CHAPTER 2

Air Conditioning Systems

APPLICATIONS
 Comfort applications for various building types are quite different and
may be categorized as

 Low-Rise Residential buildings, including single family houses,

duplexes, and small apartment buildings
 High-Rise Residential buildings, such as tall dormitories and
apartment blocks
 Commercial buildings, which are built for commerce, including
offices, malls, shopping centers, restaurants, etc.
 Institutional buildings, which includes hospitals, governmental,
academic, and so on.
 Industrial spaces where thermal comfort of workers is desired.
 Sports Stadiums - recently, stadiums have been built with air
conditioning to allow competition to take place in summer
 Can be used for many types of transportation

 Motor-cars and other land vehicles,

 Trains
 Ships
 Aircraft
 Spacecraft
 Hospital operating theatres
 Cleanrooms for the production of integrated circuits,
pharmaceuticals.
 Facilities for breeding laboratory animals.
 Aircraft air conditioning.
 Data centers
 Textile factories
 Physical testing facilities
 Plants and farm growing areas
 Nuclear facilities
 Chemical and biological laboratories
 Mines
 Industrial environments
 Food cooking and processing areas
Fundamental of Heating and
Refrigeration Operation
 Air conditioning is the dehumidification of indoor air for
thermal comfort

 Air conditioner (AC or air con.) is an appliance, system or

machine designed to stabilize the air temperature and
humidity within an area (used for cooling as well as heating
depending on the air properties at a given time)

 Using a refrigeration cycle but sometimes using

evaporation, commonly for comfort cooling in buildings and
motor vehicles.
BASIC PRINCIPLES OF REFRIGERATION
 If you were to place a hot cup of coffee on a table and
leave it for a while, the heat in the coffee would be
transferred to the materials in contact with the coffee,
i.e. the cup, the table and the surrounding air.

 As the heat is transferred, the coffee in time cools.

 Using the same principle, refrigeration works by

removing heat from a product and transferring that
heat to the outside air.
BASIC COMPONENTS
 There are five basic components of a
refrigeration system, these are:
1. Evaporator

2. Compressor

3. Condenser

4. Expansion Valve

5. Refrigerant; to conduct the heat from the

product
THE EVAPORATOR
 The purpose of the evaporator is to remove unwanted heat from the
product, via the liquid refrigerant. The liquid refrigerant contained
within the evaporator is boiling at a low-pressure. The level of this
pressure is determined by two factors:-

 The rate at which the heat is absorbed from the product to the
liquid refrigerant in the evaporator
 The rate at which the low-pressure vapour is removed from the
evaporator by the compressor

 To enable the transfer of heat, the temperature of the liquid refrigerant

must be lower than the temperature of the product being cooled.

 Once transferred, the liquid refrigerant is drawn from the evaporator by

the compressor via the suction line.

 When leaving the evaporator coil the liquid refrigerant is in vapour

form.
THE COMPRESSOR
 The purpose of the compressor is to draw the low-
temperature, low pressure vapour from the evaporator via the
suction line.

 Once drawn, the vapour is compressed. When vapour is

compressed it rises in temperature.

 Therefore, the compressor transforms the vapour from a low-

temperature vapour to a high-temperature vapour, in turn
increasing the pressure.

 The vapour is then released from the compressor in to the

discharge line
THE CONDENSER
 The purpose of the condenser is to extract heat from the refrigerant
to the outside air.

 The condenser is usually installed on the reinforced roof of the

building, which enables the transfer of heat. Fans mounted above
the condenser unit are used to draw air through the condenser coils.

 The temperature of the high-pressure vapour determines the

temperature at which the condensation begins. As heat has to flow
from the condenser to the air, the condensation temperature must
be higher than that of the air; usually between -12°C and -1°C.

 The high-pressure vapour within the condenser is then cooled to the

point where it becomes a liquid refrigerant once more, whilst
retaining some heat. The liquid refrigerant then flows from the
condenser in to the liquid line.
THE EXPANSION VALVE
 Within the refrigeration system, the expansion valve is located
at the end of the liquid line, before the evaporator.

 The high-pressure liquid reaches the expansion valve, having

come from the condenser.

 The valve then reduces the pressure of the refrigerant as it

passes through the orifice, which is located inside the valve.

 On reducing the pressure, the temperature of the refrigerant

also decreases to a level below the surrounding air. This low-
pressure, low-temperature liquid is then pumped in to the
evaporator.
THE REFRIGERANT

 Refrigeration is a
process in which work is
done to move heat from
one location to another

 The type of refrigerant

used will depend on the
pressure capabilities of
the system and the
temperatures that have
to be achieved during
refrigeration Refrigeration Cycle
 Liquid refrigerant entering the indoor coil, operating as the evaporator during
cooling. Refrigerant in the evaporator "evaporates."

 Upon entering the evaporator, the liquid refrigerant's temperature is between

5 - 10°C and without changing its temperature, it absorbs heat as it changes
state from a liquid to a vapor. The heat comes from the warm, moist room air
blown across the evaporator coil.

 As it passes over the cool coil, it gives up some of its heat and moisture may
condense from it. The cooler, drier room air is re-circulated by a blower into the
space to be cooled.

