Hvacfm by American Technical Publishers

Ronnie J. Auvil

AMERICAN TECHNICAL PUBLISHERS Orland Park, Illinois 60467-5756

HVAC and Refrigeration Systems contains procedures commonly practiced in industry and the trade. Specific procedures vary with each task and must be performed by a qualified person. For maximum safety, always refer to specific manufacturer recommendations, insurance regulations, specific job site and plant procedures, applicable federal, state, and local regulations, and any authority having jurisdiction. The material contained is intended to be an educational resource for the user. American Technical Publishers, Inc. assumes no responsibility or liability in connection with this material or its use by any individual or organization. American Technical Publishers, Inc., Editorial Staff Cover Design: Jennifer M. Hines Illustration/Layout: Nicholas W. Basham Melanie G. Doornbos Robert M. McCarthy Joshua P. Hugo Mark S. Maxwell Jennifer M. Hines Thomas E. Zabinski Bethany J. Fisher CD-ROM Development: Robert E. Stickley Daniel Kundrat Nicole S. Polak

Editor in Chief: Jonathan F. Gosse Vice President — Production: Peter A. Zurlis Art Manager: Jennifer M. Hines Multimedia Manager: Carl R. Hansen Technical Editors: Russell G. Burris Richard A. Scheffrahn Copy Editors: Talia J. Lambarki Cathy A. Mini Jeana M. Platz

Kathleen A. Moster Cory S. Butler

Microsoft, Windows, Windows Vista, PowerPoint, and Internet Explorer are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Adobe, Acrobat, and Reader are registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Intel is a registered trademark of Intel Corporation in the United States and/or other countries. Apple, Macintosh, Mac, Mac OS, and Safari are registered trademarks of Apple, Inc. Firefox is a registered trademark of the Mozilla Foundation. PowerPC is a registered trademark of International Business Machines Corporation. AMGFlex, HPDFlex, and QAS are trademarks of Quietflex Manufacturing Company. L.P., ANSI, National Electric Code, NEC, and NFPA 70E are registered trademarks of National Fire Protection Association. Aquastat is a registered trademark of Honeywell Heating Specialties Company. BACnet is a trademark of the American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc. Basofil is a registered trademark of Basofil LLC. Beckett is a trademark of R.W. Beckett Corporation. Canadian Electrical Code and CEC are trademarks of Canadian Standards Association. Comfort, Serpentuff, and Thermidistat are trademarks of Carrier Corporation. CSI MasterFormat is a trademark of The Construction Specifications Institute, Inc. Ductulator is a trademark of Trane Company. ECM is a trademark of General Electric Company. Energy Star is a registered trademark of the U.S. Environmental Protection Agency. International Building Code, IBC, International Code Council, and ICC are registered trademarks of International Code Council. Kevlar, Nomex, Suva Teflon, and Vitron are registered trademarks of E.I. DuPont de Nemours and Company. Leadership in Energy and Environmental Design, LEED, U.S. Green Building Council, and USGBC are registered trademarks of the U.S. Green Building Council. LonWorks is a trademark of Echelon Corporation. Magnehelic is a registered trademark of Dwyer Instruments, Inc. Nichrome is a registered trademark of Driver-Harris Wire Company. Silver Shield Underwriters Laboratories and UL are registered trademarks of Underwriters Laboratories Inc. Super Radiator Coils is a registered trademark of Super Radiator Coils LP Rob Holt, Jon Holt, and James Bast. Velcro is a registered trademark of Velcro Industries. Vise-Grip is a trademark of Irwin Industrial Tool Company. Quick Quiz and Quick Quizzes are either registered trademarks or trademarks of American Technical Publishers, Inc.

This book is printed on recycled paper.

The author and publisher are grateful for the technical information and assistance provided by the following individuals. Shane McCarthy Training Director The Refrigeration Workers of Ontario United Association Local 787 Arthur P. Abbey Service Apprentice Instructor United Association Industry Training Center (UA) Troy, Michigan

Jim Coates Training Director International Union of Operating Engineers Local 399 â&#x20AC;&#x201D; Chicago, Illinois

The author and publisher would like to thank the following companies, organizations, and individuals for providing images. Air Conditioning Contractors of America Allied Air Enterprises Inc. American Society of Mechanical Engineers AMTROL, Inc. Andersen Windows, Inc. ASHRAE Handbook-Fundamentals ATOFINA Chemicals, Inc. Bacharach, Inc. Baldor Electric Company R.W. Beckett Corp Carlo Gavazzi, Inc. Carrier Corporation Cleaver-Brooks Copeland Corporation Cooper Instruments Crane Valves Crown Boiler Co. Cutler-Hammer Danfoss Drives Detroit Radiant Products Company

Ductsox Dunham-Bush Dunkirk DuPont Company Dwyer Instruments, Inc. Electrical Apparatus Service Association, Inc. Empire Comfort Systems Inc. FAMCO FirstAidStore.com Fluke Corporation Fluke Thermography The Fulton Companies Furnas Electric Company The Gates Rubber Company GE Panametrics Goodman Global Group, Inc. Greenheck Fan Corp Greenless Textron Inc. Heat Wagon, Inc. Henry Valve Co. III

