Topic 1

DJU3032 AIR CONDITIONING & REFRIGERATION CONTROL SYSTEM 1
1.0 BASIC CONTROL PRINCIPLE
1.1 Basic control principle in air conditioning and refrigeration is emphasizing on controlling the
temperature, pressure, refrigerant, water, air and electrical current flow in the system.
Prinsip kawalan asas dalam penyamanan udara dan penyejukbekuan menekankan kepada kawalan
suhu, tekanan, aliran bahan pendingin, air, udara dan arus elektrik dalam system.
The main function of refrigerant control is to control the flow of the refrigerant in the air conditioning
and refrigeration system so that the refrigerant can flow smoothly and the system can operate well.
Fungsi utama kawalan bahan pendingin ialah untuk mengawal pengaliran bahan pendingin dalam
sistem penyamanan udara dan penyejukbekuan supaya bahan pendingin boleh mengalir lancar dan
sistem boleh beroperasi dengan baik.
1.1.1 Definition of control:

In the simplest term, the control is defined as the starting, stopping or regulation of heating,
ventilating, and air conditioning system. Controlling an HVAC system involves three distinct steps:
1.1 Measure a variable and collect data
1.2 Process the data with other information
1.3 Cause a control action
Benefits of a control system in air conditioning and refrigeration system:

i. Maintain thermal comfort conditions
ii. Maintain optimum indoor air quality
iii. Reduce energy use
iv. Safe plant operation
v. Reduce manpower costs
vi. Identify maintenance problems
vii. Efficient plant operation to match the load
viii. Monitor system performance
SIX types of refrigerant controls:
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i. Automatic Expansion Valve (AEV).

ii. Thermostatic Expansion Valve (TEV).
iii. Low-Pressure Side Float (LSF).
iv. High-Pressure Side Float (HSF).
v. Capillary Tube (Cap Tube).
vi. Thermal-Electric Expansion Valve.
General characteristic of refrigerant controls:

i. Function = Used in a refrigeration system to change the pressure of the refrigerant.
ii. Location = Is placed between the liquid line and the evaporator.
iii. Operational method = Reduces the high pressure in the liquid line to low pressure in the
evaporator.
Automatic Expansion Valve (AEV)
Operational method:
- With unit running, temperature in sensing bulb is about 5°C warmer than the refrigerant
temperature in the evaporator.
- This temperature difference produces different pressures and different forces. This is described as
the superheat of the bulb over the refrigerant temperature inside the evaporator.
- The pressure in the sensing bulb is greater than the pressure in the evaporator.
- As temperature increases or decreases, the pressure will also increase or decrease.
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Thermostatic Expansion Valve (TEV)
A thermostatic expansion valve keeps a constant superheat in the refrigerant vapour leaving the coil. The
valve controls the liquid refrigerant, so the evaporator coils maintain the correct amount of refrigerant at
all times.
The valve has a power element that is activated by a remote bulb located at the end of the evaporator
coils. The bulb senses the superheat at the suction line and adjusts the flow of refrigerant into the
evaporator.
As the superheat increases (suction line), the temperature, and therefore the pressure, in the remote bulb
also increases. This increased pressure, applied to the top of the diaphragm, forces it down along with the
pin, which, in turn, opens the valve, admitting replacement refrigerant from the receiver to flow into the
evaporator. This replacement has three effects.
First, it provides additional liquid refrigerant to absorb heat from the evaporator. Second, it applies higher
pressure to the bottom of the diaphragm, forcing it upward, tending to close the valve. And third, it
reduces the degree of superheat by forcing more refrigerant through the suction line.
The advantages of thermostatic expansion valve:
i. It provides excellent control of refrigeration capacity as the supply of refrigerant to the
evaporator matches the demand.
ii. It ensures that the evaporator operates efficiently by preventing starving under high load
conditions.
iii. It protects the compressor from slugging by ensuring a minimum degree of superheat under
all conditions of load, if properly selected.
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Low- Pressure Side Float Valve
The low-side float valve controls the liquid refrigerant flow where a flooded evaporator is used. It
consists of a ball float in either a chamber or the evaporator on the low-pressure side of the svstem. The
float actuates a needle valve through a lever mechanism. As the float lowers, refrigerant enters through
the open valve; when it rises, the valve closes.
Low- Pressure Side Float Valve
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High- Pressure Side Float Expansion Valve
In a high-side float expansion valve, the valve float is in a liquid receiver or in an auxiliary container on
the high-pressure side of the system. Refrigerant from the condenser flows into the valve and immediately
opens it, allowing refrigerant to expand and pass into the evaporator. Refrigerant charge is critical. An
overcharge of the system floods back and damages the compressor. An undercharge results in a capacity
drop.
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Capillary Tube
The capillary tube consists of a long tube of small diameter. It acts as a constant throttle on the refrigerant.
The length and diameter of the tube are important; any restrictions cause trouble in the system. It feeds
refrigerant to the evaporator as fast as it is produced by the condenser. When the quantity of refrigerant in
the system is correct or the charge is balanced, the flow of refrigerant from the condenser to the
evaporator stops when the compressor unit stops. When the condensing unit is running, the operating
characteristics of the capillary tube equipped evaporator are the same as if it were equipped with a high-
side float. The capillary tube is best suited for household boxes, such as freezers and window air-
conditioners, where the refrigeration load is reasonably constant and small horsepower motors are used.
Tiub rerambut biasanya digunakan untuk proses kawalan bahan pendingin. Tiup ini merupakan tiup yang
panjang dengan garispusat yang kecil. Jumlah bahan pendingin yang dimasukkan ke dalam sistem
mestilah dengan kadar yang betul kerana ianya akan masuk kebahagian tekanan rendah semasa system
berhenti. Bahan pendingin yang terlalu banyak dialikan akan menyebabkan fros terbentuk pada saluran
sedutan.Perubahan beban di dalam sistem akan menyebabkan perubahan tekanan di dalam penyejat.
Tiup rerambut tidak mempunyai injap atau liang yang boleh dilaraskan. Dengan ini, fungsi tiup rerambut
bergantung kepada perubahan tekanan di penyejat untuk menentukan jumlah bahan pendingin yang
melaluinya.
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Thermal-Electric Expansion Valve
Depends on the use of thermistors, which are directly exposed to the refrigerant in the suction line, to
control the expansion valve needle opening. Refrigerant flow is controlled by the temperature in the
suction line. Bleed valves have a small slot in the valve seat, allowing pressure to balance during the off
cycle. Allows for use of low-starting-torque compressor motors.
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FAULTS IN REFRIGERATION CONTROL
Faults in refrigerant controls caused:

