Industrial Controls HVA 203
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Date Created: 10/12/15
Front Range Community College Curriculum Content Guide For HVA 203 Industrial Controls 3 1 p 1 p 1 p 1 p 1 p 1 2 INTRODUCTION The purpose of this class is to provide the students with an understanding of the operation and maintenance of control systems for Heating Ventilation and Air Conditioning systems The student will learn the essentials of installation maintenance and troubleshooting of control systems Credit Hours 3 Contact Hours 15 lecture 53 lab Transferability Transferability of credit depends upon the Institution to which the student plans to transfer CATALOG COURSE DESCRIPTION This course covers both pneumatic and electricalelectronic control systems Students will learn installation maintenance and calibration of controls Laboratory experiences will include troubleshooting of malfunctioning systems calibration and typical installation f control systems 68 Contact Hours PREREQUISITE KNOWLEDGE AND SKILLS HVA 103 HVA 104 and HVA 124 or applicable work experience COURSE OUTLINE AND EXPECTED OUTCOMES These outcomes do not necessarily re ect the exact sequence or full scope of the course materials THERMOSTATS 7 HVAC SYSTEMS The student should 11 Electric electronic Describe the different types of thermostats 112 List the different parts of an electric thermostat 113 List the different parts of an electronic thermostat 114 Explain the function of each part of a thermostat 115 Explain how each type of thermostat measures temperature 116 Explain the function of a heat anticipator 117 Explain the difference between a low voltage thermostat and a line voltage thermostat 118 Explain the logical sequence in diagnosing problems with a heating cooling system that has a thermostat problem 12 Pneumatic 121 Explain the major differences between electric and pneumatic thermostats 122 Explain the different types of pneumatic thermostats 123 List the different parts of a pneumatic thermostat 124 Explain the operation of a pneumatic thermostat 125 Diagnose a problem with system with a malfunctioning pneumatic thermostat 126 Recalibrate pneumatic controls THERMOSTATS 7 HEATING AND COOLING The student should 21 ElectricElectronic 211 Explain the internal differences between heating only and a heatingcooling thermostat 212 Explain the difference in operation between heating only and a heatingcooling thermostat 213 Explain the logical sequence in diagnosing problems with a system that has a thermostat problem 214 Diagnose a problem with a heat pump system with a malfunctioning thermostat 22 Pneumatic 221 Explain the internal differences between heating only and a heatingcooling thermostat 222 Explain the logical sequence in diagnosing problems with a system that has a thermostat problem 223 Diagnose a problem with a commercial system that has a malfunctioning pneumatic control system HVAC CONTROL SYSTEMS The student should 311 List the major control schemes for both residential and commercial systems and explain their operation 312 Explain the difference between a residential and a commercial control system 313 Identify r of 39J quot 39 and 39 39 control systems 314 Diagnose the problem with an inoperative commercial HVAC system 315 Determine the cause when a commercial HVAC system will not provide adequate heating or cooling 316 Identify major components of Building Automation Systems and Controllers Study Guide HVA 203 Industrial Controls REFERENCES 1 Modern Refrigeration and Air Conditioning Text MRAC AlthouseTumquistBracciano 2004 Edition 2 HVAC Control Systems Text Ronnie J AuVil 2003 Edition 3 Robertshaw Fundamental of Pneumatic Controls for HVAC Robertshaw Controls Company 1986 Provided to students for use during the course INFORMATION 1 IS Information Sheet 2 IS Job Sheet 3 AS Assignment Sheet N Study Guide HVA 203 01 Industrial Controls Read IS 1 Occupational Introduction Read IS 2 Safety Complete IS 2 Study Questions Have study questions graded Read MRAC Text 2624 Review of Safety View Electrical Safety Video Proceed to HVA 20302 Study Guide HVA 203 01 Industrial Controls IS 1 Occupational Introduction Objective Upon completion of this assignment the student will know the job responsibilities desirable employee qualities occupational outlook and occupational hazards of a refrigeration and airconditioning technician Introduction A Refrigeration and Air Conditioning technician is someone who N E 4 V39 0 gt1 9 0 Plans layout Installs and repairs airconditioning equipment and systems Plans new or modi ed installations to minimize waste of materials plans access for future maintenance to prevent unsightly and hazardous wiring and plumbing so as to be consistent with local specification and electrical codes Prepares sketches showing location of plumbing and wiring of the systems andor follows diagrams or blueprints insuring that all concealed plumbing and wiring is installed prior to completion of future walls ceilings and oors Measures cuts ares bends threads assembles and installs refrigerant tubing piping and electrical conduits using tools such as tubing cutter hacksaw pipe cutters threading machine threading dies tubing and conduit benders brazing torch and brazing materials and safety equipment Pulls wiring through conduit Splices wires by stripping insulation from terminal leads with knife or stripping pliers twisting or soldering wires together and applying tape or wire nuts Installs control and distribution components such as switches relays and circuit breaker panels fastening