Modern Refrigeration and Air Conditioning

1212 Pages·2003·457.51 MB·English

by  Andrew D. Althouse

M o d e r n
a n d
R e f r i g e r a t i o r
n r n S
A i r C b n d i t i o
by
ANDREWD . ALTHOUSE8,. S.,( M.E'),M .A.
Technical-VocatioEnadlu catioCn onsultant
LifeM emberA, mericanS ocietyo f
HeatingR, efrigeratinagn, dA ir-ConditioninEgn gineers
CARI H, TURNQUISTB, .S./( M.E.)M, .A.
Technical-VocationEadlu catioCn onsultant
AssociatMe emberA, mericans ocietyo t
HealineR, efriSerdtianngd, A ir-Condilionitnngg ineers
^aembenr efrigeririnTBn Bineearnsd T echniciaAnss socidlron
ALFREDF .B MCCIANO, 8.S.,M .Ed.,E d.S P'
Technical-VocatioEnadlu catioCn onsultant
MemberR, efriSeratioSne wiceE nBineeSrso ciety
AssociatMe emberA, mericanS ocietyo f
HeatingR, efrigeratinagn, dA ir-ConditioninEgn gineers
Mem-beAr,i i ConditioninCg ontractorosf America
MemberA, isociationfo r Careear ndT echnicaEl ducation
Publisher
COMPANYIN C'
THEC OODHEART-WIttcox
TinleYP arkl,l linois
Copyrghl2004
by
TheG oodheart.WillcCoxo mpanyln, c.
Previouesd ito nsc opygl hl2 0001,9 96,j 992,i 9BBj, 9 82,1 979I, 9 7S1, 9 68
Ar ghrsr eserveNd.o p arlo fthisw orkm ayb € reproduc€d,
sloredoj r transmittetnd a nyi ormo r by anye tectronoicr
n€chanicai means nctLdingn formaUosnt oragea nd
rore varsyslemwst,lh oLtht ep riowf rien permisosn o iT he
coodhean-Wtcoi xC ompantyic, .
I4anulactLr'or tdh eU niledS tateosf A mec a.
Librafoyf C ongfesCsa tatoCga rdN umbe2r0 03052840
tsBN-139:7 8-1-59027800 ,2
ISBN1-0 :I -59070-280-8
678910-04-0807
The lechnologicach angesin the reiiigeralioann da ir conditionn g industryin aecent
yearsf iaveb eenv erye xtensveT. hea ccuracyr,e liabiljtyc,a rty, and feadinge veloft h s
bookh aveb eena chievedth roughth e asssianceo f the fottowinign dividuats:
AssociateA uthors
DanielC . Bracclano,B .S.M.ES.t eniorH VACE ngineerc,e neratU oiors
CorporationW, arren,f ulichiganAt ssociatet \,4embeAr,m erican
Socielyo f Healing,R eirigeratinagn d Air,Condiionn g Engineersi
[,,lembeRr,e frigerat]oSne rviceE ngineerSs ociely,
GloriaM , Bracciano8, .A.,l L4.AE.,d .S p.iP rincipaLt,a keO rionS choos ,
Lake Oron, lvlichiganAi ssoca 1e l\,lemberA, mericanS ocietyo f
Healing,F efrgeratinga nd Air-Condilionng Engineersli\ ,{embef,
Feffigelailoann dS erviceE ngineerSs ociely.
Consultants
Albe Buller,A utomotiveS ervice,c eneral lloiors Retailer,L apeer,
l\,4lchigan
RobenH .E dgeo n,B .S.M.EM.,. S.lV.EP.h, .DE. ngineering
Robe OttolinlB, .M.E.M, .S.M.EE.; ngineefinlgll anagerc,6 neralM otors
CorpofalionF,l int,I \,{icgha n
JesseR . Riojas8, .S.,A ssoc.C llmateC ontrolTechI.ni structoOr, aktand
CommuniiCy o lege,O aklandT echnicaCl enierI,V ichigan
Connie Habermehl,A dministratveA ssistanl,A ssocaledT 6chnical
AlrthorsP, ortH urcn,l ,,lichigan
The authorsa ndp !blisherg ratetullayc knowl€dg€ th6lollowingc ompanielso r useo i
maierialsfo rt he cover:TlFln sirumenlsIn, c.iC a(ier Corpo€tion, ResdeniiaPl roductsi
ClmatelvlasleIrn,c .
