(ii)

EDUCATION AND TRAINING EQUIPMENT

Declaration of Conformity:
Directives
(where applicable) 89/392JCEE as amended by 91/368/EEC 89/336/CEE 72/23/CEE

We declare that the following unit complies with the above EEC directives:
A660 Air Conditioning Laboratory Unit

The use of the apparatus outside the classroom, laboratory, study area or similar such place invalidates confonnity with the protection requirements of the Electromagnetic Compatibility Directive (89/336/EEC) and could lead to local. prosecution. For and on behalf of P.A. niL TON LIMITED

Technical Director

n Ii~

I
P .A. HILTON LIMITED
Horsebridge Mill, King's Sombome, Stockbridge. Hampshire. SO20 6PX. England. Tel No. National Romsev (01794) 388382 International +44 1794 388382 Fax No. +44 1794 388129 E-mail: sal~s@p-a-hilton.co.uk

(iii) INDEx.

~
SYMBOLS AND UNITS SUFFDCES and/or STATES SCHEMA TIC DIAGRAM CONTROL PANEL DIAGRAM INTRODUCTION Air Conditioning Air Conditioning Plant Hygrometers Comfort Conditions Human Comfort OPTIONAL UPGRADES Order of Installation INST ALLA TION AND COMMISSIONING Accessories Installation Description Specification Services Required Useful Data Operation Shutting Down After Use Icing at Evaporator High PressureCut-Out High TemperatureCut-Out (In Duct) High TemperatureCut-Out (Steam Generator) RECOMENDED TEST CONDITIONS Humidification De-humjdification Unit Capabilities Energy Transfers MAINTENANCE Earth LeakageTesting Refrigeration Circuit Leak Detection 2
3

4 6

7 7
7 8 8 8

10 II
12 12 13 24 2S 26 27 28 29 29 29 29 29 30 30 30 30 30

32 32 32
32

(iv)

~
Re-charging

32 33 33 33 33 33 34
3S 36 36 36 38 41

n ~1 ,~~! t

Cleaning SuperheatControl Manometers Care of Boiler Wet Bulb Sensors Testing the RCCB

I
m

DETERMINATION THEORY

OF HEAT LOSS FROM BOILER

Composition of Air Behaviour of Moist Air Summary of Definitions and Terms The Psychrometric Chart SAMPLE TEST RESULTS AND CALCULATIONS Observation Sheet Derived Results SPECIMEN CALCULATIONS Calculation of Air Mass Flow Rate Application of Energy and Mass BalancesbetweenA and B

44 4S 46
47 47

47 . 49 50 53 55 56 58
61 61 62

I ~f: '.':

Boiler - Theoretical Evaporation Rate

Refrigeration System Application of Energy and Mass Balancesbetween B and C Volumetric Efficiency of Compressor

~~I!

Application of Energy Balance between C and 0 To Oetennine the Specific Heat Capacity (Cp) of Air SPECIMENS Observation Sheet Derived Results Sheet A660A DIGITAL TEMPERATURE Operation Maintenance A660B RECIRCULATING Schematic Diagram
Introduction

UPGRADE KIT

63 6S 6S

DUcr

UPGRADE KIT

67 70 72 73

Description

(v)

~
In Duct Orifice Calibration Operating Procedure Wet Bulbs Degreeof Recirculation SampleTest Resultsand Calculations AC660A COMPUTER LINKED UPGRADE and AC660B SOFfW ARE UPGRADE Introduction 75 76 76 76

77
83 85

APPENDICES A: A660A Digital Temperature UpgradeKit Installation Instructions B: A660B Recirculating Duct Upgrade Kit Installation Instructions C: AC660A Computer Linked Upgrade Kit D: AC660B Software Upgrade E: A660C PID Control Upgrade Kit F: A660D Environmental Chamber UpgradeKit

2
SYMBOLS AND UNITS Symbol

Quantity
Fundamental --

!l!!i!

A
H h

Area Enthalpy SpecificEnthalpy Current MassFlow Rate

Power Pressure(Absolute) Heat Transfer Heat Transfer Rate Electrical Resistance Temperature(Customary)

m2 J

J kgA kg Sol W . N m-l or Pa

lit P

p Q Q R
v

J
W Q C mJ kg"

Specific Volume Time Interval Orifice Differential Pressure

s
mrn H2O

.
J1
CJ) l\

Relative Humidity Percentage Saturation Specific Humidity Changeor Difference Bar = 105N mo:= 105Pa = 100 kN mo]

.Note:

Presentationof Numerical Data In this manual, numerical quantities obtained during experiments,etc., are expressedin a nondimensional manner. That is, the physical quantity involved has beendivided by the units in which it has been measured. As an example:

This indicates that

150

loJ Nm-2

or
alternatively

p = 150 x I ij3 N m-2 p = 150 kN mol

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7
INTRODUCTION

Air Conditionlne Air Conditioning, which may be described as the control of the atmosphereso that a desired temperature, humidity, distribution and movement is achieved, is a rapidly expanding activity throughout the world. Obvious applications for air conditioning are homes,hospitals,public meeting places,mines, shops, offices, factories, land, air and sea transport, but there are numerous other applicatiQnsin which human comfort is not the prime consideration. These include textile and printing industries, computers, laboratories, photographic and pharmaceutical industries, manufacture, inspection and storage of sensitive equipment, horticulture, animal husbandry, food storageand many others.

Air Conditionine Plant Air conditioning plant usllally consistsof a numberof components(e.g. fans, filters, heat exchangers, . humidifiers, etc.) enclosed in a sheet metal casing. Intake to the plant is usually from a clean external atmosphere(plus, in some cases,air recirculated from the building) and delivery from the plant is via ducting to suitable distribution points. Alternatively small self-containedpackagedunits may be used to air condition individual rooms or enclosures.

Components

f1!!m-

Coarse

- usually wire mesh. To remove insects,leavesand other large.

airborne particles. paper or viscous or electrostatic type. airborne dust.

"

Fine-

To removemost of the

~-

are required to cause the air movement and to make good the pressuredrop due to the duct and system resistances.

HeatExchan2er5 - which usually are finned on the air side, are neededto increaseor decrease the
air temperature. Heaters may use stearn,hot water or electricity as the heating medium Coolen may be supplied with chilled water or may be of the direct expansion type in which liquid refrigerant boils at a low temperature within the heat exchanger.

Humidifiers-

are used to increasethe moisture content of the air. Water may be sprayed directly into the air, may be evaporatedfrom a moist surface,or alternatively, steam may be injected into the air. The latter also results in heating of the air. are used to reducethe moisture content of the air. This is usually achievedby cooling the air below its dew point so that surplus moisture is precipitated. Sometimeshygroscopicmaterialsare usedto achievedehumidification, but, of course, these require regeneration.

Dehumidifiers -

Eliminators-

are speciallyshaped bafflesthroughwhich the air flows and which remove entrained waterdropletsfrom the air stream.
are employed to blend two streams of air to achieve a desired condition and/or economy.

~-

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8
Instruments and Controls are neededto sensethe condition of the air at various stations, and to vary the output of the componentsto bring about the desired final condition. In many
installations these may fonn part of a total building system. energy management

AssociatedEauiDmentmay include:

for humidification and/or for the air heaters.

Refri2eration Plant - for the air coolers/dehumidifiers.

HV2rometers are instrumentsfor measuringthe,moisture.content of the atmosphere. There are many types of hygrometerranging from the paper hygrometerwhich relies on the change of dimensions of vegetablematter with moisture content, to electronic sensors. Electronic sensorsusually operate on a capacitive principle. Two electJically conducting surfaces are separatedby thin insulating material. This fonns a capacitor in an electronic circuit. The insulating material used is hygroscopic(absorbswater) and changesvolume dependingupon its water content. This changein volume affects the thicknessof the material :md hencethe capacitance. The change in capacitanceis sensedby the electronic circuit and this gives an output that may be sensedby additional electronics and displayed digitally or sent to a computer. Unfortunately such sensorsare relatively expensiveand have limited accuracy(of the order of:!:3% RH). While this is acceptablefor general purposes, it is not sufficiently accurate for use with the Hilton Air Conditioning Laboratory Unit A660. The Hilton Air Conditioning Laboratory Unit employs the well kno\\n wet and dry bulb type hygrometer for detennining air condition. This is the most accurate method and is still used in whirling hygrometers which fonn the standardby which other sensing methods are compared. A brief description of the operation of the wet and dry bulb sensors used on the Hilton Air Conditioning Laboratory Unit A660 are given in this manual in the Theory section.

.
,

Comfort Conditions All animals consumefood (Chemical Energy),do work and reject most ot the unusedenergy to their surroundings principally to the atmosphere.

A manrejectsup to about400W (according to his level of activity) to tl-.eatmosphere. This heat

loss is accounted for by a combination of convection and radiation from his body surfaces, and evaporation of moisture from his lungs and skin. As the air temperature increases,the amount of heat which can be rejected by convection and radiation decreases, thus the evapordtioncomponent must increase. If the relative humidity of the atmosphereis already high, evaporation will be sluggish, skin surfacesb~ome wet, and the person feels uncomfortable. In hot ~ humid conditions, personnelare quickly exhaustedand are unable to maintain vigorous activity. In addition, theseconditions favour the growth of moulds and fungi some of which causeskin ailments. Very low humidities on the other hand.causerapid evaporationfrom the lungs, throat, eyes,skin and nasal passages and these can also causediscomfort.

Human Comfort
Depending upon their physical activity, clothing and surroundings,most people are comfortable in gently moving air (free of draughts) which is at about 20C and which has a relative humidity of ~

.. ~_.

.f;' 'i\ ...

9
about 50%. However, there is considerable variation of what is considered comfortable between individuals and betweennations, and in any case,there is a zoneof temperatureand humidity around the "ideal" which is acceptableto most people. The prime function of many air conditioning plants. is to provide a comfortable environment in terms of air freshness,temperature, humidity and movement. The Hilton Air Conditioning Laboratory Unit A660 allows the processes governing air conditioning to be demonstratedand investigated. It also allows studentsto investigate the measurementand calculation of all the thermodynamic processesinvolved in the heating, cooling. humidification and dehumidification of air. With the addition of optional items the A660 may be expanded to allow demonstration and measurement of the mixing of tWo air streams,electronic thermometry,computeriseddata acquisition and environmental control. The Hilton Air Conditioning Laboratory Unit A660 and its optional extra componentsare a valuable teaching aid for students in a wide range of courses from technician to graduate level.

t
10
OPTIONAL UPGRADES: The baseunit has a straight-through duct. Product description: A660 Air Conditioning Laboratory Unit The supplied unit will have a product code: A660220 for electrical supply 380/415 Volts, 3 Phase+Earth+N (5 wire supply) 50 Hz. OR A660110 for electrical supply 200/220 Volts, 3 Phase+Earth (4 wire supply) 50/60 Hz. Both units use single-phasecomponents,but require 3-phasesupplies. The total current exceeds normal single-phasecapacity. The loads on the S-wire model are between Line and Neutral 220/240Y. The loads on the 4-wire model are Line to Line 200/220Y.

Installation of the 200/220V 3-phase(4 wire supply) 50/60 Hz model includesthe correct positioning of a wire in the compressorstep-up transformer. Full details appearlater in this section. The following upgrades may have been received, if ordered together: AC660A Computer Linked Upgrade (Factory Fitted) or AC660A Computer Linked Upgrade Kit (Supplied in kit form for installation on site) Installation instructions are contained in Appendix C of this manual. AC660B Computer Linked Software Upgrade (Supplied on disk) Software installation instructions are contained in Appendix D of this manual. A660A Digital Temperature Upgrade Kit (Shipped in individual packing case,accompaniedby packing list) Installation instructions are contained in Appendix A of this manual. A660B Recirculating Duct UpgradeKit (Shipped in individual packing case, accompaniedby packing list) Installation instructions are contained in Appendix B of this manual.
A660C

pm Control Upgrade(Factory Fitted)

or A660C pro Control Upgrade Kit(Supplied in kit fonn for installation on site) Installation instructions are contained in Appendix E of this manual. A660D Environmental Chamber Upgrade Kit (Shipped in individual packing case, accompaniedby packing list) Installation instructions are contained in Appendix F of this manual.

11

ORDER OF INST ALLA TION WHEN RECEIVED WITH OPTIONAL factory fitted):

UPGRADES (not

:;tj\;.,:
d-,,: ~~,

12

Remove the unit from its packing case and examine it for damage in transit. contact the insurers without delay.

If damage is found,

The Air Conditioning Laboratory Unit dissipatesto its surroundingsa maximum of about 6 kW of sensible heat plus 4 kW as latent heat (water vapour) and has an air delivery of about 0.13 m3s'l.

It is desirablethat the intake conditions should be constant,thus, the unit should be placed in a room with sufficient volume and ventilation that ambient conditions are not materially changed when it is operating.
The unit must be positioned so that there is no obstruction to the air inlet or to the air flow through the condenser.

ACCESSORIES: C30/2S PF20/2 CS7/8 C30/14 CIO/2 C30/18 A660/6/1 A660/6/2 R633n/1 R633n/2 A66on/1 SFI/SS SF3/2 SFI/S6 C20/24 IM3/2 1M12/8 IM3/5 IM3/6 AS71/4/1 C4S/3 A660/IO/I LAJ/184 AS74/37/1 C20/4 E38/4S SF20/l 2 2 I I I I I I I I I 12 12 12 4 4 4 2 I 1 I I I 1 I I 2 Reinforced Supply and Drain Hose, 15mm push fit Stem Elbow, 15mm RI34a PressureEnthalpy Diagram R 134aThennal PropertiesTables EncapsulatedPsychrometricChart, SI units PsychrometricTables, 700 to 1100 mbar SchematicDiagram, A3 SchematicText Diagram, A4 A3 SchematicHolder A4 Schematic Holder Dust Cover M6 SS Washer M6 Nylon Washer M6 x 25 Hex Head Bolt Rubber Stopper,25mm dia. 300mm Spirit in Glass Thennometer, 0 to 50C Wet Bulb Spirit in Glass Thennometer, 0 to 50C 150mm Spirit in Glass Thennometer, 0 to 50C 150mm Spirit in Glass Thennometer, -10 to +1 10C Water Measuring Cylinder CompressorCharging Valve Key 10/1lmm Open Jaw Spanner Unpacking Case Label Evaporator Gasket Hose Clip, 13 to 20mm 8mm Nut Runner M6 Plastic Fluted Nut Set of Manometer Accessories(Fluid, filling syringe, scales) Product Envelopecontaining: Experimental, Operating and MaintenanceManual Test Sheet Packing List Wiring Diagram

13 Installation Remove complete unit from packing case and check with Packing List Before discarding any packing material ensurethat all items are identified and checkedagainst the Packing List. Ensure the Sparesare also identified.
2.

Detach the downstream duct from its storage position under the main duct. Examine the two wet bulb to water reservoirs and refer to Figure 7 on Page 22. to If the necessary reservoir the correct height of I OOmm ~ fitting the duct unit. set.the internal
Remove

3 4

the bolted supportangle from the evaporator lower flange and put to one side for
-

refitting later.

Fit the rubber evaporatorgasket(AS74/37/1) and downstreamduct to the evaporatorflange using the M6 x 2Smm hex head screws (SFI/56) and M6 washers(SF3/2) provided. Refer to Figure I on Page 14. Refit the lower support angle on the outside of the duct flange. Ensure that the flange is not over-tightened as damage to the evaporator flange will result. Ensure that the flange is tightened evenly.

6.

Ensure that no powcr connection has yet been made. Refer to the wiring diagrams supplied in colour and Figure 2 on Page 1S for 220V 3ph SO/60Hz units (Drawing No 6602SM) and Figure 3 on Page 16 for 41SV 3ph SOHzunits (Drawing No

66O22M).

The 2 x I.OkW re-heaters and duct thennostat in the downstream duct are connectedto the cables in the loose flexible conduit leading from the control panel. Note that the cables are marked with numbers that correspond to the wiring diagrams in Figures 2 and 3. Locate the appropriate wiring diagram for the unit and in Area 2A of the diagram locate the I.OkW Air Heater(First Reheat)and I.OkW Air Heater(SecondReheat). By convention the first reheater is closest to the fan. Using the 415V 3ph 50Hz wiring diagram, Figure 3, as an example. Connect the red wire labelled 253 to one side of the 1.0kW Air Heater(First Reheat). Connect the black wire labelled 254 to the other side and ensure that the black link 254 to 257 is made between both heaters. Connect the red wire labelled 256 to the remaining tenninal A connector block fitted to the downstream duct allows the earth lead from the heaten (green/yellow stripe) to be connectedto the earth lead in the conduit 255. Connect the wires labelled 251 and 252 to the thennostatas shown in the diagram Note that for operator safety it is essential that the earth leads are connectedconectly. Connection of the heaters for the 220V 3ph SO/60Hzunits are carried out in a similar manner with reference to the diagram, Figure 2. Note that in the caseof 220V 3ph SO/60Hzunits the heatersare connectedbetween phasesand connectionsto both ends of the heatersare red. The correct cable numbers should always be observed according to the diagram. Finally. fit the plastic terminal cover to the duct with the hex head screws provided

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18
1\/1

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200/220v
CONNECTINCOMING

POWERSUPPLY CONNECTION
3Ph 60Hz Machines ONLY

SUPPLY HERE{

u
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LINE CABLES SHOWN

EARTH CABLESHOWN
INCOMING SUPPLY"""
FIGURE 5

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19

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20
7
220V Joh SO/60HzMachines only The condensing unit supplied is suitable for operation on BOrn 50Hz and 60Hz electrical supplies. However, it is only available for operation on 220/250 Volt supplies. Therefore a step up transfonner is provided to increasethe voltage supplied to the condensing unit (ONL Y) to a suitable value. The transfonner is located on the lower frame adjacentto the condensing unit itself. Refer to Figure 4, Page 17. Remove the screws securing the transfonner cover and locate the brown wire. This will be factory fitted to the 230V input tenninal of the transfonner. It will be necessaryto measurethe line' to linez voltage of the local supply. This should only be undertaken by a competent person. Once the local line to line voltage has beenmeasured, connectthe brown wire to the transfonner tenninal that correspondsas close as possible to the measuredvalue. Replace the transfonner cover and securewith the original screws.
8

nov Joh SO/60Hz Machines Main Wirin2 Connection

If required by the local regulations, the following should be carried out by a competent electrician. Refer to the wiring diagram 6602SM and the detailed view of the main switch enclosure,Figure S on Page 18. The unit can draw up to 32 Amps on each phaseand the supply conductors should be sized for this current according to the local regulations. Remove the main switch and enclosure cover to gain accessto the terminals Connectthe three lines (LI, L2, L3) and the earthing conductor(E) as shown in the main switch diagram. Strain relief for the supply cable or suitable conduit should be titted according to the local regulations. For operator safety it is essentialthat a low impedanceearth of adequatesize is connectedto the unit earthing tenninal. Refit the main switch and cover. 440V Joh 50Hz Machine! If required by the local regulations, the following should be carried out by a competent electrician. Refer to the wiring diagram 66022M and the detailed view of the main switch enclosure, "igure 6 on Page 19. The unit can draw up to 20 Amps on each phaseand the supply conductors should be sized for this current according to the local regulations. Remove the main switch and enclosure cover to gain accessto the tcrminals Connectthe three lines (LI, L2, L3) and the Neutral (N) and Earth to the main switch as shown in the diagram. For operatorsafety it is essentialthat a low impedanceearth of adequatesize is connectedto the unit earthing terminal. Refit the main switch and cover

21
9,

Water Supply The boiler requires fresh water (if possible distilled or de-mineralised)at a maximum rate of 10 litre/hour with a minireum head of 2m. The boiler feed point is a I Smm push-fit fining labelled "cold water inlet" locatedbelow the fan. Connect this to the local water supply via an isolating valve using the water inlet tube assembly 1/1"bore (C30/4) and elbow (PF20/2) supplied in the accessorieskit. It is recommendedthat when the unit is not in use the locally supplied isolating valve is closed. Water will not flow to the boiler until electrical power is supplied to the machine. Inside the boiler are two electrical level sensersthat control the water solenoid valve.