Honeywell Chemicals Honeywell International, Inc. Ideal Industries, Inc. INDEECO International Ground Source Heat Pump Association International Rectifier ITT Bell & Gossett Katy Instrument Sales Kebco Power Transmission Klein Tools, Inc. Lau, a Division of Tomkins Industries Lab Safety Supply, Inc. LEESON Electric Corporation Lennox Industries, Inc. Loctite Corporation L.S. Starrett Company Lunkenheimer Co. Manchester Tank & Equipment Co. March Manufacturing, Inc. McDonnell & Miller McQuay International Michigan Precision Fabricators, Inc. Miller Equipment Mill-Rose Company Milwaukee Electric Tool Corporation Mueller Co. The New York Blower Company Noritz America Corp. Omron Electronics LLC OSHA Office of Training and Education Parker Boiler Co. Parker Hannifin–Pneumatic Division North America Peerless Boilers

Plan Ahead, Inc. Ranco Inc. Reed Manufacturing Co Rheem Air Conditioning Division Riello Burners RIDGID® Rockwell Automation, Allen-Bradley Company, Inc. Rockwell Automation/Reliance Electric Rothenberger USA Inc. R. W. Beckett Corp. Siemens The Sinco Group, Inc. The Stanley Works Spirax-Sarco Inc. Sporlan Valve Company SPX Robinair The Stanley Works Sterling Super Radiator Coils Taco, Inc. TSI Incorporated Trane Turbotec Products, Inc. Unico, Inc.U.S. Boiler Company U.S. Department of Energy U.S. Energy Information Administration Vertiflo Pump Company Watts Regulator Company Weil-McLain White-Rodgers Div., Emerson Electric Co. Yellow Jacket Div., Ritchie Engineering Company, Inc. York International Corp.

SEC TIO N O N E: H VAC AND THE REFRIGERATION INDUSTRY

Unit 1: HVAC and Refrigeration Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature • Humidity • Air Circulation • Air Filtration • Ventilation • Health Effects • Causes of Poor IAQ • Control of Pollutants • HVAC Systems • Heating and Cooling • Refrigeration Processes

Unit 2: HVAC and Refrigeration System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Codes and Standards Organizations • Government Regulatory Agencies • Standards Organizations • Trade Associations • Personal Safety • Safety Labels • PPE • Fall-Protection Equipment • Environmental Safety • Emergency Showers • Confined Spaces • System Safety • Chemical Safety • Safety Programs and Training • Equipment Safety Training • First Aid

Unit 3: Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Electrical Codes and Standards • NFPA • Electrical Hazards • NEC® Hazardous Locations • Electrical Shock • Electrical Safety Devices and Methods • Electrical Personal Protective Equipment (PPE) • Grounding • Lockout/Tagout Procedure: Equipment Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Unit 4: Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Tools • Screwdrivers • Wrenches • Pliers • Hammers • Tubing and Piping Tools • Power Tools • Power Drills • Reciprocating Saws • Tubing and Piping • Working with Copper Tubing • Working with Plastic Pipe Procedure: Hand-Tapping Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Cutting External Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Cutting Copper Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Flaring Copper Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Soldering Copper Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Brazing Copper Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Cutting and Threading Steel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Cutting and Joining Plastic Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit 5: Measurement Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 56 65 66 67 68 71 72

Taking Measurements • Accuracy • Linear Measurement Devices • Rules and Scales • Calipers • Micrometers • Temperature Measurement Devices • Humidity Measurement Devices • Psychrometers • Pressure Measurement Devices • Manometers • Mechanical Pressure Gauges • Airflow Measurement Devices • Anemometers • Flow Hoods • Electrical Measurement Devices • Multimeters • Clamp-On Ammeters • Continuity Testers • Megohmmeters • Phase Sequence Indicators • Contaminant Measurement Devices • Hazardous Substance Air Monitoring • Air Quality Monitoring • Leak Detectors • Recovery, Recycling, and Reclaiming Equipment • System Evacuation • System Charging Procedure: Measuring with Dial Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Measuring with Digital Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Measuring with Outside Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Measuring with Inside Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Measuring with Infrared Temperature Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Reading Analog Multimeter Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Testing Multimeter Ohmmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 80 81 82 87 95 97

SEC TIO N TWO : H VAC AND REFRIGERATION PRINCIPL ES

Unit 6: Temperature, Pressure, and Thermodynamics . . . . . . . . . . . . . . . . . . . . . . . . . .

113

Energy • Work • Power • Horsepower • Energy Units • Matter and Measurements • Density • Specific Gravity • Heat • Sensible Heat • Latent Heat • Thermodynamics • Heat Transfer • Pressure • Atmospheric Pressure • Absolute Pressure • Pressure Gauges • Gas Laws • Temperature-Pressure Relationships • Temperature-Pressure Charts

Unit 7: Combustion and Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131

Combustion • Fuels and Heating Values • Combustion Air • Flames • Products of Combustion • Combustion Efficiency • Combustion Inefficiency • Fuel Combustion Efficiency and Emissions • Energy

Unit 8: Psychrometrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

Comfort • ANSI/ASHRAE Standard 55-2004 • Psychrometrics • Water Vapor • Dry Air • Psychrometric Charts • Dry-Bulb Temperatures • Relative Humidity • Humidity Ratio • Wet-Bulb Temperature •Specific Volume • Enthalpy • Dewpoint Temperature • Process Plotting • Plotting Two Points •Calculations Using the Psychrometric Chart • Local Outdoor Conditions Procedure: Plotting Air Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Finding Cooling Btu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Finding Heating Btu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Finding Humidifier Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Determining Mixed Air Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit 9: Indoor Air Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152 154 155 156 157

