CH.

3 AIR CONDITIONING SYSTEM

 Construction and working of Automobile air conditioning system :

Working:
1.Compressor: It is used to compress vapour refrigerant coming from the Evaporator and supply high pressure
vapour refrigerant to condenser.
2.Condenser:The function of the condenser is to condense vapour refrigerant into liquid.
3.ExpansionValve: The function of expansion valve is to meter and control the flow rate of liquid refrigerant
and reduce the temperature of liquid refrigerant.
4.Evaporator: The function of the evaporator is to give refrigerant effect by exchanging heat to the liquid
refrigerant.
5.Accumulator or Receiver Drier: The receiver drier act as storage tank for the liquid refrigerant and also
absorbs the moisture from the refrigerant.

 Function of evaporator :
a. to give refrigerant effect by exchanging heat to the liquid refrigerant.
b. It is a device in a process used to turn the liquid form of a chemical substance such as water into
its gaseous-form/vapor.
c. The liquid is evaporated, or vaporized, into a gas form of the targeted substance in that process.
d. Evaporator is an important component together with other major components in a refrigeration
system such as compressor, condenser and expansion device.
e. The reason for refrigeration is to remove heat from air, water or other substance.
f. It is here that the liquid refrigerant is expanded and evaporated.

 Construction and working of evaporator:

Construction:
1. The evaporator as shown in figure is the part of refrigeration system where the refrigerant vaporizes as it
picks up heat.
2. Heated air is forced through and past the fins and tubes of the evaporator.
3. Heat from the air is picked up by the boiling refrigerant and is carried in the system to the condenser.
4. The evaporator is usually installed in housing under the dash panel.

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Working:

1. When the air conditioning system is turned on, warm air from the passenger compartment is blown
through the coils and fins of the evaporator.
2. The evaporator receives refrigerant from the thermostatic expansion valve or orifice tube as a low
pressure, cold atomized liquid.
3. As the cold refrigerant passes through the evaporator coil, heat moves from the warm air into the cooler
refrigerant.
4. When the liquid refrigerant receives enough heat, a change of state - from a low pressure liquid into a
low Pressure vapor - takes place
5. The thermostatic expansion valve or orifice tube continually meters the precise amount of refrigerant
necessary to maintain optimum heat transfer, which ensures that all of the liquid refrigerant will have
changed to a vapour by the time it reaches the evaporator outlet.
6. The vaporized refrigerant then continues on to the inlet (suction) side of the compressor.

 Construction and working of drier :

Function:
to absorb moisture from the refrigerant with the help of drying
agent (desiccant)

Construction and working:

1. A screen is placed in the receiver/drier to catch and prevent the
circulation of any debris that may be in the system.
2. The receiver or drier is a cylindrical metal can with two fittings
and in most cases, a sight glass.
3. The drier is located in the high pressure side of the air
conditioning system.
4. In general, the construction of receiver/drier is such that
refrigerant vapor and liquid are separated to insure that 100%
liquid is fed to the thermostatic expansion valve.
5. The assembly can be divided into two parts: the receiver and the
drier.
6. The receiver section of the tank is storage compartment. This
section holds the proper amount of extra refrigerant required by
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the system to insure proper operation.
7. The receiver insures that a steady flow of liquid refrigerant can be supplied to the thermostatic
expansion valve.
8. The drier section of the tank is simply a bag of desiccant, such as silica gel, that can absorb and hold
small quantity of moisture.

 construction and working of condenser

Evaporative type condenser is used in car AC system.
Construction:
1. Sketch shows the construction of condenser used for
automobile air condition.
2. It is the other heat exchanger used in automobile air
conditioning.
3. These are usually made of aluminum or sometimes made of
copper or brass.
4. It look very much like radiator, just little thinner and since they
also depend on air flowing through them,
5. they are usually located in front of radiator as shown in the
figure above.
6. Condensers can be constructed as a series of tubes with fins
around them.
Working:
1. Its main function is to condense the refrigerant vapour from compressor.
2. The refrigerant enters the condensers as a high pressure vapour, but as it flows through the condenser
refrigerant rejects the heat to flow air over it and gets converted into high pressure refrigerant liquid

 Accumulator :
1. the accumulator is located on the low side of the
system, usually right at the evaporator outlet.
2. However, its two-fold function - to store excess
refrigerant and remove moisture from the system -
is the same as that of the receiver- drier.
3. If any liquid refrigerant is passed out of the
evaporator, it's stored by the accumulator.
4. Because liquids cannot be compressed, liquid
refrigerant can damage the compressor.
5. And, like the receiver-drier, the accumulator also
utilizes desiccant to remove moisture from the
system.