i. damage to the control devices which
ii. resulted in failure in control system.
iii. control devices had to be replaced so that the system can function as usual in order to let
the refrigerant flow well in the system.
Kesalahan dalam kawalan pendinginan menyebabkan :

i. kerosakan kepada alat-alat kawalan
ii. kegagalan dalam sistem kawalan.
iii. Alat-alat kawalan terpaksa diganti supaya sistem boleh berfungsi seperti biasa agar
bahan pendingin mengalir dengan baik dalam sistem.
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2.0 TYPES OF CONTROL
THREE categories of controls in air conditioning and refrigeration system:
i. man made control system

Example : cycle of refrigerant in an air conditioner system
ii. natural control system
Example: airflow in a room
iii. combination of man made and natural control system
Example: cycle of refrigerant mixed with airflow produced air cooled in a room
Tiga kategori kawalan dalam sistem penyamanan udara dan penyejukbekuan :
i. Sistem kawalan buatan manusia

Contoh: kitaran bahan pendingin dalam system penyaman udara
ii. Sistem kawalan semulajadi

Contoh: aliran udara dalam bilik
iii. Sistem kawalan gabungan(buatan manusia&semulajadi)

Contoh: kitaran bahan pendingin digabungkan dengan aliran udara mendinginkan bilik.
From the three categories of controls mentioned above, they can be divided into TWO major types:
i. Open loop control:
Operation:
Open loop control is by far the simpler of the two types of control theory. In open loop
control, there is some sort of input signal (digital or analog), which then passes through
amplifiers to produce the proper output, and is then passed out of the system. Open loop
controls have no feedback and require the input to return to zero before the output will
return to zero.
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ii. Closed loop control:

Operation:
In closed loop control, the system is self adjusting. Data does not flow one way, it may pass
back from a specific amplifier (such as velocity or position) to the start of the control system,
telling it to adjust itself accordingly. Many physical systems are closed loop control at the
lowest level since the data about velocity and current position modify the output (also
position) at consistent rate.
The functions of control system:

- to control motors and other devices in the mechanical systems.
- Using control system mathematics and theory, you can design systems that do nearly anything
you want it to operate in the amount of time that you desire.
Location of HVAC control system.

b) The HVAC control system is typically distributed across three areas:
i. The HVAC equipment and their controls are located in the main mechanical room.
Equipment includes chillers, boiler, hot water generator, heat exchangers, pumps, etc.
ii. The weather maker or the “Air Handling Units (AHUs)” may heat, cool, humidify,
dehumidify, ventilate, or filter the air and then distribute that air to a section of the building.
AHUs are available in various configurations and can be placed in a dedicated room called
secondary equipment room or may be located in an open area such as roof top air-handling
units.
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iii. The individual room controls depend on the HVAC system design. The equipment includes
fan coil units, variable air volume systems, terminal reheat, unit ventilators, exhausters, zone
temperature/humidistat devices, etc.
Classification of control devices

i. Thermostat (operating)
RANGE ADJUSTMENT
CAPILLARY TUBE
A thermostat is the component of a control system which regulates the temperature of a

