ftflocteS 7086

AIR CONDITIONINGS
REFRIGERATION
EDUCATION
.SYSTEM
Operating Instructions
And Experiments
TECHNOVATE
01O SOUTHWEST 12TH AVENUE POMPANO BEACH FL 33000 USA CABLE
TECHNOVA TEL 305 940 4470
1976
TECHNOVATE, INC,
PRINTED
i N U. S. A.
TECHNOVATE
PREFACE
The Air conditioning and Refrigeration Learning System, Model 7086, is a unique type of
learning system. . Its construction is such as to easily and conveniently allow all
phases of an air conditioning or heat puirip cycle to be observed, analyzed, changed or
made to malfunction. It is the most efficient way yet to learn the principles of air
conditioning and refrigeration.
Model 7086 is fully operational and is identical in many aspects to commerical air
conditioning and refrigeration equipment using Refrigerant- 12 in a closed compression
cycle.
Students can see changes taking place in the system. Glass tube "windows" in the inlet,
center and outlet sections of the evaporator and condenser coils allow students to
observe refrigerant behavior both as a liquid and a gas.
Operating conditions may be varied over a broad range by opening and/or closing the
valves that are strategically located throughout the learning system. These valves,
along with electrical faulting switches, allqw the introduction of operating
malfunctions that could conceivably occur in the field. Operating conditions can be
varied by changing speeds of the fan motors, under-or overcharging R-12, or introducing
excess oil into the system. Students then diagnose and correct these faults.
Paired thermometer and pressure gauges are located at strategic points in the
cycle. A flowmeter to measure rate of refrigerant flow is located in the liquid
line before the metering devices.
The student therefore can gather data on what is taking place both electrically and
mechanically in the cycle. He can easily understand and master the cycle operation.
Theroretical comprehension is further enhanced because the electrical circuit panel is
diagrammed completely and the windowed cabinet on the systems reverse side permits
this diagram to be related to the actual circuit wiring. .
TFTTfNOVATE
INTRODUCTION
USING THE SYSTEM
The Air Conditioning and Refrigeration "Learning System", Model 7086 is a fully
operational unit designed for classroom demonstration and student experiments. All
components (except the compressor) are mounted on a vertical panel so that their
functions and configurations may be studied separately. The learning system
complements any good text on air conditioning and refrigeration, including those
supplied by the various manufacturers of such equipment. The number and kind of
student experiments that can be created are limited only by the ingenuity of the
user. The "Learning System" is designed for lecture-demonstrations, for student
experimentation, and for learning the diagnosis and correction of a wide range of
malfunctions.
We believe that technical learning is most effective when the abstract, theoretical
principles taught in the classroom are closely matched with the actual physical
changes taking place in the system studied. The Air Conditioning and Refrigeration
"Learning System" allows the student to see, control, and measure the changes which
occur in a typical air conditioning or refrigeration system. Using this equipment
the student becomes his own teacher. His observations, tests, and experiments re-
inforce what he has learned from lectures and textbooks.
TEXTBOOKS
This manual parallels the treatment of the subject given in Modern Refrigeration
and Air Conditioning, Althouse, Turnquist and Bracciano, the Goodheart-Willcox Co.,
Inc., Homewood, Illinois. This manual may be used with any good text, however,
since the same basic principles are covered in most all air conditioning and
refrigeration texts.
CONDUCTING DEMONSTRATIONS
The Air Conditioning and Refrigeration "Learning System" is perfectly suited for
demonstrating the principles of air conditioning and refrigeration to both large and
small classes. Some topics that are particularly suited to this type of treatment
are:
(1) describing components of the system,
(2) explaining normal and reverse cycles,
(3) explaining temperature-pressure relationships throughout the
system,
(4) demonstrating heat flow within the system,
(5) demonstrating the various malfunctions commonly encountered
by service technicians.
Group Leader conducts the experiment
TECHNOmiE
3
Chalkboard diagram of the system in various types of operation will help students
understand what is happening. The layout of the system on the board makes it easy to draw
a schematic diagram with the schematic components in the same relative positions as the
"Learning System" components.
If the "Learning System" is ued for large classes the students should be allowed to examine the
system closely, particularly to see the changes of state occurring in the evaporator and
condenser. Experiments can be conducted by listing gauge and meter readings on the chalkboard
so that students can make their own calculations.
CONDUCTING EXPERIMENTS
When used for student experiment, one to five persons can use the "Learning System"
simultaneously. Three persons operating the "Learning System" is ideal; five persons is
maximum. If several persons use the device at once, it is suggested that they divide the duties
among themselves as follows:
Operator operates the controls
Reader (s) ---------------------------- reads the gauges and dials
Recorder (s) -------------------------- records gauge and dial readings
If the group contains more than five persons, the excess students should act as data recorders
to record gauge and meter readings. The readers should read temperature, pressure, and flow
rate readings aloud to the rest of the group.
RECORDING DATA
The method and technique of recording data is an important element in learning. The student
must learn to make precise observations, evaluate what he has observed, and draw the proper
conclusions. For the experiments in this manual, it is suggested that data be recorded in a
precise written form for each experiment.
In some experiments this may take a narrative form, stating the sequence of events, the time
intervals and describing what was observed. In other experiments data should be recorded in
tabular form, listing temperature and pressure readings. Later, this tabular data can be
plotted in graph form.
READING DIALS AND GAUGES
To obtain meaningful data from tests, accurate observations are necessary.
Be directly in front of meters and gauges when making readings. Take several and obtain an
average reading to record on the data sheet. Allow the unit to operate several minutes in any
condition before reading data. This allows the unit time to stabilize.
TECHNOVATE
4
DEVISING NEW EXPERIMENTS
The demonstrations and experiments suggested in this manual are general and may be
tailored to the needs of each class. Instructors can easily develop their own
experiments. In any subject there are always a few points that are particularly
difficult for students to grasp. Once the instructor has identified such a problem
area, he can prepare an experiment that will get right to the heart of the difficulty.
Students should als.o be encouraged to devise their own experiments. This requires that
the student (1) identify the problem, (2) plan a method of performing the experiment,
(3) perform the experiment, and (4) evaluate the results.
SAFETY
The Air Conditioning and Refrigeration "Learning System", Model 7086, has beem designed
to be as safe as possible both electrically and mechanically. The following are safety
features specifically incorporated into the design
(1) Main Power "Key" switch.
m Electrical overload protection.
(3) Compressor overload relay.
(4) High and low pressure control switch
(5) Transparent rigid shields over all sight glasses subject to

pressure.
(6) Excess pressure relief on all vessels.
(7) Oil tube is located so as to prevent inadvertent drain-down

below safe operating level.
In addition, most electrical components - including switches, relays and meters - are
enclosed in a power panel with a clear plastic cover for viewing with protection.
A-U Sight Tube, Refrigerant/Oil Seperator

