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Section 7

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12 views26 pages

Section 7

paul book 7

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minalzumba
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SECTION 7 RESIDENTIAL AND COMMERCIAL CONTROLS UNIT 23 AIR-CONDITIONING CONTROLS OBJECTIVES ‘After completing the study of this unit, the student will be able to define the following terms as they relate to devices providing electrical, elec- tronic, or pneumatic control for air-conditioning equipment. set point hag control point primary element deviation bimetallic element corrective action bellows cycling electronic controls differential gap humidity-sensing primary element offset pressure-sensing primary element «state six basic functions of a fully automatic control system. ‘* describe the following types of control action — 1. simple two-position control 2. timed two-position control « list the four configurations of electrical/electronic control circuits. «describe and state the function of a Wheatstone bridge. « check the system operation after the installation is complete. # troubleshoot all of the following system control circuits ~ 1. main power transformer relay coil cooling damper fan heating rayvsyer 278 ™ Section 7 Residential and Commercial Controls * list the components of a pneumatic system. * state the function of the following devices as they apply to a pneumatic system. actuator damper (normally open type and normally closed type) valve (normally open type and normally closed type) controller (thermostat) relay master-submaster control Air-conditioning equipment can be electrically, electronically, or Pneumatically controlled. Numerous combinations of each type of control are possible. Since it is not practical to attempt to describe all of the combinations in this unit, only funda- mental terms, functions, operations, and simple service techniques are presented. DEFINITION OF TERMS ‘Set point, A value on the control scale (temperature, humidity, or pressure) at which the control indicator is set is the set point. Thus, if a thermostat is set at ‘75°F, the set point is 75°F. Control point. The value of the temperature or humidity that is maintained in the conditioned space and recorded by the control is the control point. For example, a thermostat may record a temperature of 76°F (control point) even though it is set at 75°F (set point). Deviation. The momentary difference between the set point and the control point is the deviation, For example, with a set point of 75°F and a control point of 76°F, the deviation is 76°F ~ 75°F = 1°F. Corrective action, The controls will take a corrective action to maintain the control point at a value that is in reasonable agreement with the set point, The following situation is a typical example of a corrective action within a system. A drop in the Outside temperature causes a drop in the temperature inside the conditioned space. This temperature drop is recorded by the thermostat in the space, resulting in a lower thermometer or control point reading. The thermostat senses the drop and closes its contacts. In so doing, the thermostat turns on the burner in the furnace. Heat is ‘added to the space and the control point (thermostat reading) rises until it approaches or equals the set point. The thermostat senses the rise in temperature and opens its contacts. This action shuts off the furnace burners and the cycle is completed. In this situation, the thermostat acted to correct and maintain the control point. This same Sequence applies in a cooling application, when a rise in temperature occurs in the space. Cyeling. Cycling is a consistent repetition of a change in the control point, For example, if the space temperature (control point) drops several degrees below the set point, the thermostat calls for heat. Heat is added to the space, but the thermostat shuts off the burner before the space temperature reaches the set point. After avery slight drop in temperature, the thermostat calls for more heat. This time the thermo- Stat shuts off the bumer only after the space temperature is several degrees above the set point. Cycling is also known as hunting. Unit 23. Air-conditioning Controls ® 279 Differential gap. ‘This gap is the range through which the conditions of the spice unt travel to move a two-position control (on-off or open-closed) from one position to the other. If the thermostat contacts are open at 76°F and the thermostat moves to the closed position (contacts are closed) at 74°F. then the differential gap is 16°F - 74°F = °F. Offset. The sustained difference between the set point and the: ‘control point is known as the offset. Lag, Lag is a delay in the effect of a changed condition in one part of the system ona related condition in another part of the|system. As an example, consider the case when the condition at the furnace goes from no heat to heat (the burner comes on). Heat passes to the conditioned space and the control temperature increases. Tn this instance, the lag extends from the time the burner comes on until the time when the temperature condition in the space reaches its former control point. Primary element. That portion of the control which first uses energy from the con- trolled medium (such as air or water) is the primary element. For example, the