EUGENE SILBERSTEIN

1
13 SEER BEYOND...

• EUGENE SILBERSTEIN
• Suffolk County Community
  College
• JOHN
  TOMCZYK
• Ferris
  State University
• HVAC EXCELLENCE INSTRUCTOR CONFERENCE
• Imperial Palace, Las Vegas, Nevada
• MARCH 16-19, 2008

2
EER vs SEER
3
EER

• Measure of system cooling efficiency with a
  constant outdoor temp. (Usually 95F)
• Ratio of the average rate of space cooling to
  the average rate of electrical energy consumed
• Expressed in Btuh/Watt
• Commonly used when referring to window a/c units
  and heat pumps, as well as water
• source and geothermal heat pumps

4
SEER

• How efficiently a residential central cooling
  system operates over an entire cooling season
• The total heat removed from the conditioned space
  during the entire cooling season, expressed in
  btus, divided by the total electrical energy
  consumed in watt-hours
• Expressed in Btu/Watt-hour
• 13 SEER requirement as of January 23, 2006

5
SEER EXAMPLE

• 24,000 btu/hr air conditioning system
• Energy cost 0.20/kWh
• 10 SEER system
• Solution
• 24,000 btu/hr 10 btu/watt-hour 2,400 W
• 2,400 Watts 2.4kW
• 2.4 kW x 0.20 48 per hour

6
SEER EXAMPLE

• 24,000 btu/hr air conditioning system
• Energy cost 0.20/kWh
• 13 SEER system
• Solution
• 24,000 btu/hr 13 btu/watt-hour 1,846.2 W
• 1,846.2 Watts 1.846 kW
• 1.846 kW x 0.20 36.5 per hour

7
THE SAVINGS

• Cost per hour (10 SEER system) 48/hour
• Cost per hour (13 SEER system) 36.5/hour
• Cost savings per hour
• (48/hour - 36.5/hour) 48/hour 11.5/hour
• 11.5/hour 115 over the cooling season

8
13 SEER REQUIREMENTS

• Apply to residential equipment in the 1.5 to 5
  ton range (Split/Packaged A/C Heat Pump
  systems)
• Do not apply to
• Commercial Equipment
• Space Constrained Units
• Water Source

9
THE GREAT DEBATE

• How accurate are SEER ratings?
• Are all systems tested the same?
• How do the tests mimic actual system operation?
• When were the original SEER tests implemented?
• Are the SEER tests performed in third party
  testing facilities?
• Will a customers system actually deliver the
  advertised SEER?

10
SEER FACTORS

• Length of refrigerant lines
• Refrigerant charge
• Duct system
• Ambient conditions
• Constant evaporator airflow? Nope!
• Seasonal weather data
• Poor dehumidification? No problem!

11
Where will a system operate with the highest
efficiency?

• Binghamton, New York
• Yuma, Arizona
• Crescent City, California

82F 109F 65F
12
Standard Rating Conditions
13
SEER FORMULA
EERC
1
EERD
1 0.5
EERB
QD
1
QC ?
14
SEER COMPONENTS

• QD Total cooling over one complete compressor
  on and off cycle, (Btus)
• QC Total steady-state cooling capacity from
  Test C, (Btuh)
• ? Time duration for one complete compressor
  on and off cycle, (hours)
• CLF Cooling Load Factor
• CLF (QD QC ?)

15
SEER FORMULA
EERC
1
EERD
1 0.5
EERB
1
CLF
16
SEER COMPONENTS

• EERD EER from test D
• EERC EER from test C
• CD Degredation Coefficient
• CD 1 ( EERC / EERD ) / 1 CLF

17
SEER FORMULA
1 0.5 (CD)
EERB
The part-load performance factor PLF (at 0.5
cooling load) is identified as
1 0.5 (CD)
So
18
SEER FORMULA
SEER PLF (0.5)
EERB
19
SEER, EER and COP

• SEER, EER and COP are all inter-related
• SEER can be estimated using the pressure-enthalpy
  chart, by first calculating the COP of the system
• COP is equal to the systems net refrigeration
  effect divided by the heat of compression of the
  system
• Lets take a look

