Curriculum Content Guide for Industrial Controls | HVA 203, Study notes of Engineering

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Front Range Community College

Curriculum Content Guide

For

HVA 203 – Industrial Controls

I. 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. II. CATALOG COURSE DESCRIPTION This course covers both pneumatic and electrical/electronic 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 III. PREREQUISITE KNOWLEDGE AND SKILLS HVA 103, HVA 104 and HVA 124 or applicable work experience. IV. COURSE OUTLINE AND EXPECTED OUTCOMES These outcomes do not necessarily reflect the exact sequence or full scope of the course materials.

1. THERMOSTATS – HVAC SYSTEMS The student should: 1.1. Electric/electronic 1.1.1. Describe the different types of thermostats. 1.1.2. List the different parts of an electric thermostat. 1.1.3. List the different parts of an electronic thermostat. 1.1.4. Explain the function of each part of a thermostat. 1.1.5. Explain how each type of thermostat measures temperature. 1.1.6. Explain the function of a heat anticipator. 1.1.7. Explain the difference between a low voltage thermostat and a line voltage thermostat. 1.1.8. Explain the logical sequence in diagnosing problems with a heating / cooling system that has a thermostat problem. 1.2. Pneumatic 1.2.1. Explain the major differences between electric and pneumatic thermostats. 1.2.2. Explain the different types of pneumatic thermostats. 1.2.3. List the different parts of a pneumatic thermostat. 1.2.4. Explain the operation of a pneumatic thermostat. 1.2.5. Diagnose a problem with system with a malfunctioning pneumatic thermostat. 1.2.6. Recalibrate pneumatic controls.
2. THERMOSTATS – HEATING AND COOLING The student should:

Study Guide

HVA 203

Industrial Controls

REFERENCES:

1. Modern Refrigeration and Air Conditioning (Text) (MRAC) Althouse/Turnquist/Bracciano 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:
4. I.S. = Information Sheet
5. J.S. = Job Sheet
6. A.S. = Assignment Sheet

Study Guide

HVA 203.

Industrial Controls

1. Read IS #1, “Occupational Introduction”
2. Read IS #2, “Safety”
3. Complete IS #2 Study Questions. Have study questions graded.
4. Read MRAC Text 26.24 Review of Safety
5. View Electrical Safety Video
6. Proceed to HVA 203.

Some refrigeration and air-conditioning technician may find themselves working on large construction sites or in large factories. All refrigeration and air-conditioning 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
7. Effective communications with customers
8. Exhibits pride in the refrigeration and air-conditioning profession
9. Practices conservation of materials and man-hours
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 air-conditioning technician, you should also make improvements in the areas listed above. Physical strength is essential to becoming a refrigeration and air-conditioning 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 air-conditioning technician can advance to become supervisors, superintendents, or contract estimators. Many technicians start their own business.

The occupational outlook for refrigeration and air-conditioning technicians is controlled by:

1. Construction of new homes and commercial buildings.
2. Renovation of existing homes and commercial buildings.
3. Increased utilization of refrigeration and air-conditioning equipment.
4. Retirement of present technicians in the refrigeration and air-conditioning field.
5. Refrigeration and air-conditioning 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 air-conditioning 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 air-conditioning 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.

General Lab Safety Rules:

1. Keep all hand tools clean and in safe working order.
2. Report any defective tools, test equipment, or other equipment to the instructor.
3. Do not remove any safety device, example: ground straps, switch covers, etc. without the permission of the instructor.
4. Do not operate or energize any circuit that could be hazardous without first receiving instructions on how to do so safely.
5. Report all accidents to the instructor regardless of nature or severity.
6. Turn off power before leaving test equipment or circuits being worked on.
7. Do not use any solvents without first determining its properties and how to use it safely.
8. Note: Solvents should be used only in well-ventilated spaces.
9. Keep the lab floor clean of scraps and litter.
10. Clean up any spilled liquids immediately.
11. 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 air-conditioning 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.
12. Keep tools in proper working order.
13. Always put a handle on a file when you use it.
14. Use caution with your soldering iron or gun. They can burn and cause fires.
15. Exercise care in using long-nose pliers and diagonal cutters. They can pinch and cut.
16. Do not use long-nose pliers as a wrench.
17. Ease up on the pressure just before a hacksaw completes its cut.
18. Whenever possible, pull on a wrench – don’t push.
19. Be sure hammer heads and screwdriver blades are tightly in their handles.
20. Use safety glasses or goggles when soldering or unsoldering.
21. Power Tool Safety Precautions.
22. 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.
23. Keep the cord clear of the work.
24. When drilling, use a sharp drill bit. Pressure on a dull drill bit can cause an accident.