 The vapor refrigerant now moves into the compressor, which is basically a
pump that raises the pressure so it will move through the system.

 Once it passes through the compressor, the refrigerant is said to be on the

"high" side of the system. Like anything that is put under pressure, the
increased pressure from the compressor causes the temperature of the
refrigerant to rise. As it leaves the compressor, the refrigerant is a hot vapor,
roughly 50 - 60°C.
 It now flows into the refrigerant-to-water heat exchanger, operating as the
condenser during cooling.

 The refrigerant condenses here. As it condenses, it gives up heat to the loop,

which is circulated by a pump. The loop water is able to pick up heat from the
coils because it is still cooler than the 120 degree coils.

 As the refrigerant leaves the condenser, it is cooler, but still under pressure
provided by the compressor.

 It then reaches the expansion valve. The expansion valve allows the high
pressure refrigerant to "flash" through becoming a lower pressure, cooled
liquid. When pressure is reduced (as with spraying an aerosol can or a fire
extinguisher) it cools.

 The cycle is complete as the cool, liquid refrigerant re-enters the evaporator to
pick up room heat.
TYPES OF AIR CONDITIONING SYSTEMS

1. Window Air Conditioner

2. Split Air Conditioner
3. Packaged Air Conditioner
4. Central Air Conditioning System
 WINDOW AIR CONDITIONER
 The most commonly used air
conditioner for single rooms.

 All the components (compressor,

condenser, expansion valve or Supply
coil, evaporator and cooling coil) Return air grill
are enclosed in a single box. air grill

Control
 This unit is fitted in a slot made in panel
the wall of the room, or often a
window sill.
Split Air Conditioner
 Comprises of two parts: the outdoor unit
and the indoor unit.

 The outdoor unit, fitted outside the

room, houses (components like the
compressor, condenser and
expansion valve).

 The indoor unit comprises the

evaporator or cooling coil and the
cooling fan.

 For this unit you don’t have to make any

slot in the wall of the room. Further, the
present day split units have aesthetic
looks and add to the beauty of the room.
The split air conditioner can be used to
cool one or two rooms.
PACKAGED AIR CONDITIONER
 To cool more than two rooms or a larger space at your home or office.
 There are two possible arrangements with the package unit:-
 In the first one, all the components, expansion valve and evaporator are
housed in a single box. The cooled air is thrown by the high capacity
blower, and it flows through the ducts laid through various rooms.
 In the second arrangement, the compressor and condenser are housed
in one casing. The compressed gas passes through individual units,
comprised of the expansion valve and cooling coil, located in various
rooms.
 CENTRAL AIR CONDITIONING SYSTEM
 The central air conditioning system is
used for cooling big buildings, houses,
offices, entire hotels, gyms, movie
theaters, factories etc.

 The central air conditioning system is

comprised of a huge compressor that
has the capacity to produce hundreds
of tons of air conditioning.

 Cooling big halls, malls, huge spaces,

galleries etc is usually only feasible
with central conditioning units.
CHILLER AND COOLING
TOWER
Often used to cool a building's air and equipment, especially in
situations where many individual rooms must be controlled
separately, such as a hotel.
• Water chillers are used in a variety of air conditioning and
process cooling applications.

• They are used to make cold water that can be transported

throughout a facility using pumps and pipes.

• This cold water can be passed through the tubes of coils to

cool the air in an air conditioning application, or it can
provide cooling for a manufacturing or industrial process.

• Systems that employ water chillers are commonly called

chilled-water systems.
• Chilled water systems are used in many buildings for
cooling because of their flexibility and operating cost
compared with direct expansion (DX) cooling coil
systems.

• Typically chilled water is generated at a central location

by one or more chillers and distributed to coils in air
handling system.

• The quantity and temperature of the water supplied

must be sufficient to meet the needs of all fan systems.
 A chiller is a machine that removes heat from a liquid via a
vapor-compression or absorption refrigeration cycle.

 Chilled water is typically distributed to heat exchangers,

or coils, in air handling units (AHU) or other types of terminal
devices (fan coil unit, FCU) which cool the air in their
respective space(s).

 Then the water is re-circulated back to the chiller to be cooled

again.
 The cooling coils transfer heat from the air to the chilled water,
thus cooling and usually dehumidifying the air stream.

 A typical chiller for air conditioning applications is rated

between 15 and 1500 tons (180,000 to 18,000,000 BTU/h or
53 to 5,300 kW) in cooling capacity.

 Chilled water temperatures can range from 35 to 45 degrees

Fahrenheit (1.5 to 7 degrees Celsius), depending upon
application requirements.
 Cooling towers are heat removal devices used to transfer
process waste heat to the atmosphere.

 Cooling towers may either use the evaporation of water to

remove process heat and cool the working fluid.

 The condenser water absorbs heat from the refrigerant in the

condenser barrel of the water chiller, and is then sent via return
lines to a cooling tower (heat exchanger used to transfer waste
heat to the atmosphere).
TYPES OF MAINTENANCE

 Water chemistry - minimize the effects of scale,

corrosion and micro-biological / debris fouling.