161

Indoor Air Quality • IAQ Factors • Health Effects • HVAC Technician and Building Personnel Roles • Building-Related Illnesses • Sick Building Syndrome • Multiple Chemical Sensitivity • Mass Psychogenic Illness • Acceptable Indoor Air Quality • Poor Indoor Air Quality • Effects of Poor Indoor Air Quality • Contaminant Categories • Particles • Gases • Mixtures • Biological Contaminants Procedure: Complaint Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Procedure: Complaint Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Unit 10: HVAC and Refrigeration System Printreading . . . . . . . . . . . . . . . . . . . . . . . . . . 181 CSI Masterformat™ • HVAC System Prints • Print Abbreviations and Symbols • HVAC System Print Sets • HVAC Wiring Diagrams • HVAC Detail Drawings • Sequences of Operation • As Built Prints

S E C T IO N TH R EE: H VAC A N D REFRIGERATION EL ECTRICAL SYSTEMS

Unit 11: Electrical System Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191

Electrical Energy • Electrical Energy Production • Electricity • Ohm’s Law • Electrical Circuits • Load Voltage Drops in Series Circuits • Load Voltage Drops in Parallel Circuits • Resistance in Parallel Circuits • Current in Parallel Circuits • Power Quality Problems Procedure: Calculating Load Voltage Drop in a Series Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Calculating Load Voltage Drop in a Parallel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Calculating Total Resistance of Loads in a Parallel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Calculating Total Current in a Parallel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 199 200 201

Unit 12: Electrical and Electronic Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Electrical Control Systems • Electrical Control System Devices • Capacitors • Power Supplies • Overcurrent Protection Devices • Electronic Control Systems • Electronic Control System Devices • Diodes • Transistors • Integrated Circuits • Troubleshooting Semiconductor Devices • Electronic Control System Applications Procedure: Testing Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Unit 13: Electric Motors and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

227

Electric Motors • Motor Construction • Motors and Magnetism • Motor Nameplate Data •Motor Mountings • Motor Enclosures • Motor Drive Systems • Shaft Alignment • Single-Phase and Three-Phase Motors • Solenoids • Solenoid Configurations • Solenoid Operation • Solenoid Applications • Troubleshooting Motors • Mechanical Problems • Incoming Power Problems • Electrical Problems • ECM™ Motors • ECM Motor Operation Procedure: Finding Percent of Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Motor Winding Resistance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Insulation Spot Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure: Capacitor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

249 251 251 252

Unit 14: HVAC and Refrigeration Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Electrical Control Systems • Electrical Control System Applications • Troubleshooting Electrical Control Systems • Electrical Control System Malfunctions Procedure: Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Procedure: Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Procedure: Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Unit 15: Motor Starters and Variable-Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . .

271

Motor Control Devices • Contactors • Motor Starters • Motor Thermal Protection • Variable-Frequency Drives • Troubleshooting Motor Starters and VFDs • Motor Starter Troubleshooting • VFD Troubleshooting Procedure: Motor Starter Contact Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Procedure: Motor Starter Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Procedure: Variable-Frequency Drive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

SECTIO N FOUR: HEATING SYSTEMS

Unit 16: Forced-Air Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

285

Forced-Air Heating Systems • Central Forced-Air Heating Systems • Modular Forced-Air Heating Systems • Furnaces • Furnace Styles • Electric Furnaces • Furnace Energy Consumption • Special-Purpose Heating Units

Unit 17: Forced-Air Furnace Components and Controls . . . . . . . . . . . . . . . . . . . . . . . . . 295 Furnace Components • Furnace Blower Drive Systems • Blower Performance • Burners • Fuel Igniters • Gas Control Valves • Heat Exchangers • Controls • Safety Controls • Combustion Safety Controls Procedure: Gas Valve Pressure Measurement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

VII

Unit 18: Forced-Air Heating Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

319

Forced-Air Distribution Systems • Airflow Principles and Measurements • Airflow Rates • Duct System Pressures • Duct Air Pressure Instruments • Forced-Air System Blowers • Duct Dimensions • Friction Losses • Duct System Design • Supply Duct Systems • Balancing Dampers • Duct Insulation • Registers and Grills • Return Duct Systems • Duct System Layout • Duct Sizing • Retrofits Procedure: Determining Duct Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Unit 19: Hydronic Heating System Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

349

Hydronic Heating Systems • Combination Heating Systems • Boilers • Heat Production • Boiler Ratings

Unit 20: Hydronic Heating Boiler Components and Controls . . . . . . . . . . . . . . . . . . . . . 359 Boiler Fittings and Accessories • Safety Relief Valves • Pressure Gauges • Bottom Blowdown and Drain Valves • Aquastats • Low Water Cutoffs • Gas Control Valves • Burners • Fuel Igniters • Accessories for Hot Water Boilers • Air Separators • Hydronic System and Boiler Control Devices Procedure: Testing Low Water Cutoff (LWCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Unit 21: Hydronic Heating Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 Hydronic Distribution Systems • Circulating Pumps • Expansion Tanks • Air Vents • Piping Systems • Terminal Devices • Radiant Heating • Convection Heating • Forced Convection Heating • Terminal Device Controls Procedure: Testing Expansion Tank Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

