ENERGY CONSERVATION IN MINI SPLIT AIR CONDITIONERS

[1] Mir Aqueel Ali*

Email mirakeelali@yahoo.co.in
Associate professor,
Mobile - +919421852952
[2] Parvez agwan
Email parvezagwan22@gmail.com
Assistant professor,
Mobile - +919881753120
[1] & [2] B N College of Engg. Pusad.

Abstract
Energy savings in a mini split air conditioner includes correct sizing of AC, purchase, better
installation and operation coupled with reduction in cooling loads. The design options for
substantial energy saving are related to increase in heat transfer area, heat transfer
coefficient, fan, ECM motor and compressor. The cyclic changes should be cared for using
variable speed compressors along with electronic expansion valves. Refrigerants R410a,
R407c may require replacement. The future AC will have better compressor and heat
exchangers for improved performance.
Keywords Energy, mini split, Air conditioner, COP, EER.
INTRODUCTION
Air conditioner (AC) market in India is dominated by room ACs, which make up nearly 99%
of the annual sales. Room air conditioner demand is growing rapidly at rate of 20% on
average per year over the last ten years. With rising incomes and urbanization, falling AC
prices, and a hot climate, it is expected that the AC ownership is going to rapidly increase in
India. Phadke et.al. [1] have estimated the electricity demand from ACs to increase to 239
TWh/yr by 2030, which translates to a peak demand contribution of about 143 GW. Meeting
this demand requires construction of nearly 300 new coal fired power plants of 500 MW
each. The efforts to accelerate the adoption of efficient ACs can lead to reduction of the AC
demand by more than 40% cost effectively; this translates to avoiding building more than 100
new power plants. The Room AC market is increasingly dominated by split ACs. In the
financial year 2011-12, split units accounted for 75% of the total room AC sales, while the
window units accounted for the remaining 25%. Minimum Energy Performance Standard and
maximum efficiency labels of the Indian room ACs, however, are significantly lower than
that compared with other countries. Objective of this paper is to discuss the various factors
responsible for energy conservation in mini split air conditioners.
SIZING OF ACOne should go for cooling load calculation in order to arrive for appropriate sized AC. A large
sized air conditioner penalizes in the following ways
(i)It uses more energy.(ii).It costs more to purchase than appropriate size AC.(iii).The
oversized AC cycles (on and off) more frequently reduce its efficiency. Frequent cycling
makes indoor temperature to fluctuate more and results in less comfortable climate. It also
inhibits dehumidification. It, in addition wears out the compressor and electrical parts more
rapidly. [2]
PURCHASE

Todays AC uses less energy to produce same amount of cooling as vintage AC used two
decades earlier. Thus replacement is an option for energy saving. Purchase energy star
qualified AC which consumes less energy than todays conventional models. Its higher cost
will be paid during its life span. Purchase an AC with Energy saving features such as i)
Digital readout for thermostat setting, ii) A built in timer, iii) A filter that slides out easily for
regular cleaning. [3]
INSTALLATION
(i)Locate the indoor unit near the centre of room on shadiest side of north or east facing wall.
Direct sunshine on condenser decreases efficiency by as much as 10%.(ii) Minimize air
leakage by fitting the drain pipe and tubings snugly into its opening and sealing gaps with
Caulk (special sealants).(iii) The use of longer tube length and more bends between the
indoor and outdoor increase energy consumption. Longer tube lengths require higher
refrigerant charge.(iv) Most TXV sensing bulbs are installed with no insulation and improper
contact and orientation. In these conditions, shunting may arise (rapid opening and closing of
the valve) and harm the compressor while allowing liquid to enter the compressor in those
conditions resulting in increase power consumption.
OPERATION
(i)Set AC thermostat settings properly, AC uses 3 to 5 percent less energy for each degree set
above 22C, therefore set the thermostat as high as is comfortably possible in summer (2527c) [4 ].(ii)Fan speeds are available in 2 or 3 options. Set the fan speed on high, except on
very humid days. When humidity is high set the fan speed on low for more comfort. Consider
an interior fan in conjunction with AC to spread the cooled air more effectively through the
room without greatly increasing electricity use. Using fan allows one to set the thermostat
temperature higher and thus reduces the energy consumption.(iii) Dont place lamps near AC
thermostat. This may cause the AC to run longer.
MAINTENANCE
(i)The air filter, condenser and evaporator coils should be regularly cleaned with a blower.
Some units also control the air flow passage of the indoor unit by measuring the pressure
loss to warn end-users when it is necessary to clean the filter. A 5 star AC will be reduced
to a 3 star in 50- 60 days & a 1 star in 100- 120 days if filter cleaning is overlooked.(ii)
Use a fin comb to straighten the bent fins on evaporator and condenser coil.(iii) In case of
refrigerant leak evacuation should be done by vacuum pump instead of compressor, used
by mechanics.