bi- metallic element of a thermostat uses the energy resulting from a change in air temperature to open or close a set of contacts. ‘The bimetallic element is a primary element. Such an element senses either temperature, humidity, or pressure changes. Temperaturesensing primary elements can be bimetallic strips, sealed bellows, or sealed bellows attached by capillary tubing to a remote sensing bulb. Bimetaltic elements. This type of element, figure 23-1, consists of thin strips of two different metals securely attached to each other. Since different metals expand and contract-at different rites during changes in temperature, the thin strips of metal actually curve toward ot away from a given point. In this way, the thermostat makes or breaks its contacts when the temperature changes. Bimetallic elements are usually U-shaped. Touch TEMPERATURE ADJUSTER. CALIBRATION SCREW HELICAL ‘TEMPERATURE PERFORATED BIMETALLIC TUBE ANTICIPATING ELEMENT cyCLING HOUSING CONTANING en ELECTRICAL CONTACTS ANO DETENTS MAGNET ot Bimetallic elements in an electric thermostat (left) and in an insertio thermostat for a duct ‘280 ™ Section 7 Residential and Commercial Controls Bellows. As a temperature-sensing element, a bellows is first put under a vacuum and then is partially or completely filled with a liquid and sealed. Changes in temperature cause the liquid in the bellows to expand or contact, resulting in the expansion or contraction of the bellows. This action of the bellows in turn moves a mechanism which opens or closes a control valve or similar device. A remote bulb bellows operates in the manner described except that the change in temperature takes place at the bulb location, Electronic controls. A low-mass primary element is used in an electronic control. This primary element may be as simple a device as a wire whose resistance is altered asa result of changes in temperature. Although a feeble signal occurs due to a re- sistance change in the wire, the electronic circuit can amplify this signal to a usable strength. Humidity-sensing primary elements, Any material thatresponds to a change in the mois- ture content (such as hair, wood, or leather), can be used as a humidity-sensing primary clement. The moisture content of the material changes as it absorbs or gives up mois- ture. Asa result, the substance expands or contracts and moves the control mechamsm, Electronic humidity-sensing primary elements. This type of element consists of two strips of gold fused to a piece of glass. Electrical contact is maintained between the gold strips through a hygroscopic sait which is painted over the glass surface. The resistance of the salt varies according to the amount of moisture that it absorbs or releases. Small changes in re- sistance cause changes in the CONNECTION TO flow of current. These changes ‘CRANKCASE are detected and used by the ie cizeui DIFFERENTIAL SUPPLY electronic circuit. eee Fa ‘switcH Pressure-sensing primary ele- ments. These elements can be bellows, diaphragms, and in- verted bells or similar devices, figure 23-2. The pressure of the air or water (or other me- dium) moves the primary ele- ment directly. The resulting action operates the pneumatic or electrical control. TIMER SWITCH BASIC FUNCTIONS OF CONTROL SYSTEMS A fully automatic control system performs six basic func- tions as indicated in the follow- conNeCTION To OIL STARTER STARTER jing brief descriptions. PUMP DISCHARGE GVERLOAD: HOLDING © The sensing element meas- RELAYS cou tures changes in temperature, Fig. 23-2. Pressuresemsing elements (the two opposing bel- Pressure, and humidity. ows) operate the oill pressure faifure control Unit 23 Air-conditioning Controls * 281 * The control mechanism translates the changes into energy that can be used by devices such as motors and valves, ‘The connecting wiring, pneumatic piping, and mechanical linkages transmit the energy to the motor, valve, or other device that acts as the point of corrective action. ‘The device then uses the energy in its operation to achieve some corrective action. Motors operate compressors, fans, dampers, and similar devices. Valves control the flow of gas to bumners or cooling coils and petmit the flow of air in pneumatic systems. Valves also control the flow of liquids such as the water in a water-cooled condenser. * The sensing elements in the control detect the change in conditions (corrective action) and signal the control mechanism or connecting means. ‘The control stops the motor, closes the valve, or terminates the action of the device being used. As a result, the call for corrective action is ended. This action by the control prevents overcorrection. CONTROL ACTION ‘Two-position Control The use of two-position control permits the final control element (motor, valve, or similar device) to occupy one or the other of two positions. Two-position control is used to open and close gas valves for residential heaters and to start and stop motors for fans, compressors, pumps, and similar devices. ‘Simple Two-position Control In a system using a simple two-position control, figure 23-3A, the control never ‘catches up to the controlled condition. Rather, the control only corrects a condition that has just passed. The control does not act on a condition that is taking place or is about to take place. CONTROLLED VARIABLE ‘suRNER ofF \ 2 5 ‘e . a BURNER ON neta cw (8) td ee es ae