Unit 22: Steam Heating—Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Steam Heating • Steam Heating Systems • Steam Boilers • Heat Production • Steam Boiler Ratings Procedure: Taking Stack Temperature Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Unit 23: Steam Heating Boiler Components and Controls . . . . . . . . . . . . . . . . . . . . . . . 397 Steam Boiler Fittings • Safety Valves • Steam Pressure Gauges • Water Columns • Low Water Fuel Cutoffs • Fusible Plugs • Pressure Controls • Steam Boiler Accessories • Main Steam Stop Valves • Fuel Systems • Boiler Combustion Safety Controls • Draft Systems Procedure: Testing Steam Boiler Efficiency — Gas-Fired Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

Unit 24: Steam Heating Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

413

Steam Distribution Systems • Feedwater Systems • Feedwater Pumps • Condensate Pumps • Feedwater Heaters • Feedwater Regulators • Steam System Accessories • Condensate Return Tanks • Steam Piping Systems • Steam Terminal Devices • Steam Terminal Device Controls Procedure: Sizing Feedwater Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Procedure: Testing Inverted Bucket Steam Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

Unit 25: Air-Source Heat Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 Air-Source Heat Pumps • Heat Sinks • Air-Source Heat Pump Components • Reversing Valves • Expansion Devices • Heat Pump Controls • Thermostats • Defrost Controls • Operation • Heat Pump Selection • Balance Point Temperatures Procedure: Heat Pump Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

VIII

Unit 26: Water-Source and Geothermal Heat Pump Systems . . . . . . . . . . . . . . . . . . . . 459 Water and Air Heat Sinks • Water-Source Heat Pump Advantages • Water-Source Heat Pump Systems • Boiler/Tower Systems • Boilers—Supplemental Heating • Cooling Towers—Supplemental Cooling • Heat Pump Seasonal Operations • Controls • Heat Pump Control Functions • Geothermal Systems • Geothermal Loop Considerations • Ground Testing • Surface Water Design Procedure: Taking Water and Air Delta-T Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480

Unit 27: Fuel Oil Heating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

483

Fuel Oil Characteristics • Oil-Fired Heating Units • Fuel Oil Combustion Overview • Fuel Oil Burners • Fuel Oil Supply Systems • Combustion Chambers and Heat Exchangers

Unit 28: Miscellaneous Manufactured and Field Installed Systems . . . . . . . . . . . . . . . . . 493 Solar Heating and Cooling • Solar Hot Water Heating Systems • Electric Heat • Advantages and Disadvantages of Electric Heat • Electric Baseboard Heat • Ductless Mini-Split HVAC Systems • Advantages and Disadvantages of Ductless MiniSplit Systems • Draft Systems • Chimney and Vent Pipe Connections • Fuel Systems Procedure: Sizing Ductless Mini-Split Air Conditioning Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503

SECTIO N FIVE: REFRIGERATION SYSTEMS

Unit 29: Refrigeration Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

513

Refrigeration Cycle • Evaporators • Condensers • Mechanical Compression Refrigeration Systems • Heat Transfer Procedure: Replacing Air Conditioning System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518

Unit 30: Low-Pressure-Side Evaporators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

521

Low-Pressure Side • Evaporators • Evaporator Temperature Range Categories • Evaporators Designs • Evaporator Defrost • Evaporators Performance • Superheat • Evaporator Pressure Drop • Cooling Capacity

Unit 31: Low-Pressure-Side Expansion Devices and Accessories . . . . . . . . . . . . . . . . . . 535 Expansion Devices • Thermostatic Expansion Valves • Setting TXVs • TXV Equalizer Bulb Mounting • TXV Troubleshooting and Repair • Electronic Expansion Valves • Low-Pressure-Side Accessories • Distributors • Service Valves • Sight Glasses • Moisture Indicators • Suction Accumulators

Unit 32: High-Pressure-Side Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549 High-Pressure Side • Compressors • Compressor Categories • Compressor Models • Reciprocating Compressors • Scroll Compressors • Rotary Compressors • Large System Compressors • Compressor Motors in Refrigerant Atmospheres • System Maintenance and Compressor Efficiency • Compressor Performance Procedure: Finding Volumetric Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

Unit 33: High-Pressure-Side Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567 High-Pressure-Side Condensers • Air-Medium Condensers • Air-Medium Condenser Coils • Superheat and Subcooling • High-Efficiency Condensers • Low Ambient Temperature Condenser Conditions • Water-Medium Condensers • Condenser and Heat Exchanger Maintenance • Wastewater Systems • Recirculating Water Systems • Temperature Relationship Procedure: Cleaning Outdoor Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576

Unit 34: High-Pressure-Side Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581 High-Pressure-Side Accessories • Refrigerant Lines • Line Sizing • Pressure Drops • Velocity • Flow Switches and Status Indicators • Liquid Receivers • King Valves • Liquid-Line Filter-Driers • Sight Glasses • Oil Separators Procedure: Using Pressure-Drop Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585 Procedure: Using Suction-Line Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587

Unit 35: Refrigeration Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593 Refrigeration Systems Controls • Operating Controls • Thermostats • Low-Pressure Controls • LPC Installation Tips • Safety Controls • High-Pressure Controls • Lube Oil Pressure Safety Controls • Anticycle Timers • Condensing Pressure Regulators Procedure: Adjusting Low-Pressure Controls in Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 Procedure: Adjusting High-Pressure Controls in Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599

SEC TIO N SIX: REFRIGERANTS

Unit 36: Refrigerant Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

603

Refrigerants • Refrigerant Properties • Refrigerant Types and Composition • Blended Refrigerants • Azeotropic and Zeotropic Refrigerants • Substitute Refrigerants • Refrigeration System Oils • Refrigerant Oil Properties

Unit 37: Management of Refrigerants and Refrigeration Systems . . . . . . . . . . . . . . . . .