A-l Sight Tube, Outside Coil
(inlet; cooling/outlet; heating)
A-2 Sight Tube, Outside Coil
(center; cooling/heating)
A-3 Sight Tube, Outside Coil
(outlet; cooling/inlet; heating)
A-4 Sight Tube, Flowmeter
A-5Sight Glass, Liquid Line
A-6 Sight Tube, Refrigerant Receiver
A-7 Sight Glass, Compressor Sump
A-3 Sight Tube, Inside Coil
(inlet; cooling/outlet; heating)
A-9 Sight Tube, Inside Coil
(center; cooling/heating)
A-10 Sight Tube, Inside Coil
(outlet; cooling/inlet heating)
A-12 Sight Tube,Oil Receiver
8-1 Access Fitting, High Side
B-2 Access Fitting, Low Side
C Compressor
0 Drier
F Flowmeter, Liquid Line
G-l Gauge, Outside Coil
(inlet
1
; cool ing/out let heating)
G-2 Gauge, Outside Coil
(outlet; cooling/inlet heating)
G-3 Gauge, Inside Coil
(inlet; cooling/outlet heating)
G-4 Gauge, Inside Coil
(outlet; cooling/inlet; heating)
H-l Fusible Plug, Refrigerant ffeceiver
H-2 Fusible Plug, Oil Receiver
H-3 Fusible Plug, Seperator
I Inside Coil
0 Outside Coil
Q . Reversing Valve
R-l Receiver, Refrigerant
R-2 Receiver, Oil
R-3 Seperator, Oil/Refrigerant
T-l Thermometer, Outside Coil
(inlet; cooling/outlet; heating) T-2
Thermometer, Outside Coil
(outlet; cooling/inlet; heating)
G4

T-3
T-4
U-
l
U-2
i
V-
l
V-
2
V-3
V-4
V-5
V-
6
v-
;
V-8
V-9
V-10
w
X
, z-
1
Thermometer, Inside Coil (inlet;
cooling/outlet; heating) Thermometer,
Inside Coil (outlet; cooling/inlet;
heating)
Check Valve'
Check Valve
Valve, Refrigerant Receiver By-Pass Valve,
Refrigerant Receiver Inlet Valve,
Refrigerant Receiver Outlet Valve,
Capillary Metering (Cooling Only)
Valve, Thermostatic Expansion (Cooling
Only)
Valve, Seperator Inlet Valve, Seperator By-
Pass Valve, Seperator Outlet Valve, Oil
Receiver Inlet Valve, Oil Receiver Outlet
Remote Bulb (TXV)
Thermostatic Expansion Valve Strainer
(Cooling Cycle)
Strainer (Heating Cycle)
Figure 1
Y- Capillary Feed tube

Figure 2

n-i Ammeter

H-e Wattmeter

M-3 Voltmeter
S-l Key Lock Switch
5-2 Toggle Switch

5-3
Hi-Lo Range Switch (Wattmeter)

S-4 Std-Back emf Switch (Voltmeter)

S-5 Inside Coil Fan Speed Switch (u-M-H)

S-6
Outside Coil Far Speed Switch (L-M-H) Figure 3
S-7 Low Pressure Control
S-8 High Pressure Control J-l Fan and Motor
S-9 Thermostat (Outside Coil)
S-l 0 Start Capacitor Take- J-2 Fan and Kotor
Out Switch (Momentary) (Inside Coil)
S-12 Compressor Thermal Overload
K Electrical Panel S-l 3 Reverse Cycle Solenoid
S-l 4 Start Relay F Flowmeter

TECHNOVATE
7
DESCRIPTION
GENERAL DESCRIPTION
The Air Conditioning and'Refrigeration "Learning System" is a complete, closed
compression cycle system, operating with refrigerant R-12. The system is comparable to
the most common commercial refrigeration and air conditioning systems and can be
reverse-cycled to demonstrate heat pump operation. Both refrigerant and oil can be
added or removed from the system by using storage reservoirs to demonstrate the effect
of undercharging or overcharging the system. Sets of paired temperature and pressure
gauges measure the conditions of the refrigerant at critical points in the cycle.
Valves located at strategic positions allow a wide range of operating conditions. The
components of the system are described in the following paragraphs. The letters in
parentheses after component names refer to the index letters in figures 1, 2, and 3.
Detailed specifications for the components are found in the Appendix.
MAJOR COMPONENTS
COMPRESSOR (A). The compressor is an
electric motor driving a pump; this
assembly is hermetically sealed (airtight)
in a metal shell. The pump compresses the
R-12 gas from a low temperature and pressure
to a high temperature and pressure. A special
sight glass (bullseye sight glass) has been
added to the front of the compressore to
allow observation of the oil level and show
the compatibility of R-12 with oil. The
oil line is located in the compressor sump
in a position to insure that minimum oil
requirement is maintained (20 ounces; 0.59!.)
CONDENSER (B). The condenser (outside coil)
is a device that removes heat from the refrig-
erant. (Assuming "cool" condition of the
system). It is basically a heat-exchange unit.
As heat is removed from the refrigerant gas, it
condenses into a liquid. This action can be
seen through the sight glass tubes at the top,
center, and bottom of the coil. When the
system is in operation, the refrigerant flows
TECHNOWTE
8
through the coil (from top to bottom) transferring heat to the fins. The fins transfer
the heat to the surrounding air. A variable speed fan provides the air flow over the
coil, thus speeding up the heat transfer.

MOISTURE AND LIQUID INDICATOR (C). This indicator is a sight
glass with a chemical dot inside. When moisture is present
in the system, the dot changes color as follows:
Green ------------------- dry system
Chartreuse ------------- caution
Yellow ----------------- wet system
The sight glass is also used to watch for bubbles in the
refrigerant. Presence of bubbles often indicates a shortage
of refrigerant or restriction in liquid line.
FLOWMETER (D). The flowmeter shows how much refrigerant is
flowing through the system. The meter is a conical, graduat-
ed glass tube containing a steel ball. The more refrigerant
flowing through the system, the higher the ball is forced in
the glags tube. The meter is read by sighting the graduations
on the glass with respect to the center line of the ball. Note
that the flow of refrigerant can be controlled by minutely adjust-
ing valve V-4 or V-5, depending on metering device used.
DRIER (E) The drier in the liquid line removes moisture, acid,
and dirt from the refrigerant. The unit consists of a screen
mesh filter to collect dust and dirt, and beads of silica gel
which absorb water. After extended operation, or if the
refrigerant is contaminated, the filter may become clogged,
reducing or stopping the flow of refrigerant. If the silica
gel becomes saturated, the color dot in the moisture and
liquid indicator (C) will turn yellow. When this occurs, the
filter-drier must be replaced.