Connectthe remaining hose to the overflow connection and position thee free end in a floor
level open drain.

Water Overflow In the unlikely event of component failure, the overflow pipe allows excesswater to flow from the tank and prevent water entering the air duct. Reducethe level by draining into a receptacle. The solenoid valve will open again to refill. Note than an open pipe extends from the copper overflow pipe vertically upwards and ends just below the frame. Do not block this as it is a syphon break. To test operation of the unit turn on the electrical supply and the water isolating valve. Turn on the unit main switch on the instrument panel, seecontrol panel diagram on Page6, and water will be heard to flow into the boiler tank. Observethe sight glass on the steamgeneratortank. Water should be seenin the sight glass and' then the level sensorwill close and turn off the solenoid valve.
10. Instrumentation The air condition is measured by four pairs of wet and dry bulb thermometers.

The wet bulb thennometers are pre-assembled(IMI2/8) and the dry bulb thennometers are selected from the OC to 50C 300mm thennometers(IM3/2) supplied. A sectional view of a typical wet bulb station is given in Figure 7 on Page22. To support the wet and dry bulb thermometersin the duct. rubber discs (C20n4) are supplied and these are carefully slid over each thermometer from the top down towards the measuring bulb. Adjust the height of the rubber discs so that when inserted in the measuring station holes in the duct the measuring bulbs are at approximately mid duct height. Tl and 1'2 are retained by thumb screws at the fan inlet. Th~ accuracyof the wet and dry bulb measurement will influence the overall accuracyof ~nergy balancesrelating to the air stream. To ensurema.~imum measurement accura<:y the wet and dry bulb thermometersmay be calibrated in water by selecting one thermometer as a reference,or by using a locally available reference. Nole that the optional A660A Temperature Upgrade Kit replaces all of the thennometerswith thennocouples and a single switched digital temperatureindicator. Marking all tht thennometers and recording variations from the reference will then allow individual variations to ~ addc.'d or subtractedas appropriate from the in duct measurements.

22

rTt ~ ~ ~ 1

A660: CROSS SECTIOr-J OF DUCT THROUGH WET BULB RESERVOIR

t6 V

CR'y 9..lB nRr'OETER NOT St-KJWN FOO CLARITY

CENTRAL

~L RESERV~

--~,10l
WATER "-

,.

br

0 0

NT~ RESERVOR

--~,~

r
~~RV~ L~G T~ TO LfJ$TFAN At{) OOW$TFAN~T$

~ TO

.FJ

t8

WET aJLB RESERV~

FIGURE 7

23
It is recommendedthat the wet bulb thennometersare kept wet when not in use to prevent the wicks drying out. This is best achieved by keeping the wet bulb reservoir full to its minimum level. The wet bulb reservoir should be connected,then filled with distilled or demineralisedwater so that scale depositsdo not build up on the wick material. Replacementwick material is supplied for future use (RMX8/2). The refrigeration system thermometer pockets (13, 14 and 15) are designed to accept either 1SOmmO-SOC thermometers(IM3/S), or -10 to + 110Cthermometers(1M3/6). The appropriate thermometer for the three measuring stations will depend upon the local conditions and the conditions establishedin the air duct. If the red spirit reachesa temperaturenear the top of the O-SOCtube then insert the higher l:al\ge theanometer.
II. Manometer Remove the blanking caps from the two manometer tubes and retain for future use.

Connect the grey plastic tube supplied to the tapping point on the side of the downstreamduct and to the left hand tapping on the manometer.
When the unit is in its final position in the laboratory, adjust the manometer level by releasing the right hand mounting screw and adjusting according to the integral spirit level.

With no air flow adjust the knurled nut on the right hand manometertapping until the red fluid is at the zero mark. 12. Fan Speed Adiustment Refer to Control Panel Schematic, Page 6. Switch on the power supply to the unit. Check all control panel s\vitches are otTo Isolate the water supply. Rotate the fan speed control fully clockwise to maximum speed. Switch on the main switch. The main solenoid will click and the fan will start. Reduce fan speed to the minimum stop (fully anti-clockwise) and observe manometerscale. It should be approximately 3mm HID or more. The following should only be carried out by a competent person as the adjustment has to be carried out with the power switched on.

~linimum fan voltageis adjustable by means of a singletrim potentiometer fitted to the Fan SpeedControl insidethe control panel. The controlpanelhingedlid mustbe opened to gain access to the inside. CAUTION - LIVE ELECTRICS!
Locate the potentiometer on the fan speedcontrol circuit board. This is a squareplastic device approximately 2cm x Icm x O.5cmwith a small brassscrew head on the top.
With the Fan Speed Control in the minimum (fully anti-clockwise) position, rotate the potentiometer to vary the fan speed to achieve 3mm H2O duct pressure.

Before closing the control panel, take this opportunity of testing the RCCB in accordancewith the instructions listed in the MAINTENANCE section. The installation is now complete

24
DESCRIPTION - THE HILTON AIR CONDITIONING (Pleaserefer to Sthematic Diagram, Page4) LABORATORY UNIT A660

Note that optional upgradesA660A Digital TemperatureUpgradeKit and AC660A ComputerLinked Upgrade Kit. and the item label numbers are shown. With the exception of filtration and mixing, the Hilton Air Conditioning Laboratory Unit has been designedto demonstrate and to evaluatethe energy transfersoccurring in all the processes which are required in an air conditioning plant. The unit is mounted on a mobile frame which housesthe refrigeration unit and stearngenerator Untreatedair entering the ducting passesin seri~ through An axial flow radial fan with speedcontrol (9) and (10). Steam can be added by a steam injector after the fan discharge(3). A pre-heater(4). A cooler/dehumidifier with a precipitate water outlet (5) and (22). Are-heater (6). An air measuring duct orifice (7) and manometer(14).

2. 3 4

6.

The arrangementof a pre-heaterbefore the evaporator/coolingcoil is I.ot standard air conditioning practice, but the heater has been included at this point close to the !i.earn injector for a specific teaching purpose. If the local relative humidity is close to saturation, injection of steam can simply result in the duct running with water as the air cannot absorb more vapour than that required to saturateit at the given dry bulb temperature. The addition of sensibleheat as well as the steam raisesthe dry bulb temperatureand takes the air away from the saturatedcondition to a lower Relative Humidity. Similarly, the location of steam injection before the evaporator/cooling coil is not normal for air conditioning where humidity control is required. This would usually be located after the evaporator/coolingcoil. However, in locations where the relative humidity is very low, the ability to demonstratethe de-humidification processwould be impossible. Therefore by injecting steam before the evaporator/cooling coil the relative humidity of incoming air can be raised close to saturation so that dehumidification &nd the mass transfer processcan iJe demonstrated.

In caseswherethe humidity and temperature control upgrade (A660C) is purchased, the stearn injectoris relocated to a pre-installed point after the evaporator/cooling coil.
With the physical arrangementdescribed above and by selection of the individual heaters.steam injection and refrigeration/cooling system, the following data may be readily obtained: (a) The condition of the air before and after the various processes(via wet and dry bulb sensors). (b) The energy transfer rate at each heater,the boiler, fan and refrigeration unit. (c) Air mass flow rates. (d) Pressures and temperaturesof refrigerant. (e) Refrigerant mass flow rate. (f) The generation of a refrigeration cycle diagram on a pressure-enthalpy chart for the refrigerant in use. The analysis of the energy transfers in the refrigeration system. (g) Rate of precipitation at cooler. This infonnation, combined with thc use of air and refrigerant tables or charts. enables the operator
to demonstrate and evaluate all the effects likely to be met in an Air Conditioning Plant. The unit is also an excellent vehicle for demonstrating energy transfers in steady now processessince it includes heating. cooling and work transfer (at the fan).

25
SPECIFICATION Duct Centre line length:
A660 A660B A660B

= 6886mm 100% recirc. Material: PVC Thermal conductivity: 0.16 W/mK Maximum temperature:70C
Air Throughput Pre-heater
0.14 m3 s.t (max)

= 2298mrn = 6098mm 100% fresh

Extended fin electric heating elements. 2 x 1.0 kW (nominally) at 220V . Effective iength: 1.414m

Exposed tubesurface area:0.0355m 2

Exposed fin surface area: 0.2876m 2 Cooler Direct expansion,extendedfin coil. Cooling rate approx. 2.0 kW 51S"o.d. copper tube, 20swg. 4 rows deep x 5 rows high: 0.253m1exposedto air flow. 61 fin plates: 4.227m1exposedto air flow.

Re-heater

Extended fin electricheatingelements. 2 x 0.5 kW (nominally)at 220V Effectivelength:1.414m Exposed tubesurface area:0.03SSm1 .
Exposed fin surface area: 0.2876m1 Centrifugal (variable speed). Power input approx. 120W, at 240V

Fan

50Hz.

R.P.M.: 0-2400 Power: 0-0.9A, 210W Volts: 220-240 Humidifier Electrically heatedand working at atmospheric pressure. Fitted with water level float switch and in line solenoid valve. Heaters: I x 1.0 kW and 2 x 2.0kW at 220V (nominally). Volume: 2.5 litres (to mid-sight glass) under control of level control float switch. Overflow protection: A secondfloat valve will open circuit at 4 litres in the event of failure of the level control float switch. Water Solenoid Valve: Orientation: Any Inlet Pressure:0-45 bar Power Consumption: 19v A Refrigerator Hennetic unit with air cooled condenser. Refrigerant: R 134aTetrafluoroethaneCFJCH2F Compressorspeed: 2700 to 3000 rev.minl at 50Hz. according to load. 3300 to 3600 rev.minl at 60Hz. Swept volume: 25.95 cmJ rev'l.

INSTRUMENT A TION
Air Flo\v Measurement

- A660 (with no optional uDllrades) Orifice plate with inclined tube manometer. Range: O-12mm Water

26
Temperature Measurement
Refrigerant Circuit 4 pairs Wet and Dry Bulb glass thennometers300mm long.

3 x 300mm Glass thennometers.

SAFETY

Refrigerator high pressurecut-out. Temperature limit (50"C) thermostatsat the pre-heaterand re-heater

stations.

All moving parts are enclosed. All electrical components are individually switched by miniature circuit breaker switches to protect against overload and short circuit. The unit is protectedby a ResidualCurrent Circuit Breaker which cuts off the power should the current in and out differ by more than 30mA, as in a leakageto earth situation To ensure heaters are not switched on without air flowing, the fan speedregulator is pre-set to give an adequateair flow as soon as the three phasemains switch is closed.

SERVICES REQUIRED Electrical Either 380/440 volt, 3 phase,50Hz. 5 wire system comprising 3 phases,neutral and earth. Typical line currents can be up to 20 Amps per phase.

Or

2. 208/220 volt, 3 phase, 50 or 60Hz. 4 wire system

comprising 3 phasesand earth. Typical line currentscan be up to 32 Amps per phase.

Water

Approximately 10 litre per hour at a minimum head of 2m. (To reduce scaling in the boiler this water should, if possible, be distitled or de-mineralised.) Note this can be a smatl reservoir specificatly for the unit and does not have to be a mains supply.

27
USEFUL DATA (see also.Specification)

Note:

For 380/440V 3ph. 50Hz. machines, the heaters are connected line to neutral and the heater voltage may be between 220 and 254V.

For 200/220Y 3ph. 60Hz. machines, the heaters are connected line to line and the heater voltage may be between 200 and 220Y.

The fan power input can be detennined from the graph (Figure 12) on Page 48 relating the Fan Power Consumption to Supply Volts.

The specificheatof air Cplir = 1.005kJ kg" 1<'\ The specificheatof waterC,Hel\t loss from boiler: 1.33~ I<
Orifice calibration:

= 4.18 kJ kg" 1<,1 (SeePage35)

~ ma . 0.0517

kg$-1

~ VD

Where, Z = Orifice differential (mm H2O) VD = Specific volume of air at Station D (from psychrometric chart) Compressor swept volume: 25.95cmJ rev" Compressor speed: 2700 to 3000 rev.min-' (typical at 50Hz.) JJOOto 3600 rev.min-' (typical at 60Hz.)
bar =

x 105 N mol

100 kN

mol (or

100 kPa) = 14.5Ibf in2

Absolute pressure = Gauge pressure+ Atmospheric pressure Standard atmosphericpressure = 101.3 kN m-z(1013 mbar) lkW = 3412 Btu h-'

.I

28
OPERATION (Pleaserefer to Schematic Diagram, Page4, and the Control Panel Diagram, Page 6) Check the wet bulb reservoiris filled to the level mark. Turn on the water supply to the boiler and supply power to the unit. Turn on the main switch on the left of the control panel and the water solenoid valve will be heard to open. (In addition, the fan will run as soon as the main switch is turned on.) The panel voltmeter will indicate supply volts L I to N (415Y units, or LI to L2 (220V units). Ensure that water is visible in the sight glass of the steam generator before turning on any of the steamgeneratorwater heaters. The eight switches on the control panel are combined double pole switches and miniature circuit breakers. These control all of the heatersand the compressorof the refrigeration systemas indicated by the labels on the panel. The MCB button on the left of the control panel (or two buttons in the caseof a 220V 3ph SO/60Hz unit) protect the fan supply from overload conditions. If the buttons protrude from their normal position then a fault condition will be indicated and the causeshould be investigated. It will also open circuit the supply to the main magnetic contactor. The unit is therefore shut down when the fan MCB is tripped. To reset these circuit breakerssimply press the button back in. Note that if the fault still exists the button will not remain in a locked position.

ill
On the left of the control panel is the fan speedcontrol. Turning the speedcontrol clockwise will increasethe fan speed.and anti-clockwise will reduce speed. Pressingthe biased switch will causefan volts to be displayed by the voltmeter. Note that the minimum pressureindicated by the manometershould not drop below 3mm water gauge when the fan speed control is fu\Jy anti-clockwise. This should be set as part of the (nsta\Jationand Commissioning procedure. See Fan SpeedAdjustment, Page23.

Obtainin2 Stable Conditions The unit should be started according to the above procedureand, dependingupon the parametersto be investigated,the appropriate controls turned on or adjusted. The time taken for the unit to stabilise will vary dependingupon the local ambient conditions. This can vary from 10 minutes to 20 minutes. The humidification processcan be started more rapidly if all the water heatersare turned on until the water is boiling. Then turn off the heatersthat are not required. Note that the refrigeration plant will not begin to stabilise from initial start up until the refrigerant shown in the variable area glass flowmeter is a column of liquid without bubbles. When changesare made to the conditions upstreamof the evaporator.the refrigerant flow rate will be seento alter due to the increasedor decreased heat loadi~g.

29
Shuttin2 Down After Use Before switching ofT: (a) Switch off all boiler heaters. (b) Switch off all air heaters. (c) Switch off refrigeration circuit. (d) Set the fan to maximum speed. Then allow the fan to run for at least five minutes to dry the ducting, after which the main switch and isolator may be switched off. Turn off the locally supplied water isolating valve and drain the steamgeneratorto reducescalebuild up. Icin2 at Evaoontor At low air flow rates, accompanied by low ambient temperature, it is possible for the R134a evaporating conditions to fall below OC/300 kN moJ. If this happens, it is probable that ice will fonn on the air side of the evaporator tubes and fins and on the expansion valve. While no damage is likely to occur if operated in this condition for a few minutes, it is inadvisable to operate in this condition since the ice will eventually stop the air now. Icing can be avoided by increasing the air flow rate and/or switching on the air pre-heaters.

Hi2h Pressure Cut-Out If the condenserpressureexceeds 1400 kN m-2gauge(e.g. due to restriction of cooling air flow), a high pressurecut-out will switch otTthe refrigeration compressor,but the air fan will continue to run.' The high pressurecut-out is adjacent to the compressor. When the condenser pressure has fallen to about 800 kN m-1 gauge, the compressor will automatically re-start if the control panel switch is still in the On position-

Hieh Temperature Cut-Out (In Duct) In duct thennostats are !ocated at the pre-heater and re-heater stations to limit the maximum temperature to 50C. In the event that this temperatureis exceededthe main contactor relay will open, turning off the power to all of the heaters(boiler, pre-heater and fe-heater). The fan will continue to run and so help to cool the duct.
Once

the temperaturehas reducedat both thennostats,the main contactor relay will close and supply

power to the heaters.

Hi2h Temperature Cut-Out (Steam Generator) The three heater elements fined to the stearn generator are fined with automatic reset high temperature cut-out devices. In the event that the user forgot to turn on the water surply to the steam generator the elements would boil dry and overheat. The thermostatswill turn off the power at the heater and prevent a dangeroussituation developing. The thermostatswill operate more than once, but it is not recommendedthat the situation is allowed to occur repeatedly as Ihe healers will eventuallv fail.

30

r!!

RECOMMENDED TEST CONDITIONS Provided the air temperatureis not allowed to exceedSOOC, any operating conditions may be used. However, satisfactory results are more likely to be achievedif the following points are noted
(a) l~umidification

When humidification is required, the rate of steam injection should not exceed that which. can be absorbedby the air. If it is found that mist is seen distance downstream of the steam distributor, either, (i) Reduce the heat inputsome to the boiler, or . (ii) (iii) Increasethe air flow rate, or Increasethe air dry bulb temperatureby switching on more pre-heat.

(b) De-humidification (i) When it is intended to demonstratede-humidification, the air should be fairly humid (say. 650/.)at Station B. If necessary, steam may be injected. The cooler hasa large surfaceareaon which the condensationtakes place. Due to this, an appreciabletime elapsesbefore condensate is dischargedfrom the drain at the same rate as it is precipitated. The changeof moisture content of the air is easily determined from the product of the air massflow rate and the changeof specific humidity. Agreement between this, and the drainagerate wilt be obtained after a sufficient period under steady conditions.

(ii)

(iii)

Unit Caoabilities As shown in the following observations and specimen calculations, the Air Conditioning Laboratory Unit may be used to demonstrate and evaluate energy and mass balances in most of the processes found in practical air conditioning plant, (i.e. heating, cooling, humidification, and de-humidification).

In addition. the unit may be used: (i) (ii)

To detennine Cp for air. (FromQ = ri1 Cp t\t. when 0) is constant)

To provide a hot, cold, humid or dry condition under which articles may be placed. (The article must be capable of insertion into the duct through the orifice plate.) To estimatethe volumetric efficiency of the compressor To draw the cooling curve for a boiler and estimate heat loss at various temperature differences.

Ener2v Transfen All the processesin the Air Conditioning Laboratory Unit may be treated as steady flow processes with insignificant changesof kinetic and potential energy. Thus. for any portion of the unit treated as an open system

Q-P=4H
L\H is the enthalpy rate(s) of the nuid(s) leaving enthalpy rate(s) of the fluid(s) entering

31
Q is the heat transfer rate (positive if ill the system) it is the work tra.'1sfer rate (electrical or mechanical)(positive if
f!:Q!!!,

the system).

1I .:: '

"'

r .\ I E. ~
!!; ~ it'.t

32
MAINTENANCE

,"~l r'
i

:! ~ II

WARNING:
I' I !: . "

Earth Leaka2e Testin2. Due to local legislation some establishmentsmaintain a register of electrical appliancesand subject them to periodic tests for earth leakageand earth continuity. Before conducting any fonn of will subject the unit or its components to abnonnal voltages, disconnect the power supply totest thethat following optional components if they are fitted: '

A660A Digital TemperatureUpgrade AC660A Computer Linked Upgrade

The digital temperatureindicator in the A660A kit and the data logger in the AC660A kit are both plugged into a 4-way socket at the rear of the unit. Unplugging them will disconnectthem from the system These components are likely to be permanently damaged if not disconnected before the other components of the A660 are tested.

Befri2eration Circuit The refrigerant circuit was correctly charged with approximately .4 kg of R134a before it left the P.A. Hilton Ltd., works. If it is found that there is continuous gassing in the R 134a flowmeter it is possible that a leak has occurred. The refrigeration condensingunit is of a standardand widely used type. It can be serviced by any

goodrefrigeration contractor.
Note that the unit should not be charged with any refrigerant other than.Jot;~~:: "Drop in" replacement or alternatives are.!!Q! suitable for use with this ~~Z~

~134a).