 Drive system for compressor in automobile air conditioning :

1. Compressor driven off crankshaft pulley by one or two belts: Compressors are driven by one or two belts
of the engine crankshaft and have an idler pulley which is used to adjust the belt tension. Similarly, alternator or
power steering pump can be used to adjust
belt tension

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Figure: Compressor driven off crankshaft pulley by one or two belts

OR

2. Compressor driven off crankshaft by single belt:

Figure: Compressor driven off crankshaft by Serpentine belt

Compressor can be driven off the crankshaft by single belt drive along with such other accessories as power
steering pump, air pump, alternator and water pump. This system is known as serpentine drive as shown in
figure. The belt called V-rib or serpentine is tensioned by spring loaded idler pulley which rides on the back
side of the belt.

 Types of Compressor:
i) Reciprocating compressor
ii)Rotary Vane compressor
iii) Scroll compressor
iv) Screw compressor
v.)Hermetically Sealed Compressor.

 Construction and working of scroll compressor :

Construction of scroll type compressor:

1. Constructional features of scroll type compressors are as shown in the figure.
2. It consists of
a) refrigerant i) stud pin,
b) temperature sensor, j) crankshaft,
c) moveable scroll, k) eccentric bushing,
d) delivery port, l) ball coupling,
e) intake port, m) fixed scroll etc.
f) low pressure service valve,
g) front plate,
h) needle bearing,

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Working:
1. Scroll-type compressors have two metal scrolls, one fixed and one moveable, which provide an
eccentric motion.
2. As the compressor shaft rotates, an eccentric bushing on the shaft drives the moveable scroll, and
refrigerant is forced against the fixed scroll, and towards its center.
3. The motion creates an increase in pressure toward the center of the scroll.
4. The refrigerant vapor moves in a circular pattern, and its pressure is increased as it moves toward
the center of the scroll.
5. The high pressure refrigerant is released through a delivery port located at the center of the scroll.
6. Scroll-type compressors provide a longer effective compression stroke, and a smoother start-up
than other compressor designs, and they produce less vibration

OR
Construction and Working:
1. This compressor uses a unique design with two scrolls, one fixed and one is movable, both are
inter-leaved.
2. The movable spiral is able to ORBIT or oscillate without actually fully rotating.
3. The movable scroll is connected to the input shaft via a concentric bearing.
4. As the movable spiral oscillates within the fixed spiral, a number of pockets are formed between
the spiral.
5. As these pockets decrease in size the refrigerant is squeezed, the pressure increases and is
discharged through a reed valve at the discharge port in the rear section of the compressor.

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 Construction and working of reciprocating type compressor:

1. Constructional features of reciprocating compressors are as shown in the following figure.
2. It consists of oil sump, crankshaft, piston and ring assembly, valve plate, cylinder head, service
valve fitting, reed valve assembly and crankshaft seal assembly etc.

Working:
1. Piston type compressors go through
an intake stroke and a compression
stroke for each cylinder.
2. On the intake stroke, the refrigerant
from the low side (evaporator side)
of the system is drawn into the
compressor.
3. The intake of refrigerant occurs
through reed valves.
4. These one-way valves control the
flow of refrigerant vapors into the
cylinder.
5. During the compression stroke, the
gaseous refrigerant is compressed.
6. This increases both the pressure and
the temperature of the heat-carrying
refrigerant.
7. The outlet (discharge) side reed valves then open to allow the refrigerant to move into the
condenser.
8. The outlet reed valves may be considered the beginning of the high side of the system.

 Rotary vane compressor :

Compressor is heart of the refrigeration system as it circulates the Refrigerant in the system like the heart
of a human being circulating the blood In the body. Two different pressures exist in the refrigeration cycle.
The Evaporator or low pressure, and the condenser, or high pressure. These pressure areas are divided by
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the other two components. On one end, is the Metering device which controls there frigerant flow, and on
the other end, is The compressor. It compresses the low pressure refrigerant vapor from the evaporator and
compresses it into a high pressure vapor. The inlet to the Compressor is called the “Suction Line”. It
brings the low pressure vapor into The compressor. After the compressor compresses the refrigerant into a
high pressure Vapor, and the outlet ofthe compressor is called the “Discharge Line”

 Cause of fault and remedy of compressor :

 Enlist various metering device used in Automobile air conditioning:

Answer: a)thermostatic expansion valve-
1) internal equalized type
2) external equalized type
b) orifice tube

 ‘Thermostatic expansion valve’

1. The capillary tube, tube end and upper diaphragm chamber form a closed system filled with a
temperature sensing gas. (Refrigerant- carbon dioxide, similar gas).
2. The capillary remote bulb is clamped on to the evaporator outlet pipe and it is insulated from the
outside air with special tape and it measures only the temperature of refrigerant, as it leaves the
evaporator.