20
SYSTEM COP
40
112 130
21
SYSTEM COP

• NRE 72 btu/lb
• HOC 18 btu/lb
• COP NRE HOC
• COP 72 btu/lb 18 btu/lb
• COP 4
• Notice that the COP is UNITLESS

22
EER and SEER

• From our example, COP 4
• EER COP x 3.413 13.65 btuh/watt
• Parameters of SEER can be estimated to be between
  1.1 EER and 1.3 EER
• Low end ? 1.1 x 13.65 15
• High end ? 1.3 x 13.65 17.7
• For our example, the SEER rating can be between
  15 and 17.7 btu/watt-hour

23
13 SEER TransitionImpact on Consumer Demand

• Distribution/Dealers
• Shipping/Logistics
• Warehouse/Storage/Handling
• Cost/price
• Refrigerant Charge
• Coil Matching
• Consumer Comfort
• Training/New Technology
• Obsolescence

13 SEER
40 Size Increase
10 SEER

• Manufacturers
• Cost/Price
• Investment
• Engineering Resources
• Mfg. Equipment Lead Time
• Training/New Technology
• Obsolescence
• Shipping/Logistics
• Warehouse/Storage/Handling

24
RELATIVE SIZE COMPARISON
25
Consumer Benefits of 13 SEER Systems

• Improved comfort
• Variable Speed Blowers
• Modulating Compressors
• Improved Reliability
• Internal diagnostics
• Communications
• Noise Levels
• Reduced Bower Noise
• Reduced Compressor Noise

26
13 SEER Summary

• Consumers Were Originally Unaware Of Change
• Significant Increase In Costs
• Repair Vs. Replace
• Payback Period
• Significant Increase In Size
• Logistics/Handling/Warehouse Space
• New Skills/Added Training Required
• Follow Manufacturers Recommendations
• Deliver 13 SEER
• Maintain Reliability

27
NEW COIL TECHNOLOGY

• EVAPORATORS
• CONDENSERS

28
MICROCHANNELTechnology
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MICROCHANNEL TECHNOLOGY

• Meeting Efficiency Standards
• Size / Weight Reduction Goals
• Corrosion Resistance Enhancement

31
Lessons Learned

• Standard in the Automotive Industry
• HVAC Industry Concerns Identified
• - Aluminum to Copper Transition
• - Corrosion Capabilities
• - Dust Clogging
• - Field Repair
• - Cleaning
• Economics Needed to be Addressed

32
PARALLEL FLOW (PF) HISTORY

• Introduced to Automotive market in 1986
• Addressed the market requirement to reduce size
  (front end design) and weight (fuel efficiency)
  of heat exchanger
• Industry change to R-134a required a more
  effective heat exchanger
• Automotive volumes drove manufacturing
  processes (high tooling dollars per model)
• Modine developed PF (Parallel Flow)
  technology in 1980s
• Standard in Automotive Truck markets today

33
Product Advantages Easily Formed
Folded V
Bent
Increased Design Flexibility
34
Product AdvantagesIncreased Heat Exchanger
Effectiveness
EER
TONS
LATENT HEAT TRANSFER
35
Product AdvantagesReduced Heat Exchanger Size
and Weight
Cost
Fan
Shipping Cost
System Cost Savings
36
Product AdvantagesReduced Heat Exchanger Size
and Weight
Fan Noise
Customer Product Advantage
Improved System Performance
37
R-410A Drop-In Performance Comparison

• RTPF Coil
• louvered fin, 24 fpi
• rifled 3/8 tube
• Face Area 73 x 30
• 30 tubes high
• 1 row deep (0.728)
• PF Coil
• louvered fin, 23 fpi
• microchannel tube
• Face Area 70 x 29
• 74 tubes high
• 1 row deep, 3-pass
• fin height 0.312

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• TXVs
• Thermostatic Expansion Valves

39
Purpose of A TXV

• The TXV has a one- line job description
• TO MAINTAIN CONSTANT EVAPORATOR SUPERHEAT!
• The TXV Does Not
• Control Air Temperature
• Maintain Head Pressure
• Maintain System Capacity
• Maintain Constant Suction Pressure
• Control or Maintain Humidity
• Clean the House and Cook Dinner