617

Refrigerant Management • Clean Air Act—Section 608 • Prohibition of Venting • Handling Refrigerants • Servicing Refrigeration Systems • Technician Certification • Type I Certification • Type II Certification • Type III Certification • Universal Certification • Refrigerant Leaks • Recovery, Recycling, and Reclaiming of Refrigerants Procedure: Charging Systems with Refrigerant (High-Pressure Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626 Procedure: Recovering Refrigerant—Type I Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634 Procedure: Evacuating Type I Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638

Unit 38: Pressure-Enthalpy Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641 Pressure-Enthalpy Diagrams • System Graphs • Ideal Cycles • Refrigeration Effect • Actual Cycles • Heat Transfer—Actual Cycle • Refrigeration Systems Performance • Refrigeration Effect • Compression Ratio • Coefficient of Performance Procedure: Plotting Ideal Cycles on Pressure-Enthalpy Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651 Procedure: Determining Amount of Heat Transfer from Refrigeration System Devices . . . . . . . . . . . . . . . . . . . . . . . 653 Procedure: Plotting Actual Cycles on Pressure-Enthalpy Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 X

Unit

SEC TIO N SEV EN : HVAC AND REFRIGERATION SYSTEMS 39: Installing Residential Forced-Air Heating Systems . . . . . . . . . . . . . . . . . . . . . 663 Forced-Air Heating Systems • Furnace and Air Handler Installation • Furnace Locations and Clearances • Vents and Chimneys • Gas Piping • Electrical Wiring • High-Voltage Wiring Procedures—115 V • Low-Voltage Wiring Procedures—24 V • Duct Systems and Filters • Duct Dampers • Filters and Filter Racks • Furnace Startup Checks • Gas Supply, Manifold Pressure, and Gas Input Rate • Manifold Pressure Adjustment • Blower Speed and Duct Systems Static Pressure • Furnace Controls • Furnace Maintenance • Derating for High Altitudes Procedure: Installing Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673 Procedure: Installing Wiring from Service Panels to Disconnects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677 Procedure: Installing Wiring from Disconnects to Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678 Procedure: Running Low-Voltage Wiring to Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679 Procedure: Running Low-Voltage Wiring to Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 Procedure: Testing Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685 Procedure: Adjusting Pilot Flames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686 Procedure: Measuring Actual Gas Input Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687 Procedure: Changing Blower Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688 Procedure: Measuring Duct System Fan Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689 Procedure: Measuring Air Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691 Procedure: Checking Furnace Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692 Procedure: Setting Blower Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 Procedure: Converting Upflow Furnaces to Downflow Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697 Procedure: Changing Main Burner Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

Unit 40: Installing Residential Forced-Air Cooling Systems . . . . . . . . . . . . . . . . . . . . . . 701 Installing Split-System Air Conditioning • Inspection of Equipment • Location of Condensing Units •Electrical Wiring • General Condenser Wiring Guidelines • Refrigerant Piping and Installation • Cleaning Existing Line Sets and Evaporator Coils • Refrigerant Metering Devices • Manifold Gauge Sets • Liquid-Line and Suction-Line Service Valves • Leak Testing • Evacuation, Charging, and Startup • Checking Charge Using Normal Operating Pressures • Final Start-Up Checks • Operation • Maintenance Procedure: Placing Condensing Units on Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705 Procedure: Cutting Holes in Walls to Run Wires and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705 Procedure: Installing Disconnect Boxes and Electrical Whips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708 Procedure: Connecting Wiring Bundles (High-Voltage Wiring) to Service Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709 Procedure: Connecting Wiring Whips (High-Voltage Wiring) to Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 Procedure: Connecting Low-Voltage (24 V) Wiring to Condenser Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 Procedure: Running Low-Voltage (24 V) Wiring to Furnaces or Air Handlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712 Procedure: Installing Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 Procedure: Brazing Line Set Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 Procedure: Refrigerant Changeout without Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Procedure: Refrigerant Changeout with Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 Procedure: Installing Air Conditioning System Metering Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 Procedure: Accessing Service Port Schrader Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Procedure: Opening Liquid-Line or Suction-Line Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Procedure: Closing Liquid-Line or Suction-Line Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 Procedure: Leak Testing with Electronic Leak Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 Procedure: Removing Moisture from Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 Procedure: Measuring Line Set Temperatures and Outdoor Ambient Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 Procedure: Checking System Charge Using Subcooling Method—Outdoor Temperatures Below 65°F . . . . . . . . . . . . . . . . 727 Procedure: Checking System Charge Using Approach Method—Outdoor Temperatures 65°F or Above . . . . . . . . . . . . . . 727 Procedure: Installing Drain Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 XI

Procedure: Starting Up Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730

Unit 41: Servicing and Troubleshooting Residential Forced-Air HVAC Systems . . . . . . 733 Servicing Forced-Air Systems • Basic Troubleshooting Questions • Installation Manuals • Operation and Maintenance Manuals • Typical Furnace Sequence of Operations • Troubleshooting Forced-Air HVAC Systems • Natural Gas Troubleshooting Scenarios 1–11 •Oil-Fired Troubleshooting Scenarios 1–3 • Cooling System Troubleshooting Scenarios 1–15 • Humidifier Troubleshooting Scenarios 1–4 • Filter Troubleshooting Scenarios 1–4