in place with screws or bolts using hand tools and power tools Connects power cables from source to central airconditioning and heating systems and to commercial refrigeration and airconditioning systems Tests continuity of circuits to insure electrical compatibility and safety of components using testing instruments such as voltmeter ohmmeter ammeter or test light Observes operation and functioning of the installed equipment andor systems to detect hazards and need for adjustments relocation and0r replacement ll Repairs faulty or malfunctioning equipment or systems J39 39 I I Some refrigeration and air 39 39 may nd quot working on large construction sites or in large factories All refrigeration and airconditioning technicians must have a fundamental knowledge of electricity and must be able to read blueprints and troubleshoot electrical circuits There are several things a potential employer expects from an employee Some are 1 Good work attitude 2 Being punctual 3 Works well with others 4 Safety conscious follows all safety regulations 5 Take instructions readily 6 Controls temper at all times gt1 Effective communications with customers 9 Exhibits pride in the refrigeration and airconditioning profession 9 Practices conservation of materials and manhours 10 Keeps appearance professional The above list does not cover everything nor is it in set order Different employers look for different things and each has his or her ideas as to what priority the list should be in However the list is a good list to follow and practice while you are enrolled as a student Along with learning the skill of a refrigeration and airconditioning technician you should also make improvements in the areas listed above Physical strength is essential to becoming a refrigeration and airconditioning technician as all systems are usually bulky and heavy Manual dexterity agility and good health are important Good color vision is usually necessary because electrical wires are frequently identified by color Experiences refrigeration and airconditioning technician can advance to become supervisors superintendents or contract estimators Many technicians start their own business The occupational outlook for refrigeration and air Jquot 39 39 39 39 is quot be 1 Construction of new homes and commercial buildings 2 Renovation of existing homes and commercial buildings 3 Increased utilization of refrigeration and airconditioning equipment 4 Retirement of present technicians in the refrigeration and airconditioning field 5 Refrigeration and airconditioning fields is a solid foundation upon which to build a career as an electrician or as a specialist in the field of electrical and pneumatic controls and instrumentation Although their employers generally supply heavy equipment and power tools refrigeration and air conditioning technicians must furnish their own hand tools Refrigeration and airconditioning technicians must frequently work in cramped quarters for long periods of time and are exposed to a wide range of weather conditions and temperatures Refrigeration and airconditioning specialist run the risk of falling from ladders scaffolds platforms and rooftops Also they run the risk of electrical shock and the risk of being injured from falling objects However good safety practices help eliminate the majority of these incidents Study Guide HVA 203 01 Industrial Controls IS 2 Objective Upon completion of this assignment the student will 1 know general safety practices for shop work 2 be familiar with re prevention practices and 3 have a thorough understanding of electrical safety hazards and prevention measures Introduction Prevention is the best medicine for injury Respect all voltages have a knowledge of the principles of electricity and follow safe work procedures Don t take chances Personal Safety Rules 1 When working on or near rotating machinery secure loose clothing and tie hair if long 2 Check all line power cords before using and if the insulator is brittle and0r cracked DO NOT USE and report damage to the instructor 3 When measuring voltages with a meter and test probe be careful not to connect yourself to a voltage of any value 4 Be certain that oor is insulated either by tile rubber mats or the wearing of rubbersoled shoes 5 When measuring voltages expected to be greater than 30 volts turn off or disconnect live circuit before connecting test equipment 6 Note Treat voltages of 30 volts or over with great respect 7 It is recommended that only equipment with a polarized 3 prong plug be used 8 Do not defeat the purpose of any safety device such as fuses circuit breakers or interlocks Shorting across these devices could destroy or seriously damage equipment being worked on as well as cause a re 9 Do not carry sharpedged or pointed tools in your pockets 10 Do not indulge in horseplay or play practical jokes in any work area 11 Wear gloves and goggles when required 12 Do not wear rings or jewelry when working with mechanical or electrical devices 13 Exercise good judgment and common sense General Lab Safety Rules N E 4 10 11 Keep all hand tools clean and in safe working order Report any defective tools test equipment or other equipment to the instructor Do not remove any safety device example ground straps switch covers etc without the permission of the instructor Do not operate or energize any circuit that could be hazardous without rst receiving instructions on how to do so safely Report all accidents to the instructor regardless of nature or severity Turn off power before leaving test equipment or circuits being