the temperature of 1 LB of water from 40 degrees to 41 degrees would take 1 BTU. To raise the temperature of 1 LB
of water from 177 degrees to 178 degrees would also take 1 BTU. However, if you tried raising the temperature of water
from 212 degrees to 213 degrees you would not be able to do it. Water boils at 212 degrees and would prefer to change into a
gas rather than let you get it any hotter. Something of utmost importance occurs at the boiling point of a substance. If you did
a little experiment and added 1 BTU of heat at a time to 1 LB of water, you would notice that the water temperature would
increase by 1 degree each time. That is until you reached 212 degrees. Then something changes. You would keep adding
BTU's, but the water would not get any hotter! It would change state into a gas and it would take 970 BTU's to vapourize that
pound of water. This is called the Latent Heat of Vapourization and in the case of water it is 970 BTU's per pound.
So what! you say. When are you going to tell me how the refrigeration effect works? Well hang in there, you have just
learned about 3/4 of what you need to know to understand the process. What keeps that beaker of water from boiling when it
is at room temperature? If you say it's because it is not hot enough, sorry but you are wrong. The only thing that keeps it from
boiling is the pressure of the air molecules pressing down on the surface of the water. When you heat that water to 212
degrees and then continue to add heat, what you are doing is supplying sufficient energy to the water molecules to overcome
the pressure of the air and allow them to escape from the liquid state. If you took that beaker of water to outer space where
there is no air pressure the water would flash into a vapour. If you took that beaker of water to the top of Mt. Everest where
there is much less air pressure, you would find that much less heat would be needed to boil the water. (it would boil at a
lower temperature than 212 degrees). So water boils at 212 degrees at normal atmospheric pressure. Lower the pressure and
you lower the boiling point. Therefore we should be able to place that beaker of water under a bell jar and have a vacuum
pump extract the air from within the bell jar and watch the water come to a boil even at room temperature. This is indeed the
case!
A liquid requires heat to be added to it in order for it to overcome the air pressure pressing down on its' surface if it is to
evaporate into a gas. We just learned that if the pressure above the liquids surface is reduced it will evaporate easier. We
could look at it from a slightly different angle and say that when a liquid evaporates it absorbs heat from the surrounding
area. So, finding some fluid that evaporates at a handier boiling point than water (IE: lower) was one of the first steps
required for the development of mechanical refrigeration.
Chemical Engineers spent years experimenting before they came up with the perfect chemicals for the job. They developed a
family of hydroflourocarbon refrigerants which had extremely low boiling points. These chemicals would boil at
temperatures below 0 degrees Fahrenheit at atmospheric pressure. So finally, we can begin to describe the mechanical
refrigeration process.
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Definitions
Definitions
Temperature
English Metric
Convert Reset
Temperature scales are a way of describing how hot a substance is. A lump of matter contains energy. There are many forms of
energy, one of them is Kinetic energy and measuring temperature is a way of measuring how furiously the molecules contained
in a lump of substance are moving about. This molecular activity causes what we perceive as the temperature of an object. A
refrigeration mechanic must be able to deal with temperatures in various scales. Traditionally the English system has been used
(Fahrenheit degrees) and a whole series of familiar capacity measurements like Horse Power, BTU's, Tons, and PSI have been
the norm. However the metric system which is supposed to be easier to work with is encroaching in many locations. In both
systems there are standard and absolute temperature scales. Try playing with the above temperature converter. Type a value in
any one of the input boxes and click on the Convert Button. Here are several interesting values to try: -40 ºF, 0 ºR, 40 ºF, 373
ºK, 21 ºC
Fahrenheit
The Fahrenheit temperature scale was developed by no less than Fahrenheit himself back in the early 1700's. It was based on
scientifically observable occurrences such as human body temperature and melting ice. Those points were assigned arbitrary
values which made sense at the time. The newly created number scale was widened for easier reading and when boiling water
was measured at 212 degrees, Fahrenheit changed the value of freezing water from 30 to 32 degrees to achieve the more
attractive scale of 180 degrees between water's freezing and boiling points. There are 180 degrees in 1/2 of a circle and this was
a temptation too great to resist.
Celsius
In theory the Celsius scale should be much easier to work with. It is based on calling the freezing point of water zero and the
boiling point of water 100. There are therefore 100 degrees between those 2 points. The Celsius temperature scale is also
referred to as the "Centigrade" scale. Centigrade means "consisting of or divided into 100 degrees. I wonder what a comfortable
room of 70º F would be in Celsius? If you don't happen to have a conversion calculator at your disposal you can always rely on
the following 2 formulae:
Kelvin
Scientists use the Kelvin scale, which is based on the Celsius scale, but has no negative numbers. Instead of basing it's zero
point on the freezing point of water, it bases it's zero point on Absolute Zero. which is the theoretical temperature where all heat
has been removed from a substance. Hence any amount of heat added creates a positive temperature. Negative numbers can
mess up a scientist's mathematical calculations. You will find that in refrigeration, we too must use absolute temperature scales
for some things. At Absolute Zero scientists believe that molecular motion would stop.
Rankine
Rankine is the English version of an absolute temperature scale. Add 460 degrees to Fahrenheit temperatures to obtain the
Rankine temperature. Input 0º in the Rankine box on the calculator above and you will see why.
Heat
Temperature is a qualitative measurement. Heat is a quantitative measurement. The temperature "quality" of a object describes
how hot it is but not the total amount of heat it actually contains. Here's a silly example which makes clear the distinction. Let's
say we have two blocks of iron. One is a mere cubic inch, the other is 10 feet cubed. We heat each of them to 150º F and you
verify this with some sort of thermometer. They both have the same temperature but do they both contain the same amount of
heat? When you throw the little cube in your swimming pool nothing noticeable happens to the temperature of the pool water
but when you toss in the huge iron chunk the pool water can be measured to rise somewhat over time. If there was a noticeable
amount of heat transfer from the large chunk of iron but not from the small chunk of iron then surely the large chunk contained
more heat than the small one even though they were at the same temperature. The temperature of an object is a reflection of the
kinetic energy of the atoms or molecules that make it up. Fast molecules = high kinetic energy = high temperature. On the other
hand heat represents the total amount of kinetic energy in an object. Heat is measured in BTU's. Recall that 1 BTU is the amount
of heat required to change the temperature of 1 Lb. of water through 1º F. So it would take 2 BTU to raise the temperature of 2
Lb. of water through 1º F. And it would take 30 BTU to raise the temperature of 3 Lb. of water by 10º F. BTU's (or their metric
counterparts) are the fundamental unit of heat used in the refrigeration industry. Larger quantities of heat are described with the
term Ton. 12,000 BTU = 1 Ton. A building might have a 3 Ton Air Conditioning system which would be equivalent to 36,000
BTUH.
Specific Heat
Different substances have different heat holding capabilities and thermal properties. Just because 1 Lb. of water will change
precisely through 1º F when 1 BTU is applied to it does not necessarily mean that the same thing will happen with 1 Lb. of
copper or 1 Lb. of steel or 1 Lb. of ice cream. There is a need to be able to specify those differences and the method utilized is to
compare all substances to water. Water is given a specific heat value of 1. This means that it that 1 BTU is required to change
the temperature of 1 Lb. of water through 1º F. The specific heat of water can also be described in the metric system. The metric
specific heat of water is 1 calorie per gram per degree Celsius. This value also works out to 1. In other words it would take 1
calorie of heat to raise the temperature of 1 gram of water through 1 degree Celsius. Specific heat is a dimensionless quantity. It
is purely a number having no unit of measurement associated with it. In Refrigeration specific heat values are used to calculate
capacity requirements for refrigerating known quantities of product. For example one might need to be able to select
refrigeration equipment capable of cooling 5000 Lb. of beef from 55º F to -20º F. A calculation like that must take into
consideration the fact that the specific heat of a substance usually is different above and below it's freezing point.
Latent Heat
Latent Heat is the heat given up or absorbed by a substance as it changes state. It is called latent because it is not associated with
a change in temperature. Each substance has a characteristic latent heat of fusion, latent heat of vapourization, latent heat of
condensation and latent heat of sublimation.
Sensible Heat
Sensible Heat is associated with a temperature change, as opposed to latent heat. This is so-called because it can be sensed by
humans. If the air in a building was to be heated from 60 ºF to 70 ºF only sensible heat would be involved. However, if the air in
a building was to be cooled from 80 ºF to 70 ºF and humidity was to be removed from the air at the same time, then both
sensible and latent heats would be involved.
Insulator
Electrical wires are coated with an insulating material so electricity stays in the conductor (wire). Thermal insulation on the
other hand tries to keep heat from transferring. Thermal insulation does not stop heat transfer, it only slows down the rate of
transfer. The greater the amount and quality of insulation, the greater the insulating effect and the slower is the thermal transfer.
There is insulation inside cooler and freezer walls and in the perimeter walls of conditioned spaces. If fiberglass batting is being
used it should be noted that the glass fibers are actually a poor insulator. It is the tiny pockets of trapped air in-between the
fibers that actually are responsible for the insulating effect.
Conductor
The chart below shows the specific heat values of several materials. Notice the very small specific heat value that copper has.
This means it would take a mere .093 BTU to raise 1 Lb. of copper through 1 degree. Copper has a bigger temperature change
for the same heat input compared to many other materials. Copper transfers heat readily and would not make a very good
insulator, it conducts heat too well. The smaller the specific heat number, the better of a conductor a material is. You can see
why heat transfer devices like evaporators and condensers are made from materials like aluminum and copper.
Water 1.00
Air .24
Aluminum .22
Iron .12
Copper .093
Concrete .23
Glass .20
Ice .50
Rock .20
Pressure
Pressure is what occurs when a force is applied over an area. More specifically, pressure is the ratio of the force acting on a
surface to the area of the surface. The equation for pressure represents this rather straightforwardly; P=F/A This equation means
that Pressure equals Force divided by Area. Let's look at a couple of very simple examples. As is demonstrated in the sketch
below, the same weight can exert completely different pressures depending on how much surface area it is spread out over. Note
that when you multiply FT by Lb.s you get a unit called FT Lb.. (pronounced Foot Pounds) This is a legitimate unit of pressure
however in refrigeration we use pounds per square inch not pounds per square foot. This is abbreviated to PSI. Just as with
temperature, pressure has many different scales that can be used and can be described with the English system or the Metric
system. The remainder of this book will be referring to the English system of measurements. We seldom deal with gravitational
forces as shown in the diagram although it is an important concept to be aware of. Rather, we deal with the pressures and
temperatures of gases and that is what the next section is all about.
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Gases 1
Gases
Part 1
The location where the surface of a liquid meets vapour is called what?
Under what circumstances can a PT Chart predict the pressure of a refrigerant?
One PT Chart shows the pressure/Temperature relationship of all refrigerants, True?
If over 99% of a container is gas rather than liquid then the PT Chart is no longer reliable,
True?
What does Saturated Conditions mean?
When transferring new refrigerant into a jug, what percentage of a full jug must not be
exceeded?
When transferring used and possibly oily refrigerant into a jug, what percentage of a full jug
must not be exceeded?
What does hydrostatic pressures mean?
What are the 2 main components of air?
How many pounds would a 1 square inch column of air the full height of the atmosphere
weigh?
What instrument can be used to measure atmospheric pressure?
What does PSIG mean?
What is the term for removing air and moisture from a refrigeration system?
What is significant about 760 mm Hg pressure?
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Gauge Manifold Set
● The graphic simulates you turning the blue hand wheel counter
clockwise which moves the low side stem away from the seat.
● This allows the higher pressure refrigerant from the jug to flow
into the left chamber of the gauge manifold set.
● From there the refrigerant can flow in 2 directions. It flows into
the low side of the system thereby charging it and it also flows
into the Bourdon tube of the low side gauge allowing it to
register the amount of pressure you are working with.
Charge Stop
On a gauge manifold set, what does turning the blue hand wheel clockwise do?
What are the standard colours of the hoses on a gauge set?
What is the effect of turning both hand wheels clockwise?
What is the effect of turning both hand wheels counter-clockwise?
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Access Valves
Access Valves
Service Valves
Service Valves are one of the types of access points to the refrigerant side of a system. They
can be located on compressors, receivers, accessories as well as located inline in piping. They
allow a mechanic to perform tests, pump downs and isolations. The diagram below allows a
close look at how a Service Valve works. Click the Buttons and note the various positions in
which a valve stem can be placed.
1. Back Seated.
The access port is
closed. The service
valve caps are in place.
3. Mid Seated.
Best position for
evacuation. All
chambers are as open
as possible.
5. Front Seated.
Good for compressor
pump down efficiency
test with the SSV
(Suction Service Valve).
DO NOT front seat the
DSV (Discharge Service
Valve) and then run the
compressor. That would
immediately create an
extremely dangerous
1 2 3 4 5 condition as the
discharge gas would
have no where to go.
Front Seating a King
Some service valves have more than one access port. This is to accommodate the sensing
lines from pressure controls. Their port can be located in the middle chamber between the 2
seats so that they will always sense pressure no matter what position the valve stem is in. You
can verify this with the Buttons. If you ever need to replace a control tied into such a location
there is a special procedure required in order to remove the sensor lead without losing
refrigerant gas. That is one of the purposes of "pumping down" a system.
Schraeder Valves
How many distinctive positions are there with the valve stem in a typical service valve?
What is the best position of the valve stem for evacuating a system?
What valve stem position can be extremely dangerous and under what circumstances?
In what position should the valve stem be when the system is in normal use and not being
serviced?
In what position should the valve stem be when measuring system operating pressures?
What is a line tap valve used for?
What is a Schraeder valve used for?
Where should a line tap valve not be installed?
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Metering Devices
Metering Devices
Thermostatic Expansion
Valve
1 2 3 refrigerant
4 flow. This makes 5 sense because 5
if there is greater bulb pressure that means
that the sensing bulb was subjected to a
warmer suction line and that there was less
Capillary Line than the optimum amount of liquid
refrigerant in the evaporator. Under those
circumstances there would be too much
evaporator area left over for superheating
the gas. When the bulb got hotter, the bulb
pressure increased, that pressure
transferred through the capillary line to the
upper side of the diaphragm, that applies an
opening force through the push rods, flow
increases and superheat decreases. The
TXV hunts until it settles into a balanced
condition. If the load changes it
accommodates the change.
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Metering Devices
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Compressors
Compressors
Reciprocating
Start Stop
Open
Hermetic
Semi-Hermetic
Scroll
Start Stop
Rotary
Screw
Centrifugal
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The Refrigeration Circuit
We will now start taking a closer look at the refrigeration circuit. The layout below is similar to the one introduced in the Refrigeration Basics section. Three
Service Valves have been added. Can you name them as well as all the other main components and accessories?
1 2 3 4 5 6 7 8 9 10 Reset
In the graphic below refrigerant has been added and the system is in operation. The various refrigerant states are represented by different colours and you will
notice that some additional colours have been added to the reference scale. One is for superheated gas and the other is for subcooled liquid. As the refrigerant
travels through the evaporator changing state it reaches the point where all the liquid has become vapour. That should occur before reaching the end of the
evaporator. Since heat content from the air passing through the evaporator fins is still being added to the refrigerant vapour, and since there is no longer any liquid
refrigerant in direct contact with the vapour, saturated conditions no longer are present and the gas will become superheated as more heat is added to it. The gas
becomes more and more superheated as it continues to travel through evaporator. As it passes by the location of the TX Valve sensing bulb, it warms the pipe it is
travelling through which in turn warms the sensing bulb of the TX Valve. This increases the pressure of the charge inside the bulb. Bulb Pressure is one of the
operating forces of the TXV which allow the valve to throttle to maintain the desired superheat set point.
After passing the bulb location the gas continues to pick up heat through the suction line and the superheat increases further. This is especially true if there is a long
suction line going through a hot location. The temperature of the superheated gas is usually colder than ambient conditions and we know which way heat travels. It
is therefore standard procedure to insulate all suction lines but that only decreases the amount of heat transfer, it does not eliminate it. Too much superheat is
undesirable and the absence of superheat risks liquid slugging the compressor. You can see that a refrigeration system must be kept in balance if it is to work
properly and reliably. The superheated gas is drawn into the compressor where it is compressed and the Heat of Compression adds even more superheat to it. That
is heat that occurs from the work exerted on the gas in the process of compressing it. The highest temperature, pressure and superheat location in the entire system
is right there at the discharge valve. (not the Discharge Service Valve, but rather the discharge valve on the valve plate which the piston discharges through)
The discharge gas loses superheat in the first part of the condenser. It continues to cool and droplets of liquid form as enough heat is rejected. At some point all of
the refrigerant will have changed back into a liquid. There is another process that occurs next. You might think of it as the opposite of superheat. It is called
Subcooling. Recall that superheat can only occur when saturated conditions are not present in the immediate area. Likewise subcooling can only occur when
saturated conditions are not present. So as the liquid refrigerant travels away from the vapour/liquid interface and continues to reject heat into the condenser air
stream, it gets cooled below what it would be during saturated conditions. Each degree cooler is a degree of subcooling. 10º F of superheat are desirable just as 10º
F of subcooling are desirable. However subcooling has nothing to do safety margins to prevent liquid slugging. It is desirable for system efficiency and we shall see
how shortly. First lets summarize what happened to the refrigerant as it made it's way through the condenser:
After leaving the condenser and entering the receiver the refrigerant finds itself in a location where there is once again a liquid/vapour interface. There are therefore
undeniably Saturated Conditions in the receiver but below that interface the subcooled liquid resides. The vapour in the receiver can be thought of as stagnant. It is
trapped there not really participating in the flow of refrigerant travelling around the loop. Rather it just watches as subcooled liquid travels by below it. There is a
dip tube in the receiver which insures that liquid is the only thing that enters the liquid line. It travels through the King Valve at the exit of the receiver and begins
the journey down the Liquid Line. It travels through the Filter/Drier and Sight Glass and onwards.
Every system is different. Some may have very long Liquid Lines. If they are sufficiently long the refrigerant will experience a pressure drop. We have learned
what can occur to a liquid if it's pressure is lowered. Some of the liquid might flash into a gas. That would be an obvious efficiency loss as we would like all the
liquid travelling towards the evaporator to change state in the evaporator and pick up heat from the product being refrigerated. Unfortunately this process can and
does occur. If inadequately sized lines are used the problem would be even worse. Any flash gas that forms in the liquid line takes away from the delivery capacity
of the TXV. The valve is sitting there capable of metering refrigerant 100% of the time. If part of it's time is wasted by gas passing through it instead of liquid being
metered then system capacity suffers. So liquid line flash gas is something to be avoided. If a condenser is doing it's job properly some degree of subcooling will
have occurred. Each degree of subcooling achieved is a step away from allowing flash gas to occur in the liquid line.
Now you know why a sight glass can be handy. It can be a quick indicator of whether you have a full column of liquid reaching the TX Valve. To complete the
refrigerant loop we still must go through the TXV. There is such a large pressure drop as refrigerant passes through the restriction of the metering device it is
inevitable that some of the refrigerant will flash into a gas. Although this occurs in the evaporator the heat it absorbs is from adjacent droplets of liquid refrigerant
that have also just passed through the valve rather than from the intended product. Evapourator flash gas must be tolerated, liquid line flash gas should be avoided
where possible by proper piping and design practices.
What is the name of a valve installed directly on a compressor to allow high side access?
What is the name of a valve installed directly on a compressor to allow low side access?
What is the name of an accessory that has a dip tube to ensure that only liquid exits the
component?
What component sometimes is directly mounted to liquid line filter drier?
What is the name of a service valve mounted on the outlet of a receiver?
What is the name of the component where vapour changes to a liquid?
Is it true that when refrigerant has passed through the evaporator, the superheating
process is complete?
When a piston compresses a gas the work that is done creates heat. That heat is called
what?
What is it called when a liquid is cooled below Saturated Conditions?
What is the location called where gas meets liquid?
What is a desirable amount of superheat?
What is a desirable amount of subcooling?
Is subcooling desirable? Why or why not?
What is vapour in the liquid line called?
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Pump Down
A system can be pumped down by front seating the King Valve and running the compressor. When you close the King Valve you stop refrigerant flow at the
receiver. Hence the low side of the system gets emptied out by the compressor and all the refrigerant that was in the low side gets added to the high side.
The receiver should be sized so that it can contain the entire system charge and still only be 80% full. The condenser can also hold a substantial amount of
refrigerant. When you stop the compressor the low side should stay at the pressure you reduced it to. If it rises it may be an indication that the valves are
worn in the compressor and pressure is leaking back through from the high side of the system. Another possibility is that you still have some liquid in the
low side and it is slowly boiling off and increasing the pressure. When you close the King Valve everything downstream of it temporarily becomes part of
the low side. So the Filter/Drier and Sight Glass and liquid line which were all full of liquid may still have some liquid left. How much you pump down is
up to you. It depends what you are trying to accomplish. If you need to change out a Filter/Drier then you need to pump down to 1 ATM (0 PSIG) so that
when you open up the system you do not lose refrigerant and you also do not suck in any air. If you needed to change an evaporator you would need to
pump down the low side completely. Click on the Buttons and study the different effects when you pump down to varying degrees. Note that the service
valve caps and stems change, the Suction Pressure gauge changes and the state of refrigerant changes. Click back and forth to see all the changes easily. The
only thing that does not change is the high side pressure. That's because no matter how much or little liquid there is in the high side, there are still saturated
conditions.
Normal Operation: Low Side to: Low Side to: Compressor to: Compressor to:
This procedure brings the low side to equilibrium with atmospheric pressure. Once achieved you can open up any part of the low side for servicing.
Examples are, changing out Filter/Drier or sight Glass or TXV. If you are going to be involved with tedious or time consuming repairs you should pump
down the low side completely and when done, evacuate the low side with a vacuum pump.
To completely empty out the low side front seat the King Valve and run the compressor for as long as required to achieve maximum vacuum. Used when
major work is required on the low side. (e.g. replacement or relocation of evaporator, or tedious or time consuming repairs requiring the low side to be
opened up for an extended time.)
This procedure allows quick servicing of anything on the low side of the system. An example is a change of a sensing line located on the Suction Service
Valve (SSV) in a location that can not be isolated from the low side pressure. (e.g. tied in to the SSV between the 2 seats) Front Seat the SSV and run
compressor until 1 Atmospheric Pressure is reached, stop compressor, effect changes.
Compressor to Vacuum
This procedure can be used as a Compressor Efficiency Test. If you suspect a lack of capacity is being caused by a worn out compressor, front seat the SSV
and see how deep of a vacuum the compressor can pull on it's own internal volume. It is a very quick and easy test as the volume is relatively small
compared to trying to pump down the entire low side. A new compressor will pull at least 15" Hg Vac. It will also hold that vacuum if you stop the
compressor from operating and not allow it to bleed back. If the vacuum will not hold, it indicates that high side pressure is leaking back through worn,
chipped, cracked or broken discharge valves on the valve plate. Be careful that you are not getting fooled by poorly installed test gauges allowing air to leak
in or the SSV inadequately seating, either of which would spoil the bleed back test. In summary: A compressor that passes a pump down test achieves close
to 15" Hg or more and can hold that vacuum when turned off.
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Evacuation
Evacuation
The piping system of a new refrigeration system must be pressure tested and evacuated before charging with refrigerant. The same is true for systems that
have been opened up for major repairs. If service was required on the low side it may be possible to pump down and isolate the refrigerant or residual
refrigerant to the high side leaving only the low side to be pressure tested and evacuated. The size of the system and whether the refrigerant is contaminated
and an educated guess as to the amount of refrigerant left in the system will have a bearing on whether or not to recover the residual charge and start over
with fresh refrigerant. The evacuation is necessary to remove all traces of air and moisture and nitrogen used to pressure test the system. Otherwise there
would be non-condensables in the system which will cause high head pressure and moisture which is a component which leads to the formation of acids.
When the system is charged it should contain liquid and gaseous refrigerant and refrigerant oil and nothing else. Any time a system is opened up the filter/
drier should be changed. When evacuating use both hoses and put all service valve stems in the mid seated position for least restriction. Tighten the packing
glands on the service valves, and replace the service valve caps. Short, large diameter hoses are best for evacuating and greatly reduce the time required for
evacuation. Most manufacturers recommend evacuating down to at least 250 microns. You may even come across specifications requiring a 50 micron
evacuation. To achieve vacuums that low you would have to use large diameter and very short copper connections between the vacuum pump and the
system. Standard flexible hoses just do not provide enough of a seal and also present too much restriction to flow to achieve those types of vacuums.
Triple Evacuation
● 1st evacuation
● break vacuum with dry nitrogen
● 2nd evacuation
● break vacuum with dry nitrogen
● 3rd evacuation
By introducing dry nitrogen into an evacuated system a couple of times you help to "blot up" residual moisture. Dry nitrogen is capable of absorbing a small
quantity of moisture. You might consider the habit of introducing nitrogen just through the high side (especially when in the nitrogen pressure testing
process) That way you can see if there is high side to low side flow. If you determine that there is a restriction, it will be easier to rectify the situation now
rather than later when you try charging the system. If the system has an LLSV this test will not be possible (unless you energize the LLSV coil)
You have learned that there is a relationship between the pressure being exerted on the
surface of a liquid and the liquids ability to evaporate. The removal of unwanted moisture
from within a refrigeration system relys on this relationship. When the pressure is
sufficiently reduced by a vacuum pump water droplets will change state to a vapour and
be drawn off by the vacuum pump. However there is another component to the equation
and that is temperature. At cooler temperatures the water will have a greater tendancy to
stay in liquid form. So if it is possible to warm up a piping system this will improve
moisture removal. That is not always possible so it is important to note the precise effect
temperature will have on waters boiling point at various pressures. The chart on the left
demonstrates the effect of temperature. Consider for example a pleasantly cool day of 64º
F and you are evacuating a system in preparation for charging it. If you are not using a
micron gauge, your gauge manifold set might be showing a pressure of 29+ "Hg VAC.
The needle might even be buried against the stop post but there is no way you can be sure
of the exact pressure because of the relative coarseness of the scale. If in fact the pressure
was only down to 16,000 microns, you can see from the chart that you would NOT HAVE
EVEN STARTED to boil off any water inside the system. This demonstrates the
importance of using a micron gauge to determine the status and progress of an evacuation.
A micron gauge indicates when an evacuation has achieved the desired level of vacuum. It can also be
used deduce whether the system is indeed tight, has a leak, or still has moisture. If you valve off the
evacuated system to the micron gauge and monitor the pressure you can tell the difference by the type
of graph that develops over time. It is a good idea to test your vacuum pump directly on the micron
gauge. If you can not pull an adequate vacuum, make sure you do not have leaks in your gauges or
connections and/or change the oil in the pump. Vacuum pumps use a special dehydrated vacuum pump
oil and it must be changed as often as required to enable good evacuations each time. You don’t get
hundreds of hours use out of each oil change. A single dirty evacuation can be grounds for changing
your vacuum pump oil.
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Charging
Charging
Part 1
Click back and forth between buttons 1 and 2 and see how many differences in operation you can find between the two systems. Can you come to a
conclusion about the operation of these two systems? When you are done click the Answers button to find out if you came to the correct conclusions.
1 2
Answers
There are some points that should be made about the preceding example. A sight glass that is not full (while the system is operating) may indicate an
undercharged system. However there are other things that can cause that symptom as well. For example, if the LL Filter (Liquid Line Filter) was partially
clogged but still allowing some flow, the sight glass wouldn't be full yet the system could be fully charged. That condition is called a High Side Restriction.
Fortunately there is a simple way to identify this situation. A partially clogged filter/drier can cause enough pressure drop to lower the temperature of the
liquid passing through it making the drier and downstream liquid line cold. This is the refrigeration effect taking place and the drier and liquid line can even
get cold enough to allow frost to form. If the liquid line feeding the filter/drier is 105 ºF and the shell of the filter/drier cold to the touch, the high side
restriction will be obvious.
The key to diagnosing a malfunctioning system is to gather as many symptoms as you can. Several symptoms consistent with a potential cause are more
likely to lead you in the right direction than a single indicator. You must also eliminate other possible causes as with the high side restriction example.
It is logical that an undercharge will cause higher than normal superheat. Normal operation is to have as much of the evaporator as possible filled with liquid
in order to pick up heat when it changes state. At the same time it must not be so full that there is no room left over for superheating the vapour. With
undercharged conditions there is a lack of liquid and a surplus of vapour in the evaporator. That translates to a great deal of evaporator area that is available
for superheating. Hence undercharge and high superheat go hand in hand.
The refrigerant pressure in the evaporator is affected by the thermal loads imposed on the evaporator, the removal of vapour from the continual suction of the
compressor as well as the continual addition of refrigerant from the metering device. With an undercharged system the metering device can not feed the
evaporator at the rate it is supposed to because there is not a full column of liquid in the liquid line. There also may be lower than normal high side pressure
pushing liquid through the TXV. Without the required feed rate to the evaporator, the compressor tends to empty out the low side. That's why the suction
pressure becomes lower than normal. This also explains why an over sized compressor will also cause lower than normal suction pressure. (The greator
suction capacity removes vapours at a faster rate than the rest of the system was designed to keep up with.)
The Discharge Pressure is the result of compressing the low side vapours. So lower suction pressure tends to lower the high side pressure. However there are
other forces also affecting the high side pressure. This is especially true if the system has some type of head pressure control. For example, a water cooled
system has a water regulator valve that may totally mask the high side pressure from the symptoms you would expect with an undercharge. It will reduce the
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Charging
water flow trying to maintain it's head pressure setting and can possibly maintain normal high side pressure with undercharged conditions. Air cooled
systems that have some form of head pressure control will also mask the expected symptoms. Measuring several parameters will reduce the number of
possibilities and narrow the number of possible causes of problem.
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Determining Superheat & Subcooling
OEM's (Original Equipment Manufacturers) and refrigerant manufacturers provide PT Charts to the refrigeration industry. PT Charts make it possible to
diagnose the refrigerant side of a system even if you are not familiar with the particular refrigerant being used. There are a great many refrigerants out there
and they each have there own pressure and temperature characteristics. (Pressure Temperature Relationship). Examine the PT Chart shown below. Across
the top row are listed several common refrigerants. Down the first column on the left is a temperature scale in ºF. If you want to know what pressure
refrigerant R134A should be when it is 40 ºF you find R134A on the top row and go down until you line up with the 40ºF row to find 35.1 PSIG.
Remember, that will be true for Saturated Conditions only.
To calculate Superheat measure the suction pressure at the TXV bulb location and convert
that pressure to temperature by using the PT Chart. Measure the actual temperature at the
bulb location and compare the two. The difference between the two is Superheat.
To calculate Subcooling measure the high side pressure at the condenser outlet and convert
that pressure to temperature by using the PT Chart. Measure the actual temperature at the
condenser outlet location and compare the two. The difference between the two is Subcooling.
The above systems are called Close Coupled because the components are so close together. Taking a pressure reading at the SSV in the above examples was
virtually the same as taking a reading right at the bulb. However many systems are not close coupled and it may not be possible to obtain a pressure reading
right at the bulb location. There may be a couple of pounds of pressure drop in a long Suction Line due to frictional losses. A reading at the SSV location
would then be different than if taken at the bulb location. To try and be more accurate with Superheat calculations we can add in a estimated pressure loss
factor as shown below.
P1
P2
Click Button P2 to add a second temperature probe to the meter. Can you calculate the amount of subcooling that this system has? Try to come up with a
solution before clicking on the Answer Button.
Answer
(see above)
The above calculations yielded nice even figures for superheat and subcooling. You will not see those occur in the field on a consistent basis, those amounts
are just what to aim for. When troubleshooting you are keeping your eyes open for symptoms that stray far from normal.
The above two subcooling examples both had high side pressures that converted to 105 ºF. I could have used any other refrigerant as an example and the
high side pressure I chose would still have been the corresponding pressure for 105 ºF. There is a reason for that. All* systems have a design condensing
temperature of 105 ºF. Systems are designed to run under a range of condensing temperatures, typically 55 ºF to 90 ºF. If you want to reject heat into 90 ºF
air then you must be hotter than 90 ºF. You only need about a 10 ºF TD (Temperature Difference) between the evaporator and entering air to effect
reasonable heat transfer but there is an additional factor to consider with the condenser. You have the additional heat of compression to reject on top of the
heat you picked up with the evaporator. So instead of being 10º F hotter than 90º F they design to be 15º F hotter. 90 + 15 = 105. Never forget that because
with a PT Chart you can determine what a normal "text book" head pressure should be for any refrigerant you come across. It is however only a starting
point. On a very hot day, high side pressures can be a lot higher than on a cool day. Mechanics working in very hot climates are going to have a completely
different idea of what a normal head pressure is compared to mechanics working in more moderate climates.
