Air Conditioning 2004

Service Advisors
Gustave Larson A. Company

Plymouth Office: 800-827-9508
763-546-9508
Gale Patterson ext. 343
Steve LeMay ext. 346

Pewaukee Office: 800-829-9609
Steve Bukosky ext. 247
Tim Chamberlain ext. 285

Air Conditioning 2004
Thermodynamics
Installation
Air Flow
R410 vs R22
Service


Air Flow
Thermodynamics
Saturation Temperature
Density of Refrigerant Vapor
Enthalpy
Superheated Vapor
Sub-cooled Liquid

Heat Transfer
Hot Object Cold Object
HEAT
Latent and Sensible Heat
212
0
32
One pound of water being heated at one BTU per hour.
Temperature of the
water.
1310 total BTUs used.
16 144 180 966
158 340
1306
Basic Refrigeration
Basic Refrigeration
Liquid Line

Liquid Line
Metering
Device
Evaporator
Compressor
Condenser
Hi Side
Low Side
What is Saturation
Temperature?
Saturation temperature is the actual
temperature of the evaporator and
condenser coils.
In saturation conditions, both vapor
and liquid are present
How do you find Saturation
Temperature?
Refrigeration Gauges
The Only purpose of owning a
set of gauges is to find the
refrigerant saturation
temperature.
Saturated Refrigerant
Liquid Line
Suction Line
Evaporator
Condenser
Discharge Line
Compressor
Metering
Device

Saturated Refrigerant
Liquid and Vapor in
Contact with Each
Other in Equilibrium
Pressure and
Temperature Tied
Together
P/T Chart is
Applicable

Saturated Refrigeration
Example: Conditions, R-22 - 287 PSIG
128F Temperature






P-T Chart at 287 PSIG R-22 = 128F
Line Temperature = 128F

Refrigerant is Saturated
Pressure/Temperature Chart
Thermodynamics/Condenser Coil
Purpose of condenser coil is to reject the
heat load absorbed by evaporator coil, and
to cool the refrigerant to a level that is
below the saturation temperature.
-This is accomplished through (1) Latent
Heat Transfer, and (2) Sensible Ht.
Transfer.
-Proper sub-cooling prevents saturated
refrigerant from leaving the condenser,
thus optimizing metering device
performance.

Sub-Cooled Liquid
Typical sub-cooling levels - 5 to 20 degrees
-Not enough sub-cooling, or large pressure
losses in the liquid line create the
formation of flash gas will affect the
operation of the metering device.
-10 degrees overcomes 35PSIG of liquid
line pressure drop in R-22 systems.
-10 degrees overcomes 50PSIG of liquid
line pressure drop in R-410A systems.

Sub-Cooled Liquid
Sub-Cooling
Heat Removed from
the Liquid Refrigerant
that Causes its
Temperature to Drop
Below its Saturation
Temperature
P/T Charts do not
Apply- Temperature
Drops without a Drop
in Pressure

Sub-Cooling
Example: Conditions, R-22 - 280 PSIG
120F Line Temperature







P-T Chart at 280 PSIG = 125F
Line Temperature = 120F

5F

Refrigerant Sub-cooled at 5F


Sub-Cooled Liquid
Liquid Line
Suction Line
Thermodynamics/Evaporator Coil
Purpose of evaporator coil is to absorb the
heat load from the space being conditioned
and to evaporate the liquid refrigerant to a
level above the saturated temperature.
This is accomplished through (1) Latent
Heat Transfer, and (2) Sensible Heat
Transfer.
Proper superheating prevents liquid refrig
from leaving the evaporator, thus
optimizing the removal of heat from the
space and protecting the compressor from
damage
Superheat Principles
Superheat is the temperature of the refrigerant
vapor above its saturation temperature.
Superheating is done by the load. If the load is
low, the superheat will be low. If the load is high,
the superheat will be high.
Superheat is a Sensible Heat Transfer that
provides very little useful cooling. This occurs
because there is no change in state; only change in
temperature.
Refrigerants should never leave the evaporator
coil at saturation temperature, because liquid is
still present.

Superheat Principles (cont)
Latent Heat Transfer gives us our greatest energy
transfer and results in massive cooling capacity.
The evaporator surface performance is based on
the amount of Latent to Sensible Heat Transfer
taking place.