Fig. 23-3 Types of control circuits 282 ® Section 7 Residential and Commercial Controls Timed Two-Position Control The ideal method of heating or cooling a space is to replace the heat lost or re- move the heat gained in exactly the amounts needed. To do this, the control must respond to a gradual or average change in the air temperature of the conditioned space; this air temperature change is the controlled variable. An average temperature change is produced by adding a tiny heater (timing device) near the thermostat tem- perature-sensing element, figure 23-3B. . Timer Operation for Heating. While the air temperature at the thermostat is main- tained within certain limits, the thermal heater will cool to its on point and energize the heating element. The thermal element then heats to its off point and de-energizes the heating element. As a result, the thermal heater again cools to the on point and the cycle is repeated. Timer Operation for Cooling. While the air temperature at the thermostat is main- tained within certain limits, the thermal heater clement: will cool to its off point und de-energize the heating clement. The thermal heater then heats to its on and energizes the heating element. The thermal heater then cools to its off poin’ again and the cycle is repeated. The [Link] for cooling is the opposite of the sequence for heating. ‘The heater element turns off when the air at the thermostat is cool and turns on when the air is warm. When the element turns on, it adds heat at the thermostat element and causes the thermostat to call for cooling sooner than it would if the heater were not used.- This cooling is added to the conditioned space immediately. In this way, the air temperature is prevented from increasing as far as it would if the timer were not provided. ‘The use of the timer or thermal heater reduces the swing (differential) in the air temperature in the room so that the temperature remains almost constant. The tem- perature differential is much greater when the timer is not used, as shown in figure 23-3. ELECTRICAL CONTROL CIRCUITS Electrical control circuits use electrical energy to transmit signals from the con- trol to the final control device (such as a motor, valve, relay, or other device). Such controls are available with low-voltage and line voltage ratings. Low-voltage wiring and electrical devices are subjected to a voltage of 25 volts or less. Suitable transformers must be used to decrease the line voltage to a suitable low-voltage value. The line voltage applied to wiring and electrical devices is in the range of 115 to 230 volts, Line voltage may be used at its full value or it may be stepped down by a transformer to supply energy to a low-voltage circuit. The line voltage should not be confused with the term high voltage which is considered to be 500 volts or more. A potentiometer, figure 23-4, consists of a number of turns of resistance wire wound on a cylindrical form. Three connections are provided. The center connection is movable and is wired to complete the circuit at any point along the cylinder. A balancing relay, figure 23-5, contains an arma- Fig. 23-4 Potentiometer ture pivoted at one end which swings between two symbols electromagnetic coils. As the magnetic field in the two coils changes with a changing current, the armature moves toward the stronger magnetic force. The armature is usually provided with contacts so that it can complete circuits as it moves to predeter- mined positions. Relay contacts are known as in contacts if they complete circuits when the relay is ener- gized, Contacts which complete circuits when the relay is de- energized are known as out contacts. Three combinations of Jn and Qut contacts are shown in figure 23-6, In figure 23-6A a single pole, double-throw relay is shown with one in and one out contact. Figure 23-6B shows a double- pole, single-throw relay with Jn contacts. Figure 23-6C illustrates a three-pole relay with one single- pole, double-throw switch; one single-pole, single-throw switch with in contacts; and one single- pole, single-throw switch with our contacts. TYPES OF CONTROL CIRCUITS ‘Three-wire, Low-voltage Circuit Unit 23 Air-conditioning Controls ® 283 ARMATURE CONTACTS. COMMON Fig. 23-5 A balancing relay wey ud Ys Fig. 23-6 Combinations of In/Out Contacts One type of three-wire circuit uses a control containing two sets of contacts. The contacts make in sequence to start the control and break in reverse sequence to stop the control. ‘A second type of three-wire circuit has a control that makes one circuit to start, breaks this circuit, and then makes a second circuit to stop, figure 23-8, page 285. For the basic control circuit shown in figure 23-8, the following procedures illustrate what corrective action is taken when the temperature in the controlled space drops. Temperature Drop, Figure 23-88 ‘© The thermostat blade engages the blue contact. © The starting circuit is established. + The motor is energized and Starts to rotate clockwise. 