The complete HVACR lab manual / Eugene Silberstein & Jason Obrzut

Contents
Preface
A Note form the Authors
About the Authors
Acknowledgments
Part I: Subject Area Exercises
Section 1: HVACR Core Concepts (HCC)
Subject Area Overview
Key Terms
Review Test
Exercise HCC-1: Temperature Conversions
Exercise HCC-2: The British Thermal Unit
Exercise HCC-3: Heat Transfer by Conduction
Exercise HCC-4: Specific Gravity
Exercise HCC-5: Gas Laws
Exercise HCC-6: Work, Power, and Heat Energy
Exercise HCC-7: Gauge Installation and Removal on Systems Equipped with Service Valves
Section 2: Electrical Core Concepts (ECC)
Subject Area Overview
Key Terms
Electrical Core Concepts: Test Your Knowledge
Exercise ECC-1: Taking Voltage and Amperage Readings
Exercise ECC-2: Measuring Electrical Characteristics and Performing Electrical Calculations
Exercise ECC-3: Electrical Load Identification
Exercise ECC-4: Series Circuits
Exercise ECC-5: Parallel Circuits
Exercise ECC-6: Series and Parallel Circuits
Exercise ECC-7: Electrical Symbols Used in the HVACR Industry
Exercise ECC-8: Reading Basic Schematic Diagrams
Exercise ECC-9: Reading Advanced Schematic Diagrams
Exercise ECC-10: Constructing Basic Electric Circuits
Exercise ECC-11: Transformers
Section 3: Refrigeration System Components (RSC)
Subject Area Overview
Key Terms
Review Test
Exercise RSC-1: Refrigeration System Components and Their Functions
Exercise RSC-2: Air-Conditioner Component Familiarization
Exercise RSC-3: Evaporator Functions and Superheat
Exercise RSC-4: Evaluating Evaporator Performance
Exercise RSC-5: Checking an Evaporator During a Hot Pulldown
Exercise RSC-6: Condenser Functions and Desuperheat
Exercise RSC-7: Air-Cooled Condenser Performance
Exercise RSC-8: Evaluation of a Water-Cooled Condenser
Exercise RSC-9: Determining the Correct Head Pressure
Exercise RSC-10: Compressor Operating Temperatures
Exercise RSC-11: Compressor Efficiency
Exercise RSC-12: Hermetic Compressor Changeout
Exercise RSC-13: Evaluating a Thermostatic Expansion Valve
Exercise RSC-14: Capillary Tube System Evaluation
Exercise RSC-15: Troubleshooting Exercise: Refrigeration System Operation
Exercise RSC-16: Pumping Refrigerant into the Receiver
Exercise RSC-17: Changing a Thermostatic Expansion Valve
Exercise RSC-18: Adjusting the Crankcase Pressure Regulator (CPR) Valve
Exercise RSC-19: Application and Evaluation of a Refrigeration System
Section 4: Safety and Tools (SFT)
Subject Area Overview
Key Terms
Review Test
Exercise SFT-1: Safety in the Laboratory
Exercise SFT-2: Hand Tool Identification
Exercise SFT-3: HVACR Tool Identification
Exercise SFT-4: Fastener Identification
Exercise SFT-5: Machine and Set Screw Identification
Exercise SFT-6: Calibrating Thermometers
Exercise SFT-7: Checking the Accuracy or Calibration of Electrical Instruments
Section 5: Refrigerants (REF)
Subject Area Overview
Key Terms
Review Test
Exercise REF-1: Refrigerant Familiarization
Exercise REF-2: Refrigerant Pressure/Temperature Relationships
Exercise REF-3: Refrigerant Temperature Applications
Section 6: Air (AIR)
Subject Area Overview
Key Terms
Review Test
Exercise AIR-1: Comfort Conditions
Exercise AIR-2: Heat Recovery Ventilators (HRVs) and Energy Recovery Ventilators (ERVs)
Exercise AIR-3: Plotting an Air-Conditioning Process on a Psychrometric Chart (Part 1 of a Two-Part
Exercise AIR-4: Calculating Total Heat, Sensible Heat, and Latent Heat (Part 2 of a Two-Part Exercis
Exercise AIR-5: Humidification