14. 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.
15. Be sure hands are dry before using electrical tools.
16. Keep power tool guards in place. They are for your protection.
17. Operate power tools only after you have had instruction in their uses.
18. Wear safety goggles or glasses when operating power tools. Note: Flying chips can cause permanent damage to your eyes.
19. Power cords and switches should be checked before using a power tool. Electrical Cord Safety Rules:
20. Do not overload a circuit by connecting numerous cords to a single outlet by means of “octopus” adapters.
21. Do not pull the cord to disconnect. Use the plug.
22. Do not use electrical cords with frayed or worn insulation. Replace cord as necessary.
23. Do not suspend electrical cords over nails or pipes.
24. Never run electrical cords: Near heating devices, like space heaters or radiators Across walkways Under carpets or rugs Through door jams 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 – Fire protection equipment and apparatus, portable containers of flammable liquids and emergency stop buttons and switches. Yellow – 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. Orange – Dangerous parts of machines, safety starter buttons and the exposed parts (edges) of pulleys, gears, rollers, cutting devices and power jaws. Purple – Radiation hazards. Green – Safety, location of first aid equipment (other than fire equipment).

Fire extinguishers are normally red. If they are not red, they should have a red background so they can be easily located. If fire-fighters are called, be ready to direct them to the fire. Also inform them of any special problems or conditions that exist, such as downed electrical wires or leaks in gas lines. A final thought – Report to your instructor any accumulation of rubbish or usage conditions that could be a fire hazard.

Name:_________________________

HVA 203.

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 A Oily rags on floor B Soldering iron on stand C Line cord insulation frayed D Equipment isolated by transformer E Litter on floor F One hand behind back
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 co-worker was being shocked and you couldn’t find the switch, or find anything to pull him off with. Which of the following could you use to cut the wires? A. A kitchen knife B. A power saw C. Diagonal cutters D. 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. Yellow B. Red C. Green D. 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

Study Guide

HVA 203.

Air Conditioning and Heating Controls

Texts: Modern Refrigeration and Air Conditioning Althouse/Turnquist/Bracciano 2004 Edition HVAC Control Systems Ronnie J. Auvil 2003 Edition

1. Study MRAC text Chapter 26
2. Answer MRAC text 26.25 Test Your Knowledge Questions
3. Study HVAC Control Systems text Chapters 2-
4. Complete Review questions and activities 2-3 in HVAC Control Systems Workbook
5. Study HVAC Control Systems text Chapter 4-
6. Complete Review questions and activities 4-5 in HVAC Control Systems Workbook
7. Proceed to HVA 203.

Study Guide

HVA 203.

Pneumatic Controls

Text: HVAC Control Systems Ronnie J. Auvil 2003 Edition

1. Study HVAC Control Systems text Chapters 6-
2. Complete Review questions and activities 6-7 in HVAC Control Systems Workbook
3. Study HVAC Control Systems text Chapters 8-
4. Complete Review questions and activities 8-9 in HVAC Control Systems Workbook
5. Study HVAC Control Systems text Chapter 10
6. Complete Review questions and activities 10 in HVAC Control Systems Workbook
7. Study HVAC Control Systems text Chapters 11-
8. Complete Review questions and activities 11-12 in HVAC Control Systems Workbook
9. JS #1 Calibrate a pneumatic thermostat
10. JS #2 Calibrate a pneumatic receiver controller
11. JS #3 Calibrate a PE relay
12. Proceed to HVA 203.

Name:_______________________________

HVA 203.

Pneumatic Receiver Controller Calibration

JS

Reference: HVAC Control Systems Robertshaw Fundamentals of Pneumatic Controls Objective: Calibrate a pneumatic receiver controller as selected by the instructor Tools needed: Safety glasses Pneumatic training board Calibration kit Thermometer Instructor’s Initials:____________

Name:_______________________________

HVA 203.

Pneumatic Pressure / Electric Relay Calibration

JS

Reference: HVAC Control Systems Robertshaw Fundamentals of Pneumatic Controls Objective: Calibrate a pneumatic pressure / electric relay as selected by the instructor Tools needed: Safety glasses Pneumatic training board Calibration kit Instructor’s Initials:____________