Use of vacuum pump ensures dehydration and removal of non

condensable gases which may otherwise increase condenser and evaporator temperature.

This is in turn increases energy consumption.(iv) Refrigerant charge should be optimum.

Both under charging and overcharging increase energy consumption.
COOLING LOAD REDUCTION
(i) If possible go for passive cooling in the building before construction.(ii) Install window
sun shade, storm windows, blinds or drapes in front of glass, storm door, double or triple
pane windows.(iii) The cool roof, attic, floor and wall insulation will reduce the cooling
load by 15%.(iv) Use compact fluorescent lamps (CFL) and fixtures which consume
approximately 25% of electricity as compared to similar incandescent lamps and has 8 to
10 times longer life.
DESIGN OPTIONS
INCREASE HEAT TRANSFER SURFACE AREA
1. Increase Frontal Coil Area, 2.Increase Depth of Coil, 3.Increase fin density, 4.Add sub cooler
to condenser coil.
INCREASE HEAT TRANSFER COEFFICIENTS
1. Improve fin design, 2. Improve tube design, 3.Hydrophilic film coating on fins, 4.Improve
fan and fan motor efficiency
MICRO CHANNEL HEAT EXCHANGERS
IMPROVE COMPRESSOR EFFICIENCY
CYCLIC CHANGES
1. Variable speed compressor, 2.Alternative refrigerants, 3. Electronic Expansion valves,
OTHER LOSSES
1. Side louver, 2.Discharge air recirculation heat loss, 3.Suction heat gain, 4. Reversing valve,
5. Evaporative cooling.
Increase frontal coil area
Enhancing frontal area in either of the coil results in increased efficiency of the entire system.
In order to have adequate dehumidification at least 25% of the capacity should be allotted for
dehumidification. The increase in frontal coil area improves evaporator performance thereby
increasing evaporating temperature. The frontal area of coil cannot be increased beyond a
limit because it increases cabinet size.
Increase depth of coil
Vertical tube rows may be at the most 3 because each successive row in a coil is only 70%
effective as preceding row. For systems working with R-410A, the trend is to use number of
rows to 2 or 3 rows and for R-407C, it is possible to take advantage of the temperature glide

by using a configuration with more than 3 rows. Addition of horizontal row is limited by
chassis size, issue of weight and refrigerant charge.
Fin density optimization
Dominant heat transfer resistance is usually on the air-side. Fin density should be optimized
with regards to improvement in heat transfer, effect on fan power; water drainage and dirt
build up. The fin density is a function of type of coil (evaporator or condenser), fin type
(wavy, louvered, enhanced), number of tube rows and tube diameter. Current fin densities are
around 7/cm.
Sub cooler
A sub cooler can be added between condenser outlet and capillary inlet. The addition of sub
cooler will increase the size of condenser coil. The addition of sub cooler may be possible if
adequate area is available otherwise the size of air conditioner will increase thereby resulting
in increased initial cost. The increase in Energy Efficiency Ratio (EER) may be 1.4 to 3 %
for various capacities.
Improve fin design
Enhancements to the fin design have the effect of improving coils airside heat transfer
coefficient thereby improvement in overall heat transfer capability of coil.