Exercise AIR-6: Heat Recovery Ventilators (HRVs)
Exercise AIR-7: Electronic Air Cleaners
Exercise AIR-8: Using Duct Charts to Evaluate Duct Systems
Exercise AIR-9: Airflow Measurements
Exercise AIR-10: Measuring the Amperage of Furnace or Air Handler Blower Motors
Exercise AIR-11: Determining Airflow (cfm) by Using the Air Temperature Rise Across an Electric Furn
Section 7: Electric Motors (MOT)
Subject Area Overview
Key Terms
Review Test
Exercise MOT-1: Identification of Electric Motors
Exercise MOT-2: Compressor Winding Identification
Exercise MOT-3: Motor Application and Features
Exercise MOT-4: Identifying Types of Electric Motors
Exercise MOT-5: Single-Phase Electric Motors
Exercise MOT-6: Three-Phase Electric Motors
Exercise MOT-7: Electronically Commutated Motors (ECMs)
Exercise MOT-8: Hermetic Compressor Motors
Exercise MOT-9: Identification of a Relay, Contactor, and Starter
Exercise MOT-10: Contactors and Relays
Exercise MOT-11: Capacitors
Exercise MOT-12: Starting Relays for Single-Phase Electric Motors
Exercise MOT-13: Overloads
Exercise MOT-14: Electric Motor Bearings and Drives
Exercise MOT-15: Belt-Driven Blower Assemblies
Exercise MOT-16: Troubleshooting Contactors and Relays
Exercise MOT-17: Troubleshooting Overloads
Exercise MOT-18: Troubleshooting Electric Motors
Exercise MOT-19: Megohmmeter Usage
Exercise MOT-20: Replacing an Electric Motor on a Furnace or Air Handler
Section 8: Heat Pump Systems (HPS)
Subject Matter Overview
Key Terms
Review Test
Exercise HPS-1: Familiarization with Air-to-Air Heat Pump System Components
Exercise HPS-2: Using Manufacturer's Information to Check a Heat Pump System's Performance
Exercise HPS-3: Heat Pump Performance Check in Cooling Mode
Exercise HPS-4: Checking the Control Circuit in the Emergency and Auxiliary Heat Modes
Exercise HPS-5: Checking the Four-Way Valve During the Heating and Cooling Cycles
Exercise HPS-6: Wiring a Split-Type Heat Pump System
Exercise HPS-7: Checking Low-Voltage Field Control Circuits at the Individual Components
Exercise HPS-8: Troubleshooting Exercise: Heat Pump
Exercise HPS-9: Troubleshooting Exercise: Heat Pump
Exercise HPS-10: Changing a Four-Way Reversing Valve on a Heat Pump
Exercise HPS-11: Wiring a Split-System Heat Pump, Low-Voltage Control Wiring
Exercise HPS-12: Familiarization with Geothermal Heat Pumps
Exercise HPS-13: Checking the Water Flow on a Geothermal Heat Pump
Exercise HPS-14: Situational Service Ticket
Exercise HPS-15: Situational Service Ticket
Section 9: Heating (HTG)
Subject Area Overview
Key Terms
Review Test Electric Heat
Review Test Gas Heat
Review Test Oil Heat
Review Test Hydronic Heat
Exercise HTG-1: Electric Furnace Familiarization
Exercise HTG-2: Determining Airflow (CFM) by Using the Air Temperature Rise Method: Electric Furnace
Exercise HTG-3: Setting the Heat Anticipator for an Electric Furnace
Exercise HTG-4: Low-Voltage Control Circuits Used in Electric Heat
Exercise HTG-5: Checking a Package Sequencer
Exercise HTG-6: Checking Electric Heating Elements Using an Ammeter
Exercise HTG-7: Troubleshooting Exercise: Electric Furnace
Exercise HTG-8: Changing a Sequencer
Exercise HTG-9: Gas Furnace Familiarization
Exercise HTG-10: Identification of the Flame or Pilot Safety Feature of a Gas Furnace
Exercise HTG-11: Gas Valve, Blower Motor, Blower Assembly, and Draft Analysis
Exercise HTG-12: Wiring for a Gas Furnace
Exercise HTG-13: Maintenance of Gas Burners
Exercise HTG-14: Testing the Flue on a Natural Draft Furnace