CAPILLARY FEED TUBE (and strainer) (F
and W). The capillary feed tube (some-
times called cap tube")is the simplest
of metering devices. Basically, it is
nothing more than a deliberate restrict-
ion in the- liquid line - a small-diameter
section of tubing or a calibrated inside
diameter and length. The cap tube of the
Learning System is used for reverse cycle
operation as well. On most units the
length of the capillary is matched to
the capacity of the evaporator and
compressor. In this system, the capillary
TECHNOmiE
9
tubes are purposely made to permit extra flow of refrigerant so that flow may be
throttled down (with V-4) to stimulate a clogged or frozen line or to create
frostlines of varying lengths. A strainer at each end prevents clogging of capillary
tube by foreign matter.
n=^

THERMOSTATIC EXPANSION FEED VALVE
(TEV or TXV) (G). The thermostatic
expansion valve is a precision device
which serves the same purpose as the
capillary tube - it meters the flow
of refrigerant into the evaporator.
The system can be switched from capil-
lary operation to thermostatic expans-
ion valve operation by opening V-5
and closing V-4. A temperature-sens-
ing bulb (U) located on the evaporator
outlet line detects ths temperature of
the gas leaving the evaporator. The
bulb contains R-12 under pressure. A
change in temperature of the bulb changes
the pressure in the tube. This pressure
acts on a diaphragm inside the valve.
Movement of the diaphragm opens or
closes the valve, controlling the flow
of refrigerant into the evaporator. The
maximum flow may also be manually adjust-
ed by an adjusting (superheat) screw.
EVAPORATOR (H). The evaporator (inside coil) is identical
to the condenser except it operates in the reverse.
(Assuming "cool" condition of the system). The liquid
refrigerant evaporates (changes to a gas), and in so
doing absorbs heat from the tubes and fins. The tubes and
fins in turn absorb heat from the air passing over them
cooling the air. The amount of heat lost by the air is
the amount of .heat absorbed by the refriger ant as it
passes through the evaporator.
TANKS, VALVES, AND GAUGES
LIQUID REFRIGERANT RECEIVER TANK (J). This tank is a storage reservoir for surplus
refrigerant. By opening or closing the valves, refrigerant can be added to or withdrawn
from the system to overcharge or undercharge the system.
This is a convenient way to demonstrate the effects of these conditions. The tank has a glass
sight gauge to show refrigerant level and a fusible plug pressure relief,
rm
OIL AND REFRIGERANT ACCUMULATOR TANK (K). If the
evaporator is flooded, the excess liquid refriger-
ant (mixed with oil) is discharged into the tank.
This tank prevents liquid from entering the com-
pressor (which can only compress gas) and allows
the refrigerant to boil off, separating it from
the oil. Oil is then drained off to the oil storage
tank (L)
OIL STORAGE TANK (L). This tank is a duplicate of
the oil and refrigerant accumulator tank (K). It
stores oil in excess of that required to operate
the system. This excess oil (not needed in a
commercial air conditioning unit) is used to
demonstrate what occurs when too much oil is
introduced into a refrigeration system.
REVERSING VALVE (M). This pilot
operated, 4-way valve reverses
the cycle to demonstrate use of
the system as a heat pump rather
than an air conditioner. This
valve is activated by switch S-9.
ELECTRICAL SYSTEM PANEL DIAGRAM
(N). The electrical panel is
laid out in schematic order.
Most of the components occupy the
same position on the board as they
do in the schematic diagram. The diagram lines on the panel show circuit
layout. The back side of this panel is windowed (see Z) to show the wiring.
REFRIGERANT DISCHARGE OUTLET (Valve) (0) , REFRIGERANT CHARGE INLET (Valve)
(Q). These valves are for adding or removing refrigerant from the system
and would be used if the refrigerant became contaminated or if leaks occur
in the system. These valves may also be used to demonstrate charging and
purging a refrigeration system.
VALVES (V). Valves are located throughout the system to control the flow
of refrigerant. The functions of these valves are tabulated in "OPERATING
PROCEDURES."
PRESSURE AND TEMPERATURE GAUGES (P and T). These indicators are paired so
that pressure and temperature conditions can be determined at four critical
locations in the refrigeration cycle.


P-l, T-l
P-2, T-2
P-3, T-3
P-4, T-4
Compressor discharge and condenser inlet.
Condenser outlet and expansion valve inlet.
Evaporator inlet and expansion valve outlet,
Evaporator outlet and compressor suction.
the coils. The amount of water which condenses in a given time period
can be
TECHNOmTE
Compound pressure gauges
used at P-l through P-5.
These gauges indicate both
suction and pressure
and read from 30 inches of
mercury vacuum up to 200
psig. These gauges are
marked on the inner scale
to show R-12 temperature*


