LESSON

HEAT PUMPS AND COMPLETE AIR

CONDITIONING SYSTEM

LECTURE
SUB-OBJECTIVE
At the end of the Lesson the Trainees will be able to demonstrate an understanding
of heat pumps complete air conditioning systems.
1.0

ROOF TOP UNITS

Roof top systems for heating and cooling were first developed for flat roof
commercial structures such as super markets and office buildings.
There are three types:
1.
2.
3.

Heating only.
Cooling only.
Both heating and cooling.

Being factory assembled and tested, the systems are economical. They are easily
installed once hoisted to the site. However, the roof must be strong enough to carry
the extra weight. Openings must be leak proof. Units must be designed for ease
of service even in very cold or inclement weather. They are also exposed to the
wind, which may affect their operation. The service technician must carry tools and
supplies to the roof. Equipment must be adequate to service the unit in all kinds of
weather. Fig. 10-5-1 shows a typical rooftop unit for both heating and cooling.
Another assembly is shown in Fig. 10-5-2. These units are completely weather
roofed since they are exposed to all kinds of weather. Access doors for inspection
are designed to operate safely under high wind conditions. Fig. 10-5-3 is pictorial
drawing of the refrigerating mechanism of a roof top unit. A complete heating and
cooling system is shown in Fig. 10-5-4.

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Fig. 10-5-1. Roof top unit for both cooling and heating. This unit has gas-fired
furnace.

Fig. 10-5-2. Cutaway of roof top unit.

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Fig. 10-5-3. Refrigerating circuit of rooftop system. Notice service valves, sight glass
and vibration eliminators.

Fig. 10-5-4. Combination heating and cooling rooftop system.

Electric heat may also be used in rooftop units. The electric heating elements are
partially removed from the housing. These heating elements are available in about
20, 40 and 60 kW capacities. Ceramic insulators carefully protect heating

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elements. The circuit has fuses, fusible links, and thermal cutouts.
Dampers control air. Sensing elements in the mixed-air duct control a motor, which
operates:
1.
The return danger.
2.
The conditioned air damper.
3.
The exhaust air damper.
4.
The fresh air damper.
Fig. 10-5-5 shows the air control system.
circulation systems.

The air is filtered as in other air

Fig. 10-5-5. An air control system for roof top unit. Dampers are automatically
controlled to always provide desired air mixture.

2.0

CENTRAL AIR CONDITIONING SYSTEMS

Central air conditioning systems are of two types:
1.
2.

Unitary.
Field-erected.

Central unitary systems are ideal for residential air conditioning. They are a
complete, manufactured package ready for assembly. All internal wiring and piping
has been done. The condensing unit is located away from the evaporator. There
are three evaporator designs in use:
1.
2.
3.

An A-type evaporator.
Slant type evaporator.
Flat type evaporator for horizontal airflow.

Three methods are used to install central air conditioning:

1.

One can purchase the condensing unit, evaporator, controls and tubing,
assembling the conditioner on the customer's premises. Most of these
systems are installed in forced warm air heating systems. Fig. 10-5-6 is a
drawing of such an installation.

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These units vary in capacity from 1 hp (approximately 12,000 Btu/hr) to

7 hp (60,000 Btu/hr or 63 300 kJ/hr). An oil-fired furnace, complete with a
comfort cooling A - type evaporator, electronic air filter, humidifier and blower
system, is shown in Fig. 10-5-7.
2.

The unit can be ordered completely assembled and charged including

condensing unit, evaporator, controls and tubing. The complete assembly is
shipped as a single package. Necessary tubing is usually carefully wrapped
around the evaporator.
Work required at point of installation includes;
a.

Uncrating and carefully unwinding the tubing from the evaporator.

b.

Installing the condensing unit and evaporator in their proper places.

c.

Making the necessary electrical and control connections.

Fig. 10-5-6. Schematic of residential central comfort-cooling system installed in

forced-air furnace. Condensing unit is mounted outdoors.

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Fig. 10-5-7. All season air conditioner with oil burner, evaporator, electronic air
cleaner and humidifier
This type of system requires some very careful handling. Since the
condensing unit is charged with refrigerant. The service technician must be
very careful while uncrating the tubing to avoid kinks which might later crack
and leak.
Fig. 10-5-8 shows an A-type evaporator. A condensing unit is shown in Fig.
10-5-9.
3.

The technician can get a completely charged evaporator, condensing unit

and lines. However, the condensing unit, evaporator and connecting tubing
are shipped as separate items.

Some systems use the liquid line as the capillary tube. This larger bore (ID) tubing
reduces the chance of clogging from dirt or moisture. It is very important, not to
shorten or lengthen this liquid line capillary tube combination when installing this
unit.
Many systems use evaporators with aluminum fins mechanically bonded to copper
tubing. Plastic grilles are often used on the condensing unit to avoid corrosion
problems.
Field erected air conditioning systems are systems in which all the components motor compressor, receiver, evaporator, piping, and controls are assembled and
erected at the spot where the system is to be used.
There are a variety of central field erected systems. Some are large systems,
which heat and cool a number of buildings or various parts of a large building.
Others are field-erected systems, which service one domestic building or a small

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commercial building.
These systems may:
1.

Cool and/or heat air, which is then distributed by a dual system.

2.

Cool and/or heat water, which is then pumped to heat exchangers in the
paced to be conditioned. The cabinets in the spaces have fins, filters and
controls in them.

Automatic controls make it possible for a system to change from heating to cooling.
The use of outside air is also controlled if the outside air is a degree or so above
the heating thermostat setting or a degree or so below the cooling thermostat
setting. The system then becomes an air distribution and air cleaning system only.
This permits greatest economy of operation.
Other systems use more fresh air as the outside temperature approaches the
temperature desired inside the system.
Solid state controls, operated by
thermistors, make this possible.