Evaporator temperatures are selected to suit the application. They will be different for air conditioning than they are for refrigeration. Products such as
flowers and meat require high humidity conditions to keep the product from drying out. This is a problem because moisture is removed from the air as it
passes through the evaporator fins and is cooled below the dew point. However less humidity is removed from the air when there is less of a difference
between the evaporator temperature and the entering air temperature.
Moving air also dries things out. Refrigerated boxes that should have higher humidity conditions therefore use oversized evaporators to allow for less of a
temperature difference and slow moving fans to reduce air movement. There is also a type of evaporator called a gravity coil which uses no fans at all. They
are designed with wide fin spacing and a lot of pipe surface and rely on establishing natural convection currents to distribute the cooled air. These
convection currents form by gravity causing the colder denser air to sink which displaces the warmer less dense air which rises up and then sinks through
the gravity coil becoming colder etc. These convection currents are slow moving and do not dry out the product as much as fast moving air. Anytime you
see a gravity coil, you know it has been selected either with high humidity conditions in mind or because there was difficulty in providing power for
evaporator fan motors. (such as with mobile refrigeration with a belt driven compressor and condenser fan motor and no electricity available for the fans)
Although there are many variations possible with entering air temperatures, evaporator temperatures, slow or fast moving air, high or low humidity
conditions and high or low load conditions two things remains relatively constant; superheat and subcooling. At least it is hoped that they will remain
relatively constant. That is why superheat and subcooling are corner stones when it comes to diagnosing refrigeration equipment.
Will a PT Chart predict actual temperature from measured pressure with superheated
conditions?
How do you measure superheat?
How do you measure subcooling?
What is a close coupled system?
Where would you measure the temperature when making a subcooling calculation?
If a system is operating with 9 ºF superheat is there a problem?
Is there anything significant about 105 ºF?
Name 2 things that can be done to reduce humidity removal in a "high humidity
refrigeration system"
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Accessories
Accessories
Accumulator
Accumulators are used in the suction line just upstream of a compressor to help prevent liquid slugging.
They have an inverted trap which has it's inlet in the vapour section which reduces the chance of liquid
getting back to the compressor. There is a small opening on the underside of the trap which causes a
Venturi effect and sucks up oil that gets caught in the bottom of the accumulator. Oil must be returned
to the compressor sump where it belongs.
Check Valve
Check valves allow flow in one direction only. One example of where they are used is in heat pumps.
In a heat pump the liquid line reverses direction of flow when the modes change. Check valves are used
to force refrigerant flow through the appropriate metering device.
Stop Flow
CPRV
Crankcase Pressure Regulator Valves are installed in the suction line just upstream of the compressor.
They are adjustable and are set to limit the suction pressure to a pre-determined maximum. This set
point is usually the amount of pressure that causes the compressor to use all of it's FLA rating. That is
in fact how to set them. Monitor the amperage draw of the compressor and cause an overload condition
by allowing high evaporator loading. Dial the CPRV until the compressor is not exceeding it's FLA
rating. CPRV's are used with electric defrost freezer systems to keep the compressor from overloading
at the termination of every defrost when the evaporator has higher than normal temperatures. Freezer
compressors have large displacements which are intended to suck the rarefied vapours of refrigerant at
low temperatures. It is easy therefore to make the compressor overload at the initial start up. That's
because the box will have a very high load relative to cold freezing temperatures, the refrigerant will
not be rarefied and can overload the compressor driver beyond it's normally intended operating range.
The system does not necessarily have to have the final charge adjustment but there must be enough
refrigerant in the system to bring on the fans via the FDT (Fan Delay Thermostat) and load (actually
over load) the compressor. You can then adjust the CPRV to a setting that does not allow the
compressor to over load ever again. The CPRV is set to allow no more than a pre-determined maximum
outlet pressure. Think of a CPRV as a "dial-an-amp".
Crankcase Heater
If a compressor is located in a cold location refrigerant will migrate into the oil in the compressor
sump. Since the internal volume of the compressor is actually part of the low side of the system, at start
up when the crankcase pressure is reduced, liquid refrigerant entrained in the oil will flash causing the
oil to foam and be carried away with the evaporating refrigerant. This can be devastating to the
compressor. To prevent this oil slugging crankcase heaters are used to warm the oil and evaporate the
refrigerant out of it. The top image shows the leads from an internal CCH which is supplied from the
factory built in place. The bottom picture is a strap on type crankcase heater and can be added on to
hermetic compressors when required.
Air Conditioning Condensing units located outdoors are often equipped with crankcase heaters. If an
air conditioning system stays idle all winter, the CCH should be turned on the day before the initial
season start up. CCH's are low wattage and take a long time to boil off liquid refrigerant.
Distributor
Distributors are used to distribute refrigerant to parallel passes in evaporators. By distributing the flow
through multiple passes the frictional losses and therefore the pressure drop is kept to a minimum in
medium and large sized coils. Large coils can have many distributor tubes. Since the flow must be
equal through all the passes the distributor tubes must all be the same length. Since the manifolds are
all at different distances from the distributor, the distributor tubes can sometimes appear to be a snarly
mess. But, functionality over-rides neatness, so the excess tubing simply has to be bunched up as
compactly as possible without kinking. This is done at the factory so you will probably never have to
deal with it unless repairing a leak. It is just important to know that equal flow through all the passes is
mandatory.
EPRV
Evaporator Pressure Regulator Valves are used to prevent evaporator pressure from falling below a pre-
determined value set by the EPRV. That makes it possible to operate multiple boxes (multiple
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Accessories
evaporators) with different temperature set points from the same condensing unit. EPRV's are also used
to prevent coil freeze ups during low load conditions. The valves are adjustable by removing the cap
and accessing the adjustment screw. The Schraeder access port is on the inlet side of the valve so the
evaporator pressure can be monitored while setting the valve.
Hand Valve
There are many uses for refrigerant rated hand shut off valves. For example oil separators must have a
shut off valve in the oil return line. Otherwise, if the float valve happened to be open it would be
impossible to pump down the system for service because pressure would bleed back through the oil
return line. Another use is for isolating built in pressure gauges so that they can be easily changed out
should the need arise. The life of a high side gauge can be extended by closing the isolation valve so
that the gauge is not subjected to constant compressor pulsation's. The valve in the picture has flare
fittings but valves are also available with sweat fittings. When there is an arrow on an accessory, that
indicates that the component is uni-directional and will only seal or operate properly if flow is aligned
with the arrow.
Hot Gas Bypass Valves offer a method of capacity control. During low load conditions they impose a false load on
an evaporator by allowing some hot discharge gas to enter after the TXV. The compressor can therefore continue
operating. The hot gas bypass valve extends the run cycle of an air conditioning compressor which improves
humidity removal. Hot Gas Bypass Valves also limit the minimum evaporator pressure which prevents coil icing.
Contaminants such as moisture, dirt, acids, sludge and wax can attack refrigeration systems causing
higher condensing temperatures, plugged metering devices and system corrosion. Filters are designed
to trap unwanted contaminants. Proper evacuation procedures must remove as much moisture as
possible because the moisture absorbing capability of the desiccant in a filter/drier is measured in mere
droplets. Filters are available with flare as well as sweat fittings. Larger sizes are available with
replaceable cores. The first drawing shows a flare drier with the protective end caps removed. Those
caps should only be removed when the drier is ready to be installed immediately.
LLSV
Liquid Line Solenoid Valves are used in automatic pump down systems. They can also be used in a
Parallel Drop system where at the end of a refrigeration call, the LLSV, compressor and CFM all drop
out at the same time. That system does not pump down but does offer positive shut off to stop liquid
migration. The drawing shows a sweat type but they are also available with flare fittings. Look for a
direction of flow arrow on the valve body as they only block flow properly in one flow direction.
Solenoid valves are typically NC (normally closed) and must be energized to allow flow.
Muffler
Compressor pulsation's are amplified by the piping system and the resulting noise can become a
nuisance. To quiet things down mufflers are often placed in the discharge line, especially in air
conditioning systems where noise is more likely to be a problem. Mufflers contain baffles which break
up the pulsations and reduce the noise output. They are similar in appearance to some liquid line filter
driers so don't mistakenly identify a discharge line as a liquid line nor a muffler for a filter.
Oil Separator
Oil is required to lubricate the moving parts within a compressor. Unfortunately oil and refrigerant have an affinity for each other and oil is constantly being
depleted from the compressor sump and circulating about the piping system. Oil can get logged up in parts of the piping system and not return to the
compressor sump. The rate of oil depletion must be equalled by the rate of oil being returned otherwise it is only a matter of time until the compressor is
destroyed from lack of lubrication. Piping systems are designed as a trade off between pressure drop (system efficiency) and velocity (oil return). In other
words larger pipes have less pressure drop which is good for system efficiency and smaller pipes cause higher velocities which improve oil movement and
the return of oil to where it belongs. Another problem with oil getting out in the piping system is that it acts as an insulator reducing heat transfer in coils.
Oil separators capture most of the oil as it leaves the compressor and return it back to the compressor sump where it belongs. There are three types of oil
separators; impingement, helical, and coalescing.
Impingement separators use screens in the upper half to cause fine particles of oil to collect and form
larger ones. The velocity of the discharge gas is reduced when it enters the large volume of the oil
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Accessories
separator which helps the oil droplets to impinge on the screen. The droplets grow large enough in size
to fall to the bottom. When sufficient oil has been collected a float operated needle valve opens and
allows the difference in high side and low side pressure to return the oil to the crankcase. The black
arrow in the graphic is above the fitting for the oil return line. Impingement separators are
approximately 80% to 85% efficient and are in common use. The drawing shows a serviceable type
impingement oil separator. They are also available as a sealed unit.
Helical separators depend on the interior shell design to force the gas/oil mixture along a spiral path.
That creates a centrifugal force which forces the oil droplets to the outside of the spiral where they
collect and drain to the float valve below. A supposed drawback to this type of unit is that centrifugal
force only works effectively on relatively large oil droplets. This means that smaller droplets remain in
the gas and are recirculated through the system. However manufacturers of helical separators claim that
up to 99% efficiency can be achieved.
In coalescing separators, the refrigerant/oil mixture is passed through a filter of exceptionally pure,
extremely fine glass fibres, which form a capturing matrix. This matrix excites the oil molecules,
causing them to collide and form larger droplets which are forced to the filter's outer drain layer where
they drain by gravity into the sump. Coalescing units are capable of delivering between 95% to 99%+
efficiency, depending on the grade of filter core used and the design details. There are some coalescing
oil separator manufacturers that claim their units have 99.99% efficiency.
The layout diagram below shows an impingement type oil separator installed in the discharge line. Note that the oil return line must have an isolation valve.
If the system ever must be pumped down for service the hand valve can be closed to keep high side pressure from bleeding back to the low side. Although
bleed back may only occur if the float valve happens to be open, there must be a remedy for that possibility. One must be absolutely certain never to put a
system into operation with the oil return line valve shut. There is no excuse possible for ever making that mistake.
P-Trap
P-Traps can be used at the evaporator outlet to provide a place for oil to drain to during the off cycle.
An oil film on the inside of the evaporator tubing acts like an insulator. That effect is certainly not
desirable in the evaporator. The proper place for the oil is back in the compressor crankcase. If the
bottom of the P-Trap partially fills up with oil, the left over area above the oil level becomes smaller.
When the system starts operating the refrigerant flow must squeeze through this smaller volume hence
it speeds up. This fast moving refrigerant gas, whipping around the smooth curve of the P-Trap picks
up and entrains the oil and gets it moving back to it's proper location.
P-Traps and risers should be used to improve oil return. Large vertical suction line rises may have
several traps to assist with oil return. Consult piping manuals to determine when and how many traps to
use in such a situation.
Receiver
Receivers are reservoirs on the high side of a system which hold refrigerant. They have a dip tube to the
outlet side which ensures that a full column of liquid refrigerant feeds the liquid line. They store
refrigerant which may be needed at another time by an evaporator with a TXV when the evaporator
load increases and more flow is required. Capillary Line systems do not require receivers because that
type of metering device does not modulate the flow. Therefore no reserve of refrigerant will be needed
because increased flow rates will not occur. Receivers also provide a location to store refrigerant when
a system is pumped down for servicing. Extra large receivers store refrigerant which may be needed
later by refrigerant side head pressure controls for partially flooding condensers. They should be sized
to hold the entire system charge when it is pumped down and still have 20% left over for expansion of
the liquid refrigerant if the temperature increases. Receivers have safety relief valves and/or fusible
plugs to vent the refrigerant in the event of an over temperature/pressure condition such as would occur
in a a fire. Normally, high pressure conditions are sensed by a high pressure safety control and the
pressure stops rising when the compressor is shut down. In the event that pressures keep on rising there
needs to be a way to keep the receiver and piping from exploding and becoming shrapnel, hence the
fusible plug and/or safety relief valve. It is a good idea to pipe a safety relief to the outdoors, however
codes must be followed. No shut off valve may be installed in a relief vent line and the relief venting
pipe must not be sized down from the piping size of the relief itself. The piping line that goes from a
condenser to a receiver is called a condensate line. (Refrigerant that has condensed in the condenser
then flows through the condensate line.) Moisture that is condensed out of the air by an evaporator
drips into a condensate pan and then flows out a drain line also called a condensate line.
Sight Glass
A sight glass can be placed in the liquid line to show the condition of the refrigerant. There may be a
moisture indicating dot in the center of the glass. The dot changes colour when moisture is present.
Sight glass moisture indicators are available with different colours and some are capable of several
colour graduations indicating various moisture concentrations. There are colour scales to compare the
indicator dot colour to. A full sight glass should not be relied on to indicate whether a system is charged
properly. Superheat, subcooling, weighed in charges and manufacturers charging charts are much more
reliable. A sight glass can not indicate an over charge and a bubbling sight glass does not always
correctly indicate an undercharge. For example, a high side restriction upstream of a sight glass can
cause it to bubble. It is therefore proper practice to locate a sight glass downstream of a liquid line filter
drier so that a partially plugged drier will cause bubbling in the sight glass and perhaps be noticed.
Filter/driers have direction of flow arrows stamped on them. Be sure to install the sight glass on the
downstream side of the filter/drier and install the filter with respect to the correct direction of flow in
the liquid line.
Suction Filter
Suction filters are primarily used to protect a new replacement hermetic compressor from residual acid
from a previous burn out of a hermetic compressor. Residual acid must not be allowed to start attacking
the new compressor winding insulation. Suction filters must be replaced as often as required in order to
to absorb all of the residual acid. A built in Schraeder access port is usually located on the upstream
side of the filter so that the pressure can be compared to the downstream pressure which can be
measured at the SSV. The pressure drop across the suction filter can thereby be determined indicating
when it must be replaced. Some filters even come equipped with both upstream and downstream access
ports. Since system capacity is very sensitive to suction line pressure drop they must eventually be
removed. Larger systems may have permanent suction filters which accept replaceable cores. When no
longer needed for clean up of a burn out the cores are usually replaced with a felt filter that has minimal
pressure drop.
Suction/Liquid Heat Exchangers increase the efficiency of a system. Heat from the liquid line is
transferred to the cold suction line through the heat exchanger. A first impression might be that it seems
like Peter is being robbed to pay Paul and no net benefit will occur. It is not desirable to warm the
suction line. However cooling the liquid line is desirable and there is a net benefit to overall system
performance due to the decrease in liquid line flash gas attributable to the heat exchanger. Many small
capillary line systems utilize this effect by having the capillary line soldered to the suction line.
Vibration Absorber
Vibration absorbers are used to join piping to compressors to reduce vibration imposed stress on
welded piping joints. They must be aligned in parallel with the compressor crankshaft and the far end
from the compressor must be securely mounted. That leaves the opposite end free to flex in the
intended manner with the oscillations of the compressor. Those can be especially severe at start up and
shut down when the compressor "kicks" from momentum. The cut-away in the drawing shows the
flexible construction of the inner tube and how it is reinforced by an outer casing of woven metal
fibres. If a vibration absorber leaks it must be replaced.
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Piping
Piping
With a water piping system the size of the pipe is selected with the required delivery rate in mind. If pipe bigger than required
is selected the only thing that suffers is the job cost. Refrigeration piping also needs to be selected to carry the required flow
rate but there is a further complication. Refrigerant and oil have an affinity for each other. Refrigerant oil is constantly being
depleted from the compressor sump and carried away by the refrigerant. The piping system has to be designed to return that
oil back to where it belongs. The size of the pipe is an important factor in accomplishing that goal. The size selection of
refrigeration piping is a compromise between pressure drop and velocity. If the piping is too small there will be excessive
pressure drop and the capacity of the system will suffer. On the other hand if the piping is too large then velocities will be
slow and oil will not be carried along by the refrigerant. If oil is being depleted from the compressor and not being returned
then the compressor will eventually run out of oil and seize up.
Piping should be laid out to use a minimum number of fittings. If you can lay out a section of piping with 3 elbows instead of
5 elbows then that is the thing to do. It is most crucial to minimize pressure drop in the suction line so plan your piping layout
around the optimum route for the suction line.
Slope
Horizontal runs of suction line should be sloped with at least 1/4" per foot back towards the compressor so that gravity can aid
with oil return.
Dips and sags in suction lines are to be avoided. Dips and sags create
traps where oil will collect. The piping system must be laid out to
optimize oil return. This is so important with suction lines as it is mere
vapour that must make the oil travel along with it.
Kinks
If you are manually bending some soft copper and you accidentally kink the pipe, cut out and discard the kinked section and
try again. It is infinitely easier to correct the problem now than it is after the system is in operation. There is no excuse for
allowing unnecessary pressure drop to affect a system for it's entire operational life.
Flaring
When flaring pipe keep things plumb. Always leave a section of straight
pipe by the flare to allow the flare nut to be backed away from the
fitting. Leave enough room for future re-flaring of the pipe should it
become necessary. A flaring block needs a straight section of pipe to
clamp onto.
Reaming
Always ream cut pipe ends. Roller cutters deform the pipe inwards and create a ridge which will cause an unnecessary and
unwanted pressure drop. If no cut pipe ends were reamed, that unwanted pressure drop would be multiplied by the number of
cut joints in a system which can be substantial. Also be careful to knock chips clear of the pipe before inserting a fitting.
Outside Diameter
Do not "bull head" a tee in a discharge line. As the name infers, when
oriented in this manner, the flow would ram into the back wall of the tee
fitting. The compressor pulsation's in a discharge line are severe enough
that the fitting will deteriorate and cause a leak. Even a 90 º Elbow
positioned too close to the compressor can fail from compressor
pulsation's. The discharge line is the only line where this restriction
applies. It is uncommon that you would ever need to split a discharge line
into 2 runs however you should remember not to bull head the layout
when that day arrives. Reducing tees are specified by inlet size, outlet
size and branch size. Eg: 5/8" x 5/8" x 7/8".
Vibration
Loops are not possible with rigid hard drawn copper. A vibration
absorber should be welded in parallel to the compressor shaft. One end of
the vibration absorber should be fixed to something stationary. The other
end is left to take up the movement of the compressor.
In the above sketch, the P-Trap provides oil in the evaporator a place to drain to. Suction vapours whipping around the smooth
curve of the P-Trap pick up the oil and move it up the vertical pipe. This arrangement is called a P-Trap and Riser. Multiple
traps and double risers are used for suction lines with large vertical rises. There are a great many procedures that should be
followed for proper piping practice. However piping techniques is a topic unto itself and is beyond the scope of this
introductory book. Refer to manufacturers literature and text books dedicated to piping techniques for further information.
Piping Insulation
Insulation should be placed on all suction lines that are outside of the conditioned space. The above graphic demonstrates this.
The reason is to reduce the amount of heat that gets picked up by the cold suction line. Unwanted heat picked up by the
suction line is like trying to refrigerate outside of the intended conditioned space. This is a waste of energy and detracts from
system performance. The effect is even worse if a long uninsulated suction line travels through a particularly warm
environment like a hot mechanical room. Low temperature systems like freezers have colder suction lines so thicker walled
suction line insulation is a good idea. If condensation or frosting pipes are a problem, suction lines inside a conditioned space
can also be insulated. The only other pipe that should be insulated is the outdoor section of liquid line in a split system heat
pump. In that case you are trying to avoid losing heat to the cold outdoor air when the heat pump is in the heating mode.
Pipe Sizing Charts make selecting the proper piping size relatively easy. A different chart is required for each refrigerant and
for each line; suction, discharge, condensate and liquid lines. On the chart below determine what size pipe you should use for
a 30 foot suction line for a 3 Ton R22 system. For the answer click the "3 Ton" Button. You start with the length column on
the far left. From the 30 foot row, go to the right until you first reach a tonnage that meets or exceeds 3 Tons. Then go up to
the top row to see what size pipe is required. The charts are prepared with an allowance for an average amount of fittings, so
there is no need to calculate equivalent pressure drops for each fitting in the run. The Bold figures are not to be exceeded
otherwise a suction line temperature penalty occurs. The figures greater than the bold ones plus the figures in the shaded areas
are there for reference only and should not be used. Before you click on the 4 Ton Button, see if you can determine what size a
40 foot suction line should be for a 4 Ton R22 system.
What are the 2 trade offs when selecting piping sizes for a refrigeration system?
What effect does undersized refrigeration piping have?
What effect does oversized refrigeration piping have?
When can you use a short radius elbow in a refrigeration piping system?
Which refrigerant line, when run horizontally, should have some slope? Which way should
it slope and why?
Why should there not be dips and sags in suction lines.
Why should pipe cuts always be reamed?
Is water piping specified by it's OD or by it's ID?
What is a vibration loop and where is it used?
What is a P-Trap & Riser, where is it used and how does it work?
How can you figure out what size pipe to use for any given refrigeration line?
If you were to run 30 feet of suction line for a 10 Ton R-22 system, what size should it be?
If you were to run 20 feet of suction line for a 1 Ton R-22 system, what size should it be?
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Refrigerants
Refrigerants
A few short years ago managing refrigerants was a fairly simple task. The typical service truck
might have carried a mere 3 types of CFC refrigerants:
● R-12
medium temperature refrigeration
● R-22
air conditioning
● R-502
low temperature refrigeration
There were of course other refrigerants but a large amount of equipment utilized one of the 3 listed
above. CFC stands for chlorinated fluorocarbon and indicates that the refrigerant molecules
contain Chlorine and Fluorine and Carbon atoms. These refrigerants had thermodynamic
characteristics very well suited for the jobs they were given. It could be boasted that they were
colourless, odourless, non-toxic, non-flammable and non-explosive. They were a readily accepted
improvement from noxious refrigerants like Sulphur Dioxide and Ammonia. If a Sulphur Dioxide
or Ammonia leak developed a building would have to be evacuated. If a CFC leak occurred
occupants might not even be aware of the fact. However there still are concerns with CFC
refrigerants. Although they are not flammable, they can be forced to burn. Anything can be forced
to burn. An oxy-acetylene torch that cuts steel is actually burning the steel. When a welding torch
is used on refrigeration piping that contains residual refrigerant vapours, those vapours are forced
to burn. When that happens to CFC or HCFC refrigerants they are chemically changed into a
poison known as Phosgene. This issue was of little concern to anyone but refrigeration mechanics
and firemen and was generally unknown by the public. There is another issue which should at
least be mentioned. If a very large amount of refrigerant is released into an enclosed space, it is
possible that air and oxygen can be displaced to the point where human safety would be in
jeopardy. That is however a possibility with any gas, not just refrigerants.
In recent years it was discovered that there was a major issue with the use of CFC refrigerants.
CFC's and some other substances were causing depletion of the stratospheric ozone layer which
shields the planet from damaging UV-B radiation. If the ozone layer was allowed to continue to
deteriorate it was argued that global warming and the incidence of human skin cancer could rise to
extremely undesireable levels. Plankton regeneration and the entire global food chain could also
be at risk. The Montreal Protocol was originally signed in 1987 and is an international agreement
designed to protect the ozone layer. A plan was established to phase out CFC based refrigerants
and other Ozone Depleting Substances (ODS). Production of the most destructive refrigerants has
already ceased. R12 and R502 and many others are no longer being produced. Some refrigerants
with smaller quantities of the damaging components are being used but even they are scheduled
for oblivion (in 2020). Large chemical manufacturing companies jumped on the band wagon and
flooded the market with scores of "designer refrigerants" all hoping to come up with the next
widely accepted refrigerant substitutes. This has created havoc in the refrigeration industry. There
are so many alternative choices for replacement refrigerants, it is chaotic in comparison to the way
it used to be. It is necessary to take a look at the different categories of refrigerants in order to
understand which ones are ozone depleting and scheduled for control and which ones will be
allowed to stay in use. A Refrigeration mechanic must become familiar with the terms CFC,
HCFC, HFC and Blends.
The blue coloured text indicates how abbreviations like CFC were coined from the chemical
names of the substances. Note that red coloured text indicates Chlorine content and those
substances are the ones slated for control and obsolescence. The R-22 example refrigerant given
for the HCFC group has not been banned yet although it is slated for extinction in the year 2020.
R-22 has been used extensively as one of the components in the new blends of so called "ozone
friendlier" refrigerants. The following section, PT Chart Index is a large data base containing a
great number of refrigerants with their PT Charts and other data. There is much that can be learned
from noting the components of refrigerants and blends. The magic word is chlorine, if it contains
any, it is or will be banned. When you look through the data base you will see that there are a great
many more replacement options than are needed for each of the old refrigerants being phased out.
It is certainly impossible to stock one jug of each type of refrigerant in a service van.
Nomenclature
There is some technical reasoning behind the naming convention (or nomenclature) for
refrigerants. The graphic below demonstrates the procedure used by chemists to come up with the
seemingly strange names. A single C represents a Carbon atom, a CL stands for Chlorine, H is
Hydrogen and F is Fluorine.
Blends
Blends are a mixture of 2 or more refrigerants. The mixture is formulated to provide refrigerant
properties suitable for a specific temperature application. Blends come in 2 categories; Azeotropes
and Zeotropes.
Azeotropes are refrigerant blends which evaporate and condense exactly like a pure component at
some temperature and pressure. They may not behave in this fashion at all temperatures and
pressures but they will be close.
Example: R-502
Zeotropes are refrigerant blends which show some amount of temperature glide when evaporating
or condensing. In other words they may not always have a precise Temperature/Pressure
relationship like a pure refrigerant always has. Some may act like Azeotropes and glide may not
be noticeable. Zeotropes with glide greater than 3 ºF will have one end of the evaporator warmer
than the other which may affect system performance. If retrofitting to a Zeotrope it may be
necessary to change a pressure activated operating control to a temperature activated operating
control to avoid temperature swings in the refrigerated space. Other controls may have to be
adjusted as well.
Example: R-401A (MP39)
Most refrigerants are generally non-flammable. However, anything will burn if you force it to. If
refrigerant vapours are floating about in the presence of an open flame (such as a welding torch or
even the pilot burners in commercial kitchen equipment) the vapours will indeed burn and some
types of refrigerants will form dangerous combustion products. If a refrigerant containing chlorine
is forced to burn, phosgene gas is created which is poisonous. Phosgene was used in WW1 as a
poisonous gas in trench warfare so it is nothing to be taken lightly. It's chemical formula is COCl2
and it goes under the following chemical names:
● carbonyl chloride
● chloroformyl chloride
● carbon oxychloride
Phosgene has a sweet, hay-like odour at lower levels, and is extremely pungent at higher levels. So
you will usually know immediately if phosgene is being created. Phosgene is severely irritating
and corrosive to all body tissues. Irritation of the throat occurs immediately at 3 PPM, while 4
PPM causes immediate eye irritation. Exposure to 20 to 30 PPM for as little as 1 minute may
cause severe irritation of the upper and lower respiratory tract, with symptoms including burning
throat, nausea, vomiting, chest pain, coughing, shortness of breath, and headache. Brief exposure
to 50 PPM can be fatal within a few hours. Severe respiratory distress may not develop for 4 to 72
hours after exposure, at which point pulmonary edema progressing to pneumonia and cardiac
failure may occur. Phosgene vapour is irritating to the eyes, and the liquid can cause severe burns
to the eyes and skin. Phosgene is not regarded as a substance with adequate warning properties. In
short, do not weld pipes with residual refrigerant vapours and weld in well ventilated areas.
Some refrigerants do not have to be burned in order to be dangerous. Toxicity and flammability of
refrigerants has been classified by ASHRAE (American Society of Heating, Refrigeration and Air
Conditioning Engineers)
Flammability Classifications
Toxicity Classifications
R-11 A 1
R-12 A 1
R-22 A 1
R-123 B 1
R-406A A 2
R-717 B 2
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PT Chart Index
PT Chart Index
R-500 Frigen-503
R-501 FX-10
R-502 FX-40
R-503 FX-56
R-504 FX-70
R-507A FX-220
R-508B G2015 (Greencool)
R-509A G2018A (Greencool)
R-600 G2018B (Greencool)
R-600A G2018C (Greencool)
R-601 Genetron-11
R-601A Genetron-12
R-717 Genetron-13
R-744 Genetron-22
R-C270 Genetron-32
R-C318 Genetron-113
R-E134 Genetron-114
R-E170 Genetron-115
R-E245FA1 Genetron-123
Genetron-124
Genetron-125
Genetron-134A
Genetron-141B
Genetron-142B
Genetron-143A
Genetron-152A
Genetron-218
Genetron-500
Genetron-502
Genetron-503
Genetron-507A
GHG-406A
GHG-High Performance
GHG-X3
GHG-X4
GHG-X5
Great Lakes FM-200
Greencool G2015
Greencool G2018A
Greencool G2018B
Greencool G2018C
Halon 25
Halon 37
Halon 112
Halon 241
Halon1301
HC-12A
HC-290
HFC-134 (Not 134A)
HFE-134
Hoechst Reclin(R) HX4
HP62
HP80
HP81
HX4
ICI Arcton TP5R
ICI Arcton(R) TP5R2
ICI Klea-407D
ICI Klea-60
ICI Klea-61
ICOR HOTSHOT
Isceon 49
Isceon 69-L
Isceon 60-S
Isceon-218
Isobutane
Isopentane
Isotron-11
Isotron-12
Isotron-22
Isotron-141B
Isotron-142B
Isotron-500
Isotron-502
Klea-125
Klea-134A
Klea-66
McCool-406A
Meforex-124
Meforex-143A
Moncton Refrigerants NARM-12
Moncton Refrigerants NARM-22
Moncton Refrigerants NARM-502
MP33
MP39
MP52
MP66
NARM-12
NARM-22
NARM-502
N-Butane
N-Pentane
NU22
OZ Technology HC-12A
OZ Technology OZ-12
OZ-12
PFC-116
PFC-218
PFC-C318
Propane
Propene
Propylene
Puron
RC270
R-E134
R-E170
Reclin HX3
Reclin 507A
RX1
Solkane-32
Solkane-123
Solkane-141B
Solkane-142B
Solkane-143A
Solkane-507A
Starton 69
Suva HP62
Suva HP80
Suva HP81
Suva 95
Suva MP39
Suva MP52
Suva MP66
Suva-123
Suva-124
Suva-125
Suva-134A
Suva-143A
Suva-236FA
Suva-9000
Suva-9100
TP5R
TP5R2
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Refrigerant Leaks
Refrigerant Leaks
Locating and repairing refrigerant leaks is one of the common duties of a refrigeration
mechanic. Leaks can be very annoying not just for the equipment owner but for the mechanic
trying to locate the leak as well. It is down right frustrating to know that you have a leak and
not be able to find it. Regulations pertaining to ODS (Ozone Depleting Substances) make the
situation even more volatile. Many enforcement agencies mandate that leaking systems must
be made leak free. That blanket statement and hopeful goal does not precisely coincide with
reality. There is no perfect refrigeration system. All systems leak to some degree. There may
be a leak so microscopic that a system can run for decades without the small loss of
refrigerant affecting system performance nor make known it's presence. Leakage rates can be
in Lb. per second for large ruptures or smaller than ounce per thousand years, but there is no
such thing as leak free. There are many methods for finding leaks. There are pros and cons to
each method.
Pressure Testing
Whatever methods you use to locate leaks, learn to get good at it. You will not make anyone happy
by spending many hours hunting for a leak and then reporting that you have been unable to find it. It
becomes easier with experience (as does everything) and you will find that there are common places
to check. The following lists some very common leak locations:
What do systems have in common that makes it possible to sometimes locate leaks by
human senses?