40
Increased TXV Usage On Residential HVAC Equipment

• Many Manufacturers Using TXVs to Meet 13 SEER
  Requirements
• Constant Superheat Throughout Operating Range
• Less Cycling Losses Improved Cd
• Estimated SEER increase 0.5 SEER points
• Most Cost Effective SEER Improvement Technology
• Significant Increase in TXV Demand
• Manufacturing increases
• Increased Interest and Need For More Training On
  TXV Operation and Troubleshooting

41
TXV OPERATING PRESSURES

• Bulb Pressure Opening pressure
• Spring Pressure Closing pressure
• Evaporator Pressure
• Closing pressure
• Can come from the inlet or the outlet of the
  evaporator
• Bulb Press Spring Press Evaporator Press
• Valve seeks to be in equilibrium

42
Force Balance Diagram
P1
BULB
F
EVAPORATOR
For Valve To Be In Balance
SPRING
43
Superheat Is A Temperature Difference... Not Just
A Temperature
10F Superheat
10F Superheat
Both Evaporators are operating with the same
superheat
44
Superheat Measurement
45
Low Superheat
Latent Heat Transfer
Last Point of Liquid Refrigerant
Sensible Heat Transfer
46
Low Superheat can cause Crankcase Foaming from
Flooding
47
VAPOR
LIQUID
48
High Superheat
Last Point of Liquid Refrigerant
Inefficient
49
The Best Time To Take A Superheat Reading

• Steady State Condition
• Prior to Unit Cycling off on Temperature or
  Pressure
• Prior to a Scheduled Defrost

50
Normal Superheat Settings For Thermo Expansion
Valves

• High Temp 10 to 12 F (gt30F Evap. )
• Med. Temp 5 to10 F (0 to 30F Evap.)
• Low Temp 2 to 5 F ( Below 0F Evap.)

Follow System Manufacturers Recommended Superheat
51
INTERNAL BLEED VALVE

• A bleed port is an internal passage directly
  between the inlet and outlet of the TXV
• Provides for System Equalization During the off
  Cycle for Low Starting Torque Compressors

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TXV with Internal Check
Check Ball
Eliminates The Need For A Separately Installed
Check Valve For Reverse Cycle Operation
55
INTERNALLY VS EXTERNALLY EQUALIZED TXVs
56
INTERNALLY EQUALIZED TXV

• Gets its evaporator pressure from the inlet of
  the evaporator coil
• Valve has an inlet port and an outlet port
• Used on evaporators that have a small pressure
  drop between the coils inlet and outlet

57
EXTERNALLY EQUALIZED TXV

• Gets its evaporator pressure from the outlet of
  the evaporator coil
• Has three ports
• Inlet port
• Outlet port
• Equalizer line port
• Used on evaporators that have large pressure
  drops between the inlet and outlet of the coil
• Has nothing to do with equalizing pressures

58
Internally/ExternallyEqualized TXVs
External Equalizer
59
If we use an internally equalized TXV with a
spring pressure of 15.5 psig...
55 psig 30ºF
62.5 psig 36ºF
Bulb Pressure 84 psig (68.5 psig 15.5 psig)
Evaporator Outlet Temperature 50ºF
Evaporator Superheat 50ºF - 26ºF 24ºF
R-22
60
If we use an externally equalized TXV with a
spring pressure of 15.5 psig...
55 psig 30ºF
62.5 psig 36ºF
Bulb Pressure 65.5 psig (50 psig 15.5 psig)
Evaporator Outlet Temperature 38ºF
Evaporator Superheat 38ºF - 26ºF 12ºF
R-22
61
Probably the three most commonly asked questions
regarding internally and externally equalized
TXVs
62
If a system is equipped with an externally
equalized TXV, can you replace the valve with an
internally equalized valve?
63
If a system is equipped with an internally
equalized TXV, can you replace the valve with an
externally equalized valve?
64
If a system is equipped with an internally
equalized TXV, can you replace the valve with an
externally equalized valve if I simply put a cap
on the external equalizer port?
65
TXV
EXTERNAL EQUALIZER CONNECTION
66
Internal Or Externally Equalized TXV?
Externally Equalizer is Required When
Pressure Drop in The Evaporator Exceeds -
3 PSIG - Air Conditioning - 2 PSIG -
Commercial - 1 PSIG - Low Temperature
67
Expansion Valve Selection

