Technical Training BASIC REFRIDGERATION & CHARGING PROCEDURES

Instructor:

Rick Drennan

BASIC REFRIGERATION & CHARGING PROCEDURES

Richard Drennan FSR (Field Support Rep) and Instructor for Global HVAC training services Northern California and Northern Nevada 29 Years experience Certifications: 6 Nate, EPA (608 & 609), Ruud Mod Furn, 410A, Tracpipe, Wardflex, York Millennium unit, Freus (water cooled cond. unit), Clarions UV self cleaning systems, Fujitsu Mini Splits Registered Proctor: Ruud, York, ICP (Carrier), Nate, ACCA, ESCO, HVAC Excellence, General Electric (ECM Total comfort system), Fujitsu & Tracpipe Degrees: Electronics, Computer Programming and Computer Electronics

! AIRFLOW !

CFM Calculation
Proper air flow is the most import aspect of any system. With improper airflow nothing at all will work properly.

Real Life Charging Procedures

Use Engineering Data for reference Humid climates demand it Full unit capacity depends on it

Measuring CFM

First Calculate FPM

With a Magnahelic or Manometer, you can easily convert the pressure reading to FPM. Typical Static Pressure readings will be 1.5" to 4" with very large blowers maybe pushing 8" to 10". Once you have the pressure reading (Pv) from your gauge then calculate

FPM = 1096.7x Pv/D

This formula calls for knowing the air density (D), but most use 0.075 pounds per cubic foot as that is fairly close to normal room temperature air. If you test at high altitude, high humidity, or far from normal temperature, the Dwyer Instruments web site provides a detailed article on the use of pitot tubes and gives the conversion tables and factors to adjust to an appropriate density.

Converting to CFM
We calculate CFM by multiplying FPM by the area of the duct used in square feet. The formula for this is:

CFM = FPM x (Pi x R2)/144

For Example: The area of a round duct is equal to the radius squared times pi, so a 6 diameter duct (3 radius) would be 3 x 3 = 9 in x 3.14159 = 28.27 square inches. That divided by 144 = 0.196 square feet. Use the 0.196 number times the FPM number on the gauge when testing with 6" diameter duct to get CFM. The multiplier for 5 duct is 0.136. The multiplier for a 4 duct is .087.

HOW TO CALCULATE CFM USING THE

TEMPERATURE RISE METHOD

CFM = BTUH 1.08 X TD

Discharge temp. - Entering Temp. = TD TD or T = Temperature Difference

To Clock the Gas Flow: Turn up thermostat Tu n t rmos at so furnace runs steadily Turn off pilots of other appliances t r ap ianc

Check Gas Meter Calibration Che k G s te C libration

One Revolution in Seconds
60 45
Half Two

15 30

Foot

Foot

Cubic Feet

How to Calculate Gas Flow Rate w Ca l e a w at

Cubic Feet Per Revolution t n

3,600 Sec./Hr. ec r

Time for One f rO Revolution (Sec.) n Sec.

Cu. Ft. Per Hr.

0.5 x 3,600 = 24

Cu. Ft. u. Ft Per Hr.

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Using Gas Flow Rate to Calculate Heat Input Rate

Gas Flow F ow Rate x Gas Heating n Rate Heat Input = n u Rate

Cu. Ft. .F Per Hr. er r

75

1050 Btu Per B Pe

Cu. Ft. C t.

78,750 ,7
Btuh Bu

Check Temperature Rise

Supply

Return

Temperature Rise empera u R se

Supply Air 135 F 135 Return Air 70 F 70 Rise 65F F is 5
135 70

To Calculate CFM
Temperature Rise Method BTU Input ut
X
Combustion o b s o Efficiency i e cy

CFM

1.08

Temp. T Rise

Example:
Temperature Rise Method e t r s M t od
78,750 7 0
Btuh

.90
Combustion t Efficiency

1,010 ,0
CFM

1.08

65
temp rise em se

Calculating the Sensible output of the Condensing Unit

1010 CFM 20 degree Delta T CFM x Delta T x 1.08 = BTUH Output 1010 x 20 x 1.08 = BTUH Output

Calculating the Actual output of the Condensing Unit

1010 CFM ?? degree Delta Heat CFM x Delta H x 4.5 = Actual BTUH Output 1010 x ?? x 4.5 = Actual BTUH Output
Delta Heat on a properly operating system will be e p n approximately 5.6 degrees x . e

It works both ways

CFM = BTUH / Hx 4.5
OR

BTUH = CFM / Hx 4.5

Electric Heat output 3-Phase

BTUH = VOLTSxAMPS x1.73 x3.414

Now that Airflow is Correct

We can begin by checking the refrigerant charge. But FIRST, lets understand how the system works.