Libraryo f Congr6ssC ataroglngin AJbricationD ata
AllhouseA, nd.ewD an€.
Modernre lrigeraoln anda ir condilonng/ by
AndrewO .A ihouse,C ar H.TurnquslA, llredF .
tsBN1 59070,280-8
L R€trig€ration and€l iigelatng machn ery.
2.A r condiloninLg .T urnqusCl,a rlHarod,19l0-
ll. BraccianAof,r edF . ll.Ttle.
TP492.A432 003
621.5'6.-dc21
2003052840
INTRODUCTION
Modem Refrigeration and Air Conditioning provides a thorouth and authontahve course
on the basic and advanc€d pdnciples of refrigeration and air conditioning.
As the technolo8y in the field has advanced, so has the leading text in the educational 6e1d,
Modern Refrigeration and Air Conditioning. lt contains all the most recent information and
advances that arc nec€ssary to prepare the teclmician Ior today's world. lt incoryorates the lat€si
technical chanSesa nd EPA mlinSs, cove$ the newer refrigerants, and prcvides current inJomra-
tion on ihe rccovery reclaiming, and reryclint of refrigerants. It contains basic information on
numercus cedfication exams.
Mod€m Reftigeration and Air Conditionint presents all these pdnciples in a very easily
rnderstood format. To make this book more "user 6iend1y," the t'?e face has been enlarg€d,
and the readability imprcved. Sentencesa nd paraSraphs have all been reviewed so that comPre-
hension is maximized. Thrs edition retains the sequenceo f topics that has proven successful.S ome
oI ihe lrlaterial has been corelated into modules to h+ you obtain a better underctanding oI
the subjeci.
A[ dmwinSs have been coded to a standard color scheme to aid in recognition of items.
The safety seciions are highlighted in red, as in the past; ihe ser\,1cef eaturcs arc identified with
blue. Cu:rrent cylinder color coding is given for each reftgerant.
An expanded table of contents is one of many features designed to enhance the leamint
process. Each chapter has an idendJication of key words you will encounter in that chapter Learn-
ing objectives also are provided for each chapter. Test Your Knowledge questions aPPear at the
end of each chapter.
Modem Retngeratron alrd Air Conditioning is writt€n using both U.S. Conventional and
SI Metric uniis. The metric equivalent appears alongside the conventional unit throughout the
texibook. This allo}r's you to use the system with which you are most familiar.
Modem Refrigeration and Air Conditioning is intended for use in rcfrigeration and air
conditioning classesi n hith schools, technical schools, and community colleges. lt may also be
used in aduli educatron classesa nd apprenticeship pro$ams. It Prcvides the foundafion on which
a solid, thorough knowledge of refrigeration and air condiiioning may be based. It also Provides
an excellent basis of inJormation for you in the areas of sefficing and troubleshoofing
Beginnerc and apprentices will find in Modem Refrigeration and Air Conditioning an eY-
cell€nt aid lor starting and pu$uing a pleasant and prcfitable career. ExPerienced se ice tech-
nicians will find it a valuable guide and reference.
Congratulations on selechng the best seilin& most popular book on refrigeration and air
conditioning! Modern Refrigeration and Au Conditioning will Suide you to a successfii carcer
and provide you with a valuable reference in ihe Profession.
HOW TO USET HEC OTORK EY
Colors are used tlEoughout Modem Refrigeration and Air Conditionine to help show dif_
rerents tdtesa nd condition!_ofg dsesa nd Uquid!. OLherc olor. indicaLee le(tric;]. mechanicdla, nd
spe(rarc omponenis.t he touowing tey shows whdt eachc olor represents.