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3. Any increased in refrigerant temp. at
the evaporator outlet increase the
pressure in the remote bulb & tube
system.
4. This exerts downward pressure on the
diaphragm is greater than the
combination of the evaporator
pressure & the superheat spring
pressure, as a result valve is open and
increase flow of refrigerant to
evaporator coil.
5. As the temp. of refrigerant decrease,
it decreases pressure in the remote
bulb and tube system.
6. This decreases pressure on the
diaphragm & this pressure less than combination of evaporator pressure and superheat spring
pressure and allowing the valve tube close and control flow of refrigerant to the evaporator coil.

 Working of internally equalized expansion valve

1. The capillary tube, tube end (bulb, coil or plain end) and upper diaphragm chamber form a closed
system filled with a temperature-sensitive gas (refrigerant, carbon dioxide or a similar substance).
2. Any increase in refrigerant
temperature at the evaporator
outlet increases the pressure in
the remote bulb and tube
system.
3. This in turn exerts a
downward pressure on the
diaphragm.
4. This downward pressure on
diaphragm is greater than
combination of the evaporator
pressure and the superheat
spring pressure.
5. As a result, the valve will
open. Similarly, a decrease in
refrigerant temperature
decreases the pressure in the
remote bulb and tube system.
6. This decreases the pressure on the diaphragm and this pressure is less than combination of the
evaporator pressure and the superheat spring pressure and allowing the valve to close.
7. Internally equalized expansion valves permit refrigerant pressure from the outlet side of the orifice
to pass through an internal passage and push against the underside of the diaphragm

 orifice tube :

1. Fixed orifice tube has no moving parts.

2. Tube is not adjustable and its failure is usually a result of becoming clogged.
3. Cleaning of clogged orifice tube is very difficult.
4. After clogged orifice tube _________________ is necessary.

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Figure: Old and new style fixed orifice tube

Working:
1. The refrigerant entering into the evaporator is controlled by the fixed orifice tube in manner which
is based on pressure difference and sub cooling characteristics of the refrigerant.
2. Fixed orifice tube replaces thermostatic expansion valve to meter refrigerant into the evaporator.
3. The old and new expansion tubes as shown in figure are not interchangeable.

OR
State the function of metering devices. Explain the working of fixed orifice tube.
Ans. Functions: To control the refrigerant flow

Working:
1. The refrigerant entering into the evaporator is controlled by the fixed orifice tube in manner which
is based on pressure difference and sub cooling characteristics of the refrigerant.
2. Fixed orifice tube replaces thermostatic expansion valve to meter refrigerant into the evaporator.
The old
3. And new expansion tubes as shown in figure are not interchangeable.

 Actions of thermostatic expansion valve :

1. Throttling action:
1. The expansion valve separates the high side of the air conditioning system from low side.
2. Since there is pressure drop across the valve, the flow of refrigerant is restricted, or
throttled.
3. The state of liquid entering the valve is high pressure liquid.
4. The refrigerant leaving the valve is low pressure liquid.
5. A drop in refrigerant pressure is accomplished without changing the state of refrigerant.
2. Modulating action:
1. A thermostatically-controlled valve located inside the expansion valve body fluctuates
toward an open or closed position as required to control the liquid refrigerant passing
through the orifice.
2. This ensures that the evaporator receives the proper amount of refrigerant.
3. The low pressure created at the expansion valve makes it possible for the liquid refrigerant
to vaporize as it passes through the evaporator or coils, absorbing heat from the vehicle's
interior.

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3. controlling action :
1. The valve must quickly respond to changes in heat load conditions.
2. As increased heat is sensed, the valve will move toward an open position to increase the
flow of refrigerant.
3. Decreased heat loads or increased compressor output volume due to increased engine speed
will cause the valve to move toward a closed position, restricting the amount of refrigerant
entering the evaporator
 Thermostatic Expansion Valve Vs Fixed Orifice Tube :

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 Electromagnetic clutch

1. The air conditioning compressor has an electromagnetic clutch that can engage or disengage the
compressor pulley.
2. The compressor pulley always turns
when the engine is running, but the
compressor only runs when the
pulley is engaged to the compressor
driving shaft.
3. When this system is activated,
current runs through the
electromagnetic coil.
4. The current attracts it to the armature
plate.
5. The strong magnetic pull draws the
armature plate against the side of the
turning pulley.
6. This locks the pulley and the
armature plate together; the armature
plate drives the compressor.
7. When the system is deactivated, and
current stops running through the electromagnetic coil, flat springs pull the armature plate away
from the pulley.
8. The magnetic coil does not turn since its magnetism is transmitted through the pulley to the
armature.
9. The armature plate and hub assembly are fastened to the compressor drive shaft.
10. When it's not driving the compressor, the clutch pulley turns on a double row of ball bearings