Unit 42: Installing Residential Hydronic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

761

Hydronic Boiler Installations • Boiler Installation Safety • Boiler Preparation • Boiler Location • Clearances • Combustion Air • Venting • General Venting Guidelines • Gas Supply Piping • Hydronic Piping • Boiler Wiring • Pump Wiring for a Hydronic Boiler • High-Temperature Limit Control • Boiler with Low-Temperature Bypass Piping • Expansion Tank Installation • Filling a Boiler with Water • Boiler Startup • Water Quality • Air Venting • Gas Leaks • Exhaust Condensate System • Thermostats • Hydronic Boiler Startup • Operating and Control Features • Freeze Protection • Hydronic Boiler Maintenance Procedure: Determining Location to Install Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766 Procedure: Venting Boiler to Outdoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775 Procedure: Purging Air from Boiler Gas Control Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777 Procedure: Installing Hydronic Piping and Components to Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778 Procedure: Connecting Electrical Wiring to a Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781 Procedure: Draining Water from a Steel Holding Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787 Procedure: Filling a Closed-System Boiler with Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788 Procedure: Blowing Off Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791

Unit 43: Servicing and Troubleshooting Residential Hydronic Systems . . . . . . . . . . . . . 797 Servicing Hydronic Systems • Basic Troubleshooting Questions • Installation Manuals • Operation and Maintenance Manuals • Typical Hydronic Boiler Sequence of Operations • Troubleshooting Hydronic Systems • Fuel and Combustion • Water Distribution and Supply • Zone Troubleshooting Scenarios 1–2 • Boiler Troubleshooting Scenarios 1–8

Unit 44: Installing Light Commercial HVAC Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .

813

Installing Light Commercial Systems • General Installation Procedures—All Units • Ground Level HVAC Unit Security • Roof Curbs • Roof Walkway Mats and Maintenance Pads • Duct Connections • Air Filters • Installing Rooftop SingleZone Units • Rooftop Single-Zone Unit Startup • Installing Rooftop Variable-Air-Volume Units • Discharge Air Temperature and Static Pressure Sensors • Rooftop VAV Unit Controls • Rooftop VAV Unit Startup • Installing AirCooled Packaged Chillers • Air-Cooled Packaged Chiller Startup • Test Pumps and Water Flow Procedure: Checking and Preparing Site to Receive Delivery of HVAC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814 Procedure: Receiving HVAC Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815 Procedure: Setting Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818 Procedure: Rigging HVAC Equipment for Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819 Procedure: Setting HVAC Unit on Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820 Procedure: Installing Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821 Procedure: Installing Water Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 823 Procedure: Making Duct Connections to Rooftop Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824 Procedure: Installing Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 Procedure: Installing Rooftop Unit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827 Procedure: Testing Flow Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847 Procedure: Replacing a Condenser Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848 Procedure: Changing Compressor Settings (Parameters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849 Procedure: Starting a VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 Procedure: Testing VFD Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851

XII

Unit 45: Servicing and Troubleshooting Light Commercial HVAC Systems . . . . . . . . . 853 Servicing Light Commercial HVAC Systems • Basic Troubleshooting Questions • Installation Manuals • Operation and Maintenance Manuals • Troubleshooting Manuals • Troubleshooting Light Commercial HVAC Systems •Rooftop Unit Troubleshooting Scenarios 1–10 •Rooftop Unit Electronics Troubleshooting Scenarios 1–7

Unit 46: Installing, Servicing, and Troubleshooting Air-Source Heat Pump Systems . . . . 871 Installing Air-Source Heat Pump Systems • Servicing Heat Pump Systems • Basic Troubleshooting Questions • Installation Manuals • Owner Manuals • Typical Air-Source Heat Pump Sequence of Operations • Troubleshooting Air-Source Heat Pumps • Heating Mode Troubleshooting Scenarios 1–5 • Cooling Mode Troubleshooting Scenarios 1–3 Procedure: Testing Condensate Drain Pan and Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875 Procedure: Wiring a Unit for Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 877

Unit 47: Installing, Servicing, and Troubleshooting Water-Source and

Geothermal Heat Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887

Water-Source and Geothermal Heat Pumps • Water Loop Installation • Geothermal Ground Loop Installation • Startup of Water-Source or Geothermal Heat Pumps • Servicing Water-Source and Geothermal Heat Pump Systems • Water-Source and Geothermal Heat Pump Installation and Maintenance Manuals • Typical Water-Source and Geothermal Heat Pump Sequences of Operations • Cooling Cycle • Heating Cycle • Troubleshooting Water-Source and Geothermal Heat Pumps • Heating Mode Troubleshooting Scenarios 1–4 • Cooling Mode Troubleshooting Scenarios 1–3 Procedure: Preparing to Start Up a Water-Source or Geothermal Heat Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 898 Procedure: Starting Up a Water-Source or Geothermal Heat Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 899

Unit 48: Installing, Servicing, and Troubleshooting Chiller Systems . . . . . . . . . . . . . . .