Temperature gauges are mounted with
their probes immersed in the refrigerant
stream to insure sensitive, accurate
readings.
CONDENSATE COLLECTOR TRAYS (R)* These trays collect water which condenses on used for study purposes. The trays drain into a reservoir in back of the unit
(see X). '
OTHER SYSTEM COMPONENTS
SWITCHES (S). Electrical switches are used to control the compressor motor, the
operation of solenoid valves, and to simulate faults in the system. The functions of
these switches are tabulated in "OPERATING PROCEDURES."
CONDENSATE RESERVOIR (X). The reservoir is used for storing atmospheric condensate
collected from coils in collector trays (R).
ELECTRICAL CORD (Y). The electrical cord is standard 3-wire with grounded male plug,
WINDOWED ELECTRICAL CABINET (Z). The rear of the electrical panel is closed with a clear
plexiglass sheet for easy student identification of electrical components and circuitry.
TECHNOmiE
12
REFRIGERANT
The system uses refrigerant-12 (popularly known as R-12) as designated by the American
Society of Heating, Refrigerating and Air Conditioning Engineers' Standards. It is
dichlorodifluoromethane (CCI2F2), end is one of the most widely used commercial refrigerants
today. This popularity is due to its suitability for use in the vapor compression cycle.
The thermodynamic properties of R-12 are given in E.I. du Pont de Nemours Co. Bulletin No.
T-12S. Briefly, R-12 boils at -21.7F at atmospheric pressure, and condenses at moderate
pressures under normal operating temperatures. The fact that R-12 has a relatively small
heat of vaporization value is not a serious disadvantage. In fact, in small systems the
greater weight of refrigerant R-12 which must be circulated is a decided advantage in that
it permits closer control of the liquid. Even in a large system, the reduction in compressor
displacement by using refrigerant 22 or 500 is not important.
The safety properties of refrigerant R-12 are a matter of record with such organizations as the
American Standards Association (ASA B9 Safety Code) and the National Board of Fire
Underwriters. In fact, refrigerant R-12 is considered safe, non-toxic, non flammable and non-
explosive. Furthermore, it is a highly stable compound, even under extreme operating
conditions. It will, however, break down into a dangerous gas (phosgene) if brought into
contact with an open flame or an electrical heating element.
The effects of moisture present a great problem. Halocarbons hydrolyze slightly, and will form
small amounts of acids. The amount of moisture must be maintained below the level which would
cause freeze-ups, which generally is a safe level to prevent corrosion. Dryers installed in a
closed circuit have proven very satisfactory.
Oil is miscible (mixes) with refrigerant R-12 at all normal operating conditions. In liquid
lines the oil-refrigerant mix flows without any problem.
Gas lines must be designed to operate at a velocity that will carry the oil along. The minimum
velocity in vertical upflow suction lines, to assure oil flow with gas flow, has been found to
be 1,000 feet per minute.
Leak detection is done in three ways. The old reliable soap bubble test works well, as all
portions of the refrigerant R-12 system can be pressurized. For very small leaks, either a
halide torch or an electronic tester may be used.
When shipped from the factory, the Model 7086 Air Conditioning and Refrigeration "Learning
System" has the following amount of R-12 and oil.
Normal charge of refrigerant R-12 --------- 26 ounces (0.774)
Extra refrigerant R-12 in receiver 26 ounces (0.774)
Normal charge of oil -------------
Extra oil in receiver storage
20 ounces (0.594)
16 ounces (0.424)
TECHNOVATE
13
OPERATION
MODES OF OPERATION
The Air Conditioning and Refrigeration "Learning System" operates in three general modes
of operation: normal capillary cooling, thermostatis expansion valve cooling, and
capillary tube reverse cycle heating. In addition, both oil and/or refrigerant can be
added to, or removed from, the system by connecting respective storage reserviors to the
system.
INSTALLATION
Connect the system to a 115-volt, single-phase, 60 hertz, 3-wire source by means of the
cord and plug (Y) furnished. This power source should be protected for 25 amperes service
with a time delay fuse or circuit breaker. If the system is supplied for other
voltage/phase/hertz connect accordingly.
CONTROLS
Switches and valves used to control the operating modes of the system are described in
figures 4 and 5. Figure 6 tabulates the positions of these controls for the various modes
of operation. Normally, all valves are opened or closed to a light stop. However, all
valves can be opened or closed to minutely regulate refrigerant flow at any part of the
cycle.
PRE-START INSTRUCTIONS
Before starting, set all valves and switches to the positions listed in figure 6 under the
column heading "prestart". With the valves and switches in prestart position, open the
valves indicated in the table for the mode of operation desired.
TECHNOmTE
14
SWITCH FUNCTION
S-l
Key lock switch to prevent unauthorized use. Turn clockwise to energize
main power lines.
S-2
Main power switch and 25 ampere circuit breaker. When placed in the up
position (on), supplies power to all components.
S-3
Wattmeter range selector switch. Selects high or low wattmeter range.
CAUTION: Keep switch in HIGH POWER position during normal operation to
prevent damage to meter mechanism. Switch to low range only if wattmeter
reading on high range is below 750 watts.
S-4-
Voltmeter mode select switch. Connects the voltmeter to measure either
LINE VOLTAGE or BACK EMF
S-5
S-6
Fan speed selector switches for condenser and evaporator. Switches have
four positions: off (0), low (L), medium (M), high (H).
S-7
Low pressure cut-out control. Stops compressor if low side pressure falls
below 7 psi (48 KPA)
S-8
High pressure cut-out control. Stops compressor if high side pressure
exceeds 225 psi (1550 KPA).
S-9
Reversecycle thermostat switch. When placed in warmer position, switch
activates the solenoid (S-13) in the reversing valve (M( which reverses
refrigerant flow for reverse cycle operation.
S-IO
Compressor power switch. Starts and stops compressor motor and lights
indicator lamp.
S-ll
Start capacitor switch. Normally closed momentarily open push button
switch for taking the start capacitor electrically out of the circuit.
S-12
Automatic compressor thermal overload relay. Stops compressor if motor becomes
overheated. Located in compressor electrical outlet box.
S-13
Solenoid which operates the four-way reversing valve (M). Solenoid is
energized by switch S-9.
Figure 4. Switch Functions
TECHNOVATE
S3
15
VALVE FUNCTION
V-l
Liquid refrigerant receiver tank bypass valve. Open to bypass liquid
refrigerant.receiver tank.
V-2
Receiver inlet valve. Open to pump refrigerant into reservoir.
V-3
Receiver outlet valve. Open to pump refrigerant out of reservoir and
into system.
V-4
Normal cycle capillary selector valve. Open to select normal cycle
capillary tube operation. NOTE : This valve can be used as a metering
valve to change rate of refrigerant through capillary. This in effect
simulates changing the length of the capillary.
V-5
Thermostatic expansion valve selector valve. Open to select
thermostatic expansion valve operation.
V-6 Accumulator inlet valve. Open to bypass accumulator tank.
V-7 Accumulator bypass valve. Open to bypass accumulator tank.
V-8
Accumulator outlet valve. Open to allow liquid refrigerant to boil
off and return to the system as a gas.
V-9
Accumulator oil drain valve. Open to allow oil to drain from
accumulator tank to oil storage tank.
V-10 Oil storage tank outlet valve. Open to add oil to system.
Figure 5. Valve Functions
16
SWITCH OR VALVE
SWITCH OR VALVE POSITION FOR OPERATING MODE
.. ...................................................................................................... 1
No. Name Pre.start
Normal
Capillary
Normal
TXV
Reverse
Cycle
Stop
3

V-l Receiver Bypass closed open . closed .open/closed closed
V-2 Receiver Inlet closed closed open open/closed
3
open
V-3 Receiver Outlet closed closed open open/closed closed
V-4 Capillary Control closed open closed closed closed
V-5 TXV Control closed closed open open/closed open
V-6 Accumulator Inlet closed closed

closed open
V-7 Accumulator Bypass closed open open open closed
V-8 Accumulator Outlet closed closed closed closed closed
V-9 Oil Drain closed closed closed closed closed
V-10 Oil Outlet/Return closed closed closed closed closed
V-ll R/V check
A A A A A
V-12 R/C check
A A A A A
S-l Key Lock CCW(off)

CW(on)

CCW(off)
S-2 Main Power down(off)

up(on)