system so that the system’s temperature is maintained near a desired set point temperature.
ii. Metering device (regulating)
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Metering devices, such as expansion valves and float valves, control the flow of liquid
refrigerant between the high side and the low side of the system. It is at the end of the line
between the condenser and the evaporator.
iii. Fusible plug (safety)
A fusible plug is a threaded metal cylinder usually of bronze, brass or gunmetal, with a tapered
hole drilled completely through its length. This hole is sealed with a metal of low melting point that
flows away if a pre-determined, high temperature is reached. A fusible plug operates as a safety
valve when dangerous temperatures are reached in a closed vessel in air conditioning system.
Palam berfius beroperasi sebagai injap keselamatan apabila suhu berbahaya tercapai dalam
ruang tertutup di dalam sistem penyamanan udara.
Suitable location to install the fusible plug:

At the system that generates high pressure. It is because the fusible plug is used to release pressure in
the system when pressure in the system is higher than the point set.
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3.0 BASIC WIRING CIRCUITS AND SYMBOLS
i. switch (on-off)
Function = to connect current supply to the wiring circuit.
Operational method = manually operated electromechanical device with one or more sets
of electrical contacts.
ii. relay (coil and switch)
relay (coil and switch)

Function = to function as switch and current supply control in the wiring circuit.
Operational method = an electromagnetic operated switch which consist of coil of wires,
armature, spring and contacts.
iii. contactor (control and power circuit)
Function = to function as switch and wire connectors in the wiring circuit which
connected to high current load devices.
Operational method = an electrically controlled switch which controlled by a circuit
which has a much lower power level than the switched circuit and are usually designed
for both normally closed and normally open applications.
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iv. timer (delay ON and OFF)

Function = to control the sequence of wiring circuit connections from a specified time
interval.
Operational method = an electromagnetic operated device which consist coil, contact
points, normally closed and normally open applications.
BASIC DIRECT ON LINE CONTROL STARTER SCHEMATIC WIRING DIAGRAM:
FUNCTION OF DIRECT ON LINE (DOL) CONTROL STARTER
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- To function as a safety switch for several air conditioning and refrigeration system 1 phase
(240 Volt) such as :
 window unit
 commercial refrigerator
- It is also used as a safety switch for several air conditioning and refrigeration system 3 phase
(415 Volt) such as :
 cold room
- In split unit, there is no need to use direct on line (DOL) starter, because it is already has `built
in starter’ ins its indoor unit. (Split unit consist of indoor and outdoor unit).
- In 3 phase, the control circuit remains the same. We simply just added the supply line (3 life
line = L1, L2 and L3) instead of just 1 life line (L) in 1 phase circuit.
CAPACITY RANGE OF DIRECT ON LINE (DOL)

- The capacity range of DOL is normally 1-5 Horsepower (Hp).
OPERATIONAL METHOD OF DIRECT ON LINE (DOL)

- When current is supplied to the circuit and we press the ON push button, the magnetic
contactor will operates. The contactor is an electrically controlled switch which controlled by a
circuit which has a much lower power level than the switched circuit and are usually designed
for both normally closed (NC) and normally open (NO) applications.
- We need to connect the circuit to the normally open (NO) in the magnetic contactor to hold the
ON’ position in the circuit, otherwise it will disconnect the current.
- The running pilot lamp will shows its light to indicate that the circuit is in operation.
- When overloading current occurs in the direct on line control circuit, overload relay will
disconnect the current supply from the circuit and connects it to the `TRIP’ pilot lamp to
indicate that the circuit is tripped.
- We need to reset it by pressing the ÒN’ push button.
- When overloading current occurs and cannot be tolerate by the circuit, the fuse will blow. We
need to replace the fuse. Normally, the ampere of the fuse is 20 Ampere.
The term of holding the ÒN’ position in the direct on line control circuit is called `holding
contact’.
Nama istilah yang digunakan untuk memegang kedudukan `HIDUP’ dalam litar kawalan
penghidup talian terus ialah `pemegang sesentuh’.
When overloading current occurs in the direct on line control circuit, overload relay will
disconnect the current supply from the circuit and connects it to the `TRIP’ pilot lamp to indicate
that the circuit is tripped. We need to reset it by pressing the ÒN’ push button.
Apabila beban arus lebih berlaku dalam litar kawalan penghidup talian terus, geganti beban
lampau akan memutuskan bekalan arus daripada litar dan menyambungkannya kepada lampu
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pandu `TRIP’ bagi menunjukkan bahawa system telah trip. Kita perlu melaraskan semula litar itu
dengan menekan butang `HIDUP’.
BASIC STAR DELTA CONTROL STARTER SCHEMATIC WIRING DIAGRAM
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L = LIFE N = NEUTRAL
LP1= PILOT LAMP 1
LP2 = PILOT LAMP 2
PB1 = OFF PUSH BUTTON
PB2 = ON PUSH BUTTON
FUNCTION OF STAR DELTA CONTROL STARTER