• Refrigeration Type
• Evaporator Temperature
• Evaporator Capacity
• Condensing Temperature/Pressure
• Liquid Temperature
• Distributor Type (if used)

Note The valve is sized to the evaporator and
not the compressor.
68
SCROLL COMPRESSORS
69
SCROLLS
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CONTINUOUS SMOOTH COMPRESSION WITH LESS MOVING
PARTS.
73
LIQUID TOLERANT
74
Next Generation Copeland Scroll
Improved Temperature Protection

• New Design Benefits
• 2-6 Efficiency
• Enhanced Reliability
• 2-4 dBA Quieter

Pressure Protection
New Quiet Shutdown Solution
Optimized Scroll/Seal For Higher Efficiency
Larger Shaft Bearing System For Enhanced
Reliability
Common Shell/Tubing Configuration
High Efficiency Motor
KFZblc/2006/Hardi 5.06.ppt 4/26/2006 74
75
Copeland Scroll UltraTechProduct Design
Modulation Ring/Bypass Seals
Solenoid Return Spring
Solenoid Actuator Coil
76
Copeland Scroll UltraTechContractor Field Test
Results
Reduces Humidity 8 While Improving Humidity
Control 50
77
Copeland Scroll UltraTech Featuring Two-Stage
Capacity

• Superior Efficiency (16 SEER)
• Better Comfort
• (67 Part Load Capacity)
• Quieter Operation
• (Sound And Vibration)
• Simpler Design
• Inherent Scroll Design
• No shutdown to change capacity
• Less Applied Components
• Proven Copeland Scroll Reliability

78
Comfort Alert Diagnostics

• Technology Using Scroll as a Sensor
• Significant Customer Need For 13 SEER
  Differentiation
• Lower No Defect Found Field
  Failure Rates
• High Contractor Interest

79
COMFORT ALERT DIAGNOSTIC MODULE

• Installed in the outdoor unit
• Diagnoses a variety of system problems
• Compressor acts as a sensor monitoring and
  analyzing system performance data
• Relays the information
• Quickens and Improves diagnostic accuracy
• Guides service technicians to the root of the
  problem quickly.

80
Future Capability to Send Signal to Thermostat
and Download Fault History to PC/Palm Device
Green POWER LED
Pass Through Ports Spade Connectors Detect
Tstat Demand and Pilot Voltage
Yellow ALERT LED Red TRIP LED
Diagnostics Key
81
System And Electrical Alert Codes

• Long Run Time (Code 1)
• System Pressure Trip (Code 2)
• Short Cycling (Code 3)
• Locked Rotor (Code 4)
• Open Circuit (Code 5)
• Open Start Circuit (Code 6)
• Open Run Circuit (Code 7)
• Welded Contactor (Code 8)
• Low Voltage (Code 9)

82
Comfort Alert Fault Codes And Causes
83
Resetting Alert Codes

• Automatic Reset
• Code 1 - 30 Alert Free On And Off Cycles
• Code 2 ? 4 - 4 Alert Free On And Off Cycles
• Codes 5 ? 8 - Occur And Reset Immediately
• Code 9 - Resets When Voltage Rises Above 19VAC
• Manual Reset
• All Alert Codes Can Be Reset By Cycling 24VAC
  Power

84
ROLLING PISTON AND SLIDE VANE

• ROTARY COMPRESSORS

85
ROLLING PISTON ROTARY COMPRESSOR
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SLIDING VANE ROTARY COMPRESSOR
88
REFRIGERANT CHARGING

• Proper refrigerant charge helps ensure system
  efficiency
• Systems can cool a space with an undercharge or
  an overcharge
• Use superheat method for cap tube or fixed bore
  metering devices
• Use subcooling method for TXV systems

89
ECM MOTORS
90
A/C SYSTEM EFFICIENCY WITH ECM MOTORS

• With low system load, compressor speed can be
  reduced
• The indoor and outdoor fan speeds must be reduced
  in proportion to the load on them
• By reducing the indoor fan speed, the humidity in
  the conditioned space can be controlled because
  suction pressure is maintained.
• By reducing the condenser fan speed, the head
  pressure will be maintained.

