E3 HVACR Controls and Devices

E3 HVACR Controls and Devices
#1 Thermostats and Heating controls
© 2005 Refrigeration Training Services - E3#1 Thermostats and Heating Controls v1.0  1
Line Voltage Thermostats
• Primarily used in refrigeration equipment

• Electro-mechanical type uses a sensing
bulb and bellows to operate switching
• Electronic type uses a circuit board and
thermistor
• Refrigeration tstats require adjustable cut-
in cut-out differentials
© 2005 Refrigeration Training Services - E3#1 Thermostats and Heating Controls v1.0   2
Line Voltage Electronic Tstat
Circuit
board
Thermistor
This tstat is sensing evaporator temperature:

▪ Cuts-out when the coil temperature drops to 25°.
▪ Cuts-in when the coil temperature rises to 37°.
Cut-out Cut-in
Differential Temperature
Sensing
Bulb
Bellows
Line Voltage Refrigeration Tstat

Low Voltage Thermostats
• Safer than high voltage tstats (24 volts)

• Close temperature differential (usually 2°)
• Uses smaller wires (18 gauge)
• Requires a step-down transformer
Step-down Transformer
L1
T1
240 volt Induced 24v Secondary
voltage
Primary T2
L2
Ratio 10 : 1
Voltage 240 : 24
High Voltage / Low Voltage Circuits
• Low voltage controls can control high

voltage loads
Low voltage & High voltage Circuits
L1 L2
COMP
C C
CFM
A 240 volt motor is
IFM
controlled by a
IFR 24 volt thermostat.
C
CR
HPS LPS CIT
240v
TRANS
On G 24v
IFR Check out fan circuit
Auto
R Y Turn Fan “ON”
CR
CT
Low Voltage Thermostat
• Following is a standard Honeywell diagram

• The standard low voltage color code is:
• Red for power to the thermostat
• White for heat
• Yellow for cool
• Green for fan
Honeywell Q539A Subbase
AT ON
HE
OFF POSITION
FF
FA
O
N
60 70
80
OL
50
AUTO
CO
B G
Red is always energized O
50 80
60 Y70
R
W
Color coded wires to tstat
Fan Gas Compressor

Relay Valve Contactor
POWER TO
POWER
THERMOSTAT
COMMON
Adapted from a diagram by TRANSFORMER

Honeywell Controls
Thermostat Switching
• The front portion of a thermostat contains the

temperature sensors
• The subbase contains the switches and
circuits to direct the power where it is needed
Switch to Cool
AT ON
HE
OFF POSITION
FF
FA
O FAN AUTO
N
OL
COOL POSITION
AUTO
CALL FOR COOLING
CO
POWER
B G TO 'G'
AUTOMATICALLY
STARTS FAN
Y THERMOSTAT
R POWER
TO 'Y' CALLS FOR COOL
W
Fan Gas Compressor

Compressor
Relay Valve Contactor
Contactor
POWER TO
THERMOSTAT
POWER
COMMON
Adapted from a diagram by TRANSFORMER

Honeywell Controls
Thermostat and Subbase
• The next slide shows how the Thermostat

and the Subbase are electrically
connected.
Combination Diagram
Temp. TEMPERATURE
R1 Rises RISES
T87F Fixed cool
Tstat anticipator
(top) Adjustable
heat anticipator COOLING
ANTICIPATOR
HEATS UP
W1 Y1
FAN
COOL POSITION HEAT OFF COOL AUTO ON
W Y G R
Q539A
Subbase Gas Valve
(bottom) Compressor Fan Relay
POWER TO
Adapted from a diagram by THERMOSTAT
Honeywell Controls
Anticipators
• Human comfort requires a 2° temperature
differential
• The tstat must “anticipate” the room
temperature
• Heating and cooling anticipators are
needed to maintain a close differential
• The following slide shows what would
happen if the tstat did not have a heat
anticipator during a heating cycle
T-Stat Operation Without a Heat Anticipator
Tstat cycles on Room begins to Residual furnace heat
warm overheats the room
80°
Tstat cycles off
Room Temperature
79°
78°
(OVERSHOOT)
77°
76° Comfort Zone 2° Diff. 4° Diff.
75°
(LAG)
74°
73°
Room temperature falls
72° while furnace heats up
Time
With Heating Anticipator
• When the heating thermostat cycles on the