284 ™ Section 7 Residential and Commercial Controls JUNE VOLTAGE TRANSFORMER THERMOSTAT FLEXIBLE BLADE RIGID BLADE SS TRANSFORMER. THERMOSTAT Gaeeeees TRANSFORMER, THERMOSTAT THOU @, ) THERMOSTAT SATISFIED (C)SLisHT TEMPERATURE DROP TRANSFORMER THe TAT " oe ** JERMOSTAT sos TRANSFORMER THERMOSTAT (D) FURTHER TEMPERATURE DROP (E)HOLOING cincuIT ESTABLISHED ee TRANSFORMER THERMOSTAT sees TRANSFORMER THERMOSTAT NO (F) SLIGHT TEMPERATURE RISE (G) FURTHER TEMPERATURE RISE Fig. 23-7 A three-wire, low-voltage control circuit (C) HOLDING CIRCUIT ESTABLISHED (D) HOLDING CIRCUIT BROKEN Fig. 23-8 (Cont'd.) (Courtesy Minneepotis Honeywell) 286 ™ Section 7 Residential and Commercial Controls (E) TEMPERATURE RISE (F) HOLDING CIRC" IT REESTABLISHED Fig. 238 Holding Circuit Established, Figure 23-8C As the motor and cam rotate: . © The left blade Of the maintaining switch makes contact with S1 and the holding circuit is established, This circuit is independent of the starting circuit. Once the holding circuit is made, it furnishes current to the motor regardless of the action of the thermostat. © If the thermostat holds the blue contact closed, a small amount of current passes through the holding circuit because it offers the path of least resistance. Holding Circuit Broken, Figure 23-8D When the motor shaft has rotated 180 degrees: The cam breaks contact S2 All circuits are incomplete. The motor stops. Negligible current passes through the heater resistance; the current is insufficient for motor travel. Temperature Rise, Figure 23-8E A temperature rise in the controlled space and the heat from the resistance heater produce the following actior © The thermostat blade moves to the right and engages the white contact. Unit 23 Air-conditioning Controls ™ 287 © The starting circuit is completed . ‘© The motor starts to rotate clockwise. ‘As stated previously, the additional heat provided by the resistance heater causes the thermostat to close sooner than it would for a simple two-position control. Asa result, the temperature differential is minimized. Holding Circuit Reestablished ‘The right blade of the maintaining switch contacts S2. « The motor continues to rotate until it makes half a turn. © At this point, the holding circuit is again broken at contact SI and the motor stops. One cycle is complete. ‘Two-Wire Line Voltage Circuit The two-wire line voltage CONTROLLER circuit in figure 239 contains a ___________»@ control that makes the circuit when the control switch is LINE closed and breaks the circuit fower when the control switch is open. Although the three-wire cir- cuits described in previous sec- Fig. 23-9 The two-wire, line voltage circuit tions were low-voltage circuits, they can also be designed as line voltage circuits. ‘Similarly, two- wire, line voltage circuits can be modified to two-wire, low-voltage circuits. ELECTRONIC CONTROL CIRCUITS Electronic circuits are used to control all types of heating and cooling equipment for both commercial and residential ap- plications. Electronic controls feature quick response to tem- perature changes, As a result, temperature averaging is accom- plished readily. . Fig. 23-10 Basic Wheatstone bridge Basic Electronic Control Circuit ‘The Wheatstone Bridge circuit, figure 23-10, is the basis of many clectronic contro! circuits. The bridge consists of two sets of resistors connected in series. The series resistors, in turn, are connected in parallel across a dc voltage source. One set of series resistors is shown by R1 and R2 in figure 23-10. ‘The second set of resistors is R3 and R4. The voltage source (E) is connected between points A and B. A sensitive current indicator (galvanometer.G) is connected across the sets of resistors at points Cand D. MoroR ¢ 288 ™ Section 7 Residential and Commercial Controls When switch S is closed, the voltage from E flows through both sets of resistors. If the potential at point C is the same as that of point D, the galvanometer gives a zero reading. In other words, there is no potential difference between the two points. ‘Thus, the bridge is balanced. When any one of the resistors has a different voltage, the galvanometer registers a value other than zero. This reading indicates that there is a current between points C and D. Such a current indicates that the bridge is unbalanced. Control manu- facturers modify the basic bridge circuit to use it in electronic control circuits. A typical bridge circuit modification is shown in figure 23-11. Modified Bridge Circuit In the modified circuit of figure 23-11, the de voltage is replaced by a 15-volt ac supply. In addition, the switch is eliminated and the galvanometer is replaced by an amplifier-switching relay unit. Resistor R2 is replaced by a temperature-sensitive clement, TI. TRANSFORMER f Simeone Fig. 23-11 Modified bridge circuit To simplify the description of the modified bridge, a resistance of 1,000 ohms is assigned to cach of the three fixed resistors (R1, R3, and R4) and to the thermo- stat element TI. When the desired conditions in the space are met, the resistance in TI does not change. Thus, the voltage across the amplifier-relay is zero. Since there iso voltage across the amplifier-relay, the final control element (a motor, a valve, or other device) cannot be energized. The bridge circuit is balanced. When the air temperature in the conditioned space changes, the thermostat element senses the change. A corresponding change in the resistance at T1 occurs and the bridge becomes unbalanced. Voltage now flows through the amplifier-relay to the final control element. In a heating application, a drop in temperature in the conditioned space causes a decrease in the resistance of T]. The resulting voltage relationships in the bridge circuit cause the amplifier-relay