The unit contains sufficient Ester oil for its lifetime operation. Do not add any oil to the refrigerant circuit.

Leak Detection (i) Assuming that the refrigerant pressuregaugesread aboveatmosphericpressure,leaksare readily detectedby normal methods,e.g. electronic leak detector, or soap solution. Note that electronic leak detectorspreviously used for detecting CFC12 are often not suitable for detecting leaks of HFC134a. Check with the leak detector supplier for their suitability. (ii) If the refrigeration circuit is completely discharged,the systemmay be pressurised(through the charging valve) to about 600 kN m-2gaugewith dry nitrogen. Having located and rectified the leak, the refrigeration circuit must be evacuatedto IOmm.Hg.Abs.to ensureno moisture exists in the circuit, before it is re-charged. Always slacken the gland nut before turning the service valves. Retighten after movement. A 10/11 mm open jaw spanneris provided for this purpose.

Re-chareine Having establishedthat there are no leaks in the circuit, a cylinder of Rl34a should be connected to the charging point in the compressorsuction line. Purge the connecting pipe with R 134abefore tightening the connection to the compressor.

33
Turn the back seating valve spindle on the compressorsuction line two turns clockwise and allow the pressure in the system to rise to about 600 kN mo2. then switch on the compressorand allow refrigerant to flow into the circuit. Only R134a gas (not liquid) must be allowed to enter the system (i.e. the valve on the R13'~acylinder must be at the top). The charging processshould be interrupted at intervals of 2-3 minutes to allow the plant to stabilise. Continue to charge the circuit until the gassing in the flow meter ceases-and then add a further 0.5 kg. Back. seat the charging valve and disconnect the Rl34a cylinder. Retighten the glanc;inut on the service valves and replace the caps. Cleanine:

The air cooled condensermust be kept clean. If dust or fluff is seento build up on the heat transfer surfaces, it may be removed with a soft brush or with a compressedair jet.

Superheat Control The superheatcontrol is set to give approximately 3 to 5 K of superheatat normal conditions. If it is necessaryto adjust this, remove the cap nut from the expansionvalve. Rotatethe screw clockwise to increase the superheat. Any adjustments must be made with the unit running and in small increments (i.e. 1,4 turn), allowing time for the unit to stabilise between each adjustment. After adjustment, replace the cap nut.

Manometers This has been correctly filled and had a sealing cap fitted before leaving our works. The cap must be removed and the appropriate tube fitted before the manometeris used. If the manometerneeds re-filling or topping up, the correct fluid (supplied with the unit) should be used. If an alternative is used, ensure that it has the correct specific gravity as stated on the manometerscale. Care of Boiler If distilled or demineralised water is used, the boiler should require little attention. If untreated water is used: (i) It is possible that the heating elementswill require de-scaling after prolonged operation. Local experience with the de-scaling of the heating elements in electric kettles will guide the user in this matter.

(ii) There may be a tendency for the water in the boiler to "foam" as the concentrationof impurities increases. Foaming will cause the water level in the sight glass to behave erratically and water may be dischargedwith the steam into the duct. If this happens,switch off the heatersand turn off the water supply. Drain the water from the boiler through the drain point provided. Then turn on the water, check that the level rises to the normal position and switch on the heating elements as required. The frequency at which the boiler must be drained and re-tilled will be found by experience it is, of course, advisable to do this before foaming occurs.

Water for Wet Bulb Sensors It is necessaryto use distilled or demineralised\vater to fill the reservoir for the wicks of the wet bulb sensors. This is to prevent impurities building up in the wicks and reducing their absorption properties.

I
I I
, ,

34
The condensate from the air cooling/de-humidifying section may be regardedas distilled water and can be used for the above purpose.

, ' ! !':

If it becomesnecessary to replacethe wicks on the wet bulb sensors,it is essentialthat the new wick is in f1rn1 thennal contact with the bulb. This is achievedby pulling the wick in an axial direction (which will cause it to contract circumferentially) and then securing it with heat shrink sleeving supplied. T~tinl! the RCCB The Residual Current Circuit Breaker (RCCB) is situated inside the control panel adjacent to the power cable connector and main switch. The RCCB should be testedby a comoetent oerson at intervals as required by the local regulations. Remove the hex headscrews and open the switch panel. Supply power to the unit and turn on the main switch. Press the button marked 'Test' or 'T' on the RCCB, but DO NOT TOUCH ANYTHING ELSE INSIDE THE UNIT. The large lever on the RCCB should turn from the ON ('I') to OFF ('0') position immediately and the unit isolated from the supply. If this does not occur, the RCCB may be faulty and needsto be repaired/replaced by a qualified electrician. Return the lever to the ON ('I') position and the unit should be switched on again. Close and secure the switch panel in position with the hex head screws.

35
DETERMINATION OF HEAT LOSS FROM BOILER

Note that this can only be undertaken if the A660A Temperature Upgrade Kit has been fitted or if a thermocouple type temperature indicator is available. Tape a thennocouple onto the outer surface of the boiler at about the mid water depth. Switch on the heatersand raise the water temperatureto 100C. Switch (i) (ii) (iii) off the heating elements and then note, at intervals: The temperature indicated by the thennocouple. The time The ambient temperature (tJ. .

Draw a graphof temperature v. time, and from this estimate the rateof cooling(~ whenthe temperature is t OOC. L\time

Figure 8

From the dimensions of the boiler calculate the mass of water present (mw)' The water equivalent (mJ of the boiler is 0.54 kg.

Heat loss rate from boiler,

= (m.

+ m.>

x 4180

(~> A time

This is at a temperaturedifference of (100 - t.) K.

Thus,

Typically, for the boiler

Q=
AI

.33 ~ K

36
THEORY (Note: In the following, "stearn" and "water vapour" are interchangeable.)
~

I r

t "1

I.r I
I e I
I

ti i

Introduction Fresh air contains about 23% oxygen and 76% nitrogen by mass. The remainder is composedof small quantities of other gasesand vapours, and of thesethe most important is water vapour. The vaponr content of the atmosphereis loosely referred to as the HumiditY. Although the water vapour content is usually very small, (usually < 2%), it has a considerableeffect on the rate of evaporation from moist surfacesand materials. An understandingof the moisture content of the atmosphereand of how it may be controlled is an important part of the education of all engineersand technologists.

,1.

:t , .

:\.,
W.i

Behaviour of Moist Air Dalton's and Gibb's Laws give us the following conclusions, (i) Each gas or vapour in a mixture obeys its own physical laws as if it were the sole occupant of the space, at the sametemperatureas the mixture. (ii) The enthalpy, internal energy and entropy of a mixture is the sum of the enthalpies, internal energiesand entropiesrespectively, which each constituent would have if it alone occupied the spaceat the sametemperatureas the mixture.

Examole (See p-v diagram for steam) Let us consider air of specific humidity, i.e. massof steam mass of dry air of 0.0I at atmosphericpressureand 20C. The density of this air will be approximately 1.2 kg mo) The composition of I.Om} of this "air" will be:
lQ.Q.x 12 = 101

188 kg of dry air (i.e. the gases) 0.012 kg of HzO

.2

101

From Dalton's Law the H2O behavesas ifit was the sole occupantof the space(1.0m3). Thus the H2O is at 20C and has a specific volume of:

-L
0.012

= 83 m3 kg"

(Point A)

From steamtables we seethat at 20C, VI = 57.8 mJ kg-I and P...= 0.0234 bar (2.34 kN m-2),(Point B). The steam at A is therefore superheated and at a lower pressurethan 0.0234 bar. At low densities, water vapour very nearly obeys Boyle's Law, thus p" V" = PBVB

p" =

0.0234x 57.8 = 0.0163 bar (1.63 kN m-2)

83

In a stearn/air mixture, the ratio actual ressure 0 steam pressure of saturated steam at the same temperature

is called the RelativeHumidity (+).

37

~
..

.
p

..!;., ...,. _.2

p - V ~grOIl

for SleoII

\
\
0"2.34
200(

\
~.B

0016 0.0087

~
5(

"*
c

';::::~~:~:;;
, x. 0.56
~

578

83

147

-;Jkg-:r

Figure 9

= 83m} kg"' at 14C, Point C).

If our sample of air is cooled, at constantvolume, to 14C the steamwill just become saturated(v.

This temperature is known as the Dew Point. If the air is cooled, in thennal equilibrium, to a temperaturebelow the dew point, the steam in it must become wet, e.g. if the steam is cooled to 5C (Point D) when v. = 147m] kg-I, the dryness fraction (x) will be y- = .J1 = 0.56 v. 147 Thus, of the 0.012 kg of H2O in the air, 0.56 ;It 0.012 = 0.0067 kg will be saturatedsteam and, 0.44 x 0.012 = 0.0053 kg will be saturatedwater (liquid).

;tfl'

38
The liquid may appear as mist (i.e. suspendedwater droplets), or as condensationon the cooling surface.

~:

In this example it has been assumedthat (i) the air is cooled at constant volume (ii) the water vapour obeys Boyle's Law

However,the resultsare also substantially correctfor constant pressure cooling over the same temperature range.
From the foregoing it will be seenthat if the relative humidity is high, (up to 1000/0) the air cannot

absorb moresteamunless its temperature is raised).

The lower the relative humidity, the greaterwill be the readiness with which air absorbsmore steam. It is now necessaryto define some tenns of reference.

Summary or Definitions and Terms

Humidity When an atmosphere hasa large water vapour component,(e.g. in a room containing large quantities of exposedhot water), we say (loosely) that the humidity is high. Morc clearly defined terms are:
(i)

Absolute or Specific Humidity I) is the ratio (in a given atmosphere),

moss of water vapour

mossof dry air

Percentap;e Relative Humiditv (cjI)is the ratio,

(~ kg)

(ii)

p. = partial pressure of the steam in an atmospher;;x 100 (%)

p.
(iii)

saturation pressure of steam at the same temperature

Percentae.e Saturation (~) is the ratio, mass of steam in a given atmoshperex 100 (%) mass of steam to salUrate the atmosphereat the same temperature

~:

Under nonnal atmosphericconditions, the Relative Humidity=PercentageSaturation(within 1%).

The easewith which the air takes up moisture from any surfaceor processdependsupon how close the air is to being saturatedrather than its absolutevapour content. The relative humidity or percentagesaturation is therefore of greater significance than the absolute Q! specific humidity when drying or air conditioning processes are being considered.

39
Measurementor Air Condition
Dew Poin!

The dew point is the temperature at which the steamin the air becomes saturated and therefore beginsto condense to a liquid.
Above the dew point the steam in the air is superheatedat a pressure < Pili for the temperature. Below the dew point the water in the air will be a mixtUre of saturatedsteam and liquid water. Hence by slowly cooling a polished metal surface and observing when water begins to condenseas mist, the dew point temperaturecan be determined if the temperatureof the surface is known. The partial pressureof the steam in the atmosphereat the dew point temperatureis the saturationpressure of the water vapour at that temperature. Hence if~e know the atmospherictemperatureand the dew point temperature,we can determine the Relative Humidity with referenceto the Relative Humidity definition. For example, if the Ambient temperatureis 20C and the dew point temperaturehas been measured as 11C, from Steam tables
Temperature 20C II"C Saturation Pressure 0.02337 Bar absolute 0.01312 Bar absolute

Relative Humidity = 0.01312 x 100% 0.02337

= 56.1 %

.
The measurementof dew point temperature is carried out to measureair condition, but the use of "wet and dry bulb" temperaturemeasurementis more convenient.

II
Wet and Dry Bulb Temperature Measurement If a steam of air flows past a temperaturesensor having a wet sleeve of cotton or linen around it, the temperature recorded will be less than the actual temperatureof the air. The temperaturefalls due to evaporation from the wetted sleeveand as a result there is a transfer of heat from the air to the wetted sleeve to sustain the evaporation. The temperature falls to a steady state value called the wet bulb temperaturewhen the rate of heat transfer balancesthe loss of energy due to vaporisation. The actual temperature of the air is sometimes called the dry bulb temperature to emphasisethe destination. The lower the relative humidity of the air the more rapid the evaporation from the wet bulb and the larger the difference between the wet bulb and dry bulb temperature. When the air is saturated(RH = 100%) the wet bulb, dry bulb and dew point temperatureare the same. Since the evaporation.and hencewet bulb temperature, dependsupon the heat and masstransferrates trom the wetted sleeve, any slight draught increasesthe wet bulb depression. It is found, however, that though the wet bulb temperature falls for velocities up to approximately 2 mIs, it remains sensibly constant up to approximately 40 rn/s.

II

40

r
;

Provided that the air velocity remainswithin this range,the relative humidity can be determinedfrom the wet and dry bulb temperaturesalone. The wet bulb temperaturewithin the 2 m/s - 40 m/s air velocity range is often referred to as the "Sling temperature". The following equation may be used to determine the vapour pressurePv of the water in the air.
P.

- P., - 101.325 A (t~ - t..,

C

Where p.,

,.,
A

= Saturatedvapour pressureat tsli.. kPa = Sling wet bulb temperature ,., = Dry bulb temperature C

= 5.94 x

= 6.66x I O~K" whentsiinS ~ OC

10'" Ko1when t. < OoC sI,n.

(Ref. Chartered Institute of Building ServicesEngineers Guide, Volume C, 1988.) For example, if the dry bulb temperatureis 25C and the "Sling" wet bulb temperature is 20.6C, then, From Steam Tables at 20.6C Psi D 2.426 kPa

Hence,

Pw

2.426

101.325 x 6.66 x 10-4(25 - 20.6)

= 2.426- 0.2969 = 2.129 kPa p., = 3./66kPa

Relative Humidity =

From Steam Tables at 25C Hence, from the definition,

P.

p2.129 x 100% 3.166 67.2%

The above method allows relative humidity to be determined from wet and dry bulb temperatures and also allows for computerisedmonitoring and calculation of relative humidity. From Relative Humidity and dry bulb temperature all of the other relevant parameters may be determined by calculation, from tables or the psychrometric chart.

41
THE PSYCHROMETRIC CHART
While it is possible to calculate the properties of moist air from Dalton's and Gibb's Laws, it is far more convenient to use the encapsulatedpsychrometric chart provided. For the majority of situations the standardlarge psychrometricchart supplied in the spareskit (Part No C 10/2) will be sufficiently accurate. This chart is calculated for a barometric pressureof 1013.25mBar which is a figure for a standard atmosphereat sea level. However. under extreme weather conditions or at-very high or very low (below sea level) altitudes the effect of barometric pressurewill become significant. In order to allow for thesesituations a set of small charts are also supplied that cover the range from 700 mBar to 1100 mBar in 2S mBar steps. In order to use thesecharts measurethe local barometric pressureand convert ifnecessary to mBar. Note: mBar

= 0.001

Bar

= 100 N/m2 = 0.749mm Mercury

The nearest applicable chart should then be used for all calculations under those conditions. Given any two independentproperties, a state point may be marked on the chart, and from this a number of properties may be determined. The propertiesrelated by the chart are: . (i) (ii) (iii) (iv) (v) (vi) Dry bulb temperature Wet bulb temperature(sling) Specific volume Specific humidity Specific enthalpy Percentagesaturation (which may be taken as equal to relative humidity)

It should be noted that the specific enthalpy scale is the enthalpy of the dry air ~ the enthalpy of the steam associatedwith it (both reckoned from OC) but expressedin kJ/kg of 5!!Y. air. Example Observed Wet bulb temperature = 20.6C Observed Dry bulb temperature = 25C The state point on the psychrometric chart is located at the intersectionof 25C Dry bulb and 20.6C Wet bulb (sling) - see Figure 10, Page42. From the chart it will be seen that, at this state, the air has the following properties: (i) (ii) (iii) and (iv) Specific volume (v) = Specific humidity (co) = Specific enthalpy (h) = Percentagesaturation = 0.862 m]/kg 0.0135 kgikg 59.3 kJ/kg 67%

The percentagesaturation may be compared with the Relative Humidity calculated from the same wet and dry bulb conditions of 25C dry bulb and 20.6C wet bulb. From the chart, PercentageSaturation = 67% By calculation on Page40, Relative Humidity = 67.2%

42

0 I
~. I
..,.

/
-

/'

'.

.
.

.."... . 1 .. \. . .
..

\ \
..c

I;