heat anticipator starts to warm
• The anticipator’s heat “fools” the
thermostat into shutting off a little sooner
• The room temperature stays within a 2°
swing
T-Stat Operation With a Heat Anticipator
80°
Tstat Cycles on
Room Temperature
79° Residual heat warms

room to 76°
Room Warms
78°
Tstat cycles off
77°
76°
75° Comfort Zone 2° Diff.
74°
73° Heat anticipator Because tstat
warms thermostat “thinks” it is 77°
72°
Room temperature falls
while furnace heats up
Time
Basic Gas Heating Controls
Three types of controls:
1. Fan controls
2. Safety controls
3. Ignition controls
A fan control delays the blower until the heat

exchanger is warm
Note: It also delays blower shut down after
burners have cycled off
Heating Mode – Auto Fan
L1 L2
1 Comp
C C
2 IFR CFM
High
3 5 - Fan motor starts on low speed
Low
4
IFM
FS 4 - Furnace heat rises,
5
fan switch closes
TRANS
6
On G
7 IFR (3,4) 3 - Gas valve opens
Auto
Cool Y
8 CR (1) 2 - Room temperature falls
9
R Off CT
10
W
GV
1 - Switch t-stat to heat
Heat
HT LS
Furnace OVERHEATS
L1 L2
1 Comp
C C
2 IFR CFM
High
3
3 –Blower runs until heat
Low
4 exchanger has cooled down
IFM
FS
5
TRANS
6
On G
7 IFR (3,4)
Auto
Cool Y
8 CR (1) 2 – Gas valve shuts off
9
R Off CT
10
W
GV
1 – Limit switch opens
Heat
HT LS
Gas Furnace Direct Ignition
• There are more components in a direct

ignition system than on the old standing pilot
furnaces
• The next slide will introduce those
components as well as the high voltage
connections of the system
L2 L1 (HOT)
High Voltage Gas Direct Ignition Controls
Adapted from a diagram by
Honeywell Controls
THERMOSTAT
COMBUSTION AIR
R G BLOWER MOTOR
BLOWER RELAY
HIGH
Combustion Air
LIMIT Y W DUAL
SWITCH GAS
VALVE
FAN CENTER
MV
VALVE L2
R C MV VALVE (GND) HSI
24V L1
Transformer AIR TH-W HSI
PROVING 24V-GND
SWITCH
Y G W HOT
GND (BURNER) SURFACE
FAN IGNITER-
RELAY VENT SENSOR
DAMPER PLUG
Relay
coil
Burner
Ground
FAN LIMIT
HOT SURFACE IGNITION CONTROL

Lo
C Hi
FAN MOTOR
Direct Ignition
• Although complex, the low voltage wiring is
logical
• On a call for heat the following sequence
occurs:
– The combustion blower starts
– The air proving switch closes sending low
voltage to the control module
– The igniter and gas valve are energized
L2 L1 (HOT)
High Voltage
Gas Direct Ignition Controls
Adapted from a diagram by
Honeywell Controls
THERMOSTAT
Tstat calls for COMBUSTION AIR
Heat BLOWER MOTOR ON
R G
BLOWER RELAY
HIGH
Combustion Air
LIMIT Y W DUAL
SWITCH GAS Gas valve energized
VALVE
FAN CENTER Igniter
MV
MV Energized
C VALVE L2
R MV
MV VALVE (GND) HSI
24V L1
Low Voltage AIR TH-W HSI
PROVING 24V-GND
SWITCH
Y G W Air HOT
GND (BURNER) SURFACE
FAN RELAY Switch IGNITER-
Proven VENT SENSOR
Relay DAMPER PLUG
coil
Burner
Ground
FAN SWITCH Fan switch
closes
HOT SURFACE IGNITION CONTROL
Lo Burners warm
C Hi
heat exchanger
FAN MOTOR
Electric Heating Controls
• Electric resistance heaters are used for:

– Supplemental heaters in heat pumps
– Duct heaters
• Sequencers
– Provide a time delay for each heater
– Prevents high initial current draw
Schematic of Electric Heaters with Sequencers
L1 L2
SEQ #3
M2 M1
SEQ #2
M2 M1
SEQ #1
M2 M1
1st Heater is ON
NO
High
IFR FAN SWITCH Blower Starts