Superheat
Heat Added to
Refrigerant Vapor that
Causes its Temperature
to Rise Above its
Saturation
Temperatures
P/T Charts Do Not
Apply - Temperature
Rises Without a Rise in
Pressure

Superheated Refrigerant

Example: Conditions, R-22 - 75.0 PSIG
Suction Line - 54F
Line Temperature = 54F
P-T Chart at 75.0 PSIG= 44F
10F
Coil Operating at 10F Superheat

Superheated Gas

Superheated Refrigerant
Compressor
Suction Line
Liquid Line
Discharge Line
What is R-410A?
R-410A is a blend of two refrigerants,
near Azeotropic mixture of 50% HFC-32
and 50% HFC-125.
Many of us have been using refrigerant
blends for awhile, R-502.
The Temp. Glide is negligible (< 0.3F).
There is no significant change in
composition due to system leaks.

What is R-410A?
The Ozone depletion potential(ODP)
for R-410A is 0.00 Vs 0.05 for R-22
(1.0 is R-12 which is the baseline
established by EPA).
The ASHRAE safety classification is
A1/A1, the same as R-22.
Boiling point is -62.9F Vs -41.4F for
R-22.


What is R-410A?

Flammability classified as non-
flammable.
Combustibility can occur when
mixed with air under pressure
(same as R-22).
Toxicity is classified as low.

WHAT IS R-410A?
Thermal stability is similar to R-22.

Handling cautions are the same as R-
22.

Remember 50 to 70% higher pressures
require the proper tools for
servicing.
R-410A POE Oil
Oil is different than R-22
polyolester rather than mineral oil.. POE
POE is hygroscopic. It absorbs
moisture rapidly.
Liquid line driers must be changed when
the system has been open. A good
vacuum will not get all the water out.

R-410A POE Oil
Non-contaminated POE oils will
not harm skin.
Non-contaminated POE oil has a
light sweet odor.
POEs are classified as non-
hazardous.

R-410A POE Oil
POE oils from a severe acid
system will smell like dirty
diapers.
Severe burn outs create acids
and alcohol and moisture.
Waste oil may be disposed
through waste recyclers.


R-410A POE Oil
Synthetic oil will attack many roofing
materials. When servicing equipment
mounted on a roof, the roof must be
protected from oil spray or spills. Use
a plastic covering or tarp to protect
the work area.
Wiping up a spill will not stop long
term damage to the roofing materials.

R-410A POE Oil
* System contains POE oils that
absorb moisture faster than
current mineral oil.
* Unopened containers have less
than 50 ppm/ water.

R-410A POE Oil
Open containers can absorb
1500 to 2000 ppm/ water.
Keep containers sealed when not
in use.
Use reasonable refrigeration
practices.


R-410A POE Oil
Vacuum pumps will not
completely remove moisture,
driers must be replaced every
time a refrigerant component is
replaced.
Not even a deep vacuum will
remove moisture from POE oils!

Oil Moisture Absorption Rate
(POE Oil)
Time Minutes
Discus Compressors/Polyol Ester Oil
Moisture Content Versus Time
100
200
300
Sample Size: 13
237 PPM
129 PPM
93 PPM
75 PPM
270 PPM
156 PPM
Filter Change at 60
Days Operating
30 PPM
20 PPM
Exit Copeland
Exit-Rack
Manufacturer
At Jobsite At Jobsite
30 Days 75 Days
DRIERS
Suction line driers must only be used
on the low side of the system.
Operating temperatures and
pressures may be exceeded if applied
on the high side.

High temperatures will cause the
activated alumina in suction line
driers to decompose, causing more
acid.

Inside the Filter-
Drier box you will
find this
pamphlet.
LEAK DETECTION
Electronic leak detectors must
be capable of detecting HFC
gases. Halide torches detect
chlorine and will not work with
HFC refrigerants.

Fluorescent dyes are not
approved for Trane equipment.