down(off)
S-3 Wattmeter Select HIGH POWER

S-4 Voltmeter Select LINE VOLTAGE
S-5 Condenser Fan 0 (off) as desired
High (H) or
Medium (M)
0 (off)
S-6 Evaporator Fan 0 (off) as desired
High (H) or
Medium (M)
0 (off)
S-7 Low pressure Cont
AA AA AA AA AA
S-8 High Pressure Cont
AA AA A A AA AA
S-9 Thermostat cool(CW) cool(CW) cool(CW) heat(CCW)
either (CW or
CCW)
S-10 Compressor on on on. on off
S-11 Start Capacitor
AAA AAA AAA AAA AA
Figure 6. Valve and Switch Positions for Operating Mode
TECHNOmTE
17
NOTES FOR FIGURE SIX
* Check valve - opens automatically
when required
** Normally closed contacts - no attention
required .
*** Normally closed - momentary open - used
for faulting
Always energize the electrical system from left to right on
the panel and de-energize from right to left.
1. Position key-lock switch S-l clockwise (on) and observe that only
the large Red panel lamp is lit indicating power available. If any meters
or other pilot lights are energized, turn S-l counterclockwise (off) and
repeat the prestart settings in figure 6.
2. Flip main power switch S-2 up (on). Voltmeter should indicate
approximately 115 volts (or line voltage if other than 115-V).
C A U T I O N
DO NOT OPERATE WITH LESS THAN 103 VOLTS OR MORE
THAN 126 VOLTS.
3. Position fan motor switch S-5 to M (medium). Verify that condenser
fan operates at medium speed.
4. Position fan motor switch S-5 to L (low). Verify that fan now
operates at low speed.
5. Position fan motor switch S-5 to H (high). Verify that condenser
fan operates at high speed.
NOTE
Ammeter should read below 1 amp and wattmeter should
read approximately 75 watts (see step 7)
6. Repeat above procedure for fan motor switch S-6.
NOTE
Both fans are now operating. Ammeter should read below 2
amps and wattmeter should read approximately 150 watts (see
step 7).
7. Position wattmeter switch S-3 to LOW POWER to test wattmeter on low
scale and then return switch S-3 to HIGH POWER before continuing.
8. Position switch S-10 up (on). Compressor indicator light (IL-5) is
now energized. Compressor should now be functioning and the needle on pressure
gauges P-l and P-2 should start going up. The needle on pressure gauges P-3,
and P-4 should start going down. When operating in reverse cycle, gauges will
respond in opposite sense, as high and low pressure sides of unit change
positions.
To remove excess^ oil from the system close V-4 and V7; open V-8 and V-9.
V-2, V-5,.V-6 OPEN counterclockwise to a light
stop
TECHNOWTE
18
9. Allow system to run for 5 minutes. Close valve V-4 until no bubbles are present in
moisture indicator, flowmeter and the bottom tube on the condenser is full of
refrigerant. Open valve V-4 slowly until a flow rate of 1.0 to 1.5 P.P.M. is
indicated on the flowmeter. Gauges F-l and P-2 should read between 120/140 psig;
if not open V-3 to allow more refrigerant into the system. Close V-3. Allow a few
minutes for system to settle. Repeat until desired pressure is obtained. If too
much pressure is obtained, slowly open V-2 and bleed off desired amount of
refrigerant into reserve tank.
ADDING AND REMOVING REFRIGERANT
Operate the system for about 5 minutes in normal cycle capillary operation (see figure
6). Add refrigerant to the system by opening valve V-3. When sufficient refrigerant
has been added (to fill sight glass) close valve.
To remove refrigerant from the system, slowly open V-2 and bleed off the excess
refrigerant into the reservoir. It is recommended that the sight glass of the reservoir
be marked to show when a normal charge is in the system. This will make it easy to
return to normal charge if the system is over - or undercharged.
ADDING AND REMOVING OIL
To add oil to the system, momentarily open valves V-6 and V-9 so that the pressure in
the accumulator and oil reservoir is equal to suction line pressure. Close valve V-4
and V-5, when suction line pressure is between 10 psi and. 0 psi, open valve V-10. Oil
will flow from the oil reservoir to the compressor crankcase. When the oil has been
added, close V-10 and open V-4 or V-5. If foam appears in the bullseye, there is some refrigerant
in the oil and it is boiling out. This is a normal reaction; observe that
the R-12 and oil are completely miscible.
After 15-30 seconds slowly open V-10. After the desired amount of oil has been removed
close V-10, V-8 and V-9; open V-7
SHUTDOWN INSTRUCTIONS
These instruction apply when system is in "cooling" mode of operation. Pjosition
valves as follows:
V-l, V-3, V-4 )
V-7, V-8, V-9 ) CLOSE clockwise to a light stop.
V-10 )
TECHNOmTE

19
Allow refrigerant level to build up in liquid refrigerant receiver tank (J), compressor
may stop if low side pressure drops below 7 psi (48 KPA); then close V-2. Position
switches as follows and in the indicated sequence (right to left)
Valves V-l through V-10 can be adjusted to regulate refrigerant flow as
necessary. In normal practice, most valves are left fully open or fully
closed.
The high pressure cut-out switch (S-8) stops the compressor if the high
side pressure exceeds the cut-out setting and restarts when the pressure
drops.below the cut-in setting. This switch has been preset to stop the
compressor motor at 225 psig (1550 KPA). Higher pressures may damage
bourdon tubes in the pressure gauges. The low pressure cut-out switch
(S7) stops the compressor if the low side pressure fails below 7 psig
S-
10
S-6
S-5
S-2
S-l
Down (off)
0 (off)
0 (off)
Down (off)
Counterclockwise (off)
MANUAL ADJUSTMENTS
(48 KPA).
Start the system using the starting procedure for normal cycle
PURPOSE : To show how the system operates using a
thermostatic expansion
Start the system using the procedure for thermostatic expansion
TECHNOWTE
20
DEMONSTRATIONS AND EXPERIMENTS
INTRODUCTION
Demonstrations and experiments in this section are in three categories: demonstrations
for large classes illustrating basic principles, general experiments for shop or lab
designed* to familiarize students with fundamentals, and servicing experiments