The

improvements are partly due to increased air turbulence over coil caused by enhanced fin
design. The fin improvement can be achieved by using a corrugated or wavy fin pattern or a
louvered or lanced fin pattern. Recent progress also includes decrease of the fin thickness.
The fin thickness is around 0.1mm.
Improved tube design
The refrigerant side heat transfer coefficient with grooved tubing is greater than that for
smooth tubing. Improvement of refrigerant heat transfer coefficient with grooved tubing is a
function of width, height and spacing of grooves as well as oil concentration within the
refrigerant. The effect of refrigerant pressure drop should be optimized. In order for the heat
exchange increase not to be too detrimental to the refrigerant pressure loss in the heat
exchangers, the diameter of the copper tube is adapted to the refrigerant conditions, with
larger diameters for the gas state and lower diameters for liquid or two phase conditions.
These measures also enable to decrease the refrigerant charge resulting in lower power
consumption. Tube diameters currently used are 7mm.The system performance due to
different heat exchanger fin and tube designs data from Chinese texts on air conditioner
technology is given in Table 1 which summarizes the heat transfer and pressure drop
enhancement factors. The enhancement factors are relative to flat fins and smooth tubing (i.e.,

flat fins and smooth tubing have heat transfer and pressure drop enhancement factors of 1.0).
The value used for the heat transfer enhancement factor is the multiplication factor for airside heat-transfer coefficient of the coil. [5]
Table 1 Heat transfer and Pressure drop
Enhancement factor
Design

Heat Transfer
Enhancement
Factor

Pressure
drop
Enhancemen
t Factor

EVAPORATOR TUBE
1.12
1.5
1.8
2.4
CONDENSOR TUBE
Wavy Fin smooth
1.11
Slit Fin groove
1.44
Slit Fin groove
1.57
Groove
2.2

Wavy Fin smooth

Slit Fin smooth
Slit Fin groove
Groove

1.05
1.2
1.2
1.5
1.05
1.25
1.25
1.4

Hydrophilic film coating on fins

The formation of water condensate upon the heat exchanger fins causes a bridging effect
between the fin spacing. This results in a decrease in the heat transfer performance as well as
an increased drop in air pressure. The addition of the hydrophilic coating on the heat
exchanger fins reduces the thickness of the condensate layer and enables an increased ability
for the water to drain off the fins allowing a reduced air side pressure drop and an increased
airflow across the heat exchanger. The aluminum fins will not corrode due to separation of
water droplets. In the US it has been shown that the use of such a hydrophilic film coating on
the heat exchanger fins can reduce the pressure drop between 20-50% when operating in high
humidity room-side air environments. Therefore cooling capacity is improved as compared to
air conditioning systems using untreated fins.
Fan & fan motor
The evaporator fan is usually a blower wheel (centrifugal forward curved fan) while
condenser fan is propeller typed. The evaporator and condenser fan motor consume 3% and
7 respectively of total energy consumption of room AC. Propeller fans previously made of
processed metals, are now made of plastics. The shape of blade must be such that it should
increase the volumetric efficiency and decrease the noise level. Opportunities for conserving
energy are also available by improving the efficiency of air delivery system and fan motor. In
addition, improving fan motor efficiency results in additional compressor energy saving.
Earlier fan motors were of low efficiency shaded pole typed but now permanent split
capacitor (PSC) motors having efficiency in the range of 50% to 60 are used. Electronically
commutated motors (ECM) have the efficiency in range of 70 to 80%. In an ECM power is

pulsed on and off electronically. By varying the timing and duration of pulses, the electronic
controller can accomplish speed control as well as maintain high torque at the start and over a
broad speed range. [6] The cost of ECM is 2.5 to 5 times more and EER increases by 0.4 as
compared to PSC motors.
Micro channel heat exchangers
Micro channel heat exchangers are smaller and yet have the same performance as a
conventional heat exchanger, in other words improved performance in same volume as that of
conventional heat exchanger. The smaller size of the exchanger reduces refrigerant pressure
drop, improving overall compressor performance. However, micro channels also have
weaknesses, such as large pressure drop, high cost of manufacture, dirt clogging, and flow
mal-distribution, especially for two-phase flows. Smaller condenser weight and refrigerant
charge in micro channel heat exchangers reduce the thermal mass of the heat exchanger, and
therefore contribute to better seasonal performance. Atthakorn Chaikhumrop and Worrasid
Trutassanawin [7] performed the test on split type air conditioning unit with a cooling
capacity of 18,000 Btu/hr. the results showed that as the condenser air inlet temperatures
increased from 35oC to 38oC and to 42oC, the effectiveness of microchannel condenser were
higher than those of fin-and-tube condenser by 3.66%, 5.65%, and 3.64%, respectively. The
EERs of the split type air conditioning system with the microchannel condenser were higher
than those of the system with the fin-and-tube condenser as the condenser air inlet
temperatures were increased from 35oC to 38oC and to 42oC by 1.14%, 3.08%, and 2.80%,
respectively.
Improved compressor efficiency
Compressors are the heart of refrigeration system. Energy consumed by the compressor has a
lions share in air conditioners total energy. Compressor efficiency is improved through the
use of high efficiency motors, high grade materials in the pumping mechanism combined
with advance production methods and equipment. Progresses have been made to reduce
friction losses in rotary compressors. The Swing compressor manufactured by Daikin has the
roller solidarized with the blade; this avoids leakages between high and low pressure sides.
The compressor has 15 % higher global efficiency. Other manufacturers (Toshiba, Fujitsu,
Sanyo) have adopted a rotary compressor with two stages or twin rotary compressor that
enables to improve the efficiency by 10 %. [8] Advantages of scroll over reciprocating are 1
Highest volumetric efficiency- approximately 100%, 10% to 20 higher EER, 2 Low sound
characteristics- approximately 5 decibels lower than reciprocating, Smoother and continuous
compared to rapid piston movement which ensures low vibration and lower discharge pulse 3