0..
0-. _:~

1"-..A

~~~ ..:
-0-.\)

.. \ ~
. .

"'0 (/)

~ qq.

,---

w ;o.~ ,:..:-:!.

(") :J:

L: ~

~.j

> ~ -t

-< ('") :J: ~ 0 3: m -t ~

('")

= ~
=

-e' ~ ..)-. I,
2 "" III III C 2 "' C ~

/'"
0':-:

~ III '" 0 0 z ~ ~ ~ 2 0 ~ ~ .. 2 n

~ ;0

~#

.;. w ~

"
..,..~ ~

.. ..

.
of'"

'!.
"co

I
~ G "t ~ " ~.. ~ ~ ~
.

-,..

1.1. ,..","r.. 0"". . .,. c ...r0" ~.'. ~_'J'~ ..

~
01

1..
I"""\-; C"

.,.jor:';':","";O"~..r-.;

~I

~
..'
. o~ -c . . c .. .

'~,;;-::'if:::
. .-'

-."

... ~

w 0

_w 1ft

~ .. 1ft . >.. C .

1ft:: n

. 0

.. ..

. n
.. Z
)a ..
... ~ . )~

,'-fl"'.!~""';"I~r~!.

I~~: ~..
~

0: z

~..

~ =
-~:."" ". "" ':""""'~:'::';':'.": ';':'::-

CHSTUlf

(;

-,.

..
00

..

.s

".

CI

43

.~ ~

W Q: => ~ [[

"
"I m ~

\D
W

44
SAMPLE TEST RESULTS AND CALCULATIONS The following pages give typical observations and derived results from a test with the Air Conditioning Laboratory Unit. Note that if the AC660A Computer Linked Upgrade Kit has been fitted. the test results may be automatically recordedusing the data logging software. The data may then be converted to spread sheet fonnat and analysedon any suitable spreadsheet package. ; All, or any of the processes may be investigated in anyone test provided that the restrictions given in the RecommendedTest Conditions, Page 30, are heeded. i In the following results, all of the facilities are in use and the changesof the properties of the air, i.e. the wet and dry bulb temperatures the specific enthalpy the relative humidity or percentagesaturation the specific humidity or moisture content

and

are clearly illustrated and evaluatedby referring to the statepoints and processpaths plotted on the psychrometric chart. It should be appreciated that individual units will give slightly different results and that local atmosphericconditions will have a large effect on the initial condition of the air. I In addition, as statedin Useful Data on Page27, the actual output from all heaterswill be influenced by the supply voltage and this can be calculated using the heater resistance,and the 'local mains voltage which is given by the panel meter. The conditions for the following example test results were: lkW Pre-heating 2kW + IkW Steam Injection Cooling/Compressoron Re-heating IkW Air flow set to a low rate of 3-4mm water gauge (fthe A660A Digital TemperatureUpgrade Kit hasbeenfitted, then eachof the temperaturesreferred to on the schematic diagrams may be selectedand displayed on the digital indicator. ;

45
A660 OBSERVATION SHEET Atmospheric Pressure: mBar 2 I.
t1
tJ

TEST REF.
A Air at Fan Inlet

Dry Wet Dry Wet

Dry Wet Dry Wet

23.5
18.3 38.0 29.2

'C
C

After Pre-heat or Steam Injection After Cooling/ Dehumidification After Re-heating

t.

'C
DC

c n

t,
t,
t7

25.2 24.7
37.0 27.4 21.5

C
C

t.
tlJ tJ4

'C

Evaporator Outlet Condenser Inlet Condenser Outlet Supply Volts: Ll to N (415V) or LIto L2 (220V) Evaporator Outlet Pressure Condenser Inlet Pressure Condenser Outlet Pressure Duct Differential Pressure Fan- Supply Voltage ---Condensate Collected Time Interval RI34a Mass Flow Rate

'C
DC

81.0
43.0 225
290

tis VL
PI
p~

'C
VAC kN m1(g) kN ml(g) kN m1(g)
mm "10

1008 1000 3.9

100

PJ

z
Vr
m.

123
5

600 14.2

iii..,

g 5"

4~
I A660 DERIVED RESULTS
TEST REF.

--

Fan Power
(see Fan Volts v. Fan Watts curve)

P,

kW kW kW kW kW kW kW kW
kN m1 (abs) kN m1 (abs) kN m1 (abs)

0.080

1st Pre-heat Power ,,2/R @ 235V 2nd Pre-beat Power V1/R @ Boiler, Lower 2kW Power V2/R @ Boiler, Upper 1kW Power Vl/R @ 23SV Boiler, lkW Power V1/R @ 235V 1st Re-heat Power y2/R @ ..., 2nd Re-beat Powcr V1/R @ Evaporator Outlet Pressure Condenser Inlet Pressu~ Condenser Outlet Pressure Evaporator Inlet
Condensate Rate

a
C1
Q

,180

p p p
p

2.254 ISS

n
n
(}

p p
PI

390 1109 .101

PI PI
tli

'C
kg/sec

8.0
0.205

m.

!
47
SPECIMEN CALCULATIONS From the psychrometric chart on Page 42 the following air properties may be obtained:

I, = 23.3 C
~ = 18.3 C
t)

h"
Q)"

= 0.0109kg kg"'
= 94.4 kJ kg"'

51.3 kJ kg-'

= 38.0 C

hB
Q)B

t4 = 29.2 C

= 0.0219 kg kg"

ll~

= 25.2 C ~ = 24.7 C
ts

hc = 75.0kJ kg-' roc = 0.0195kg kg-

~ = 37.0.C
ta = 27.4 C

ho = 86.1 kJ kg".
(1)0

= 0.0190kg kg-I
= 0.905 m) kg"

Yo

11

From Steam tables:

For the ambient air the enthalpy of the water vapour, h. at atmospheric pressure = 2676 kJ kg-' Boiler feed water, hj at 20C (assumed)

= 84 kJ kg-'

CALCULATION

OF AIR MASS FLOW RATE

From Useful Data, Page27. Air mass flow rate, m,

ria,

= 0.0517 ~ ~ "0

0.0517

m,

~~ 0.101 k! 'y-l

APPLICATION

OF ENERGY AND MASS BALANCES BETWEEN A AND B

Using the Fan Power curve, Figure power is approximately 80 Watts.

on Page43, at a fan supplyvoltageof 100 Volts, the fan

'I ,

The majority of this will result in heating of the air streams via losses in the motor and friction effects. For the boiler heatersat 235 VL:
Upper 2kW Heater Power =

'Ii :.~ I~ '" :11

II

~
R. 2352
il

'i tl

= 2.254kW
lkW Heater Power Rb

24.S

2352 47.8 1.155 kW

48
Boiler Total Po~r InpIlI

Hence,

. 3.409 kW

2.254

1.155

For the 1st IkW Pre-heaterat 235 VL: Heater Power.

-~
R, =~
46.8 = 1.lAo kW

'-

..~
Figure 11 For the system enclosedby the chain line:

Ob

3.409 kW

By conservation of mass,

. 0.105(0.0219 - 0.0109) . 1.15 x 10-3 iI ~:I

111.(1).

- (I)..)

Applying SFEE, Heat Transfer Rate Work Transfer Rate Heat Transfer Rate. Work Transfer Rate:

Enthalpy ChangeRate

= Q. + Q, - -PI
= 3.400 + 1.180.. 0.080kW = 4.669kW

49

Enthalpy Change ~ate:

= m.(h. - h..) = 4.515 kW

This indicates a discrepancy of 154 W.

- m. h.
IS
X 10-3 X 84

= 0.107(94.4 - 51.3) -

There is also heat loss from the boiler, from Useful Data,Page27, heat loss rate from boiler = 1.33W/K. Allowing for a temperature difference of 100 - 23.5= 76.5K,theheatlossfrom the boiler is 1.33x 76.5 = ~ . .
Other discrepanciesmay be attributed to inaccuraciesin measurement,the use of the psychrometric chart and heat loss from the duct.

BOILER
Iheoretical Evaporation Rate Assumptions: ! (i) Steamproduced is saturatedat atmosphericpressureand has a specific enthalpy of 2676 kJ kg"'. I (ii) The feed water is at 20C and has a specific enthalpy of 84 kJ kg"'. (iii) The rate of heat transfer is 3.125kW 0.102 kW (calculated loss).

Rate of Evaporation
=

R
= t 1~ ._.~

3.12S
~

Ah

- 0.102 kg ,,"
x tn-) I.U lrn &6" ~-1

2676- 84

This may be comparedwith 1.15 x 10.) kg s.\ obtainedfrom the changeof specific humidity between A and B. ;

.,t~ : ;l: "~?'

..~t.. c"

:\t

REFRIGERATION SYSTEM The pressuresrecorded from the system are in gauge units relative to atmosphere. In order to convert these to absolutepressurethe local ambient pressuremust first be added. The ambient pressurewas
1010

mBar

or 0.757mm Mercury or 29.8" Mercury This equatesto 101 kN/m2. Hence, Evaporator Outlet 290 + 101 = 390 kN m-t 1008 + 101 = 1109 kn mot CondenserOutlet = 1000 + 101 = 1101 kN mot

Condenser Inlet
II

Ii

,I

Note that a measurablepressuredrop exists in the condenserdue to friction effects. The condenser is a commercial unit and as such is designedby the manufacturerswith minimum cost as a prime consideration. The evaporator,however, is purposedesignedfor the A660 unit and utilises oversize diameter tube to reduce the pressuredrop to a negligible value. Using the absolutepressuresand temperatures recordedaroundthe refrigeration system,a full cycle diagram may be drawn on a refrigerant Rl34a pressure-enthalpy diagram. The state points may be detenninedas follows. Refer to Figure 13 on Page51 where the state points are shown diagrammatically.

Evaporator Outlet/Compressor Inlet (State Point 1) Locate the 390 kN molhorizontal pressureline and its intersectionwith a superheatedtemperature of 21.5C (t,J. The vertical Enthalpy line hi at this point is 314 kJ kg-' and the specific volume is 1.056 mJ kg.l.

Condenser Inlet (State Point 2) Locate the 1108 kN m-: horizontal pressureline and its intersectionwith a superheated temperature of 81.0C (tI4). The vertical Enthalpy line hz at this point is 364.4 kJ kg-I.

Condenser Outlet (State Point 3) Locate the 110 kn moz horizontal pressureline and its intersectionwith the vertical sub-cooled liquid line from 43.0 saturatedliquid condition. It will be found that the point in this case is Q.!!the saturatedliquid line. This indicates that the liquid is not sub-cooled and reinforces the fact that the condenser is a commercial design. The Enthalpy h) at this point is 163 kJ kg"l. After leaving the condenserthe liquid enters the receiver and passesto the expansion valve where it is assumedto expand adiabatically from 1100 kN m-zto 390 kN mol. Hence a vertical line is drawn from State point 3 to State Point 4. The 390 kN mo2 horizontal pressureline also corresponds to a line of constanttemperaturebetweenthe saturatedliquid and saturatedvapour conditions at 390 kN mo2. The temperatureof saturation at 390 kN mo2 is Soc. The state points are shown on a real R134a Pressure-Enthalpy Diagram for reference in Figure 14, Page 52. The conditions may also be determined from the R 134atables provided.
From

the test results the following conditions may be detennined for the refrigeration system:
hi
~,

314.0 kJ kg-.

CI

51

0
OJ :J
-"'

<;~
> ~ a. d

.
~ > t)o \ W

L-

rr1

d L0

w
Ct:
~ ... '0 In

/'

. '1;1

:) ~ ~

In

II

01
&OJ (D C OJ U C 0 U

~ ~

,
~. m'1.1 :i:
~ .-

>.. a. 0 .c
c: w

0 ...;t

l!

l!

,c .Q
a. x w ~ """ ~ 0 ~

. .
: 1 f

+=

OJ
:J 0

""

(.
LOJ (J) C QJ U C 0 U
La a La

!
1 I

I
'I I

d > LU

a.

M I
m \D \D w

53

vI
h 1 h J =h 4

m,.,

0.056 mJ kg.' 364.4 kJ kg-' 161.9 kJ kg-I 14.2 g/s

APPLICATION

OF

ENERGY

AND

---

MASS

BALANCES

~-

BETWEEN

BAND ~

C-

he 9'.' kJ kg-1
we . 00219 kg kg-I B

:/
, I I \

,~

"

-"'. -

-" "
I I I ,

hC

.
.

75.0 kJ kg-1

J..L.

wC . 0.0195 kg kg-1
(
. ~ -1 O. ~7 kg s

\
\ \

r:tJ
..'~

}
..

I_b:~
t

..

'.."

"

"'

h1

314.0 kJ kg"'

~"C~lEnsote 0123kg 116005 iIe 0.205 x 1)-3

3kg -1 v1 . 0056m

~ . 1619 kJ kg-1

Figure IS From the observedand calculated data, the following parameterscan be stated for the system that fonns the evaporator of the refrigeration system between Stations B and C of the air conditioning system, Calculated rate of condensation from air stream: = '".(Co). Co)c) = 0.107(0.0219 - 0.019S)

= 0.256 x 10-3 q

.I-I

Observed rate of precipitation The discrepancy can be attributed to errors of measurement and the use of the psychrometric chart, to water retention by the fins on the evaporator.and to re-entrainmentof water into the air stream.

Application of the Steady Flow Energy Equation, Heat transfer rate. Enthalpy change rate There is no work transfer rate between Band C, thus Q,-c : m.(hc

- Work transfer rate - h)

- h,>

+ mh; + m,J.h.

(.Thi~ tenn is frequently ignored.)

54 m.(hc

- h.>

+ m.h;

. 0.107(75 - 94.5) +
= -2.07 kW

0.205 x 10-3 x 84 kW

m,J-h.

- hJ

=
a

14.2 x 10-3(314.4 - 161.9)

2.16 kW

<J.-c
<J.-c
I

-2.07 + 2.16 kW

= 0.09 kW

This indicates that there hasbeen a small external heat transfer betweenB and C. as the heat gained by the refrigerant is slightly higher than the heat given up by the air stream. Condenser Power Dissipation The refrigeration systemcondenserservesto reject heat from the systemthat hasbeenextracted from the air stream, via the evaporatorand the compressionwork input to raise the pressurefrom that of the evaporator to the condenser.

,
FO.R.

Application of the Steady Flow Energy Equation, Heat transfer rate = Enthalpy change rate

Work transfer rate

There is no work transfer rate in the above system, hence Qco.-lISU = tn", (~ = 14.2 X

- ~)
10-3 (161.9 - 364.4)

= -2.87 kW

Comoressor Power Inout and Coefficient of Performance

!!

the optional AC660A Computer Linked Upgrade is fitted then the compressor current will be recorded.

This, together with the mains voltage, provides an indication of the compressor electrical power input.

Typically the compressorcurrent under the test conditions, I. = 7.0 Amps. Hence the compressorreactive power
= 3 = VL x IC 235 x 7 1645 VA

55
Note that the true or active power would be V L Ic x Cos eJ Where Cas '2} is the power factor. The power factor is always less than 1.0 for an induction motor and is typically between 0.5 and 0.8 depending upon the quality of the motor. The coefficient of perfonnance of a Refrigerator Heat removedat Evaporator Qs-c Compressorwork W Based upon the refrigerant enthalpy change acrossthe compressor,
W = dire! (hi

= =

14.2 X -0.715 kW (Work into the system)

- ~) 10-] (314.0 - 364.4)

This compareswith the 1645 VA electrical input. The difference may be accounted for by power factor (Cas 0). motor losses and volumetric losses. From the example test results,

R heating losses,friction

Qs-c (basedon refrigerantenthalpy) = 2.16 kW

CoP for a refrigerator based on refrigerant enthalpy changeat the compressor.

- -2.16
0.715 3:.02

CoP for a refrigerator based on electrical input, 2.16 1.645 Ul It can be seen that the theoretical CoP is much higher than that based on electrical input.

~
Volumetric Efficiencv of Compressor Volume flow rate at compressor intake,

yI = =

m,q

VI

~r~ lit

0.0142 x 0.056
7.952 x 10-4 m3 .\'-1

'rom Useful Data on Page 27, assumea mean compressorspeedof 2700 + 3<XX> = .2
t.( /), I'X

2850 rpm at 50Hz. ~~\'i

,r...

Compressor swept volume,

56
VI I . _,i'~lf~:

11.

III

Swept volume x 10-4 . 7.952 c:c;'~'!" 1.232 X 10-J =.6ift APPLICATION OF ENERGY BALA~CE BETWEEN C AND D

For the final Re-heaterat 23SV,

Heaterpower Q,

Y! 2
R, 23S2
46.4 1.19 kW

hC - 75.0 k. kg,-1
wC a 0.0195 kg

hD - 86.1 kJ kg
,' t

g.,"
C

'~:r.'!

,
wD 0

. 0.0190 kg kg

rho - 0.10 kg s
". I '1

Or z

j'

1.19kW

Figure 17 Since there has been no increaseor decreasein the moisture content betweenC and D, (J)c and (J)D should be equal. The small discrepancycan be accountedfor by observation and instrument errors. Applying the SFEE between C and D,

Q = m(ho - hc>
ma(ho -hc)

= 0.107(86.1 - 75)
= +1.18kW

Discrepancies betweenelectrical input and air enthalpychangecalculationswill arise due to measurement and instrument errors. I

57
It should be noted that since there is no change in moisture content between C and D, the enthalpy change of the air may be calculated from,

t :-

A.H = m.
=

Cp(tO4

m. Cp(T7 T,> = 0.107 x 1.005[(37 + 273.15) = 1.26 kW

- tC)
(25.2 + 273.15)]

The difference between this and the previously calculated value of 1.18 kW can be accOUnted for by the factors mentioned above.

n
tf

I I I I I I I
~

58 ~o ~.EIERMINE THE SPECIFIC HEAT CAPACITY IC,\ OF AIR Providedno changeof moisturecontentis involved, the specific heat capacityof air may be determined by any convenient steadyflow process (e.g.heating or cooling).
Procedure Having switched on the Air Conditioning Laboratory Unit, the air flow should be set to a convenient value and the pre-heatersswitched to give 2 kW (nominal) heating. When conditions have stabilised the following observationsshould be made,
i

TvoicaJ Dry bulb temperatureat fan inlet t,

20.5 C 45.0 C 33.0 .C 17.3 C 4 mm H2O 110 V 110 V 1010 mbar

i i

I ! Ii

Dry bulb temperatureafter pre-heater t) Dry bulb temperatureafter re-heating t7 Wet bulb tempetatureafter re-heating ta Orifice differential pressure Supply Voltage Fan Supply Voltage Atmospheric pressure Z VL V,

Typical observationsare given in the following Observation Sheet,

Calculations Specific volume of air at orifice (from psychrometric chart and t7 and I.)

0.876 m) kg-I

Alternatively, since the relative humidity is fairly low (18%), the specific volume may be calculated from the gas equation,

..
=

RT ~1
P

xJ:}3.0+

273}. m3 kg-I

1.010 x IOS

0.870 m3 k-t

(The discrepancy betweenthe two values is due to ignoring the moisture content of the air. Using the Fan Power curve, Figure power is approximately 100 Watts. Air mass flow rate,
:

on Page 43, at a fan supply voltage of 110 Volts the fan

0.0517

. 0.0517 rI
a

rI ~"0
kg $-1

0.110 ia .I-I

~Wj

Applying the Steady Flow Energy Equation between StationsA and B Fan Power .. Q, = m. (h, - hA)

Iii

S9
A660 OBSERVATION SHEET Atmospheric Pressure. 1010 mBar 2 3 4

TEST REF.
A Air at Fan Inlet

Dry Wet

t.
t2
t)

'C

20.S

'C 'C 'C

'C 'C 'C 'C 'C
33.0 17.0 45.0

After Pre-heat or Steam Injection After Cooling! Dehumidification

Dry Wet
Dry Wet

t.
ts

c n

I,
t~

After Re-heating

Dry
Wet

t.
tu

Evaporator Outlet f:()ndenser Inlet Condenser Outlet Supply Volts: Ll to N (415V) or Lito L2 (220V) Evaporator Outlet Pressure Condenser Inlet Pressure Condenser Outlet Pressure Duct Differential Pressure Fan Supply Voltage Condensate Collected Time Interval RI34a Mass F1ow Rate

t,.
tl! VI.

'C
'C
VAC kN m1(g) kN m1(g) kN mZ(g)
mm H1O
4,0

235

PI

p,
P1

z
Vt
m.

10

iii ~,

g 5..

60
As there is no moisture change betweenA and B (there is no steam injection),

. m. C,..(t.~- fA)

m. Cp..(t)

fa>

C = Fan Power + Q. . P. m .) (t - t 1 )
From the mains voltage V L and the Pre-heaterresistances,

Q = ~ , #.8

+ .2352

= 2.39 kW -

46.4

This compareswith 1.005 kJ kg-' K-' as the acceptedvalue. This proceduremay alternatively be undertakenacross Station C to Dusing Re-heating.

61
A660 OBSERVATION SHEET

Atmospheric Pressure:

mBar

TEST REF.
A Air at Fan Inlet After Pre-heat or Steam Injection After Cooling! Dehumidification After Re-heating Dry Wet

t.
IJ tJ

'C 'C 'C 'C

Dry
Wet Dry Wet Dry Wet

t.
t!

c
D

'C 'C
'C

t, t, t,
tl)

'C
'C 'C 'C
VAC kN m2(g) kN ml(g) kN m1(g)
mm "10

Evaporator Outlet Condenser Inlet Condenser Outlet Supply Volts: LI to N (4ISV) or LIto L2 (220V) Evaporator Outlet Pressure Condenser Inlet Pressure Condenser Outlet Pressur~ Duct Differential Pressure Fan Supply Voltage Condensate Collected Time Interval
RI34a Mass F1ow Rate

t'4 t'$
VI.

PI

PI
PJ

z
Vt
m~

I
lit rcl

g 5-1

62
A660 DERIVED RESULTS

TEST REF. FaD Power (ste Fan Volts v. Fan Watts curve)
1st Pre-beat Power V1/R @ 235V

1.

P,

kW kW kW kW kW kW kW kW
kN ml (abs) kN ml (abs) kN ml (abs)

n
n
Q

2nd Pre-heat Power y1/R @ Boiler, Lower 1kW Power

V1/R @

p p
p p

Boiler, Upper 2kW Power V1/R @ 235V Boiler, lkW Power

n n
Q

y1/R @ 23SV
1st Re-beat Power y2/R @ 2nd Re-beat Power yz/R @ Evaporator Outlet Pressure Condenser Inlet Pressure Condenser Outlet Pressure Evaporator Inlet
Condensate Rate

p p
PI

p,
PJ
I"

'C
kg/sec

m.

1:11

63

Free Standing Instrument Case housing a Digital Indicator and 15-way Selector Switch with attached wet and dry thermocouples

65
OPERATION There are no special instructions for operation of the A660A Digital TemperatureUpgradeKit once correctly titted. When power is supplied to the A660 unit the display will automatically illuminate and display the temperatureselected. The numbers on the selector switch correspondto the temperature channel numberson the schematic diagram. Temoerature Indicator The digital temperature indicator has five function keys on its front fascia. These are used only

during manufacture to configurethe instrument..

Pressing the keys may disturb the displayed value. The displaywill revert to nonnal after a 60 second delay. The individual temperaturepoints referred to in the schematicdiagram are selected and displayed on the indicator by switching to the correspondingnumber on the selector switch below the digital temperature indicator.

MAINTENANCE In the unlikely event that the digital temperature indicator should fail to illuminate or show unexpected temperatures,check the following. .

Failure to IlluDlinate: Check that the 3-pin UK plug is inserted correctly in the 4-way socket at the rear of the unit.
2.

The digital display operatesat 220/230V on ~ local supplies. On European voltage (220V L-N) machines the supply is 1 phase and a neutral giving 230V. On 220V L-L machines the supply is 2 phasesgiving 220V. The 3-pin UK plugs contain a cartridge fuse in addition to the panel mounted miniature circuit breakers. Check the continuity of this fuse.

3.

Unexpected Temperatures Displayed: Check that the correct temperaturesensor is in the correct location. If necessary,remove the sensor from its expectedlocation and warm it to ensureits responseis correct. If necessaryand ice and water mix can be used to check the values indicated by all sensors. Broken thennocouples usually result in an extreme positive or negative display or a fault indication. If this occurs, the internal thennocouple connections may be checked after first removing the 3-pin UK plug from its socket or disconnecting the A660 unit from its power supply.

67

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72
INTRODUCfION The addition of the A660B Recirculating Duct Upgrade Kit allows investigation of the more usual practice of recirculating some of the used air from an air conditioning system. When properly proportioned, this reduces the energy requirements for obtaining the desired conditions within an enclosure. However, when incorrectly adjusted, either by negligence or by the desire to reduce running costs excessively,the result can be a condition sometimesknown as "sick building syndrome". Recirculatedair can contain dust,micro-organisms,smokeparticles (from cigarettes)and undesirable smells. Though the standardair conditioning fittings can remove larger particles. it is not normal for these to be capable of removing micro-organisms,smells and very small particles. Hence over a period of time conditions in the building deteriorate to the point where occupants become physically affected. The A660B allows the thentlodynamics of the mixing and recirculation process to be investigated for different recirculation ratios. A typical recirculating air conditioning system is shown in Figure I

- ~ Fresh = Air

FIGURE

Here two fans circulate air within the system,one passingair into the systemand another discharging air from the system. The ratio of recirculated air to recirculated air is controlled by a combination of adjustable volume control dampers and/or the fan speed. The addition of the recirculating duct to the A660 unit establishes a similar system but using one fan and one damper.
See Figure 2.

Refer also to the main Schematic Diagram on Page68. causesall of the air flow to be dischargedfrom the duct.

The volumecontrolwhen~

When the volume control damper is fully open the resistanceto air flow caused by the fresh air intake orifice causesthe majority of the air flow to be recirculated. By adjusting the volume control damper to intermediate positions the ratio of recirculated to fresh air may also be adjusted.

t:9; ,.. :II

73

"

FIGURE 2

DESCRIPTION Compare the Schematic Diagram for A660 Air Conditioning Laboratory Unit and Upgrade Kits
A660A, A660B, A660C and AC660A on Page 70 with the standard Schematic Diagram for A660 Air Conditioning Laboratory Unit and Upgrades A660A and AC660A on Page 68.

It can be seenthat all of the featuresof the original A660 unit are retained after the addition of the recirculating ductwork. The air flow from the fan at top left is still from left to right. Measuring Station A is still at the fan inlet. This is followed by the stearninjector and 2 x IkW preheaters then measuring Station B. The evaporator/chiller is between measuring Stations Band C and 2 x lkW Re-heatersare between measuring Stations C and D. The discharge orifice from the basic A660 at Station D is removed and replaced by a return bend. This brings the air flow down to a duct section with measuring Station E and an internal orifice plate. The orifice plate allows the volume of air passingthrough the fan to be measured. After the orifice plate is a T section with an exhaustand gravity operated flap valve on discharge. following the T section is the main volume flow control damper and mixing T. Fresh air is brought into the system through an orifice plate at measuring Station F. This orifice plate is retained from the discharge of the basic A660 unit. By comparing the total flow through the internal orifice plate at Station E and the fresh air at Station F. the volume of recirculated air may be calculated. After mixing, the air continues to the fan inlet measuringStation A. /\11of the functionality of the refrigeration system is also retained and energy balancesacrosseach component may also be carried out. The experimental procedure with recirculation is identical to that used for the basic A660 unit and is dealt with in the main manual from Sample Test Resultsand Calculations onwards.