Exercise HTG-15: Combustion Analysis of a Gas Furnace
Exercise HTG-16: Determining Airflow (cfm) Using the Air Temperature Rise Method: Gas Furnace
Exercise HTG-17: Main Burner, Ignition System, Flame Sensing System, Fan and Limit Control, Transfor
Exercise HTG-18: Troubleshooting Exercise: Gas Furnace
Exercise HTG-19: Changing a Gas Valve on a Gas Furnace
Exercise HTG-20: Changing a Fan Motor on a Gas Furnace
Exercise HTG-21: Testing Ignition Controls and Measuring Flame Rectification Signals
Exercise HTG-22: Testing Furnace Safety Controls
Exercise HTG-23: Familiarization with Oil Furnace Components
Exercise HTG-24: Oil Burner Maintenance
Exercise HTG-25: Electronic Controls for Oil Burners
Exercise HTG-26: Checking the Fan and Limit Control
Exercise HTG-27: Adjusting an Oil Burner Pump Pressure
Exercise HTG-28: Combustion Analysis of an Oil Burner
Exercise HTG-29: Troubleshooting Exercise: Oil Furnace
Exercise HTG-30: Filling a Hot Water Heating System
Exercise HTG-31: Determining Expansion Tank Pressure
Exercise HTG-32: Near-Boiler Piping Component Identification
Exercise HTG-33: System Configuration Identification
Section 10: Mechanical System Troubleshooting (MST)
Subject Area Overview
Key Terms
Review Test
Exercise MST-1: Gauge Installation and Removal on Systems Equipped with Service Valves
Exercise MST-2: Evaporator Operating Conditions
Exercise MST-3: Condenser Operating Conditions
Exercise MST-4: Manufacturer's Charging Procedure
Exercise MST-5: Charging a System in the Field Using Typical Conditions (Fixed-Bore Metering Device)
Exercise MST-6: Charging a System in the Field Using Typical Conditions (Thermostatic Expansion Valv
Exercise MST-7: Troubleshooting Exercise: Central Air Conditioning with Fixed-Bore Metering Device
Exercise MST-8: Troubleshooting Exercise: Central Air Conditioning with Thermostatic Expansion Valve
Exercise MST-9: Changing a Hermetic Compressor
Exercise MST-10: Changing an Evaporator in an Air-Conditioning System
Exercise MST-11: Troubleshooting Refrigeration, Heating, or Air-Conditioning Systems
Exercise MST-12: Situational Service Ticket
Exercise MST-13: Situational Service Ticket
Section 11: Controls (CON)
Subject Area Overview
Key Terms
Review Test
Exercise CON-1: Automatic Controls
Exercise CON-2: Bimetal Switches
Exercise CON-3: Air-Conditioning Circuit Evaluation
Exercise CON-4: Controlling Temperature
Exercise CON-5: Low-Voltage Thermostats
Exercise CON-6: Line-Voltage Thermostats
Exercise CON-7: Pressure Switches
Exercise CON-8: Pressure-Sensing Devices
Exercise CON-9: Controlling the Head Pressure in a Water-Cooled Refrigeration System
Exercise CON-10: Direct Digital Controls (DDC)
Exercise CON-11: Single-Function Solid-State Modules
Exercise CON-12: Multifunction Solid-State Modules
Exercise CON-13: Electric Heating Controls
Exercise CON-14: Gas Heating Controls
Exercise CON-15: Oil Heating Controls
Exercise CON-16: Troubleshooting Simple Electric Circuits
Exercise CON-17: Troubleshooting Electric Circuits
Exercise CON-18: Troubleshooting Thermostats
Exercise CON-19: Troubleshooting Pressure Switches
Exercise CON-20: Troubleshooting Heating Controls
Exercise CON-21: Troubleshooting Refrigeration, Heating, or Air-Conditioning Systems
Exercise CON-22: Smart Thermostats
Section 12: Domestic Appliances (DOM)
Subject Area Overview
Key Terms
Review Test
Exercise DOM-1: Domestic Refrigerator Familiarization
Exercise DOM-2: Domestic Freezer Familiarization