Fig. 10-5-8. An A-shaped evaporator designed for installation in warm air furnace
plenum chamber.

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Fig. 10-5-9. Condensing unit is for cooling system which uses an evaporator
installed in plenum chamber of warm-air furnace.
3.0

LARGE COMFORT SYSTEMS

Central station comfort cooling, part of a complete system is available in many
styles. One unit uses shell-and-tube construction in both the water-cooled
condenser and water chiller evaporator. This unit has a variable capacity system,
which unloads cylinders as the load decreases. These hydraulic controls also
unload the compressor to minimize starting load.
Another air-conditioning system circulates chilled water is the various cooling coils
in the multiple installation. Chilled water systems are used for many industrialprocessing installations. One of these units is shown in Fig. 10-5-10. The three
gauges shown are for suction pressure, oil pressure and high pressure. A
compressor of 10 to 15 ton capacity is shown in Fig. 10-5-11.
A water chiller using a serviceable hermetic compressor is shown in Fig. 10-5-12.
Its design permits the unit to be moved through regular doors. The chilled water
evaporator has built-in freeze protection. The motor compressor is a six-cylinder
unit with two cylinders in each bank. Fig. 10-5-13 shows internal construction.

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Fig. 10-5-10. Complete water chiller unit is typical of those used for industrial
processing.

Fig. 10-5-11. Cross-section of "Hermeticom" hermetic compressor. It is for use in

units ranging from 10 ton to 15 ton.

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Fig.10-5-12. This water chiller uses serviceable hermetic compressors.

Fig. 10-5-13. Cutaway of a six cylinder serviceable hermetic compressor motor.

Note arrangement of three piston rods on each crank throw.

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Fig. 10-5-14. Centrifugal compressor for hermetic chilled water system uses rotors
instead of pistons.
Many large comfort-cooling installations use centrifugal type compressors. Large
centrifugal units are frequently designed with capacities of 100 to 2000 tons. Their
basic design is shown in Fig. 10-5-14.
These systems use low-pressure
refrigerants, and the evaporator operates at below atmospheric pressures. Both
condenser and evaporator are the shell-and-tube type. Water lines vary in size
from 6 ips to 14 ips internal pipe size). The compressor is two-stage centrifugal,
driven by a hermetically sealed motor. Inlet vanes to the two-stage centrifugal
compressor control capacity.
The vanes may be either electronically or
pneumatically controlled or hydraulically operated. During starting vanes are
closed to reduce the starting load. Fig. 10-5-15 shows compressor construction.
The compressor has a forced lubrication system. A separate motor drives the oil
pump. The compressor motor is a three-phase unit of 208, 240, 440, 480, 550,
2300 or 4160 volts. Note bolted construction for service purposes.
These systems have an automatic purging device for removing non condensible
gases. Design and construction details of the condenser and the evaporator are
shown in Fig. 10-5-16. Because of their capacity, these units must have thorough,
accurate control.
Persons responsible for the operation of these units should receive thorough
training in their correct operation. These units are also used to cool process
liquids. The evaporator, compressor suction line and chilled liquid lines are always
insulated.

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Fig. 10-5-15. Two-stage centrifugal compressor. Oil pump is driven by separate

power source.

Fig. 10-5-16. Condenser and evaporator of large chilled water system which uses
centrifugal compressor.

4.0

REVIEW OF SAFETY
It is very important to be experienced (have some on-the-job training as an

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assistant to a service technician) before installing, maintaining or servicing air

conditioning systems.
It is vital to know the regional and local legal codes and regulations in force before
doing any type of work on air conditioning systems.
Whenever one works with equipment, which has electric circuits, fuels, vapor or
liquids under pressure, safety is the first thing to be considered.
One should always use instruments to check the equipment only by knowing what
the voltages are, what the pressure can one be reasonably certain of one's safety.
Avoid using any ignition source where there is any change of a fuel being present.
A friction spark, an electric (opening or closing switches) or a flame can ignite a
mixture fuel vapors and air which could be fatal and also damaging to property.
TEST YOUR KNOWLEDGE
1.

Where is steam jet refrigeration most used?

2.

What is the most common application of the heat pump?

3.

In automobile air conditioning, how is the compressor usually driven?

4.

What is the basic principle of operation of a room air conditioner installed in a

window opening?

5.

In automobile air conditioning, why is it necessary to use a magnetic clutch on the

compressor drive pulley?

6.

What changes from a liquid to a vapor in a humidifier?

7.

Will a dehumidifier, operating in a room, change the temperature within the room?

8.

In a heat pump installation, is the direction of flow of refrigerant vapor reversed

through the compressor when the cycle is reversed from heating to cooling?

9.

What is a common application of the vortex tube cooling system?

10.

Why are some furnaces known as gravity type?

11.

Can an air filter be used on a forced warm air heating plant?

12.

What is a hydronic heating system:

13.

What fluid action takes place to provide cooling in a cooling tower?

14.

Why is an automatic draft control needed on an oil burned installation?

15.

Name three common ways of heating the water in a hydronic heating system.

16.

In a window or through-the-wall air conditioner, what does the evaporator of the

heat absorb?

17.

In a complete central air conditioning system, where is the condensing unit usually
located?

18.

In an air-to-air pump installation, where is the heat to warming the room obtained?

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19.

Why is it necessary to provide supplementary electric heating on some heat pump

installations?

20.

Is steam jet refrigeration recommended for use where temperatures below freezing
are desired?

21.

What is one of the chief advantages when using a cooling tower?

22.

Where are the heating elements usually placed in radiant heating installations?

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