NC Low
IFM Switch to HEAT
Energize Sequencer #1
LS TRANS Seq #1 also closes A1-A2
SEQ #2
On G SEQ #3 A2 A1
IFR
Auto SEQ #1
Y SEQ #2 A2 A1
CR
R CT
Heat-Cool W FAN SWITCH SEQ #1
Switch HT
Schematic of Electric Heaters with Sequencers
L1 L2
SEQ #3
M2 M1
3rd Heater is ON
SEQ #2
M2 M1
SEQ #1
2nd Heater is ON
M2 M1
NO
High
The heat is on and
IFR FAN SWITCH
the blower is running
NC Low
IFM until the thermostat is
satisfied.
LS TRANS
SEQUENCER #3 SEQ #2
On G SEQ #3 A2 A1
IFR
Auto SEQ #1
Y SEQ #2 A2 A1
CR
R CT SEQUENCER #2
Heat-Cool W FAN SWITCH SEQ #1
Switch HT
Thermostat (T/S) Troubleshooting Chart
Adapted from Honeywell, Inc
old ts
en
a rm
o c hoo
le
oft
; to n’t
gh ’t cyc
ow
s
S:
; to ers
rt.
ing
ting es
too
EM
sta
set p. do
ting . ov
wo ed;
wo ed;
ive sw
en esn
les
rks
n’t
BL
tem per
tem per
set mp
ess mp
cyc
ly.
do
ach m
ou
O
sys jum
sys jum
T/S m te
Re om te
exc om te
PR
oft tem
m
ste
T/S
T/S
en
o
s
Ro
Ro
Ro
Sy
Sy
SOLUTIONS:
T/S not at fault; check elsewhere
T/S wiring hole not plugged; drafts
T/S not exposed to circulating air
T/S not mounted level (mercury
switch types)
T/S not properly calibrated
T/S exposed to sun, source of heat
T/S contacts dirty
T/S set point too high
T/S set point too low
T/S damaged
T/S located too near cold air register
Break in T/S circuit
Heat/Cool Anticipator; System size
Thermostat (T/S) Troubleshooting Chart
(No animation) Adapted from Honeywell, Inc
old ts
en
a rm
o c hoo
le
oft
; to n’t
gh ’t cyc
ow
s
S:
; to ers
rt.
ing
ting es
too
EM
sta
set p. do
ting . ov
wo ed;
wo ed;
ive sw
en esn
les
rks
n’t
BL
tem per
tem per
set mp
ess mp
cyc
ly.
do
ach m
ou
O
sys jum
sys jum
T/S m te
Re om te
exc om te
PR
oft tem
m
ste
T/S
T/S
en
o
s
Ro
Ro
Ro
Sy
Sy
SOLUTIONS:
T/S not at fault; check elsewhere
T/S wiring hole not plugged; drafts
T/S not exposed to circulating air
T/S not mounted level (mercury
switch types)
T/S not properly calibrated
T/S exposed to sun, source of heat
T/S contacts dirty
T/S set point too high
T/S set point too low
T/S damaged
T/S located too near cold air register
Break in T/S circuit
Heat/Cool Anticipator; System size
END OF
Thermostats and
Heating Controls

E3 HVACR Controls and Devices

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E3 HVACR Controls and Devices

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E3 HVACR Controls and Devices

#1 Thermostats and Heating controls

• Primarily used in refrigeration equipment

This tstat is sensing evaporator temperature:

Line Voltage Refrigeration Tstat

• Safer than high voltage tstats (24 volts)

• Low voltage controls can control high

• Following is a standard Honeywell diagram

Color coded wires to tstat

Fan Gas Compressor

Adapted from a diagram by TRANSFORMER

• The front portion of a thermostat contains the

Fan Gas Compressor

Adapted from a diagram by TRANSFORMER

• The next slide shows how the Thermostat

COOL POSITION HEAT OFF COOL AUTO ON

(bottom) Compressor Fan Relay

• When the heating thermostat cycles on the

79° Residual heat warms

A fan control delays the blower until the heat

• There are more components in a direct

HOT SURFACE IGNITION CONTROL

• Electric resistance heaters are used for:

IFR FAN SWITCH Blower Starts

Heat-Cool W FAN SWITCH SEQ #1

Heat-Cool W FAN SWITCH SEQ #1

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