 Mechanical maintenance - proper lubrication, adequate

liquid refrigerant (freon, ammonia), oil levels and pump
curve tests.

 Operational procedures - oil analysis, calibration of

gauges and meters
CHILLER MAINTENANCE
 Inspect the chiller as recommended by the chiller manufacturer. Typically, this
should be done at least quarterly.
 Routinely check refrigerant and inspect for refrigerant leaks.
 Check compressor operating pressures.
 Check all oil levels and pressures.
 Check motor voltages and amps for balanced loading.
 Check all electrical starters, contactors and relays.
 Check un-loader operation.
 Check water flow rates.
 Review water chemistry to ensure proper heat transfer.
 Review cooling tower operation.
SAFETY CONTROLS
• When an unsafe condition exists, the compressor should stop
automatically. Safety cutout controls may have automatic or manual
reset and include the following:

a. High condenser pressure.

b. Low refrigerant pressure or temperature.
c. Back-up for the low chilled water temperature controller (on some
reciprocating chillers).
d. High motor temperature.
e. Motor overload.
f. Low oil pressure.
g. Low oil sump temperature.
h. High oil sump temperature.
i. Chilled water flow interlock.
j. Condenser water flow interlock.
COMMON PROBLEMS IN AIR
CONDITIONING
REFRIGERANT LEAK
• Problem - doesn’t cool in an efficient manner.
• If air conditioner is low on refrigerant
• undercharged at installation or
• it leaks.

• If it leaks, simply adding refrigerant is not a solution.

• Should fix any leak, test the repair, and then charge the system
with the correct amount of refrigerant.
• Refrigerant leaks can also be harmful to the environment.
INADEQUATE MAINTENANCE
• If the filters and air conditioning coils are allowed to become
dirty, the air conditioner will not work properly, and the
compressor or fans are likely to fail.

Filter Cooling coil

 ELECTRICAL CONTROL PROBLEM
• The compressor and fan controls can wear out, especially when
the air conditioner turns on and off frequently.
• Corrosion of wire and terminals is also a problem.
• Electrical connections and contacts should be checked during
maintenance/service.

Compressor

http://www.autopartswarehouse.com/sku/Replacement/A-fs-C_Compressor/REPC191101.html
SENSOR PROBLEMS
• Room air conditioners feature a thermostat sensor, located behind the
control panel, which measures the temperature of air coming into the
evaporative coil.
• If the sensor is knocked out of position, the air conditioner could cycle
constantly or behave erratically.
• The sensor should be near the coil but not touching it; adjust its position by
carefully bending the wire that holds it in place.

Epoxy Coated Temperature Sensor Probe

DRAINAGE PROBLEMS
• Condensate drain lines collect condensed water and drain it
away from the unit.
DRAINAGE
• They are located on the side of the inside fan unit.
Sometimes there are two drain lines - a primary drain
line that’s built into the unit, and a secondary drain line
that can drain if the first line becomes blocked.
• Inspect the drain line for obstructions, such as
algae and debris.
• If the line becomes blocked, water will back up into the
drain pan and overflow, potentially causing a safety
hazard or water damage to your home.
• Make sure the hoses are secured and fit properly.
COOLING COIL
• Turn off the main power switch to the unit, then cover off.
• Inspect the coils and fins to see if they are within reach.
• Fill a bucket with warm soapy water and wipe the coils clean.
• Do not use harsh chemicals or cleaners that could damage your AC unit.
• Wipe the coils clean.
• Call a professional to have the coils steam cleaned with a solvent-based cleaner if there is
still mold and other debris left behind.
• Finally, pour a mixture of bleach and water into you drain pan to help keep the drain line
clean.

a) b)

a) Cooling coil
b) Condensor
CONDENSER

• Remove any leaves, spider webs and other

debris from the unit.
• Straighten any bent fins with a tool called a fin
comb.
• Add lubricating oil to the motor.
• Clean the evaporator coil and condenser coil at
least once a year. When they collect dirt, they
may not function properly.
CLOGGED EVAPORATOR COIL
 Good job of keeping filter changed, however,
the indoor evaporator coil proves differently.
 Their air conditioning system and heating
unit was working overtime but not getting
much cooling, heating or comfort.
 High electric and gas bills.

Evaporator coil
EXPANSION VALVES

• The common types of expansion valves or

devices:
• Capillary tube, and (small size unit)
• Thermostatic expansion valve (large size unit)
 THERMOSTATIC EXPANSION VALVE

http://www.air-conditioner-selection.com/air-conditioner-expansion-valves.html
THERMOSTATIC EXPANSION VALVE
• The rise and drop in pressure will push, or pull the
diaphragm. This diaphragm is directly connected to the
spring loaded valve seat. The seat is arranged such that
it will increase flow under high pressure, and vice versa -
operate under varying load conditions.

• Filter is used to trap unnecessary solids from equipment

wear and tear, into the valve seat of the expansion
valves.
OTHER PROBLEMS

 Noisy unit which could be causing internal

damage.
 Older Heat/AC unit

 Running up energy bill - efficiency

Avod gaps and missing insulation along the refrigeration lines