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Chapter (4)
CONTROL ELEMENTS
4.1 Introduction
Sensors are detectors that have the ability to measure a physical quality such as
pressure, temperature and velocity. The sensors send these signals to the actuator (
electronic, electric or mechanical devices) that is going to be doing the action.
Today, the touch screen that you have on your phone has sensors, and they use
pressure sensors for opening the doors at the market.
4.2.1 Thermostat
Thermostat is a contact type electro-mechanical temperature sensor or switch. It
consists of two different metals such as nickel, copper, tungsten or aluminum etc,
that are bonded together to form a Bi-metallic strip. The different linear expansion
rates of the two dissimilar metals produces a mechanical bending movement when
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Chapter (4): Primary Control Element
the strip is subjected to heat. The bi-metallic strip can be used itself as an electrical
switch or as a mechanical way of operating an electrical switch in thermostatic
controls and are used extensively to control hot water heating elements in boilers,
furnaces, hot water storage tanks as well as in vehicle radiator cooling systems.
There are two main types of bi-metallic strips based mainly upon their movement
when subjected to temperature changes. There are the “snap-action” types that
produce an instantaneous “ON/OFF” type action on the electrical contacts at a set
temperature point Fig.(4.2) and the slower “creep-action” types that gradually
change their position as the temperature changes, Fig.(4.1).
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Chapter (4): Primary Control Element
Snap-action type thermostats are commonly used in our homes for controlling the
temperature setpoint of ovens, irons, immersion hot water tanks and they can
also be found on walls to control the domestic heating system.
Creeper types generally consist of a bi-metallic coil or spiral that slowly unwinds or
coils-up as the temperature changes. Generally, creeper type bi-metallic strips are
more sensitive to temperature changes than the standard snap ON/OFF types as the
strip is longer and thinner making them ideal for use in temperature gauges.
Although very cheap and are available over a wide operating range, one main
disadvantage of the standard snap-action type thermostats when used as a
temperature sensor, is that they have a large hysteresis range from when the
electrical contacts open until when they close again.
For example, it may be set to 20oC but may not open until 22oC or close again until
18oC. So the range of temperature swing can be quite high. Commercially available
bi-metallic thermostats for home use do have temperature adjustment screws that
allow for a more precise desired temperature set-point and hysteresis level to be
pre-set.
Thermistors are generally made from ceramic materials such as oxides of Nickel,
manganese or Cobalt coated in glass which makes them easily damaged. Their
main advantage over snap-action types is their speed of response to any changes
in temperature, accuracy and repeatability.
Most types of thermistor’s have a Negative Temperature Coefficient of resistance
or (NTC), that is their resistance value goes DOWN with an increase in the
temperature, and of course there are some which have a Positive Temperature
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Chapter (4): Primary Control Element
Figure (4.4)
At 25oC
At 100oC
By changing the fixed resistor value of R2 (in our example 1kΩ) to a potentiometer
or preset, a voltage output can be obtained at a predetermined temperature set point
for example, 5V output at 60oC and by varying the potentiometer a particular
output voltage level can be obtained over a wider temperature range. The
thermistor’s are non-linear devices (exponential change with temperature).
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
Code British BS
Conductors (+/-) Sensitivity
Type 1843:1952
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
This type of wiring diagram has branch runs all shown as parallel circuits going
from the left line (L1) to the neutral line (N). They look like the rungs in a ladder
hence the name ladder schematic. The EFM (Evaporator Fan Motor) must run all
the time so that the box temperature stays uniform and the thermostat senses the
average box temperature not some pocket of stratified air. Press the Off Cycle
Button to see the circuit through the EFM. Now Press the On Cycle Button to close
the T-STAT (thermostat) and call for refrigeration. The T-Stat "makes" on a rise of
temperature. Notice that the COMPR(compressor) and the CFM (Condenser Fan
Motor) both come on. A T-Stat that "makes on a rise" is a cooling T-Stat. A T-Stat
that "makes on a fall" is a heating T-Stat, Fig.(4.9).
Also note that just because the wiring on the left side of the T-Stat is not colored
red when the T-Stat is open, that does not mean there is no electricity there. There
is a full electrical potential on that line and if you were to come along and stick
your finger at that point you would be shocked. The red colored wiring indicates
the logical flow routes. Non red wires are not necessarily without voltage potential.