74
The mixing processmay be investigated by the method in the following sections. However, the orifice plate at measuring Station F is in a "standard" situation in that the coefficient may be calculated from a standard reference (in this case,ISO TR IS377:1998). However, the in-duct orifice plate at Station E cannot be precededby the recommendednumber of effective duct diametersdue to size restraints. Therefore it is necessaryfirst to calibrate the in-duct orifice at Station E with the orifice plate at measuringStation F.

I,

75
IN-DVcr ORIFICE CALIBRATION --

The in-duct orifice plate at Station E may be calibrated by first fully closing the volume flow control damper. Ensure that the reservoirs for the two additional wet bulb stations at E and F (t,. and t12)are filled before operating the unit. Level and zero the in-duct and fresh air intake manometersand then turn on the unit., Set the fan speed at maximum and do not turn on any heaten or the refrigeration system. Fir the intake orifice, m,

- 0.0517 rI ~ v,

With the specific volume essentially constant and by conservation of mass, the coefficient for the air duct orifice may be obtained from,
iii.

In -duct

Coefficient

For example, the following conditions were recorded

~ -

21.3C Dry bulb at Station E

tlO = I S.4C Wet bulb at Station E tll - 19.6C Dry bulb at Station F tIt - 14.9C Wet bulb at Station F z. - S.4mm HzO Intake differential pressure(E) Zp; - S.OmmH2O In-duct differential pressure(F)
(The small differences in temperatureare due to the heating effect of the fan.) At Station F (the fresh air intake), tll = 19.6C and tl1 = 14.98C. From the psychrometric chart,
v

.
.

0.84,..3 kg-I

Hence, lit
= O.~17 f1I ~0:i4

o.l3.1 kg .r-1
110

At Station

the in-ducl orifice

r.= 21 3C and = 15.4C.

From the psychrometric chart.

v, .
0.131 =

0.84.1 m) kg-I

Hence
iii . . In-duct Co~ffic;~nt x ~ ~o:u;

MS3.8 =

In -duct Co~fficient

The value for each A660 unit is likely to be slightly different due to manufacturing tolerancesand local operating conditions.

76
OPERATING PROCEDURE Pleaserefer to the Schematic Diagram on Page70 (A660 with Recirculating Duct) and the Control Panel Diagram on Page6. The operating procedureis identical to that for the basic unit as given in the main manual from Page 28 onwards and including RecommendedTest Conditions. The only difference is that in order to control the degreeof recirculation the volume control damper in the lower duct is adjusted. The volume of fresh air entering the system is shown by the manometerand orifice plate at the fresh air intake Station F. The volume of air being passedthrough the air conditioning processes is given by the in-duct orifice and associatedmanometerat Station E. The difference betweenthe two figures is the amount of air retirculated.

Wet Bulbs
The recirculating duct has addedtwo wet and dry bulb measuringstations at E and f (t91trOttal and t.J. As the wet bulb reservoirs are in the lower section of the duct they have individual water reservoirs which must be filled with demineralisedor distilled water.

~
I~

De2ree or Recirculation Adjustment of the volume control damper allows the recirculation to be varied from 0 to approximately 100%. However, the maximum sustainabledegreeof recirculation will dependupon the local ambient conditions and the amount of stearn or heating that is applied, assuming that the refrigeration plant is also nmning. With no refrigeration, the heat put into the system will causethe temperatureto rise until the high temperaturecut-out operatesat a duct ajr temperatureof 50C. Similarly, a high degreeof recirculation together with steam injection can result in a large amount of water collecting in the lower duct where temperatureswill be lower due to heat losses.

77
SAMPLE TEST RESULTS AND CALCULATIONS The following pages give typical observations and derived results from a test with the A660 Air Conditioning Laboratory Unit with the addition of the A660B Recirculating Duct Upgrade Kit. Only the mixing section is dealt with as the procedures and calculations for the other sections of the system are identical to those given in the main manual from Page 44. Note that if the AC660A Computer Linked Upgrade Kit has been fitted, the test results may be automatically recorded using the data logging software supplied. The data may then be converted to spreadsheet format and analysed on any suitable spreadsheet package. It should be appreciated that individual units will give slightly different results and that local atmospheric conditions will have a large effect on the initial condition of the air.

The conditions for the following example test results were: IkW Re-heat I kW Steam Injection Air flow set to a low rate with moderaterecirculation

78
A660 OBSERVATION SHEET Atmospheric Pressure:

mBar I

TEST REF. Air at Fan Inlet Dry Wet

t,
fa tJ

'C
'C

21.9
16.6

After Pre-heat or Steam Injection After Cooling! Dehumidification Arter Re-heating

Dry Wet
Dry Wet Dry Wet Dry Wet Dry Wet

'C
'C 'C 'C 'C 'C 'C
'C
30.4 21.S 18.4 14.1

t.

c
D

t, t,
t.,

t. t,
t'l ill

Return Air

Fresh Air Intake

'C 'C 'C 'C

'C
VAC kN mJ(g) kN mJ(g) kN mJ(g)

tlJ
tlJ

Evaporator Outlet Cnndenser (nlet Condenser Outlet Supply Volts: LI to N (415V) or LI to L1. (1.1.0V) Evaporator Outlet Pressure Condenser Inlet Pres5ur~ Condenser Outlet Pressure Fresh Air Intake Differential Pressure Duct Differential Pressure Fan Supply Voltage Condensate Collected

t'4
t.s
VL

PI

PI p>

z,
ZE

mm HID
mm H1O

1..5

v,
ffi.

VAC g

It

Time Interval

I ritm
g 5".

RIJ4a Mass Flow Rate

79
RECIRCULATIONIMIXING

From the test results and the psychrometric chart. at the Fresh Air Intake Station F:

z, ttt tlJ V, W , h,
Hence,

1.5mm H2O 18.4C Dry bulb 14.loC Wet bulb 0.836 mJ kg.' 0.0082 kg kg"' 39.5 kJ kg-'

= =

iii,

0.0517 -'

~
v,

= 0.OS17 r:::i:L

~0:i36 = 0.069 kg .I-I

By conservation of mass this equals the air dischargedat the air exit. At the in-duct orifice Station E:

~ ~ = tit VE = WE= hE -

4.lmm H2O 30.4C Dry bulb 21.5C Wet bulb 0.876 m' kg-. 0.0124 kg kg-. 62.5 kJ kg-'

The air passing through the fan in A also passesthrough Station E.

mA
:

O.OS38 ~

~~

from the earlier In-duct Orifice Calibration, Page 75. Note that the value obtained for the unit in use should be used.
iii
A

= O.OS38

~ ~o:m

O.1163q.r-l

80
From Figure 3 and by conservationof mass, the air flow recirculated back to the mixing section

- m-m A ,
= 0.1163- 0.069

mA- m, = 0.0474 kg $-1

Assuming no heat loss or gain from the mixing section (adiabatic flow) and applying the Steady Flow Energy Equation:
hA

.
5.688 01163 ~ kJ kg-I

Substituting for the known values:

hA

By mass balance,

iii.. w..

mF WF + (mA - mF) WE

m, w, + (mA - mF) WE
w..
iii..

Substituting for the known values,

WA

= 0.JX)22kg kg-I Using the intersectionofh,. = 46.5 kJ kg". and w,. = 0.0099 kg kg-I, the State Point A may be plotted (Refer to Page42 PsychrometricChart) and comparedwith the observedvalue from t. and ~" the differences can be attributed to measurementerrors and heat loss/gain from the surroundings. Note that from the Steady Flow Energy Equation and conservationof mass, m.. h.. = mF hF + (m.. - mF) hE mA It can be shown that,

= m, + (mA- m,)

(mA- m,)
This is the ratio of
From the mass flows

m~-

~~ hA- h,.

0.069 0.0474 1.4SS:1

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85
INTRODUCTION The data logging software supplied with the AC660A Upgrade is an interim measure. Windows software will be supplied without further charge when available. The software provided is a fully operational copy of P.A. Hilton's HEAT97 data logging software with pre-configured tiles that relate to the transducerchannelsin use on the A660 unit. If the AC660A Computer Linked Upgrade Kit was factory fitted by P.A. Hilton Ltd. the configuration files on the disc supplied will be pre-calibrated to match the transducers on the particular machine. If the AC660A was user fitted, the calibration is carried out s part of the AC660B Software Upgrade installation carried out by the user. The GETTING STARTED section of the AC660B Software Upgrade manual deals with initial operation of the data logging software. The pre-configured files for use with the factory fined AC660A are: Channel config.fiIe Conversion Factors file Output file
)

66OCHAN 660CON 6600UT

The first screen displayed when starting the HEA1'97 software shows the file names of the. configuration files in use. The file namescan be changed by moving the highlight bar to the line required then pressingEnter. The flashing cursor will indicate that text can be changed. Then pressing Enter again will confinn . the change. Changescan be made repeatedly in the case of errors. Note that if a filename is entered for which there is no pre-configured file, a new file will be created. However, each parameterfor the system will have to be specified. Use of the above pre-configured files will ensurenonnal operation until familiarity with the software has been gained. It is recommendedthat the DLS Data Logging SystemSoftware User Guide. DLS/SOFT Issue .01, Ref. August 97 is read in order to expand on the capabilities of the data logging software. For reference.the Hilton Data Logger and Controller Connections,Specificationsand Instrumentation Set Guide is also supplied. This gives details of hardwareconnectionsto the data logger and ASCII serial commands for studentswishing to write software to accessdata directly from the data logger.

I
I

Free Standing Instrument Case housing a Digital Indicator and 15-way Selector Switch with attached wet and dry thermocouples

,
A660A DIGITAL TEMPERATURE FITTING INSTRUCTIONS UPGRADE KIT

Al

SUITABLE FOR: A660 Air Conditioning Laboratory Unit WITH OR WITHOUT: A660B Recirculating Duct Upgrade Kit OR: A660C prD Control Upgrade Kit

SKILLS REOUIRED: I. This upgrade is well within the capabilities usually found in a Laboratory Technician or similar tradesman. Only fitting of pre-wired thennocouples into the duct is involved. The A660A Digital Temperature Upgrade Kit is built and shipped on a transit rack to obviate tangles. The rack is hung on the rear of the evaporator. Each thermocoupleis unwound in turn and titted in place of a spirit thermometer. The power supply cable is simply plugged into a built in 4-gang socket outlet on the A660. One person can perform this upgrade. Expect the job to take less than two hours. No special safety considerations apply, with the exception of discoMection of electrical and water supplies in some cases,to gain accessto the rear of the unit. Operation of the A660 is unaffected. Temperature data is conveniently gathered at a centJal point.

STANDARD PARTS SUPPLIED:

-~--

Q1Y
6 3 6

DESCRIPTION Transit Rack, containing: Instrument Case with indicator and I S-way selector switch Dry Bulb, Type K Duplex Thennocouple, I SOmmacrylic Dry Bulb, Type K Duplex Thennocouple, IOOmmcopper Dry Bulb, Type K Duplex Thennocouple, 300mm acrylic Power Supply Cable (attached)

PREPARATION: Examine the packing case and infonn the shipping insurers immediately if damaged. 2
;' ,

Unpack and check ofT the contents against the Packing List. Note that the above list is for guidanceonly. The Packing List supplied in the product envelopeis fully detailed and accurate. Isolate the electric and water suppliesto the A660. Disconnectthem, if movementon the castor wheels is necessaryto gain accessto the rear of the unit. Movement may strain or fracture the supply lines. Remove and retain the existing wet/dry spirit thennometers Store them as a back-up system. Note that T9 to TI2 are only used when the A660B Recirculating Duct Upgrade Kit is

),

4.

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A3
INST A LLA TION:

Carry the assembly to the rear of the A660 unit.

2.
3

Unhook the elastic strap and releasethe instrument casefrom its transit position. Use one hand to hold the case and the other to hold the rack to avoid straining the umbilical cables.

that it hangsdown behindthe evaporator.

Place the instrument case on top of the evaporator and engagethe hooked edge of the rack so

4.

Rotate the tilting legs beneaththe caseand place on top of the evaporator. Unwind the wet/dry thennocouplesin turn and tit them into their duct locations or thennometer pockets as applicable. The schematicdial!rams show the correct Dositionsfor TI to TIS.

s.

6. Ensure the wet bulb locates inside the in-duct reservoir by entering centrally and at 90 to the
duct.

7.

Use the self-adhesive nylon clips to tidy the routing of the wires. Excess length may be left coiled on the rack.

8. Uncoil the power supply cable and plug into the 4-gang socket outlet.
9.

Ensure the wet bulb distilled water reservoir is filled to the Max level mark.

10. Restore power and water supplies and switch on the main switch. The digital temperature indicator will perform a self-test, then display the temperatureof the selectedchannel. The push buttons on the face of the indicator were used to pre-configure the instrument to read Type K thennocouples. They are not assignedto perfonn any function during nonnal use. Pressing the buttons may disturb the display, but the measuredvalue will return after a short pause. 12. Select each channel in turn to verify correct operation. Each dry bulb will indicate the duct air temperature. The wet bulb temperaturedepressionwill be a function of RH% and dry bulb temperature.

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84
A660B RECIRCULATING INSTALLATION DUCT UPGRADE KIT

INSTRUCTIONS A660 Air Conditioning Laboratory Unit A660A Digital TemperatureUpgrade Kit AC660A Computer Linked Upgrade Kit

SUITABLE FOR: WITH OR WlmOUT:

SKILLS REOUIRED: This upgradeis well within the capabilitiesIJsualJy found in a Laboratory Technicianor similar tradesman. Only titting of and tightening of fasteningsis involved. One person can perfonn this upgrade, but two arc preferred when manoeuvring long duct sections. Expect the job to take less than half a working day. No special safety considerationsapply, with the exception of disconnectionof electrical and water supplies in some cases. Where this upgrade is perfonned on a computer linked A660, a second differential pressure transducermust be coMected to the data logger. The ability to follow a wiring diagram would apply in this case. Follow instructions in Appendix C: Computer Linked Upgrade.

STANDARD PARTS SUPPLIED: PART No. A660B/I/I A660B/I/2 A660B/1/3 A660B/I/4 A660/6/4 A660B/4/2 A660B/4/4 A660B/4/5 A660B/4/6 A660/3/4 A574/37/1 RMX58/1 IMI2/8 IM3/2 C20/24 RMX57/1 C13/41 IMI6i'1 SFI/54 SFI/28 SFI/41 SFI/t02 SF3/2 SFI/55 SF4/4 RMX29/1 SF20/1 QTY DESCRIPTION 1 Air Duct 180 Return Elbow 1 Air Exhaust Tee I Air Inlet 90 Elbow 1 Air Volume Control and Mixing Tee (trolley mounted) I A3 Schematic Diagram 2 Duct Support Strap 1 Support Frame, Front I Support Frame, Rear I Castor Wheel SupportAngle I Duct Support Angle 4 Rubber Gasket, Duct Flange 3 End Caps to blank manometer 3 Wet Bulb Spirit in GlassThermometer,0 to SOC 3 300mm Spirit in GlassThennometer,0 to sooC 3 Rubber Stopper,25mm dia. I Duct Tape, 50mm wide I SqueezeDispenser,230ml I Inclined Manometer,0 to 12.5mm WG 2 M8 SS Washer 2 M8 x 20 Hex Head Screw 10 M6 x 20 Hex Head Screw 48 M6 x 30 Hex Head Screw 96 M6 Nylon Washer 116 M6 Plain Washer 58 M6 Nylock Nut JOOcm6mm bore Clear PVC Manometer Hose 4 M6 Plastic Fluted Nut

B5
A660B/5/2 Tool Kit (ratchet handle, IOmm/13mm tools)

PREPARATION:

2.

Ensure the area around the A660 Air Conditioning the completed recirculating duct.

Laboratory Unit is large enough to accept

Dimensions: Hei~60 mm Length 3630 mm Depth 530 mm

3.

A pre~assembled length of duct will be passed,from the fan end, under the existing duct. Total length of floor space required during assemblyis 6.6m. Unpack and check off the contents against the Packing List. Note that the Standard Parts Supplied list is for guidance only. The Packing List supplied in the product envelope is fully detailed and accurate. Isolate the electric and water suppliesto the A660. Disconnectthem if movement on the castor wheels will strain or fracture the supply lines.

4.

5.

6.

7.
8.

Remove and retain the wet/dry thermometers(T: and 1'2) at the intake to the fan.
Disconnect damage. the 12 water reservoir and drain into a receptacle, or tie the hose up to prevent

9. Remove and discard the fan finger guard by unscrewing the duct clamp.
EXTENDED FRAME SUB-ASSEMBL X Comprising: PART No. A660B/4/4 A660B/4/5 A660B/4/6 A660/3/4 SF1/41 SFI/55 SF4/4 SF20/1 QTY I I I I 10 20 10 4 DESCRIPTION Support Frame,Front Support Frame, Rear Castor Wheel Support Angle Duct Support Angle M6 x 20 Hex Head Screw M6 Plain Washer M6 Nylock Nut M6 Plastic Fluted Nut

10. Assemblethe three-sidedC-shapedframe to the right-hand end of the main frame. (See Figure I for correct positioning of the lower cross bar and castor wheels.) Do not fully tighten the attachmentscrews until they are all fitted. Fit the duct support angle shown in detail A of Figure to the plastic duct flange first using 2

86
plastic M6 thrum nuts as temporary fixings. Then use the remaining 2 plastic thumb nuts to secure the duct support angle to the newly fitted front and rear frames. 12. The castorwheel is fitted with jacking pads. Screwthesefully down, they may be adjustedafter passing the lower return duct assemblythrough the frame.

I
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EXIT ORIFICE

--

PLATE

SHIPPED SUB-ASSEMBLIES
180. RETURN ELBOWS

VOLUME CONTROL. MIXING TEE AND FRESH AIR INLET {TROLLEY HOUNTED)

RETURN DUCT. WITH FLOW ORIFICE AND EXHAUST TEE

FIGURE

-=

89
LOWER RETURN DUCT ASSEMBLY
-

Comprising: PART No. A660B/I/2 A660B/I/4 A660B/4/2 A574/37/l SF1/54 SFI/28 SFl/IO2 SF3/2 SFI/55 SF4/4 SF20/1 QTY I I 2 I 2 2 12 24 24 12 4 DESCRIPTION Return Duct with Flow Orifice and Exhaust Tee Air Volume Control and Mixing Tee (trolley mounted) Duct Support Strap Rubber Gasket,Duct Flange M8 SS Washer M8 x 20 Hex Head Screw M6 x 30 Hex Head Scre.w M6 Nylon Washer M6 Plain Washer M6 Nylock Nut M6 Plastic Fluted Nut

13. Connect the two horizontal duct sections (refer to Figure 2 to identify the duct work components)together on the floor to make the complete lower run of duct. Refer to Figure 3. 14. Refer to diagram for correct assemblyand note: . Use a steel washer and nylon washerunderthe headof each hex bolt and each nut. Do not over tighten. Use a rubber gasket betweeneach flange. . Exhaustgrille faces front, duct window is on top and thennometer reservoir faces towards the operator. The volume control handle facestowards the operator.

15. The exit orifice plate (removed at Step6 above)may now be fitted as the fresh air intake orifice. Refer to Figure 2. 16. Remove the TIO internal wet bulb reservoir from the bottom of the duct to avoid damage. Rotate the external reservoir to a horizontal position. This will be refitted later. 17. The duct sectionsare now ready for installation. Preparethe frame to acceptthe duct by laying the two flat strips provided on top of the lower main frame. Theseprovide a flat surface for the duct flange to slide along without damage. 18. Located betweenthe castor wheels,below the fan, there are two M8 captive nuts. These re the anchor points for the trolley. Screw in two M8 x 20mm Hex bolts with large M8 washers,from below. Enter by three threadsonly, final tightening will be done after docking the trolley. Comprising: PART No. SF1/54 SFI/28 QTY DESCRIPTION 2 M8 SS Washer 2 M8 x 20 Hex Head Screw

INSTALLATION

OF PRE-ASSEMBLED DUCT

19. The assistance of a second person is advised. 20. Position the pre-assembled duct in line with the existing duct at the fan end. Lift the return duct to rest the flange on the support straps.

B10
21. Push the duct through until the slots in the trolley engagewith the M8 anchor bolts. Do not tighten the M8 anchor bolts at this stage.

I !

812
VERTICAL DUcrs
Comprising. PART No. A660B/I/2 A660B/I/3 A574/37/1 RMX57/1 SFI/I02 SF3/2 SFt/55 SF4i4 QTY I I 3 I 36 72 72 36 DESCRIPTION Return Duct with Flow Orifice and ExhaustTee Air Inlet 90 Elbow Rubber Gasket, Duct Flange Duct Tape, sOmmwide M6 x 30 Hex Head Screw M6 Nylon Washer M6 Plain Washer M6 Nylock Nut

Refer to Figure 2 to identify the ductwork components. 22. Connect the 90 duct betweenmixing tee and fan inlet. Usethe duct tape to hold the alignment of the cin:ular stub with the fan intake, then fit the fast clamp. I 23. The TIO internal reservoir was removed at Step 16 above. Refit and reconnectto the external

reservoir. Referto Figure4.

24. CoMect the 1800double elbow to complete the circuit to the return duct. Refer to Figure S 25. Once all componentshave been coupled together,tighten the flange bolts, frame bolts (replace any plastic thumb nuts with the stainlesssteel locking nuts provided). Finally tighten the t"wo M8 bolts securing the lower return duct assembly. .

MANOMETERS
Comprising: PART No RMXS8/ I IMl6l1 QTY DESCRIPTION 3 End Caps to blank.manometer 1 Inclined Manometer, 0 to 12.5mm WG

26. Fit the new inclined manometerat the fresh air intake and adjust until the spirit level bubble is

central.

27. After levelling, the transit caps should be removed from both ports before zeroing the scale by use of the knurled adjusting nut. (Ensure the mm ~O scale is fitted.) 28. Connectthe hose betweenfresh air intake duct tapping and the manometerright-hand port. The left-hand port remains open to atmosphere. 29. The other inclined manometermust be removed from the upper duct and relocatedon the lower return duct. Disconnectthe manometertube and fit end caps to both ports to prevent spilla'ge of manometerfluid. Transfer to the new location on the return duct. 30. Level and zero as for the fresh air manometer,but connectthe hoseseither side of the in-duct orifice in accordancewilh the schematicdiagram, Page82.

I~

r'1 0' 0' ~ m

H13

A660

CROSS SECTION OF DUCT THROUGH WET BULB RESERVOIR t6 \i woe T W LB nJIOTER PART~ 1H12/8
DRY Bll8 T~~ HOT SHO'w'N ~ (LARTY

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B 'E.T B..I..B FE SE ~

814

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HIS
THERMOMETERS
Note that if the A660A Digital TemperatureUpgradeKit has beenpurchased,the thennometerswill be ultimately replaced by the thermocouplesensors. Comprising: PART No 1M12/8 1M3/2 C20/24 CIJ/48

QTY 3 3 3 I

DESCRIPTION Wet Bulb Spirit in Glass Thennometer, 0 to 50C 300mm Spirit in Glass Thennometer, 0 to 50C Rubber Stopper,25mm dia. SqueezeDispenser,230m.

Refer to schematicdiagram on Page '82 for the location of the temperaturemeasuring points 31. Connect the new T2 internal wet bulb reservoir to the main reservoir systemand replenish with distilled water. 32. Fill the new external reservoi~ located at TIO and Tl2. 33. Fit T 1'2, 1'9, TIO, TII and Tl2 wet and dry thermometers.