SECTION ONE C N N
REFRIGERANT PRESSURES, STATES & CONDITIONS

Load out to ambient o u m i

Load in o n from f house

Heat flows from hot to cold. e f t c d

Evaporator Side Terms Evapo at r ide Ter

Evaporating Pressure v g e s Low Side Pressure d s r Suction Pressure u n r s Back Pressure ure

Condenser Side Ter s C nd en s r S d Terms

Condensing Pressure C res Head pressure H u e High side pressure Hg Discharge pressure D e u e

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Compressor
Pumps refrigerant vapor only! u p ig r t r ly! Divides low and high side. D w

Discharge Line harg L ne

Connects the compressor to the condenser.

Condenser d e
Rejects heat from the refrigerant. t e at rom i t.

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Liquid Line Liqu d Line

Supplies liquid refrigerant p e n from the condenser to the o c n e e o h metering device. t e

Metering Device M ng Dev c

Controls the flow of refrigerant. Divides low and high side.

Evaporator rat r
Absorbs heat into the refrigerant.

Removes moisture from the air R e m ture o

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Suction Line Su i n L n
Returns superheated vapor from the evaporator to the compressor

Receivers e v
An accessory added in the liquid line to store refrigerant for different loads placed on the system.

Accumulators mu at rs
An accessory added in the Suction line to store liquid refrigerant for different loads placed on the system to prevent liquid flood back to the compressor. Predominantly installed on Heat Pumps.

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CONDENSER
Temperatures m e t

Pressures e re

States

CONDENSER INLET ON E R N

High Pressure h ssu High Temperature h e p r e Superheated Vapor p e Saturation Point a Po

(vapor c n changing to a ( g liquid as l u a heat is removed)

Near Ambient Temperature e rA b n m e t High Pressure i r Subcooled Liquid o u

OUTLET OU LE

EVAPORATOR E APO RAT OR

Temperatures Te p Pressures P s ur es States State

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Evaporator p inlet t

Metering Device vc

Low Pressure wP e r Low Temperature L wT m e t About 80% Liquid, iq id t 0 q 20% Vapor %V Saturated vapor S u t d r (Temperature in ( r which liquid is liq d changing to a c o vapor) va o

Evaporator v p or Outlet

Low Pressure L wP e re Low Temperature T m Superheated Vapor t p

SECTION TWO W
SUBCOOLING & SUPERHEAT (Compressors)

Scroll Compressor S l pr Operation Op i

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Subcooling and Superheating r a g Su bc o lin n

The concepts of subcooling and ps ubcool ng superheating are the two most perheat ng e t t m t important principles that the i mport a ri p es that t service t e ci m t v ce technician must understand before attempting to o st a b f e at e t systematically troubleshoot any s se eshoot i ly r hvac/r systems. ac s s em .

Subcooling S bc o lin g
Subcooling is any heat removed c i n s a he e from the completely saturated s urat om t com t liquid that results in a drop in ts n d in l q d that r temperature (sensible heat change) tem perat e ( sens bl e heat cha e of the refrigerant. the efr ge r nt

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210 psig = 105 F -95 F Subcooling 10 F

R-22 2

Condenser Subcooling e er ub ool i

TOTAL OTA SUBCOOLING SU OOLI G

210 psig = 105 F -90 F Subcooling 15 F

Superheat u rh a t
Superheat is any heat added to completely n e t a d ed o p t ly p rh a saturated va o that results in a rise in t r e vapor at es ri se temperature (sensible heat change) of the gas. e p r t re se ib e t h g ) f h .