The graph below shows how an operating control cycles. The control is set to start
refrigeration if the box warms up to 40 °F That's called the Cut In point. The
system keeps running until it reaches the Cut Out point which is 37 °F where it
shuts off and awaits the next call for cooling. In this example there is a 3
°F differential between the cut in and cut out points. The differential must be wide
enough that the equipment does not short cycle. Short cycling means to turn on and
off too rapidly. Starting is hard on the equipment, so you want to keep the number
of starts per hour to a reasonable amount, not an excessive amount. The 40 °F point
is a very special temperature. It is the standard cut in point for most refrigeration
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
Figure (4.11) Primary Control Element With Adjusting Switch for room
thermostat.
The adjustment knob on a commercial T-Stat sets the cut in point. The differential
is adjustable by setting a slider inside the enclosure. Thermostatic controls are
manufactured with an wide range of variations. They have fixed differentials,
adjustable differentials, different operating ranges and various accuracy's, various
electrical load ratings, different types of sensors, electro-mechanical, electronic etc.
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Chapter (4): Primary Control Element
The Pressure drop through the capillary tube is due to the following two factors;
i. Friction due to fluid viscosity, resulting in frictional pressure drop.
ii. Acceleration due to the flashing of the liquid refrigerant into vapor resulting
in momentum pressure drop.
iii. The cumulative pressure drop must be equal to the difference in pressure at
the two ends of the tube.
For a given state of refrigerant:
The pressure drop is directly proportional to the length and inversely
proportional to the bore diameter of the tube.
Capillary tube is the most commonly used expansion device in small
refrigeration units, such as domestic refrigerators, window type air
conditioners, water coolers etc.
The advantage of a capillary tube are its simplicity , low cost and the absence
of any moving parts.
4.6.1 Advantages of capillary tubes
i. It is inexpensive.
ii. It does not have any moving parts hence it does not require maintenance
iii. Capillary tube provides an open connection between condenser and the
evaporator hence during off-cycle, pressure equalization occurs between
condenser and evaporator. This reduces the starting torque requirement of
the motor since the motor starts with same pressure on the two sides of the
compressor. Hence, a motor with low starting torque can be used.
iv. Ideal for hermetic compressor based systems, which are critically charged
and factory assembled.
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Chapter (4): Primary Control Element
flooded and the liquid refrigerant may flow to compressor and damage it
when it starts. Therefore critical charge is used in capillary tube based
systems. Further, it is used only with hermetically sealed compressors where
refrigerant does not leak so that critical charge can be used. Normally an
accumulator is provided after the evaporator to prevent slugging of
compressor.
The refrigerant must be free from moisture and dirt otherwise it will choke
the tube and stop the flow of refrigerant.
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Chapter (4): Primary Control Element
Assume the spring is adjusted initially to maintain a pressure of 1.5 bar in the
evaporator at a given load. If the pressure falls below 1.5 bar due to decrease in
load, the spring pressure will exceed the evaporator pressure and causes the valve
to open more and increases the flow of refrigerant. If the pressure in the evaporator
increases due to increase in load above 1.5 bar, the evaporator pressure will exceed
the spring tension and valve move in closing direction. This reduces the quantity of
refrigerant flow in the evaporator.
To adjust the static superheat, turn the valve's setting stem. Turning clockwise
increases static superheat and effectively reduces refrigerant flow through
the valve. Turning counterclockwise reduces static superheat and increases
refrigerant flow.
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Chapter (4): Primary Control Element
compressor. To correct for this, TEV is provided with a tapping, which feeds the
pressure PE - ΔPE from evaporator exit to the bottom of bellows. This will result in
a degree of superheat equal to the set value ΔTs. A TEV with this provision is
called TEV with External Pressure Equalizer. In this TEV a stuffing box is
provided between pushpins and the valve body so that evaporator inlet pressure is
not communicated to the bottom of bellows.
In any case a large evaporator pressure drop leads to a lower COP; hence a number
of parallel paths or circuits are provided in the evaporator. The refrigerant is fed to
these paths by a single TEV fitted with a distributor. In such a case, it is
recommended that external pressure equalizer be used and care taken to ensure that
all the paths are symmetric and have the same length, Fig.(4.15).
Example (4-1):
In a factory of assembly domestic and window air conditioning unit, it is required
to detect the length and diameter of capillary tube suitable for a unit under the
following specifications:
Capacity of Compressor "Refrigeration Capacity": 1.5 TR
Refrigerant used : R22
Condensation Temp., : 130oF
Evaporation Temp., : 45oF
Amount of Subcooling : 15oF
Return gas Temp., : 95oF
Solution
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Chapter (4): Primary Control Element
Example (4-2):
The evaporation pressure of a refrigeration system using R12 as a working fluid
and TEV charged with liquid refrigerant reads 2.5 bar. What is the bulb
temperature which fitted at evaporator exit if the amount of desired superheat is
5oC? What is the spring pressure in that case?