909

Chilled Water System Components • Water Loop System Components • Chiller Operations • Chiller Temperatures • Chiller Pressures • Installing Chillers • Servicing and Troubleshooting Chillers •Installation Manuals • Operation and Maintenance Manuals • Servicing Chillers • Chiller Service Procedures • Troubleshooting Chillers • Chiller Troubleshooting Scenarios 1-8 Procedure: Operating Chiller Motors in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923 Procedure: Checking Operation of Chiller Flow Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 924

SEC TIO N EIG H T: HVAC SYSTEM L OAD CAL CUL ATIONS, DESIGN, AND BAL ANCING

Unit 49: Heating and Cooling Load Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929 Heating and Cooling Load Factors • Local Design Temperatures • Building Structures • Load Calculations • Calculation Methods • Building Data • Standard Load Calculations • Load Calculation Analysis • Final Load Adjustments Procedure: Finding Heating and Cooling Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945

Unit 50: HVAC Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949 Forced-Air Heating Systems • Distribution Systems • Heating Airflow • Forced-Air Cooling Systems • Hydronic Heating Systems • Piping Systems • Terminal Devices • Heating Water Flow • Hydronic Cooling Systems • Cooling Water Flow Procedure: Finding Air Conditioner Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 954 Procedure: Finding Temperature Decrease of Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 956

Unit 51: Forced-Air System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII

961

Forced-Air Distribution Systems • Supply Plenum Systems • Return Duct Systems and Open Returns • Principles of Airflow • Ductwork Design • Layout Drawings • Duct Sizing • Register and Grill Sizing Procedure: Finding Static Pressure Drop in Duct Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 977

Unit 52: Hydronic System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 981 Water Distribution Systems • Principles of Water Flow • System Design • Piping System Design • Fittings and Valves • Terminal Devices • Circulating Pump Sizing • Controls Procedure: Finding Equivalent Length of Pipe—Iron Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 985 Procedure: Finding Total Pipe Static Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 988 Procedure: Designing Hydronic Piping Systems for Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 994

Unit 53: Residential and Light Commercial System Testing and Balancing . . . . . . . . . 1005 Testing, Adjusting, and Balancing • TAB Process • Forced-Air Distribution System Tab • Fans and Airflow • Ductwork and Airflow • Hydronic System TAB • Circulation Pump Testing and Water Flow Rates Procedure: Finding Average Airflow Rates Using Anemometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 Procedure: Finding Hydronic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020

SECTIO N N IN E: B U IL DING AUTOMATION SYSTEMS

Unit 54: Building Automation Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1025 Building Automation Systems • Direct Digital Control Systems • BAS Controllers • BAS Inputs • Analog Sensors • Digital Input Devices • BAS Outputs • Analog Output Devices • Digital Output Devices • DDC Strategies • DDC System Controls

Unit 55: Terminal Unit Heating and Cooling Control Methods . . . . . . . . . . . . . . . . . . . 1047 Air-Handling System Characteristics • Air-Handling System Designs • Air-Handling System Ventilation • HVAC System Air Control Components • Air-Cleaning Methods • Air-Handling Distribution Systems • Terminal Units • VAV Terminal Boxes • Fan Coil Units • Unit Ventilators

Unit 56: Installing Building Automation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077 Controller Mounting • Power Sources and Wiring • Back-Up Batteries • Communication Wiring • Common Testing and Diagnostic Procedures • Testing Analog Input Resistance Values • Testing Digital Input and Output Wiring Procedure: Testing 24 V Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086 Procedure: Testing RS-485 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086 Procedure: Testing Wall Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087

Unit 57: Servicing and Troubleshooting Building Automation Systems . . . . . . . . . . . . 1089 Building Automation System Troubleshooting • Standard Troubleshooting Procedures • Troubleshooting Information • BAS Troubleshooting Scenarios 1-5

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SEC TIO N TEN : ENERGY EFFICIENCY TECHNOL OGY

Unit 58: Building Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1095 Commissioning • Commissioning Authorities • Building Types • Commissioning Types • Typical Commissioning Process • Commissioning Checklists • Commissioning and Equipment Maintenance

Unit 59: Building Energy Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Audit Information Sources • Utility Users • Electrical Consumption and Demand • Utility Energy Costs • Utility Cost Calculations • Audit Process • Energy Information • HVAC Equipment • Non-HVAC Building Energy Use • Audit Reports

Unit 60: HVAC and Refrigeration System Efficiency and Retrofitting . . . . . . . . . . . . .

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HVAC Equipment • Energy Efficiency Standards • Energy Star • Leadership in Energy and Environmental Design • Retrofitting Residential and Light Commercial HVAC Systems • Humidity • Indoor Air Quality • Retrofitting Air-Handling HVAC Systems • Typical AHU Retrofits • Typical Packaged Chiller Retrofits Procedure: Retrofitting Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1134 ®

• • • • •

Quick Quizzes® Illustrated Glossary Forms and Documents Interactive Animations Library

• • • • •

Step-by-Step Procedures Flash Cards Media Library Review Questions ATPeResources.com

HVAC and Refrigeration Systems covers all aspects of residential and light commercial heating, ventilation, and air conditioning systems, focusing specifically on the operation, installation, service, maintenance, and troubleshooting of these systems. The textbook covers heating and refrigeration fundamentals, psychrometrics, building mechanical systems, and electrical and electronic devices and controls. The textbook also covers air- and water-source heat pump systems and chiller systems and includes 100 installation and 65 step-by-step service procedures. Energy efficiency practices, energy auditing, building commissioning, and retrofitting are covered as part of Energy Star速 and LEED速 certifications. HVAC and Refrigeration Systems offers proven and thorough content in a format organized by sections and units. Section and unit color designations help learners find the desired pages in the textbook. The appendix contains many useful tables and charts, as well as refrigerant information.