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60 F F 76 psig = 45 F 15 F F Component superheat n e

Evaporator Superheat t uper at v p

Total or System m l S Superheat upe h e t

Suction line S ucti n l ne Temperature 80F T p r 80 76 psig = 45F 7 s ig 45 45 System S up Sy te Superheat 35F at 35

SECTION THREE H
METERING DEVICES

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Capillary Tube u e a illa

Thermostatic Expansion h r o a i c xp n n Valve a Va

Automatic Expansion u o a ic Exp n n Valve l ve

Fixed Bore Piston ixe o Pist n

Capillary Tubes Ca illa y Tubes

Low Cost device t e Have no moving parts e g r Can be used on a wide range n u ed d e of obsolete applications o te p c s

Thermostatic x T r os a t c Expansion Valve i V v

Most efficient M s f ci Maintains co M nta ns a constant evaporator ev ap a superheat sup r eat Helps prevent compressor e compress H p flooding flo i

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TXV Types ype s

Pressure Limiting e i i g Balance Port P r
Externally equalized n l a z Internally Equalized te nt y l

Electric operated c r te

TXV Bulb Placement B l ent

TXV External Equalizer Tap Location r a ua z ap ati

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Automatic Expansion Valves oma i c E xpansi on a l es

Maintain a constant evaporator c n t va o t r a pressure ssu Used on U sed on small systems which a ic e s have constant loads h ve c n a t a s

Fixed-Bore Metering Devices Fixeded i s

Most common today on Residential st o m n o a R s d n ial i systems 10 seer and below e s 10 e d w Dual purpose device u p se d vic Works as metering a device e k a ee g Works as a check valve h c rk a lve Critical charge C it a c a

SECTION FOUR SE I R
System CHARGE

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Is The Refrigerant Charge Correct? s ha g e

All refrigeration systems differ in the A r fr g n y f amount of charge they hold. t e There are guidelines, charts, and r i a techniques to follow. i es o o System design & layout must be known s m i o kn

How long & what size s e is the line set? s t

Whats the volume of hat e the filter drier? i

TXV CHARGING RULES C RG N 1. Charge system under a high load C s t l 2. Charge as a liquid when possible 2 C r d pos 3. Throttle liquid blends into low side d nt l d 4. Record evaporator & compressor Re d at com s superheat & Condenser subcooling s e r ub ool

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AIRCONDITIONING SYSTEMS ON IO G YS Capillary Tube l e or Fixed Orifice O ii

#1 Weigh in the correct charge W i n he #2 Manufacture's charging charts 2 anuf c s har #3 Use system superheat method s y em e

Requirements for system i e s or y m superheat charging per tc g

Proper evaporator air flow o P or to a w Accurate remote bulb temperature tester c tes r Accurate gauge manifold set A g e a

SYSTEM SUPERHEAT CHARGING CHART

Indoor Wet-Bulb Air Temp rature 52 54 56 58 60 62 64 66 68 70 72 74 76 Condenser Entering Air Temperature 65F 70F 75F 80F 85F 90F 95F 100F 6 10 7 13 10 6 16 13 9 5 19 16 12 8 21 19 15 12 8 5 24 21 18 15 27 24 21 18 30 27 24 21 33 30 28 25 36 33 31 28 26 24 22 20 38 36 34 31 30 27 25 23 41 39 37 35 33 31 29 27

11 15 19 22 9 13 16 20 6 10 14 18 8 12 15

To increase superheat remove

refrigerant. To decrease superheat add refrigerant.

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System Superheat S m Supe he t

Suction line tio li Temperature 60 F em pe a 76 psig = 45 F p i Superheat 15 Supe h 15 F

Alternate charging method R22

Alternate charging method R410A

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Alternate charging method Lineset length and Grade separation

SAMPLE QUESTIONS U T

The high and low pressures in a refrigeration system are separated by: a. b. c. d. The compressor. The evaporator. The metering device. The filter drier.

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Subcooling can be defined as:

a. b. c. d.

The cooling effect of an evaporator. Any sensible heat removed from 100% saturated liquid. The superheat that is removed at the top of the condenser. The cooling of the compressor motor by returning refrigerants.

Always charge a TXV with a receiver and sightglass under a: a. b. c. d. No load condition. Low load condition. High load condition. None of the above.

Superheat is defined as:

a. The heat added the the saturated liquid. b. Heat removed from the saturated liquid in the condenser. c. The heat added to the saturated vapor exiting the evaporator. d. The heat removed from the saturated vapor exiting the evaporator.

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Definition of EXPERIENCE
Something acquired after you need it Allow us to give it to you before you need it, to be ready! "Experience is a hard teacher because she gives the test first, then the lesson afterwards."