- To function as a safety and sequence operating control for water pump motor, condenser fan
motor and evaporator fan motor in 3 phase (415 Volt) air conditioning and refrigeration system
such as :
 Chiller system
 Package unit
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CAPACITY RANGE OF DIRECT ON LINE (DOL)

- The capacity range of Star Delta is normally 6-24 Horsepower (Hp).
OPERATIONAL METHOD OF STAR DELTA
1. Apabila punat tekan hidup (PB2) ditekan, bekalan arus akan melalui sesentuh lazim tertutup (D1),
GLM1 dan gegelung bintang S akan mendapat bekalan.
2. Pada masa yang samasesentuh lazim terbuka (S1) akan tertutup dan gegelung C akan mendapat
bekalan lalu menyebabkan sesentuh lazim terbuka (C1) akan tertutup dan sesentuh lazim tertutup
(S2) akan terbuka. Pada masa ini sambungan bintang berlaku.
3. Selepas mencapai masa yang dilaraskan, sesentuh lazim tertutup (GLM1) akan terbuka
menyebabkan gegelung S tidak mendapat bekalan.
4. Pada masa yang sama, sesentuh lazim terbuka (S1) terbuka semula dan sesentuh lazim tertutup
(S2) tertutup semula. Ini akan menyebabkan gegelung D mendapat bekalan dan menyebabkan
sesentuh lazim tertutup (D1) akan terbuka dan memutuskan pengaliran arus ke gegelung S dan
GLM.
5. Pada masa ini sambungan litar delta berlaku dan lampu pandu (LP1) menyala. Sekiranya terdapat
lebihan arus, sesentuh lazim tertutup (GBL) akan terbuka dan memutuskan bekalan ke litar
kawalan sebaliknya membekalkan bekalan kepada lampu pandu (LP2) menyebabkan lampu
menyala.
Star-delta starters and a special 6-lead motor that allows for the motor winding to be connected in
either a wye or delta configuration are needed for this. During the start, the windings are
connected in the wye resulting in 58% of line voltage applied across any two windings. This
reduces both inrush and starting torque to 33% of the delta connected values. After a preset time
delay, the motor leads are switched to the delta connection.
Wye-Delta starters come in 2 variations being open and closed transition. Open - transition type
momentarily interrupt power during the starting cycle, and Closed transition starters are supplied
with an additional contactor and resistor bank used to keep the motor windings energized for a
few cycles until the transition from wye to delta is complete.
AUTOTRANSFORMER CONTROL CIRCUIT
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CAPACITY RANGE OF AUTOTRANSFORMER is 25 hp and above.

GUIDANCE:
SO = OFF Push Button SO = ON Push Button KI = Star Contactor
K2 = Transformer Contactor K3 = Main Contactor K4 = Timer Relay
K5 = Contactor Relay
F1 = Main Circuit Fuses
F2 = Overload Relay
F3 = Control Circuit Fuse
AUTOTRANSFORMER POWER / MAIN CIRCUIT
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OPERATIONAL METHOD OF AUTOTRANSFORMER
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Autotransformer control circuit is normally used for starting compressor motor in commercial
system. With an auto transformer, a standard 3-lead motor is used. Autotransformers provide
reduced voltage to the motor terminals during starting through the use of a tapped,
autotransformer. Typical auto transformers deliver 50%, 65%, or 80% of full line voltage during
start-up. After a preset period the transformer is switched out of the circuit and the motor is
connected directly to full line voltage supplying 50%, 65% or 80% of the current inrush seen
during a full voltage start. The resulting starting torque will be 25%, 42% or 64% of full voltage
values, as will be the current draw on the line. Autotransformers provides maximum torque with
minimum line current. Autotransformer starters provide the highest starting torque per ampere of
line current, and is an effective means of motor starting for applications where the inrush current
must be reduced with a minimum sacrifice of starting torque.
SCHEMATIC WIRING DIAGRAM FOR SPLIT UNIT (1)
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SCHEMATIC WIRING DIAGRAM FOR SPLIT UNIT (2)
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SCHEMATIC WIRING DIAGRAM FOR DOMESTIC REFRIGERATOR
SCHEMATIC WIRING DIAGRAM FOR WATER COOLER
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SCHEMATIC WIRING DIAGRAM FOR DISPENSING VENDING MACHINE
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4.0 CONTROL ACCESSORIES
THERMAL LIMITER
FUNCTION:
A thermal limiter assembly for controlling an electrical circuit in response to the existence of a
sensed condition beyond a predetermined time period.
OPERATIONAL METHOD:
A housing body of the assembly includes a gas-filled cavity in which are disposed functional
electrical elements in the form of a heater element and a thermally responsive switch or fuselike
element. The heater element is arranged to raise the temperature of the thermally responsive
element to a critical temperature at which it changes its state of conductivity and is thereby
adapted to alter an external circuit connected to it. As disclosed, the heat transfer relationship
between the heater element and the thermally responsive element is relatively independent of
environmental temperature conditions so that the time period to actuate the thermally responsive
element is not substantially affected by such temperature conditions. The housing body includes
means to indicate the state of conductivity of the thermally responsive device in a visually
perceptible manner externally of said housing.
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SUPERHEAT SWITCH
FUNCTION:
It is inserted into the rear of the AC compressor. It is designed to " sense suction gas
temperatures".
OPERATIONAL METHOD:
It is comprised of an electrical switch and a sensing tube. The tube is inserted into the
compressor. The purpose of the superheat switch is to prevent compressor damage due to loss of
refrigerant charge. The switch cuts off the compressor in the event of loss of refrigerant.
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WATER CONTROL VALVE
FUNCTION:
The control valve which used to regulate the water distribution and prevent the reversal of flow of
water in a system is water control valve.
OPERATIONAL METHOD:
Water valves are used in refrigeration systems with water-cooled condensers to maintain
constant condensing pressure under varying loads. The water valves can be used for common
refrigerants provided the operating range of the valves is not exceeded. The WVS can be used for
R 717 (ammonia). always install an FV filter ahead of the water valve to exclude dirt from the
moving parts of the valve. To prevent vibrations from being transmitted to the bellows housing
the housing must be connected to the discharge line after the oil separator, via a capillary tube.
Water control valve can be catagorised into FIVE types:

i. Globe valve
ii. Butterfly valve
iii. Gate valve
iv. Ball valve
v. Diaphragm valve
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Globe valve
A valve in which the flow of water is controlled by a movable spindle which lowers to a fixed seat, thereby
restricting the flow through the valve opening; the spindle is fitted with a washer to provide tight closure;
usually enclosed in a chamber having a globular shape.
Butterfly valve
A valve used to control the flow of fluids; a disk controls flow through the port. Also called a butterfly
damper.
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Gate valve
Gate valves are probably the most common valves in use today due to their widespread use in domestic water
systems, but it should be noted that their popularity in industry has declined in recent years. However, they are still
used where an uninterrupted flow is required, because the gate fully retracts into the bonnet, creating a minimal
pressure drop, when the valve is in an open position. Gate valves are specifically intended for use in isolation
applications.
Ball valve
A valve for regulating the flow of fluids by a movable ball which fits in a spherical seat.
Diaphragm valve
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The features of Diaphragm Valve makes it the most suitable & preferred valve for aseptic and
sterile operations. The Diaphragm valve has outstanding self-draining characteristics. The
diaphragm of the valve is the key performance component providing leak tight shutoff between
upstream and downstream. The Diaphragm also isolates the top works or actuating parts from the
process media. The operating mechanism of a diaphragm valve is not exposed to the media
within the pipeline.
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RELIEF VALVE
a) Type of relief valve:

i. Conventional
The conventional relief valve is a differential pressure device. Back pressure on the outlet of
the relief valve affects it. They are only useful if they discharge to the atmosphere.
Discharging to a relief/flare header is not practical as the back pressure is always varying and
will affect the conventional relief valve.
ii. Balanced Bellows

The balanced bellows relief valve addresses the back pressure problem with conventional
relief valves but is not a complete solution. The balanced bellows relief valve flow
performance starts getting impacted at back pressures in excess of 30% of relief valve set
point. Large balance bellows relief valves cannot take more than 60 psig back pressure
without it causing a failure of the bellows.
iii. Pilot Operated

The pilot operated relief valve is not normally affected by back pressure (as to its ability to
pop at set). The effect of back pressure on the performance of the relief valve is also minimal.
They can have up to 80% back pressure with it only rerating the capacity by 20%. The
sensing line for the remote pilot must use a special pickup to allow it to capture the dynamic
pressure part of the gas.
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FUNCTION:
Relief valve is a type of valve used to control or limit the pressure in refrigeration and air
conditioning piping system.
OPERATIONAL METHOD:
A pressure relief valve is installed in a refrigeration system primarily to protect the receiver. Since
it is not intended to be an overload or high pressure cutout, we recommend that the pressure relief
valve be set at the working pressure marked on the receiver, regardless of the type of refrigerant
used.
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5.0 DOMESTIC CONTROL SYSTEM