Solution
PB Pressure inside the bulb
PE Evaporator pressure
PS Spring pressure
From table at P = 2.5 bar:
The saturation temperature = TEV = 266.9 K
TB = Bulb temperature = TE + 5 = 266.9 + 5 = 271.9 K
Force balance:
Example (4-3):
A TEV is connected to external equalizer and using R12 with a pressure drop of 68
kPa in the evaporator. The temperature at inlet to the evaporator is 5 oC while the
spring pressure is assumed to be equal 52 kPa. Determine the amount of superheat
at the evaporator exit.
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Chapter (4): Primary Control Element
Solution
PB Pressure inside the bulb
PE1 Inlet evaporator pressure
PE2 Exit evaporator pressure
PS Spring pressure
TEV = 5 oC PEV,I = 360.6 kPa
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
The liquid refrigerant will cool the thermistor and increase its resistance. Hence in
presence of liquid droplets the thermistor offers a large resistance, which allows a
small current to flow through the heater making the valve opening narrower. The
control of this valve is independent of refrigerant and refrigerant pressure; hence it
works in reverse flow direction also. It is convenient to use it in year-round-air-
conditioning systems, which serve as heat pumps in winter with reverse flow. In
another version of it the heater is replaced by stepper motor, which opens and
closes the valve with a great precision giving a proportional control in response to
temperature sensed by an element.
Benefits of EXVs
Precise How control over a wide range of capacities.
Rapid response to load changes.
Better control at low superheats.
More surface for evaporation results in higher evaporating temperature and
better efficiency.
The valve can close when the system shuts down, which eliminates the need
for an additional shut-off solenoid valve.
Signal from a suitable thermistor placed at the evaporator outlet will vary,
depending on whether it senses dry refrigerant gas or liquid traces. It can be used to
control the current through a thermal element to modulate the expansion valve.
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Chapter (4): Primary Control Element
The valves can be direct acting or pilot operated. Small solenoid valves are usually
direct acting; they are fitted in small diameter pipes and their power demand is low,
about 15 W. Pilot-operated solenoid valves are used in large-diameter pipes as the
pressure differences across the valve provide the force to carry out the closing and
opening actions.
Solenoid valves are simple and robust, and their functioning is generally reliable
and accurate as they usually operate in an on-off mode. They have some
drawbacks. They are not gastight, particularly for large pipe sections. Their most
usual failure is coil breakdown, which is not foreseeable so it is impossible to
detect during maintenance operations. Unless they are vapor-tight condensation of
water vapor on their cold side may occur, particularly when they are installed in
rooms with high humidity and working in medium-temperature conditions.
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Chapter (4): Primary Control Element
Three-way valves may be either mixing (two flow streams are merged into one) or
diverting (a single flow stream is broken into two), as shown in the figure. With all
three configurations shown, the valves modulate flow through the cooling or
heating coil to vary the capacity of the coil. With the two-way configuration, flow
through the circulation system is variable.
In the three-way configurations, flow remains relatively constant through the
loop which includes the pump and varies in the loop containing the coil. These
are often used in chilled water cooling systems where the chiller often requires
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Chapter (4): Primary Control Element
a constant flow. In other systems it may be constant flow in the coil is important,
perhaps to prevent freezing, In this case the pump can be in the coil loop. Control
valves typically come in three valve styles: globe, butterfly, and ball. The globe-
type valve has been the most common for many years, but the characterized ball
valves are becoming very popular and are starting to become a significant part of
the working marketplace. Below 50 mm size, they have usually sweat (soldered) or
screwed connections, while above 50 mm they are typically flanged.
Dampers for HVAC work are normally made of galvanized steel or extruded
aluminum. Aluminum is preferred on outdoor air intake dampers due to its
resistance to oxidation. Other materials are available, such as stainless steel, for use
in corrosive atmospheres in industrial facilities. Frames and blades must be heavy
enough to operate without warping or twisting. Shaft bearings should be
permanently lubricated bronze, stainless steel or PTFE to minimize friction.
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Chapter (4): Primary Control Element
Blades come in three common shapes: a flat, one-piece (single metal sheet) blade; a
single-skin blade with a triple-v-groove shape; and a double-skin airfoil-shaped
blade. The triple V and airfoil blades are shown in Figure (4.20) with external
linkages. The face area of the damper is F1 by F2 and frame depth is D. Blade
width is typically about the same as the frame depth. The flat blade is typically
used only for single-blade dampers in round and oval ducts. The latter two blade
types are used in rectangular dampers. The more expensive air foil shape reduces
pressure drop and noise caused by turbulence as air passes over the blades. The
triple-v-groove blade is typically rated only up to 10 m/s, and possible noise
problems must be considered above about 7.5 to 8.5 m/s.