to increase the voltage to | the final control element. As a result, heat is added to the space. As the heat is added, Unit 23. Air-conditioning Controls ® 289 the resistance at TI increases. The voltage change that occurs in the bridge circuit stops the heating by shutting off the burner. ‘The modified bridge circuit of figure 23-11 can also be used for cooling applica- tions. Depending upon whether the bridge voltage fed to the amplifier-elay is in phase or out of phase with the supply voltage, the final control element is opened or closed. SYSTEM CHECKOUT The control system should be installed according to manufacturers’ instructions and applicable codes. After the system is installed, the following checks should be made to insure the proper operation of the system. * All wiring connections must be examined for tightness. All wires are to be traced to insure that the connections are made according to instructions and code guidelines. © The thermostat calibration must be checked. If recalibration is necessary, the technique described shortly is to be used. « The technician must insure that the system starts when the thermostat calls for heating and cooling, and stops when the thermostat is satisfied. ‘Thermostat Calibration (Heating and Cooling Applications) ‘The following procedure is to be used if the thermostat requires calibration. * For a thermostat having a timer heater, a thermostat setting is used that stops the operation of the system. An allowance of ten minutes is to be made for the heater element to settle out. ‘* The thermostat must be in a level position if it has a mercury switch, figure 23-12. NEUTRAL zone Abvosrins MERCURY TUBE THERMOSTAT SCREW one mont wounTine Serencx SCREWS HEATING CALIBRATION ‘ADJUSTMENT: SCREW COOLING CALIBRATION ADJUSTMENT SCREW Fig. 23-12 (Courtery Minneapolis Honeywell) 290 ® Section 7 Residential and Commercial Controls * Calibration Procedure for Heating: 1. Place the system switch in the heating position and the fan switch (if used) in the automatic position. 2. Move the set point indicator to a value above the room temperature. The thermostat contacts should open. 3. If the thermostat contacts remain closed, turn the heating calibration nut (mercury switch) or screw (snap action switch) counterclockwise until the contacts just open. Do not turn the nut (screw) beyond this point. 4. Step back and allow the thermostat to dissipate the heat picked up from the hands. (Usually, a few minutes are required.) 5. Move the set point indicator to the value of the room temperature. 6. Turn the calibration nut (screw) clockwise only to the point that the con- tacts close. Do not turn the nut (screw) beyond this point. 7. Recheck the calibration. Move the set point indicator toward the lower end of the scale. Step back and wait for several minutes until the heat dissi- pates. Move the set point indicator up-scale until the contacts just close. The contacts should close when the set point indicator has the same value as the room temperature. If the temperature values do not coincide, re- calibrate the thermostat. * Calibration Procedure for Cooling: 1. Move the system switch to the cooling position and the fan switch to automatic. 2. Move the set point indicator to the room temperature value. The cooling contacts should just close. 3. If the cooling contacts remain open, turn the cooling calibration screw or nut clockwise until the contacts just close. 4. Turn the cooling calibration screw or nut counterclockwise until the con- tacts just open. 5. Step away from the thermostat and allow the heat to dissipate, 6. Recheck the calibration by moving the set point indicator down-scale until the contacts just close. Slowly raise the set point indicator up-scale until the contacts just open. The contacts should open when the indicator reaches the same value as that of the room temperature. If the temperature values do not coincide, recalibrate the thermostat. TROUBLESHOOTING Centrally located control panels are commonly used to provide a -dily accessi- ble means of checking all of the circuits in the system from one locati A typical troubleshooting procedure for such a central control panel is described j1 the follow- ing paragraphs. If this type of panel is not available, each circuit desc’ ibed can still be checked in the same manner, but at the points in the system where th : components (such as the fan motor, damper motor, thermostat, and transformer) are located. Unit 23 Air-conditioning Controls ™ 291 Power Circuit, Figure 23-13 The troubleshooting pro- ye cedure always starts with a voursce. test for power ahead of the transformer. Connect a suitable test light across the power terminals of the panel (Terminals 1 and 2). If the light is on, the power source is functioning proper- ly. If the light stays off, check for blown fuses or loose or broken connections. Correct the problem and re- test the power terminals. Transformer Circuit, Figure 23-14 Connect a test lamp of suit- oes able voltage to the power lead on the line voltage (primary) side of the Treas enwinat boane transformer. If the light turns on, the Fig. 23-14 Transformer circuit power to the transformer TROUBLE LAMP, is correct. If the light stays off, check the COn- spaxsronuen <—— nections and the power cir- Secongaer TE AME, voLTAGe cuit, Make any repairs 'ReLAY necessary. Fig. 23-15 Transformer circuit