worked on Do not use any solvents without rst determining its properties and how to use it safely Note Solvents should be used onlv in wellventilated spaces Keep the lab oor clean of scraps and litter Clean up any spilled liquids immediately Store all cleaning rags in metal cans or containers Note Cleaning rags could contain oil Hand Tool Safety Precautions A refrigeration technician is required to use hand tools and power tools to maintain and repair refrigeration and airconditioning systems Many accidents are caused by the thoughtless use of tools Thoughtless use of tools includes using a tool carelessly or incorrectly Accidents result from using a tool to do something for which it was not intended There is a right way and a wrong way to use any tool Learn to use tools in the right way ws wwe Keep tools in proper working order Always put a handle on a le when you use it Use caution with your soldering iron or gun They can burn and cause frres Exercise care in using longnose pliers and diagonal cutters They can pinch and cut Do not use longnose pliers as a wrench Ease up on the pressure just before a hacksaw completes its cut Whenever possible pull on a wrench 7 don t push Be sure hammer heads and screwdriver blades are tightly in their handles Use safety glasses or goggles when soldering or unsoldering Power Tool Safety Precautions Power tools usually operate on 120 volts This voltage can cause serious shock burns or under certain conditions death Always check the power tool before you use it Be sure the cord is in good condition and that the plug and switch are not broken Keep the cord clear of the work 13 When drilling use a sharp drill bit Pressure on a dull drill bit can cause an accident 4 Securely fasten the work being drilled Note The drill will turn both the bit the work and possibly the operator which can cause serious injury Be sure hands are dry before using electrical tools Keep power tool guards in place They are for your protection Operate power tools only after you have had instruction in their uses Wear safety goggles or glasses when operating power tools Note Flying chips can cause permanent damage to your eyes Power cords and switches should be checked before using a power tool HHHH coucpr 0 Electrical Cord Safety Rules 1 Do not overload a circuit by connecting numerous cords to a single outlet by means of octopus adapters Do not pull the cord to disconnect Use the plug Do not use electrical cords with frayed or worn insulation Replace cord as necessary Do not suspend electrical cords over nails or pipes Never run electrical cords Near heating devices like space heaters or radiators Across walkways Under carpets or rugs Through door jams Elk59 Safety Color Codes Federal law OSHA has established specific colors to designate certain cautions and dangers Study the colors listed until you are familiar with all of them OSHA Safety Color Codes Red 7 Fire protection equipment and apparatus portable containers of ammable liquids and emergency stop buttons and switches Yellow 7 Caution marking physical hazards waste containers for explosive or combustible materials caution against starting using or moving equipment under repair and identification of a starting point or power source of machinery Orang 7 Dangerous parts of machines safety starter buttons and the exposed parts edges of pulleys gears rollers cutting devices and power jaws Purpl 7 Radiation hazards Green 7 Safety location of first aid equipment other than fire equipment Fire Safety The chance of re may be greatly decreased by following rules of good housekeeping Keep debris in a designated area away from the building If a re should occur however the rst thing to do is give an alarm All students and the instructor should be alerted and the re department should be called In the time before the re department arrives a reasonable effort can be made to contain the re In the case of smaller res portable re extinguishers which should be available at the site can be used Fire Prevention Practices 1 Use extension cords only within there designated areas 2 Never let multioutlet assemblies or cube taps cause overloads 3 Never use frayed or deteriorated cords 4 Never tamper with fuses to change their electrical ratings The following list gives the four common types of re Each type is designated by class Class A res are res occurring in wood clothing paper rubbish and other such items This type of re can usually be handled effectively with water but C02 may do the job for small res Symbol 7 green triangle Class B res occur with ammable liquids such as gasoline fuel oil lube oil grease thinners paints etc The agents required for extinguishing this type of re are these which dilute or eliminate the air by blanketing the surface of the re Foam and C02 are used but not water Symbol 7 red square Class C res occur in electrical equipment and facilities The extinguishing agent for this type of re must be a nonconductor of electricity and provide a smothering effect C02 extinguishers may be used but not water Symbol 7 blue circle Class D res occur in combustible metals such as magnesium potassium powdered aluminum zinc sodium titanium zirconium and lithium The extinguishing agent for this type r must be a dry powdered compound The powdered compound must create a smothering effect C02 may be used but not water Symbol 7 yellow star One of the above mentioned symbols should appear on each extinguisher A red sign should point to the location of the extinguisher Because all re extinguishers cannot be used on all types of res the