91
ECM MOTORS

• Ultra-high efficiency, programmable, brushless,
  DC motors.
• They operate with high voltage, single-phase
  inputs.
• They have a permanent magnet rotor.
• Have a built-in AC to DC inverter to produce the
  DC that actually operates the motor.

92
ECM MOTORS

• Single-phase alternating current is supplied
• AC power is converted to DC
• The DC power is then passed through a transistor
  bank
• An artificial three-phase power source is
  generated to power the motor

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Q1 Q2
Q3
Q4 Q5
Q6
96
0 30 60 90 120 150 180
210 240 270 300 330 360
Q1
Q2
Q3
Q4
Q5
Q6
97
0 30 60 90 120 150 180
210 240 270 300 330 360
Q1/Q4
Q2/Q5
Q2/Q5
Q3/Q6
Q3/Q6
98
ECM MOTORS

• More efficient than PSC motors
• Have a wider temperature operating range
• Have a Soft Starting Feature for lower inrush
  current
• Start at a low RPM and gradually ramp up to
  design speed
• Reduced amperage spikes
• Soft Starting places less stress on the motor,
  fan, and other mechanical parts
• Preset for a specific CFM requirement.

99
ECM MOTORS

• DC motors have a rotating magnetic field in the
  stator to create a rotating force in the
  permanent magnet armature.
• The speed of the magnetic field is controlled by
  an electronic motor controller.
• Electronic motor controllers can provide constant
  CFM, constant RPM, or variable CFM.

100
ECM VARIABLE SPEED MOTOR ADVANTAGES

• Power savings
• Load reduction based on demand
• Soft starting (No LRA)
• Better space temperature and humidity control
• Solid state motor starters (Controllers)
• Load and capacity matching
• Run at part load for future expansion

101
ECM MOTORS

• Can be a constant airflow (CFM) motor by
  regulating torque and speed over a wide range of
  static pressures
• Provides variable speed motors for gas furnaces,
  A/C systems, heat pumps, commercial
  refrigeration, and oil burner systems. Are also
  used on compressor motors
• ECM consists of a motor section and a control
  section. Each can be replaced separately.
• ECM motors use permanently lubricated ball
  bearings

102
ECMs CONSTANT CFM QUALITIES WITH STATIC
PRESSURE CHANGES
103
CONSTANT AIR FLOW (CFM)

• Compensates for poor duct design
• Compensates for inadequate duct volume
• Compensates for abnormally high static pressure
• - Use of flex duct
• - Loaded air filter
• - Zone changes
• - Obstructed supply register

104
ECM VARIABLE SPEED MOTOR ADVANTAGES

• Power savings
• Load reduction based on demand
• Soft starting (No LRA)
• Better space temperature and humidity control
• Solid state motor starters (Controllers)
• Load and capacity matching
• Run at part load for future expansion

105
INFORMATION SOURCES

• WWW.EMERSONCLIMATECONTRACTOR.COM
• WWW.EMERSONCLIMATE.COM
• WWW.ARI.ORG/STANDARD/210-240-2006.HTM
• WWW.COPELAND-SCROLL.COM
• WWW.APPLIANCEDESIGN.COM (April, 2006)
• WWW.MODINE.COM

106
finis
JOHN TOMCZYK tomczykj_at_tucker-usa.com
EUGENE SILBERSTEIN silbere_at_sunysuffolk.edu (631)
851-6897
107
Comfort AlertProduct Overview

• Nearly 40 Of Compressor Warranty Returns
  Classified As No Defect Found
• Field Technicians Are Not Accurately
  Troubleshooting System Problems
• Comfort Alert Key Benefits
• Improves Service Technician Diagnostic Accuracy
  And Speed Of Service
• Delivers Homeowner Peace Of Mind And Improved
  Reliability
• Helps Differentiate Mainline Vs. Entry Equipment
• Comfort Alert Product Description
• Diagnostics For Systems With Copeland Scroll
  Compressors
• Detects System And Electrical Problem Conditions
  Using Scroll Compressors As Sensor (No Added
  Sensors Needed)
• Compatible With A/C, Heat Pump And UltraTech
  Modulated Systems
• Can Communicate Check System To Thermostat

