Technical Training

BASIC REFRIDGERATION
&
CHARGING PROCEDURES
Instructor: Rick Drennan
 BASIC REFRIGERATION
&
CHARGING PROCEDURES

Richard Drennan

FSR (Field Support Rep)

and Instructor for Global HVAC training
services Northern California and Northern Nevada

29 Years experience

Certifications: 6 Nate, EPA (608 & 609), Ruud Mod Furn, 410A, Tracpipe, Wardflex, York
Millennium unit, Freus (water cooled cond. unit), Clarion’s UV self cleaning systems, Fujitsu
Mini Splits

Registered Proctor: Ruud, York, ICP (Carrier), Nate, ACCA, ESCO, HVAC Excellence,
General Electric (ECM Total comfort system), Fujitsu & Tracpipe

Degrees: Electronics, Computer Programming and Computer Electronics

! AIRFLOW !

1
 CFM Calculation
• Proper air flow is the most import aspect of
any system.

• With improper airflow nothing at all will

work properly.

Real Life Charging Procedures

• Use Engineering Data for reference

• Humid climates demand it
• Full unit capacity depends on it

Measuring CFM

2
 First Calculate FPM

With a Magnahelic or Manometer, you can easily convert the

pressure reading to FPM. Typical Static Pressure readings will be
1.5" to 4" with very large blowers maybe pushing 8" to 10". Once
you have the pressure reading (Pv) from your gauge then
calculate

FPM = 1096.7x Pv/D

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

Converting to CFM

• We calculate CFM by multiplying FPM by the area of the duct

used in square feet. The formula for this is:

CFM = FPM x (Pi x R2)/144

For Example: The area of a round duct is equal to the radius

squared times pi, so a 6” diameter duct (3” radius) would be 3 x 3 =
9 in x 3.14159 = 28.27 square inches. That divided by 144 = 0.196
square feet.

Use the 0.196 number times the FPM number on the gauge when
testing with 6" diameter duct to get CFM. The multiplier for 5”
duct is 0.136. The multiplier for a 4” duct is .087.

HOW TO CALCULATE CFM USING THE

TEMPERATURE RISE METHOD

CFM = BTUH
1.08 X TD

Discharge temp. - Entering Temp. = TD

TD or ∆T = Temperature Difference

3
4
To “Clock” the Gas Flow:
•Turn
Tu n up thermostat
t rmos at
so furnace runs
steadily
• Turn off pilots of
other
t r appliances
ap ianc

Check
Che k Gas
G s Meter
te Calibration
C libration
One Revolution in Seconds

60

45 15
Half Two
Cubic
Feet
30
Foot Foot

How
w to Calculate
Ca l e Gasa Flow
w Rate
at
Cubic Feet Per 3,600
Revolution
t n x Sec./Hr.
ec r
Cu. Ft.
Time for
f r One
O
= Per Hr.
Revolution
n (Sec.)
Sec.

0.5 x 3,600
= 75
24 Cu.
u. Ft.
Ft
Per Hr.

5
 Using Gas Flow Rate to
Calculate Heat Input Rate
Gas Gas Heat
Flow
F ow x Heating
n Input
= n u
Rate Rate Rate

75 x
1050 =
78,750
,7
Btuh
Bu
Cu.. Ft.
F Btu
B Per
Pe
Per
er Hr.r Cu.
C Ft.
t.

Check Temperature Rise

Supply Return

Temperature
empera u Rise
R se

Supply Air 135°

135°F
Return Air – 70°
70°F
Rise
is 65°F
5F

135 70

6
 To Calculate CFM
Temperature Rise Method

BTU Combustion
o b s o
X Efficiency
i e cy
Input
ut
= CFM
Temp.
T
1.08 X
Rise

Example:
Temperature
e t r Rise
s Method
M t od

78,750
7 0
X
.90
Btuh Combustion
t
Efficiency
= 1,010
,0
CFM

1.08 X 65
temp
em rise
se

Calculating the Sensible output of

the Condensing Unit

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

7
 Calculating the Actual output of the
Condensing Unit

• 1010 CFM
• ?? degree Delta Heat
• CFM x Delta H x 4.5 = Actual BTUH Output
• 1010 x ?? x 4.5 = Actual BTUH Output

Delta Heat on a properly

e operating
p n system will be
approximately
x 5.6
. degrees
e

It works both ways

CFM = BTUH / ∆Hx 4.5

OR
BTUH = CFM / ∆Hx 4.5

Electric Heat output 3-Phase

BTUH = VOLTSxAMPS x1.73 x3.414

8
 Now that Airflow is Correct
• We can begin by checking the refrigerant
charge.
• But FIRST, lets understand how the system
works.