What is the name of the leak locating device which burns propane?
Why is professional leak detecting soap any better than plain old liquid dish washing soap?
What advantage do some electronic leak detectors have over a Halide Torch?
What is the biggest drawback of the UV leak detection system?
If you run out of Nitrogen can you use Oxygen to finish pressure testing a system?
How do ultrasonic leak detectors work?
How many common leak locations can you list?
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Refrigerant Oils
Refrigerant Oils
Before the world became aware of the problems with ODS refrigerants, and before all the new designer refrigerants came on
the market, mineral oil was the predominant oil in use for compressor lubrication. There were different makes and a few
different viscosity’s for different temperature applications but by in large the same procedures could be used for handling
refrigerant oils in all applications. Threaded refrigeration fittings could be lubricated with the oil and moderate care was
taken when exposing refrigerant oil to the atmosphere. All that has changed.
The above chart is only a general guide. The proper way to determine which oil to use is to follow equipment manufacturers
recommendations. Before ODS regulations and the new flurry of designer refrigerants came along, new equipment was
always shipped containing oil. Now some equipment is shipped without any oil so that the appropriate oil can be selected for
the refrigerant being utilized. You must insure that the equipment is not started without oil in the compressor sump or the
new compressor will be destroyed in short order. Note that the oils in the above chart are arranged in order of increasing
hygroscopic characteristics. Hygroscopic means to readily absorb moisture, as from the atmosphere. So the moment you
remove the cap from a jug of hygroscopic oil it starts absorbing moisture from the atmosphere. Moisture is the enemy of a
refrigeration system. It can freeze up at the metering device and stop the flow of refrigerant. It is also an essential ingredient
in the formation of acids. So applying a hygroscopic refrigerant oil to a threaded fitting or an O-ring is not good practice. The
use of hygroscopic oils should be planned out thoroughly and great care used so that exposure to the air is minimized. When
a container of PAG oil is opened, some say that any left over oil should be appropriately disposed of rather than kept around
as stock. This is a difficult procedure to accept as PAG oil is very expensive. However, moisture related problems can be a
lot more expensive than some discarded oil.
the oil jug to the oil sump. In this picture the oil sump is
open to atmosphere. A superior method would be to screw
an adapter into the oil plug fitting which the service hose
could then be screwed onto.
Oil Breakdown
Things like high head pressure and undercharged conditions cause high discharge temperatures. The place of highest pressure
and highest temperature in the refrigeration loop is the point of discharge from the compressor. As the compressed discharge
gas and oil mist passes this point, the oil will suffer break down if the temperatures are too high. The oil will break down into
carbon, sludge's and if moisture is present it will form acids.
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Air Conditioning
Air Conditioning
Part1
Definition
The human comfort zone is an area that has had great amounts of study. Besides the obvious
temperature and humidity, factors that affect whether a person feels comfortable or not
include age, sex, geographical location, clothing, psychological disposition, and activity level.
Entering a conditioned space from outdoors also has a great effect on ones perception of what
is comfortable. After being inside and getting accustomed to conditions perception can again
change. The human comfort zone as it applies to the conditions of air is one of those things
that can only be described by a bell curve. There is no one comfort zone that will satisfy all
people. Nonetheless guidelines have been established to accommodate the majority of people
under average conditions. The human comfort zone is typically in the 70 ºF to 85 ºF (Dry
Bulb) range and 30% to 70% relative humidity range. Air Conditioning systems are designed
to satisfy cooling loads inside buildings in order to achieve those conditions.
Cooling Loads
Many factors contribute to the total cooling requirements for a building. There are building
loads, infiltration and fresh air requirement loads, solar gain, people loads, and equipment
loads. All these things added together total the Cooling Load. The first thing that designers do
in order to calculate a cooling load is to establish the indoor and outdoor design temperatures.
Design Temperature refers to the outdoor temperature accepted as a design standard for the
geographical region where a building is located. Meteorological data has been gathered,
researched and compiled into lists of design temperatures so it is a simple matter to look up
the official data for practically any location. Design temperatures are established by averaging
weather conditions over long time periods. It allows equipment capacities to be selected
which reasonably cover the typical range of conditions that can be expected to occur. This
does not mean that specified equipment will be capable of completely meeting the load
requirements on extremely hot days which are very untypical for the region.
The indoor Design Temperature on the other hand can be specified at will. Typically 70 ºF is
used which is the bottom of the so called human comfort zone. With these 2 temperatures
known everything else can be calculated. The difference between outdoor and indoor design
temperatures has a great effect on the total load. Consider the cooling requirements on a
southern latitude building compared to a northern latitude one. If the indoor temperature was
to be 70 ºF in each case yet the outdoor design temperatures were 100 ºF and 80 ºF
respectively, the TD's or Temperature Difference would be 10 ºF in one case and 30 ºF in the
other. The greater the TD, the greater the rate of heat transfer will be. So the same size
building can require quite different equipment capacities depending on the design
temperature. Also, when TD's are large the tendency is to raise the Indoor design temperature
so that there is less of a shock when entering and exiting the conditioned space.
Humidity
Air Filtration
Air Filtration has two purposes. One is to protect the evaporator (and other components) from
clogging up with airborne particulate debris. The other is to lessen the amount of airborne
debris in the conditioned space. There are a wide range of filtration capabilities available from
various filtration systems.
Pleated Filters
Replaceable Media
Bag Filters
Air Movement
Refrigeration equipment
needs to be move air through
condenser coils and reject it
from the immediate area. In
the case of evaporators, air
only has to circulate about
the refrigerated box. Those
are not very demanding air
movement requirements and
typically propeller type fan
blades can move sufficient
air to satisfy those needs.
However with air
conditioning there is often a
duct distribution system
associated with the
equipment. Propeller fans
can not be used with duct
systems because propeller
fans can not push against the
static pressure inherent with
ducts. A blower wheel type
Name the "conditions of air" that are controlled by an air conditioning system.
How many factors that affect the way a person perceives air conditioning comfort can you
list?
Name 4 factors that contribute to a building's cooling load.
How is outdoor design temperature determined?
How is indoor design temperature determined?
What does Psychometrics refer to?
What effect on humidity does an oversized air conditioning system have?
Name 2 purposes of an air filtration system.
Which type of filtration system can remove particles as small as cigarette smoke?
What type of fan is required to overcome the pressure drop in duct systems?
What are the effects of inadequate and excessive airflow through a duct system?
What is the difference between a packaged and a split AC system?
What are the 2 main components of a split system?
What is another name for an incremental unit?
What does an Absorption System use as it's energy source?
What 5 functions do computer room air conditioners provide?
What capability does a package AC system have that split systems do not?
What does the term "Minimum Fresh Air" refer to?
What is the combination of outdoor air and return air called?
What does the term Mechanical Cooling refer to?
What does the term Free Cooling refer to?
What mixed air temperature set point do the dampers of a free cooling system try to
maintain?
What is the name of the controls that choose between free and mechanical cooling?
Why must overly humid air not be used for free cooling?
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Heat Pumps
Heat Pumps
Part 1
A heat pump is an Air Conditioning system which can also provide very efficient heating. It takes less energy to relocate heat than it does to create it. Just as
a refrigeration system removes and relocates heat from a cooler or freezer, so too does a heat pump remove heat from cold outdoor air and relocate it to
within a building. A 4 way reversing valve is used to swap the functions of the evaporator and condenser in order to change from cooling to heating mode.
To avoid confusion it is common practice to call heat pump coils the "indoor" and "outdoor" coil. The diagram below shows a heat pump piping layout.
Click back and forth between Buttons 2 and 3 and note how the discharge from the compressor is diverted to different coils in each mode. You can also
view the 2 modes showing the refrigerant states with Buttons 4 and 5.
Piping
Layout
1 2 3 4 5
Here is another view of how the 4 way valve diverts flow; the pipe on the single stub side of the valve
is always the discharge from the compressor. The discharge is diverted to the condenser, the middle
stub is always suction going to the compressor, and the left over stub is always from the evaporator.
The switching function is accomplished by the sliding back and forth of an internal barrel which has
diverting passages. The systems own high side pressure is used to ram the barrel to the desired end by a
pilot duty solenoid valve. On the diagram below, click back and forth between Buttons 3 and 4 to see
the barrel slide to opposite ends. Then try Buttons 5 and 6 to see the refrigerant flow being diverted.
4 Way Valve: Labels: Barrel Left: Barrel Right: Left Flow: Right Flow:
1 2 3 4 5 6
The Liquid line always carries liquid but the direction of flow reverses in each mode. Each coil has it's
own metering device with a check valve piped in parallel. When refrigerant flow meets a check valve in
the blocked direction it has no choice but to divert through the TXV. When refrigerant flow meets a
check valve in the allowed direction it will take the route of least resistance and go through the check
valve and ignore the TXV. There are TXVs that have this check valve function built right into the valve
itself. The Bi-Flow filter/drier works in a similar manner. Inside a bi-flo drier there are check valves
which ensure that refrigerant flow goes through the drier core in the same direction regardless of the
liquid line flow direction. The drier core must experience flow in one direction only. Otherwise, if
counter-flow was allowed debris that had been filtered out would unload and re-enter the system.
Accumulator
The accumulator attempts to protect the compressor from liquid refrigerant in the suction line. This is
accomplished by use of an inverted trap. However at the same time it can trap oil entrained in the
refrigerant. This could eventually hold back the entire oil charge which would cause compressor
failure. To overcome this problem a small orifice is located on the underside of the inverted trap. A
Venturi Effect occurs and any trapped oil is sucked through the orifice and carried away by the suction
vapours to be returned to the compressor sump where it belongs.
Defrost
The outdoor coil of a heat pump can ice up just like a freezer evaporator. The tendency to ice up increases with humidity and low ambient temperatures.
There is fortunately a convenient method of defrosting the outdoor coil. That is to make the system run in the cooling mode. The outdoor coil becomes the
condenser and the ice can be melted away. To keep the heat where it is wanted the outdoor fan motor is temporarily shut off. All this happens automatically
and is controlled by a solid state defrost control board. Every so often it will check the temperatures of some thermisters (temperature sensitive resisters) and
if a defrost is needed it will activate the defrost mode. Otherwise it will wait for the next trial for defrost. As the system progresses in a defrost it will get to
the point where clouds of steam will billow out of the unit. New heat pump owners should be advised to expect this. Otherwise nuisance calls may be placed
by the unknowing customer. They have even been known to call the fire department thinking the unit is on fire.
In the piping diagram above, place the unit in the defrost mode (Button 2). Note that the outdoor coil has hot gas entering it which is going to condense into
a liquid as it melts the ice build up. There is no danger to the compressor because this liquid must travel through a TXV and evaporator before getting back
to the compressor. However simulate the end of a defrost by putting the system back into heating mode. (Button 3). Note that the compressor is now directly
sucking the contents from the outdoor coil (liquid) without the benefit of any TXV or evaporator to protect it. You have just seen the need for the
accumulator in all heat pump systems.
Why is a heat pump more efficient than other types of heating systems?
What component swaps the function of the indoor and outdoor coils in a heat pump
system?
How many metering devices does a heat pump have?
Which metering device is active during the heating mode?
Which coil is the condenser in the air conditioning mode?
Which coil is the evaporator in the heating mode?
What component do heat pumps have to help protect from liquid slugging?
What type of metering device can be used in lieu of a TXV and a check valve?
How does a heat pump get defrosted?
Why does a heat pump need an accumulator?
What makes the barrel in a 4 way reversing valve slide from one end of the valve to the
other?
Name 2 main types of split system heat pumps.
Which is a more efficient system, an all electric heat pump or an add on to a fossil fuel
furnace? Why?
What does COP stand for?
When are air source heat pumps most efficient?
Which is more efficient, an air source or a ground source heat pump?
How much condenser airflow is required by heat pumps?
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Psychrometrics
Psychrometrics
Psychrometrics is the study of the properties of air. Those include temperature, moisture content, enthalpy and volume.
These properties can be displayed in graphical form on what is called a Psychrometric Chart. To air condition a space,
the properties of air and mixtures of air must be brought to within acceptable conditions. The processes which must be
provided to bring about these changes are easily demonstrated when graphed on psychrometric charts. Given any two
properties of air, the remaining properties can be determined graphically.
Psychrometric Chart
Click the DB button to highlight the dry bulb lines on the above psychrometric chart. As you can see, the units are in
degrees Fahrenheit and are along the horizontal axis. A dry bulb measurement is that which is taken with any standard
thermometer and is a reading of sensible heat.
RH - Relative Humidity
Relative humidity represents the amount of moisture in the air compared to what the air is capable of holding at a given
temperature. In other words, 50% RH means that the air contains exactly half of the moisture that it is capable of holding
at the given temperature. The warmer air is the more moisture it can contain. The colder it is, the less moisture it can
contain. That's why air passing through cold evaporator fins relinquishes some of it's moisture and droplets of
condensation form.
Enthaply
The Enthalpy of air is the total amount of heat that is contained in a pound of air. It includes both latent and sensible heat.
It is expressed in BTU/Lb.
SH - Specific Humidity
Specific Humidity also called Absolute Humidity is the amount of water vapour by weight in the air. It is usually referred
to by Grains of moisture per pound of dry air. One Grain = 1/7000th of a pound. Some charts have a humidity ratio scale
which represents the ratio of Lb. water to Lb. of air per cubic foot.
Total heat = sensible heat + latent heat. The Sensible heat ratio is that portion of the total heat that is sensible.
Volume
Volume refers to the number of cubic feet that one pound of air occupies. If the temperature is increased so too will the
volume increase.
DP - Dew Point
If the air is saturated with as much humidity as it can hold, the RH will be 100% and the dew point will have been
reached. On a psychrometric chart the dew point line is therefore the 100% relative humidity line. Any cooling of the air
below the dew point will cause moisture to condense out of the air. So for a cooling coil to do any dehumidification, it
must operate at a temperature below the dew point of the air to be dehumidified.
1 2 3 4 5 6 7 8 9 10
Determining Humidity
Use the chart from button 1 to find the following: What is the relative humidity of air that has measurements of 75 ºF DB and
57 ºF WB? (Button 2 displays the solution)
Is the condition that was just plotted in the button 2 chart within the typical human comfort zone? (Button 3 shows the
comfort zone)
Since cold air can hold less moisture than warm air, there typically needs to be humidification along with the heating process
in order to bring conditions within the comfort zone. Button 4 demonstrates these 2 processes.
Since hot air can hold more moisture than warm air, there typically needs to be de-humidification along with the cooling
process in order to bring conditions within the comfort zone. Button 5 demonstrates these 2 processes.
Dew Point
If air has a DB temperature of 90 ºF and a WB temperature of 77.5 ºF, what is it's dew point?
Solution:
First plot the given data on the psychrometric chart. Button 6 demonstrates this. When air is cooled without a change in
moisture content this is represented on the psychrometric chart by a horizontal line. Press button 7. The horizontal line
crosses the 100% relative humidity line (or dew point line) at about the 73 ºF WB point. The dew point is therefore 73 ºF
WB. If you drop a vertical line down to the DB temperature scale, press button 8, you can see that if the original 90 ºF air is
cooled to 73 ºF moisture will condense out of the air. This shows why dew starts forming when things cool down in the late
evening after a hot, humid day.
The mixing of air streams with different states can be shown on a psychrometric chart. The results of the mixture will depend
on the quantities as well as the conditions of the air streams. For example, an air conditioned commercial space must have
10% fresh air provided with the supply air (or some similar amount according to the prevailing jurisdictional codes). Click
button 9 to show a 10% mixture of hot humid fresh air mixed with the return air of an air conditioning system. Note how the
temperature and moisture content of the MA (Mixed Air) has increased from the RA (Return Air) conditions but the mixture
result is closer to the original RA conditions than to the OA (Outdoor Air) conditions due to the greater quantity of RA in the
mixture. Also note the increased requirements placed on the mechanical cooling system due to the extra load from the FA
(Fresh Air) Both the sensible and latent cooling loads are increased and these processes are represented by the blue arrows.
This increased cooling capacity requirement can be very significant and must not be ignored when performing load
calculations and specifying equipment capacity. System designers use psychrometric charts for many types of airflow
calculations.
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Water Cooled
When an air cooled condenser rejects heat into an air stream, the air is called the Condensing Medium. Water can also be used as a condensing medium.
There are several types of water cooled condensers used in water cooled equipment:
This type of water cooled condenser is made with one tube inside another tube. Water flows through
the inner tube and refrigerant flows in the space between the 2 tubes. The water side of this type of
condenser can be cleaned manually by removing the end plates and rodding out the water tubes with
special brushes.
Co-axial
A co-axial tube condenser also has a tube within a tube. It gets it's name from the fact that both the
tubes are coiled about the same theoretical axis. Usually, the water flows through the inner tube and the
refrigerant flows in the space between the 2 tubes. It is not feasible to mechanically clean a spiral tube
so if the water side of this type of condenser becomes fouled a chemical cleaning becomes the only
resort. This type is commonly used in small to medium sized water cooled condensing units.
Shell and Coil condensers have a coil of copper encased inside a steel shell. Water flows through the
coil and refrigerant is discharged into the shell where it condenses on the outside of the cold water
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Water Cooled
tubes. It is not feasible to mechanically clean a spiral tube so if the water side of this type of condenser
becomes fouled a chemical cleaning becomes the only resort. Shell and Coil condensers can also act as
receivers.
Shell and Tube condensers have many parallel lengths of straight tubing running inside a steel shell.
They are manifolded together at each end. Water flows through the tubes and refrigerant is discharged
into the shell where it condenses on the outside of the cold water tubes. This type of condenser can be
cleaned manually by removing the end plates and rodding out the water tubes with special brushes.
Shell and Tube condensers can also act as receivers.
The water lines on a water cooled condenser should be hooked up so that there is counterflow between the refrigerant and water. (The 2 fluids should be
moving in opposite directions) This optimizes heat transfer as the temperature difference (TD) between the refrigerant and the water along the length of
travel is greatest this way. If the 2 fluids ran in the same direction they would get closer in temperature as they travelled along and the heat flow would
decrease.
Air is free but water usually has a cost. Even so, there are times when water cooled equipment is a better choice than air cooled equipment. One example is a
commercial kitchen. A commercial kitchen can get very hot and greasy. Space is always at a premium and condensing units get shoved into awkward places
with inadequate ventilation. This apparently seems like a good idea until equipment starts failing in the not too distant future. Water cooled condensers are
immune to ambient air temperature. They are also immune to airborne grease which loves to clog up the fins of an air cooled condenser. So although water
cooled equipment is more expensive to purchase and operate it can be cheaper in the long run compared to the maintenance, repair costs and product loss
that can occur when air cooled equipment is placed in adverse conditions.
The graphic below shows a water cooled system. There is a water valve that regulates the quantity of water passing through the condenser. There is really no
difference with what happens to the refrigerant compared to an air cooled condenser. Heat is being rejected to a condensing medium and hot refrigerant gas
is condensing into a liquid. Water cooled systems should be equipped with a high pressure safety control to stop operation should the water supply be
interrupted.
The Water Regulator Valve (WRV) controls the flow of water through the condenser. When
refrigeration is off there should be no water flow. When refrigeration starts, the WRV modulates the
flow of water to maintain a pre-set head pressure. The sensing line is hooked up to high side refrigerant
pressure. If the head starts to rise above normal, the increase in pressure causes the valve to allow more
water flow. That lowers the head which in turn allows the water flow to be reduced. The valve reaches
an equilibrium and maintains a pre-set head pressure. The 2 operating forces are apparent in the sketch.
The spring is visible in the top half of the valve assembly and the diaphragm enclosure is visible in the
bottom half of the assembly. The 2 operating forces are spring pressure and high side refrigerant
pressure. By adjusting the stem on the very top of the valve the spring tension can be adjusted which in
turn sets the head pressure.
The WRV should be located on the water inlet side of the condenser. It is also uni-directional which
means flow should be in the direction indicated by the arrow on the valve body. The piping stubs are
usually marked so it is easy to ensure you are piping things to ensure counterflow as well.
A WRV can be set to maintain the head pressure to any setting that you want. An appropriate place to
start is the corresponding pressure for 105 ºF. All normal systems will operate perfectly fine with this
setting. If you lower the head it will consume more water. If you raise the head less water will be
consumed. High head causes high discharge pressures and increased amperage draw. High discharge
temperatures break down refrigerant oil and take the temper out of valves. So all things are a
compromise.
A WRV will sometimes mask refrigerant side problems because it will try to maintain a fixed head
pressure. A WRV is a form of head pressure control.
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Cooling Towers
Cooling Towers
Refrigeration systems reject the heat they have picked up into a condensing medium
(usually air or water) When there is a very large amount of heat to reject the cost
effectiveness of a monstrous air cooled condenser (or a great number of smaller
condensers) and the large amount of refrigerant involved can become an issue.
Water cooled condensers can be built large enough and are a lot more compact than
air cooled condensers however the water consumption becomes an issue with very
large systems. Air is free, water costs money. A solution for rejecting large
quantities of heat is the cooling tower. In a cooling tower system heat is initially
rejected into a water cooled condenser but the water is not just piped to the drain.
Instead it is pumped to the cooling tower where it can be cooled and recirculated.
There are several variations of cooling towers but they all allow a small quantity of
the water to evaporate in order to cool the remaining water which is then returned to
the condenser to pick up more heat. The latent heat of vapourization of water is
utilized which is 970 BTU's per pound. The basic concepts for heat transfer are
utilized to optimize vapourization of the water. Some cooling tower designs (as shown in the diagram below) spray the water
through nozzles which greatly increases the surface area of the water. Air is blown or sucked through the tower to interact
with the droplets. Some designs use a "fill", or a large number of plates to act as more surface area for the water to spread out
on. The fill can be made of metal, plastic or even treated wood. A float valve automatically adds water to make up for the
evaporated water. A drain valve continuously bleeds off a small portion of the water to keep the water hardness from getting
excessive. Chemical treatment can be utilized to reduce algae and fungus growth. Notice that there is no WRV (Water
Regulator Valve) when units are tied into a tower. If need be, water temperature can be controlled in the tower by cycling
fans and other methods.
Evaporative Condensers
Evaporative Condensers are similar to cooling towers. The refrigerant piping is tied into the condenser and water is
distributed over the pipes directly. Once again the evaporative process is used to cool and condense the refrigerant and only a
small portion of the water is evaporated away. Make up water, bleed off water and water treatment are also required as with
cooling towers.
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Burn Outs
Burn Outs
Mechanical Failures
There are two main categories of compressor failures; mechanical breakdowns and electrical burnout's. A mechanical failure can be caused by
several things including old age, metal fatigue, liquid slugging and lack of oil to lubricate moving parts. High discharge temperatures can take the
temper out of discharge valves and make them brittle causing them to crack and chip apart. You may find anything from pieces of valves and rings
to chunks of pistons and connecting rods lying in the sump of a compressor that has suffered mechanical failure. The broken pieces will be
reasonably clean, especially if all the oil was washed out of the compressor by liquid refrigerant. Examining the insides of a failed compressor can
provide the answer as to why it failed. That is invaluable information if you are going to be replacing the compressor with a brand new one as you
don't want it to immediately suffer the same fate. If you can determine the cause of the failure you may be able to rectify the situation and stop a
repeat failure. Any type of compressor can fail mechanically.
A hermetic compressor (or semi-hermetic) has the compressor driver built in. In other words the motor windings are inside the refrigeration system.
Those are the only types that can suffer an electrical burnout. There are 3 ways that the windings can fail:
When windings fail an electrical flash can occur. The inside of the system contains high pressure, oil, refrigerant and sometimes traces of water.
When an electrical spark occurs those ingredients combine to form acids and oil sludge. If the failure occurs when the system is operating it is called
a "running burn out" and the contaminants are spread throughout the system by the moving refrigerant. If the failure occurs when the compressor is
trying to start, the refrigerant is not yet circulating so the contaminants don't spread out like they do with a running burn out.
The hottest point in the refrigeration loop is at the discharge valves. If a system operates with high head pressure (for any of a myriad of reasons)
then the temperature at the discharge valves gets even hotter. A refrigerant undercharge also causes high discharge temperatures. (There are less
molecules to share a given quantity of heat so the temperature increases) Oil starts breaking down above 250 ºF and forms carbon, sludge and if
moisture is present acids. Those acids attack the insulation on the windings and lead to burn outs. When you open up a system that has burned out
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Burn Outs
you will know it immediately by the pungent odour. New refrigerant oil is clear. As it starts to break down it darkens in colour and develops an
odour. The more severe the break down, the darker the colour and the more odiferous the oil becomes. Under the worst conditions it can become
totally black and create large quantities of sludge. Use protective gear like safety glasses and rubber gloves when working about acidic oil. Other
than with open internal overloads, any hermetic compressor that has an open ohm reading or grounded windings is a burnout. There are acid test kits
which will tell you the severity of the burnout. When you replace the compressor of a burned out system you put the new compressor at risk of
failure from the residual acids of the previous burnout. To avoid this unpleasant circumstance special procedures must be taken to protect the new
compressor. The LL Filter/Drier must of course be changed but you must also install a suction line filter immediately upstream of the compressor.
The suction filter must be replaced as many times as required until the oil is no longer acidic. Then the SL Filter should be removed as pressure drop
in the suction line greatly detracts from system capacity. You can easily measure the pressure drop across the SL Filter because they come equipped
with a Schraeder access valve on the upstream side. You can compare the reading there to that at the SSV. If the filter has clogged enough to cause a
2 PSI pressure drop it's time to replace it with a fresh filter. If the oil is no longer acidic you can remove the SL Filter.
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ODS Conversions
ODS Conversions
CFC refrigerants were thought to be harmless until it was discovered that chlorine attacks the
atmospheric ozone layer. The ozone layer acts as a protective filter and reduces the amount of UV
radiation from the sun that reaches our planets surface. As the ozone layer becomes thinner due to
the chemical attack of Ozone Depleting Substances , the amount of UV radiation getting through
the stratosphere increases. Reportedly, so too does the incidence of skin cancer in humans and the
risk of damage to crops, plankton and the rest of the global food chain.
ODS are now "under control". This does not mean that the ozone layer situation is necessarily
under control but rather that controls are in place to phase out ODS substances. Production of the
worst offenders, those with the highest ozone depleting factors, was banned in 1996 and tentative
cease production deadlines have been set for the lessor offenders. For example, R-22 is in wide
spread global use but it is an HCFC refrigerant and it's production will cease around 2020. (if that
date is not moved up, that is) As one can see from looking through the PT Charts section there are
a great many replacement refrigerants but most of them utilize some ODS component and are
therefore only temporary substitutes.
Refrigerants are not the only thing becoming obsolete. Procedures thought of as standard in the
past are now also banned and illegal as well. It was common practice to blow off refrigerant from
systems when it was expedient. It was common practice to triple evacuate systems breaking the
vacuum each time with refrigerant and then blowing that off. It was common practice to use trace
amounts of refrigerants mixed in with high pressure Nitrogen to pressurize systems for leak
locating and when done simply blow off that mixture. Those and similar procedures are all now
illegal. There must be no more venting of refrigerants to the atmosphere. Many countries and
regions have adopted refrigerant legislation and more are joining all the time. One used to need a
refrigeration licence to work on refrigeration equipment in most localities. Now one must also take
training courses and acquire ODS certification regarding the safe handling of refrigerants and
learn about the new procedures that must now be followed.
Recover
Since venting of refrigerants is prohibited you MUST recover all refrigerants. That means you
must have a recovery machine. Recovery machines simply extract refrigerant and place it into a
recovery jug, usually along with all the other refrigerant (of the same type) that you have
recovered from elsewhere. You may return recovered refrigerants to your supplier who will send
them back to the manufacturers who are obligated to accept them.
Reuse
Re-using recovered refrigerants is discouraged. A recovery jug is new and clean only once. As you
recover refrigerant from various systems the mixture is bound to become more and more
contaminated. It can contain unknown quantities of acid, moisture, non-condensables, and
mixtures of oils as well as mixed refrigerants.
Recycle
A very expensive form of a recovery device is called a re-cycler. It recovers refrigerant but also
attempts to improve the quality to a useable status. However, all it can really do is a reasonable
amount of filtering and a reasonable amount of acid removal. There is no way of determining the
final status of the recycled refrigerant and how closely (or not) it conforms to factory
specifications.
Reclaim
Reclaiming is what the refrigerant manufacturers are capable of. They can recondition recovered
refrigerant and most importantly can do laboratory tests do determine if the results are pure
enough to place back on the market place. Reclaimed refrigerant is indistinguishable from pure
virgin refrigerant.
ODS Retrofitting
In the past when a mechanic discovered a failed compressor in a refrigeration system it was his or
her's duty to inform the owner of the equipment of the available repair options and make
recommendations. Those options would be to:
There are pros and cons and varying costs and warranties to each of those options. Factors like the
equipment's age, reliability issues and budget concerns have to be considered to determine the
appropriate course of action. Now that some refrigerants are no longer available the equation gets
more complicated. Almost none of the new refrigerants are "drop in" replacements. That means
you can't just "drop in" the replacement refrigerant and walk away. Several things must be taken
into consideration. Usually, the old CFC refrigerant oil was a mineral oil (MO) and usually the
replacement refrigerant requires a synthetic oil such as AB, POE or PAG. The replacement
refrigerants are blends and have varying amounts of glide. In other words, the operating pressures
and temperatures may wander and not follow a precise temperature/pressure relationship like a
pure refrigerant would do. Sometimes this effect is insignificant, other times it can become an
issue. Controls and metering devices and accessories may have to be adjusted. A refrigerant that
claims to be a drop in replacement may have flammable components like propane. So there are a
great many issues to consider when considering retrofitting equipment that was operating on an
obsolete refrigerant. Now the choices look like this:
Class 1 Conversion
Some of the new replacement refrigerants require 95% of the mineral oil to be removed from the
system before it is considered viable for conversion. Other refrigerants require only 80% of the
mineral oil to be removed. Remember, oil spreads out through the entire system. It's one thing to
swap out a compressor and replace the oil in an accumulator. It's another to address the problem of
the oil everywhere else. The only way to get the rest of the oil is to first change the oil in the
compressor with the new type while the compressor is still operational and the CFC refrigerant is
still in place. The system must be left operating for a substantial amount of time so that the CFC
refrigerant can entrain the residual mineral oil and return it to the compressor where it mixes in
with the new synthetic oil. Then you must change the oil again. This process must be repeated
further diluting the concentration of mineral oil until it has depleted to acceptable limits. A
refractometer can be used to determine the concentration of mineral to synthetic oil. A
refractometer is a precision optical instrument which can be used to determine the refractive index
of liquid solutions. Such a reading allows the determination of the percent of residual mineral oil
remaining in the system. Once the oil problem has been overcome the old refrigerant can be
recovered and the new refrigerant can be introduced. Obviously this type of conversion can only
be done while the system is fully functional. It is perfectly fine to leave systems operational with
CFC refrigerants so long as the systems are not leaking. It is also possible to do a preparation for a
Class 1 conversion (oil change out) and still leave the system operating on a CFC refrigerant in
anticipation of a conversion being required in the future.
Class 2 Conversion
If an obsolete CFC refrigerant system loses it's gas through a leak then it is too late to consider a
Class 1 conversion. Any refrigerants that require Class 1 oil status are no longer possible to
consider as replacements. One oil change will typically only remove 50% to 80% of the mineral
oil. Manufacturers original recommendations for refrigerants that use AB oil were to not allow
more than 20% residual mineral oil, although they seem to be backing away from that
recommendation somewhat as time passes. When multiple oil changes are not possible the only
option is a Class 2 conversion with a single oil change. However field experience has shown that
refrigerants such as MP39, R-409A, MP66, and HP81 can work successfully with the existing
mineral oil in close coupled systems where the oil does not have to travel large distances.
General Guidelines
Where possible use OEM recommended oil type, quantity and viscosity. Many new replacement
compressors contain AB oil as shipped from the supplier. HFC refrigerants usually require POE
oil and a 95% reduction in MO oil content. There are far too many replacement choices for
obsolete refrigerants. This industry does not need 20 or 30 replacement choices for each of the
refrigerants being phased out. One or two for each would be fine. The chart below shows one
manufacturers replacement line up for some of the common refrigerants. If every possible
replacement was shown the list would be pages long. Look through the PT Chart section to see the
large number of possibilities.