designed to teach a logical approach to troubleshooting in the field. The
demonstrations require observation by students but no calculations. The general
experiments require data recording, calculations and evaluation. Servicing experiments
show the cause and effect relationships of various types of malfunctions.
DEMONSTRATIONS
DEMONSTRATION 1 - Capillary Tube Operation (Normal Cycle)
PURPOSE : To show how the system operates with a capillary tube metering
device.
PROCEDURE :
capillary tube operation. Allow unit to run for 5 minutes to stabilize.
(2)
Observe refrigerant flow rate at flowmeter (D) and the temperature
pressure of the refrigerant entering and leaving the evaporator
(T-3, P-3, T-4, and P-4).
(3) Operate evaporator fan at various speeds and observe charge in
temperature and pressure.
DISCUSSION : All elements of the system can be seen in operation. Most
textbook discussions start at some point in the cycle and follow the
refrigerant around the closed loop. The cycle can be demonstrated using this
same sequence. The condition of the refrigerant is shown by temperature and
pressure readings at critical points in the cycle. Condensation and
evaporation can be seen taking place through the sight glasses.
DEMONSTRATION 2 - Thermostatic Expansion Valve Operation (TXV)
valve metering device.
PROCEDURE :
valve operation. Allow the unit to run for 5 minutes to stabilize.
TECHNOVATE
21
(1) Observe refrigerant flow rate on the flowmeter (d), and the
temperature and pressure of the refrigerant entering and leaving the
evaporator (T-3, P-3 and T-4, P-4).
(2) Operate fan at various speeds and observe changes in flow rate,
temperatures and pressures.
DISCUSSION : The thermostatic expansion valve controls the flow of refrigerant
in response to temperature changes of the sensor bulb. Warmer temperature causes the
valve to open, cooler temperature causes the valve to close. When the fan speed is
increased, the temperature load of the evaporator is raised, and the valve opens to
let more refrigerant flow through.
DEMONSTRATION 3 - Reverse Cycle Operation
PURPOSE : To show reverse cycle or "heat pump" operation (capillary tube only).
PROCEDURE :
(1) Start system using the starting procedure for normal cycle expansion
valve operation. Allow the unit to run until cold air comes from the
evaporator.
(2) Insure that V-4 is closed. Move thermostat (S-9) knob from "cooler"
to "warmer".
(3) Observe reversal of refrigerant flow through sight glasses and note
that functions of the condenser and evaporator are reversed.
(4) Observe temperature and pressure changes in the system.
Note : Flowmeter (D) is not in the circuit so flow rate is not
observed.
DISCU.SSION : Reverse cycle operation reverses the functions of the inside
coil (evaporator) and outside coil (condenser), The cycle is actually the same
but the refrigerant is rerouted. Nothing in the cycle has changed except the
intended use of the system; i.e., heating is desired in this case instead of
cooling.
DEMONSTRATION 4 - Heat, Cold and Temperature
PURPOSE : To demonstrate the concepts and heat, cold, and temperature with
respect to air conditioning and refrigeration systems.
PROCEDURE :
(1) Start the unit using the procedure for normal cycle capillary tube
operation. Allow the unit to run for 5 minutes to stabilize.
(2) Record the temperature at each measuring point in the system.
(3) Place a thermometer in front of both evaporator and condenser, and
measure temperature of air.
DISCUSSION : Heat is a form of energy evidenced by molecular motion. Cold
is the absence of heat. Temperature is an arbitrarily selected scale to measure the
level of heat energy. A change in temperature indicates a gain or loss of heat energy.
Heat only flows from a body of higher temperature to a body of lower temperature
(second Law of Thermodynamics) Heat eneters the system through the evaporator and
through the compressor in the form of electrical energy. Heat leaves the system
through the condenser and through heat losses in the pipes. When the gas is
compressed, energy is added to the gas by the motor (heat of compression) This same
heat is removed in the condenser.
DEMONSTRATION 5 - Changes of State
PURPOSE : To demonstrate the concept of change from liquid state to gas state
and back to liquid state.
PROCEDURE :
Start the unit using the procedure for normal cycle capillary
tube. Allow the unit to run for 5 minutes to stabilize.
Close valve V-4 slowly until the temperature on T-4 is exactly
equal to the temperature of T-3 (phase change at constant
temperature, i.e., no superheat).
Record the temperatures and pressures entering and leaving both
the condenser and the evaporator.
DISCUSSION : Of the three states of matter, solid, liquid and gas, only 'the liquid gas
states are important in refrigeration and air conditioning.
A refrigerant is chosen for several reasons, one of which is the temperature that it
changes from liquid to gas (boiling point). Changes of state are the result of heat
energy transfer to or from the refrigerant Addition of heat from the air causes
boiling; extraction of heat to the air causes condensation. The temperature at which
this process takes place is related to the pressure. A vapor which is evaporating from
or condensing to its liquid state is said to be a "saturated" vapor. These
temperature-pressure relationships for R-12 are given here for reference.
(D
(2)
(3
)
DEMONSTRATION 6 - Specific Heat, Sensible Heat, Latent Heat, and Superheat
PURPOSE : To demonstrate the concepts of specific heat, sensible heat, latent
heat and superheat.
PROCEDURE :
(1) Start the unit using the procedure for normal cycle capillary
tube operation. Allow the unit to run for 5 minutes to stabilize.
(2) Close valve V-4 slowly until temperature T-4 is exactly the same
as T-3 (no superheat).
(3) Close V-4 further until there is a 20-degree temperature difference
between T-3 and T-4 (20 degree superheat).
TECHNOVATE ______________________________________
23