 Construction and working of ‘Remote Bulb’:

Construction:
1. One end of capillary tube
is connected to remote
bulb and other end is
connected to
thermostatic expansion
valve.
2. A remote bulb filled with
refrigerant same like
refrigerant in A/C
system.
3. It is located at evaporator
outlet.
4. It maintains pressure on diaphragm against evaporator pressure and spring pressure.
Working-
As temperature of refrigerant at the outlet of evaporator increases, the temperature in the remote
bulb also increases and get vaporized and vapour exerts pressure on diaphragm and diaphragm get
open.

 Refrigerant is chemical used in a cooling mechanism, such as an air conditioner or refrigerator, as

the heat carrier which changes from gas to liquid and the back to gas in the refrigeration cycle.

 Classification of refrigerant:
1. Halocarbons or ferons:
2. Azeotropic refrigerant

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3. Zeotropic refrigerant
4. Inorganic refrigerant
5. Hydrocarbon refrigerant

 Selection criteria of Refrigerants for Car Air–Conditioning :

1.low boiling point.
2.above atmospheric pressure.
3.high latent heat of vaporization
4.toxicity should be low.
5.non corrosive.
6.non- inflammable.
7. Stable in nature.
8. Low viscosity.
9. High thermal conductivity.
10. Easy and safe to handle.
11. Easily available at low cost.

 Properties of refrigerant: (Any four properties- 1 mark each)

o Thermodynamic properties:
a) It should have Low Boiling Point
b) It should be below the evaporator temperature.
c) It should be above atmospheric pressure.
d) It should have low condensing pressure.
e) It should have high latent heat of vaporization.
f) It should be above the condensing temperature & pressure.

o Chemical properties:
1. Toxicity should be low.
2. It should be corrosive.
3. It should not be inflammable.
4. It should be stable in nature.
o Physical properties:
1. It should have low viscosity.
2. It should have high thermal conductivity.
o Other properties:
1. It should be easy and safe to handle.
2. It should be easily available at low cost.
3.It should have high COP & low power requirement

 Colour Codes Of Refrigerant :

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 State the functions of;

(i) Thermostatic Expansion Valve. (ii) Fixed orifice tube.

(iii) Accumulator. (iv) Receiver.

v) Drier

1. Thermostatic Expansion Valve:

a)The expansion valve separates the high side of the air conditioning system from low side.

b)To vaporize refrigerant as it passes through the evaporator or coils, absorbing heat from the vehicle's
interior.

2. Fixed Orifice Tube:

a).The refrigerant entering into the evaporator is controlled by the fixed orifice tube in manner which is
based on pressure difference and subcooling characteristics of the refrigerant.

b)Fixed orifice tube replaces thermostatic expansion valve to meter refrigerant into the evaporator. The old
and new expansion tubes as shown in figure are not interchangeable.

3. Accumulator:

a)To store excess refrigerant and

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b)Remove moisture from the system.If any liquid refrigerant is passed out of the evaporator it is stored by
accumulator because liquid cannot be compressed. Liquid refrigerant can damage the compressor. Like the
receiver drier the accumulator also uses desiccant to remove moisture from

the system.

4. Receiver:

a)It maintain sufficient amount of refrigerant in system

b)It condensate vapour refrigerant & convert it into liquid refrigerant which further passes to thermostatic
valve.

c)It removes moisture, dust dirt from liquid refrigerant.

5. Drier:

a) The function of drier is to absorb moisture from the refrigerant with the help of drying agent.

b) This agent, which is usually in the form of a silica gel, is known as "desiccant."

 Condensers

The Condenser function is to act as a heat exchanger and allow heat to flow from the hot refrigerant to the
cooler outside air. Refrigerant entering the condenser will be a high-pressure high temperature vapor. As
the Refrigerant vapor travels through the tubes of the condenser heat is given off to the cooler ambient air;
the refrigerant vapor condenses and changes to a liquid state. At this point a large amount of heat is given
off by the Refrigerant . The refrigerant will now be a hot, high pressure liquid.

Design types

 Serpentine  Parallel flow design

This type of condenser consists of one long tube
which is coiled over and back on itself
withcooling fins in between the tubes.
This design is very similar to a cross flow
radiator. Instead of refrigerant travelling through
one passage (like serpentine type), it can now
travel across numerous passages. This will give
larger surface area for the cooler ambient air to
contact

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