Connect a test iight, figure 23-15, across the low-voltage (secondary) terminals of the transformer and disconnect one transformer lead. If the light turns on, the transformer is functioning correctly. If the light stays off, check and tighten the transformer line voltage connections. If the light still does not tum on, replace the transformer. “on Relay Coil Circuit, Figure 23-16 . Attach a test lamp of © suitable voltage to one of the relay leads as shown. If the ligkt tums on, the relay is functioning. If the light stays o'f, test — oune vane the power to the coil by ze connecting a test lamp "peconciany across the circuit from the Fig. 23-16 Relay circuit coil 282 ™ Section 7 Residential and Commercial Controls transformer, figure 23-17. If the light turns on, re- place the coil. If the light does not tum on, the wiring between the transformer and the relay coil is de- fective. Repair the wiring Reconnect the test light to one lead of the coil. If the light still does not turn on, replace the coil. If light tums on, the relay coil is functioning correctly. Cooling Circuit, Figure 23-18 * If any cutout devices are used, these devices must be reset before the troubleshooting procedure is started. Install a jumper between the thermostat leads (Y to R). 1. If the starter does not operate, the starter coil, pressure switches, or over- loads may be defective, 2, Jumper the pressure switches and the overload. If the starter still does not operate, the pressure switches or the overload are defective. 3. Replace all defective parts as necessary. If the starter still does not operate, replace it. Fig. 23-18 Cooling cireuit Unit 23 Air-conditioning Controls ® 293 If the starter operates but the compressor does not start up, jumper across the starter (L1 to Tl and L3 to T3). 1. If the compressor operates, replace the starter contacts. 2, If the compressor does not operate, the trouble is in the cooling equipment of its wiring. Check out the wiring and each component (such as the motor and relay). Repair or replace any defective devices as necessary. Damper Circuit, Figure 23-19 ‘¢ Jumper the thermostat terminals (O to R). 1. If the damper operates, the problem is in the control (thermostat) circuit Repair or replace the circuit components as necessary. 2. If the damper does not operate, the problem is in the wiring to the damper or the damper motor. Repair or replace the wiring as necessary. Fig. 23-19 Damper circuit Fan Circuit, Figure 23-20 © For the fan circuit shown in figure 23-20, page 294, the fan is energized by the thermostat or through the starter. © Jumper the thermostat terminals (G to R). © Ifthe fan relay does not operate, replace the fan relay. © If the fan starts, the control (thermostat) circuit is defective. Repair or replace the circuit components as necessary. © If the relay operates but the fan does not, jumper the fan relay terminals (F to F). 1. If the fan operates, replace the relay. 2. If the fan does not operate, the fan motor wiring or the fan motor is de- fective. Repair or replace components as necessary. 294 ® Section 7 Residential and Commercial Controls THERMOSTAT OF, SELECTION ‘SWITCH Heating Circuit, Figure 23-21 «Jumper the thermostat terminals (W to R). 1. If the heating relay does not operate, replace the relay. 2. If the burner starts, the control (thermostat) or its wiring is defective. Re- pait or replace components as necessary. 3, If the relay operates, but the burner does not start, the heating components or their wiring is defective. Check the wiring and each component; repair or replace as necessary. PNEUMATIC CONTROLS Pneumatic controls, figure 23-22, are used principally in large commercial air- conditioning systems. Although they may be used in residential applications. This Unit 23. Air-conditioning Controls ™ 295 PRESSURE REGULATOR AND FILTER To OTHER PARTS OF SYSTEM LOW-PRESSURE GAUGE coMPREssOR unit PRESSURE SwiTcH ioe ‘GAUGE ASME RELIEF VALVE PLugseD INSPECTION HOLES (2) MOUNTING HOLES (4) Rain cock Fig. 23-22 Diagram of a basic pneumatic control system type of control is operated by air pressure supplied by a compressor. A pneumatic control system consists of the following components: * Compressor © Copper tubing to carry the air * Air temperature, humidity, and pressure controllers * Relays and switches * Valves and motors The compressor supplies air through the copper tubing to the controller (ther- mostat). The tubing from the compressor to the thermostat is called the main line because it carries the main air supply directly from the compressor. The tubing from the thermostat to the operating valve is called the branch line because this line does not carry air directly from the compressor, but from a controller. The air pressure is maintained by the compressor at a value of approximately 20 to 35 psi for low-pressure systems. A reducing valve at the compressor reduces the pressure of the air that enters the main line to 15 psi for systems that supply heating only or cooling only (one-temperature systems). For systems that supply both heating and cooling (two-temperature systems), two reducing valves are used. Thus, two different pressures are available to the main line. These pressures vary according to the type of controller used. Pneumatic Operation The air from the compressor flows through the main line to the thermostat (or other controller). The