SECTION
C N ONE
N

REFRIGERANT
PRESSURES, STATES
&
CONDITIONS

Load
o out
u to ambient
m i

Load
o in
n
from
f
house

9
Heat
e flows from
f hot to
t cold.
c d

Evaporator
Evapo at r Side
ide Terms
Ter

Evaporating
v g Pressure
e s

Low Side
d Pressure
s r

Suction
u n Pressure
r s

Back Pressure
ure

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

Condensing
C Pressure
res

Head
H pressure
u e

High
H g side pressure

Discharge
D
D e pressure
u e

10
 Compressor
 Pumps
u p refrigerant
ig r t vaporr only!
ly!
 Divides
D low
w and high side.

Discharge
harg Line
L ne
 Connects the compressor
to the condenser.

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

11
 Liquid
Liqu d Line
Line

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

Metering
M ng Device
Dev c
 Controls the flow of refrigerant.
 Divides low and high side.

Evaporator
rat r
 Absorbs heat into the refrigerant.
Removes
R e moisture
m ture from
o the air

12
 Suction
Su i n Line
Ln
 Returns superheated vapor from
the evaporator to the compressor

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

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

13
 CONDENSER
Temperatures
m e t

Pressures
e re

States

CONDENSER
ON E R INLET
N
⇓
High
h Pressure
ssu
High
h Temperature
e p r e →
Superheated
p e Vapor

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

Near
e r Ambient
A b n Temperature
m e t
High
i Pressure
r →
Subcooled
o Liquid
u
OUTLET
OU LE ⇑

EVAPORATOR
E APO RAT OR
Temperatures
Te p

Pressures
P s ur es

States
State

14
 Evaporator
p
inlett Metering Device
vc

⇓
Low
w Pressure
P e r
←Low
L w Temperature
T m e t
Aboutt 80%
0 Liquid,
iq
q id
20%
% Vapor
V
Saturated
S u t d vaporr →
(Temperature
( r in
which liquid
liq d is
changing
c to
oa
vapor)
va o ←Low
L w Pressure
P e re
⇑ Low Temperature
T m
Evaporator
v p or Superheated
t Vapor
p
Outlet

SECTION TWO
W

SUBCOOLING
&
SUPERHEAT

(Compressors)

Scroll
S l Compressor
pr
Operation
Op i

15
Subcooling
Su bc o lin and
n Superheating
r a g

The conceptsp s of subcooling

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

Subcooling
S bc o lin g

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

16
 210 psig = 105 ºF
-95 ºF
Subcooling 10 ºF

R-22
2

Condenser
e er Subcooling
ub ool i

TOTAL
OTA
SUBCOOLING
SU OOLI G

210 psig = 105 ºF

-90 ºF
Subcooling 15 ºF

Superheat
u rh a t

Superheat
p rh a is any
n heat
e t added
a d ed to completely
o p t ly
saturated
t r e vavapor
o that
at results
es in a rise
ri se in
temperature
e p r t re (sensible
se ib heate t change)
h g ) off theh gas..