The year 2020 deadline is still far enough away that using a temporary replacement refrigerant
(HCFC) is not much of an issue. After all, equipment is only designed to have a 15 year life
expectancy. Although many keep equipment in repair for much longer than that. As we get closer
to the deadline refrigerant choices will certainly become more important. By that time new choices
will probably be available which may make decisions easier or harder, who knows.
In 1996 after production of CFC refrigerants was banned, there followed several years when CFC
and reclaimed CFC refrigerants could still be purchased from suppliers. Presumably the same
thing will occur in 2020 after HCFC production stops. Equipment operating on obsolete
refrigerants have (at least in North America) been allowed to continue in operation as long as leaks
do not develop. If a leak develops it must be repaired "immediately".* An equipment owner does
not have to authorize the repair of a leak but his only other legal choice is to have the refrigerant
recovered from the leaking system and shut it down. If he authorizes neither, then it is the onus of
the technician to report him to the appropriate authorities. The authorities will be happy to explain
that there is no choice in the matter other than who does the necessary work. They have the
jurisdiction to levee very large fines for non-compliance.
*some jurisdictions have differing regulations depending on system size, others have standard regulations for all
equipment.
As you can see from the samples shown in the above chart Discharge Pressures are higher and
refrigeration capacity generally improves. All other parameters vary in seemingly random ways. If
you are going to be doing a Class 1 retrofit it is advisable to take a complete set of readings before
the retrofit so that you will have something to compare things to afterwards. You most certainly
want to discover any pre-existing problems before you start alterations so that they can be brought
to the appropriate persons' attention. You don't want assumptions made that you caused problems
by your conversion if you in fact did not.
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Head Pressure Control
A Water Regulator Valve controls the head pressure of a water cooled system by modulating the flow of water through the condenser. There is also a need
to have head pressure control with air cooled systems. If it gets very cold outside the high side pressure can get so low that there can be insufficient pressure
drop across the metering device to provide sufficient refrigerant flow. It is after all the pressure difference between the high side and the low side that causes
refrigerant to flow through the restriction of the metering device. One of the factors that affects the rate of heat transfer is the TD. (Temperature Difference)
between refrigerant and the condensing medium (air). When the air temperature is at 90 ºF and the refrigerant is at 105 ºF the TD would be 15 ºF. But when
outdoor temperatures drop to say 40 ºF the TD would be 65 ºF. That is a significant difference and you can see why head pressures would drop drastically
under those conditions. It falls back to the PT relationship that all refrigerants have; lower temperature = lower pressure. Several methods have been devised
to allow an air cooled system to operate properly during low ambient conditions.
Fan Cycling
Probably the simplest type of head pressure control is to cycle the condenser fan(s). A
pressure control (Fan Cycling Control) is installed to monitor high side pressure and if
pressure drops below the set point of the control the fan motor shuts off. While it is off
there will be much less heat being rejected so the head pressure will start to rise. When it
reaches the cut in point of the control the condenser fan motor will cycle on briefly to
keep the head pressure from rising above normal. The condenser does not stop rejecting
heat while the fan motor is off but thermal transfer is greatly reduced. When the fan
comes back on the rate of heat transfer is large due to the large temperature difference
between the hot refrigerant gas and the cold ambient air so the fan only needs to be on
briefly. This type of system by itself is better than nothing but causes large swings in
operating pressures. It is best used in combination with other forms of head pressure
control such as refrigerant side head pressure control.
A fan speed controller (also known as an infinite speed controller) provides much
smoother refrigerant operating pressures than fan cycling. It is an electronic device which
senses condenser pressure or temperature and varies the power output to the condenser fan
motor which causes the motor to slow down or speed up accordingly. This moves the
appropriate quantity of air to maintain normal condensing pressures during low ambient
conditions. The fan motor must be approved for use with a speed control device. Some
designs use a thermister (a temperature sensitive resister) to sense the temperature at an
end bend on the condenser rather than sensing the high side pressure directly.
Condenser Dampers
This ingenious device uses the systems own high side pressure to actuate a set of dampers.
When the pressure is high more airflow is needed and the increased pressure forces a
piston to move inside an actuator which causes the dampers to open wider. More air flow
is thereby allowed through the condenser which reduces the head pressure. When the
pressure is low, less air is needed and the damper actuator pressure is less able to meet the
opposing spring force in the actuator so the dampers modulate to a more closed position
and head pressure rises to a normal level. The down side of this type of system is that the
dampers can get clogged with ice or debris and if the seals in the actuator wear out you
can lose the refrigerant charge.
This is a widely used system and provides very smooth and reliable operation. It is often assisted with
fan cycling control. There are 3 components with this system. The main function is performed by the
ORI valve. This valve, which is located at the outlet of the condenser, will only allow flow when the
condenser pressure is high enough. During cold ambient conditions the head pressure would tend to be
lower than normal so the ORI valve stops the flow. With the flow stopped the condenser starts to fill up
with liquid refrigerant. That excess of liquid refrigerant takes away from the condenser area available
for condensing purposes. As more hot discharge gas enters the condenser it finds that there is not much useable condenser area available for rejecting heat.
Hence the pressure starts to rise. It's as though the condenser is temporarily undersized. The condenser pressure continues to rise until it reaches the normal
operating high side pressure and the ORI valve starts to throttle open and allow flow. This arrangement comes to an equilibrium and the system operates
with normal pressures as though it wasn't even cold outside. The ORI has a removable cap which exposes an adjustment screw for changing the set point.
The ORD valve is used to ensure that a full column of liquid is provided to the TXV. It opens if there is less than a 20 PSI difference between the true head
pressure and the head pressure on the downstream side of the ORI valve. When the ORD allows flow, pressure is applied to the top of the liquid/vapour
interface in the receiver as you can see from the piping layout. That in turn pressurizes the liquid line to maintain that full column. The ORD is pre-set and
not field adjustable.
The final component required for refrigerant side head pressure control is a larger receiver. When the condenser is flooded that extra refrigerant has to come
from somewhere and it would starve the rest of the system if it were not available from the oversized receiver. When not required that extra refrigerant
resides in the receiver. If you charge a system with refrigerant side head pressure control during summer conditions you will have given it the "Summer
Charge". Extra refrigerant is required to allow the head pressure control system to work properly. When it is fully charged it then has the "Winter Charge".
The OROA valve incorporates all functions of the ORI/ORD system into a single valve. It is not adjustable and also requires a larger receiver to
accommodate the winter charge.
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Capacity Control
Capacity Control
There are situations when it is beneficial for a system to have some form of capacity control. A compressor that can unload some of it's cylinders and start
with less than full capacity will draw less amperage at start up. That's desirable with large compressors which have large LRA (locked rotor amperage).
Another use of capacity control occurs with air conditioning systems. Air conditioning systems are usually designed to match the design cooling load.
However, the actual load can vary significantly. Recall that it is important for an air conditioning system to have a long run cycle in order to have adequate
time to dehumidify the air. If for example a 6 Ton system was called upon when there was a mere 1 Ton load, it would be able to satisfy that load in short
order and would shut off and await the next call. The sensible load would be satisfied but the latent load, the removal of moisture would have been poor.
Those circumstances would result in cool yet clammy, moist, uncomfortable conditions. If however the AC equipment had 2 stages, it would be a different
matter all together. If there were instead 2 stages of 3 Tons each, the first stage would be called upon to try and satisfy the load by itself. Half the capacity
would have twice the run time before satisfying the temperature set point and would therefore have twice the humidity removal resulting in more comfortable
conditions. It is also possible to reduce energy consumption by matching equipment capacity to the actual load.
Benefits:
● unloaded starts
● extended run cycle for improved humidity removal & less wear from cycling
● reduce energy consumption by matching capacity to the load
Multiple Stages
Roof top package cooling units with multiple stages of cooling are an example of capacity
control. The design cooling load is met by the capacity of both stages but during times of
low load the 1st stage tries to satisfy the load by itself yielding a long run cycle and
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Capacity Control
Multiple Compressors
Load conditions don't just vary in air conditioning systems, they sometimes vary in
refrigeration systems vary as well. Although refrigeration systems have no humidity
considerations with respect to comfort conditions there are concerns regarding energy
consumption. It can make a large difference to utility bills sometimes operating one of 2
smaller compressors rather than short cycle a single large compressor during times of low
load. Short cycling a system also wears out the operating controls. Contactor and relay
contacts arc and pit, motors strain under LRA starting conditions.
When there is a call for cooling one compressor will operate by itself trying to satisfy the load. If it does, then there was a cycle with one compressor only
operating. A longer run cycle is easier on equipment. If a single compressor can not satisfy the load then the second unit will come on to increase the cooling
capacity and satisfy the load. Dual compressor refrigeration systems will usually have a lead-lag control system. This means one compressor will be the lead
compressor (will start first) during one cycle and the other compressor will lag behind waiting to see if it is called upon. The next cycle the roles will reverse.
That way one compressor does not wear out faster than the other.
Systems should be kept in balance. The components should match each other in capacity. Pumping capacity must match evaporating and condensing capacity.
When evaporator load decreases, the metering device reduces the feed rate to compensate. That's why one compressor can match the lower load. The
condenser should also have capacity control to help keep things in balance.
*note that the discharge tee in the diagram is not "bull headed"
Another method of achieving capacity control is through use of 2 speed compressors. The residential air conditioning market has many manufacturers and
energy efficiency is a driving competitive force. One manufacturer boasts that their 2-Speed Heat Pump operates on the lower of the two speeds 80% of the
time. This can dramatically lower operating costs and improve humidity control simultaneously. Microprocessor Control Board's are used to control when the
compressor's speed is changed and also to squeeze out any conceivable bit of energy savings. For example, the indoor blower fan can be left on for a few
minutes of extra run time at the end of each cycle so that additional dehumidification and sensible cooling can occur until the cold evaporator coil warms up.
There are several energy efficiency standards that allow consumer comparison shopping. This pushes the OEM's to find ways of making their equipment more
efficient than the next manufacturer's.
● AFUE:
Annual Fuel Utilization Efficiency: a percentage measurement of a furnace's heating efficiency.
● HSPF:
Heating Seasonal Performance Factor: (Heat Pump Heating Efficiency) The higher the HSPF rating, the more efficient the equipment is.
● EER:
Energy Efficiency Ratio: calculated by dividing the cooling capacity in Btu's per hour (BTUH) by the power input in watts at a given set of rating conditions, expressed in BTUH per
watt.
● SEER:
Seasonal Energy Efficiency Ratio: a measure of cooling efficiency for air conditioning products. The higher the SEER rating number, the more energy efficient the unit.
● COP:
Coefficient of Performance: A ratio calculated by dividing the total heating capacity provided by the heat pump, including circulating fan heat but excluding supplementary
resistance heat (Btu's per hour), by the total electrical input (watts) x 3.412.
Variable speed compressors can be used to precisely match the load at any given time. For example a chiller with a variable speed compressor drive has very
precise control on chilled water temperature and provides energy savings at the same time. The idea is to just meet the actual need and use no more than the
actual amount of energy required to accomplish the task. A reduction in noise level is an additional benefit. The OEMs of variable speed systems boast energy
savings up to 50% compared to traditional systems.
Cylinder Unloading
Internal Unloader
There are several types of cylinder unloaders but they all set out to accomplish the same results. The purpose is to de-activate a cylinder so that it does not
perform any work. The internal unloader does this by holding the suction valve depressed with a small push rod. The piston is still oscillating up and down but
since it can not compress any gas with the suction valve held open, no work is performed. The push rod can be activated by oil pressure or even high side
refrigerant pressure. Press the buttons to see the external solenoid valve energize and allow high pressure oil to allow the cylinder to become loaded. Note that
the spring pressure causes the compressor to start unloaded. This makes it much easier to get the compressor started and up to speed. After the compressor
gets up to speed oil pressure develops and loading up the compressor becomes an available option.
Suction Cut-Off
The Suction Cut-Off method disables a cylinder by isolating it (or cutting it off) from the suction vapours. After one or two strokes there is no longer enough
vapour inside the cylinder to form enough pressure to open the discharge valve so the piston simply oscillates without doing any work.
Whether an unloading mechanism be mechanical, electrical, hydraulic, pneumatic or refrigerant pressure activated, the basic premise is to de-activate certain
cylinders. Since compressors can have up to 12 cylinders there can be significant flexibility possible when choosing the number of cylinders to be equipped
with unloading devices. For example, a 4 cylinder compressor equipped with 3 staged unloaders can provide capacity stages of 25%, 50%, 75%, and 100%.
However, the piping system must be designed to be capable of carrying the full quantity of refrigerant at 100% load and yet still have sufficient velocities for
oil return during unloaded conditions. P-Trap/Double Riser piping is utilized for vertical suction lines on systems that unload.
The minimum operating capacity possible with the cylinder unloading method is subject to the number of cylinders on the compressor. Hot gas bypass should
be given consideration where substantial operating time is anticipated below the minimum unloading step. During low load conditions Hot gas bypass valves
impose a false load on an evaporator by allowing some hot discharge gas to bypass it's normal route to the condenser and enter the low side of the system.
Although the diverted hot gas can be routed to the suction line after the evaporator, a far superior location is to tie in after the TXV. That way the evaporator
can serve as a mixing chamber for the bypassed hot gas and the liquid/vapour mixture from the expansion valve. The TXV will respond to the increased
superheat of the vapour leaving the evaporator and will provide the liquid required for desuperheating. Oil return from the evaporator is also improved since
the velocity in the evaporator is increased by the hot gas.
When used in combination with cylinder unloading it becomes possible to operate equipment at down to 10% of it's fully loaded capacity. Hot gas bypass
valves extend the run cycle of air conditioning equipment which improves humidity removal. They also limit the minimum evaporator pressure which
prevents coil icing. Longer run cycles means fewer starts and stops which decreases wear and tear on components.
If the hot gas line has a particularly long run an external equalized hot gas valve should be used. A solenoid valve should also be placed in the hot gas line to
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Capacity Control
prevent the possibility of liquid migration back to the compressor during the off cycle.
With multi-evaporator systems it may be necessary to bypass directly into the suction line. However that risks overheating the compressor and trapping oil in
the evaporator. Increased suction temperatures and therefore increased discharge temperatures cause breakdown of the refrigerant oil which leads to
compressor failures. On close-coupled systems, this can be eliminated by locating the main expansion valve bulb downstream of the bypass connection where
the hot gas enters the suction line. That way the TXV can sense that it can feed more liquid which will help to de-superheat the mixture and reduce risk to the
compressor.
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Hot Gas Defrost
All freezer systems form ice on the evaporators and periodically require some form of defrost. Electric defrost systems with electric resistance heater
elements are very popular because of their relative simplicity. However, electric resistance heat uses a lot of energy. Some systems are designed to use hot
discharge gas from the compressor to defrost evaporators and accomplish the task much more efficiently than electric resistance heaters. Hot gas defrosting
uses less energy because it is takes less energy to relocate heat than it does to create heat. (A heater element uses electrical energy to create heat. The
refrigeration effect uses a lot less electrical energy to relocate heat rather than create it) The trade off with hot gas defrost is the increase in complexity and
increase in electro-mechanical parts that must be relied on. Nonetheless some systems are prime candidates for using hot gas rather than electric defrost. A
heat pump system already has all the switch over capability required to create a hot gas defrost system. Heat pumps merely required a control system to
initiate and terminate the defrost sequence. That type of defrost is called a reverse cycle defrost. Ice cubers are another prime candidate for hot gas defrost.
That's because they have a huge demand for defrosts as they produce ice then immediately require heat to free up the cubes from the evaporator. Since this
process repeats continuously, energy efficient defrosts are desirable. Very large systems also are candidates for hot gas defrost systems because defrosting
large evaporators takes a lot of heat and once again energy consumption becomes an issue.
Refrigeration
Defrost
The simple layout above uses 2 solenoid valves to change from refrigeration to defrost. During defrost hot gas is diverted to the evaporator to melt any ice
build up. This system relies on very little condensation taking place when the hot gas travels through the evaporator. After giving off some heat for
defrosting, the cooled gas re-enters the compressor where it warms up from the heat of compression and is sent back to the evaporator to reject more heat to
melt more ice. An accumulator is used to protect the compressor from small amounts of liquid refrigerant. This type of hot gas defrost system does work but
it is not applicable for all situations.
A much more powerful defrost can be achieved when the hot gas is allowed to condense and give off the Latent Heat of Condensation. But by doing that the
hot gas changes into a liquid which can not be allowed to return to the compressor or liquid slugging would occur. The liquid must be re-evaporated first. A
system with multiple evaporators allows for an eloquent solution. Through use of 4 solenoid valves the defrost gas can be allowed to condense in the
defrosting evaporator and then be routed through the other evaporator to be re-evaporated before returning to the compressor.
Refrigeration Defrost 1
Defrost 2
When a timer calls for a defrost of evaporator 1 (click the Defrost 1 button) it toggles the condition of 2 solenoid valves:
● SLSV 1 (Suction Line Solenoid Valve 1) closes stopping the normal flow of suction vapours from evaporator 1.
● HGSV 1 (Hot Gas Solenoid Valve 1) opens allowing hot discharge gas to flow to evaporator 1.
The hot gas flows backwards into evaporator 1 (it enters at what is normally the outlet) and exits around the TXV through a check valve. There is nothing
stopping the refrigerant from going through the TXV, it just takes the route of least resistance through the check valve which is favourably oriented and
allows unrestricted flow. The now condensed refrigerant finds itself in the liquid line enroute to evaporator 2. When it gets there it finds that there is another
check valve in parallel with TXV 2. However, this time the orientation of the valve is opposite to the direction of flow and it is forced to go through the
restriction of the TXV. The liquid is re-evaporated in evaporator 2 and then returns through the open SLSV 2 to the accumulator and compressor where it
restarts the loop. The precise opposite happens when it is time for evaporator 2 to be defrosted. There are many variations of hot gas defrost systems in the
field. Some systems use a water reservoir as a thermal mass instead of a second evaporator as a heat source. Some have a small evaporator that is only used
for re-evaporating. There are many combinations possible.
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Electricity 1
Electricity
Part 1
H He
Li Be B C N O F Ne
Na Mg Al Si P S Cl Ar
K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr
Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe
Cs Ba La Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn
Fr Ra Ac Unq Unp Unh Uns Uno Une
Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu
Th Pa U Np Pu Am Cm Bk Cf Es Fm Md No Lr
Melts Boils
Colour Legend
Atoms
The elements have various numbers of electrons in their valence ring and therefore have
varying abilities to allow electrical current to flow. Those elements which do not hold on
tightly to the electrons in their valance ring are called conductors as they conduct electron
flow readily. Conductors are said to have a large number of free electrons. Free electrons are
not bound to an atom and may move or be shared with other atoms within a substance.
Elements like Copper, Aluminium, Carbon and Silver are examples of good electrical
conductors. Elements that do not allow electrical current to flow easily are called insulators.
Insulators hold on tightly to the electrons in their valence ring and resist electron flow. Some
examples of good insulators are Quartz, Teflon and Polystyrene.
Voltage
A difference in charge between two objects means there is a difference of voltage potential
between them. A difference in electric potential between two charged bodies is the Electrical
equivalent of pressure. Voltage is also known as ELECTROMOTIVE FORCE or EMF.
Resistance
● 1 KiloOhm = 1,000
● 1 MegOhm = 1,000,000
Amperage
Ohms Law
What is the name of the smallest subdivision of matter that still retains identifiable
characteristics?
What is it called when electrons flow from one atom to another?
Name 4 materials that conduct electricity well.
What does EMF stand for?
What is the standard unit of measurement of resistance?
What is one MegOhm?
Name 4 factors that affect the resistance of a material.
How much amperage does it take to be a risk to human life?
What 2 factors determine how much amperage will flow?
What does AC and DC stand for?
What is Hertz?
Do opposite magnetic poles repel or attract each other?
What creates lines of force?
Magnetic lines of force are always parallel to the electrical flow. True or False?
Are Magnetic lines of force additive?
Are Magnetic lines of force weakened or strengthened when near iron?
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Motor Types
Motors
IMAGE LABELS
Motor Types
*Motor types are shown in order of increasing starting torque (weakest first)
Shaded Pole
Split Phase
PSC
CSIR
CSCR
3 Phase
Motor Speeds
2 Pole Motors
60 revolutions/second x 60 seconds/minute
= 3600 revolutions per minute.
CYCLES:
1/2 1 RUN STOP
4 Pole Motors
30 revolutions/second x 60 seconds/minute
= 1800 revolutions per minute.
CYCLES:
1/2 1 RUN STOP
What type of motor is commonly used for very small evaporator fan motors?
Are start windings made of thinner or thicker wire than run windings?
What drops out the start winding in a split phase motor?
What drops out the start winding in a PSC motor?
Name 2 types of relays that are used to drop out start windings.
How many capacitors does a CSIR motor use?
How many capacitors does a CSCR motor use?
Which has thicker coil wires, a current relay or a pot relay?
Does a current relay have NO or NC contacts?
Does a potential relay have NO or NC contacts?
Which has more starting torque; a CSIR motor or a CSCR motor?
Why do some motor designs leave a capacitor in the start winding circuit?
What are the hot lines called in 3 phase power?
How many capacitors are used with a 3 phase motor?
How do you reverse the rotation of a 3 phase motor?
Which has a slower RPM, a 2 pole or a 4 pole motor?
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Starting Gear
Start gear, or starting gear refers to the apparatus required to get a single phase motor started.
(Three phase motors require no start gear) Keeping a rotor spinning is somewhat electrically
straightforward. Getting it moving from a stopped condition to a rotating condition is a little
more complicated. Capacitors, relays and other devices are used to accomplish this task.
Capacitance
C = C + C ...
TOTAL 1 2
Start Capacitors
Potential Relay
Current Relay
Thermal Starting Relays are another type of starting apparatus used on some domestic
refrigerators. There are a couple of types. One uses a resistance heater wire near some bi-
metal warp switches to make and break contacts. Another type known as a Hot Wire Relay
uses a wire in series with the motor windings which stretches or shrinks due to current flow
and actuates contacts that way.
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Controls
Controls
Part 1
Refrigeration systems require operating controls so they can cycle on and off to maintain a certain
temperature. They also require safety controls to stop operation if unsafe conditions occur. There are
many varieties of controls. Different types respond to temperature, pressure, humidity, liquid levels,
other controls, manual intervention and other things.
Thermostatic Control
Also note that just because the wiring on the left side of the T-Stat is not coloured red when the T-Stat
is open, that does not mean there is no electricity there. There is a full electrical potential on that line
and if you were to come along an stick your finger at that point you would be shocked. The red
coloured wiring indicates the logical flow routes. Non red wires are not necessarily without voltage
potential.
The graph below shows how an operating control cycles. The control is set to start refrigeration if the
box warms up to 40 ºF. That's called the Cut In point. The system keeps running until it reaches the
Cut Out point which is 37 ºF where it shuts off and awaits the next call for cooling. In this example
there is a 3 degree differential between the 2 points. The differential must be wide enough that the
equipment does not short cycle. Short cycling means to turn on and off too rapidly. Starting is hard on
the equipment, so you want to keep the number of starts per hour to a reasonable amount, not an
excessive amount. The 40 ºF point is a very special temperature. It is the standard cut in point for
most refrigeration systems. Above 40 ºF, bacteria growth rates in stored food increase dramatically.
Below 40 ºF, bacteria growth rate is subdued.
The cut out point is more of a compromise than anything else. Some products may store better at
colder temperatures but colder temperatures might adversely affect other products in the same box.
There is also a concern about keeping the evaporator from icing up. There is no active defrost system
in a standard refrigeration system. (defrost systems are only a standard item with freezers) If you
forced a refrigeration system to CI at 36 ºF and CO at 33 ºF, the evaporator would be operating about
10 ºF colder than each of those points and you would have forced the evaporator to operate in the
temperature range of 26 ºF to 23 ºF. Since the freezing point of water is 32 ºF, you can see that
moisture in the air is going to sublimate onto the evaporator surface and grow into thicker and thicker
layers of ice. Not only does ice act like an insulator and reduce thermal transfer, it can totally block
airflow through the evaporator fins and virtually stop thermal transfer. Some people try to push this
wall a little and it is possible to squeak out a degree or 2 colder than a 40 ºF cut in point. However,
anything more than a couple of degrees will risk icing the evaporator.
A countering force is the "off cycle defrost" effect. Since a refrigerator is designed to have a
temperature of 40 ºF, the recirculating air will tend to melt ice build up on the evaporator during the
times it has it has cycled off. There are of course refrigeration systems that are designed to operate in
the 35 ºF (and colder) range. However these typically have some form of defrost system. Systems that
are designed to operate below 32 ºF are freezers and they typically operate in temperature ranges like
0 ºF, -10ºF, -15 ºF as well as much colder.
The sensing bulb of the control should be mounted so that it senses the evaporator inlet air. During
the off cycle the constant fan recirculates the air in the box. The temperature of the air becomes an
average of the product temperature, the wall temperature, any infiltrated air and any other loads such
as caused by a person entering the box. When the air temperature reaches the cut in point of the
control it brings on refrigeration.
When refrigeration is operating, 40 ºF air passes through the evaporator and drops in temperature
several degrees. That's why the sensor can not be placed in or near the discharge air stream. If it was
placed there, the control would think that the whole box was cold and shut off the system as soon as it
started. It is the average box temperature that should be monitored, not the discharge air temperature.
Some thermostatic controls are designed with a capillary line temperature sensor which is intended to
be inserted between the evaporator fins on units that have a tendency to ice up. A commercial cooler
in a hot environment which is constantly being accessed would tend to ice up. A Constant Cut In
Control, also known as a beverage cooler control forces an off cycle defrost at the end of each run
cycle. The control will remain open until the evaporator has reached a temperature which indicates
that any frost accumulated during the previous run cycle has been melted. This type of control is used
in appliances like beverage coolers. Adjusting the knob on this type of control changes only the Cut
Out setting, the Cut In setting remains fixed.
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Troubleshooting 1
Troubleshooting
Part 1
Always pay attention to the complaint. Lot's of the time it may seem like useless
information when the customer or operator rambles on and perhaps mentions things like the
fact that they turned thermostat "way up". Even that however is informative. When a non
technical person says they turned up a cooling stat they probably do not mean they turned it
up to a higher setting, they probably mean that they turned it up to "full capacity". (In other
words they turned it down to a lower setting which insured it was calling) The point is that
you will have to remember to set the operating control back to it's proper setting after
remedying the problem. That however should be something that you always check each and
every time before leaving a job site. Sometimes you will learn something more helpful if you
listen carefully. What if someone was rambling on about how this is blowing the budget what
with the bill you will be providing and the plumbers bill from yesterday...That contained some
possibly informative information if the equipment you are about to work on is water cooled.
There is a possibility that the plumber had the water shut off and unknowingly tripped a high
pressure switch on the water cooled equipment. Always pay attention.
Start with a wide focus. Is the operating control calling, is there main power? Look over a
piece of equipment as you are approaching it. If the equipment looks OK from an overall
perspective, start visually examining things that are quick and easy to tentatively eliminate.
Inspect coil surfaces. Are the evaporator and condenser coils free of ice and dirt? Are belts in
place and pulleys and motors turning? Are the things that are supposed to be in operation
actually operating? Is the compressor operating? It would be non-productive to bury your
head in a maze of controls and start measuring things when you could have noticed a
condenser fan blade broken off or a broken blower belt.
Follow the lead. Lets say that the first thing that was noticed to be out of the ordinary was an
inoperative compressor. There are many things that could be the cause. The compressor could
be faulty. Or perhaps it is OK but is being held off by some safety control. That's probably the
next main category to determine. Is the compressor off due to a power side or a control side
problem? Use your meter and measure if you have proper main power and control voltage as
per the nameplate or wiring diagram. If you have proper control voltage available at the
control voltage transformer and you have proper main power to the compressor contactor you
will have narrowed down the field of possibilities considerably. If control voltage is not
getting to the compressor contactor coil then your next task would be to find out where it is
being stopped. If for example you had an open LPC that would indicate where to look next.
An open HPC would steer you in another direction.
But what if the system has a leak and has lost enough gas to trip a low pressure safety switch?
Couldn't you have checked the refrigerant pressure right at the start and be that much further
ahead? You can jump about from pillar to post or you can continue on in a logical process of
elimination. Either one can win first. If you use the "hop scotch method" of electrical
diagnosis you start at the beginning of the control circuit and keep on hopping from one
control to the next until you find the open control or open circuit. If it turns out to be an open
low pressure control you would certainly want to verify things with pressure gauges.
As another example, the compressor could be locked out on an open high pressure control.
Using gauges at the outset would not have done you any good under those circumstances.
You would merely be looking at off cycle pressures. Finding an open high pressure control
would not be the end of your search. You must find what caused the trip. Did it trip for a
legitimate reason? Is the problem intermittent? Is the cut out setting correct? Operate the
system with gauges on, is the operating head pressures too high at the moment? If it is, the
next thing you would do is start mentally listing all the things you can think of that could
cause high head pressure; dirty condenser, high ambient, inadequate air or water flow, non-
condensables, deteriorated fin bond, recirculated air, mixed refrigerants, over charged. etc..
Out of that list you might try to eliminate the things that are easiest to eliminate first.
Remember it was suggested to visually inspect the overall system right from the outset? If a
dirty condenser had been noticed you could have gone straight from that to checking the high
pressure switch. As a matter of fact, one of the first things an experienced mechanic will do is
glance at reset buttons to see if they are tripped and possibly narrow the focus instantly. So it
You might not even notice an experienced mechanic feel the airflow as he approaches a unit.
It can be fun to proclaim a clogged condenser and watch the look on someone's face when
they get down on their knees to look underneath a horizontal type condenser to inspect the fin
surface and their mouth drops open in amazement.
A mechanic will feel other things as well. One of the first things he or she will do is grab on
to the suction line and get an idea of the temperature of the suction gas. This is a habit that
develops and is merely a way to possibly narrow the focus when troubleshooting. For
example, if the last 4 air conditioning systems suction lines you felt were all cold and the next
one is kind of warm you get a big hint that there could be some sort of refrigerant side
problem or compressor problem.
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Electrical Symbols
Electrical Symbols
Manufacturers use variations of electrical symbols on their schematics and wiring diagrams. However
the symbols are usually fairly cryptic. Some of the more common symbols and variations used in the
HVAC field are shown below.
Switching Devices
Open Closed Description Abbreviation
Switch
Single Pole SPST
Single Throw
Switch
Single Pole SPST
Single Throw
Switch
Single Pole SPST
Single Throw
Momentary Switch
Single Pole SPST
Single Throw
Switch
Single Pole SPDT
Double Throw
Switch
Single Pole SP3T
Three Throw
Switch
Double Pole DPST
Single Throw
Switch
Double Pole DPDT
Double Throw
Fused Disconnect
3PDT
Switch
Liquid Level
Activated
Breaks on rise
Liquid Level
Activated
Breaks on fall
Flow Switch
Low Pressure
Control LPC
Breaks on fall
High Pressure
Control HPC
Breaks on rise
Thermostatic
Control
T-Stat
Makes on rise
Cooling control
Thermostatic
Control
T-Stat
Makes on fall
Heating control
Thermostatic
Control
T-Stat
Makes on fall
Heating control
Bi-metal Disk
Thermal Element
Circuit Breaker
CB-1, CB-2 etc.
2 pole
Circuit Breaker
3 pole with CB-1, CB-2 etc.
thermal overloads
Circuit Breaker
3 pole with CB-1, CB-2 etc.
magnetic overloads
Loads
Resistive Load
HTR
IE: heater
Resistive Load
HTR
IE: heater
Resistor
Variable Resistor
Resistor
Variable Resistor
Positive Temperature
Coefficient Resistor PTC or PTCR
(Electronic Start Relay)
Light Bulb
Motor
Motor
Miscellaneous
Transformer
Transformer with
multiple taps
Diode
Light Emitting
LED
Diode
Capacitor
Capacitor
Battery
Battery of cells
Fuse
Fuse
Supply Voltage
230 Volts
alternating current
Junction of conductors
Junction of conductors
are sometimes shown
like this
Crossing of conductors
with no electrical
connection
Crossing of conductors
with no electrical
connection are also
shown like this
Electrically hot
Electrically neutral
Common
Ground
Line 1
Line 2
Line 3
Line
Single Phase
Three Phase
Help Hint
CFM seized.
COMPR seized.
EFM seized.
HPC tripped.
LPC open.
No Faults.
No power.
Unlisted problem.