FUNCTIONAL TEST 34. Restorepower and water supplies and switch on the main switch. Run the following functional test with air heatersand compressoroff. 35. Open the volume control device and verify that 1000/.recirculation can be achieved. The exhaust gravity grille should close automatically and the inclined manometerat the fresh air intake should be reading approximately zero (denoting no incoming fresh air). 36. Adjust the fan speed conh"ol to vary the air now velocity through the duct. The total orifice differential pressurecan be set to any value betweenminimum flow (3mm H2O)and maximum indicated now (12.5mm H2O) Water Gauge. The maximum value achieved will dependupon the local mains supply voltage. 37. Shut the volume control and check that the exhaustgrille opens automatically. Both inclined manometersshould read approximately the samevalue, indicating that all incoming fresh air is passingthrough the exhaust. There may be a discrepancybetweenthe two readingsat identical mass flow. The in-duct orifice may be calibrated from the intake orifice when the specific volume of the air (m)/kg) is the same,i.e. TII = 1"9. A calibration constantmay be calculated and this is dealt with in the supplementto the main manual. 38. The maximum flow will decrease to lessthan full range of the manometer,possibly 9mm H2O. This is due to reduced pressureat the fan intake. Air at atmospheric pressureis now being drawn into the fan, but during the recirculation test air was being pushedinto the fan. The flow is further restricted by the work done to open the exhaustgravity grille and to force the flow through the two orifice plates. 39. Vary the position of the volume control to achievea visual representationof 50% recirculation, such as intake orifice = 2mm, total orifice = 4mm. Try 75% recirculation at, say, intake = 3mm, total flow = 12mm. (3/12 x 100/1 = 25% fresh) 40. The unit is now ready to perform the experimentslisted in the main manuaJunder the heading .,Additional Experiments with A660B Recirculating Duct Upgrade".

Must be preceded by, or concurrent with A660A Digital Temperature Upgrade Kit

Cl
AC"OA COMPUTER LINKED UPGRADE KIT INSTALLATION

- WtlEN

RECEIVED WITH FACTORY FITTED AC660A

Yau have turned to this APPENDIX C in compliance with the Installation instructions contained in the main manual. They are restatedhere. ORDER OF INSTALLATION WHEN RECEIVED WITH OPTIONAL UPGRADES:

On completion of the factory fitted computer linked upgrade, the Duct Differential Pressure Transducerwas disconnectedfor transit. The signal cable (labelled Channel20) remains connected at the Data Logger end and is coiled and tied to the frame. The logger power supply cable may have been unplugged during packing. They must be reconnected to complete the installation on site. The A660A Digital Temperature Upgrade is obligatory in accordancewith Appendix A of this manual, as is the AC660B Software Upgrade. Where this upgrade is perfOrD1ed on an A660 with A660B Recirculating Duct Upgrade, both differential pressuretransducers (Channels 20 and 21) must be connectedto the data logger and thermocouplechannels 1'9, TIO, Til and T12 utilised. Where this upgrade is perfonned on an A660 with A66OC PID Control Upgrade,the PID Controllers and the data logger may share the output from the duct RH% (Channel 22) and duct temperature (Channel 23) transducers. STANDARD PARTS SUPPLIED: PART No. 1M20/5 ES/4 ESnB E5/133 SFI4/1 E45/4 C7/3 C13/44 SF2S;2 C 19/6 RMX29/1 QTY DESCRIPTION 2 Differential Pressure Transducer,0 to 25.4mm H10 WG (one fitted) 2 IJA Plug 3 JA Cartridge Fuse 1 4-gang Extension Lead 4 Self Tap x 9.5 Diff PX 1 External Serial Lead, 25F 25 Cable Tie 20 Cable Tie. long 5 Cable Tie and Base 10 Self Adhesive Cable Clip 300cm 6mm bore Clear PVC Manometer Hose

C2
C48/2 AC660B 43/3

6mm Plastic Tee for manometerhose Computer Linked Upgrade Software 2mm Hex Saewdriver for Logger 25M to 9F Serial Converter Wiring Diagram, Logger to Transducers,Drg No 66OC04M

PROCEDURE: Isolate A660 unit from power and water supplies, 2

3 4

Plug the logger power supply cable into the 4-gang socket outlet. Connect the external serial lead by plugging' into the 'socketat the Status/Sample lamps The second4-gang extension lead is provided for use by a computer, monitor or printer, able to use the 220-240V AC available from the A660 socket outlet. This may be at 50 or 60 Hz. Unclip the coiled "Channel 20" cable attachedto the rear of the frame.

6.

Route the cable to the downstreamduct differential pressure transducer. Use self-adhesiveclips on the dud and cable ties to the frame to keep it tidy.

7. Connect the cablesto the transducerterminals specified on the wiring diagram No 66OC04M.
A660B only - Fit the spare transducer to the recirculating duct abo~ the inclined manometer. Pre-drilled fIXing holes exist in the ductfor this purpose. Connect the manometerhoses by teeing into the existing i1k."lined manometerhoses. The SchematicDiagram may be usedas a guide. Unclip the coiled "Channel 21" cable attached to the rear of theframe and connect.

8. All channels are now connectedwith the exception of the temperaturechannels. Install the
A660A Digital TemperatureUpgrade Kit in accordancewith Appendix A of this manual, but return to this section before doing a functional test. The leadsstowed in the tenninal blocks plug into the correspondingsocketson the data logger. Note that the coloured numberson the thermocouplewires relate to the channelnumberson the data logger tenninal label. Hence I (Brown or Green) is Channel 01+, 01-, terminals 02,04. The plugs are pre-wired in order and all that is required is to check the correct location of one channel on each block of 8. Refer to Figure 1 below.

T(J=

C3
FUNCTION TEST: ---

9.

Restorethe water and electrical supplies.

10. Switch on the main switch, the fan will run and the digital temperatureindicator will illuminate. II. Observethe Data Logger at the moment of switching on. The Sample/FaultLED should flash a few times as it perfonns a self-test, then go out. This LED will come on each time a logging sampleis taken when the computer is connected. The Power LED will glow continuously when power is supplied. 12. If satisfactory, continue with loading software and proving all channels. SeeAppendix D.

C4
AC660A COMPUTER LINKED UPGRADE

DISCLAIMER The upgradeproceduresoutlined in the following manual may, at additional cost, be carried out by Hilton personnelat our factory in the UK. If this option is chosenthen the normal Hilton parts and labour warranty will be applied to the modification. If the above option is not chosen and the upgrade is carried out by the customer or non-Hilton personnel,then P.A. Hilton lid disclaim all responsibility for accidents,damageor injury resulting from or during the upgrade procedureand/or by operation of the upgradedmachine.

AC660A COMPUTER LINKED UPGRADE KIT

-USER INSTALLED

C5

SUITABLE FOR: A660 Air Conditioning Laboratory Unit WITH OR WITHOUT: A660B Recirculating Duct Upgrade Kit A660C PID Control Upgrade Kit MUST BE PRECEDED BY OR CONCURRENT WITH: A660A Digital TemperatureUpgrade Kit NOTE: Customers who have purchasedA660A Digital Temperature Upgrade Kit and AC660A Computer Linked Upgrade Kit together should install the AC660A kit first followed by A660A, in accordancewith ApP.endixA of this manual.

SKILLS

REOUIRED:

WARNING:

Local regulations may prohibit unqualified personnel from undertaking any form of refrigeration work. Pressurised refrigerant within the systemcould escapeif fitting instructions are not followed exactly. Refrigerant gas or liquid under pressure can damage eyes, cause frost damage to skin, and suffocation if inhaled to the exclusion of oxygen. Compliance with the procedures listed below will reduce these risks.

WARNING:

This upgrade is well within the capabilities usually found in a Refrigeration Technician, Electrician or Electronics Technician. Operatives must have the ability to read a wiring diagram and make safe electrical connections.

Minimal computing skills are required, full instructions ar:eincluded in this Appendix, One person can perform this upgrade. Expect the job to take one working day.
Where this upgrade is perfonned on an A660 with A660B Recirculating Duct Upgrade, both differential pressure transducers (Channels 20 and 21) must be connected to the data logger and thennocouple channels 1"9, TIO, TII and Tl2 utilised. As it is possible at any time to purchase and fit the A660B Recirculating Duct Upgrade Kit it is recommended that BOTH the differential pressure transducers are connected to the data logger so that both can be calibrated for future use.

Where this upgrade is perfonned on an A660 with A66OC PID Control Upgrade, the PID Controllers and the data logger may share the output from the duct RH% (Channel 22) and Temperature(Channel 23) transducers.

C6
AC660A COMPUTER LINKED UPGRADE KIT CHANNELS USED CHANNEL
Numbr
LOCATION .widl recirculating duct models twidl PID control models A Fan Inlet Air (Dry)

SYMBOL
TI (AJ n(A.) TJ (8,) T4 (8.)

UNITS

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J 4

A Fan Inlet (Wet) B After Steam/Prebeat (Dry) B After Steam/Preheat (Wet) C After Cooling/Dchumidification C Alter Cooling/Dehumidification 0 After Reheat -+ to Room (Dry) (Dry) (Wet)

-c -c
8(:

s
6

TS (C,) T6 (C.) 1"7(0,) TI (0.) T9(E,) TIO (E.) TII (F,) TI2 (F.) TI3
T14

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9

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E Rettlrn from Room (DIy)E RebJrn from Room (Wet)F Fresh Air Intake (Dry).

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14

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F fresh Air Intake (Wet)Evaporator Outlet Temperatule ---

Condenser Inlet Temperature Condenser Outlet Temperature

Supply Volts - LI to N or LI Pressu~ to L2 (Hot) .

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16

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Outlet .

I'
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CondenserInlet Pressure
Condenser Oudete Pressure Duct Differential Pressure

21 22 2J 24
25

Fresh Air Intake DifferentiaJ Pressure-

Return Aw RH-I.t

Set Set Value Value % 0/.

Return Air Temperaturet Set Value OC

Fan Power (see Fan Volts Ys. Fan Watts curve) 1st Rc-hcat Power VIR @ 2nd Rc-heat Power VIR @ RI34a Flow Rate Boiler Lower 2kW Power V~ Boiler Upper 2kW Power V~ Boiler IkW Power VIR @ @ @

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OUTPUT
OUTPUT 2

C~ressor ~plc

Current

lamp

SIaIUS Lamp

On/OtT

C7
STANDARD PARTS SUPPLIED: Figure 2 or Figure 3 Figure 4

Wiring Diagram, Connection to Switch Panel (4l5V) Drg No 66OCO5M Wiring Diagram, Connectionto Switch Panel (220V) Drg No 66OCO7M Wiring Diagram, Logger to TransducersDrg No 66OC04M

PART No. QTY DESCRIPTION AC660/6/1 1 Refrigerant Flowmeter ft2, 0.05 to 1.6 Vmin AC660B 1 Computer Linked UpgradeSoftware PFI/34 1 3/8 Flare Copper Gasket E3/124 I Flowmeter Lead I Pre-wired DIN Rail Assembly (CT & Volts) AC660/5/1 SF4/3 2 M5 Nylock Nut 16 M5 SS Washer SFI/47 SF3/1 12 M5 Nylon Washer SFl/18 16 M5 x 12 Hex Head Screw AC660/2/1 I Heater Relay PCB 3 PressureTransducer,-I to +15 Bar (gauge) IM49/2 CIJ/56 3 P Clip for pressuretransducer C6I14 3 Capillary Tube with depressor 3 M8 x 25 Hex Head Screw SF1/29 SF1/54 3 M8 Washer, 19 o.d. 1 Data Logger with Hex key DLS/l/l 1 RS232 Socket. Statusand Sample Lamps HC655/5/1 2 Data Logger Mounting Plate AC660/1/1 1 Data Logger Power Supply Cable, 13A plug E3/249 4 Self Tap x 20 Logger SFI/118 C7/J 25 Cable Tie CIJ/44 20 Cable Tie, long SF25/2 5 Cable Tie and Base 10 Self Adhesive Cable Clip C19/6 RMX15/5 6cm 1/4" Nylon Tube RMX29/1 300cm 6mm bore Clear PVC Manometer Hose C48/2 3 6mm Plastic Tee for manometerhose E2/22 6 Crimp Terminal, 3.5mm fork E4/16 2 3 core, 0.5mm Cable, 4m long 1M20/5 2 Differential Pressure Transducer,0 to 25.4mm H2Q WG E5/4 2 13A Plug E3nS 3 3A Cartridge Fuse E5/133 I 4-gang Extension Lead 4 Self Tap x 9.5 Diff PX SFI4/1 E45/4 I External Serial Lead, 25F C20/28 2 Grommet for 30mm hole E43/3 125M to 9F Serial Converter

Small scale copies of the larger colour drawings supplied are contained in Figures 2, 3 and 4 for identification purposes. Ensurethat the correct mains wiring diagram is referredto, e.g. 415V or 220V as appropriateto the unit ordered and the local supply.

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Cll
STANDARD TOOLS SUPPLIED: A660/10/1 1 IO/llmm Open Jaw Spanner C4S/3 1 CompressorCharging Valve Key C4S/2 I Refrigerant Charging Line C13/63 I 4mm Flat Blade Insulated Screwdriver CI3/62 I 3.2mm Flat Blade Logger Terminals Screwdriver B500/10/3 1 No.2 Pozidrive Screwdriver AC660/3/1 2 3/4 x 7/8 AF OillE Spanner T/I/I I 90 Adjustable Spanner B500/IO/I 1 8" Parrot Nose Adjustable Spanner

TOOLS AND EOUIPMENT NOT SUPPLIED: Vacuum pump Tool kit Multimeter Wire preparation tools

PREPARATION: Examine the packing case and inform the shipping insurers immediately if damaged
2.

Unpack and check ofT the contents against the Packing List. Note that the Standard Parts Supplied and Standard Tools Supplied lists are for guidance only. The Packing List supplied in the product envelope is fully detailed and accurate. The refrigerant flow transducer and the pressure transducers are to be introduced into the refrigerant system. To achieve this without loss of charge, the RI34a must be pumped down into the liquid receiver. Run the compressorto facilitate pumping down Slacken the gland seal on the liquid receiver back-seatvalve then close (front seat) the valve. Retighten the gland seal.

,
7.

6. The refrigerant in the refrigerant flowmeter glass tube will stan to boil then becomedry.
The suction pressurewill fall to Zero bar (gauge). If allowed to continue to run, the pressure may fall to sub-zero. Ideally, switch QfE the compressorat zero so that opening the systemwill not causeair to rush in to fill the vacuum. A ~ positive pressureis more acceptable. The Rl34a is now retained in the liquid receiver. Close (front seat) the suction valve at the compressor(after slacking the gland seal). Close the liquid stop valve at the inlet to the expansion valve, thus isolating the system to be opened to atmosphere. Disconnect if

\0. Switch off and isolate the electric and water supplies to the A660 unit. movement in the castor wheels will strain or fracture the supply lines.

II. Open the main control panel to expose the DIN rail by removal of the MS hex retaining screws 12. Leave the A660 in the pumped-downcondition and proceed with bench assemblywork

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C13
DATA LOGGER PREP~RATION AND FITTING PARTS REQUIRED: PART No. SFl!47 SF3!1 SFl!18 AC660/1fl DLS/l!l QTY 16 12 16 2 I DESCRIPTION MS SS Washer MS Nylon Washer MS x 12 Hex Head Screw ~ata Logger Mounting Plate Data Logger with Hex key

Remove the 2mm hex socket screws with the Hex key provided and lift off the Data Logger cover. (Refer to Figure 5 on Page CI2.)
2.

Set the binary identification on Switch S17 (see following page for method). I
Move the Hz jumper ~osuit the electrical supply, 50 or 60Hz.

3.

4.

s.

All thennocouple grounding switches should be,!!r.. The duplex thennocouples are grounded via the digital temperatureindicator. I The power supply must always be set for 240V when fitted to the A660.

6. Refit the cover but use the top four screws only. The remaining screws will not be accessible
when fitted to the A660.

7.
8.

Remove the four rubber feet from the baseand fit the two mounting plates horizontally, in their place. ; Fit the assemblyto the rear of the upstreamduct betweenthe Evaporator and Preheatercover. Threadedbrass inserts: exist in the duct for this purpose. The Logger terminals must be nearest the Evaporator. the terminal label will then be the correct way up.

C14
AC660A LOGGER

-SWITCH

S17. BINARY IDENT SWITCH

The RS232 addressof the logger must be set to identify the type of machine. The first portion of the switch, labelled P & L on the PCB, are for identifying how many loggers are daisychainedtogether. The AC660A utilises a single logger therefore P & L are both set to the off position. 2 The software for the straight through A660 air conditioner will have less temperaturestations than a recirculating duct A660B air conditioner. The remaining six switches.labelled D. E. V. I. C and E. are used to identify the machine. A660 = 25. A660B = 26 and A660C (pID Control Upgrade) = 27. LOGGER NUMBER No.3 ON ON
No.2

No
ON OFF

OFF ON

Single Logger OFF OFF

SWITCH NUMBER OFF

0 I 0 2 -

BINARY VALUE
P L D E V
Single logger off, off=O On-I On=2 00=4 00=8 On = 16 On = 32

2 3 4 S 6 1 8

OFF OFF OFF OFF OFF OFF OFF

3 C 4 5

AC660 Fitted to A660 (STRAIGHT THROUGH) LOGGER No ZERO Off 0 I 0 .t 2 :I 4 P L D E V I C On=8 On = 16

Bin ary MachiRe Identity No. 25

2 3 4 S 6 7 I

Off ON OFF OFF ON ON OFF

Single logger off, off=O

On=l

S E Total = 2S DUCT UPGRADE) 0 0 P L 0

V

AC660 Fitted to A660B (RECIRCULATING LOGGER No ZERO

..
~

OFF OFF OFF ON OFF ON ON OFF

2 3 4

Single logger off, off=O

On = 2
00=8 On = 16

Bin ary Machine Identity No. 26

S 6 ~ 1 ~ .

3
4 S
C E

Total = 26

CIS
AC660 Fitted to A660C (pm CONTROL UPGRADE) LOGGER No ZERO OFF 0 I 0 I 2 3 4 S P L D E V I C E 00=8 On = 16 Single logger off, off=O

Binary Machine Identity No. 27

2 3 4

OFF ON ON OFF ON ON OFF

On=1 On=2

6 7 8

Total ~ 27

C16
CONNECTIONS

-SWITCH
1 1 QTY I 2 8 4 6 I I 25

PANEL TO DATA LOGGER

PARTS REOUIRED: Figure 2 or Figure 3 PART No. AC660ISI1 SF4/3 SFl/47 SF3/1 SF1Il8 AC660/2/1 HC6SSISII C7/3 Wiring Diagram, Connectionto Switch Panel (415V) Drg No 66OCO5M Wiring Diagram, Connectionto Switch Panel (220Y) Drg No 660CO7M DESCRIPTION Pre-wired DIN Rail Assembly (CT & Volts) M5 Nylock Nut M5 SS Washer M5 Nylon Washer M5 x 12 Hex Head Screw Heater Relay PCB RS232 Socket, Statusand SampleLamps Cable Tie

Removethe 4Ommplug from the baseof the switch panel. This hole will be the exit route for the RS232 connector and other cablesto the Logger. RS232. Status and Samole Lamos 2. Remove the 92mm x 92mm dummy DIN casefrom the hinged lid and fit the RS232 module in place of it.
),

Route the RS232, status and sample cables out via the 40mrn hole. You may prefer to mark these wires now, to avoid confusion when making the connection at the logger end.

Heater Relay PCB 4. Fit the heater relay PCB to the centre of the rear face of the switch panel. Four captive nuts exist for this purpose. The terminal block with short red and black wires should be at the bottom.

s,

Route the two multi-core cablesout from the PCB via the 40mm hole. Wire to the logger later.

6. Connect the Red and Black cables from the PCB to DIN rail terminals specified on the wiring
diagram.

Pre-wires DIN Rail 7. Fit the pre-wired DIN rail assemblyto the baseand to the right of the existing DIN rail. 8. Route the metre flying leadsout to the logger via the sparecable gland on the right.

9. Connect the short flying leadsto the DIN rail tenninals specified on the wiring diagram above.
Note that the wire from the Line Filter must passthrough the Current Transfonner to enable compressorcurrent to be sensed. The redundantcompressorwire may be left in the loom but cut the exposedcopper wires ofT where it was disconnectedfrom the DIN rail. Connect to the Data L022er 10. Route all cables to the logger tenninals through the tnmking provided. Connect all cables to the logger terntinals specified on the wiring diagram above. 12. Tidy excesslengthsand securewith cable ties. Ensurethe hinged lid can be openedand closed without straining cables. J. The 40mm plastic plug should be drilled or punchedout, cut and refitted to protect cablesfrom sharp edges.

C17
CONNECTIONS

-TRANSDUCERS

TO DATA LOGGER

PRESSURE TRANSDUCERS (CHANNELS 17. 18 and 19) PARTS REQUIRED: Figure 4 PART No. IM49/2 CI3156 C6I14 SF1/29 SFI/S4 T/I/I 8500/10/1 QTY 3 3 3 3 3 1 1 Wiring Diagram, Logger to TransducersDrg No 66OC04M DESCRIPTION PressureTransducer,-1 to +15 Bar (gauge) P Clip for pressuretransducer Capillary Tube with depressor M8 x 25 Hex Head Scre..w M8 Washer, 19 o.d. 90 Adjustable Spanner 8" Parrot Nose Adjustable Spanner

Examine the capillary coupling tubes. Note that one end contains a depressorpin and both ends are fitted with an "0" ring. The depressorwill unseata Schraedervalve when fitted to the rear of the pressuregauge,giving accessto system pressure. Fit a capillary tube to each pressuretransducerwith the depressorat the free end. Use two spannerto tighten - one to hold the hex boss of the transducer,one to turn the capillary nut. Detach the pressuregauge housing fi"om the frame plate and rotate it to gain accessto the Schraederpressuretappings. (The housing remains tethered by the system capillary tubes.)

4. Remove the dust caps from the Schraedervalves.

s.

Have the 90 adjustableand parrot nose spanners ready. The next operation must be perfOmted smartly to avoid loss of refrigerant charge.

6. Attach the first capillarytube,makingsureit is not cross-threaded. The first threaddoesnot

cause the Schraedervalve to open. Finger tighten the nut to reach the "0" ring seal quickly. Finish tightening immediately, using the 90 adjustablespannerto hold the gauge tee and the parrot nose spanneron the nut.

7.

Repeatthis operation for the other two gauges.

8. Fit the large "P" clips to each pressuretransducerand secure to the M8 captive nuts on the
pressuregauge housing.

9. The condenserinlet and outlet pressuregaugeswill be indicating pump-down pressureat this

time. Do a leak test using soap and water solution to confirm these connectionsare gas tight. A complete system leak test will be done later. 10. Identify the cables to avoid cross-channelconnection at the logger. II. Securethe gauge housing to the frame plate.

12. Route the cables to the logger via the tnmking attachedto the condenser. 13. Connect all cables to the logger tenninals specified on the wiring diagram above. Tidy excess lengths and securewith cable ties.

CONNECTIONS

-TRANSDUCERS

TO DATA LOGGER

DUCT DIFFERENTIAL

PRESSURE TRANSDUCERS (CHANNELS 20 and 21)

Channel 2] applicable to A660B Recirculating Duct Upgrade only. However it is recommendedthat it is connected to the Data Logger and calibrated by connecting in parallel with the Duct Differential Manometerfor later use. Once calibrated in accordance with the AC660B Software Upgrade Kit it may be disconnectedand stored. PARTS REQUIRED: Figure 4 PART No. RMXlS/S RMX29/1 C48/2 E2/22 E4/16 IM20/S SFI4/1 CI9/6 Wiring Diagram, Logger to TransducersDrg No 66OC04M QTY DESCRIPTION 6cm 1/4" Nylon Tube 300cm 6rnrn bore Clear PVC Manometer Hose 3 6rnrn Plastic Tee for manometerhose 6 Crimp Terminal, 3.5mm fork 2 3 core, O.5mmCable, 4m long 2 Differential PressureTransducer,0 to 25.4mm H2O WG 4 Self Tap x 9.5 Diff PX 10 Self Adhesive Cable Clip

Cut the 1/4" nylon tube into four equal lengths and fit to the pressureports on the Differential Pressuretransducers. They will then match the inclined manometerport size.
2.

Fit the transducers to the ducting, adjacentto the inclined manometers. Pre-drilled fixing holes exist in the duct for this purpose. Preparethe 3-core cable by fitting the crimp terminals to the transducerend. Route the cable back to the logger and apply self-adhesiveclips to the duct or cable tie to the frame to keep it tidy. Connect the cable to the logger tenninals specified in the wiring diagram. Connect the manometer hoses by teeing into the existing inclined manometer hoses. Schematic Diagram may be used as a guide.

3.
4.

5. 6.

The

f11