Installation Considerations:
Airflow, Airflow, Airflow
Manual J
Refrigerant lines
Outdoor units
Indoor units
Back-up heat
Accessories
Controls

Installation Considerations:
Check unit Is it the right one???
i.e., correct size, voltage, etc.
Check Product Data Sheets,
Installation Guide, and/or Service
Facts
FCCV/TXV?
Air Flow

Installation Considerations:
Air, moisture, and dirt WILL cause a
failure or problemsooner or later
Replace liquid line drier anytime the
system is opened after initial install
Use oxy-acetylene for brazing
Rap valves, etc with wet rag to
protect
Installation Considerations:
Purge with Nitrogen when brazing
Remove valve core
Evacuate to 500 microns
(MICRON GAUGE)
Micron Gage
(430-535F)
(1190-1465F)
Installation Considerations:
Installation Considerations:
High Side Change Outs:
Capacity?
Efficiency?
Line Set?
Condition of Evaporator Coil
Oil Logged?
Clean?


Refrigeration Piping
Refrigeration Piping
Why This Is Important:
Oil Return
Suction Line Velocity
Capacity Losses
Flash Gas Liquid Line
Flood Back - Compressor
Refrigeration Piping
Points To Remember:
OK up to 50 Ft
Elbows add EQUIVALENT length
>10 Ft rise CALL
>50 Ft EQUIVALENT - CALL
When You Call

What is the actual length?
What size tubing or pipe
How many elbows are expected?
Long sweep or short?
Is condenser above or below
evaporator?


Air Flow

Air Flow

Air is Invisible
Everyone assumes adequate airflow
Reality is Airflow is frequently 30-
50% LOW
Duct leakage or high static pressure
Air properties MUST BE MEASURED
Air Flow

The Equipment or the System???
Cannot get proper performance from
equipment with CORRECT AIRFLOW
Cannot accurately charge a fixed
orifice system without CORRECT
AIRFLOW
So.What do we do?

Air Flow Basics
Total Air Volume Cubic Feet Per Minute
(CFM)
Velocity Feet Per Minute (FPM)
Static Pressure
Velocity Pressure
Total Pressure
Converting Static Pressure into Velocity
Air Movement
Static Pressure
Velocity Pressure
Total Pressure
Air Movement System
Duct Losses
30% not uncommon!
Fix duct losses and get more capacity!
Return loss
Bottom pan
Supply loss
Leaking humidifier bypass damper
Duct Leaks
Leaks can cause dirty, unconditioned
air to enter a residence.
Leaks also contribute to loss in
efficiency and capacity: 1% in total
airflow = 1% loss in capacity
2.5 ton 30,000 BTUH 1000 CFM
-3,000 BTUH -100 CFM*
27,000 BTUH 900 CFM
*10% loss in air and capacity
Air Movement System
If any part of the distribution
process is oversized or undersized,
closed off or restricted, the entire
system can be disrupted. This can
cause: Comp. Flooding; Drafty rooms;
Humidity problems; Mold/Mildew;
Sweating ductwork; Motor wear;
Noisy systems; Dust; Hear Exchanger
failure; Electrical problems; Positive
or Negative house pressure
Air Flow Measurements

Total Static Pressure

CFM Measurements:
-Temperature Rise
-Evaporator Pressure Drop
-Air Velocity
-Temperature Drop*
Static Pressure Measurement
The key to system airflow diagnostics
A companion to airflow measurement
It takes less than 5 minutes to
measure
Similar to blood pressure diagnostics
Total Static Pressure

Total External Static
Pressure
+.65 (Supply side reading)
-.45 (Return side reading)
1.10 Total External Static Pressure

Air Flow Measurement-

Temperature Rise Method
to determine CFM


Airflow Measurement
(Temperature Rise Method)
(Red Book, Pg. 33)

CFM By Temperature Rise
BTUH OUTPUT
T X 1.08*

= CFM
*1.08 = constant number for std air. Its a
combination of a number of values that are in the
complete equation. Std air is 70F, sea level
CFM By Temperature Rise
55,200 BTU output
60 X 1.08
= 850 CFM
64.8
CFM Per Room?
-7,500 BTUH Heat Loss
-Room temperature = 72 F
-Supply air = 125F
-How many CFMs required?
CFM Per Room?
-Use formula: CFM= BTUH
T X 1.08