SystemS chematicf or Refrigerationa nd Heating
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AbsorDtioSnv st€ms
High-Pressure Water and Ammonia (Weak Solution-Hot) Brown-neal
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Low-Prcssure Water and Ammonia (Srrong Sotution--4o1d) truquotseJ
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CONTENTS
Chapte1r
FUNDAMENTATOSF REFRIGERATIO2N5
'1.30
HISTORYA ND FUNDAMENTAOLSF REFRICERAIION CriticaPl ressure5 2
MODULE 25 1.31 Enthalpy5 2
1.1 Developmenotf Refrigeration2 5 ] 32 Cryogenics 52
1.2 How a MechanicaRl efriSeratOorp erates2 6 1.33 PerfectC as Equation 53
1.3 ColorC odingS ystemin ThisT ext 26 1.34 Dalton'sL aw 54
1.4 Heat 27 1.35 Evaporator 54
1.5 Cold 28 1.36 Vapor Cas 54
1.37 Humidity-RelativeHumidity5 4
1.38 ElementaryR efrigerator 54
TEMPEMTURPER, ESSURAEN,D MEASUREMENTS
1.39 MechanicalR efrigeratinSg ystem 56
MODULE2 8 '1.40
Reviewo f Abbreviationsa nd Symbols 57
1,6 Ternperatuafen dT emperatuMrce asu€ment 28
1.7 BasiAc rithmetic3 0 1.41 Reviewo f Safety 57
1.8 TemperatuCreo nversion3 2 1.42 TestY our Knowledge 58
1.9 TemperatuDrei fferencCe alculations3 3
1.10 Dimension3s 3
1.11 Pressure3 7
1.12 TheT hreeP hysicaSlt ates3 9
1.13 Density4 1
1.14 Force 41
1. 15 Work 42
1.16 Energy4 2
1.17 Powet 42
1.18 Unito f Heat 43
1.19 Effecot f Pressuroen Evaporating
Temperature4s6
1.20 Effecot f Pressuroen FreezinTge mpetature
of Water 47
L21 RefrigeraiinEgf fecot l lce 47
1.22 AmbienTt emperature4 9
1.23 Heato f Compression4 9
1.24 EnergUyn its 50
RETRIGERATISOYNS TEMASN D TERMS
MODULE5 0
1.25 Refrigeran5t0
1.26 HeatT ransfer5 0
1.27 Brinea ndS weeWt ater 51
1.28 Dryl ce 51
1.29 CfiticaTl emperatur5e2
Chapte2r
REFRIGERATITOONO TSA ND MATERIATS6 1
TUBINCA ND FITTINCSM ODUTT 6,I
2.1 Tubing 61
2.2 Cuuinga nd BendjngT ools 64
2.3 ConnectinTgu bing 66
solde^-do - Brd,,pd-tJbrlFgi I rgs bq
4.1
ruoeL oupIng5 /5
2.6 SwagingC opperT ubing 75
2.7 TubeC onstficror7 6
2.8 PipeF ittlngasn dS izes 76
REFRIGERATITOONO TSM ODULE 77
2.9 HandT ools 77
INSTRUMENTASN D CAUCESM ODULE 88
2.10 Instrumenatsn d Cauges 88
2.11 MeasurinTgo ols 92
SUPPTIEASN D USEM ODULE 94
2.i 2 FasteninDge vices 9,1
2.13 RefrigeratioSnu pplies 96
2.14 ServiceV alves 98
2.15 Purging 99
2-l6 EvacuatinS9 9
2.17 Reviewo i Salety 99
2.18 TestY ourK nowledge 100
Chapter3
BASICR EFRIGERATISOYNS TEMS1 03
3.1 lce RefrigerationI0 3 3.12 CascadeR efrigeratinSgy nems 113
3.2 EvaporativeR efrig€ration (DesertB ag) 104 3.13 ModulatingR efrigeratioCny ce I1.1