Blades are made to overlap and interlock for tight closure. To reduce leakage, a
compressible sealing strip may be attached to the blade edges. The material used
varies from inexpensive foam rubber to longer-lasting silicone rubber or extruded
vinyl. The seals can significantly modify the damper performance particularly as
the damper nears fully open and fully closed. Jambs (where the blades align on
each side with the frame) may also be sealed to reduce leakage, typically by using a
compressible metal or vinyl gasket. Leakage through a standard damper may be as
high as 250 L/s per m2 at 250 Pa pressure. Low leakage dampers (usually use air-
foil blades) leak as little as 50 L/s per m2 at 1,000 Pa pressure. Shut-off dampers
that are normally used in HVAC systems are low leakage type, which usually leak
around 10 L/s per m2 at 250 Pa. Leakage of air through dampers causes false
control readings resulting in poor control of the controlled variables. Leakage also
causes energy waste and ultimately money. A leakage of 20 L/s per m2 is an ultra-
low leak damper and a 50 L/s per m2 is a low leakage damper. The ultra-low
leakage requirements are for places with very high cooling loads or cold air
infiltration challenges.
Linkages are required on multi-blade dampers to make the blades open and close in
unison. On marginally less expensive dampers, the linkage is attached directly to
the blades, exposed to the air stream as shown in Figure (4.20). On marginally
more expensive dampers, linkages are concealed in the frame and typically involve
rotating the shaft through the blade. Keeping the linkage out of the air stream
reduces pressure drop and minimizes the effects of corrosion. It also provides a
higher strength interconnection between blades, which provides for a better seal
when dampers are closed, particularly after the damper has aged and blades begin
to stick. Exposed linkages under these conditions tend to cause the blades to bend
and warp so that they will not close tightly, Fig.(4.22).
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
require larger operators to overcome the friction of the jamb seals, and parallel
blade dampers typically require larger operators than opposed blade dampers.
Manufacturers rate operator torque in Nm. They also provide the torque data for
their dampers in terms of Nm per square meter of damper area. For example, the
requirement for a particular damper could be for 10 N.m / m2 with a minimum
torque of 25 N.m. The minimum torque is to deal with the load when getting the
damper moving against the friction of the seals. As a general rule, dampers and
their actuators should be set up for normally open operation. If power is lost, the
damper will open and allow its flow to pass until repairs can be made to its
automatic operation. The exception to this would be dampers protecting coils from
freezing, and dampers guarding dangerous, hazardous waste, or isolation systems.
It is sometimes called a remote bulb sensor and is usually provided with fittings
suitable for insertion into a duct, pipe, or tank. Averaging bulbs, where the
temperature sensitive element is extended to sense more than a single point, are
used where stratification is expected (such as after outdoor air/return air mixing
boxes).
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
The differential pressure in Equations 4-1, 4-2, and 4-3 in this case is the difference
between the total and static pressures, a quantity called the velocity pressure. As
can be seen in Figure 4-36, the inner tube senses total pressure of the fluid, which
due to the static pressure plus the force exerted by the fluid’s velocity, called the
velocity pressure. The outer tube has openings in the sides, which are not impacted
by the fluid flow and therefore sense only static pressure. The difference between
the two is used in Equations 4-1, 4-2, and 4-3 to determine fluid velocity. In an
ideal pitot tube, the C coefficient is a constant regardless of geometry.
For air flow at standard density, velocity may be calculated from the pitot tube
velocity differential pressure as:
…………………………………………………………………………….. (4-3)
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
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Chapter (4): Primary Control Element
To start the compressor after it has been stopped and the contacts of the oil failure
switch have opened, a time delay mechanism works in conjunction with the
compressor motor controller. The time delay switch should open 10 to 30 seconds
after the compressor motor has started. The oil pressure will normally build up within
this time interval. The oil pressure switch will have made contact to keep the
compressor motor electrical circuit energized after the time delay switch opens. If the
oil pressure has not built up within about 30 seconds after the compressor is started,
the contacts of the oil pressure differential switch will not have closed. The
compressor will stop because the time delay relay switch is open, Fig.(4.29).
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Chapter (4): Primary Control Element
4.16 Relay
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, Fih.(4.30), but other operating principles are also
used, such as solid-state relays. Relays are used where it is necessary to control a
circuit by a separate low-power signal, or where several circuits must be controlled
by one signal. The first relays were used in long distance telegraph circuits as
amplifiers: they repeated the signal coming in from one circuit and re-transmitted it
on another circuit. Relays were used extensively in telephone exchanges and early
computers to perform logical operations.
Fig.(4.30) Relay.
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