(Audel technical trades series)rex miller, mark richard miller, edwin p anderson audel air conditioning home and commercial audel(2004)

TM

Audel

Air Conditioning: Home
and Commercial
All New 5th Edition



TM

Audel

Air Conditioning: Home
and Commercial
All New 5th Edition

Rex Miller
Mark Richard Miller
Edwin P. Anderson


Vice President and Executive Group Publisher: Richard Swadley
Vice President and Executive Publisher: Robert Ipsen
Vice President and Publisher: Joseph B. Wikert
Executive Editor: Carol A. Long
Editorial Manager: Kathryn A. Malm
Development Editor: Kevin Shafer
Production Editor: Vincent Kunkemueller

Text Design & Composition: TechBooks
C 2004 by Wiley Publishing, Inc. All rights reserved.
Copyright 

Published simultaneously in Canada
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10 9 8 7 6 5 4 3 2 1


Contents
Acknowledgments

xix

About the Authors

xxi

Introduction
Chapter 1

xxiii
Air-Conditioning Fundamentals
Properties of Air
Air Circulation
Cleaning and Filtering
Basic Information
Heat Transfer
Sensible Heat
Specific Heat
Latent Heat

Latent Heat of Fusion
Latent Heat of Evaporation
Superheat
Pressure–Temperature Relationship

Chapter 2

1
1
2
2
3
3
4
4
4
4
5
5
5

Measurements and Measuring Devices

7

Thermometer
Barometer
Sling Psychrometer
Pressure Gages
British Thermal Unit

Refrigeration Capacity Measurements

7
8
9
10
10
10

Summary
Review Questions

12
13

Psychrometry
Air and Water-Vapor Mixtures
Humidifying and Dehumidifying
Relative Humidity

15
15
15
15

Relative Humidity Measurements
Grains of Moisture
Specific Volume

16

16
17

v


vi Contents
Dew-Point Temperature
Effective Temperature
Dry-Bulb Temperature
Wet-Bulb Temperature
Wet-Bulb Depression
Temperature-Humidity Index
Total Heat Content

Psychrometric Charts
Psychrometric Chart Instructions
Calculation Examples

Chapter 3

18
19
19

Comfort Chart
Summary
Review Questions

25

27
27

Heat Leakage
Calculation Examples

29
30

Example
Solution

Chapter 4

17
17
17
17
18
18
18

30
30

Reference Tables
Summary
Review Questions

30

52
52

Ventilation Requirements
Air Leakage
Natural Ventilation

53
53
53

Wind Forces
Temperature-Difference Forces
Combined Wind and Temperature Forces
Roof Ventilators
Ventilator Capacity

53
54
55
55
56

Fresh-Air Requirements
Mechanical Ventilation

57
58

Volume of Air Required

Duct-System Resistance

58
59

Air Filtration
Effect of Dust on Health
Various Dust Sources

60
60
61


Contents vii

Air-Filter Classification
Dry Filters
Wet (or Viscous) Filters

Filter Installation
Humidity-Control Methods
Humidifiers
Air-Washer Method
Pan Humidifiers
Electrically Operated Humidifiers
Air-Operated Humidifiers

Dehumidifiers
Electric Dehumidification

Controls
Adsorption-Type Dehumidifiers

Air-Duct Systems
Heat Gains in Ducts
Resistance Losses in Duct Systems

Fans and Blowers
Air Volume
Horsepower Requirements
Drive Methods
Fan Selection
Fan Applications
Fan Operation
Attic-Fan Installation
Fan Operation

Summary
Review Questions
Chapter 5

Room Air Conditioners
Operation
Cooling Capacity
Capacity Requirements
Installation Methods
Double-Hung Window Installation
Casement Window Installation
Outside Support Bracket

61
62
63

66
69
69
69
70
71
71

73
74
75
76

77
79
85

89
90
90
91
92
93
94
95
97

97
98
101
101
103
103
104
106
111
115


viii Contents
Console-Type Room Air-Conditioning
Systems

Electrical System
Electrical Components
Fan Motors
Thermostats
Unit Control Switch

Service Operations
Dismantling Window Air Conditioners
Electrical Testing
Compressor and Motor
Oiling of Motors
Leaks in System
Filters

Interior Cleaning
Winter Care
Refrigerant-System Service

Chapter 6

116

122
124
127
128
129

129
130
130
135
137
137
137
137
137
138

Troubleshooting Guide
(Window-Mounted Units)
Summary
Review Questions

143
143
145

Refrigerants
Desirable Properties
Chlorofluorocarbon Compounds (CFCs)
Classifications
Early Types of Refrigerants

147
147
147
148
150

Sulfur Dioxide
Methyl Chloride
Ethyl Chloride
Ammonia
Carbon Dioxide
Freezol (Isobutane)
Calcium Chloride (CaCl2 )