Input
Access Submit
Code
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Advanced Troubleshooting Help
The advanced troubleshooting section allows you to diagnose equipment problems by measuring all major operating parameters. High and low
side refrigeration gauges display operating pressures. A digital temperature meter allows measurement of refrigerant and air temperatures in
several key locations. PT charts are provided for the refrigerant being utilized. Electrical measurements can be taken at any of the test points on
the electrical schematic. This is your opportunity to apply all of the theory and diagnostic techniques taught in this e-book and troubleshoot
problems with realistically portrayed equipment faults. Below is a screen shot of the advanced troubleshooting user interface. The key features
are indicated with circled red numbers. The features are explained in detail below the screen shot.
The title informs you which equipment type and refrigerant you will be diagnosing. You must know whether the system is a high, medium or
low temperature application so that you can come to conclusions about operating pressures and temperatures.
The Hint Button sometimes provides clues such as might be given by the equipment owner.
The PT Chart Button opens a new window containing the PT Chart relevant to the equipment being diagnosed.
The Abbreviations Button opens a new window which lists the meanings of the abbreviations in the Notes section (13)
When you believe that you have correctly diagnosed the problem click the Submit Diagnosis button to open a new window where you may
submit your diagnosis and find out if you are correct.
The low side and high side pressure gauges can be activated by clicking the small Buttons labeled P1, P2 and P3. Each Button corresponds
to identically named test points on the refrigeration piping diagram (8). Note that when you click one of the buttons it turns green and the
corresponding test point on the piping diagram also turns green.
The piping layout also contains temperature test points which are labeled T1, T2, T3 etc. It also contains pressure test points which are
labeled P1, P2 and P3. Test points turn green when activated by the corresponding test instrument. (gauges or temperature meter)
The electrical schematic operates exactly like the diagrams you have already experienced in the previous troubleshooting sections. The test
points turn green when activated by the Volt/Ohm/Amp meter.
The Volt/Ohm/Amp meter operates exactly as in the previous troubleshooting sections. The mode buttons turn green when clicked to indicate
the test mode.
The digital temperature meter has 9 buttons which correspond to the 9 temperature test points on the piping diagram. When you select a
button it changes to green and the corresponding test point on the piping diagram also changes to green providing a helpful visual reference.
The unit nameplate provides electrical ratings for the equipment components.
Click the Abbreviation Button (5) to see the meaning of the abbreviations listed in the Notes section. The Notes section allows you to record
pertinent information as you gather it. For example, when determining superheat, it is helpful to have a handy place to record data such as low
side pressure (LO), suction line temperature (SLT) and the corresponding PT Chart temperature (CORR). Each time you gather more data
about the operating parameters record it in the Notes section. You may not need to fill it in completely to make a diagnosis. On the other hand,
the more information you gather, the greater is the likelihood that your diagnosis will be correct.
Electrical Measurements
Amps When the meter is in amps mode and you click a test point, the amperage draw of all the loads in that electrical branch are displayed in the
meter. If there are "sub branches" those loads are included.
Volts When the meter is placed in the voltage mode one test point is automatically selected. This is typically either the Common leg or Line 2. You
must select the 2nd test point. The volt meter then displays the voltage potential between those 2 points. A volt meter reports a voltage
potential across an open circuit and across loads.
Ohms The power in an electrical circuit must be turned off before using an ohm meter. If you fail to do so you may damage the ohm meter or at
least blow the meter's fuse. Anytime you put the meter into ohms mode it is assumed that the power has been turned off. To measure the
resistance of a component select the 2 closest test points. It is assumed that any parallel loads have been taken out of the circuit. If you try
measuring a circuit with several loads in parallel or series you are likely to receive the following alert:
In real life you will have an ohm reading representing the combination of all the series and/or parallel resistances between the 2 test points
you selected. However those types of readings are seldom useful when troubleshooting. That is why you must isolate components from the
rest of the circuitry to take a resistance measurement. You may still attempt any measurement you wish and are not restricted to adjacent
test points only. When it is somewhat obvious that a specific component or wiring circuit is being tested you are likely to be given a reading.
The further apart your test points are, the greater is the liklihood that you will receive the above alert instead of a meter reading.
When you take a reading that has direct continuity (zero resistance) between 2 test points and there also happens to be a measureable
resistance in parallel, the measureable resistance load is ignored. This is true in real life as well as in these troubleshooting boards. That is
because electricity will favour taking the route of least resistance.
If you have completed the previous 100 troubleshooting boards, that doesn't mean the
diagnostic challenge is over. If you are ready for the biggest challenge yet, click the button
below to randomly select a troubleshooting board. Note that there will be no "Help" nor
"Hint" nor "Abbreviation" Buttons. You will not be able to recognize the fault board by the
file title; they are all renamed to "Random Board" If you try to determine the file name you
will discover that they have all been changed to unrecognizable binary numbers like 1001100.
There will be neither technical discussions nor explanations if you submit a correct diagnosis.
You will merely be informed whether your diagnosis is correct or incorrect. If you are wrong
you will be sent to a new randomly selected board. You will be locked into full screen mode
where there is no Back Button, so you will have no way to back track and make a second
guess. The random boards section is similar to real life troubleshooting. You don't get to
choose which machine breaks down next and you are expected to make correct diagnoses first
time, every time. So be methodical and thorough. Troubleshooting should be fun, not
exasperating. If you do poorly you need to retrace your steps and master the diagnostic skills
that are explained in this book. Do have fun and I hope that you enjoy the challenge.
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Safety
Safety
The Refrigeration Trade is considered by some to be the most dangerous trade. Surely a bomb
squad technician or perhaps law enforcement officials or high steel workers face greater
perils than a mere refrigeration mechanic. However the reasoning behind this assumption is
understandable. An HVAC/R mechanic must deal with high voltage electricity and work
from ladders and spend time on construction sites where all manner of dangerous situations
arise. He deals with high pressure gases, operating machinery with spinning pulleys and belts,
welding gases and hot pipes. He spends time on roofs and working with cranes and heavy
suspended objects. If all of this isn't enough, he also spends much time wearing out his knees
and back lifting heavy objects and kneeling in front of electrical control cabinets to
troubleshoot live components or replacing a compressor, fan motor or some awkwardly
placed component. Why do we do it? Why is a cop a cop? Why does a high steel worker
romp about on skinny beams hundreds of feet up? The short answer is that it can be a well
paying career. The real answer is that we find it extremely interesting. You have to be cut out
for the job. It is possible to do anything if you have enough interest but the vast majority of
technicians who end up staying in the trade find that they were born for the work. And that
does not mean that everything is a bed of roses for the "right type" of person. It means you
have to be capable of taking the good with the bad but believe that the interesting parts
outweigh the miserable parts.
If you are the type of person who finds he has an interest in mechanics and thermodynamics
then you should also be the type of person that is always thinking ahead about consequences
and choices while doing your job. Ninety-nine percent of staying safe in this trade or perhaps
any job is thinking ahead and creating safety as you go. For example, it is less likely that you
will set off a fire with your welding torch if you use a protective shield over nearby
flammable surfaces. If a fire does develop it will likely be much less of a problem if you were
following normal safety procedures and had a fire extinguisher standing by within immediate
grasp.
The most dangerous time for an HVAC mechanic is his or hers first years on the job. That's
because everything is new and exciting and it's hard not to be overwhelmed by the vast
assortment of amazing things to learn. A proper apprenticeship is the only way to learn how
to do things the safe way. How else can you learn about the hidden dangers and tricks unless
it is through the supervision of someone with experience. The first time you are standing on a
roof assisting with the placement of a heavy roof top unit onto it's curb you will be thinking
about the control system and where the T-Stat will be placed and anticipating all the wonders
you are about to be exposed to. You may not be thinking about the large amount of
momentum that a heavy unit has as it slowly moves while slung from the crane. If you
happen to be standing in-between the unit and the edge of the roof you may not realize that if
it swings in your direction it will sweep you off the roof like you weighed nothing at all. Any
stabilizing you were considering doing for the unit can just as easily be done without placing
your body in a position of danger. It's those types of things that turn out to be the most
dangerous. The subtle things hiding in plain view in combination with a lack of experience.
Never stop thinking ahead about safety.
Attempting to manipulate a live electrical connection can sometimes save a lot of grief. This
is certainly not a perfect world and there are an infinite number of improperly labeled or
unlabeled circuits on electrical panels. Sometimes you can not shut down a whole panel and it
becomes very tempting to work on a live circuit rather than spend an unknown amount of
time tracing the disconnect switch or circuit breaker. Sooner or later you will face that
dilemma. Remember to try to measure the amount of grief your loved ones will have if you
are killed or injured compared to the amount of aggravation you would apparently be
avoiding. If that logic doesn't do it for you then try to look at it this way; you can legitimately
charge for the time it takes to trace a circuit and properly label it. It's the same pay for
marching as it is for fighting. So why not take the time to do things the right way. Work
safely and create a safer environment for the next guy at the same time. That is a far superior
attitude than jumping from pillar to post trying to get things done in a hurry to please your
boss or please yourself. It is up to you to make your own rules and decide what is safe, what
is not, and where you draw the line. It is smarter to do that before you are looking up from a
hospital bed or blankly staring out from a coffin. If you need no convincing and wish to do
things safely then you only need to keep that mind set and keep an eye out for the myriad of
little things that are all waiting to get you. Each time you learn of some danger file it away in
your head and never forget it. When learning the refrigeration trade there are lots of mistakes
that can be made and lots of mistakes one can get away with. Safety is not always that
forgiving. There are some mistakes that you just may not live through. You must learn right
from the outset to anticipate dangers and avoid them. There has probably never been a
refrigeration book written that does not mention that oil must never be placed on the threads
of an oxygen fitting nor must oxygen ever be used to pressure test a piping system that
contains oil. Still we read about the unknowing who do either of those things and blind or kill
themselves with their own unintentional bomb.
If it was possible to list ten thousand dangerous circumstances it would certainly not cover all
possibilities. However the short list below, in no particular order, may be helpful as it exposes
several dangers and also includes some recommendations.
Safety Tips
● Wear safety boots with steel shanks, steel toes and di-electric soles.
● Wear knee pads when kneeling on concrete for extended periods.
● Wear hard hats when appropriate.
● Wear safety harness and safety rope when working on heights.
● Carry safety equipment like fire extinguishers and maintain them.
● Keep ladders in good repair.
● Secure ladders on roof racks properly.
● Always tie off extension ladders.
● Do not wear jewellry when troubleshooting electrical equipment.
● Do not wear long ties or loose hanging clothing near pulleys and belts.
● Shut off power before working on electrical components when possible.
● Lock off and tag electrical switches when working on line voltage wiring.
● Wear protective clothing when welding pipes because you will graze into hot pipes
sooner or later.
● Wear safety glasses when welding, drilling, grinding or any other time debris may
threaten your eyes.
● Wear safety glasses and gloves when working with refrigerants.
● Acquire a proper fuse puller. No other tool removes cartridge fuses as safely.
● Don't carry things up a ladder when you can haul them up with a rope.
● Keep proper slope on extension ladders.
● Don't stand between the roof edge and a suspended crane load.
● Don't place parts of your body in jeopardy when a tool can be used instead.
● Get in the habit of standing aside and looking away from electrical control panels
when throwing disconnect switches and breakers.
● When possible, don't have any part of your body other than your di-electric safety
boot soles touching electrical grounds when working on live electrical components.
● Don't troubleshoot electrical equipment in the rain.
● Don't pop out electrical knock outs with your finger, use a tool. If your finger slips it
can rip your finger nail clean off. .
● Find out what type of refrigerant is leaking before allowing any type of open flame in
the area. Some of the new refrigerants have flammable components.
● Use the proper tool for the job. A wrench is not a hammer, a knife is not a wire
stripper.
● Don't lay an acetylene tank on it's side while brazing.
● Don't lay down a torch that you just used until you test it for a smouldering flame by
cracking the fuel knob.
● You are responsible for the danger from hot pipes that you create while brazing. Wet
rag them before walking away. Don't subject other's to extreme burns by walking
away from hot pipes.
● Leave the area and make others do the same if you create phosgene while welding.
● Don't assume power is dead just because a switch is off.
● Discharge capacitors with a 20 KiloOhm 2 Watt resistor before handling them.
● When hooking up an electrical device tie in the ground first so that if electricity
suddenly appears it has somewhere to go other than through you. Tie in Neutral
second and Lines last.
● Don't assume a low voltage control circuit can only have low voltage present.
Mistakes are made, always check for actual voltage with a test meter.
● Never oil oxygen fittings.
● Never pressurize a refrigeration system with oxygen.
● Do not exceed manufacturers maximum pressure ratings on pressure vessels.
● Do not remove or leave safety controls bypassed. You must not put other's in
danger.
● Test a voltage meter on a live source before relying on it's read out of a supposed
dead circuit.
● Discharge capacitors with a resistor before handling them.
● Lock off and tag a remote disconnect switch that could put you in danger while
working downstream of it.
● Never allow a compressor to run with the DSV front seated.
● Close off your welding tank before walking away from it.
● Close panels on live electrical control sections before walking away from them.
There is another ominous type of danger. That is the danger that comes with complacency. As
you get used to working under what can be dangerous circumstances it eventually becomes
common place and you may lower your guard a little bit. At the opposite end of the scale
from a novice apprentice is the seasoned veteran. He is set in his ways and knows many
things. He has lots of short cuts and over the years has learned to compromise safety in the
name of expediency. Sooner or later that will catch up with him. Don't let that happen to you.
Work safe, keep aware of the dangers around you, don't become complacent about safety.
Enjoy a long healthy life.
Here's your chance to see how much of the material in this book you have grasped. There is no time limit for this test but it is not an open book
test. (do not look at any reference material) When you complete all the answers click on the Submit Button at the end of the test and your score
will be displayed in percentage. Don't despair if you do poorly the first time through. You will have learned what sorts of things you should
know outright or be able to figure out with a little thought. You may find it interesting to do the test several times and watch your score
improve over time as you learn more of the concepts and material in this book. Have fun.
5 ºF
10 ºF
15 ºF
25 ºF
Kelvin, Celsius
Celsius, Rankine
Kevin, Fahrenheit
Fahrenheit, Centigrade
8. Which Latent Heats are involved if water is frozen then thawed and then boiled?
14.7 PSI
760 mm
29.92 "Hg
all of the above
If the type and temperature of a refrigerant are known, then the pressure being exerted by the refrigerant can be calculated
Recovered refrigerant must not fill a jug more than 60% by weight
Dangerous hydrostatic conditions can occur if a jug is filled 100% full with refrigerant vapour.
New jugs of refrigerant are shipped from the manufacturer 80% full by weight
11. A low side refrigerant gauge open to atmosphere will register what pressure?
0 PSI
29.92 "Hg
14.7 PSIG
0 PSIG
1/1000th mm Hg
29.92 "Hg/1000
the 1st two are both correct
1/1000th x 760 mm Hg
increase superheat
decrease superheat
increase bulb temperature
2nd & 3rd answers are both correct
17. Which of the following lists of Metering Devices have fixed flow rates?
Hermetic compressors are popular because they are inexpensive and the valves and valve plates can be changed should the need
arise
Open compressors are direct drive or belt driven
Scroll compressors are more tolerant to liquid content than are reciprocating compressors
Hermetic compressors are suction cooled
Vapour charging is appropriate if introducing refrigerant into the high side while the system is running
Front seating a King Valve causes the high side to pump down
Front seating the SSV causes the compressor to pump down
Mid seating a service valve causes the most restriction for evacuation
22. To determine subcooling you need to measure the temperature of what pipe?
suction line
discharge line
capillary line
condensate line
23. To determine superheat you need to measure the temperature of what pipe?
discharge line
suction line
liquid line
condensate line
Humidity
Psychometrics
Air Conditioning
Enthalpy
Superheat
Superheat, Subcooling, amperage draw
Head Pressure, Discharge Temperature, amperage draw
Head Pressure, Suction Pressure, amperage draw
30. Which of the following lists motor types in order of increasing starting torque?
The pole structure of a shaded pole motor causes formation of a rotating magnetic field by delaying the build up of magnetic flux
CSCR motors have a capacitor in series with the run winding and a capacitor in series with the start winding
Pot relays have thick wires in their coil to withstand the high voltage potential that they are subjected to
PSC motors can use current or pot relays
36. If in good condition, the NC contacts on a relay should show the following resistance:
MR
open
continuity
infinite resistance
37. If in good condition the coil on a potential relay should show the following resistance:
MR
open
zero Ohms
infinite resistance
Voltage increases
Current decreases
Unrestricted electron flow occurs
EMF and magnetic effect cease
I = R/E
I=ExR
I = Voltage divided by current
I = E/R
E = IR
R = E/I
All of the above
none of the above
300 CFM/Ton
350 CFM/Ton
400 CFM/Ton
450 CFM/Ton
300 CFM/Ton
350 CFM/Ton
400 CFM/Ton
450 CFM/Ton
partial pressures
volume & pressure
volume & temperature
pressure & temperature
partial pressures
volume & pressure
volume & temperature
pressure & temperature
partial pressures
volume & pressure
volume & temperature
pressure & temperature
46. It can be a good idea to lubricate O-rings and threaded refrigeration fittings with oil:
always
false
not true for PAG and POE
if using PAG
48. What does turning the blue hand wheel clockwise on a gauge manifold set do?
receiver
accumulator
LLSV
Suction/Liquid Heat Exchanger
50. Which of the following pump down tests indicates a good compressor?
51. A volt meter is used to take a couple of readings. The first reading measures the voltage potential across a relay coil that has no
problems. The second reading is across a coil that is burnt open. The two readings will be:
identical
opposite
measurable voltage and zero volts respectively
zero volts and a measurable voltage respectively
0 PSIG
28 "Hg VAC
250 microns
750 to 800 microns
56. When testing to see if an evacuation holds, the micron reading starts to rise but then levels off.
coalescing
rotary
impingement
helical
60. A receiver should be sized to hold the entire charge and be:
on the water inlet side of the condenser and with parallel flow
on the water outlet side of the condenser and with counter flow
on the water inlet side of the condenser and with counter flow
on the water outlet side of the condenser and with parallel flow
68. Refrigeration oil breaks down and forms carbon, sludge and possibly acids at:
250 ºF
350 ºF
450 ºF
550 ºF
69. What component can be used so that multiple evaporators with different temperatures can be operated with one condensing unit?
CPRV
EPRV
AEV
Hot Gas Bypass Valve
74. Where should the sensing bulb of a walk in cooler T-Stat be positioned when being used as the operating control?
79. On a schematic diagram, a relay labelled CR2 could have contacts labelled:
electricity
thermal expansion and contraction
magnetism
inductance
81. Which combination of capacitors, if wired in parallel, could safely replace a faulty 270 MFD 370VAC capacitor?
70 MFD 370 VAC + 100 MFD 370 VAC + 100 MFD 115 VAC
200 MFD 600 VAC + 35 MFD 440 VAC + 35 MFD 600 VAC
70 MFD 270 VAC + 200 MFD 270 VAC
none of the above
83. Which of the following refrigerant lists are not banned or scheduled to be banned from production?
84. Which of the following is the absolute minimum that must be done?
recycle
reuse
recover
reclaim
recycle
reuse
recover
reclaim
recycle
reuse
recover
reclaim
87. Which of the following can tell you the percentage of MO in an oil mixture?
hygrometer
refractometer
odometer
acid test kit
blends
refrigeration oils
oil separators
filter cartridges
93. What capacity stages can a 4 cylinder compressor with 3 unloaders provide?
94. Where is the best place to tie in the discharge line from a hot gas bypass valve?
95. Does oil pressure load or unload an internal cylinder unloading system?
load
unload
neither
both
96. Which of the following symptom sets could be from an overcharged system?
97. Which of the following symptom sets could be from an undercharged system?
high: head pressure, discharge temperature, suction pressure, superheat, amperage draw
low: subcooling
98. Which of the following symptom sets could be from an system contaminated with non-condensables?
high: head pressure, discharge temperature, suction pressure, superheat, amperage draw
low: subcooling
refrigerant overcharge
high side restriction
high evaporator airflow
low condensing ambient
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Index
3 Phase
4 way reversing valve
AB
Absolute Zero
AC
access valves
accessories
accumulator
Accurator
Add On Heat Pump
adiabatic
AEV
AFUE
AHU
air (components of)
air (conditions of)
air conditioning
air filtration
alkylbenzene oil
All Electric Heat Pump
Alternating Current
Annual Fuel Utilization Efficiency
Automatic Expansion Valve
amperage, also
anti-short-cycling device
anticipation
ASHRAE
atom
Azeotropes
Back Seated
Balance Point
barometer
bi-metal disk
Bourdon
Boyle's Law
British Thermal Unit
BTU
bull headed tee
burn outs
capacitor
Capacitor Start Capacitor Run Motor
Capacitor Start Induction Run Motor
capacity control
capillary line
Celsius
centrifugal compressor
ceramic capacitor
check valve
charging
Charle's Law
Class 1 Conversion
Class 2 Conversion
Close Coupled
coalescing oil separators
Class 1 conversion
Class 2 conversion
compressors
compressor driver
Compressor Efficiency Test
condensate line
condensate pan
Condenser Dampers
condensing medium
Condensing Unit
conduction (electrical)
conduction (thermal)
conductor (thermal)
controls
Constant Cut In Control
convection
cooling anticipator
cooling load
cooling tower
COP also
Coulomb
CPRV
cracked
crankcase heater
CSIR
CSCR
current relay
cut in
cut out
Daulton's Law
DC
Defrost Termination Thermostat
design temperature
Dew Point
Defrost Termination Stat
dielectric
Direct Current
Discharge Service Valve
discharge temperature
distributor
drop in replacement
DSV
dual pressure control
EER
EEV
electric defrost
electrical symbols
electricity
Electro-Magnetism
electrolytic capacitor
Electromotive Force
Electronic Expansion Valve
EMF
energy
Hertz
High Side Float
High Side Restriction
holding circuit
Hop Scotch Method (troubleshooting)
Hot Gas Bypass Regulator, also
hot gas defrost
Hot Wire Relay
HSPF
hydrostatic pressure
hygroscopic
human comfort zone
humidity
impedance
impingement oil separators
incremental unit
insulation (electrical)
insulation (thermal)
Kelvin
King Valve
ladder schematic
Latent Heat, also
lead-lag
Line Tap Valve
liquid/vapour interface
Liquid Line Filter/Drier
Liquid Line Solenoid Valve
liquid slugging
LLSV
lock out circuit
locked rotor amperage
Low Side Float
low voltage controls
LRA
magnetism
MAT
Mechanical Cooling
MegOhm
Mercury
mercury bulb thermostats
Metering Device, also
MFD
micron
micron gauge
Mid Seated
migration
mineral oil
Minimum Fresh Air
Mixed Air
MO
molecule
Mollier Charts
motor theory
motor types
muffler
multiple compressors
multiple stages
Non-Recycling Pump Down
OAT
ODS
ODS Conversions
OEM
off cycle defrost, also
Ohm, also
Ohm's Law
oil failure controls
oil separator
oil slugging
open compressor
ORD
ORI
OROA
Ozone Depleting Substance
Packaged Systems
PAG
Parallel Drop
Permanent Split Capacitor Motor
phosgene
piping
POE
polyalkylglycol oil
polyolester oil
potential relay
pressure
pressure control
Pressure-Enthalpy Diagram
Pressure Temperature Relationship
PSC
PSIG
Psychometrics
P-Trap
PTC
PT Charts
PTCR
pump down, also
Radiation
Rankine
receiver
reciprocating compressor
reclaim
recover
recycle
refractometer
refrigerants
refrigerant leaks
refrigerant oils
Refrigerant Side Head Pressure Control
Refrigeration (definition of)
Refrigeration loop
relay
resistance
retrofitting ODS
reuse
reverse cycle defrost
rotary compressor
rotor also
run capacitor
running burn out
safety
safety controls
Saturated Conditions
Schraeder Valve
screw compressor
scroll compressor
Seasonal Energy Efficiency Ratio
Secondary Refrigerant
SEER
semi-hermetic compressor
Sensible Heat
Service Valves
set back
Shaded Pole Motor
short cycling
sight glass
Specific Heat
Split Phase Motors
Split Systems
Squirrel Cage
Start Capacitor
Start Gear
stator also
Subcooling, also
suction filter
suction/liquid heat exchanger
Suction Service Valve, also
Superheat, also
SSV, also
suction cut-off
tackified
Temperature
TD (Temperature Difference)
TEV, also
Thermal Starting Relays
Thermostatic Expansion Valve, also
thermostats - low voltage
three phase motors
time delay fuse
time delay relay
Ton
toxicity
transformer
troubleshooting
TXV, also
unloader
vacuum
vibration absorber
vibration loop
voltage, also
wall mounted t-stats
water cooled condensers
water cooled system
water regulator valve
Zeotropes
Part 2
Main Components
There are 4 main components in a mechanical refrigeration system. Any components beyond these basic 4 are called
accessories. The compressor is a vapour compression pump which uses pistons or some other method to compress the
refrigerant gas and send it on it's way to the condenser. The condenser is a heat exchanger which removes heat from the hot
compressed gas and allows it to condense into a liquid. The liquid refrigerant is then routed to the metering device. This
device restricts the flow by forcing the refrigerant to go through a small hole which causes a pressure drop. And what did we
say happens to a liquid when the pressure drops? If you said it lowers the boiling point and makes it easier to evaporate, then
you are correct. And what happens when a liquid evaporates? Didn't we agree that the liquid will absorb heat from the
surrounding area? This is indeed the case and you now know how refrigeration works. This component where the
evaporation takes place is called the evaporator. The refrigerant is then routed back to the compressor to complete the cycle.
The refrigerant is used over and over again absorbing heat from one area and relocating it to another. Remember the
definition of refrigeration? (the removal and relocation of heat)
One thing that we would like to optimize in the refrigeration loop is the rate of heat transfer. Materials like copper and
aluminium are used because they have very good thermal conductivity. In other words heat can travel through them easily.
Increasing surface area is another way to improve heat transfer. Have you noticed that small engines have cooling fins
formed into the casting around the piston area? This is an example of increasing the surface area in order to increase the heat
transfer rate. The hot engine can more easily reject the unwanted heat through the large surface area of the fins exposed to the
passing air. Refrigeration heat transfer devices such as air cooled condensers and evaporators are often made out of copper
pipes with aluminium fins and further enhanced with fans to force air through the fins.
Metering Device
We will now take a closer look at the individual components of the system. We will start with the metering device. There are
several types but all perform the same general function which is to cause a pressure drop. There should be a full column of
high pressure liquid refrigerant (in the liquid line) supplying the inlet of the metering device. When it is forced to go through
a small orifice it loses a lot of the pressure it had on the upstream side of the device. The liquid refrigerant is sort of misted
into the evaporator. So not only is the pressure reduced, the surface area of the liquid is vastly increased. It is hard to try and
light a log with a match but chop the log into toothpick sized slivers and the pile will go up in smoke easily. The surface area
of zillions of liquid droplets is much greater than the surface area of the column of liquid in the pipe feeding the metering
device. The device has this name because it meters the flow of refrigerant into the evaporator. The next graphic shows a
capillary line metering device. This is a long small tube which has an inside diameter much smaller than a pencil lead. You
can imagine the large pressure drop when the liquid from a 1/4" or 3/8" or larger pipe is forced to go through such a small
opening. The capillary line has no moving parts and can not respond to changing conditions like a changing thermal load on
the evaporator. I have also added a few labels showing the names of some of the pipes.
The Evaporator
The metering device has sprayed low pressure droplets of refrigerant into the evaporator. The evaporator could be the forced
air type and could be constructed of many copper tubes which conduct heat well. To further enhance heat transfer the pipes
could have aluminium fins pressed onto them. This vastly increases the surface area that is exposed to the air. And this type
of evaporator could have a fan motor sucking air through the fins. The evaporator would be capable of reducing the
temperature of air passing through the fins and this is a prime example of the refrigeration effect. If that evaporator was
located in a walk in cooler, the air would be blown out into the box and would pick up heat from the product; let's say it is a
room full of eggs. The flow of heat would be egg core/egg shell/circulating air/aluminium fins/copper evaporator pipe/liquid
droplet of refrigerant. The droplet of refrigerant has the capability of absorbing a large quantity of heat because it is under
conditions where it is just about ready to change state into a gas. We have lowered it's pressure, we have increased surface
areas and now we are adding heat to it. Just like water, refrigerants also have ratings for Latent Heats of vapourization in
BTU's per LB. When heat is picked up from the air stream, the air is by definition cooled and is blown back out into the box
to take another pass over the eggs and pick up more heat. This process continues until the eggs are cooled to the desired
temperature and then the refrigeration system shuts off and rests. But what about our droplet of refrigerant. By now it might
have picked up so much heat that it just couldn't stand it anymore and it has evaporated into a gas. It has served it's purpose
and is subjected to a suction coming from the outlet pipe of the evaporator. This pipe is conveniently called the suction line.
Our little quantity of gas joins lots of other former droplets and they all continue on their merry way to their next destination.
The Compressor
The Condenser
The condenser is similar in appearance to the evaporator. It utilizes the same features to effect heat transfer as the evaporator
does. However, this time the purpose is to reject heat so that the refrigerant gas can condense back into a liquid in preparation
for a return trip to the evaporator. If the hot compressed gas was at 135 degrees and the air being sucked through the
condenser fins was at 90 degrees, heat will flow downhill like a ball wants to roll down an inclined plane and be rejected into
the air stream. Heat will have been removed from one place and relocated to another as the definition of refrigeration
describes. As long as the compressor is running it will impose a force on the refrigerant to continue circulating around the
loop and continue removing heat from one location and rejecting it into another area.
There is another very common type of metering device called a TX Valve. It's full name is Thermostatic Expansion Valve,
and you will be thankful to know that its' short form is TXV. (It can also be called TEV) This valve has the additional
capability of modulating the refrigerant flow. This is a nice feature because if the load on the evaporator changes the valve
can respond to the change and increase or decrease the flow accordingly. The next graphic shows this type of metering
device and you will note that another component has been added along with it.
The TXV has a sensing bulb attached to the outlet of the evaporator. This bulb senses the suction line temperature and sends
a signal to the TXV allowing it to adjust the flow rate. This is important because if not all the refrigerant in the evaporator
changes state into a gas, there would be liquid refrigerant content returning down the suction line to the compressor. That
could be disastrous to the compressor. A liquid can not be compressed and if a compressor tries to compress a liquid
something is going to break and it's not going to be the liquid. The compressor can suffer catastrophic mechanical damage.
This unwanted situation is called liquid slugging. The flow rate through a TXV is set so that not only is all the liquid
hopefully changed to a gas, but there is an additional 10 degree safety margin to insure that all the liquid is changed to a gas.
This is called Superheat. At a given temperature any liquid and vapour combination will always be at a specific pressure.
There are charts of this relationship called PT Charts which stands for Pressure/Temperature Chart. Now if all the liquid
droplets in an evaporator have changed state into a gas, and they still have 1/4 of the evaporator to travel through, this gas
will pick up more heat from the load being imposed on the evaporator and even though it is at the same pressure, it will
become hotter than the PT Chart says it should be. This heat increase over and above the normal PT relationship is called
superheat. It can only take place when there is no liquid in the immediate area and this phenomena is used to create an
insurance policy of sorts. Usually TXV's are set to maintain 10 degrees of superheat and by definition that means that the gas
returning to the compressor is at least 10 degrees away from the risk of having any liquid content. A compressor is a vapour
compression pump and must not attempt to compress liquid liquid.
That extra component that got added in along with the TX Valve is called a receiver. When the TXV reduces the flow there
has to be somewhere for the unneeded refrigerant to go and the receiver is it. Note that there is a dip tube in the outlet side to
insure that liquid is what is fed into the liquid line. Liquid must be provided to the TXV not a mixture of liquid and gas. The
basic premise is to change a liquid to a gas so you don't want to waste any of the evaporator's capacity by injecting useless
vapour into it. The line that comes from the condenser and goes to the receiver is also given a name. It's called the condensate
line.
Accessories
Even though there are only 4 basic components to a refrigeration system there are numerous accessories that can be added.
The next graphic shows a liquid line filter and a sight glass. The filter catches unwanted particles such as welding slag,
copper chips and other unwanted debris and keeps it from clogging up important devices such as TX Valves. It has another
function as well. It contains a desiccant which absorbs minute quantities of water which hopefully wasn't in the system in the
first place.
The sight glass is a viewing window which allows a mechanic to see if a full column of liquid refrigerant is present in the
liquid line.