-CFM = 7500 BTUH
(125-72F) X 1.08

-CFM = 131
BTUH Per Room?
-Air delivered to room = 131 CFM
-Room temperature = 72F
-Supply air = 125F
-How many BTUs delivered?
BTUH Per Room?
-Use formula:
BTUH = CFM X T X 1.08

-BTUH = 131 CFM X (125-72F) X
1.08
-BTUH = 131 X 53 X 1.08
-BTUH = 7,498
CFM
By Evaporator
Pressure Drop
Velocity

Velocity = FPM
CFM= FPM X Area in Square Feet
Free Area


Measuring Air Velocity
Measuring Air Velocity
Measuring Air Velocity
Measuring Air Velocity
Measuring Air Velocity
CFM By Temperature Drop*
It can vary depending on outside
temperature and indoor wet-bulb
What if the system is undercharged,
overcharged or dirty condenser?
What if its too cold outside?
Have you ever seen a manufacturers
written specification for it?

Humid Air
Dry Air
Fan Speed Taps
Check Service Facts for proper air
speed tap to use
Match tap to size (BTUH) of unit
Blower should always be on high speed?
2 TON 800 CFM
Break-timeBe
Back in 10
minutes
Time Remaining
10 Minutes
Time Remaining
9 Minutes
Time Remaining
7 Minutes
Time Remaining
6 Minutes
Time Remaining
5 Minutes
Time Remaining
4 Minutes
Time Remaining
3 Minutes
Time Remaining
2 Minutes
Time Remaining
1 Minute
Time Remaining
15 Seconds
OK, Times Up!
Let get the show on the road!!!
Basic Tasks-Spring Tune-Up
Wash Condenser
Check for clean filters and evaporator
Service blower
Check drainage
Check controls
Check refrigerant charge
Check overall Performance
System Charging
System Charge Airflow!
Correct starting point for ANY
refrigeration system diagnostics
Validate proper airflow
Gauge pressure reads low, but is low
charge the real problem?
Dont automatically add gas.
SYSTEM CHARGING
The sub-cooling method is required when charging
TXV systems.
The super-heat method is required when charging
fixed orifice systems.
Charging charts are included in the Service Facts
document that come with the outdoor equipment.
Remember to allow sufficient time for the system
to stabilize before adjusting the refrigerant
charge.




Beer Can Cold and
Sweaty
How do I know what I have?
What kind of metering device?
Remember, TXVs may be built with
evaporator and not apparent.

Block condenser air to raise head
pressure
Piston/cap tube - gage pressures
will rise at a fairly even rate
TXV will tend to keep suction
pressure stable as head pressure
increases
SYSTEM CHARGING(SC)
Using the Charging Chart-TXV
Measure temperature and pressure at
liquid line.
Use line length & lift to choose which curve
to use.
Plot the intersection of temp. & pressure.
If above the curve, remove refrigerant.
If below, add refrigerant
Wait 20 minutes to stabilize.

Sub-Cooling Calculation
Low Sub-Cooling indicates LOW
charge
High Sub-Cooling indicates OVER
charge ( or possible liquid line
restriction)
Rule of thumb = 10 - 15 degrees of
sub-cooling Manufactures usually
design to 10 degrees
(390 PSIG & 115 F)
SYSTEM CHARGING(SH)
Using the Charging Chart-Fixed Orifice
Measure indoor dry bulb* (R/A)
Measure outdoor dry bulb (at unit)
Measure suction pressure
Measure suction temperature, before
suction service valve
Use chart to determine SH
Above 5 F above, add. If 5 F below,
remove.
If below 5 F limit line, DO NOT ADD.
*If RH >70% or <20%, use ID wet-bulb
Superheat Calculation
Superheat indicates that complete
vaporization of liquid refrigerant in the
evaporator coil has taken place
Low Superheat means liquid refrigerant is
present at or near the outlet of the
evaporator - compressor damage is
immanent
High Superheat means liquid is boiling off
too soon and could mean evaporator is
starved
As Little As...
As Much As...
Sub-cooling and
Superheat
Indoor Coil Outdoor Coil
High Pressure,
High Temperature
Vapor
Saturated
Vapor
High Pressure,
Sub-cooled Liquid
Low Pres.
Liquid
Saturated
Vapor
Superheated
Vapor
minus -
LL Pres. to Saturation
LL Temperature
equals =
Sub-cooling
Basic Refrigeration Circuit
Properly Charged Unit
SL Temperature
SL Pres. To Saturation
equals =
Superheat
minus -
Sub-cooling & Superheat
Calculation Explained
S
e
n
s
i
b
l
e