thermostat receives the main line air at a constant pressure and delivers it to the valve (controlled device) through the branch line at pressures that vary according to the temperature recorded by the thermostat. The valve, in 296 © Section 7 Residential and Commercial Controls ‘tum, moves toward the open or closed ‘position depending upon the variation in air pressure in the branch line. In this manner, a change in room (space) temperature causes the thermostat to change the air pressure in the branch line. The change in pressure in the branch line causes the valve to move toward the open or closed posi- tion depending upon whether the room temperature has increased or decreased. When the valve moves toward the open position, more heating is added to the room. When the valve moves toward the closed position, less heat is added. A similar principle applies to the cooling process. Pneumatic Components Actuators. An actuator is a motorized valve or damper, figure 23-23. The motor used in each case is usually the same in that it moves (performs work) according to changes in the branch line pressure, A pneumatic motor contains either a bellows, a diaphragm, or a cylinder and piston, and an opposing spring. A damper linkage or valve stem is connected to the bellows (or diaphragm, or piston). When the branch line pressure to the motor decreases, the bellows expands due to the internal spring pressure. As the branch line pressure increases, the bellows contracts as a result of the air pressure. The expansion and contraction of the bellows moves the linkage or valve stem so that the damper or valve opens and closes. TeLRerrRoUie Normally Open Dampers. A normally open damper is one that is installed so that it moves toward an open position as the air pressure in the damper motor decreases, figure 23-244. Normally Closed Dampers. A normally closed damper is one that is installed so that it moves toward the closed position when the air pressure in the damper motor decreases, figure 23-24B. MOTOR DAMPER DAMPER ‘CONTROLLER CONTROLLER ‘BRANCH BRANCH (A) NORMALLY-OPEN DAMPER (B) NORMALLY-CLOSED oA! Fig. 23-24 Unit 23 Air-conditioning Controls # 297 * TO CONTROLLER TO CONTROLLER FO CONTROLLER FLow Fig, 2325 Singleseated nor. Fig. 23.26 | Dowblesested Fig, 23.27 Thrseway mixing ‘mally open valve normally closed valve valve, normally closed to straight through flow Normally Open Valve, A normally open valve moves toward the open position when the branch line pressure decreases, figure 23-25. Normally Closed Valve. A normally closed valve moves toward the closed position when the branch line pressure decreases, figures 23-26 and 23-27. In general, normally open valves are selected for heating applications and normal- ly closed valves are selected for cooling applications. Controllers (Thermostats). There are four types of controllers: direct acting, reverse acting, graduate acting, and positive acting. A direct-acting thermostat increases the pressure of its branch line when the air ‘temperature increases in the room. A reverse-acting thermostat decreases the pressure of its branch line when the air temperature in the room increases. A graduate-acting thermostat gradually changes its branch line pressure when the air temperature changes in the room. This type of thermostat can maintain any pressure from 0 psi to 15 psi. A positive-acting thermostat abruptly changes its branch line pressure when the room temperature changes. In this case, the branch line pressure is either 0 si or 15 psi. ‘The thermostat does not maintain pressures between these vatues. The thermostat ‘has a two-position control action: either full-open or full-closed. Humidity and pressure controllers operate in the same manner as air tempera- ‘ture controllers (thermostats). Relays, Relays are installed between a controller and a controlled device (between a ‘thermostat and a valve) to perform a function that cannot be accomplished by the controller. For example, a diverting relay is installed to do the following tasks: ‘* In one position, the relay can supply branch air; exhaust the branch air. ‘© The relay can supply air to either of two branches without exhausting the other branch. © The relay can shut off the branch air without exhausting the branch. in the second position, it can 298 ™ Section 7 Residential and Commercial Controls 2ND OPERATING OTHER EQUIPMENT Fig. 23-28 Diagram of a single application for a diverting relay The operation of a simple diverting relay is shown in figure 23-28. The relay is used to supply and exhaust a branch line. © With the manual switch in position 2 (the switch makes contacts 2-3 and 4-5), the main line pressure of 15 psi forces diaphragm (A) against spring (B). As a result, valve (C) opens and allows air to exhaust from the pressure chamber and from the telay branch line connected to the motor. Valve (D) remains closed. With the manual switch in position 1 (switch makes contacts 2-5 and 3-4), the Pressure in the pilot line is 0 psi. Spring (B) forces diaphragm (A). upward. Supply valve (D) opens and exhaust valve (C) closes. The controller (thermo- stat) now controls the motor through valve (D). A differential diverting relay can make one or the other of two controllers operate the valve, A positive diverting relay, figure 23-29B operates around snap spring (G). ‘The snap spring gives a positive open-closed action, rather