Earlier we discussed heat transfer rates and mentioned surface area as one of the factors. Let's put some fins on our condenser
and evaporator. While we are at it lets also add a couple of fan motors to move air through those fins. They are conveniently
called the condenser fan motor and evaporator fan motor.
Part 3
To make our cyber space refrigeration system a little more realistic lets separate the evaporator away from the compressor
section and put it inside an insulated box. The left over components can now be called a Condensing Unit. The insulated box
does not conduct heat well. If we lower the temperature of a refrigerated product inside the box we want to slow down the rate
of thermal gain from the rest of the world outside the box. There has been oil added to the compressor sump to keep the
moving parts inside the compressor lubricated. The suction line returning to the compressor has been sloped to aid in returning
oil to the compressor. The oil is slowly depleted from the sump by getting entrained in the refrigerant and proper piping
practices must be used to insure its' return. Also notice that the liquid line has been made smaller. The same quantity of
refrigerant can be contained in a much smaller pipe when it is in the liquid form. The suction line has been connected to its'
proper place on the evaporator; the bottom. Consider the direction of flow, the liquid refrigerant (which probably contains oil
stolen from the compressor) enters the top of the evaporator and now has gravity on its' side to return the oil where to it
belongs (just like the sloped suction line).
Consider the heat flow within the insulated box. The evaporator is constantly recirculating air in a forced convection loop
around the box. As the cold air passes over the product to be refrigerated, once again we see a thermal transfer taking place. If
there were a bunch of boxes of warm eggs placed in the cooler some of their heat content would be picked up by the cold air
and that air is sucked back into the evaporator. We know what happens then. The heat is transferred through the fins, through
the tubing, and into the refrigerant and carried away. That same air has been cooled and is once again discharged back over the
product. The next graphic shows this loop and the pink and blue colours represent air with more heat content and less heat
content respectively.
The next graphic is a more pictorial representation of what an actual installation might look like.
Summary
I hope you enjoyed the original Refrigeration Basics section. It covered a lot of material but this was done by just barely
skimming the surface of things. You should now have a general idea of what refrigeration is and how it is accomplished. There
are of course many issues that must be looked at in much greater depth. We will try to do this in the same easy to understand
fashion using pictures, animation's and interactive objects where possible. You may jump around all you want to different
areas of this book however it has been designed in a way where subsequent sections are often based on the previous sections
information. You will probably find things easier to comprehend by following the sections in the order they are presented.
Definitions
Part 2
Energy
Energy is the capacity of a system to do work where "system" refers to any physical system, not just a refrigeration system.
Enthalpy
Enthaply is the total amount of heat in one Lb. of a substance. It's units are therefore BTU/Lb. The metric counter part is kJ/
Kg. (kilo joules/kilogram)
Entropy
Entropy measures the energy dispersion in a system divided by temperature. This ratio represents the tendency of energy to
spread out, to diffuse, to become less concentrated in one physical location or one energetic state. That spreading out is often
done by molecules because molecules above absolute zero always have energy inside of them. That's why they are
incessantly speeding through space and hitting each other and rotating and vibrating in a gas or liquid. Entropy is measured
in BTU per Lb. per degree change for a substance.
Mollier Charts
Mollier charts are used in designing and analyzing performance of vapour compression refrigeration systems. Each
refrigerant has it's own chart which is a graph of the Enthalpy of a refrigerant during various pressures and physical states.
Mollier charts are also called Pressure-Enthalpy diagrams.
The above chart is for refrigerant MP39. Although this particular chart is in Metric units you can see that pressure and
enthalpy are the units on the verticle and horizontal axis. Several other parameters are also shown on the chart including
temperature, volume, saturation quality and entropy.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
The series of graphics above shows how the refrigeration cycle is graphed onto the pressure-enthalpy chart and goes into
details about how certain parameters can be determined from the chart.
Gases
Part 2
Air
There are other gases that refrigeration mechanics deal with besides
refrigerants. A mechanic even interacts with ordinary air in many ways. Air is
composed of the elements listed in the image on the left. Air exerts a pressure
on everything around us. This pressure is due to the weight of all the air
molecules above us in the atmosphere which is over 60 miles thick. Although
air seems like it weighs almost nothing consider a column of air 1 inch x 1 inch,
going all the way from sea level right out through the stratosphere and beyond.
That rather significant column of air would have a weight of 14.7 pounds. That
is how the standard conditions of atmospheric air pressure are derived. One
Atmospheric Pressure is said to be 14.7 Pounds per Square Inch, or 14.7 PSI.
Air pressure varies from the standard conditions just described. If you measure
atmospheric pressure at a higher altitude than sea level you are going to observe
less pressure. That's because there would be less atmosphere above you and
therefore less weighing down on you. Atmospheric pressure also varies with
temperature and weather conditions. These changes can be measured with an
instrument called a barometer. An inverted tube (open at the bottom and sealed
at the top) is placed in a pool of liquid. The Atmospheric pressure pushing
down on the surface of the liquid in the reservoir will support a column of
liquid rising up the tube. Water could be used in a barometer although 1
Atmospheric pressure would support a column of water over 30 feet in height.
That certainly wouldn't be a very handy nor portable test instrument. So instead
of water, mercury is used. Hg is the chemical nomenclature for Mercury.
Mercury is much heavier than water and 1 Atmospheric pressure (or 14.7 PSI)
will support a column of Mercury 29.92 inches in height. (or 760 mm if using
the Metric system.)
To make things easier, refrigeration gauges are calibrated to the zero point
when they are under atmospheric conditions. Notice that the gauge in the
picture is open to the atmosphere but is reading zero PSI, not 14.7 PSI. (refer to
the outer scale) Pressure readings taken on a gauge like this are given the term
PSIG which stands for Pounds per Square Inch Gauge. You can tell that this is
a Low Side gauge for reading the suction side of a system because it's scale
does not go very high. A High side gauge will go up to 450 PSI. Also, this
gauge shows vacuum pressures below 0 PSI. High side gauges never do that.
Pressures below 0 PSIG are inches of Mercury Vacuum. ("Hg vac) It makes
sense that the vacuum scale goes to -30 because 1 atmospheric pressure is
equivalent to 29.92 "Hg.
A gauge design which is in common use to this day was invented in 1849 by
Eugene Bourdon. The Bourdon tube gauge functions as shown in the adjacent
demonstration. When pressure is applied to the tube spring, it will try to
straighten out just like those party whistles that unwind when you blow in them
and curl up when you stop blowing. As the spring tube moves in response to
pressure, the movement is transferred via a linkage to pivot arm which then
transfers the motion by gear teeth to the indicator needle.
Decrease Increase
Vacuum
The atmosphere creates a pressure of 14.7 PSI at sea level. If you went to outer
space where there is no atmosphere there would obviously also be no pressure.
You have probably heard the expression "the vacuum of space". We can
simulate those conditions here on earth and are required to do so when
preparing a refrigeration system for charging with refrigerant. When you
introduce refrigerant into a new system it must be devoid of air and moisture.
You want nothing but liquid and vapourous refrigerant to be in the system, not
a mixture of refrigerant and air and moisture. This is done by hooking up a
vacuum pump to a system and evacuating it. The needle on the suction gauge
starts off at zero gauge pressure. As evacuation continues the gauge starts to
drop into the negative scale. The portion of the scale below zero is not in PSI
but rather is inches of Mercury ("Hg) just like a barometer. Although "Hg is a
finer scale than PSI, it is nowhere near a fine enough graduation to register the
amount of vacuum that we require. Recall that 29.92" Hg is equivalent to 760
mm Hg. If we obtain a vacuum of 1 mm Hg, that is still not precise enough to
measure the results we are after. The Metric system solves our problem nicely.
If you divide a mm into 1000 parts, each is called a micron. Those are the units
that we must evacuate down to in order to remove air as well as allow any water
moisture to evaporate at room temperature conditions and be drawn off by the
vacuum pump. Recall that a liquid will change to a gas if you remove enough of
the vapour pressure keeping it from doing so. A separate test instrument is
required to measure microns of pressure. A micron gauge will tell you whether
or not you have achieved an adequate evacuation. It can also be used to tell the
difference between a very small leak and the presence of moisture
contamination. The top graphic is a digital type of micron gauge and the lower
graphic is the read out scale from analog type.
Gas Laws
Boyles and Charles Laws can be combined to provide the following gas law equation. This equation can be used to solve
mathematical gas pressure problems however the results only refer to ideal gases. Ideal gases are theoretical in that they undergo
Adiabatic expansion and contraction. This would occur if a gas was placed in a perfectly insulated cyclinder with a frictionless
piston. The work required to compress the gas would create heat which would increase the temperature of the gas and therefore the
pressure. No heat would escape nor enter the imaginary piston chamber. To use the equation, Temperature and Pressure must be in
absolute units.
Charging
Part 2
Let us assume that you have located and repaired the leak which caused the undercharged conditions. You now wish to top up the refrigerant charge and have
hooked up a jug of the appropriate refrigerant. Click the Charge button to open the low side hand wheel on the gauge set and start charging. Notice all the
things that change as you are charging. The yellow colour is used to indicate the route that the refrigerant takes when you allow flow from the jug. Gas will
flow because the pressure in the jug is greater than the pressure in the low side of the system. High pressure flows to low pressure just as high temperature
flows to low temperature. When you open the low side hand wheel you can see the suction pressure increasing on the low side gauge. You can also notice a
slight increase in high side pressure and you now know why.
Stop Charge
You can see that there is a liquid/vapour interface in the refrigerant jug and that you are drawing refrigerant from the vapour portion. This vapour is being
introduced into the suction of the compressor and there is nothing wrong with that. This method works well with small to medium sized systems but if you
need to charge a large system you might be there for very long time indeed. If you vapour charge for several minutes you will notice a decrease in available
pressure from the jug. You will also notice that the jug is getting colder and colder. That makes sense because we know low pressure goes hand in hand with
low temperature. We can't get away from the laws of physics. When you draw off some vapour from the jug the Pressure Temperature Relationship forces
some liquid to flash into a gas to make up for the vapour you just removed and keep the Pressure Temperature Relationship in balance. But by changing state
that liquid has created the refrigeration process and removed heat from the surrounding area which in this case is the rest of the liquid refrigerant in the drum.
If you continue vapour charging long enough the drum may get so cold that you lose all of your pressure differential and can no longer continue. One
solution is to warm up the contents of the jug. Don't even think of playing a torch on the jug. You must never do that. A safe method to warm up a jug is to
place it in a pail of warm water or if you prefer run warm water over the jug in a sink. Keep a gauge in place so you can monitor the pressure at all times.
Develop safe working habits, there are more than enough dangerous circumstances to go around without creating any of your own.
Charging
Part 3
A liquid charging valve is an access valve which is installed downstream of the King
Valve. This location allows for some fancy maneuvering. Note in the diagram below
that the high side hose has been removed from the DSV and that the DSV has been
back seated and capped off as it is no longer needed. The high side hose has been
relocated to the liquid charging valve and is sensing high side pressure from that
1 2 3 4 5 6
location instead. In this case the liquid charging valve is a Schraeder Valve but it could
also have been another service valve. The pressure is still the same other than
perhaps some tiny bit of pressure drop from frictional losses through the condenser.
When you measure high side pressure from the DSV it is called True Head Pressure. It
can still be called Head Pressure as measured from anywhere on the high side of the
system but the distinction of being called True Head Pressure is reserved for
measurements from the DSV location.
We are looking for a way to charge with liquid refrigerant rather than vapour and the
first problem to overcome is getting liquid out of the jug. Refer to the diagram below
and click Button 2 for the solution. So now we have access to liquid and we have our
hose hooked up to a place where it would be fine to introduce it but there is another
problem. The pressure in the high side of the system may be equal to or higher than
the pressure in the jug so we might not get any flow. But what if we pump down the low
side...click Button 3 to front seat the King Valve. The low side empties. Note that the
Liquid charging Valve is now part of the low side. The pressure reading on the high
side gauge is indicating the same low pressure as the low side gauge. We now have a
pressure differential between the liquid in the jug and the liquid line where it is safe to
introduce liquid. Press Button 4 to start charging liquid. Notice that the sight glass
starts to show liquid, the suction gauge pressure increases and the high side gauge
reflects the pressure from the jug, not from the high side of the system. Press 5 to
continue charging. Are you noticing that the amount of area being used for
superheating is decreasing? (An increasing amount of the evaporator is being used for
evaporation so there is less room left over for excessive superheating) We may
achieve a fuller Sight Glass but this is not a reflection of system operating conditions.
We do not have a loop, we have a front seated King Valve. All the refrigerant you are
adding is merely being relocated into the isolated high side. First it changes to a gas in
the evaporator, then it is in a form to be safely drawn into the compressor and finally it
is condensed in the condenser and ends up in the receiver which starts to fill up.
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/charging3.htm (1 of 2)4.3.2007 10:29:10
Charging 3
We have gone over several techniques about manipulating a system through use of it's valves and charging refrigerant. There is of course a great deal more to
diagnosing and understanding the refrigerant side of systems than we have touched on so far. To do that we must start dealing with specific values and that is
what we shall do next.
R-11
R-11
Temp Pressure
-40 -28.5 Hg
-35 -28.2 Hg
-30 -27.9 Hg
-25 -27.5 Hg
-20 -27.1 Hg
-15 -26.6 Hg
-10 -26.1 Hg
-5 -25.5 Hg
0 -24.8 Hg
5 -24.0 Hg
10 -23.2 Hg
15 -22.2 Hg
20 -21.1 Hg
Trade 25 Freon
-20.0 Genetron
Hg
Name 30 Isotron
-18.7 Hg
etc -11
35 -17.2 Hg
40 CCL-15.7 Hg
Formula 3F
45 -13.9 Hg
50 -12.0 Hg
Chemical 55 -10.0 Hg
trichloroflluoromethane
Name 60 -7.8 Hg
65 -5.3 Hg
Oil 70 MO-2.7 ABHg
75 0.1
80 1.6
ARI
85 3.2
GUIDELINE 90 5.0
N-1995 95 6.9
colour 100 8.9
assignment 105 11.1
orange 110 13.4
115 15.8
120 18.5
125 21.3
130 24.2
135 27.4
140 30.8
145 34.3
150 38.1
155 42.0
160 46.2
165 50.6
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r11.htm4.3.2007 10:29:11
R-176
R-176
R-12
R-12
Temp Pressure
-50 15.4 Hg
-48 14.6 Hg
-46 13.8 Hg
-44 12.9 Hg
-42 11.9 Hg
-40 11.0 Hg
-38 10.0 Hg
-36 8.9 Hg
-34 7.8 Hg
-32 6.7 Hg
-30 5.5 Hg
-28 4.3 Hg
-26 3.0 Hg
Trade -24Freon
1.6 Genetron
Hg
Name -22Isotron
0.3 Hg
etc -12
-20 0.6
Formula -18
CCl2F1.3
2
-16 2.1
-14 2.8
Chemical -12 3.7
dichlorodifluoromethane
Name -10 4.5
-8 5.4
Oil -6
MO AB 6.3
-4 7.2
-2 8.2
ARI
0 9.2
GUIDELINE 2 10.2
N-1995 4 11.2
colour 6 12.3
assignment 8 13.5
white 10 14.6
12 15.8
14 17.1
16 18.4
18 19.7
20 21.0
22 22.4
24 23.9
26 25.4
28 26.9
30 28.5
32 30.1
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r12.htm4.3.2007 10:29:12
R507A
R507A
R-507A
Temp Pressure
-50 0.9
-48 1.7
-46 2.6
-44 3.5
-42 4.5
-40 5.5
-38 6.5
-36 7.6
-34 8.7
-32 9.9
-30 11.1
-28 12.4
-26 13.7
-24 15.0Genetron
-22 16.4Solkane Reclin
Trade Name -20 17.8 etc- 507A
-18 19.3Allied Signal
-16 20.9AZ50
-14 22.5
-12 24.1R-125/143a
Formula
-10 25.850% 50%
-8 27.6
Oil -6 29.4POE
-4 31.3
-2 33.2
Replaces 0 35.2R502
2 37.3
4 39.4AZ50 is used in
6 41.6new OEM
8 43.8equipment with
10 46.2POE oil. Retro-
12 48.5fitting R502 to
14 51.0R507A is difficult
because nearly
Note 16 53.5
all the mineral oil
18 56.1in the system
20 58.8must be
22 61.5removed.Liquid
24 64.3& Vapour
26 67.2pressures very
28 70.2
30 73.3
32 76.4
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r507a.htm (1 of 2)4.3.2007 10:29:13
R507A
similar.
ARI
GUIDELINE N-
1995
colour
assignment
blue-green
(teal)
R-13
R-13
Temp Pressure
-40 73.4
-35 82.3
-30 91.7
-25 101.9
-20 112.7
-15 124.3
-10 136.6
-5 149.6
0 163.5
5 178.2
10 193.7
15 210.2
20 227.5
Trade 25Freon
245.8Genetron
Name 30Frigen
265.1Arcton etc-
3513 285.3
40 306.6
Formula 45CCLF329.0
3
50 377.1
55 408.0
Chemical 60chlorotrifluoromethane
436.9
Name 65 467.5
70 500.2
Oil MO AB
ARI
GUIDELINE
N-1995
colour
assignment
light blue
(sky)
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r13.htm4.3.2007 10:29:13
R717
R-717
R-717
Temp Pressure
-40 -8.8 Hg
-35 -5.4 Hg
-30 -1.6 Hg
-25 1.3
-20 3.6
-15 6.2
-10 9.0
-5 12.2
0 15.7
5 19.6
10 23.8
15 28.4
20 33.5
Trade Name 25 39.0 Ammonia
30 45.0
35 51.6NH3
Formula
40 58.6
45 66.3
Oil 50 74.5MO and others
55 83.4
ARI
60 92.9
GUIDELINE N-65 103.1
1995 70 114.1
colour 75 125.9
unassigned 80 138.4
85 151.8
90 166.0
95 181.1
100 197.2
105 214.3
110 232.4
115 251.5
120 271.8
125 293.2
130 315.7
135 339.5
140 364.5
145 390.8
150 418.5
155 447.5
160 478.0
165 510.0
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r717.htm4.3.2007 10:29:14
R-21
R-21
R-21
Temp Pressure
-40 -27.2 Hg
-35 -26.7 Hg
-30 -26.1 Hg
-25 -25.5 Hg
-20 -24.7 Hg
-15 -23.9 Hg
-10 -22.9 Hg
-5 -21.8 Hg
0 -20.6 Hg
5 -19.3 Hg
10 -17.8 Hg
15 -16.1 Hg
20 -14.2 Hg
Trade 25 -12.2 Hg
R-21 Halon 112
Name 30 -10.0 Hg
35 -7.5 Hg
40 CHCL-4.8 FHg
Formula 2
45 -1.9 Hg
50 0.7
Chemical 55 2.4
dichlorofluoromethane
Name 60 4.2
65 6.2
Oil 70MO 8.4AB
75 10.7
80 13.3
ARI
85 16.0
GUIDELINE
90 18.9
N-1995
colour 95 22.0
unassigned 100 25.3
105 28.9
110 32.7
115 36.7
120 41.0
125 45.6
130 50.4
135 55.5
140 60.9
145 66.6
150 72.7
155 79.0
160 85.7
165 92.8
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r21.htm4.3.2007 10:29:14
R-412A
R-412A
R-22
R-22
Temp Pressure
-50 6.2 Hg
-48 4.8 Hg
-46 3.4 Hg
-44 2.0 Hg
-42 0.5 Hg
-40 0.5 Hg
-38 1.3
-36 2.2
-34 3.0
-32 4.0
-30 4.9
-28 5.9
-26 6.9
Trade -24Freon7.9Genetron
Name -22 9.0 etc -22
Isotron
-20 10.1
-18 11.3
CHCLF
Formula 2
-16 12.5
-14 13.8
Chemical -12 15.1
chlorodifluoromethane
Name -10 16.5
-8 17.9
Oil -6MO19.3AB
-4 20.8
-2 22.4
ARI
0 24.0
GUIDELINE 2 25.6
N-1995 4 27.3
colour 6 29.1
assignment 8 30.9
light green 10 32.8
12 34.7
14 36.7
16 38.7
18 40.9
20 43.0
22 45.3
24 47.7
26 49.9
28 52.4
30 54.9
32 57.5
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r22.htm4.3.2007 10:29:15
R-115
R-115
R-115
Temp Pressure
-40 -1.2 Hg
-35 1.3
-30 3.4
-25 5.6
-20 8.1
-15 10.8
-10 13.7
-5 16.9
0 20.3
5 24.1
10 28.1
15 32.4
20 37.0
25
Freon42.0
Genetron
Trade
Name 30 47.4
Arcton
35 53.1
etc- 115
40 59.1
Formula 45
CCLF65.6
2CF3
50 72.5
55 79.8
Chemical 60 87.6
chloropentafluoroethane
Name 65 95.8
70 104.5
Oil 75
MO 113.8
AB
80 123.5
85 133.8
blend component for R-
Note 90 144.6
502
95 156.0
100 168.0
ARI 105 180.7
GUIDELINE 110 193.9
N-1995 115 207.9
colour
120 222.5
unassigned
125 237.9
130 254.0
135 270.9
140 288.5
145 307.6
150 327.3
155 348.1
160 369.9
165 393.0
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r115.htm4.3.2007 10:29:16
R-23
R-23
R-23
Temp Pressure
-40 88.2
-35 99.2
-30 111.1
-25 124.0
-20 137.7
-15 152.5
-10 168.3
-5 185.2
0 203.2
5 222.4
10 242.8
15 264.5
20 287.6
25 312.0
Freon Suva
Trade Name 30 337.9
Genetron
35 365.3
Solkane
40 394.2
etc -23
45 424.8
Formula 50 457.1
CHF3
55 497.4
60 534.3
Chemical 65 573.4
trifluoromethane
Name 70 614.8
ARI
GUIDELINE N-
1995
colour
assignment
light blue-gray
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r23.htm4.3.2007 10:29:16
R-32
R-32
R-32
Temp Pressure
-40 11.0
-35 14.4
-30 18.2
-25 22.3
-20 26.8
-15 31.7
-10 37.1
-5 42.9
0 49.2
5 56.1
10 63.5
15 71.5
20 80.0
25 Genetron
89.2
Trade Name 30 Forane 99.1 Solkane
35 109.7
etc -32
40 121.0
Formula 45 133.1
CH2F2
50 145.9
55 159.6
Chemical 60 174.2
difluoromethane
Name 65 189.6
70 206.0
Oil 75 223.4
POE
80 241.8
85 261.2
ARI
90 281.7
GUIDELINE N-
1995 95 303.3
colour 100 326.1
unassigned 105 350.2
110 375.5
115 402.1
120 430.0
125 459.4
130 490.3
135 522.6
140 556.6
145 592.3
150 629.7
155 668.9
160 710.1
165 753.5
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r32.htm4.3.2007 10:29:16
R-503
R-503
Oil MO AB
ARI
GUIDELINE N-
1995
colour
assignment
blue-green
(aqua)
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r503.htm4.3.2007 10:29:17
R-113
R-113
R-113
Temp Pressure
-30 -29.4 Hg
-25 -29.2 Hg
-20 -29.1 Hg
-15 -28.9 Hg
-10 -28.7 Hg
-5 -28.5 Hg
0 -28.3 Hg
5 -28.0 Hg
10 -27.6 Hg
15 -27.2 Hg
20 -26.8 Hg
25 -26.3 Hg
30 -25.8 Hg
35 -25.2FreonHg
Trade Name40 -25.4 Hg
Genetron etc-
45 -23.8113Hg
50 -22.9 Hg
Formula 55 -22.0CCLHg 2FCCLF2
60 -21.0 Hg
65 -19.9 Hg
70 -18.6 Hg
1,1,2-trichloro-
Chemical Name 75 -17.3 Hg
1,2,2-
80 -15.8 Hg
trifluoroethane
85 -14.2 Hg
Oil 90 -12.5MOHgAB
95 -10.6 Hg
100 -8.6 Hg
ARI 105 -6.4 Hg
GUIDELINE110 N- -4.0 Hg
1995 115 -1.4 Hg
colour
120 0.7
assignment
dark purple
125 2.1
(violet) 130 3.7
135 5.3
140 7.1
145 9.0
150 11.0
155 13.2
160 15.5
165 17.9
170 20.5
175 23.2
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r113.htm4.3.2007 10:29:18
R-405A
R-405A
R-114
R-114
Temp Pressure
-40 -26.1 Hg
-35 -25.5 Hg
-30 -24.7 Hg
-25 -23.9 Hg
-20 -22.9 Hg
-15 -21.9 Hg
-10 -20.7 Hg
-5 -19.3 Hg
0 -17.9 Hg
5 -16.2 Hg
10 -14.4 Hg
15 -12.4 Hg
20 -10.2 Hg
25 -7.9 Hg Genetron
Freon
Trade Name 30 -5.2 Hg
Forane
35 -2.4 etc-Hg
114
40 0.4
Formula 45 CCLF 2.0 2CCLF2
50 3.8
55 5.7
Chemical 60 1,2-dichloro-
7.8
Name 65 10.0
1,1,2,2-
70 tetrafluoroethane
12.4
75 15.0
Oil 80 MO 17.8 AB
85 20.8
90 23.9
ARI 95 27.3
GUIDELINE N- 100 30.9
1995 105 34.7
colour
110 38.7
assignment
dark blue
115 43.0
(navy) 120 47.6
125 52.4
130 57.5
135 62.8
140 68.5
145 74.4
150 80.7
155 87.3
160 94.2
165 101.5
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r114.htm4.3.2007 10:29:19
R-408A
R-408A
FX-40
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_fx40.htm4.3.2007 10:29:20
R-116
R-116
R-116
Temp Pressure
-40 65.2
-35 73.5
-30 82.5
-25 92.1
-20 102.4
-15 113.4
-10 125.1
-5 137.6
0 150.8
5 164.9
10 179.8
15 195.5
20 212.1
25 229.6
PFC-116 Freon-
Trade Name
30 248.1
116
35 267.4
40 287.8
CF3CF3
Formula
45 310.9
50 334.8
Chemical 55 360.2
hexafluoroethane
Name
ARI
GUIDELINE N-
1995
colour
assignment
dark gray
(battleship)
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r116.htm4.3.2007 10:29:20
R-409A
R-409A
R-123
R-123
Temp Pressure
-40 -28.9 Hg
-35 -28.7 Hg
-30 -28.5 Hg
-25 -28.2 Hg
-20 -27.9 Hg
-15 -27.5 Hg
-10 -27.1 Hg
-5 -26.6 Hg
0 -26.0 Hg
5 -25.4 Hg
10 -24.6 Hg
15 -23.8 Hg
20 -22.9 Hg
25 -21.9Suva HgGenetron
Trade Name30 -20.8 Hg Forane
Solkane
35 -19.6etc-Hg123
40 -18.2 Hg
Formula 45 -16.7CHCL Hg2CF3
50 -15.0 Hg
55 -13.2 Hg
60 -11.2 Hg
2,2-dichloro-
Chemical Name 65 -9.0 Hg
1,1,1-
70 -6.7 Hg
trifluoroethane
75 -4.1 Hg
Oil 80 -1.2 MOHgAB
85 0.9
90 2.5
Replaces R-11 R-113
95 4.2
100 6.1
105 8.1
ARI
110 10.3
GUIDELINE N-
115 12.6
1995
colour 120 15.1
assignment 125 17.7
light blue-gray130 20.6
135 23.6
140 26.8
145 30.2
150 33.8
155 37.6
160 41.7
165 45.9
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r123.htm4.3.2007 10:29:21
R-404A
R-404A
R-404A Vapour
Temp Pressure
-50 0
-48 1
-46 2
-43.5 3
-41 4
-39 5
-37 6
-35 7
-33 8
-31.5 9
-30 10
-28 11
-26 12
-24.5 Suva13 HP62
Trade Name
-23 Atochem
14 FX-70
-21.5 15
-20 R-125/143a/134a
16
Formula -19 44% 17 52% 4%
-18 18
-16.5 19
Oil POE
-15 20
-13.5 21
Replaces -12 R-50222
-11 23
-10 The 24average
-8.5 saturated
25 liquid
-7 temperature
26 is
-6 within
27 .5 degrees
-5 F28 (decimal five)
Note -4 of29 the saturated
-3 vapour
30
-2 temperature,
31
-1 therefore
32 liquid
temperatures are
0 33
not shown.