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C19

I~

I A660 REFRIGERANT FLOWMETER ASSEMBLY (PART NO. AC660/6/1J r NOTE ORIENT A TION

FIGUft

-=

C20
CONNECTIONS

-TRANSDUCERS TO DATA

LOGGER

REFRIGERANT FLOW TRANSDUCER (CHANNEL 17)

PARTSREQUIRED:
Figure 4 Wiring Diagram. Logger to TransducersDrg No 66OC04M QTY 1 1 1 2 DESCRIPTION Refrigerant Flowmeter 1\2, O.OS to 1.6 I/min 3/8 Flare Copper Gasket Flowmeter Lead 3/4 x 7/8 AF OJDE Spanner

PARTNo.
AC~6/1 PFI/34 EJ/124 AC66OI3/1

The end fittings must be gas tight on completion. Keep all parts clean
2.

Examine the refrigerant pipelines to identify the location for fitting the refrigerant flow transducer. Below the glass tube refrigerant flowmeter there is a copper tube, 125mm long, connectedto a 3/8" male flare equal coupling. The combined length of these two is identical to the length of the new sub-assembly. Removal of this length must be perfonned with care to avoid breaking the glass tube. Two colTectly sized spannersare provided. Use the 3/4 AF spannerto hold stationary the fitting at the baseof the glass tube. Use the 1/8 AF spannerto undo the flare nut. Tilting the fitting will crack the glass. DiscOMect the lower flare nut and remove the combined tube and male flare. Blo\v through the flow transducerby mouth, noting the direction-of-flow arrow, to verify the turbine rotates freely. Note the 3/8" female flare coupling fitted to the outlet side. Refer to Figure 6 on PageC19. A copper flare gasket will provide the seal between here and the inlet to the glass tube flowmeter. Hold the flow transducervertical and drop the 3/8" flare copper gasketinto the outlet side. Use a ballpoint pen to align centrally then hand tighten the complete assemblyonto the 3/82 male flare at the bottom of the glass tube flowmeter. Couple the flare nut at the inlet side of the flow transducerand tighten both ends using the 3/4 AF and 7/8 AF spannersprovided. Plug in the flow transducersignal lead by locating the keyway, then tighten the nut.

4
oS

6.

8.

10. The body of the flow transducermay be rotated around the vertical axis, having swivel end fittings. Route the cable to the Joggervia the trunking attachedbeneaththe ducting. 12. Connect the cable to the logger tenninals specified on the wiring diagram. 13. Tidy excesslengths and securewith cable ties.

C2t
CONNECTIONS
COMBINED -I.aH

- TRANSDUCERS
TEMPERATURE

TO DATA LOGGER
PROBE (CHANNELS 23 and 24)

Note:

Channels23 and 24 applicable to A660C PID Control Upgrade only.

PARTS REOUIRED:

Figure4 PARTNo. EJ/6S

Wiring Diagram, Logger to TransducersDrg No 66OC04M

QTY DESCRIPTION 30Ocm 5-core Cable (stowed inside the PID enclosure)

The output from the combined probe may be shared between the PID controllers and the Data Logger.

2. Gain accessto the PID DIN rail by removal of the transparentcover.

3.
4.

Locate the coil of cable, which is already connectedto the DIN rail tenninals from where the signal may be taken. Route the 3 metre cable out via the spare cable gland provided. Route the cable to the logger via existing trunking or cable tie to the frame to keep it tidy.

5.

6. Connect the Yellow, Clear and Blue wires to the logger tenninals specified on the wiring
diagram.

C1.1.
AC660A COMPUTER LINKED UPGRADE KIT COMPLETION OF INSTALLATION

PARTS REQUIRED: E3/249 I E514 2

E5/133
SFI4/1
4514 43/3 A660/ICNI C45/3 C45/2

Ens

4
I I I I I

Data Logger Power Supply Cable, 13A plug 13A Plug 3A Cartridge Fuse 4-gang Extension Lead Self Tap x 9.5 Diff PX External SeriaJLead, 25F 25M to 9F Serial Converter 10/II mm Open law Spanner CompressorCharging Valve Key Refrigerant Charging Line

All channels are now connectedwith the exception of the temperaturechannels. Install the A660A Digital TemperatureUpgrade Kit now in accordance with Appendix A of this manual, but return to this section before doing a functional test. 2. If already fitted, simply plug in the tenninal blocks to the logger edgeconnector. Take care not to cross channels. The logger power supply lead must be fitted with the 3A fuse provided Plug into the logger and the 4-gang socket outlet.

,
6.
1.

Connect the RS232 9-pin serial link to the logger Connect the external serial lead by plugging into the socket at the Status/Samplelamps. The second4-gang extension lead is provided for use by a computer, monitor or printer, able to use the 220-240V AC available from the A660 socket outlet. This may be at SOor 60Hz. The refrigerant system is now contaminatedwith air and must be leak testedbefore use. This can be achievedby one of two methods: Method I: With Vacuum Pump

8.

I
2.

Removethe cap nut from the compressor suction valve and connectthe vacuum pump. Set the valve to the mid-position and start the vacuum pump. Open the refrigerant stop valve at the inlet to the expansionvalve. The vacuum pump now has access to the system from liquid receiver stop valve, through the evaporator to compressorsuction valve. Run the vacuumpump to achieve IOmmHg (Abs) to ensurethat no moisture remainsin the system. Open (back seat) the suction valve, disconnectthe vacuum pump and refit the cap nut
Open the liquid receiver front-seatedvalve to fill the lines with refrigerant pressure,then close again.

],

4
s,

6.

Use soap and water solution to check for refrigerant leaks. If available, an electronic leak detector for R 134a is preferred. Rectify any leaks found before continuing.
vacuum RumR

Method 2: Without

Refrigerant pressurecan be usedto push the air out if a vacuum pump is not available. 2 Confirm that the compressor suction valve is still front-seated and cap fitted. refrigerant stop valve at the inlet to the expansionvalve is still closed. Open the liquid receiver front-seatedvalve to fill the lines with refrigerant pr~re, close. then

3.

4.

Use two spannersto slacken the nut at the entrance to the refrigerant stop valve (at the expansion valve). Allow air and a sma11 amount of refrigerant to leak out before retightening. Use soap and water solution to check for refrigerant leaks. If available, an electronic leak detector for Rl34a is preferred. Rectify any leaks found before continuing. Open (back seat) the suction valve. Open the refrigerant stop valve at the inlet to the expansion valve.

s.

6.

1.

Functional Test after Air Pur2e

I.

Restorewater and electrical supplies. Switch on the main switch, the fan will run and the digital temperatureindicator will illuminate. Observe the Data Logger at the moment of switching on. Refer to Figure I on Page C2 or Figure 5 on PageCIZ. The Sample/FaultLED should flash a few times as it performs a selftest, then go out. This LED will flash each time a logging sample is taken when the computer is connected. The Power LED will glow continuously when power is supplied. Start the compressorand slowly open the liquid receiver valve until fully back-seated.

2.
3.

4.

s. Refrigerant flow in the glass tube flowmeter should become gas free liquid, i.e. no bubbles.
(Assuming no significant loss of charge.) relationship should align with the P-h chart. High pressureis a sign 6. The pressure/temperature that air has enteredthe system. In this case,refrigerant recovery, vacuum and re-chargeare the only cure.

,.

If satisfactory, continue with loading software and proving all channels.

For referencepurposes,Figure 7 {PageC24 gives the wiring details of the internal serial lead and Figure 8 (Page C25) gives the details of the external serial lead. If accidentally damaged,the leads can be easily repaired.

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Must be preceded by AC660A Computer linked Upgrade Kit

Dl
AC660B COMPUTER LINKED SOFIW ARE UPGRADE KIT SOFTWARE INSI'ALLATION PARTS REOUIRED. PART No. AC6fJJB QTY DESCRIPTION 1 ComputerLinked UpgradeSoftware comprising 31h..Floppy Disk, pre-configuredDEAT97 Software RecordSheet SoftwareUser'sGuide- VersionHEAT97.EXE, Issue1.01DI.SIOl/Soft Copyright Notic~ COMPUTER REOUIREMENTS: IBM PC or compatible; 286 processoror higher; 1MB RAM; DOS or Windows; VGA or colour monitor; RS232serial port COMI or 2, and 31/28 floppy drive. PRINTER TYPE: If hard copy is required during logging or data retrieval - EPSONcompatibledot matrix printer connected to the LPTI parallel port.

PLOTrER TYPE:
For plotting am plot overlay of retrieveddata- 2-pen (minimum). RS232serial COMl or COM2. 9600 baudand HPGL compatible. DISK CONTENTS: 1. HEAT97.EXE is the pre-configuredoperatingsoftware. When usedON LINE, the RS232 seriatlink must be connectedbetweenthe Data Logger and the PC. Data may be monitored on screenand savedto disk.
2.

HEA 1'97.EXE may alsobe usedwid1Out the DataLoggerconnected whenOFF LINE hasbeen selected. This facility allows reviewingpre-recordeddata remove from the laboratory.
CONVERT .EXE facilitates export to spreadsheet such as ExcelTM, TALK.EXE allows interrogation of individual channels at maximum update rate.

3.

4.

FUroRE SOFrW ARE UPGRADES: Data logging software is suppliedwith this AC660A Upgradeas an interim measure. Windows softwarewill be suppliedwithout further chargewhen available.
Windows software will include real time Psychrometric Chart and Refrigeration Enthalpy plotting. Options to display raw data, calculated results, or convert numeric data to spreadsheet compatible format. The logging software, however, will still have a place when training mechanical engineers. Understanding data acquisition, transducers and presentation of data to non-technical personnel is essential. P.A. Hilton Ltd. has been working with the United Nations Industrial Development Organisation to help developing countries to make the change from Ozone depleting CFC refrigerants. The Data Logger has proved an invaluable tool for showing refrigeration plant performance. before and after conversion.

D2
GETfINGSTARTED I
Setup yoor COmplierwid1inreachof thepower supplyandthe RS232serial link connected to the A6(i} unit. Com:M:ct the serial link to COM I or 2. Usethe 25 109-pin converter if required. DQ00( use a port assigned 10a serial mouse.

2.

3. Connectyour Dot Matrix printer to the parallel port, if applicable.

4.

After complying widt your local IT regulationsfor virus checkingof new software, copy this disketteto a new directory or folder called HEA1'97. The originals shouldbe kept as a back up. Switch on the A~ to power up the logger aIxi establish serial communication.

6. From the C: drive, doubleclick on REAT97.EKE in its C:\HEAT97 directory.

7

Put d1C DnJseto ~

left/right arrow keys,

side. Navigationthroughmostof d1e programme is by useof the up/<kJW, - T1-, or useof the highlightedor !Lnderlinedletter keys.

8. The first screenis the pre-configuredSystemconfigurationmenu:

PressD to move the highlight to log-all nata file.

10. PressEnter- to changethe file name, type the new name,suchas XXXI. 11. PressL 10DX>ve to me LoggerJX)rt dlat dte seriallink basbeen~ted to in 2 above. Press Enter- to switch betweenCOMl and COM2 as appropriate. PressEnter to ~ept.
12. Press M [0 move the highlight to Main menu.

13. PressEnter- to accept

D3

14. PressY to savethe change. 15. A smiley face@ appears in d1etop left of dIe screen. Note that d1ecentre Red LED is 00, the
data logger will flash as each channel is programmed. This can take up to 30 seconds.

16. Wait, then the Main menu appears:

<Enter> to confirN
17. Press D to move the highlight to collect & Qisplay data, or use the down arrow to move the bar. 18. PressEnter"" to accept.

D4
19. The collect & l2isplay menuappears;

<Enter)

to confi,..

20. PressEnter'" to acceptNumerical display 21. The active channelsare displayed

Note: This is not real data. but analyse each channel to check the data is reasonable. Switch on a pre-healer arKi expect an iocrease in TJ. Also expect logic .ON. indication from Channel 31 or 32.

22. The smiley face appears in the t~ left of the screen. Data is being savedin the root directory of the C: drive in a file namesXXXI aIx1at the interval chosen1in the Systemconfiguration menu. 23. To stop logging. pressthe FI functionkey

DS
24. The collect &.D.isplay menuappears:

<Enter> to confirm
25. PressM to move the highlight to Main menu, then Enter-. 26. The main Menu appears:

<Enter> to confirN
27. PressR to selectRetrievestoreddata. then Enter28. The Retrieve storeddata menuappears

06

<Enter)

to

confir.

29. PressEnter to acceptNumerical display. the data file list is offered

30. Accessto all datafiles may be gainedfrom the abovescreen. Only one data file exists at this time so pressingEnter"" will fiOOthe default file. 31. ~ retrieveddataappears, startingwith Data Point I. Pressing N for Next screenwill advaoce through the storeddata. -"i~1

~
1
3 5

l;.':Z.
1
7

Label T1 Ad
T39d T5 Cd

"-8'.'-

u.l~

Det.,.lnt Z
21.I'G
21f.'Se 18.288 Z5.I88.C

~it .C
.C .C

C~.l 2
1+ 60 8

T2 Aw r. 8~ T' Cw

L--l

Ualu.
11.119 1t_2G8 1$.21. 18.~98 11.11e 11.218 29.1;e 2ltS.1ee 851.""8 1.551+ 66.Z88 1a... 781t

~it
.C 'c .C .c .C .C .C U AC kN.2 .. H2o AH'VOlTS None HonG No".

17 Dd toROCM

,
11 13 15
11 19

T~ Ed RETURN
TI1Fd FRESH T13 EUAP OUT T15 CONDOUT
EUAP OUT Px C~ OUT p~

2e . 6'8

.C

Ia
12 ,I.
H2o 11 2~ 2Z

21.6~ AC 1~.229.C 2C.t19 vC

255.289 825.~~9 kN.2

kN.2
~

21 23

25 21 29

FRESH DIFFP~ RETURN TEMP I.t REHEAT

8.518 Z8.1f~9

T8 Dw t I)R(XI T1efw R!:T~ T12Fw FRESH T11f COHO IN SUPP\.V UOLTS COND IN Px OOCT 01FF' Px I.:;T~N ~"%.
FAN YOLTACE

oC

2'

R1~ FlO~ UPPERH2o2kW

I.eo~ ZIf.1~9 I .eee

31
JJ

l,t

PREHEAT

C~ESSOR

Non. g/"c ~ 1.~e8 None "~a NoFS

ii 2. 3~ 3Z

and REHEAT
LOVER H2o2kM H2o IkW Znd PREHEAT

1.~e' None
1-00B
I.B8a 1.eee

D7
32. This endsthe -Getting Started- guided toUT. 33. PressM for the Retrieve storeddataMenu. 34. PressM for the main Menu. 35. PressEnter- to accept.
36. Press Q to Quit to OOS.

37. Exit the MEAT91 programmefrom DOS or closethe Window. The aboveprocedurehas given experience of:

. . . .

Navigating through the menusand options Collect & display of data in numeric format Retrieval of storeddata in numeric fonnat All channelshave beenshown to function, but may needfurther calibration.

The Software User's Guide should now be read to discover the full potential of tb~ data logging system.

D8
TRANSDUCER CALIBRATION Factory fitted AC660A Computer Linked Upgrades will arrive in a calibrated condition, but cmtomer imtaJled upgradesshould be followed by t~ procedure. Calibration is also a useful student training exercise, being representativeof the engineering problemswhich they will encounter. ~bratioo is requiredto makeeachtransdoceriOOicate correctly. The subjectis explainedin'the Software User's Guide, sectionCANCaN 1.0.0 (Page22 onwards)
All transd\K:Crs used in dJe kit have an OUqxIt proponional to the measured value. Thermocouples produce approximately 40 microvolts for each ilegree of Celsius. The refrigerant transducer output ilx:reases by 1 Volt DC for each 3.2 Bar ilx:rease in pressure. The flowmeter produces one pulse each time a blade of its paddle wheel breaks a beam of light. The frequency (Hz) is therefore proportional to flow rate.

To conven theseoutputsinto engineering units, we mustrefer to the DataSheetwbkh accompanies each sensor. From the manufacturers statedrangeand outputwe can calculatean exchange rate Stx:h as PSI/Voit or litres/~. ~ plottedin x/y graphform thesevaluesprodocea sl~ (K2) and zero offset (Kl). Kl

= Engineeringunits to display when transduceroutput = zero electronicunits. e.g.

PressuretransducerKl

Pressure transducer Kl = -00.9 PSI (Gauge)at zero volts output Refrigerant flow transducer Kl = 0 g/sec at zeroHz output K2 = Engineeringunits represented by eachunit of electronicoutput, e.g.
Pressure transducerK2 = +46.4 PSlNolt Refrigerant flow transducerK2 = 0.00 g/puise Duct differential pressuretransducerK2 = 5mmHzONoit If using Excel be careful (0 have the unirs of inpu( (0 the logger on the baseline (x a.,-is) and the measured valueon the vertical (y axis). The answerwill thenbe preseored in an acceprable form: mm/Volt or g/pulseor Amps/IDAor .C/mV. etc. The pre-configured HEAT97 "conversionfactors file- 6l:ON usesthe abovecalculatedKl and K2 valuesto converttransducer outputinto unitsdisplayed on screen. The transduceroutputshave been regarded as li~ar. producing a straight line. Non-li~ curves require the use of the polynomial equationand K3 and K4 (seethe SoftwareUser's Guide).
During the "Getting Scaned" tests in the previous section lhere may have been some disagreement betWeenme value displayed on screen and me indication by the inclined manometer or refrigerant flowmeter. For example, calibration dlroogh software enablesus to make the transducers agree wim the instruments. For the purpose of this exercisewe sbaJl regard the manual indicator as the 8Master8 gauge.

- -4.2 Bar (Gauge)at zero volts output

A secondset of configurationftIes hasbeensuppliedon disk to enablefast gatheringof data from the channelsundergoingrecalibration. Use of the TALK.EXE programmemay also be explored later TALK. or Windows TM Hyper

D9
Terminal, allow any single channel to be accessed direct from the keyboard and displayed repetitively. Note that TALK-EXE can only Operate1via COMl using upper casekeys, i.e. Caps Lock. Refer to the SoftwareUser's Guide.

CALmRA TION PROCEDURE Switch on the A6fJ>to power up the logger andestablish serial communication.
2.

From the C: drive, doubleclick on HEA~.EXE

in its C:\HEAT97 directory.

3.

Put die mouse to one side. Navigation dtrOUghmost of the progranune is by use of the up/dow,

left/right arrowkeys,- r 1-, or useof the' highlighted or !.lnderlined letterkeys. 4. The flfSt screenis the pre-configuredSystemconfigurationmenu. For example,

,.
6.

The file namesshould be changedto those shown below. Move the highlight bar to select .c.hannel config. file, pressEnter-. Type the new file name66OPROD then pressEnter again.
Repeat the procedureto amendthe conversionfactors and log-allllata file nameto 6roCAL and PROD 1 as shown below. I;

7.

PressL to moveto the Loggerport that the serial link hasbeenconnectedto. PressEnter- to switch betweenCOM I or COM2 as appropriate. I Move to Main menu(henpress Enter-.

DIO
8
9.

PressY to savethe change A smiley facee appearsin the top left of the screeD.

10. Wait, then the Main menuappears

<Enter> to confir.
ll. Press D to move the highlight to collect &. D;isplaydata, or usethe down arrow to move the bar. 12. PressEnter- to accept. 13. The collect & Display menuappears

<Enter> to confir8
14. PressEnter""to acceptNumerical display 15. The new list of -.:.tivechannelsis displayed. Note that the Value displayed is in default units of Volts or Hz. The conversionfactors for thesecbarmels havebeenleft at default:

Dll
16. If the A660B Recirculating Duct UpgradeKit is not fitted to your A660 unit there will be no Fresh Air Intake inclined manometer,only a Duct manometer. In this caseChannel21 may be ignored. However, in the event that the Computer Upgrade Kit will la(er be used with an A6WB Recirculating Duct UpgradeKit, or that the A6WB is already fitted, it will be necessary to calibrate the Fresh Air Intake transducer. If the A660B RecirculatingDuct UpgradeKit is not yet fitted, the Fresh Air Intake transducer may be coupledto, andcalibratedagaimt, the Duct Differential Pressureinclined manometer. 17. Vary the Fan Speed aJxiVolume Control (ChanlM:121 only) to increase the ioclined manometer readings from minimum to maximum in Imm H2O steps. At each setting record the volts output for Channels20 and 21. (Photocopythe observationsheeton the next page.) 18. Switch on the compressor to causethe refrigerant flowmeter to function. 19. Run without pre-heatand at minimum fan speedto reducethe load on the evaporator to a minimum. If the recirculatingduct is fitted, 100%recirculationof chilled air will achievethe lowest refrigerant flow rate. 20. Record the Hz (Channel27) and the indicatedrefrigerant flow rate at this setting. 21. Now increase the evaJX>rator load to maximum(0 achievemaximumrefrigerant flow. i.e. both pre-heaters on and maximum fan speed. 22. Record the Hz and indicatedrefrigerant flow at this setting. 23. Use the data gatheredto constructnew curves and calibration factors for the abovechannels. This may be donelonghand asexplainedin the SoftwareUser's Guide, or by use of third party spreadsheet software. 24. The pre-configured conversion flie must now be amendedto the more correct Kl and K2 values.

012
RECORD V ALVES to ~eneratean EXCEL SPREADSHEET Note, depending upon local supply voltage, the maximum manometer reading may be below l2mm H.O.
CHANNEL20 RECORD VDC'
DUCT DIFFERENTIAL PRESSURE INCLINED MANOMETER mm H1O

SET TO APPROX mm 1. 3 4 5 6 7

RECO_~_~~~~

,
10 11

u
ResultiJl,g;calibration factors

1:1 -

K2DUCT DIFFERENTIAL PRESSURE INCUNED MANOMETER mm 810 SF:r TO APPROX IDD1

CHANNEL 21 RECORD VDC

RECORD ACTU.~ DUn

2 J 4 5 6 7 8 It 10 11 U

~~I!i~_ca!i~~~ factors
CHANNEL 27

K.l-~~Q~-';~

K2Rl34a VARIABLE AREA FLOW

RECORD Hz

Resulting calibration factOrs

KI-

D-

013

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D17
AMENDING CONVERSION FACTORS 1
2.

Switch on the A6a> to power up the logger andestablishserial communication. From the C: drive. double click on HEAT97.EXE in its C:\HEAT97 directory.
Put the mouse to one side. Navigationthroughmostof the programmeis by useofdte up/dow,

3.
4.

left/rightarrowkeys,- r 1-, or useof dtehighlighted or !,!nderlined letterkeys.

The first screenis the last usedSystemconfigurationmenu.

s
6.

Move the highlight bar to select{;.hannelconfig file, pressEnter-. Type the new ftIe name 66OCHAN then pressEnter- again. Repeatthe procedureto amendthe conversionfactors and log-all nata file nameto 66OCON and XXX I as shownbelow.

1.

Move to Main menuthen pressEnter"", PressY to savethe change. A smiley facee appearsin the top left of (he screen Wait, then the Main menu appears

8.

9.

018

<E..l~r>

to c.;onrlr..

10. Press C to moved1e highlight to,CbanDe1 configuration. or usethe00wn arrow to move~ bar
II. Press Enter. me .(:haImel configuration appears
!f!i~r""1-, "'"" -" 1Jrf""

--

12. Usethe arrow keys(0 moveacrossto the ConversionNo column and down to Channel20. as above. 3. PressEnter- aM the conversionfactors dialoguebox is superimposed

D19
14. Use the arrow key to moveacrossto Kl column. PressEnter- then type in the new KI value from the Excel spreadsheet.In this examplewe changeKl to 1.56. K2 to 5.31.

8:;:.

15. We enteredthroughChaIU1e120 and must exit the sameway. Move the highlight to 20.

s s

21 22 23

Polyno8ial Polyno8ial Polyno8ial Polyno8ial

e -29

1.56 e

5.31 5.98 29 29

e 9 e

If the FreshAir transducerhas beencalibratedandK 1 and K2 factors are known, then repeat the aboveprocedurefor Channe121starting from Point 12 overleaf. 16. PressM for Menu, the ~hannel configurationreturns:

D20
17. Notice the rangehasdefaultedto encompass the total rangeof a +8V -8V channel. If this is not adjustedto representthe range of likely duct pressures,the resolution of the graphical display would be unsuitable.Ametxl the UpperLimit to 15mmH2OaOO Lower Limit to zero:
19 28 21

kN.2 DIFF Px.. H2o FRESH DIFFPx.. H2o

COND OUT Px
DUCT

19 29 21

L L L

1698 lS lS

e k-~

8 e 8

y y y

18. Channel 21 may be ~00ed

in the same way

19. The fmal example will be the Refrigerant Flow transducer Move the highlight to select Channel21 for amendment. -

20. Press Enter- to see the conversionfactors dialogue oox channel, input optionsare offered:

Becausethis is a digital input

21. Press Enter"" aOOchoose frequeocy from the following:

1 21 23 22

~AE$H

DX~~P.

--

H~o

2.. 25

AETUtON A~ AETUAN TE"~ ~"'N ~OWEA 1G~ Ae:HE"'T

AH7. oC WATTS Non-

'-

23 z',