than the inherent modu- lating action of pneumatic controls. An averaging graduate relay, figure 23-30, maintains a branch line pressure to the motor. This pressure is equal to the average of the branch line pressures of the controllers. . CONTROLLER x ADJUSTMENT CONTROLLER VALVE (AYAN APPLICATION IN WHICH THE RELAY PUTS ONE OF Two CONTROLLERS (B) DIAGRAM OF POSITIVE DIVERTING RELAY IN COMMAND OF THE VALVE Fig. 23-29 Positive diverting relay Unit 23 Air-conditioning Controls © 299 CONTROLLER CONTROLLER Fig. 23-30 An averaging graduate relay MASTER CONTROLLER SUBMASTER CONTROLLER MOTOR OR VALVE Fig. 23-31 Diagram of a compensated master-submaster control system Master-Submaster Control, The master control, figure 23-31, regulates the control point of the submaster control. This type of system makes it possible to have com- pensated control. The master thermostat can be located outside where it will measure the outside temperature; the submaster control can then be located inside to measure the inside temperature. Although the master thermostat changes the control point of the submaster thermostat, the master thermostat never-operates the valve or motor directly. SUMMARY * Air-conditioning controls can be electrical, pneumatic, or electronic in nature. * The set point is the temperature, pressure, or humidity at which the con- trol indicator is set. © The control point is the temperature, pressure, or humidity recorded by the control. «Deviation is the momentary difference between the control point and the set point. 300 ® Section 7 Residential and Commercial Controls . . Corrective action is action taken to maintain the control point in reasoi able agreement with the set point. ‘The differential gap is the range through which a controller travels from the point at which its contacts open to the point at which they close. Offset is the difference between the set point and the control point. The primary element is that part of a control that first uses the energy resulting from a change in the controlled medium, Primary elements can be bimetallic strips, bellows, resistance wire, hair, wood, leather, or gold strips. A fully automatic control system is one that senses a change in conditions and takes action to correct the change. Control action is classified as either simple control or timed two-position control. Electrical controls use electrical energy to transmit signals. Low voltage is defined as 25 volts or less. Line voltage is 115 to 230 volts or less. Control circuits are installed in the following configurations: 1, three-wire low-voltage circuit 2. line voltage circuit 3. two-wire low-voltage circuit 4. two-wire line voltage circuit Electrical control circuits can be used on all types of heating or cooling equipment, ‘The Wheatstone Bridge circuit is used as the basis for electronic control circuits. Check the system operation after the installation is completed. 1. Examine the wiring for tightness 2. Check the thermostat calibration 3. Insure that the system starts and stops on command from the thermostat Centrally located control panels simplify troubleshooting because they make it possible to test all of the system circuits at a central point. The main circuits that should be tested are: 1. Main power 2. Transformer 3. Relay Coil 4. Cooling 5. Damper 6. Fan 7._Heating Unit 23 Air-conditioning Controls 301 = Most troubleshooting can be done with suitable test lamps and jumper wires. © Pneumatic controls are used principally for large commercial buildings; however, they are also suitable for small commercial and residential applications. Pneumatic controls are operated by air pressure. © A pneumatic system includes: 1. Compressor 2. Copper tubing air lines 3. Temperature, humidity, and pressure controllers 4, Relays and switches 5. Valves and motors © A pneumatic motor or valve is either normally open or normally closed. If normally open, it moves toward the open position when the air pressure decreases; if normally closed, it moves toward the closed position when the air pressure decreases. © Controllers are either direct, reverse, graduate or positive acting. In a master-submaster control combination, the master control changes- the control point of the submaster control, but it never operates the valve or motor directly. REVIEW LL What are the three major types of controls that can be used for air-conditioning systems? Define the following: Set point Primary element Control point Low voltage Differential Line voltage Offset . Name five primary elements or materials used in primary elements. |. Sketch a Wheatstone Bridge circuit and identify the parts of the circuit. |. What three steps are to be followed to check system operation after the in- stallation is completed? .. Name seven basic electrical circuits that are part of control systems. 7. What are the two basic tools used to pinpoint troubles in a control circuit? |. Is it true that pneumatic controls are used only in large commercial buildings? Explain. ).. Why are pneumatic controls called pneumatic? 302 ™ Section 7 Residential and Commercial Controls 10. Name five parts of a pneumatic control system and describe four types of pneu- matic control action achieved, a. Name the parts: (yy Q) @) a () ee eee 2s Fs SS -—.—SSS —————__ esse b. Describe the control action: a) Q) @) (4)

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