3.3 EvaporativRee frigeratio(Sn nowM aking) 104 3.14 lceM aker 115
3.1 CompressionS ysternU singL ow Side Float 3.15 DrinkingW aterC ooler 116
ReirigerantContro1l0 5 3.16 ExpendablRee frigeraRnte frigeratioSny stem I17
3.5 External-Drive(O pen)R efrigefatinSg ystem 106 3.17 ThernroelectrRice friSeration1 18
3.6 CompressioSny stemU slngH igh-SidFe loar 3.18 Dry lce Refrigeration1 18
RefrigeranCi ontro 107 3.19 IntermittenAtb sorpiionS ystem 120
3.7 CompressioSny nemU singA utomatjcE xpansion 3.20 ConiinuouCs ycleA bsorptionS ysternI 22
Valve{ AEV)R efrigeranCi ontrol I 08 3.21 SolidA bsorbenRt effigeralion1 24
3.8 CompressioSny stemU singT hermonatically 1.22 SophisiicateCdo mmerciaSl ystenrs1 25
ControlledE xpansioVna v e (TEV) 108 3.21 Hot-CasD efrost 125
3.9 CompressioSny stemU singC apillaryT ube 3.24 ElectricD elrost 128
RelrigerantContro1l 09
1.25 TestY ourK nowledge 129
3.10 MultipleE vaporatoSry stem 110
3.ll CompoundR efrigeratinSgy stems1 11
Chapte4r
COMPRESSIOSNY STEMASN D COMPRESSORS1 31
.I31
COMPRESSIONS YSIEMSM ODUTE
4.1 Lawso f Refrigeration1 31
4.2 CompressioCny cle 131
4.3 Evaporator1 34
4.4 Accumulator1 34
4.5 SuctionL ine 134
4.6 Compressor1 35
4-7 Oil Separator1 36
4.8 Condenser1 37
4.9 LiquidR eceiver1 39
4.10 LiquidL ine I39
4..I 'ypFso JR efriBeraFqllo \^C onlrol I40
4.'12 MotorC ontrol 145
COMPRESSORMSO DULE 146
4.13 Extefnal-DriveCompresso1r4s6
4.14 HermeticC ompressors1 47
4.15 Typeso f Compressorc 147
4.16 Motors 168
4.17 SeryiceV alves 168
4.18 Mufflers 169
4.19 CompressoCro oling 169
4.20 Lubrication1 70
4.21 CompressoVro lumetriEc fficiency1 70
4.22 CompressioRna tio 172
4.23 CheckV alves 172
4.24 Urloader 172
4.26 O Rings 172
4.27 CrankcaseH eater I73
4.28 Reviewo f Satety 173
4.29 TestY our Knowledge 174
Chapter5
.I77
REFRIGERANTCONTROTS
5.'l CompfessionS ystemR efrigeranCt onirols 177 5.5 Reviewo f Safety 203
5.2 ComparingR efrigeranCt ontrols 202 5.6 TestY our Knowledge 204
5.3 CheckV alve 202
5.4 SuctionP ressureV alves 202
Chapte6r
EI.ECTRICAT-MAGNFEUTINCD AMENTAI.2S0 7
ELECTRICFAULN DAMENIAMTSO DULE2 07 APPTIEDE LECTRONICASN D EIECIRICITY
6.1 CeneratinESle crricity2 07 MODULE 234
6.2 Typeso f Electricity2 08 6.6 Eiectronics2 14
6.3 CircuiFt undamenta2ls1 0 6.7 ElectricaPl ower 242
6.4 ElectricMala terials2 22 6.8 ElectricaClo des 250
6.5 Magnetism2 24
6.9 CircuitP rotection2 50
6.10 Reviewo f Safety 253
6.11 TesYt ourK nowledge2 54
Chapte7r
ELECTRMICO TORS 257
ETECTRIMC OTORSM ODULE 257 7-14 StandarMd otorD ata 278