17
 60 °F
F
76 psig = 45 °F
15 °F
F
Component
n superheat
e

Evaporator
v p t Superheat
uper at

Totall or System
S m
Superheat
upe h e t
Suction
S ucti n line
l ne
Temperature
T p r 8080°°F
76
7 psig
s ig = 45°
45°F
45
System
Sy te S Superheat
up 35°°F
at 35

SECTION THREE
H

METERING
DEVICES

18
 Thermostatic
h r o a ic Expansion
xp n n
Capillary
a illa Tube
u e Valve
a
Va

Automatic
u o a ic Expansion
Exp n n
Valve
l ve Fixed
ixe –Bore
o Piston
Pist n

Capillary
Ca illa y Tubes
Tubes
 Low Costt devicee
 Havee no movingg parts
r
 Cann be used
u ed on a wide
d range
e
of obsolete
o te applications
p c s

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

 Most
M s efficient
f ci

 M
Maintains
nta ns a constant
co evaporator
ev ap a
superheat
sup r eat

 Helps
H p prevent
e compressor
compress
flooding
flo i

19
 TXV Types
ype s

 Pressure
e Limiting
i i g

 Balance Port
P r
 Externally
n l equalized
a z
 Internally
ntte y Equalized
l

 Electric
c operated
r te

TXV Bulb
B Placement
l ent

TXV External
r a Equalizer
ua z Tapap Location
ati

20
Automatic
oma i c Expansion
E xpansi on Valves
a l es

 Maintain
a a constant
c n t evaporator
va o t r
pressure
ssu

 Used
U sed on
on small
a systems
e s which
ic
have
h ve constant
c n a t loads
a s

Fixed-
ed-Bore Metering
Fixed i Devices
s

 Most
st common
o m n today
o a on Residential
R s d n ia
i l
systems
e s 10
10 seer
e and
d below
w

 Dual
u purpose
p se device
d vic
Works
k as
a metering
e e g a device
e
Works
rk as
a a check
h c valve
lve

 Critical
C it a c charge
a

SECTION
SE I FOUR
R

System CHARGE

21
 Iss The Refrigerant Charge
ha g Correct?
e

 All
A refrigeration
r fr g n systems
y differ
f in the
amountt of charge
e they hold.

 There
r are guidelines,
i charts, and
a
techniques
i es to follow.
o o

 System
s m design
i & layout
o must be known
kn

How long & what size

s e
is the line set?
s t

What’
hat s the volume e of
the filter drier?
i

TXV CHARGING
C RG N RULES

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

22
 AIRCONDITIONING
ON IO G SYSTEMS
YS

Capillary
l Tubee
or
Fixed Orifice
O ii

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

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

 Proper
P evaporator
o to air
or a flow
w

 Accurate
c remote bulb temperature tester
tes r

 Accurate
A gauge
g e manifold
a set

SYSTEM SUPERHEAT CHARGING CHART


Indoor Wet-Bulb Air Temp rature
52 54 56 58 60 62 64 66 68 70 72 74 76
65ºF 6 10 13 16 19 21 24 27 30 33 36 38 41
Condenser 70ºF 7 10 13 16 19 21 24 27 30 33 36 39
Entering 75ºF 6 9 12 15 18 21 24 28 31 34 37
Air 80ºF 5 8 12 15 18 21 25 28 31 35
Temperature 85ºF
90ºF
95ºF
 8
5 
11 15 19 22
9 13 16 20
6 10 14 18
26
24
22
30
27
25
33
31
29
100ºF 8 12 15 20 23 27

To increase superheat remove refrigerant. To decrease superheat add refrigerant.

23
 System
S m Superheat
Supe he t
Suction
tio line
li
Temperature
em pe a 60 °F
p i = 45 °F
76 psig
Superheat
Supe h 15 °F
15

Alternate charging method

R22

Alternate charging method

R410A

24
 Alternate charging method
Lineset length and Grade separation

SAMPLE
QUESTIONS
U T

The high and low pressures in a

refrigeration system are separated by:

a. The compressor.
b. The evaporator.
c. The metering device.
d. The filter drier.

25
Subcooling can be defined as:

a. The cooling effect of an evaporator.

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

Always charge a TXV with a receiver and

sightglass under a:
a. No load condition.
b. Low load condition.
c. High load condition.
d. None of the above.

Superheat is defined as:

a. The heat added the the saturated

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

26
27
 Definition of
EXPERIENCE
Something acquired after
you need it…

Allow us to give it to you

before you need it, to be
ready!

"Experience is a hard
teacher because she
gives the test first, then
the lesson afterwards."