Freon Refrigerants
Classifications
Properties of Freons

151
151

152
153
154
154
154

156
156
157


Contents ix

Pressure-Temperature Chart
Refrigerant Characteristics

160
160

Critical Temperature
Hydrofluorocarbons (HFCs)
Latent Heat of Evaporation
Specific Heat
Power Consumption
Volume of Liquid Circulated

160
162
162
163

163
164

Simple Refrigeration System
Handling Refrigerants

164
166

Storing and Handling Refrigerant
Cylinders
Cylinder Capacity
First Aid

Chapter 7

166
167
168

Summary
Review Questions

169
169

Compressors for Air Conditioners
Mechanical Components

171

171

Compressors
Condensers
Receivers
Evaporators
Refrigerant Controls
Expansion Valves

Refrigeration Cycle
Refrigerants
Compressors
Reciprocating Compressors
Drive Methods
Compressor Valves
Pistons and Piston Rings
Connecting Rods
Crankshafts
Shaft Seals
Lubrication and Cooling

Rotary Compressors

171
173
173
173
174
174

174
175
176
177
177
178
178
181
181
183
184

184


x Contents

Scroll Compressors
Scroll Compression Process
Operation
Scroll Compressor Models

189
191
192

Centrifugal Compressors

192

Construction Features
Lubrication System

195
196

Installation and Maintenance
Foundation
Motor and Belts
Compressor Flow-Back Protection
Valve Maintenance
Shaft-Seal Leaks
Compressor Knocks
Stuck or Tight Compressor
Compressor Removal
Compressor Replacement
Compressor Startup
Winter Shutdown of Water-Cooled
Compressors

Chapter 8

189

198
198
199
199
200
201

202
202
202
203
203
204

Compressor Characteristics

205

Compressor Performance
Compressor Capacity
Mechanical Efficiency
Volumetric Efficiency
Compressor Efficiency Test

205
205
205
205
205

Troubleshooting Guide
Summary
Review Questions

214
214
215

Condensing Equipment for Air
Conditioners
Air-Cooled Condensers
Water-Cooled Condensers

217
217
219

Cooling-Water Circuits
Types of Water-Cooled Condensers

220
220


Contents xi

Head-Pressure Control Methods
Water-Cooled Condensers
Evaporative Condensers
Air-Cooled Condensers

Condenser Maintenance
Cleaning Precautions
Charging the System
Cleaning Time
Flushing the System
Cleaning Evaporative Condensers

Removing Scale Formation
Gravity and Forced Circulation

Chapter 9

228
228
229
230

232
233
235
235
235
235
236
236

Outdoor Condensing Units
Summary
Review Questions

237
238
239

Evaporators for Air Conditioners
Types of Evaporators

241
241

Finned Evaporators
Plain-Tubing Evaporators
Evaporator-Coil Construction

242
242
243

Refrigerant-Control Methods

245

Superheat
Chilling Units
Dry-Expansion Coil Arrangements
Capacity Requirements

Evaporator Calculations
Exterior Conditions
Surface-Area Determination

Evaporator Maintenance
Cycling the Condensing Unit
Time Clocks

245
247

249
251

251
253
253

255
255
256

Accessory Equipment

257

Heat Exchangers
Surge Drums
Oil Separators
Driers

257
260
260
263


xii Contents

Chapter 10

Dehydrators
Strainers
Mufflers
Subcoolers
Check Valves

264
265
266
266
267

Summary
Review Questions

269
271

Water-Cooling Systems
Atmospheric Cooling Methods

273
274

Water Towers
Cooling Ponds
Spray-Cooling Ponds

New Developments
Cooling-Unit Piping

Liquid Lines
Suction Lines
Oil Circulation
Discharge Lines
Refrigerant-Piping Arrangement

Chapter 11

274
278
279

279
280
281
282
283
283
284

Summary
Review Questions

287
288

Air-Conditioning Control Methods
Types of Air-Conditioning Controls

289

289

Manual Control
Automatic Control
Semiautomatic Control

Basic Control Types
Room Thermostats
Twin-Type Thermostats
Duct Thermostats
Immersion Thermostats
Hygrostats
Pressure Regulators

Limit Controls
Control Valves

289
290
290

290
291
294
294
295
295
297

297

298


Contents xiii

Dampers
Relays
Refrigerant Control Devices
Automatic Expansion Valves
Thermostatic Expansion Valves
Sizing of Thermostatic Expansion
Valves
Low-Side Float Valves
High-Side Float Valves
Capillary Tubes
Crankcase Pressure-Regulating Valve
Evaporator Pressure-Regulating Valve
Reversing Valves

Chapter 12

300
300
302
303
305
305
305
306
306

Summary
Review Questions

308
309

Weather Data and Design Conditions
Indoor Design Conditions
Outdoor Design Conditions

311
311
312

Winter
Summer

Chapter 13

299
299
300

312
313

Interpolation among Stations
Weather-Oriented Design Factors
Summary

Review Questions

326
326
328
329

Year-Round Central Air Conditioning
Central System Features

331
331

Air-Supply System
Mixing Chamber
Heating Coils
Preheaters
Cooling Coils
Air-Supply Fans
Filters
Air Washers
Control Method