Outstanding reliability with regards to lower failure rate and tolerance to liquid refrigerant as
well as debris. [9] Developments of linear compressors for air conditioners will be able to
decrease motor losses and increase compression efficiencies. However, no linear compressor
is presently commercially available for air conditioners.
Variable speed compressors
A compressor working with variable speed motor and its speed modulated to match the load
offers the advantage of substantial reduction in power consumption and increase in EER by
1.2.Variable speed compressor matches the load in a room. Advantages of variable speed
compressors are (i) Quieter Operation at low speeds.(ii) Enhanced comfort by eliminating
large fluctuations in room temperature. The control of variable speed compressors is
accomplished through the use of electronic ASD at the motor. Because electronic ASD are
compact and do not have to be mechanically coupled to motor, they can be applied to
fractional size motors of room ACs. Inverter based ASD are common for induction motors
while converter based ASDs are used for ECM motors. ASD perform well both with rotary
and scroll compressors. The major benefits of the inverter air conditioning system over a
conventional air conditioning system include excellent thermal comfort, noiseless, and
precise controllability. In addition, an inverter-driven conditioner provides not only precise
capacity modulation, but also energy conservation. [10] Although more efficient than single
speed systems at full load conditions. Because of parasitic losses associated with the
electronics required to operate variable speed compressor, they may actually draw more
power at full load conditions. Thus, variable speed systems may exacerbate peak power
concerns for electric utilities.
Alternative refrigerants
Currently, the main refrigerants used in household air-conditioners are (HCFCs)
hydrochlorofluorocarbons, particularly R-22, and (HFCs) hydrofluorocarbons, mostly R410A. There are two approaches to the replacement of HCFCs at present: one is the use of
HFCs and the other is to use hydrocarbon (HC) refrigerants. At present, the most common
internationally-applied alternative for room air conditioners is HFC R-410A; however this
refrigerant has a high Global Warming Potential (GWP) of 2088. Given the current concerns
and increasing demands for protection of the climate, high GWP alternatives are facing
elimination in the medium to long-term. Compared with HCFCs and HFCs, HC refrigerants
offer zero ODP and negligible GWP and, in regard to their performance, they offer in general:
high efficiency, reduced charge sizes, good miscibility with mineral oils, lower compressor
discharge temperatures, and better heat transfer within heat exchangers.R-290 and R32 are