Valves applied to domestic system:
DISCHARGE
VALVE
SUCTION
VALVE
Figure: Main Parts of Service Valve

i. Suction Valve : is a valve attached to suction pipe in the system
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FUNCTION: It is used to let the refrigerant gas charged in the system, for pump down
and vacuum process.
OPERATIONAL METHOD: Turn anti-clockwise (using Allen key) to open and allowing
the refrigerant gas to enter the compressor.
ii. Discharge Valve = is a valve attached to discharge pipe in the system.
FUNCTION: It is used to let the refrigerant liquid charged in the system.
OPERATIONAL METHOD: Turn anti-clockwise (using Allen key) to open and allowing
the refrigerant liquid to enter the compressor.
iii. Service Valve = An extra valve exists in the system where there is no suction valve.
FUNCTION: used for charging, pump down and vacuum process in the system.
OPERATIONAL METHOD: Attach to manifold gauge and control the gauge valve
according to service purposes. (charging, pump down or vacuum)
Figure: Cross Sectional Area of Service Valve
Apart from car air conditioning, all domestic control system used Capillary Tube
(picture below) as the refrigerant control. Its located between the liquid line and the
evaporator. (Please refer page 6 for further details.)
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FUNCTION: Used in a refrigeration system to change the pressure of the refrigerant.

OPERATIONAL METHOD: Reduces the high pressure in the liquid line to low pressure
in the evaporator.
b) . Factors to consider in designing a capillary tube:

i. Tube length
ii. Inside diameter
iii. Tightness of tube windings
iv. Temperature of tubing
(4 marks)
ii. Advantages of the capillary tube:
i. It is inexpensive.
ii. It does not have any moving parts hence it does not require maintenance.
iii. Capillary tube provides an open connection between condenser and the evaporator
hence during off-cycle, pressure equalization occurs between condenser and
evaporator. This reduces the starting torque requirement of the motor since the motor
starts with same pressure on the two sides of the compressor. Hence, a motor with
low starting torque (squirrel cage Induction motor) can be used.
iv. Ideal for hermetic compressor based systems, which are critically charged and
factory assembled.
(Accept any THREE(3) of the answers above)
6.0 COMMERCIAL REFRIGERATION CONTROL SYSTEM

a) Two-temperature valve (picture below) has a temperature control. It is built much like
a thermostatic expansion valve and works much the same. It operates from the
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temperature of the evaporator or temperature of the air entering or leaving. It has a

capillary tube and a sensing bulb much like the thermostatic expansion valve. A bellows
moves a rod as different pressures are created in the sensing bulb.
Figure: Internal Parts of Two Temperature Valve
Thermostatic expansion valve
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Figure: Internal Parts of Thermostatic Expansion Valve

Sensing bulb —includes liquid-charged, gas-charged, liquid cross-charged, and gas cross-charged.
•Note: Liquid-charged and gas-charged use the same refrigerant in the system and bulb. Cross-charged
uses a fluid in the sensing bulb different from the system refrigerant. Flow is through the valve into the
evaporator. Low-side pressure, the temperature of the evaporator outlet, and spring pressure control flow.
Provides a high flow rate as the evaporator empties (warms). Reduces flow as the evaporator fills (cools)
with refrigerant.
- With unit running, temperature in sensing bulb is about 5°C warmer than the refrigerant
temperature in the evaporator.
- This temperature difference produces different pressures and different forces. This is described as
the superheat of the bulb over the refrigerant temperature inside the evaporator.
- The pressure in the sensing bulb is greater than the pressure in the evaporator.
- As temperature increases or decreases, the pressure will also increase or decrease.
- When compressor stops, low-side pressure and the sensing bulb pressure tend to equalize.
- The needle is forced into its seat. Refrigerant flow stops.
- A thermostatic expansion valve keeps a constant superheat in the refrigerant vapour leaving the
coil. The valve controls the liquid refrigerant, so the evaporator coils maintain the correct
amount of refrigerant at all times.
- The valve has a power element that is activated by a remote bulb located at the end of the
evaporator coils. The bulb senses the superheat at the suction line and adjusts the flow of
refrigerant into the evaporator.
- As the superheat increases (suction line), the temperature, and therefore the pressure, in the
remote bulb also increases. This increased pressure, applied to the top of the diaphragm, forces
it down along with the pin, which, in turn, opens the valve, admitting replacement refrigerant
from the receiver to flow into the evaporator. This replacement has three effects.
Disadvantages of thermostatic expansion valve:

o TEV is more expensive.
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o Proper precautions should be taken at the installation of TEV.

o TEV cannot be used since only a very small extent of superheating is available for
operation.
o The feeler bulb should preferably be insulated to reduce the influence of the ambient air.
Automatic Expansion Valve (AEV).
Figure : Internal Parts of Automatic Expansion Valve
- Operated by low-side pressure as the closing force and spring pressure as the opening force.
- Throttles liquid refrigerant in the liquid line down to a constant pressure. While compressor is
running, liquid refrigerant is sprayed into the evaporator.
- Sometimes called a dry system, since evaporator is never filled with liquid refrigerant, but with a
mist.
- Valve capacity should equal the evaporator capacity. Valve seat is softer than needle. Spring is
attached at both ends. May be adjusted for either pressure or tension.
- Attached to the evaporator by threaded fittings or a two-bolt flange.
Page 39
- Used mainly on domestic air conditioning units or vending machines.