technician should be aware of how to identify which re extinguisher should be used Always read instructions before using an extinguisher Also never use water against electrical or chemical res Water also should not be used against gasoline lel or paint res as it may have little effect and only spread the fires NOTE Carbon tetrachloride and other toxic vaporizingliquid re extinguishers are prohibited by Federal law 0SHA Fire extinguishers are normally red If they are not red they should have a red background so they can be easily located If re ghters are called be ready to direct them to the re Also inform them of any special problems or conditions that exist such as downed electrical wires or leaks in gas lines A nal thought 7 Report to your instructor any accumulation of rubbish or usage conditions that could be a re hazard Name HVA 20301 IS 2 Safety Study Questions 1 From the list of conditions listed below select the conditions that are unsafe and safe by placing an X in the appropriate columns UNSAFE SAFE Oily rags on oor Soldering iron on stand Line cord insulation frayed Equipment isolated by transformer Litter on oor One hand behind back quotUD JUOUJCD 2 If you noticed that a line cord was frayed which of the following would be the best thing for you to do A Notify the instructor or supervisor B Unplug it from the wall C Repair it or replace it D All of the above are correct 3 If your coworker was being shocked and you couldn t nd the switch or nd anything to pull him off with Which of the following could you use to cut the wires A B C D A kitchen knife A power saw Diagonal cutters A fire axe 4 If you are in a shop area and a fire suddenly occurred Which of the following colors would help you to locate the fire extinguisher A B C D Yellow Red Green Orange 5 Match the terms on the right to the correct spaces Answers may be used more than once A Electrical Fire 1 Class A B Wood Fire 2 Class B C Oil Fire 3 Class C D Paper Fire 4 Class D The class of re that you would most normally nd to occur in an electronics lab would be A Class A B Class B C Class C D Class D In order to extinguish a Class A re you would probably use the following A Pressurized water B Soda acid C Foam D All the above In an electrical re you should never use the following A Carbon dioxide B Pressurized water C Dry chemical D None of the above When working with electrical test equipment you should be certain that the is turned off before you leave it for some reason A Lights B Water C Power D Sound If you have or seen anyone else have a work related accident you should immediately Report it to a supervisor B Keep on working C Correct the condition that caused it D Call the Police Study Guide HVA 20302 Air Conditioning and Heating Controls Texts Modern Refrigeration and Air C 1quot AlthouseTumquistBracciano 2004 Edition HVAC Control Systems Ronnie J Auvil 2003 Edition 1 Study MRAC text Chapter 26 2 Answer MRAC text 2625 Test Your Knowledge Questions 3 Study HVAC Control Systems text Chapters 23 4 Complete Review questions and activities 23 in HVAC Control Systems Workbook 5 Study HVAC Control Systems text Chapter 45 6 Complete Review questions and activities 45 in HVAC Control Systems Workbook 7 Proceed to HVA 20303 Study Guide HVA 20303 Pneumatic Controls Text HVAC Control Systems O N Ronnie J Auvil 2003 Edition Study HVAC Control Systems text Chapters 67 Complete Review questions and activities 67 in HVAC Control Systems Workbook Study HVAC Control Systems text Chapters 89 Complete Review questions and activities 89 in HVAC Control Systems Workbook Study HVAC Control Systems text Chapter 10 Complete Review questions and activities 10 in HVAC Control Systems Workbook Study HVAC Control Systems text Chapters 1112 Complete Review questions and activities 1112 in HVAC Control Systems Workbook J S 1 Calibrate a pneumatic thermostat J S 2 Calibrate a pneumatic receiver controller JS 3 Calibrate a PE relay Proceed to HVA 20304 Reference Objective Tools needed Name HVA 20303 Pneumatic Thermostat Calibration JS 1 HVAC Control Systems Robertshaw Fundamentals of Pneumatic Controls Calibrate a pneumatic thermostat as selected by the instructor Safety glasses Pneumatic training board Calibration kit Thermometer Instructor s Initials Reference Objective Tools needed Name HVA 20303 Pneumatic Receiver Controller Calibration JS 2 HVAC Control Systems Robertshaw Fundamentals of Pneumatic Controls Calibrate a pneumatic receiver controller as selected by the instructor Safety glasses Pneumatic training board Calibration kit Thermometer Instructor s Initials Reference Objective Tools needed Name HVA 20303 Pneumatic Pressure Electric Relay Calibration JS 3 HVAC Control Systems Robertshaw Fundamentals of Pneumatic Controls Calibrate a pneumatic pressure electric relay as selected by the instructor Safety glasses Pneumatic training board Calibration kit Instructor s Initials Study Guide HVA 20304 Electric Electronic Controls Text HVAC Control Systems Ronnie J Auvil 2003 Edition 1 Study HVAC Control Systems text Chapters 13 2 Complete Review questions and activities 13 in HVAC Control Systems Workbook 3 Study HVAC Control Systems text Chapters 14 4 Complete Review questions and activities 14 in HVAC Control Systems Workbook 5 Study HVAC Control Systems text Chapters 15 6 Complete Review questions and activities 15 in HVAC Control Systems Workbook Final Exam will be based on Chapter 26 of the MRAC Text and the HVAC Control Systems Text Quizzes on the CDRom in the back of the text
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