DISCUSSION : Specific heat is a measure of how much heat a fixed amount of
a certain substance can hold. Specific heat is normally measured in terms of the
amount of heat needed to raise the temperature of one pound of a substance one
degree Fahrenheit without changing state (Btu/pound). Sensible heat is any amount
of heat added or subtracted to a substance to raise or lower the temperature
without changing state. Latent heat is the amount of heat required to change state
without changing temperature. Superheat is merely sensible heat added to the gas
after it has evaporated. The heat being absorbed by the evaporator consists of two
parts: (1) that due to the latent heat, and (2) that
due to sensible heat (superheat) added. The heat being absorbed by the evaporator
can be calculated as follows:
heat absorbed = (flow rate)(latent heat) + (flow rate) (specific heat) (sensible
heat)
TECHNOVATE
24
GENERAL EXPERIMENTS
EXPERIMENT 1 - Determination of Superheat
PURPOSE : To determine how to measure superheat; to assess the factors
controlling the amount of superheat; to learn the effects of superheat.
PROCEDURE :
(1) Start the system using the starting procedures for normal cycle capillary
operation. Allow the unit to run for 5 minutes to stabilize. Turn
evaporator fan to low. Condenser fan to medium or high.
(2) Close valve V-4 slowly until the temperature of T-4 reads the same as T-
3. In this condition there is no superheat in the evaporator.
(3) Turn evaporator fan to medium. After two minutes record temperature; T-3 and T-4.
The temperature difference is the amount of superheat added to the vapor.
(4) Open V-4 slowly until T-3 and T-4 have the same temperature. Turn
fan speed to high. Record the readings and repeat the procedure switching
fan to high.
(5) Close V-4 until temperature differential is 40F. Let unit run for
10 minutes in this condition.
EVALUATION : Superheat is additional heat (sensible heat) added after the
liquid is completely evaporated. The superheat of the vapor can be changed either
by changing the refrigerant flow with valve V-4 or the air flow over the evaporator
coil. Tabulate the temperature reading and determine superheat for each condition
(T4 minus T-3). Calculate the amount of heat added per hour to the system as
superheat.
Heat added - (flow rate)(specific heat) (temperature change)
EXPERIMENT 2 - Work, Energy and Power
PURPOSE : To determine the power requirements for the system.
PROCEDURE :
(1) Operate only the fans (high speed) and record the wattmeter reading
(2) Start the system using the precedure for normal cycle capillary
operation and allow it to run for 5 minutes to stabilize.
(3) Read and record the wattmeter reading.
(4) Subtract the wattmeter reading for fans (step 1) from wattmeter
reading (step 3), Convert watts to both horsepower and Btu/minute.
EVALUATION : Energy is the capacity to do work. Work is defined as force
(mechanical energy) multiplied by the distance traveled. Work can be
expressed as mechanical work (foot-pound) or heat work (Etu).
Power is the time rate of doing work (foot-pound per minute, Btu per minute). The
wattmeter reading, less the power drawn by the fans, is the power being drawn by
the compressor motor. This is the heat energy (except for friction and other
losses) being added to the system.
EXPERIMENT 3 - Condenser Heat Rejection
PURPOSE : To calculate the heat (Btu/min) rejected by the condenser into the
air.
PROCEDURE :
(1) Start the system using the procedure for normal cycle capillary operation.
Allow the unit to run for 5 minutes to stabilize.
(2) Measure the average velocity of air passing over the condenser with a pitot
tube or velocimeter. Take numerous readings to get a good average,
(3) Measure the temperature of the air entering and leaving the
condenser.
(4) Calculate the pounds per minute of air flowing past the condenser as
follows:
a. cu ft/min = (air velocity) (area of fan)
b. lb air/min = (cu ft/min) (density of air)
c. density of air = 0.075 Ib/cu ft
(5) Calculate heat rejected by the condenser as follows:
a. heat rejected = (lb air/min)(specific heat of air)
(temperature difference of air)
b. heat rejected = Btu/min
c. specfic heat of air - 0.24 Btu/lb/F
(6) Check this answer by determining the heat rejection in another
manner as follows: Record T-l, P-l, T-2, P-2 and refrigerant
flow rate.
(7) Calculate heat rejected as follows:
a. heat rejected = (latent heat) + (sensible heat)
b. latent heat = (latent heat of vaporization)(flow rate)
c. sensible heat = (specific heat vapor)(flow rate)
(temperature difference) + (specific heat liquid)
(flow rate)(temperature difference)
TECHNOWTE
26
EVALUATION : Heat is transferred from the hot refrigerant vapor to the
condenser tubes and fins and finally to the air. In steps 2 through 5, this rate
of heat rejection is calculated by measuring the amount of heat picked up by the
air. In steps 6 and 7,the rate of heat rejection is calculated by measuring the
amount of heat given up by the refrigerant. Differences between the two values
obtained can be due to several factors: un-measured heat loss from the tubing
leading
to and from the condenser, inaccuracies in measuring air flow rate and/ or
temperature.
EXPERIMENT 4 - Evaporator Heat Absorption
PURPOSE : To calculate the heat (Btu/min) absorbed by the evaporator from the
air.
PROCEDURE :
(1) The procedure is essentially the same as in experiment 3 except that
measurements are made at the evaporator.
(2) Compare the results of this experiment with the results of
experiment 3.
EVALUATION : The same principles apply in evaporator heat absorption as in
condenser heat rejection (experiment 3) except that the process is reversed.
Theoretically, in a completely insulated system, the difference between the
heat given off by the condenser and the heat gained by the evaporator would
be the energy added to the system to run the compressor. That is, the
condenser heat loss should be the sum of the evaporator heat absorption plus
the watts needed to run the compressor motor.
EXPERIMENT 5 - Evaporator Heat Absorption (Alternate Method)
PURPOSE : To calculate evaporator heat absorption by a different method.
PROCEDURE :
(1) Using a psychrometric chart, determine the change in total heat content
(Btu/lb of dry air) using the wet bulb readings entering and leaving the
evaporator. The total heat content is the difference in enthalpy between the
entering and leaving wet bulb temperatures.
(2) Change the Btu/lb of dry air to Btu per cubic foot of dry air by
multiplying the Btu/lb of dry air by the specif density (lb/ cu ft) of the
air.
The specific density (Ib/cu ft and dry air) is the reciprocal of the
specific volume. The specific volume can be obtained from a psychrometric
chart using the wet and dry bulb temperatures of the leaving air.
except that the psychrometric chart makes allowance for
moisture in the air.
If the system is in use, turn off system and allow it
to sit idle
TECHNOWTE
27
(3) Multiply the cu ft/min by the change in total heat content across the
evaporator expressed in Btu/cu ft of dry air to determine the Btu/min.
heat absorption = (cu ft/min) (Btu/cu ft)
EVALUATION : This experiment is similar to experiment 3, steps 2 through 5,
EXPERIMENT 6 - Time to Reach Steady State
PURPOSE : To determine how long it takes the system to reach stead-state
conditions.
PROCEDURE :
for at least one-half hour.
(1) Record all temperature and pressure readings, prior to start-up.
(2) Start the system in normal cycle, capillary tube operation and
record all temperature, pressure and flow readings every 30 seconds
for 5 minutes.
(3) Plot a graph for each gauge showing temperature or pressure on the
vertical scale and time on the horizontal scale.
EVALUATION : Each time a change is made in the operation system, it takes a
certain time for the system to stabilize. When the system is stabilized,
heat flow is steady, neither increasing nor decreasing.
EXPERIMENT 7 - Thermostatic Expansion Valve Operation
PURPOSE : To show the operation of a thermostatic expansion valve, the effect
of evaporator and condenser air flow variations.
PROCEDURE :
(1) Start the system using the procedure for normal cycle, thermostatic
expansion valve operation. Turn both fans to high.
(2) After 5 minutes warmup time, record the readings on the following gauges every 30
seconds for 5 minutes: flow meter, P-2, P-3, T-2, T-3.
(3) Switch the evaporator fan from high to medium, then to low. Leave the switch
in each position for 5 minutes and record readings on the flow meter, P-2, P-
3, T-2, and T-3 every 30 seconds.
(4) Plot a graph of each gauge and the flow meter showing flow rate or
pressure on the vertical scale and time on the horizontal scale. Plot
all graphs on a common time scale.
TECHNOVATE
28
EVALUATION : The thermostatic expansion valve opens and closes, increasing
or decreasing refrigerant flow in response to the temperature changes of the
sensor bulb.
EXPERIMENT 8 - Determination of Efficiences
PURPOSE : To determine the volumetric efficiency and the coefficient of
performance of the system.
PROCEDURE :
(1) Start the system using the procedure for normal cycle capillary
operation. Allow the system to run for 5 minutes to stabilize.
(2) Determine volumetric efficiency (percent) as follows:
volumetric efficiency = (actual volume pumped) (100)
theoretical volume pumped
= lb/min ____________
(pump displacement)(rpm)
Volume actually pumped can be obtained directly from,the flowmeter.