332
332
333
333
334
334
335

335
335


xiv Contents
Zone Control
System Selection

Absorption-Type Air Conditioning

338

Absorption versus Compression
Cycle of Operation

338
339

Reverse-Cycle Air Conditioning
(Heat Pumps)

341

Reversing Valve Operation
Control Equipment
Defrost-Cycle Operation
Installation and Maintenance
Indoor Arrangement
Refrigerant Tubing
Quick-Connect Couplings

System Troubles

342
345
346
347
347
348
350
353

Reversing-Valve Troubleshooting Guide
Nonportable Air Conditioners
Construction Principles
Plumbing Connections
Water-Cooling Tower
Heating Coils

Suspended-Type Air Conditioners
Casings
Coils
Filters
Controls

Chapter 14

336
337

354

354
358
358
359
361

361
362
362
363
363

Air-Conditioning Troubleshooting
Guide
Summary
Review Questions

363
366
366

Automobile Air Conditioning
Air-Conditioning System Operation
Component Description

369
373
375

Compressors

Condensers
Receiver-Dehydrator

375
376
377


Contents xv
Thermostatic Expansion Valves
Evaporators
Solenoid Control
Magnetic-Clutch Control
Suction-Throttle Control
Air Distribution
Air-Conditioner Control System

Service and Maintenance
Insufficient or No Cooling
Air Output Not Normal
Air Output Normal
Checking Suction Pressures
Checking Control Systems
Air Distribution
Defective Compressor
Compressor Clutch
Condenser
Thermostatic Expansion Valve
Evaporator
Refrigerant Lines

Suction-Throttle Valve
Use of Receiver Sight Glass for Diagnosis

Chapter 15

377
380
380
381
382
384
384

384
385
385
385
386
386
386
386
387
387
387
388
388
388
389

Installation Procedure

Troubleshooting Guide
Summary
Review Questions

389
395
395
396

Motors and Motor Controls
Motor Voltage
Polyphase Motors

399
399
399

Squirrel Cage Motors
Wound-Rotor Motors
Synchronous Motors

Single-Phase Motors
Split-Phase Motors
Capacitor-Start Motors
Two-Value Capacitor Motors

400
401
403

406
406
407
408


xvi Contents
Permanent Split-Capacitor Motors
Repulsion Induction Motors
Repulsion-Start Induction Motors
Capacitors

AC Motor Controls
Squirrel Cage Motors
Wound-Rotor Motors
Synchronous Motors

Single-Phase Motor Controls
Overload Protectors
Start Relays

413
413
414
416

418
418
419

Compressor Motor Controls

420

Temperature-Motor Control
Pressure-Motor Control
Solenoid Valves
Condensing-Water Controls

420
421
421
421

Belt Drives
Motor Maintenance
Horsepower Calculations
Motor Horsepower Calculated from
Meter Readings
Horsepower Calculated from Load
(Mechanics’ Data)
Horsepower Calculations for Specific
Applications (Approximate)
Power-Conversion Factors

Chapter 16

408
409
409

411

422
422
423
423
424
424
425

Troubleshooting Guide
Summary
Review Questions

425
425
428

Maintenance
General Procedure
Head Pressures
Suction Pressure
Back Pressure
Refrigerant Charge
Compressor Service Valves

431
431
432
433

434
434
435


Contents xvii

Gages
Combination Gages
Adding Refrigerant
Removing Refrigerant
Adding Oil
Removing Oil
System Pump-Down
Purging System of Noncondensables
Leak Test

436
437
437
439
439
439
440
441
441

Halide-Torch Method (For Freon
Refrigerants)
Electronic Leak Detector

441
442

Evacuating the System
Checking Compressor Valves
Troubleshooting Guide
Summary
Review Questions

443
444
444
450
451

Appendix A Professional Organizations

453

Glossary

459

Index

481

Acknowledgments
No book can be written without the aid of many people. It takes a
great number of individuals to put together the information available about any particular technical field into a book. The field of air
conditioning is no exception. Many firms have contributed to the
information, illustrations, and analysis of the book.
The authors would like to thank every person involved for his
or her contributions. Following are some of the firms that supplied
technical information and illustrations.
Acme Industrial, Inc.
American Society of Heating and Ventilating Engineers
American Standard Controls
Armstrong Machine Works
ASHRAE
Automatic Products, Inc.
Barneby Cheney Corporation
Buffalo Forge Company
Cargoaire Engineering Corporation
Carrier Corporation
Controls Company of America
Copeland Refrigeration Corporation
Crocker-Wheeler Corporation
Dunham-Bush, Inc.
Frick Company
General Electric Company
General Motors Corporation
Gibson Refrigerator Sales Corporation
Honeywell, Inc.
Hotpoint Co.
Lennox
Marsh Instruments Co. Inc.

Mueller Brass Co.
Paragoan Electric Company
Penn Controls, Inc.
xix