~~~;~;::.,;~.-:0 ~~ P..-J.od ..
.--a e..

D21
22. Press Enter 17 EUAP to see OUT the conversion factors dialogue box:

18 29

CO

NO

IN
I1

19

DUCT

CONDDIFF OUTP
DIFF

l1li 26

Polyno8ial

e
9 9

21

FRESH

28

Polyno8ial

1 9666 1

8 8 8

e e e

23. Ameoodle CbaIU1el27 K2 factor to thenew calculated value. In this example.0.0948g/pulse.

11 18 19 28 21 ~-

24. Remember to exit via No 27. PressM for Menu or the ~pe returns:

key. the ~hannel configuration

25. Move the highligi)t to Return and pressEnter. Note how the Channel27 unitShavedefaulted back. to Hz. Amend to read g/sec again. Also the rangehasdefaultedto the maximum g/sec at maximumHz measuring by the logger,4(XX) Hz. Amendthe Upper Limit and Lower Limit to the valueson the variable area flowmeter, i.e. 30 and 4.

~""'adl;c
,...~
.c CC "c'~~

-~~

1S 16 11 18 19 29 21 22 23 lit 2S 26 21 28 29 39 31 32

e e e e e 9 9 59 9 9 9 9 9 9 e 9 8 e

y y y y y y y y y y y y y y y y y y-

I ~~1;l8!J I

D~2
26. PressM to get back to the Main menu. PressY to savethe changes and wait. 27. Verify all ch~ls are oow functioningby logging somedata. Comparethe on screenvalues with the iOOications on the inclined manometeram refrigerant flowmeter. they should now agree. 28. It is recommended that a back-upcopy of the configuration files is madeso that if files are altered in error they can be recoveredfrom the back-up disc. It is recommended that the original AC~ pre-configuredsoftwaredisc suppliedwith the AC~B Software Upgradeis usedfor this pnrp>se. 29. The following flies will havebeenmodified as part of the calibrationprocess 6(OCHAN.DFT
6(OCON .DFT

SYSTEM.DFT XXXI To make a back-upof thesefiles copy them from their location on the comguter hard disc to the AC6ro preconfiguredsoftwaredisc. The files will be loca1ed with the HEAT97.EXE programmein the directory createdfor this purposewhen the softwarewas loaded. Note that the files will havethe samenameas the original versionson the floppy disk and ~ copies on the flORD! d~ should be overwritten.

0 n

~
~