Index to procedures includes title and page number for ease of reference.

Unit introduction previews content to be covered.

Unit objectives identify main concepts addressed within each unit. Electrical Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Tables include U.S. and Canadian references.

QR codes at the end of each unit allow quick access to digital media.

QuickLinks allow access to digital media without QR code reader.

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Color designations help learners find specific sections. Detailed illustrations depict fundamental concepts.

HVAC industry equipment and procedures shown in typical real-world troubleshooting applications.

3D modeling used to develop illustrations depicting installation, servicing, and troubleshooting fundamentals. Residential and commercial application photographs supplement text and illustrations. Icons indicate media clips and interactive animations, available in the Digital Resources.

Clear, concise text is used throughout the textbook.

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Enlarged, detailed drawings simplify complex equipment and systems.

Step-by-step procedures with illustrations detail specific tasks.

Illustrated sequences of operation for residential and light commercial equipment facilitate understanding.

Tech tips provide supplemental information related to topics presented.

Troubleshooting principles and procedures are covered throughout

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3D Residential House The residential house 3D model used in the installation, servicing, and troubleshooting units is a typical residence for the United States and Canada. The house is designed with a forced-air heating system with central air conditioning. The ductwork, dampers, filters, chimney, registers, and grills are clearly depicted. The house has also been designed with a hydronic heating system. The piping, control valves, safety valves, gauges, air eliminators, circulating pump, and expansion tank are all in place.

3D Light Commercial Building The light commercial office building 3D model used in the installation, servicing, and troubleshooting units is a typical light commercial building for the United States and Canada. The building is designed with forced-air and air conditioning rooftop units. The supply and return ductwork, filters, dampers, registers, grills, and vertical air handlers are clearly depicted. The building has also been designed with a pressurized floor with no supply ductwork, a hydronic heating system with heat pumps, and a hydronic heating system with geothermal ground loops, heat pumps, and complete control systems.

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HVAC and Refrigeration Systems also includes access to digital resources that reinforce and enhance learning. These resources can be accessed by either:

The Digital Resources include the following: • Quick Quizzes® that provide 20 interactive questions per section, with embedded links to textbook content and to the Illustrated Glossary • An Illustrated Glossary that provides a helpful reference to commonly used terms, with selected terms linked to illustrations and media clips • Flash Cards that provide a self-study/review tool for identifying common HVAC terms, symbols, tool types, measurement devices, and fuels • Forms and Documents, which are a collection of various HVAC equipment and maintenance forms; company safety, invoice, and related documents; and IAQ and system design documents and data sheets • Interactive Animations that provide an interactive experience with fundamental HVAC topics, such as identifying components of an HVAC system, using standard HVAC procedures to perform a task, troubleshooting burner and flame problems, recovering refrigerant from Type I systems, using a psychrometric chart and virtual test meters, and assembling and wiring a motor control enclosure • A Library containing illustrations from the textbook that can be enlarged and manipulated for greater clarity, such as building prints, electrical schematics, and manufacturer equipment manuals • Step-by-Step Procedures covering 100 common installation procedures and 65 service procedures with illustrations that detail specific task steps • Review Questions that allow learners to demonstrate comprehension of unit content • A Media Library consisting of animated illustrations and video clips that reinforce textbook content • ATPeResources.com, which links to online instructional resources that support continued learning XX

Quick Response (QR) codes located at the end of each chapter offer easy access to related information on the Internet via mobile device technology. To access content using a QR code, follow these steps: 1. Download a QR code reader app to a mobile device. (Visit atplearning.com/QR for more information.) 2. Open the app and scan the QR code on the book page. 3. Instantly access the digital content.

Augmented Reality (AR) icons located next to specific figures offer easy access to interactive 3D models on the Internet via mobile device technology. To access AR content, download the HVAC AR app from the iTunes App Store™ or Google Play™ and use the following steps: Getting Started

Using AR

Available on the App Store™ and Google Play™

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Study Guide The HVAC and Refrigeration Systems Study Guide includes review questions and activities that reinforce and expand upon the information presented in the textbook. Review Questions for each unit include true-false, multiple choice, and completion questions that reinforce comprehension of chapter concepts.

Activities include identification questions and activities based on real-world service calls to help learners understand and apply unit concepts.

Instructor’s Resource Guide The HVAC and Refrigeration Systems Instructor’s Resource Guide provides a comprehensive teaching resource that includes a detailed Instructional Guide, editable PowerPoint® Presentations, an interactive Image Library, Assessments, and Answer Keys as well as access to the digital resources used with the textbook. • The Instructional Guide explains how to best use the learning resources provided and includes Instructional Plans for each chapter that identify images and media pieces for an enhanced learning experience. • PowerPoint® Presentations provide a review of key concepts from each chapter of HVAC and Refrigeration Systems and include illustrations, chapter objectives, and review questions. Instructor notes are also provided. • The Image Library provides all the numbered illustrations in a format that can be manipulated for maximum instructional use. • Assessments include sets of questions based on objectives and key concepts from each unit and consist of a pretest, posttest, and test banks. The test banks can be used with popular test development software packages and learning management systems. • Answer Keys list answers to pretest, posttest, and study guide questions. To obtain information on related products, visit the American Technical Publishers website at atplearning.com. The Publisher

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