108
Comfort AlertDiagnostic Alert Codes

• How It Works

109
Comfort Alert Wiring Schematic

• Provides 4 Inputs To Diagnose Faults (Run
  Circuit, Start Circuit, Common Circuit,
  Thermostat Demand Y)
• Algorithms Determine The Patterns And Timing Of
  Symptoms To Diagnose Faults

110
Copeland Scroll Motor Protector Is The Key

• Protector Is Embedded In Motor Windings
• Located In Hot Spot Of Motor
• Reacts To A Temperature Set Point
• High Current Results In High Temperature
• Lack Of Cooling Results In High Temperature
• Protectors are sized Specifically For Each
  Motor-Compressor Combination

111
Sensing Motor Protector Trips

• Comfort Alert Detects A Motor Trip When
• Thermostat Demand Y Is On
• No Current Is Measured To Compressor
• Interpretation Compressor Isnt Running When
  System Wants It To Run
• Root Causes
• Motor Protector Open
• Power Disconnected (Fuse, Switch, Etc.)
• Comfort Alert Not Wired Properly
• Pattern Of Trips Leads To Alert Codes

112
Sensing Long Run Time (Code 1)

• Comfort Alert Detects A Code 1 When
• Thermostat Demand Y Is On And Current Is
  Detected 18 Hours Continuously
• No Protector Trips Are Detected For Code 1
• Interpretation Compressor Cannot Meet Cooling
  Demand Evaporator Iced Up
• Root Causes
• Low Refrigerant Charge
• Evaporator Blower Failure
• Liquid Line Restriction
• Thermostat Set Extremely Low

113
Sensing System Pressure Trip (Code 2)

• Comfort Alert Detects A Code 2 When
• Four Consecutive Protector Trips Occur
• The Average Run Until Trip Time Is Between 1
  Minute And 15 Minutes
• Interpretation High Pressure Condition Causes
  Compressor To Run Briefly Before Tripping
• Root Causes
• Blocked Condenser Coils
• Condenser Fan Not Running
• If LPCO In System, Low Pressure Condition

114
Sensing Short Cycling (Code 3)

• Comfort Alert Detects A Code 3 When
• A Pattern Of Short Cycles Emerges
• The Run Time For The Past 4 Runs Is Less Than 3
  Minutes Each
• No Protector Trips Are Detected For Code 3
• Interpretation Compressor Is Running Only Short
  Periods Of Time
• Root Causes
• Safety Cutout Switch Interrupting Y
• Faulty Thermostat
• Intermittent Contactor
• If HPCO In System, High Pressure Condition

115
Comfort Alert Memory

• Comfort Alert Displays Last Alarm At Each Power
  Up
• Displays Code If Alarm Occurred During Last Power
  Cycle
• Display Lasts For One Minute
• Alarm History Is Kept In Memory
• Seven Day History Of Alarms
• Overall Count Of Alarms Since Factory Testing

116
SUPERHEAT

• ANY SENSIBLE HEAT GAINED AFTER THE 100 SATURATED
  VAPOR POINT IN THE EVAPORATOR.
• THE 100 SATURATED VAPOR POINTS TEMPERATURE WILL
  BE AT THE EVAPORATORS TEMPERATURE WHICH
  CORRESPONDING TO THE EVAPORATING PRESSURE.

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R-22
118
SUBCOOLING

• ANY SENSIBLE HEAT LOST AFTER THE 100 SATURATED
  LIQUID POINT IN THE CONDENSER.
• THE 100 SATURATED LIQUID POINTS TEMPERATURE IN
  THE CONDENSER WILL BE AT THE CONDENSING
  TEMPERATURE WHICH CORRESPONDS TO THE CONDENSING
  PRESSURE.

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R-410A SUBCOOLING METHOD CHARGING PROCEDURE
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Electronically Commutated Motors (ECM)