Exercise DOM-3: Charging a Refrigerator Using the Frost-Line Method
Exercise DOM-4: Charging a Freezer by the Frost-Line Method
Exercise DOM-5: Charging a Freezer Using a Measured Charge
Exercise DOM-6: Refrigerator Operating Conditions During a Hot Pulldown
Exercise DOM-7: Testing a Compressor Electrically
Exercise DOM-8: Freezer Gasket Examination
Exercise DOM-9: Troubleshooting Exercise: Refrigerator
Exercise DOM-10: Removing the Moisture from a Refrigerator After an Evaporator Leak
Exercise DOM-11: Changing a Compressor on a Sealed Refrigeration System
Exercise DOM-12: Window Air-Conditioner Familiarization
Exercise DOM-13: Checking the Charge Without Gauges
Exercise DOM-14: Charging a Window Unit by the Sweat-Line Method
Exercise DOM-15: Charging a Unit Using Scales
Exercise DOM-16: Situational Service Ticket
Exercise DOM-17: Situational Service Ticket
Section 13: Installation and Start-Up (ISU)
Subject Area Overview
Key Terms
Review Test
Exercise ISU-1: Flaring Tubing
Exercise ISU-2: Soldering and Brazing
Exercise ISU-3: Joining PVC Pipe Sections
Exercise ISU-4: Bending Copper Tubing
Exercise ISU-5: Standing Pressure Test
Exercise ISU-6: Performing a Deep Vacuum
Exercise ISU-7: Triple Evacuation
Exercise ISU-8: Charging a System with a Charging Cylinder
Exercise ISU-9: Charging a System with Refrigerant Using a Digital Scale
Exercise ISU-10: Charging a Fixed-Bore Split-Type Air-Conditioning System
Exercise ISU-11: Charging a TVX Air-Conditioning System with Refrigerant
Exercise ISU-12: Power Circuit Wiring
Exercise ISU-13: Low-Voltage Control Circuit Wiring
Exercise ISU-14: Wiring an Air-Conditioning Packaged Unit
Exercise ISU-15: Wiring a Split System with a Fan Coil Unit
Exercise ISU-16: Wiring a Split-System Air-Conditioning Unit with a Gas Furnace
Exercise ISU-17: Wiring a Split-System Heat Pump
Exercise ISU-18: Using the Halide Leak Detector
Exercise ISU-19: Using Electronic Leak Detectors
Exercise ISU-20: Refrigerant Recovery
Exercise ISU-21: Evaluating an Air-Conditioning Installation
Exercise ISU-22: Start-Up and Checkout of an Air-Conditioning System
Section 14: Building Sciences (BSC)
Subject Area Overview
Key Terms
Review Test
Exercise BSC-1: Gross Wall Area and Net Wall Area Calculations
Exercise BSC-2: Determining the Heat Transfer Rate Through a Wall
Exercise BSC-3: Heat Loss Exercise
Section 15: Commercial and Industrial Systems (COM)
Subject Area Overview
Key Terms
Review Test
Exercise COM-1: Icemaker Data and Familiarization
Exercise COM-2: Icemaking Methods
Exercise COM-3: Cleaning and Sanitizing an Ice Machine
Exercise COM-4: Commercial Ice Cube Machines
Exercise COM-5: Chilled-Water System Familiarization
Exercise COM-6: Chiller Barrel Approach Temperature
Exercise COM-7: Mechanical-Draft Cooling Tower Familiarization
Exercise COM-8: Mechanical-Draft Cooling Tower Evaluation
Exercise COM-9: Using a Heat Exchanger Pressure-Drop Chart
Exercise COM-10: Using a Megger (Megohmmeter)
Exercise COM-11: Packaged Air Conditioner Familiarization
Exercise COM-12: Hand Signals for Communicating with the Crane Operator
Exercise COM-13: Variable Air Volume (VAV) Box Familiarization
Part 2: Exercise Correlations
Main Text Reference Guide

The Complete HVACR Lab Manual is a comprehensive resource that covers the essential knowledge and skills required to be an HVAC technician. Featuring over 250 lab exercises, this lab manual is designed to support the hands-on application and practice needed to confidently approach HVAC/R system issues.