- Has stops to prevent excessive movement of the diaphragm.
- Diaphragm separates the atmospheric pressure and the system pressure.
o Three forces control valve: Adjustable spring.
o Spring beneath diaphragm.
o Outlet pressure underneath the diaphragm.
Solenoid Valve
Solenoid valve is an electromechanical valve frequently used to control the flow of liquid or gas.
It is commonly used in refrigeration and air conditioning systems, as to control the flow of
refrigerant in liquid form. Its function is simply to turn refrigerant flow on and off.
A solenoid valve operates in the following way:
i. When the solenoid coil is electrically energized, it produces a magnetic field that attracts iron
and many of its alloys.
ii. An iron armature or plunger is drawn up into the core of the solenoid.
iii. A stem and pin or poppet attached to this plunger opens the valve port.
iv. When the solenoid valve is de-energized, the plunger falls, and the poppet closes the valve
port.
Common applications for solenoid valves:
i. Pump-down cycle
ii. Temperature control of separate units in a multiple system
iii. Suction applications
iv. Compressor unloading
v. Hot-gas bypass
vi. Hot-gas defrost
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b) Solenoid valves can generally be divided into two types:

i. Direct acting
Function and operational method of direct acting solenoid valve :
i. Terdapat satu jarum pelocok pada injap ini dikawal oleh bekalan elektrik. Apabila bekalan
dibekalkan, ia akan membuka liang dan akan menutup semula liang apabila bekalan
diputuskan.
ii. Biasanya digunakan untuk tiub yang bersaiz kecil. Jika dipasang pada tiub yang besar ,
bahagian pelocok dan injapnya menjadi berat. Ianya memerlukan satu gegelung elektrik yang
besar dan ini secara tidak lansung akan mengganggu pergerakkan pelocok.
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ii. Pilot operated
Function and operational method of pilot acting solenoid valve :
i. Injap solenoid jenis pandu ini biasanya digunakan untuk system yang lebih besar. Ini adalah
kerana ia tidak akan membuka injap secara terus kerana ia akan membuka pot pandu terlebih
dahulu dan ini akan mengurangkan tekanan di bahagian atas jarum injap.
ii. Dengan ini, ketidakseimbangan tekanan akan berlaku pada tetumpu injap. Perbezaan tekanan
yang lebih tinggi akan menyebabkan injap terbuka.
iii. Jika bekalan elektrik tiada, jarum pelocok akan jatuh ke bawah dengan sendirinya dan akan
menutup liang saluran bahan pendingin tersebut.
Page 42
Pressure Switches
HIGH & LOW PRESSURE SWITCH
Low Pressure Adjustment Differential Adjustment High Pressure Adjustment
Connection to Suction Line Connection to Discharge Line
High and low pressure switch is a safety switch to protect compressor

from overloaded by cutting off the supply to compressor when pressure is too low
or too high. Three terms that we have to consider when operating this device are:
i. Cut In – the level when compressor starts to operate.

ii. Cut off - the level when compressor stops to operate.
iii. Differential – the gap between cut in and cut off.
When operating this device, determine the low pressure reading, high
pressure reading and differential (the good differential is between 3 to10). Adjust
these three items (low pressure, high pressure and differential).
Note: Mostly, these items had already been adjusted by manufacturer or

factory, according to the usage of the pressure switch in certain system, notably
commercial refrigerator, cold room and commercial air-conditioning system. In
Page 43
certain cases, we need to re-adjust these items according to the suitability of the
system. Make sure that the re-adjustment matches the requirement of the
system.
The chart below shows the basic example of relation between low pressure,
temperature and differential in the system which used R-22 as refrigerant, notably cold
room. Note that the low pressure reading (Cut In) is 68 Psig, while the differential is 4
Psig. So, the ‘Cut Out’ reading = Cut In – Differential
68 - 4
= 64 Psig
The same applied to the measurement in temperature. (If we want to measure in ◦F or

◦C). This factor is considered as when pressure is rising, then temperature is rising too.
In adjusting the high pressure reading, for example, we set 120 Psig (Cut In) and
differential 4 Psig. So, the ‘Cut Out’ reading = Cut In + Differential
120 + 4
124 Psig
Conclusion is, when we set low pressure, the ‘Cut In’ minus the differential.
While, in setting high pressure, the ‘Cut Out’ plus the differential
Page 44
The difference between low pressure control and high pressure control of pressure switches:
Low pressure control High pressure control