also alternatives for R-22.In India Godrej Industries now sells split systems with R 290 and
Daikin and Panasonic offers split systems with R32.Another Alternative R 407C can be used
drop in substitute.
Electronic expansion valves
As compared to capillary the thermostatic expansion valves (TXV) can adapt better to
changes in operating conditions such as those due to variation in ambient temperatures, which
affect the condensing temperature. TXV can lead to small variations around the set point
depending on the evaporating pressure. Moreover, at very low load, there are stability
problems that may lead to the shunting of the valve and significant energy losses. The
electronically controlled expansion valve enables a correct and adaptable level of throttling
based on electronic signaling from a micro-computer which determines the air conditioner
operating state. A pulse motor fed by an electronic signal is used to control the valve, which
in turn controls the degree of throttling. This enables the efficient control of the refrigerant
flow, depending on the operating state. The operating characteristics are similar to the TXV
except for the increased precision achieved by the electronic valve which in turn enables
lower superheat values and the ability to overcome the limits of the TXVs thermo-mechanical
design. As is the case with the variable speed compressors, the key benefit of electronic
expansion valves is the improvement of seasonal energy efficiency. An added benefit of the
electronic expansion valve (as with TXV with hermetic closure) is the capability to stop
refrigerant migration under on/off cycling or when the unit is off.
Other losses
i. side louvers
Side louvers have a significant impact on unit performance. Side louvers separate the
airstreams to and from the condenser and reduce recirculation and enhance the movement of
air over the outdoor coil. Units without side louvers operate at a lower efficiency due to
additional compressor power (around 4%) required for compensating the decreased air flow
over the condenser coil.
ii. Discharge air recirculation heat loss
Short circuiting of discharge air into the AC reduces heat content of the mixture, thereby
reducing capacity (around 6%). The EER decreases since the energy input is same.
iii. Reversing valve
A reversing valve allows a room AC to operate as a heat pump and provide space heating in
addition to cooling. The reversing valve adds an additional load to the system that increases
the units power requirement by an estimated 5%.

iv. Suction line heat gain

It takes places due to motion of refrigerant from indoor to outdoor section and hence
capacity decreases. The heat gain can be reduced by better insulation on suction line.
v Evaporative cooling
A problem related with application of air condenser in hot weather conditions (about 50oc) is
related to the high storeyed buildings. In these buildings the hot air from air conditioners of
lower story rises up and provides a hot flow field around the air conditioners of higher
storeyed. Sometimes, the increase in the air temperature is so high that the air conditioner trip
down. Improvement of system performance in a split-type air conditioner with various types
of indirect evaporative cooling systems was experimented by Chainarong Chaktranonda, and
Peachrakha Doungsonga [11], the conclusions are:
(i). Ambient temperature has much influenced the power consumption of compressor and
COP. When ambient temperature is raised by 1OC, electrical power consumption increases by
around 4%. (ii). Due to high contact surface between water and air-stream, the evaporative
cooling system using spray water cooperating with cellulose cooling pad can decrease the
power consumption by around 15%, and can increase COPR up to 45%.
Conclusion
The various methods of energy conservation are discussed. The design adoption depends
upon modification cost and energy saved. Improvement in compressor EER may be the first
priority followed by use of better heat exchangers. Our nation has taken a welcome step by
improving BEE star label for room AC compulsory from January 2014.
References
[1] Nihar Shah, Paul Waide, Amol Phadke Cooling the Planet: Opportunities for
Deployment of Superefficient Room Air Conditioners LBNL-XXXX
[2] Consumer energy information Energy efficiency and renewable energy network
fact sheet.
[3] Room air conditioner energy efficiency and renewable energy.
[4] Guide on energy efficient Room air conditioner.
[5] Technical and economic analysis of energy efficiency of Chinese room air
conditioner, February 2001 LBNL 4555O ,29
[6] Brushless D C motors Trane Engineers Newsletter volume334
[7] Atthakorn Chaikhumrop and Worrasid Trutassanawin, Study, and Testing of a SplitType Air Conditioning Unit by Using Microchannel Condenser The Second TSME
International Conference on Mechanical Engineering October 19-21, 2011, Krabi
[8] Preparatory study on the environmental performance of residential room conditioning
appliances (airco and ventilation) Draft report of Task 6 July 2008
[9]Scroll compressors presented by kirloskar Copeland ltd. at national conference on
RAC, Chennai.

[10] Ing Youn Chen, Y.M. Chen, C.S. Wei , C.C. Wang , A comparative study between a
constant-speed air-conditioner and a variable-speed air-conditioner. ashrae transactions
jan 2009
[11] Chainarong Chaktranonda, and Peachrakha Doungsonga An Experimental
Evaluation of Energy Saving in a Split-type Air Conditioner with Evaporative Cooling
Systems 2010 International Transaction Journal of Engineering, Management, & Applied
Sciences & Technologies Volume 1 No.1. eISSN: 1906-9642