7.1 ElectricM otorA pplications2 57 7.15 FanM otors 278
7.2 TheM otorS tructure2 57 7.16 Shaded-PoMleo io|s 279
7.3 Typeso f ElectricM otors 258 7.17 ElectroniVca riableS peedM otors 280
7.4 Motor Speeds 261
7.5 Sta{inga nd RunningW indings 262
7.6 StartingC urrent 263
/./ MOtOCr onnecton\ 164 SERVICINCEL ECTRIMCO TORSM ODULT 282
7.18 SeryjcinEg lectricM otors 282
7.8 HermeticS ystemM otors 265
7.19 Pulleys 287
7-9 DirectC urenta nd UniversaMl otors 272
7.20 Belts 288
7.10 Motof Horsepowera nd Motor
7.21 Motor T€siing Stand 290
Lnatactefl9ircl5/J
7.22 Servicinagn d RepairinHg ermeticM otors 290
7.11 ElectricM otorC rounding 273
7.12 MoIor Prctectior 274 7.23 Revie\r,oSi aiery 292
7.13 MotorT emperaiure2 77 7.24 TesiY our Knowe dge 292
Chapte8r
ELECTRICCIRCUITASN D CONTROLS2 95
ELECTRICCO NTROLC IRCUITSM ODULT 295 8.9 RemoteT emperatureS ensingE lenrents 316
8.1 ElecticalCifcuits-CompleteWiring 8.10 PressurMe otorC ontfos 317
Diagram 295 8.11 MotorS afetyC ontfols 317
8.2 Eiectical Circuits-Laddet Diag]am 297 8.12 MotorS radingR elays 319
8.3 ControlSystems-Fundamenta2l9s7 8.13 AutomaticD efrostC ontrols 324
8 l4 Sen;aLrorrri(D et.onC ontrols l2t
8.15 Hot-CasD efrosCt ontrols 327
8.16 lce BankC ontrols 328
ETECTRICCO NTROTSM ODULE 309
8.17 De-lceC ontrols 329
8.4 Refrigeratoarn d FreezerC ontros 309
8.1B Hum;dityC ontfols 330
8.5 lceM akerC ontrols 310
8.19 DefrostinTgi mers 330
8.6 ComlorCt ooiingA ir ConditioninCg ontrols 314
8.7 CentraAl ir ConditioninCg onlrols 315 8.20 Reviewo l S.rfety1 31
8-8 WaterC oolerC ontrols 316 8.21 TesYt ourK nowledge1 31
I
Chapte9r
REFRICERANT3S3 5
9.1 Refrigerantasn d the Ozone Layer 335 9.12 RefrigeraCnty linders 355
9.2 Requirementsi or Refrigerants 337 9.13 Use of Pfessure-TemperaiuTraeb les 357
9.3 Useo f Pressure-TemperatuCru€ rves 337 9.14 HeadP ressure(Hs ighS ide) 357
9.,1 Cfouping and classificationo f Refriseranis 338 9.15 RetrigeratorTemperatu3re5s7
9.5 CroupA Retrigerant3s 38 9.16 RefrigeraAntp plications3 58
9.6 CroupB Reffigerants3 51 9.17 Changing/ldentifyingRefriger3a5n8ts
9.7 CombustiblRe efrigerant3s 52 9.1I Amounto f RefrigeranRte qujredin a System 158
9.8 ExpendableR efrigerants3 52 9.19 RefriseratioOni l 36'l
9.9 Watera s a Refrigerant 354 9.20 Moisturein Refrigeran3t 61
9.10 FoodF reezanis3 54
9.21 Revi-.wo f Safety 362
9.1I CryogeniFc luids 354
9.22 TestY our Knowledge 363
Chapter1 0
REFRIGERANRTE COVERY/RECYCLING/RECLAIM3IN6G5
10.1 Chlorofu orocarbon(sC FCs),