Connected to the low pressure side Connected to the high-pressure side
Pressure between 60 – 75 psig Pressure 250 psig
Cuts current when pressure in the low Cuts current when pressure in the low
side is low from the pressure set point. side is high from the pressure set point.
OIL PRESSURE SWITCH
Rajah: Skematik Dalaman Suis Tekanan Minyak
Page 45
Kendalian Suis Tekanan Minyak:

i. Suis tekanan minyak digunakan untuk memutuskan litar apabila berlakunya penurunan
tekanan minyak di pemampat. Biasanya pemampat mempunyai pan minyak di dalamnya.
Pam minyak ini akan mendesak minyak mengalir keluar ke semua bahagian bergerak di
dalam pemampat.
ii. Disebabkan tekanan di dalam kotak engkol pemampat lebih besar daripada tekanan
saluran sedutan, maka tekanan minyak mestilah lebih besar dari tekanan sedutan.
iii. Suis ini mempunyai dua belos perasa tekanan. Satu disambung kebahagian sedutan
pemampat manakala satu lagi disambungkan ke bahagian nyahcas pam minyak atau
kotak engkol.
iv. Apabila berlaku kekurangan tenaga minyak, suis kebezaan tekanan akan tertutup.
Tindakan ini akan member tenaga kepada elemen-elemen pemanas jika pemula rotor
tertutup. Pemanas dan bilah dwi-logam adalah pelewat masa yang akan membenarkan
pemampat bergerak sekejap sahaja setelah mencapai takad putus suis tekanan. Ini akan
membolehkan pemampat membina tekanan minyak yang normal. Jika tidak berlaku,
bilah dwi-logam akan di lending oleh pemanas menyebabkan litar terbukan. Tindakan ini
akan menyah tenaga kepada gelung penahan pada pemula motor dan menghentikan
pemampat.
Page 46
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DJU3032 AIR CONDITIONING & REFRIGERATION CONTROL SYSTEM 1

1.0 BASIC CONTROL PRINCIPLE

1.1.1 Definition of control:

Benefits of a control system in air conditioning and refrigeration system:

SIX types of refrigerant controls:

i. Automatic Expansion Valve (AEV).

General characteristic of refrigerant controls:

Automatic Expansion Valve (AEV)

Thermostatic Expansion Valve (TEV)

Low- Pressure Side Float Valve

Low- Pressure Side Float Valve

High- Pressure Side Float Expansion Valve

Thermal-Electric Expansion Valve

FAULTS IN REFRIGERATION CONTROL

Faults in refrigerant controls caused:

Kesalahan dalam kawalan pendinginan menyebabkan :

2.0 TYPES OF CONTROL

THREE categories of controls in air conditioning and refrigeration system:

i. man made control system

Tiga kategori kawalan dalam sistem penyamanan udara dan penyejukbekuan :

i. Sistem kawalan buatan manusia

ii. Sistem kawalan semulajadi

iii. Sistem kawalan gabungan(buatan manusia&semulajadi)

ii. Closed loop control:

The functions of control system:

Location of HVAC control system.

Classification of control devices

A thermostat is the component of a control system which regulates the temperature of a

ii. Metering device (regulating)

iii. Fusible plug (safety)

Suitable location to install the fusible plug:

3.0 BASIC WIRING CIRCUITS AND SYMBOLS

ii. relay (coil and switch)

relay (coil and switch)

iii. contactor (control and power circuit)

iv. timer (delay ON and OFF)

BASIC DIRECT ON LINE CONTROL STARTER SCHEMATIC WIRING DIAGRAM:

FUNCTION OF DIRECT ON LINE (DOL) CONTROL STARTER

CAPACITY RANGE OF DIRECT ON LINE (DOL)

OPERATIONAL METHOD OF DIRECT ON LINE (DOL)

BASIC STAR DELTA CONTROL STARTER SCHEMATIC WIRING DIAGRAM

FUNCTION OF STAR DELTA CONTROL STARTER

CAPACITY RANGE OF DIRECT ON LINE (DOL)

OPERATIONAL METHOD OF STAR DELTA

AUTOTRANSFORMER CONTROL CIRCUIT

CAPACITY RANGE OF AUTOTRANSFORMER is 25 hp and above.

F3 = Control Circuit Fuse

AUTOTRANSFORMER POWER / MAIN CIRCUIT

OPERATIONAL METHOD OF AUTOTRANSFORMER

SCHEMATIC WIRING DIAGRAM FOR SPLIT UNIT (1)

SCHEMATIC WIRING DIAGRAM FOR SPLIT UNIT (2)

SCHEMATIC WIRING DIAGRAM FOR DOMESTIC REFRIGERATOR

SCHEMATIC WIRING DIAGRAM FOR WATER COOLER

SCHEMATIC WIRING DIAGRAM FOR DISPENSING VENDING MACHINE

4.0 CONTROL ACCESSORIES

WATER CONTROL VALVE

Water control valve can be catagorised into FIVE types:

a) Type of relief valve:

ii. Balanced Bellows

iii. Pilot Operated

5.0 DOMESTIC CONTROL SYSTEM

Figure: Main Parts of Service Valve