1 34
2 35
3 36
4 37
5 38
6 39
7 40
8 41
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r404a.htm (1 of 2)4.3.2007 10:29:22
R-404A
ARI
GUIDELINE N-
1995
colour
assignment
orange
R-124
R-124
Temp Pressure
-40 -22.2 Hg
-35 -20.9 Hg
-30 -19.6 Hg
-25 -17.9 Hg
-20 -16.1 Hg
-15 -14.4 Hg
-10 -11.9 Hg
-5 -9.4 Hg
0 -6.7 Hg
5 -3.7 Hg
10 -0.4 Hg
15 1.6
20 3.5
25 Halon
5.7 241 Suva
Trade Name 30 8.0
Genetron
35 Meforex
10.5 etc- 124
40 13.2
Formula 45 CHCLFCF
16.1 3
50 19.2
55 22.6
Chemical 60 2-chloro-1,1,1,2-
26.3
Name 65 30.2
tetrafluoroethane
70 typ34.45% R124a
75 38.9
Oil 80 AB 43.7
85 48.8
90 54.2
Note blend component
95 60.0
100 66.1
ARI 105 72.6
GUIDELINE N- 110 79.5
1995 115 86.8
colour 120 94.5
assignment 125 102.7
deep green 130 111.2
(DOT green) 135 120.3
140 129.8
145 139.8
150 150.3
155 161.3
160 172.9
165 185.0
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r124.htm4.3.2007 10:29:22
FX-220
FX-220
R-125
R-125
Temp Pressure
-40 6.9
-35 9.7
-30 12.8
-25 16.2
-20 20.0
-15 24.1
-10 28.5
-5 33.3
0 38.5
5 44.1
10 50.2
15 56.7
20 63.7
25 Suva
71.2 Genetron
Trade Name 30 Forane
79.3 Klea
35 etc-125
87.8 Halon 25
40 97.0
Formula 45 106.7
CHF2CF3
50 117.1
55 128.1
Chemical 60 139.8
pentafluoroethane
Name 65 152.2
70 165.3
Oil 75 179.2
POE
80 193.9
85 209.3
Note blend component
90 225.7
95 242.9
ARI 100 261.0
105 280.1
GUIDELINE N-
1995 110 300.2
colour 115 321.3
assignment 120 345.3
125 366.9
medium brown
(tan) 130 391.5
135 417.4
140 444.7
145 473.6
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r125.htm4.3.2007 10:29:23
R-406A
R-406A
R-1270
R-1270
Temp Pressure
-40 5.9
-35 8.4
-30 11.2
-25 14.2
-20 17.5
-15 21.0
-10 24.8
-5 29.0
0 33.5
5 38.2
10 43.4
15 48.9
20 54.8
25 61.1Propene,
Trade Name
30 67.8Propylene
35 74.9
40 82.5CH3CH=CH2
Formula
45 90.5
50 99.0
Oil 55 108.0
all
60 117.6
ARI 65 127.6
GUIDELINE N-70 138.2
1995 75 149.4
colour 80 161.1
unassigned 85 173.4
90 186.4
95 200.0
100 214.2
105 229.1
110 244.7
115 261.0
120 278.1
125 295.9
130 314.4
135 333.7
140 353.9
145 374.9
150 396.7
155 419.4
160 443.1
165 467.6
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r1270.htm4.3.2007 10:29:24
R-414A
R-414A
R-134
(NOT R-134a)
Temp Pressure
-40 -17.6 Hg
-35 -15.8 Hg
-30 -13.8 Hg
-25 -11.6 Hg
-20 -9.2 Hg
-15 -6.4 Hg
-10 -3.4 Hg
-5 -0.1 Hg
0 1.7
5 3.7
10 5.9
15 8.2
20 Freon-134,
10.8 HFC-
Trade Name
25 13413.6
30 16.7
35 CHF20.0 CHF
Formula 2 2
40 23.6
45 27.5
Chemical 50 1,1,2,2-
31.7
Name 55 tetrafluoroethane
36.2
60 41.1
Oil 65 POE46.4 PAG
70 52.0
75 58.1
Note
80 (Not
64.5R-134A)
85 71.4
ARI 90 78.8
GUIDELINE N-95 86.7
1995 100 95.0
colour 105 103.9
unassigned 110 113.3
115 123.3
120 133.9
125 145.1
130 156.9
135 169.3
140 182.4
145 196.2
150 210.7
155 225.9
160 241.9
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r134.htm4.3.2007 10:29:25
R-410A
R-410A
R-134A
R-134a
Temp Pressure
-50 -18.4 Hg
-48 -17.7 Hg
-46 -17.0 Hg
-44 -16.2 Hg
-42 -15.4 Hg
-40 -14.5 Hg
-38 -13.7 Hg
-36 -12.8 Hg
-34 -11.8 Hg
-32 -10.8 Hg
-30 -9.7 Hg
-28 -8.6 Hg
-26 -7.7 Hg
-24 -6.2SuvaHg Genetron
Trade Name-22 -4.9 Hg
Forane
-20 -3.6KleaHgetc -134a
-18 -2.3 Hg
Formula -16 -0.8CH2HgFCF3
-14 0.3
-12 1.1
Chemical -10 1,1,1,2-
1.9
Name -8 2.8
tetrafluoroethane
-6 3.6
Oil -4 POE4.5 PAG
-2 5.5
0 6.5
Replaces R-12
2 7.5
4 8.5
6 9.6
ARI 8 10.8
GUIDELINE N-
10 12.0
1995
12 13.1
colour
assignment 14 14.4
light blue (sky) 16 15.7
18 17.0
20 18.4
22 19.9
24 21.4
26 22.9
28 24.5
30 26.1
32 27.8
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r134a.htm4.3.2007 10:29:26
R-13B1
R-13B1
R-13B1
Temp Pressure
-40 17.8
-35 21.5
-30 25.4
-25 29.7
-20 34.3
-15 39.2
-10 44.6
-5 50.3
0 56.5
5 63.1
10 70.2
15 77.8
20 85.8
Trade 25 94.4
Freon-13B1 Halon
Name 301301
103.5
35 113.2
40CBrF
123.5
Formula 3
45 134.3
50 145.8
Chemical 55 157.9
bromotrifluoromethane
Name 60 170.7
65 184.1
Oil 70MO198.2
AB
75 213.1
80 228.6
Replaces
85R-12
245.0
90 262.0
ARI 95 279.9
GUIDELINE 100 298.6
N-1995 105 318.0
colour 110 338.3
assignment 115 359.5
pinkish-red 120 381.5
(coral) 125 407.8
130 432.9
135 459.2
140 487.0
145 516.2
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r13b1.htm4.3.2007 10:29:26
R-744
R-744
R-744
Temp Pressure
-40 131.0
-35 146.4
-30 163.0
-25 180.9
-20 200.0
-15 220.5
-10 242.4
-5 265.8
0 290.7
5 317.1
10 345.3
15 375.1
20 406.7
Trade Name 25 440.1
Carbon Dioxide
30 475.5
35 512.8
CO2
Formula
40 552.3
45 593.8
50
Chemical Name 637.6
Carbon Dioxide
55 683.7
ARI
60 732.2
65
GUIDELINE N- 783.3
1995 70 837.0
colour 75 893.7
unassigned 80 953.6
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r744.htm4.3.2007 10:29:27
R-141B
R-141B
R-141b
Temp Pressure
-40 -29.1 Hg
-35 -28.9 Hg
-30 -28.7 Hg
-25 -28.4 Hg
-20 -28.1 Hg
-15 -27.8 Hg
-10 -27.4 Hg
-5 -27.0 Hg
0 -26.5 Hg
5 -26.0 Hg
10 -25.4 Hg
15 -24.7 Hg
20 -23.9 Hg
25 -23.1 Hg
Genetron
30 -22.1 Hg
Solkane
Trade Name35 -21.0 Hg
Isotron
40 -19.9 Hg etc-
Forane
45 -18.6 141b
Hg
50 -17.1 Hg
Formula 55 -15.6 CHHg3CCL2F
60 -13.8 Hg
65 -12.0 Hg
Chemical Name 70 -9.9 Hg
1,1-dichloro-1-
fluoroethane
75 -7.7 Hg
80 -5.3 Hg
Oil 85 -2.7 MOHgAB
90 0.1
Note 95 1.6
solvents
100 3.2
105 4.9
ARI 110 6.8
GUIDELINE N- 115 10.2
1995
120 13.2
colour
unassigned
125 15.6
130 18.2
135 21.0
140 23.9
145 27.0
150 30.3
155 33.8
160 37.5
165 41.4
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r141b.htm4.3.2007 10:29:27
R-142B
R-142B
R-142b
Temp Pressure
-40 -22.2 Hg
-35 -21.0 Hg
-30 -19.7 Hg
-25 -18.3 Hg
-20 -16.7 Hg
-15 -14.9 Hg
-10 -12.9 Hg
-5 -10.7 Hg
0 -8.3 Hg
5 -5.7 Hg
10 -2.8 Hg
15 0.2
20 1.9
25 Genetron
3.7
Trade Name 30 5.7
Isotron Solkane
35 7.9 Forane etc-
40 10.2142b
45 12.8
Formula 50 15.6CH3CCLF2
55 18.5
60 21.7
Chemical Name 65 25.11-chloro-1,1-
70 28.8difluoroethane
75 32.8
Oil 80 37.0AB
85 41.5
90 46.3
Note blend component
95 51.4
100 56.8
ARI 105 62.6
GUIDELINE N- 110 68.7
1995 115 75.2
colour
120 82.1
unassigned
125 89.4
130 97.0
135 105.2
140 113.7
145 122.7
150 132.1
155 142.1
160 152.5
165 163.5
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r142b.htm4.3.2007 10:29:28
R-143
R-143
R-143
Temp Pressure
-40 -26.7 Hg
-35 -26.1 Hg
-30 -25.4 Hg
-25 -24.6 Hg
-20 -23.7 Hg
-15 -22.7 Hg
-10 -21.6 Hg
-5 -20.3 Hg
0 -18.8 Hg
5 -17.2 Hg
10 -15.4 Hg
15 -13.4 Hg
20 -11.1 Hg
Trade Name 25 -8.6 Hg
R-143
30 -5.9 Hg
35 -2.8 CHHg
Formula 2FCHF2
40 0.3
45 2.1
50 1,1,2-
4.1
Chemical Name
55 trifluoroethane
6.2
60 8.6
Oil 65 11.2
POE PAG
70 14.0
75 17.0
ARI 80 20.3
GUIDELINE N-
85 23.8
1995
90 27.6
colour
unassigned 95 31.7
100 36.2
105 40.9
110 46.0
115 51.4
120 57.1
125 63.3
130 69.8
135 76.8
140 84.1
145 91.9
150 100.1
155 108.8
160 117.9
165 127.5
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r143.htm4.3.2007 10:29:28
R-411A
R-411A
R-143A
R-143A
Temp Pressure
-40 5.8
-35 8.4
-30 11.3
-25 14.4
-20 17.9
-15 21.6
-10 25.7
-5 30.1
0 34.9
5 40.1
10 45.6
15 51.6
20 58.0
25 64.8
Solkane Suva
Trade Name 30 72.1
Genetron
35 80.0
Meforex etc-
40 88.3
143a
45 97.2
Formula 50 106.6
CF3CH3
55 116.6
60 127.3
65 138.5
Chemical Name
1,1,1-
70 150.4
trifluoroethane
75 163.0
Oil 80 176.3
POE PAG
85 190.4
90 205.1
Note blend component
95 220.7
100 237.1
ARI 105 254.4
110 272.5
GUIDELINE N-
1995 115 297.6
colour
120 311.6
unassigned
125 332.6
130 354.7
135 377.9
140 402.2
145 427.7
150 454.6
155 482.9
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r143a.htm4.3.2007 10:29:29
R-411B
R-411B
R-152A
R-152a
Temp Pressure
-40 -16.0 Hg
-35 -13.9 Hg
-30 -11.5 Hg
-25 -8.9 Hg
-20 -5.9 Hg
-15 -2.7 Hg
-10 0.5
-5 2.4
0 4.5
5 6.9
10 9.4
15 12.2
20 15.2
25 18.5Freon
Trade Name 30 22.1
Genetron
35 25.9Forane etc-
40 30.1152a DFE
45 34.6
Formula 50 39.4CH3CHF2
55 44.5
60 50.1
Chemical Name 65 56.01,1-
70 62.3difluoroethane
75 69.0
Oil 80 76.2POE PAG
85 83.8
90 91.9
Replaces R-12
95 100.4
100 109.5
Note 105 119.1
blend component
110 129.3
ARI 115 140.0
GUIDELINE N- 120 151.4
1995 125 163.3
colour 130 175.9
unassigned 135 189.1
140 203.0
145 217.5
150 232.9
155 248.9
160 265.7
165 283.3
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r152a.htm4.3.2007 10:29:30
R-G2018C
R-G2018C
ARI
GUIDELINE N-
1995
colour
unassigned
R-218
R-218
Temp Pressure
-40 -4.2 Hg
-35 -0.7 Hg
-30 1.6
-25 3.7
-20 6.0
-15 8.5
-10 11.2
-5 14.2
0 17.5
5 21.0
10 24.9
15 29.0
20 33.5
25 Freon
38.3 Genetron
Trade Name 30 43.5Isceon PFC
35 etc-
49.0218
40 55.0
Formula 45 CF
61.3
3CF2CF3
50 68.1
55 75.4
Chemical 60 octafluoropropane
83.1
Name 65 91.2
70 99.9
Oil 75 109.1
POE PAG
80 118.9
85 129.2
Note blend component
90 140.1
95 151.5
ARI 100 163.6
GUIDELINE N-105 176.4
1995 110 189.8
colour 115 203.8
unassigned
120 218.6
125 234.1
130 250.3
135 265.3
140 283.5
145 302.7
150 323.2
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r218.htm4.3.2007 10:29:31
R-E170
R-E170
R-E170
Temp Pressure
-40 -15.3 Hg
-35 -13.1 Hg
-30 -10.7 Hg
-25 -8.0 Hg
-20 -5.0 Hg
-15 -1.7 Hg
-10 1.0
-5 2.9
0 5.1
5 7.4
10 10.0
15 12.7
20 15.8
25 19.0Dimethyl Ether
Trade Name
30 22.6DME
35 26.4
40 30.5CH3-O-CH3
Formula
45 34.9
50 39.6
Oil 55 44.6MO AB
60 50.0
Replaces 65 55.8R-11 R123?
70 61.9
75 68.5
ARI 80 75.4
GUIDELINE N-
85 82.8
1995
90 90.6
colour
unassigned 95 98.8
100 107.5
105 116.7
110 126.5
115 136.7
120 147.4
125 158.8
130 170.7
135 183.1
140 196.2
145 209.9
150 224.2
155 239.2
160 254.9
165 271.3
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_re170.htm4.3.2007 10:29:31
R-227EA
R-227EA
R-227ea
Temp Pressure
-40 -20.5 Hg
-35 -19.0 Hg
-30 -17.2 Hg
-25 -15.3 Hg
-20 -13.1 Hg
-15 -10.7 Hg
-10 -8.0 Hg
-5 -5.1 Hg
0 -1.8 Hg
5 0.9
10 2.8
15 5.0
20 7.3
25 R-227ea
9.8 Halon
Trade Name 30 12.6
37
35 Great
15.5Lakes FM-
40 20018.8
45 22.3
Formula 50 CF 26.0
3CHFCF3
55 30.1
60 34.4
Chemical 65 1,1,1,2,3,3,3-
39.1
Name 70 44.1
heptafluoropropane
75 49.4
Oil 80 POE55.1 PAG
85 61.2
90 67.6
Note blend component
95 74.5
100 81.8
ARI 105 89.5
GUIDELINE 110 97.6
N-1995 115 106.3
colour
120 115.4
unassigned
125 125.0
130 135.2
135 145.9
140 157.2
145 169.0
150 181.4
155 194.5
160 208.2
165 222.6
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r227ea.htm4.3.2007 10:29:32
R-236EA
R-236EA
R-236ea
Temp Pressure
-40 -27.1 Hg
-35 -26.6 Hg
-30 -26.0 Hg
-25 -25.2 Hg
-20 -24.4 Hg
-15 -23.5 Hg
-10 -22.4 Hg
-5 -21.2 Hg
0 -19.9 Hg
5 -18.4 Hg
10 -16.7 Hg
15 -14.9 Hg
20 -12.8 Hg
Trade Name 25 -10.5 Hg
R-236EA
30 -7.9 Hg
35 -5.1
CHFHg
Formula 2CHFCF3
40 -2.1 Hg
45 0.6
Chemical 50 1,1,1,2,3,3-
2.4
Name 55 hexafluoropropane
4.4
60 6.5
Oil 65 POE 8.8 PAG
70 11.3
75 14.0
Replaces 80 R-114
17.0
85 20.1
ARI 90 23.5
GUIDELINE 95 27.1
N-1995 100 31.0
colour 105 35.1
unassigned 110 39.5
115 44.3
120 49.3
125 54.7
130 60.3
135 66.4
140 72.7
145 79.5
150 86.6
155 94.2
160 102.1
165 110.5
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r236ea.htm4.3.2007 10:29:32
MP33
MP33
R-236FA
R-236fa
Temp Pressure
-40 -25.7 Hg
-35 -24.9 Hg
-30 -24.0 Hg
-25 -23.0 Hg
-20 -21.9 Hg
-15 -20.6 Hg
-10 -19.1 Hg
-5 -17.5 Hg
0 -15.6 Hg
5 -13.6 Hg
10 -11.3 Hg
15 -8.8 Hg
20 -6.0 Hg
Trade Name 25 -3.0 Hg
Suva-236FA
30 0.2
35 CF2.0
Formula 3CH2CF3
40 4.0
45 6.1
Chemical 50 1,1,1,3,3,3-
8.5
Name 55 hexafluoropropane
11.0
60 13.8
Oil 65 POE16.7 PAG
70 19.9
75 23.4
Replaces 80 R-114
27.1
85 31.0
ARI 90 35.3
GUIDELINE 95 39.8
N-1995 100 44.7
colour 105 49.9
unassigned 110 55.4
115 61.2
120 67.4
125 74.0
130 81.0
135 88.4
140 96.2
145 104.5
150 113.2
155 122.4
160 132.0
165 142.2
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r236fa.htm4.3.2007 10:29:33
R-245CA
R-245CA
R-245ca
Temp Pressure
-40 -29.0 Hg
-35 -28.8 Hg
-30 -28.5 Hg
-25 -28.2 Hg
-20 -27.9 Hg
-15 -27.5 Hg
-10 -27.0 Hg
-5 -26.5 Hg
0 -25.9 Hg
5 -25.2 Hg
10 -24.5 Hg
15 -23.6 Hg
20 -22.6 Hg
Trade Name25 -21.5 Hg
R-245CA
30 -20.3 Hg
35 -19.0
CH2FCFHg CHF
Formula 2 2
40 -17.4 Hg
45 -15.8 Hg
Chemical 50 -13.9 Hg
1,1,2,2,3-
Name 55 -11.9 Hg
pentafluoropropane
60 -9.6 Hg
Oil 65 POE-7.2 Hg PAG
70 -4.5 Hg
75 -1.5 Hg
Replaces 80 R-11 0.8 R-123?
85 2.5
ARI 90 4.4
GUIDELINE 95 6.4
N-1995 100 8.6
colour 105 10.9
unassigned 110 13.4
115 16.1
120 19.1
125 22.2
130 25.5
135 29.1
140 32.9
145 36.9
150 41.2
155 45.8
160 50.6
165 55.8
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r245ca.htm4.3.2007 10:29:34
R-245CB
R-245CB
R-245cb
Temp Pressure
-40 -19.7 Hg
-35 -18.1 Hg
-30 -16.3 Hg
-25 -14.2 Hg
-20 -11.9 Hg
-15 -9.4 Hg
-10 -6.7 Hg
-5 -3.6 Hg
0 -0.2 Hg
5 1.7
10 3.7
15 5.9
20 8.3
Trade Name 25 R-245CB 10.8
30 13.6
35 CH 16.6
Formula 3CF2CF3
40 19.9
45 23.4
Chemical 50 1,1,1,2,2-
27.1
Name 55 pentafluoropropane
31.2
60 35.5
Oil 65 POE40.1 PAG
70 45.1
75 50.3
ARI 80 55.9
GUIDELINE
85 61.9
N-1995
90 68.2
colour
unassigned 95 74.9
100 82.0
105 89.5
110 97.4
115 105.8
120 114.6
125 123.9
130 133.7
135 144.0
140 154.8
145 166.1
150 178.0
155 190.5
160 203.6
165 217.3
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r245cb.htm4.3.2007 10:29:34
R-290
R-290
R-290
Temp Pressure
-40 1.4
-35 3.4
-30 5.6
-25 8.1
-20 10.7
-15 13.6
-10 16.7
-5 20.0
0 23.7
5 27.6
10 31.8
15 36.3
20 41.1
Trade Name 25 46.3 HC-290
30 51.8
35 57.7CH3CH2CH3
Formula
40 63.9
45 70.6
Chemical Name 50 77.6Propane
55 85.1
Oil
60 93.0all
65 101.4
70 110.2
ARI 75 119.5
GUIDELINE N-80 129.3
1995
85 139.6
colour
90 150.5
unassigned
95 161.9
100 173.9
105 186.4
110 199.6
115 213.4
120 227.8
125 242.9
130 258.6
135 275.1
140 292.3
145 310.2
150 328.9
155 348.3
160 368.7
165 389.8
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/pt_r290.htm4.3.2007 10:29:34
R-400(50/50)
R-400(50/50)
R-400(50/50) R-400(50/50)
Vapour Liquid
R-400(60/40)
R-400(60/40) R-400(60/40)
Vapour Liquid
R-401A
ARI
GUIDELINE N-
1995
colour
assignment
pinkish-red
(coral)
R-401B
R-401C
R-402A
R-402B
R-403A
R-403B
FR-12
Freezone
R-407A
R-407B
R-407C
R-407D
R-410B
R-413A
R-500
R-500
Temp Pressure
-90 -24.9 Hg
-80 -22.9 Hg
-70 -20.3 Hg
-60 -17.0 Hg
-50 -12.8 Hg
-40 -7.6 Hg
-35 -4.6 Hg
-30 -1.2 Hg
-25 1.2
-20 3.2
-15 5.4
-10 7.8
-5 10.4
0 13.3
Freon
Trade Name 5 16.4 Genetron
10 19.7Isotron etc- 500
15 23.3
20 27.2R-12/152a
Formula 25 31.473.8 26.2%
30 36.0
35 40.8
Oil MO AB
40 46.0
45 51.6
Replaces 50 57.5R-502
55 63.9
60 70.6
ARI 65 77.8
GUIDELINE N-70 85.3
1995 75 93.4
colour 80 101.9
assignment 85 111.0
yellow
90 120.4
95 130.5
100 141.1
105 152.2
110 164.0
115 176.3
120 189.2
125 202.8
130 217.0
135 231.8
140 247.4
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R-502
R-502
R-502
Temp Pressure
-150 -29.1 Hg
-140 -28.5 Hg
-130 -27.8 Hg
-120 -26.7 Hg
-110 -25.3 Hg
-100 -23.3 Hg
-90 -20.6 Hg
-80 -17.2 Hg
-70 -12.8 Hg
-60 -7.2 Hg
-50 -0.2 Hg
-40 4.1
-35 6.5
-30 Freon
9.2
Trade Name -25 12.1 Genetron
-20 15.3
Isotron etc- 502
-15 18.8
-10 22.6
R-22/115
Formula -5 26.7
48.8% 51.2%
0 31.1
5 35.9
Oil MO AB
10 41.0
15 46.5
20 52.4
liquid and
Note 25 58.8
vapour
pressures
30 65.6
virtually identical
35 72.8
40 80.5
ARI 45 88.7
GUIDELINE N-50 97.4
1995 55 106.6
colour 60 116.4
assignment 65 126.7
light purple 70 137.6
(lavender) 75 149.1
80 161.2
85 174.0
90 187.4
95 201.4
100 216.2
105 231.7
110 247.9
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R-414B
R-414B
R-417A
NARM-502
R-501
R-504
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R-508B
R-508B
ARI
GUIDELINE N-
1995
colour
assignment
dark blue (navy)
R-509A
R-600
R-600
Temp Pressure
-40 -25.0 Hg
-35 -24.2 Hg
-30 -23.3 Hg
-25 -22.3 Hg
-20 -21.2 Hg
-15 -19.9 Hg
-10 -18.5 Hg
-5 -16.9 Hg
0 -15.2 Hg
5 -13.3 Hg
10 -11.2 Hg
15 -8.9 Hg
20 -6.4 Hg
Trade Name 25 -3.7 Hg
N-butane
30 -0.7 Hg
35 1.3 CH3-CH2-CH2-
40 3.0
Formula 45 4.9 CH3
50 6.9 (C4H10)
55 9.1
Oil 60 11.4all
65 13.9
70 16.6
ARI
75 19.5
GUIDELINE N-
80 22.5
1995
colour 85 25.8
unassigned 90 29.3
95 33.0
100 37.0
105 41.2
110 45.6
115 50.3
120 55.3
125 60.5
130 66.1
135 71.9
140 78.0
145 84.5
150 91.3
155 98.4
160 105.9
165 113.7
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R-600A
R-600A
R-600A
Temp Pressure
-40 -21.6 Hg
-35 -20.4 Hg
-30 -18.9 Hg
-25 -17.4 Hg
-20 -15.6 Hg
-15 -13.7 Hg
-10 -11.5 Hg
-5 -9.2 Hg
0 -6.6 Hg
5 -3.8 Hg
10 -0.7 Hg
15 1.3
20 3.1
Trade Name 25 5.0
Isobutane
30 7.1
35 9.4CH(CH3)2-CH3i-
Formula 40 11.8
45 14.4(C4H10) (C4H10)
50 17.2
Oil 55 20.2all
60 23.5
65 26.9
ARI 70 30.6
GUIDELINE N-
75 34.5
1995
80 38.6
colour
unassigned 85 43.0
90 47.7
95 52.7
100 57.9
105 63.4
110 69.3
115 75.4
120 81.9
125 88.7
130 95.8
135 103.4
140 111.2
145 119.5
150 128.2
155 137.2
160 146.7
165 156.6
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G2018C
G2018C
ARI
GUIDELINE N-
1995
colour
unassigned
R-601
R-601
Temp Pressure
-40 -29.2 Hg
-35 -29.0 Hg
-30 -28.9 Hg
-25 -28.6 Hg
-20 -28.4 Hg
-15 -28.1 Hg
-10 -27.8 Hg
-5 -27.4 Hg
0 -27.0 Hg
5 -26.5 Hg
10 -26.0 Hg
15 -25.4 Hg
20 -24.7 Hg
Trade Name 25 -24.0 Hg
N-pentane
30 -23.1 Hg
35 -22.2 CHHg3-CH2-CH2-
Formula 40 -21.2 Hg
45 -20.0 CHHg2-CH3
50 -18.8 Hg
Oil 55 -17.4 all Hg
60 -15.9 Hg
65 -14.3 Hg
ARI 70 -12.5 Hg
GUIDELINE N-
75 -10.6 Hg
1995
80 -8.5 Hg
colour
unassigned 85 -6.2 Hg
90 -3.8 Hg
95 -1.1 Hg
100 0.9
105 2.4
110 4.0
115 5.8
120 7.6
125 9.6
130 11.7
135 14.0
140 16.4
145 19.0
150 21.7
155 24.6
160 27.7
165 30.9
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R-601A
R-601A
R-601A
Temp Pressure
-40 -28.7 Hg
-35 -28.5 Hg
-30 -28.2 Hg
-25 -27.9 Hg
-20 -27.5 Hg
-15 -27.1 Hg
-10 -26.7 Hg
-5 -26.1 Hg
0 -25.5 Hg
5 -24.9 Hg
10 -24.1 Hg
15 -23.3 Hg
20 -22.4 Hg
Trade Name 25 -21.4 Hg
Isopentane
30 -20.2 Hg
35 -19.0 (CH Hg) CH-CH -
3 2 2
Formula 40 -17.6 Hg
45 -16.1 CHHg3
50 -14.5 Hg
Oil 55 -12.7 all Hg
60 -10.8 Hg
65 -8.7 Hg
ARI 70 -6.4 Hg
GUIDELINE N-
75 -3.9 Hg
1995
80 -1.2 Hg
colour
unassigned 85 0.8
90 2.4
95 4.0
100 5.8
105 7.6
110 9.7
115 11.8
120 14.1
125 16.5
130 19.1
135 21.9
140 24.8
145 27.9
150 31.2
155 34.7
160 38.4
165 42.2
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R-C270
R-C270
R-C270
Temp Pressure
-40 -8.6 Hg
-35 -5.7 Hg
-30 -2.5 Hg
-25 0.5
-20 2.5
-15 4.5
-10 6.8
-5 9.3
0 12.0
5 15.0
10 18.2
15 21.6
20 25.3
Trade Name 25 29.3 R-C270
30 33.5
35 38.1-CH2-CH2-CH2-
Formula
40 43.0
45 48.2
Chemical Name 50 53.8cyclopropane
55 59.7
ARI
60 66.0
GUIDELINE N-65 72.7
1995 70 79.8
colour 75 87.3
unassigned 80 95.2
85 103.6
90 112.4
95 121.7
100 131.5
105 141.8
110 152.6
115 163.9
120 175.8
125 188.3
130 201.4
135 215.0
140 229.3
145 244.2
150 259.7
155 276.0
160 292.9
165 310.5
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R-C318
R-C318
R-C318
Temp Pressure
-40 -24.4 Hg
-35 -23.4 Hg
-30 -22.3 Hg
-25 -21.1 Hg
-20 -19.7 Hg
-15 -18.1 Hg
-10 -16.3 Hg
-5 -14.4 Hg
0 -12.2 Hg
5 -9.8 Hg
10 -7.1 Hg
15 -4.2 Hg
20 -0.9 Hg
Trade 25 1.3
PFC-C318
Name 30 3.2
35 5.2
40-CF -CF
7.5 -CF -CF -
Formula 2 2 2 2
45 9.9
50 12.5
Chemical 55 15.4
octafluorocyclobutane
Name 60 18.4
65 21.7
Oil 70POE25.2PAG
75 29.0
80 33.1
Note
85blend component
37.4
90 42.0
ARI 95 47.0
GUIDELINE 100 52.2
N-1995 105 57.8
colour 110 63.7
unassigned 115 69.9
120 76.5
125 83.5
130 90.9
135 98.7
140 106.9
145 115.6
150 124.7
155 134.3
160 144.4
165 155.0
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R-E134
R-E134
R-E134
Temp Pressure
-40 -27.5 Hg
-35 -27.0 Hg
-30 -26.4 Hg
-25 -25.7 Hg
-20 -24.9 Hg
-15 -24.0 Hg
-10 -22.9 Hg
-5 -21.8 Hg
0 -20.4 Hg
5 -18.9 Hg
10 -17.2 Hg
15 -15.3 Hg
20 -13.2 Hg
25 -10.9 Hg HFE-
R-E134
Trade Name
30 -8.3 134Hg
35 -5.4 Hg
40 -2.3 CHFHg-O-CHF
Formula 2 2
45 0.6
50 2.5
55 bis 4.5
Chemical Name60 (difluoromethyl)
6.7
65 9.1ether
70 11.8
Oil 75 14.6
MO AB
80 17.7
85 21.0
Replaces R-114
90 24.5
95 28.4
ARI 100 32.5
GUIDELINE N- 105 36.8
1995 110 41.5
colour 115 46.5
unassigned
120 51.8
125 57.5
130 63.5
135 69.9
140 76.6
145 83.8
150 91.3
155 99.3
160 107.7
165 116.5
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R-E245FA1
R-E245FA1
R-E245fA1
Temp Pressure
-40 -29.1 Hg
-35 10.0 Hg
-30 8.9 Hg
-25 7.8 Hg
-20 6.7 Hg
-15 5.5 Hg
-10 4.3 Hg
-5 3.0 Hg
0 1.6 Hg
5 0.3 Hg
10 0.6
15 1.3
20 2.1
Trade Name 25 R-E245FA1
2.8
30 3.7
35 CHF
4.5 -O-CH -CH
Formula 2 2 3
40 5.4
45 6.3
50 2-7.2
Chemical 55 (difluoromethoxy)-
8.2
Name 60 1,1,1-
9.2
70 70.2
trifluoroethane
80 84.2
Oil 90 MO99.8 AB
100 117.2
105 128.5
Replaces R-11 R123?
110 136.4
120 157.7
ARI 125 171.4
GUIDELINE N- 130 181.0
1995 135 196.1
colour 140 206.6
unassigned
145 217.5
150 234.6
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GHG-High Performance
GHG-High Performance
GHG-X5 (experimental)
HC-12A
HX4
NARM-12
NARM-22
OZ-12
Air Conditioning
Part 2
Air Conditioning systems come in many forms. Two main categories are Packaged Systems and Split
Systems. The picture on the left is of a packaged roof top heating/cooling system. It is called packaged
because all the mechanical equipment is "packaged" into one self contained box. It merely needs to
have power wiring, control wiring and a duct system added to it. Split systems are "split" into 2 or
more sections. There will be an air handling unit (AHU) inside the building and a remote condenser
such as shown on the right on the outside of the building. The components in a split system are joined
together by refrigeration piping and electrical wiring. There are many other types of AC systems some
of which are listed below:
● Absorption
- a chemical refrigeration process with few moving parts that uses heat as it's energy source - can be very large systems in the hundreds of Tons used to air condition large buildings - small
systems are used in mobile RV refrigeration as a propane source is easier to provide than AC electrical source - they are in common use where waste heat can be recycled and in hot
climatic regions where solar panels can be used
● Chilling Systems
- systems which cool liquids such as chilled water or a water/glycol mixture - this Secondary Refrigerant is distributed to one or more locations where it picks up heat and then returns to the
chiller where heat is removed - it is more cost effective to distribute chilled water throughout a large building than it would be to use large amounts of refrigerants - there are many types and
capacities ranging from a small reciprocating compressor drinking fountain to larger reciprocating chillers, screw chillers and large centrifugal chillers in the hundreds of Tons capacity
● Computer Room Air Conditioning
-expensive specialized equipment designed to maintain a tightly controlled environment for computer rooms - heats, cools, humidifies, dehumidifies and has good air filtration
● Ductless Split System
- small split system which can have up to 3 air handlers - handy for locations where there is no room to install ductwork
● Evaporative Coolers
- called swamp coolers in some locations - available in many capacities - they use the evaporative cooling capability of water to cool air - best suited to very dry climates
● Heat Pumps
- an air conditioning system which has a reverse cycle - it provides cooling in the summer and in the winter it provides efficient heat by relocating heat from outdoor ambient air, water or
ground - comes packaged or split - also used in heat reclaim and perimeter loop systems
● Incremental Unit
- similar to a window AC unit however is installed through a wall instead of through a window - can come with electric heat and in a heat pump configuration - typically used in motels - Also
called PTAC, for Packaged Terminal Air Conditioner
● Packaged System
- any system which has it's main mechanical components packaged into a single box - Roof Top Package Systems are one example - Water Cooled Package AC units are another
● Split System
- any system which has it's main mechanical components situated in different locations and joined by refrigeration piping - also called field built.
● Spot Cooling
- portable air conditioner that blows conditioned air at a particular spot - used in locations where a central AC system is not practical - example: blow cool air on a worker in a high
temperature work environment
● Mobile Air Conditioning
- any mobile comfort cooling system - includes cars, trucks, buses, heavy equipment, planes, trains, and boats - specially designed equipment, commonly open compressors belt driven from
an engine pulley
● Water Cooled Package System
- a self contained AC unit which uses water as the condensing medium rather than air - it may or may not have ductwork attached to it - available in many capacities
● Window Air Conditioner
- small self contained unit - as small as 5000 BTUH, up to about 32,000 BTUH, installed through a window, air conditions a single room - They can be noisy and since they throw air from a
single location they do not have the air distribution capabilities of a duct system
The type of system that is chosen is largely dependent on the physical layout of the building. If there is no flat roof space available a split system may be the only
viable choice. However, Package Systems have capabilities that splits do not. Package units have fresh air capabilities either in the form of a fixed damper in a fresh
air hood or a free cooling section that has a minimum fresh air position. By Code, commercial buildings must have a minimum percentage of Fresh Air. With split
systems fresh air requirements must be accounted for by natural infiltration or by some other means.