Hydrochlorloufo rocarbon(Hs CFCs),
andt he OzoneL ayer 365
10.2 RecoveryR,e cyclingR, eclaiming
of Refrigerants3 67
10.3 RefrigeranRte coverEy quipment3 67
10.4 RelrigprdnRr^ ,\ r lirS EqLipme'rl {-/
'10.5
RefrigeranRte claiminPgr ocedure3 75
10.6 Retrofit 377
10.7 MobileA ir Conditioning3 78
10.8 Revie$orf Saiety l/9
10.9 TestY ourK nowledge3 79
Chapter1 1
DOMESTIRCEFRIGERATOARNSD FREEZERS3 81
11.1 PreseNinFgo odsb y RefriSefation 1l .l0 UprightF reezers4 07
and Freezing3 81 11.11 Careo f Refri8eratoor r Freezef 409
11.2 Refrigeratoar nd FreezerI nsulation 382 11.12l ceA ccumulatioinn CabinetI nsulation4 10
11.3 RefrigeratoSr ingle-DooMr,a nualD efrost 382 11.13B utterC onditioner4 10
ll.4 Re-flSer"loFFreezMe drudl Defrosl J84 11.14C abineHt ardware 411
11.5 Refrig€rator-FreezAeru tomaticDefrost3 87 11.15C abineCt askets 412
11.5 Refrigerator-Freezer-Frost-Fre3e9 4 11.16R epairinFgin ishes4 13
11.7 RefrigeratoFFreezer-Frost-Free, 11.17C abineTr hermometers4 13
Side-by-Side 395 11.18R evicwo f Safety 414
11.8 Solid-Statlcee M aker 401 11.19T estY ourK nowledge4 14
11.9 Chest-TypeF reezers 401
Chapter1 2
SERVICINGA ND INSTALIINC SMALL HERMETICS YSTEMS 417
12.1 InstrumentTso, olsa, ndS upplies 4j7 12.9 LocatingR efrigeranLt eaks 444
12.2 InstallingR efrigemtorasn d Freezers 419 12.10R epairinLge aks 448
12.3 TroubJeshootinthge Hermetic 12.11 RefrigeranRt ecoverya nd Evacuaiion 449
RefrjgeratoFFreeze4r 21 12.'12D iagnosinCgo mponenPr roblems 452
12.4 HermeticS ervicing4 27 12.13R eplacinSSy stemC omponents4 59
ExternaSl eruicingO perations 427 12.14E vacuatinag S ynemw ith a VacuumP ump 463
12.6 InternalS erviceO perations 433 12.15O verhaulinag HermeticS ystem 470
12.7 Cauge( ServjceM) anilold Types
12.16R eviewo f Satety 470
and Construction 434
12.4 HermeticS erviceV alvesa nd Adaptors 438 I2.17 TesYt ourK nowledge4 71
Chapter1 3
COMMERCIASI.Y STEMS4 73
COMMERCIASLY STEMMSO DULE 473 3.8 VendingM achineC ontrols 519
13 .1 Constructioonf RefrigeratioCno mponents473 3.9 DeirosTt imers 520
13.2 RefrigeratioCno mponents4 73 3.10 PressurRee gulatinVga lves 524
13.3 PackageCdo mmerciaSl ysterCn omponents475 3.ll CompressoPr rotectionD evices 529
13.4 CommerciaEl vaporators4 96 3.12 ManualV alves 536
3.13 RelrigeranLti nes 539
COMMTRCIAIS. YSTEMS--{ONTROtSM ODULE 513 3.14 Engine-DriveSny stems5 43
'13.5
RefrigeraCnto ntrols 513
3.15 Reviewo f Safety 544
13.6 MotorC ontrols 513
3.16 TesYt ourK nowledge5 44
13.7 lceM akerC ontrols 519
sutlpat a2kknd uDanmt Ltudrh c6El
10