L
a
t
e
n
t

S
e
n
s
i
b
l
e

S
e
n
s
i
b
l
e

L
a
t
e
n
t

55
10
45
76#
98
10
220#
108
What Happen If?
Over-Charged System
versus
Under-Charged System
Over-Charged System

High Sub-Cooling reading indicates excessive
amount of refrigerant in the condenser coil
Head pressure reading will be high
Saturation temperature will be high
Liquid line temperature at or near ambient
Unit will use excessive wattage to do the same
amount of work

If TXV is working properly, work at indoor coil will
be basically the same as properly charged system
and Superheat will be normal

Indoor Coil Outdoor Coil
High Pressure,
High Temperature
Vapor
Saturated
Vapor
High Pressure,
Sub-cooled Liquid
Low Pres.
Liquid
Saturated
Vapor
Superheated
Vapor
minus -
LL Press. to Saturation
LL Temperature
equals =
Sub-cooling
Basic Refrigeration Circuit
Over Charged Unit
SL Temperature
SL Pres. To Saturation
equals =
Superheat
minus -
Sub-cooling & Superheat
Calculation Explained
S
e
n
s
i
b
l
e

L
a
t
e
n
t

S
e
n
s
i
b
l
e

S
e
n
s
i
b
l
e

L
a
t
e
n
t

55
10
45
76#
118
17
316#
135
Under-Charged System
-Low Sub-Cooling reading indicates lack of
refrigerant in the condenser coil.
-Head pressure reading will be low
-Saturation temperature will be low
-Liquid line temperature will be high
-Unit will use excessive wattage due to do
extended run times to do the same work
-TXV will not work properly, due to lack of liquid
seal resulting in capacity loss

-Superheat will be high - coil starved.

Indoor Coil Outdoor Coil
High Pressure,
High Temperature
Vapor
Saturated
Vapor
High Pressure,
Sub-cooled Liquid
Low Pres.
Liquid
Saturated
Vapor
Superheated
Vapor
minus -
LL Press. to Saturation
LL Temperature
equals =
Sub-cooling
Basic Refrigeration Circuit
Under Charged Unit
SL Temperature
SL Pres. To Saturation
equals =
Superheat
minus -
Sub-cooling & Superheat
Calculation Explained
S
e
n
s
i
b
l
e

L
a
t
e
n
t

S
e
n
s
i
b
l
e

S
e
n
s
i
b
l
e

L
a
t
e
n
t

68
42
26
50#
95
0
182#
95
Mechanical
versus
Air Flow

Troubleshooting

Proper Tools
-Gauges
-Amp Probe
-Digital Thermometer
-Sling Psychrometer
-V-O-M
-Magnehelic
-Paperwork
Troubleshooting.
Verify AIR FLOW is proper
Identify problem
Observe and record operation of
equipment BEFORE adding gas!
When in doubt call for assistance
Slightly
Or Normal
75 IDB
63 IWB
95 OAT
75#
237#
5 DEG SH
8-13 SUB

Base Line Data
Customer Complaint:
System does not cool like it before
when it was new

What do you do?



+ Check the Enthalpy of the Evaporator
Coil to verify system capacity
Use the Formula:
Total Heat Removed =
CFM X 4.5 X Change in Enthalpy (Heat
Content)

Enthalpy
Same as TOTAL HEAT
The sum of sensible heat and latent
heat
Wheres the 4.5 come from?
Its how many BTUs are in one
pound of DRY air (0%Rh)
Total Heat =CFM X 4.5 X Enthalpy Change


69 WB=33.25
60 WB=26.46
Difference = 6.79
800 X 4.5 X 6.79
= 24,444 BTUH !
The 10% Rule
It is difficult to duplicate the
accuracy of factory laboratories
But, field results within 10% are
generally adequate.
Wall of Shame
Truth in Advertising