Theoretical volume pumped is obtained by multiplying the pump displacement
by the rpm of the motor.
(3) Determine the coefficient of performance as follows:
coefficient of performance = refrigerant effect
compressor power
= (flow rate)(enthalpy change)
watts
Flow rate and watts can be obtained directly from the flowmeter and
wattmeter. Watts are converted to Btu/min by multiplying by 0.05692
Btu/min/watt, Enthalpy change consists of two parts : enthalpy due to the
effective latent heat of vaporization, and enthalpy due to superheating the
vapor. Effective latent heat is the total latent heat of vaporization at the
temperature and pressure of the evaporator minus the heat required to cool
the refrigerant from temperature T-2 to T-3.
enthalpy change = [(latent enthalpy at temperature T-3) - (liquid
enthalpy at temperature T-2)] + (difference
between vapor enthalpy at T-4 and vapor enthalpy at
T-3)
EVALUATION : Volumetric efficiency is a measure of the compressor efficiency.
Losses are due to gas frction, imperfections in the design of valves, and
incomplete filling and exhausting of the cylinder on each stroke. Coefficient
of performance is a measure of how much energy must be expended to pump the
heat.
TECHNOVATE
29
SERVICING EXPERIMENTS
SERVICING EXPERIMENT 1 - Effect of Excess Refrigerant in System
PURPOSE : To show what effect an overcharge of refrigerant has on system
operation.
PROCEDURE :
(1) Operate the system in normal cycle capillary operation. Allow unit to run
for about 5 minutes to stabilize.
(2) Read and record the condenser pressure, P-2,and wattmeter reading.
(3) Bleed some refrigerant out of system by opening valve V-2, Run
5 minutes and again read and record P-2 and wattmeter readings.
(4) Overcharge system with R-12 by opening valve V-3. This may be hastened by
opening valve V-5 allowing greater flow of R-12 to the evaporator. When
desired refrigerant is in system, close V-3.
(5) After stabilization, read P-2 and wattmeter.
(6) Compare pressure and wattmeter readings.
NOTE : To remove excess refrigerant from the system, open valve V-2,
when refrigerant level in tank R-l is satisfactory, close valve V-2.
EVALUATION : Increasing the refrigerant in the system increases the load on
the compressor, causing it to draw more power.
SERVICING EXPERIMENT 2 - Effect of Excess Evaporator and Condenser Load
PURPOSE : To show the effect of excess refrigerant (flooding) in the evaporator
and condenser.'
PROCEDURE :
(1) Operate the system for 5 minutes with a normal refrigerant charge in normal
cycle capillary operation with both fans on medium (M).
(2) Record all temperature and pressure readings, flowmeter reading, and
electrical meter readings.
(3) Turn evaporator fan speed control to H, M, and L positions. Allow system to
stabilize with the fan operating at each speed and record readings on all
gauges and meters. Turn evaporator fan speed back to M and switch the
condenser fan through the same three speeds.
Allow the unit to stabilize and take readings of all gauges and meters at each
of the three fan speeds.
EVALUATION : When the evaporator is flooded, the low side pressure rises and
SERVICING EXPERIMENT 4 - Effect of Defective Start Capacitor
TECHNCWTE
30
evaporation takes place at a higher temperature. When the condenser is flooded,
the high side pressure increases and excessive superheat is added in the
evaporator. In both cases the compressor works harder and draws more power.
SERVICING EXPERIMENT 3 - Effect of Excess Oil in System
PURPOSE : To show the effect of too much oil in the system.
PROCEDURE :
(1) Operate the system in normal cycle capillary mode. Allow system to run for
5 minutes. Record temperature and pressure readings throughout the system.
(2) Add excess oil (see OPERATION page ) to the system until the
oil level in the compressor reaches the top of the bullseye sight
glass.
(3) Operate the system for 5 minutes and re-read temperatures and
pressures.
EVALUATION : Excess oil in the system has the effect of reducing flow through
the .capillary tube.
NOTE : To remove excess oil see OPERATION, page
PURPOSE : To show the effect of a defective starting capacitor.
PROCEDURE :
(1) Put system in normal cycle prestart position except Push and
Hold switch S11 in. Perform start-up sequence.
(2) Observe action of fans, compressor motor, and thermal overload
relay in compressor electrical connection box. Observe ammeter and
wattmeter readings.
EVALUATION : Condenser and evaporator fans will operate; compressor motor
may hum but will not start; thermostatic overload relay in compressor electrical
box will cycle. This will be seen by readings of ammeter and wattmeter.
The use of a start capacitor in series with the start winding causes
the current in thewinding to lead the voltage, whereas thecurrent
in the running winding lags the voltage because of the high inductance of the
winding. This causes the phase displacement to approach 90 degrees so that true
two-phase starting is achieved. For this reason the starting torque is very high,
which makes it ideal for small compressors that must start under full load.
L (low)
31
APPENDIX
TECHNICAL DATA
(subject to change without notice)
COMPRESSOR
Ma'e and Model' ..................
Bore ............................
Stroke ..........................
Displacement ....................
Oil capacity (Suniso 3GS) ...
Motor Ratings :
Horsepower ..................
Electrical Characteristics
RPM .........................
CONDENSER, EVAPORATOR
Fins:
Material ....................
Number ......................
Thickness ...................
Tubing :
Material ....................
Number (passes) ..............
Length of Pass ...... .......
Size ........................
Fan:
Blades (propeller type
Number ......................
Pitch .......................
Diameter ....................
Motor :
Type ........................
Electrical Characteristics
Speed
H (high) .................
M (medium) ..............
FLOWMETER
Construction ...................................... Aluminum frame, copper fittings,
& Buna "N" seals pyrex tube
Range (Ib/min R-12 @ 100F & 131.86 psig) .. 0.5 to 3.0 lb/min
FILTER-DRIER
aluminum 14 per inch 0.010
in,
copper
20
12 in.
3/8 in.od,(0.016 in. wall)
3
27 degrees 12
in. nominal
shaded pole (1/30 HP)
115 v, 60 cps, 1.0 amp
1500 rpm (prox)
1025 rpm (prox)
800 rpm (prox)
Copeland, Model JRL4-0050-1AA
1.550 in.
0.625 in.
1.178 cu. in.
20 fluid oz.
1/2 hp
115 v, 60 Hz, 9.7 amps 3500
Material
Capacity
Fillant
brass/copper
5 cu in.
silica gel
Outlet 1/2 in, SAE
Type Toggle, DPST
Cutout 225 psig
Cutout 7 psig
Type Toggle, SPST
32
CAPILLARY FEED TUBE (and strainers)
Strainer ................. , ................... 2
Rated ......................................... 1/2 ton
THERMOSTATIC EXPANSION FEED VALVE
Type and Model ................................ TCL5()FW55
Range ......................................... +50F to -40F
Rating ........................................ 1/2 tons
Threads
Inlet ...................................... 3/8 in. SAE
LIQUID REFRIGERANT RECEIVER TANK, OIL AND
REFRIGERANT ACCUMULATOR TANK, AND OIL STORAGE TANK
Diameter ...................................... 2-15/16 in. id
Gauge Glass ................................... high pressure
REVERSING VALVE
Solenoid Characteristics ...................... 115 v, 60 cps, 9.5 watts
SWITCHES
S-l, Key Lock :
Type ....................................... Locking, DPST
S-2, Main Power On-Off (with circuit breaker):
S-3, Wattmeter Range Selector:
Type ....................................... Toggle, DPDT
Positions (2) ............................... 0 to 750 & 0 to 1500 watts
S-4, Voltmeter Selector :
Type ....................................... Toggle, SPDT
Positions(2) ............................... LINE VOLTAGE & BACK EMF
S-5, S-6, Fan Control :
Type ....................................... rotary, 4-position
Positions (4) ............................ 0 (off), H (high), M (medium),
S-7, S-8, Pressure Relief:
High
Reset ........................ ....... Auto
Low
Reset .............................. Auto
S-9, Reverse Cycle:
Type ....................................... Thermostat, DPDT
Positions(variable) ........................ Cooler, Warmer
S-10, Compressor ON-OFF :
S-ll, Start Capacitor (faulting)
Type ....................................... Push button SPST (M)
L (lo
Scale 0 to 200 psxg
Type - bi-metal
33
MISCELLANEOUS COMPONENTS
Capacitor
Start Capacitor :
Value .................. . ................. 233 to 280 uf
Rating .................................... 110 volts ac
PRESSURE GAUGES
Type .............................................. bourdon
Dial Diameter ..................................... 3-1/2 in,
Accuracy .......................................... 2%
TEMPERATURE GAUGES
Dial Diameter ............................ ........ 2 in.
Scale ............................................. 0 to 200F
Accuracy ...................
Althouse, Turnquist, and Bracciano, Modern Refrigeration and Air
Conditioning, The Goodheat-Wilcox Co., Homewood, Illinois
Dossat, Principles of Refrigeration, John Wiley and Sons, Inc.,
New York, New York.
Lang, Principles of Air Conditioning, Delmar Publishers, Inc.,
Albany, New York
Marsh and Olivo, Principles of Refrigeration, Delmar Publishers, Inc., Albany,
New York
Fundamentals of Refrigeration, Carrier Air Conditioning Co., Syracuse, New York.
(Sixteen pamphlets with companion colored slides, each covering a single basic
subject such as evaporators.)