OFF: MIN Fresh Air: Free Cooling: Free Cooling: Free Cooling:
1 2 3 4 5
Button 1 shows a roof top package heating/cooling unit in the off condition. This would occur if there was a power failure or if an energy saving set back condition was in
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Air Conditioning
progress. If a unit supplies a commercial space then codes demand that no less than a specified minimum quantity of fresh air be mixed in with the supply air. Stipulated
amounts of Minimum Fresh Air vary by regional code but they are usually around 10%. During a set back period when the building is unoccupied, the blower motor is off, the
outdoor air dampers are shut all the way and the compressor and condenser fan motors are sitting idle. Nothing will run unless a setting is reached which calls for heating or
cooling. When it is near the time when the building will become occupied again, the heating or cooling starts to bring the conditioned space back to design occupied set points.
When the indoor blower motor starts the OA dampers open to their minimum fresh air position. Press Button 2 to see this. The return air and the outdoor air combine and are
then called Mixed Air. Note that it does not take a very wide opening to bring in 10% outdoor air.
Mechanical Cooling is when the compressor and condenser fan motors are operating. This of course costs energy. Sometimes the outdoor conditions are such that there is no
need to run the compressor and condenser fans and cooling can be accomplished by bringing in outdoor air, hence the term Free Cooling. If it is cool enough to accomplish
this a damper motor causes the OA dampers to open wider and at the same time the RA dampers close down a corresponding amount. Press Buttons 3, 4, and 5 to see this. The
dampers modulate automatically to try and maintain a mixed air setpoint of about 55 ºF. This 55 ºF air is distributed throughout the space to satisfy the cooling demands. If the
outdoor conditions change so that free cooling is no longer possible then the system reverts back to mechanical cooling and the dampers revert back to the minimum fresh air
setting.
The decision to use free cooling or mechanical cooling is made by Enthalpy Controls. These include an OAT - Outdoor Air Thermostat, MAT - Mixed Air Thermostat as well
as a humidity sensor. If the outdoor air contains excessive humidity then it can not be used for free cooling even if it's temperature might seem cool enough. You can't
introduce excessively humid air and still stay within the bounds of the human comfort zone. Even when the fresh air dampers are in the minimum 10% fresh air position,
humidity in the fresh air being introduced takes away from the sensible cooling capacity. (If a portion of the cooling capacity is used to condense moisture out of the air, there
is then less capacity left over to accomplish Sensible Cooling) This requirement must be taken into account when cooling load calculations are performed at design time.
Heat Pumps
Part 2
Balance Point
The Balance Point of a heat pump is the outdoor temperature (usually between 30 °F to
45 °F) at which a heat pump's output exactly equals the heating needs of the conditioned
space. Below the balance point, supplementary heat is needed to maintain indoor design
conditions.
COP
It is possible to relocate heat from the ground or water with a heat pump. Most of the time
ground and water temperatures are higher than winter air temperatures so they are more
efficient to use as heat sources. For example there can be a raging snow storm with air
temperatures in the 0 ºF range yet the ground temperature 6 feet down might be 40 ºF.
However those mechanical systems are a lot more complicated than air source heat pumps
and although COPs of 4:1 or higher can be achieved, the much greater installation costs and
increased maintenance and repair costs should be carefully considered compared to the
expected extra energy savings.
Airflow Requirements
It is important that the indoor air handler and duct distribution system are capable of moving
an adequate quantity of air to satisfy the air flow requirements of the indoor coil when it is in
the condenser mode. A typical rule of thumb for air flow requirements is 400 CFM per Ton
(cubic feet per minute) for air conditioning systems and 450 CFM per ton for heat pump
systems. Inadequate condenser air causes high head pressures which lead to compressor
failures.
Electricity
Part 2
DC - Direct Current
AC - Alternating Current
Magnetism
Electro-Magnetism
Electric motors
Start Stop
Electric motors rely on electromagnetism. The above animation is a simplified example of a 2 pole
AC motor. AC is causing the poles to reverse continuously on the stators (as in stationary) or field
windings. If the rotor (as in rotational) was given an initial nudge to get it started, it would
continue to rotate as long as the AC remained live. Note how sometimes opposite poles are
attracting the rotor and other times like poles are repelling the rotor. In both cases the forces keep
the rotor spinning in the direction it is going. Motors must of course be able to start automatically,
without requiring an initial nudge to get them going. The next section shows a number of ways
that this is accomplished with different types of AC motors.
Controls
Part 10
A refrigeration system operating in the 40 ºF range usually does not require a defrost system. If a slight build up of frost happens to
occur on the evaporator fins the system should be diagnosed to find and remedy possible malfunctions. If particular circumstances
make frosting unavoidable, hopefully any frost build up will completely melt during each off cycle. This is quite possible because
cooler evaporator fans are operating continuously and the air being circulated through the evaporator fins is about 40 ºF, an 8 ºF TD
from the freezing point of water. A system that frosts up yet defrosts satisfactorily in-between run cycles is said to have an Off Cycle
Defrost.
Off On
Electric Defrost
An off cycle defrost would be no good at all for a freezer system. The temperature of the recirculating air passing through the
evaporator fins is below the freezing point of water and is incapable of thawing ice. The most common type of defrost system for
freezers is an electric defrost. An "Electric Defrost Evaporator" is one which has electric resistance heater elements built in to the
evaporator. A defrost timer must be incorporated into the control circuit to control the defrosts. The NC and NO contacts are
commonly referred to as the "A" and "B" contacts. The A contacts bring on refrigeration, the B contacts bring on the defrost
elements. Note how the EFM circuit is controlled by the timer. The EFM must be off during defrosts for several reasons; to allow the
heat that builds up in the evap to stay there and defrost ice, we don't want heat blowing out into the refrigerated space warming up
product and we don't want humid air blowing out into the refrigerated space sublimating all over the place.
1 Diagram
When the defrost terminates the evaporator is warm and wet. The evap fans
must not be allowed to come on instantly and blow moisture all over the room.
Droplets would refreeze all over the ceiling, walls and product. The fans are
temporarily kept off by the FDT, the Fan Delay Thermostat. The compressor is
allowed to run without the fans on and re-freezes any moisture left on the fins
from the defrost. Once the temperature of the evap is down below the freezing
point of water the FDT closes and the evap fans are once again operational.
Many freezer evaporator manufacturers use bi-metal disk fan delay controls.
They are a sealed unit with an indentation on the bottom which allows it to fit
over a pipe or evaporator end bend with good contact. The unit locks in place
with a spring clip and senses the pipe temperature. A FDT (Fan Delay
Thermostat) will typically make at 25 ºF which is a good temperature to assume
that any residual water moisture left on the fin surface has been re-frozen.
Some bi-metal disks have 3 wires instead of 2. That indicates that the switch
has a secondary function built in. That other function is usually a defrost
Bi-Metal Controls
COLD HOT
Materials, especially metals, expand with heat and shrink with cold. However they do not all expand and contract at the same rate. A
bi-metal control utilizes this phenomena to create a temperature sensitive warp switch. Two metals (as in bi-metal) with differing
coefficients of thermal expansion are bonded together and fixed in place at one end. If the lamination is warmed up, the differing
expansion rates of each layer cause it to warp or curl. A electrical contact is attached to the end that moves and makes a connection
between 2 fixed electrical contacts when the bi-metal bends.
Bi-metal disk controls use round shaped layers of metal rather than bar shaped layers. Take another look at the schematic wiring
diagram above in the electric defrost section. Toggle between buttons 3 and 4 and the popping action that the FDT (Fan Delay T-
Stat) symbol takes should now make sense as representative of the warping action of the bi-metal. In the explanation above about
fan delay T-Stats it was explained that a FDT keeps the evaporator fan off until the evaporator is cold enough to have frozen any
residual defrost water on the fins. That control is said to "make on a fall of temperature". The DTT (Defrost Termination T-Stat)
does the opposite and "makes on a rise of temperature". These 2 opposite functions, heating T-Stats and cooling T-Stats can be
accomplished by varying the design of bi-metal controls.
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Controls
Controls
Part 2
A Pressure control can also be used as an operating control. The electrical circuitry is the same as with a
temperature controller as can be seen by clicking the Buttons. The LPC makes on a rise of pressure.
The graph below shows what is happening. The control is set to start refrigeration if the box warms up to 40
ºF. However when using a pressure control the Cut In, Cut Out and differential are in PSIG not ºF. The
corresponding pressures must be determined for the refrigerant being utilized and the differential must be
wide enough so that the equipment does not short cycle.
Controls
Part 3
A Pressure control can also be used as a safety control. The electrical circuitry shown below has two
controls in series. Therefore, if the LPC trips, the compressor will not run even if the T-Stat is calling. The
LPC in this example is set to protect the system from a loss of refrigerant charge and is set to cut out at a
pressure that is lower than anticipated low side operating pressure. The compressor should not be allowed to
operate with an undercharge as the windings can overheat and other types of damage can occur as well.
Unless there is a loss of charge the LPC will therefore remain permanently closed during all off cycles and
run cycles. The LPC's contacts are therefore said to be normally closed (NC). Small leaks cause a gradual
loss of refrigerant and a LPC might only trip once in a while during the initial stages of a refrigerant leak.
As time passes the safety will trip more and more often and can eventually get to the point where the system
will only run for a few seconds before cutting out. After a short time the high and low side pressures will
equalize and the system will try starting once again. This is called short cycling. It's not good for the system
but is certainly better than letting the compressor destroy itself by operating indefinitely with an
undercharge or no refrigerant.
More safety controls can be added such as a High Pressure Control. If high head pressure occurs for any
reason the switch will open protecting the compressor. Controls can be automatic reset or manual reset. If
the manual reset type trips, a little button pops out and the unit will not restart until the button is manually
reset. This is to force attention to the fact that there has been a safety trip.
Controls
Part 4
It is possible to have a system automatically pump down every time a run cycle ends. With Open type compressors this is mandatory so that the off cycle
pressure is not applied to the shaft seal. (When operating, the suction pressure is relatively low but during the off cycle the pressures equalize and the low
side pressure increases.) Pump downs are also used to empty out the low side at the end of each run cycle. This eliminates the possibility of refrigerant from
the evaporator slugging the compressor at start up. It also eliminates the possibility of refrigerant migrating to the compressor sump during the off cycle and
washing out the oil at start up. The components of a pump down system are a LPC, a T-Stat and a solenoid valve which is installed in the liquid line. When
installed in that location it is called LLSV for Liquid Line Solenoid Valve.
Note that the suction gauge decreases in pressure which is to be expected. However, do you know why the high side pressure did not increase when the
system is pumped down? The amount of refrigerant in the high side increased but the pressure does not because of what you have learned about the PT
relationship of refrigerants. When there are saturated conditions the pressure will correspond to the pressure that the PT Chart predicts regardless of the
quantity of liquid refrigerant.
The schematic below depicts a simple pump down system. Press the "Off Cycle" Button and note that the evap fans are running constantly. The T-Stat is the
operating control but does not directly control the compressor. Press "T-Stat On" and see that it allows a circuit to the LLSV. When the LLSV is energized it
allows refrigerant flow from the high side to the low side. When the low side pressure builds to the cut in point of the LPC, the Compressor and condenser
fans come on. (Press LPC on) The system operates until the T-Stat is satisfied. Press "T-Stat Off" and note that the LLSV is de-energized but the compressor
is still operating. It will run until the cut out point of the LPC is reached and that has been set at 1 PSI. In other words, the low side of the system will pump
down to just a slight positive pressure at the end of every run cycle. Press "Off Cycle" to simulate the end of the pump down. The next time the T-Stat calls
the sequence repeats.
Controls
Part 5
Relays
When a system is pumped down sometimes a little liquid refrigerant is left over in a long liquid line
or in the evaporator. This liquid will evaporate and can build up the pressure to the cut in point on the
LPC. The compressor will restart and run for a few moments and pump down some more. Sometimes
this can happen several times in a row. If the compressor valves are a little worn and don't hold back
properly, discharge pressure can leak back and cause a pumped down system to short cycle
indefinitely through what is supposed to be an off cycle. It is not good to short cycle a compressor or
for that matter any electrical motor. Valve wear can of course be severe enough to warrant
compressor repair or replacement but short of that there is a way to address both of these situations
with a control system. The Non-Recycling Pump Down control system makes use of a couple of
relays.
1 Diagram
3 T-Stat On: call for cooling, NRR coil energised (Non-Recycling Relay), LLSV opens, pressure starts to rise
4 LPC On: power flows through NRR contacts and energizes HOLD coil...continued...
6 T-Stat Off: starts pumping down. circuit maintained through HOLD contacts even though NRR dropped out
8 LPC On (False Call from bleed back) held off by NRR contacts
You may not come across a non-recycling pump down very frequently but this circuitry is still a
"must know". This control circuitry introduced the:
It demonstrated how a relay can be held in by it's own contacts. It also demonstrated how complex
functionality can be accomplished with a small number of controls.
Troubleshooting
Part 2
Measuring Electricity
Amperage
the reading.
Volts
Ohms
Measurable Resistance
Help Hint
Unit Nameplate
CFM seized.
COMPR seized.
EFM seized.
HPC tripped.
LPC open.
No Faults.
No power.
Unlisted problem.
LO
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Controls
Part 11
Low voltage controls are typically constructed with smaller parts and placed inside less robust enclosures
than high voltage controls and are therefore less expensive to manufacture. They can be connected with
small gauge control wire which is also inexpensive. However, some jurisdicons require even low voltage
wiring to be placed inside conduit. Wall mounted thermostats are made in all manner of shapes and styles.
A few main types are shown below.
Anticipation
Imagine a fairly precise thermostat controlling a oil fired furnace which has a large heat exchanger with a
lot of mass. At the end of a call for heating the T-Stat shuts off the oil burner at the exact setting of say 74
ºF. However, the indoor fan continues to operate as it should until the cut out point is reached on the furnace
fan control and in the process a lot of residual heat is extracted from the large thermal mass of the heat
exchanger. This residual heat continues heating the space and as a result the temperature overshoots the
setpoint.
In order to avoid overshoot, a technique called heat anticipation is used. A small low wattage heater is
included inside the thermostat. It is positioned near the bi-metal coil (or what ever sensing device is being
used) and connected in series with the heating contacts. Whenever the heating circuit is made, the heat
anticipator generates "false heat" which makes the thermostat end the heating call sooner. (The temperature
sensor cannot differentiate between false heat and space heat) In the example of the oil furnace this solves
the overshoot problem caused by the residual heat in the heat exchanger. Cooling anticipation is also
utilized, however a cooling anticipator is placed in parallel with the cooling contacts. So in the case of a
heating anticipator false heat is generated when the heating contacts close. A cooling anticipator generates
false heat when the cooling contacts open. When there is a cooling call, electricity takes the route of least
resistance and ignores the route througn the cooling anticipator when it can travel through the closed
cooling contacts.
Troubleshooting
Part 3
1 2 3 4 5 6
Button 1.
With the meter in the Volts mode, the probes have been placed on test points 1 and 2 which are actually L1 and Neutral. The meter reads
120 VAC which means there is a voltage potential of 120 volts between those 2 points.
Button 2.
One probe has been left on N. The other has been moved to test point 4. There is an electrical circuit between point 4 and L1 so the
meter still reads 120 VAC. Electrically this is identical to the previous circumstance.
Button 3.
We can move one probe to test point 6 and still nothing has changed from the meter's perspective. It is still reading a voltage potential of
120 VAC.
Button 4.
If we move to test point 7 still nothing has changed. The meter can read the potential to L1 through the closed contacts of the LPC. As a
matter of fact we have just used the volt meter to tell us whether the LPC is open or closed.
Button 5.
Note the circuit to L1 that is being sensed by the volt meter.
Button 6.
When we move to test point 8 everything changes. We are now on the other side of the HPC and apparently it is open because we are no
longer reading a voltage potential. That is indeed the case. Note how the meter can no longer read the voltage potential to L1. The signal
can not get past the open HPC control. By checking the voltage before and after the control we can be sure that it is open. If there are a
whole series of safety controls and one of them is open but you don't know which one it is, hop from one to the next to the next and so on
until you locate the open control. You have just learned how the "Hop Scotch Method" of electrical troubleshooting works. The same
method is utilized with 230 VAC circuits. One probe is left on L2 and the other probes hops from test point to test point.
Controls
Part 6
Contactors
A contactor is like a large relay. Relays are generally used for switching light
loads like control circuitry and relatively small motors. Contactors are used for
bringing larger loads online like compressors and large motors. Contactors can
have 1,2,3 or 4 sets of contacts. Contactors have NO contacts but can also have
auxiliary contacts which can be NO or NC.
The buttons demonstrate how the contacts pull in when the coil is energized.
The schematic symbol also toggles showing the contacts in the open and closed
conditions. Contactor coils are available in several voltages, for example; 24
VAC, 120 VAC, 208 VAC, 230 VAC, or dual rated at 208/240. A typical use
for a contactor is using a 24 VAC control circuit to switch a high voltage/high
amperage load like a compressor. Some larger contactors have changeable
coils.
Although the contacts snap shut quickly, arcing occurs between the contacts as
they approach the closed position. This arcing eventually wears out the
contacts. It is wise to inspect the condition of contacts reasonably frequently
and replace the contactor before they become so pitted and burnt and carboned
up that the compressor (or whatever load) is placed in danger. If contacts stick
shut, a compressor can continue operating regardless of any operating or safety
controls that may open. It can continue operating in the absence of evaporator
and/or condenser fan motors which can cause compressor failure in short order.
Coil Contacts
Off On
Starters
"Starters have overloads, contactors do not". If you can remember that little phrase then you will remember the difference between
contactors and starters. The 3 phase schematic diagram below shows a circuit with a starter. The starter has 3 sets of contacts and a
coil just like a contactor. However it also has amperage sensitive heaters and overloads which are placed in series with the coil. If
any of the lines draw more amperage than the rating of the heaters in series with the starter contacts, then the corresponding overload
will open. Since all of the overload switches are in series with the starter coil, any one that opens will de-energize the coil and stop
the compressor. As a matter of fact all the safeties are in series in this schematic and any safety that opens will stop the compressor.
Sometimes a manufacturer designs in a lock out circuit to protect the equipment. They group a particularly important bunch of safety
controls in series and surround the group with a lock out circuit. If any safety control within the group opens, the compressor stops
and will not restart even if the safety control resets. Press the Normal button. Note how there is no electrical flow through the LO
(Lock Out) coil even though it looks like there should be. That's because the LO coil is a high impedance coil (high resistance) and
the electricity takes the route of least resistance through all the closed safety controls. However if any of the controls in the group
open the electricity has no choice than to flow through the LO coil. Press the Lock Out button and see this happen when the HPC
opens. The LO coil becomes energized and it's NC contacts open. This forces the LO coil to remain energized which stops electrical
flow to the group of safety controls permanently. So even if the HPC was to reset the compressor would still be held off by the open
LO contact which disallows a circuit to the compressor contactor (CC).
A lock out forces attention to a problem situation rather than allowing the equipment to cycle indefinitely on a safety control and
perhaps go unnoticed until damage occurs. Interrupting the power will reset the lock out if the safeties are reset. However, if all the
controls in a lock out group have reset it is not possible to tell which one caused the lock out. An inspection of the equipment may
reveal the cause. For example a dirty condenser might indicate that the HPC had tripped and reset after the high pressure condition
subsided (while the system was off).
If there are no visible indications there is a trick that can be used to determine which control is opening. Wire a very small capacity
fuse (1/100 AMP) in parallel with each of the safety controls. As long as nothing trips the electricity will once again take the route of
least resistance through the series of closed safety controls. However as soon as one of them opens, the electricity will attempt to
flow around the open control through the fuse which will blow instantly due to it's extremely small rating. The next time the
equipment is inspected it will not matter if all of the safeties in the lock out group have reset. The fuses can be Ohmed out and the
one that is blown will indicate which safety opened.
Controls
Part 8
● lack of oil in
compressor
● clogged oil inlet
strainer
Controls
Part 7
Transformers
The power capabilities of a transformer is specified by the unit VA which stands for Volt/
Amps. A very small control voltage transformer might have a rating of 20 VA. A transformer
this small would only be capable of powering a small number of relay coils and might be
satisfactory for a heating only control circuit. To power the multitude of controls that come
with a cooling control system you might need to move up to a 40 VA transformer. So to
specify a transformer you need to state the primary voltage, the secondary voltage and the VA
rating. Transformers are one of the simplest things to troubleshoot. Simply measure the
primary and secondary voltages. If you have no secondary voltage check to see if there is a
built-in fuse. A good transformer should have continuity through the primary winding and
continuity through the secondary winding. There should be no continuity between the two.
Help Hint
Unit Nameplate
CFM seized.
COMPR seized.
EFM seized.
HPC tripped.
LPC open.
No Faults.
No power.
Unlisted problem.
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Controls
Part 9
Humidistat
The sensing element in a humidity control is made of a hygroscopic material such as hair or
wood or nylon ribbons. The material is arranged such that a mechanical linkage causes an
electrical contact to make or break. Electronic humidity controls use a substance which varies
in resistance with humidity changes.
Help Hint
Unit Nameplate
CFM seized.
COMPR seized.
EFM seized.
HPC tripped.
LPC open.
No Faults.
No power.
Unlisted problem.
LO
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Help Hint
Unit Nameplate
CC coil open
CFM seized.
COMPR seized.
EFM seized.
Heater open.
HPC open.
LPC open.
No Faults.
No power.
LO
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Help Hint
Unit Nameplate
CC coil open
CFM seized.
COMPR seized.
EFM seized.
Heater open.
HPC open.
LPC open.
No Faults.
No power.
LO
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Help Hint
Unit Nameplate
CC coil open
CFM seized.
COMPR seized.
EFM seized.
Heater open.
HPC open.
LPC open.
No Faults.
No power.
LO
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Help Hint
Unit Nameplate
CC coil open
CFM seized.
COMPR seized.
EFM seized.
Heater open.
HPC open.
LPC open.
No Faults.
No power.
LO
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1 2 3 4 5 6 7 8 9
Unfamiliar Territory
Troubleshooting means running into unfamiliar equipment time after time. In a perfect world every piece of equipment would have a clearly layed out
schematic and wiring diagram and sequence of events list. You rarely run into equipment with all 3. Over time, you have to develop the ability to
follow through a schematic and figure out the intended sequence of events from the electrical schematic as well as your understanding of the HVAC/R
task at hand. The above schematic of a roof top packaged heat/cool unit may look complex at first glance. However, we are going to go through the
sequence of events with this equipment to give you a feel for the sorts of complexities that are designed into a control circuit. You cannot troubleshoot
something if you don't have the foggiest idea whether a given control should be energized or whether a contact should be open or closed at particular
times. You must dissect the operational steps in order to understand the intentions of the designers. Only then will you be in a position to diagnose
faults. So before we start throwing faults at you, lets look at the normal operation of this unit.
Button 1
Button 2
This shows power on, with the unit standing by waiting for the T-Stat to call for heating or cooling. Electricity has got as far as many of the open
contacts but can go no further unless some contacts close. The red wires are intended to show the logic of how the electricity flows. It is therefore
important to understand that just because a wire or component is shown as black, this does not necessarily mean that there is no electrical potential at
that location. With power on there is only one load that is operational. That is the compressor crankcase heater which is tied into constant power. The
black dots and the numbered test points indicate junction points. If wires cross over each other with no junction dot then they are not joined
electrically. Also note how the T-Stat is surrounded by a dashed line indicating the boundary of the T-Stat components. The T-Stat is poised in-
between the heating and cooling position. If it "made" to the heating position nothing would happen because the T-Stat system switch is in the cooling
mode. The vertical bar that joins the Y and Y1 terminals represents the T-Stat system switch. It would have to be slid to the left in order to enable the
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Troubleshooting 6 Sequence of Events
heat. The first circuit that we will examine is the indoor blower motor circuit. The customer has the option of operating the blower any time they want.
Note the other "bar" on the right side of the T-Stat under the word AUTO. Switch the fan from the AUTO mode to the ON mode by clicking button 3.
(if left in the AUTO mode, the fan would automatically come on when ever there was a call for cooling or heating)
Button 3
Moving the fan switch to the on position sent a signal through the G terminal to the K2 blower relay. The circuit was completed by returning to C, the
common side of the 24 VAC control voltage transformer. The designation G is almost always used for the fan circuit. Click back and forth between
button 2 and 3 and notice that the K2 relay has a pair of contacts which reverse positions. When the NO contacts close the HI speed fan is energized.
We'll put the fan switch back to the AUTO position and see what happens if the T-Stat calls for cooling.
Button 4
Even though the fan switch was in the AUTO position, when the T-Stat called for cooling the K2 Blower Relay still got energised (by way of the Y1
circuit) and the indoor blower motor started operating in high speed once again. That's proper, the AC mode requires full airflow. The Y (cooling
circuit) also became energized. That pulled in 2 more relays, the K1 and K3 relays. K1 is the compressor contactor and it's 2 NO contacts K1-1 closed
to bring on the compressor. K3 closed it's contact K3-1 which brought on the OFM (outdoor fan motor) which is of course the condenser fan motor.
So on a call for cooling we energised the COMPR, OFM and IBM on HI speed. The PTC device in parallel with the COMPR run cap provides extra
starting torque and switches itself out of the circuit after start up. Click button 2 to end the cooling call.
Button 5
The T-Stat is calling for heat but nothing is happening. R1 made to W1 but that's as far as the signal got. That's because the T-Stat system switch is
still in the cooling position and only cooling is enabled. Some T-Stats have an AUTO position not only for the fan but also for the system switch. That
would enable the heating and cooling modes to automatically switch whenever required. Press button 6 to manually enable heating.
Button 6
If the T-Stat system switch is in the heat position and the T-Stat calls for heat the K4 heat relay becomes energized. The squarish jagged design of the
heat relay symbol indicates that it is a time delay relay. It sequences the closing of it's contacts over time (also known as a sequencer). The K4-1
contacts down by the IBM close bringing the fan into low speed operation. That is proper for the heating mode. Less airflow causes a higher supply air
temperature, is less draughty and is also quieter. The heating mode does not require the large amount of airflow that the cooling mode does. The K4-2
contacts close bringing on the 1st bank of electric heat. Press buttons 7.
Buttons 7, 8 and 9
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Troubleshooting 6 Sequence of Events
After a short delay, the sequencer brings on the 2nd bank. Electric resistance heating elements draw a lot of power and it is customary to bring them on
in sequence rather than all at once to avoid causing severe voltage drop and dimming the lights. The K4 (AUX) contacts also close and energise
another time delay relay, the K5. After time delays, the 3rd and eventually the 4th banks of heat are sequenced on by the K5 relay by it's K5-2 and K5-
3 contacts. Press buttons 8 and 9 to bring them on in sequence. Note the K5-1 contacts over by the IBM. They are in parallel with the K4-1 contacts
and are there to insure that there is airflow over energised elements 3 and 4. For example, if the K4-1 contacts ever fail the K5-1 contacts will bring on
the blower anyway. There is no sense in burning out elements from lack of airflow caused by a faulty contact when an extra electrical contact can
reduce that risk. When the heating demand is satisfied the T-Stat breaks the heating control circuit. The control relays de-energize the elements in
reverse order. The blower will continue operating until both fan contacts on the relays have opened.
Summary
You can see that there are a lot of things that take place in specific orders to provide heating and cooling from a simple 1 stage cool, 1 stage heat (4
sequenced banks) system. There are a few components that didn't get mentioned yet. The items marked CB are circuit breakers. Those and the high
temperature safety limits are normally closed devices and don't come into play unless there is a fault. F1 through F5 are fuses. The PTC device in
series with the start winding of the compressor is a solid state start assist device which takes itself out of the circuit automatically when the compressor
gets up to sufficient speed. Now that you have an understanding of what is supposed to take place under normal conditions, you can attempt to
diagnose some faults.
LO
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Unit Nameplate
CB-1 tripped.
CB-2 tripped.
CB-3 tripped.
CB-4 tripped.
CCH open.
COMPR seized.
Element 1 open.
Element 2 open.
Element 3 open.
Element 4 open.
F1 open.
F2 blown.
F3 blown.
F4 blown.
F5 blown.
IBM seized.
K1 coil open.
K2 coil open.
K3 coil open.
Limit 1 open.
Limit 2 open.
Limit 3 open.
Limit 4 open.
LPC open.
No Faults.
No power.
OFM seized.
LO
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Unit Nameplate
CB-1 tripped.
CB-2 tripped.
CB-3 tripped.
CB-4 tripped.
CCH open.
COMPR seized.
Element 1 open.
Element 2 open.
Element 3 open.
Element 4 open.
F1 open.
F2 blown.
F3 blown.
F4 blown.
F5 blown.
IBM seized.
K1 coil open.
K2 coil open.
K3 coil open.
Limit 1 open.
Limit 2 open.
Limit 3 open.
Limit 4 open.
LPC open.
No Faults.
No power.
OFM seized.
LO
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Unit Nameplate
CB-1 tripped.
CB-2 tripped.
CB-3 tripped.
CB-4 tripped.
CCH open.
COMPR seized.
Element 1 open.
Element 2 open.
Element 3 open.
Element 4 open.
F1 open.
F2 blown.
F3 blown.
F4 blown.
F5 blown.
IBM seized.
K1 coil open.
K2 coil open.
K3 coil open.
Limit 1 open.
Limit 2 open.
Limit 3 open.
Limit 4 open.
LPC open.
No Faults.
No power.
OFM seized.
LO
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Unit Nameplate
CB-1 tripped.
CB-2 tripped.
CB-3 tripped.
CB-4 tripped.
CCH open.
COMPR seized.
Element 1 open.
Element 2 open.
Element 3 open.
Element 4 open.
F1 open.
F2 blown.
F3 blown.
F4 blown.
F5 blown.
IBM seized.
K1 coil open.
K2 coil open.
K3 coil open.
Limit 1 open.
Limit 2 open.
Limit 3 open.
Limit 4 open.
LPC open.
No Faults.
No power.
OFM seized.
LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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LO
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AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_50.htm4.3.2007 10:31:36
Advanced Troubleshooting 51
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_51.htm4.3.2007 10:31:37
Advanced Troubleshooting 52
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_52.htm4.3.2007 10:31:38
Advanced Troubleshooting 53
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_53.htm4.3.2007 10:31:39
Advanced Troubleshooting 54
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_54.htm4.3.2007 10:31:40
Advanced Troubleshooting 55
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_55.htm4.3.2007 10:31:41
Advanced Troubleshooting 56
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_56.htm4.3.2007 10:31:42
Advanced Troubleshooting 57
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_57.htm4.3.2007 10:31:43
Advanced Troubleshooting 58
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_58.htm4.3.2007 10:31:44
Advanced Troubleshooting 59
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECW
LCW
CTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FREON%20SA%20INTERNETA/1024x768/troubleshooting_advanced_59.htm4.3.2007 10:31:45
Advanced Troubleshooting 60
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Troubleshooting HP80 (R-402A) Walk In Freezer - Problem 63 Hot Gas Defrost, no re-evaporation
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
[Click
images for
ECA
reference
diagrams]
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbreviations Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
Help Hint R22 PT Chart Abbr. Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EIA
LIA
ITD
EOA
LOA
OTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FR...SA%20INTERNETA/1024x768/troubleshooting_advanced_85.htm4.3.2007 10:32:23
Advanced Troubleshooting 86
Help Hint R22 PT Chart Abbr. Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EIA
LIA
ITD
EOA
LOA
OTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FR...SA%20INTERNETA/1024x768/troubleshooting_advanced_86.htm4.3.2007 10:32:24
Advanced Troubleshooting 87
Help Hint R22 PT Chart Abbr. Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EIA
LIA
ITD
EOA
LOA
OTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FR...SA%20INTERNETA/1024x768/troubleshooting_advanced_87.htm4.3.2007 10:32:25
Advanced Troubleshooting 88
Help Hint R22 PT Chart Abbr. Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EIA
LIA
ITD
EOA
LOA
OTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FR...SA%20INTERNETA/1024x768/troubleshooting_advanced_88.htm4.3.2007 10:32:26
Advanced Troubleshooting 89
Help Hint R22 PT Chart Abbr. Submit Diagnosis Full Screen Note
LO
COR
SLT
SH
HI
COR
LLT
SC
EIA
LIA
ITD
EOA
LOA
OTD
AMP
DLT
file:///C|/Documents%20and%20Settings/Branko/Desktop/FR...SA%20INTERNETA/1024x768/troubleshooting_advanced_89.htm4.3.2007 10:32:28
Advanced Troubleshooting 90
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT
LO
COR
SLT
SH
HI
COR
LLT
SC
EEA
LEA
ETD
ECA
LCA
CTD
AMP
DLT