CH.

2 CASE AND DUCT SYSTEM

 Requirements in car air-conditioning system design :

1. Occupancy data
2. Dimensions and optical properties of glass
3. Outside weather conditions
4. Dimensions and thermal properties of materials in car body

 Function of Duct System:

1. To deliver and remove air.
2. The needed air flows,for example, supply air,return air,and exhaust air.
3. Ducts commonly also deliver ventilation air as Part of the supply air

 Air Intake, Core and Distribution section :

 Air Intake Section:

1. Figure shows schematic sketch of air intake or inlet section.
2. It consists of fresh (outside) air inlet; re-circulate (inside) air inlet, a fresh re-circulate air door, a blower
with motor, and an air outlet.
3. The fresh air inlet provides the system with fresh outside air supply; the re-circulate air inlet provides re-
circulated in-car air supply.
4. The position of vacuum motor operated fresh/re-circulate door depends on system mode.

 Core Section:
1. Following figure shows schematic sketch of core section.
2. It is the central section of duct system.
3. It is also called the plenum section.
4. It consists of heater core, the air conditioning evaporator, and a blend door.
5. Air flow is from right to left in the figure.
6. The blend door usually Bowden cable operated, provides full range control of airflow either through or
bypassing the heater core.
7. All air passes through air-conditioning evaporator.
8. In this section full range temperature conditions are provided for in-car comfort.
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 Distribution Section:
1. A schematic sketch of distribution section is as shown in the following figure.
2. It directs conditioned air to be discharged to the floor outlets, the defrost outlets, or the dash panel
outlets.
3. Also, depending upon the position of the mode doors, conditioned air may be delivered to any
combination of outlets.

 Air Intake Section :

1. Figure shows schematic sketch of air intake or inlet section.

2. It consists of fresh (outside) air inlet; re-
circulate (inside) air inlet, a fresh re-circulate air
door, a blower with motor, and an air outlet.
3. The fresh air inlet provides the system with fresh
outside air supply; the re-circulate air inlet
provides re-circulated in-car air supply.
4. The position of vacuum motor operated
fresh/re-circulate door depends on system
mode.
5. Actually in all modes except maximum
cooling, the air supply isfrom outside.
6. In maximum cooling, the air supply is from
inside.
7. Even in the maximum cooling mode, some
systems provide for up to 20% fresh air.
8. This is to provide for a slightly positive in-car
pressure.

 Core Section :
1. Figure shows schematic sketch of core section.
2. It is the central section of duct
system.
3. It is also called the plenum section.
4. It consists of heater core, the air
conditioning evaporator, and a
blend door.
5. Air flow is from right to left in the
figure.
6. The blend door usually Bowden
cable operated, provides full range
control of airflow either through or bypassing the heater core.
7. All air passes through air-conditioning evaporator.
8. In this section full range temperature conditions are provided for in-car comfort

 Classification of Duct System:

1.Independent case system withupstream blower.

2.Independent case system withdownstream blower.

3.Split case system.

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4.Hybrid case system.

 Downstream Duct System.

Construction:
1. A schematic sketch of independent case system with downstream blower is as shown in the following
figure.
2. It consists of fresh (outside) air inlet, a re-circulate (inside) air inlet, fresh / re-circulates air door,
evaporator, heater, temperature blend door, restricted air door, blower motor and conditioned air outlets
for defrosters, panel, floor etc.

Working:
1. The heater water valve is open to allow hot engine coolant to flow through the heater core.
2. Cool outside fresh air is heated as it passes through the heater core.
3. The air conditioner is not operational; therefore, it has no effect on the air temperature as the air first
passes through evaporator.
4. The desired temperature level is achieved by the position of the blend door. This allows a percentage of
the cool outside air to bypass the heater core.
5. The heated air and cool air are then blended in plenum to provide desired temperature level before
passing on to the air distribution section.
6. From the plenum this air is passed to distribution section with the help of blower.
7. Depending upon the position of mode door conditioned air may be delivered to the floor outlets, the
defrost outlets, or the dash panel outlets, or any combination of outlets.
8. In other than maximum cooling (MAX A/C), fresh outside air passes through the air conditioning
evaporator and is cooled before delivery into the car.

 Independent case system withupstream blower.

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 Split Case System:

Construction:
1. This system is used to house the heater core and the air conditioner evaporator, and to direct the selected
supply air through these components into the passenger compartment of the car.
2. An upstream integral blower or an independent blower is used on split case system.
3. This system is used on larger cars and located on both sides of engine fire wall.
4. A schematic sketch of split case system with upstream blower is as shown in the following figure.

Working:
1. The outside fresh air is forces to the evaporator with the help of blower.
2. Since the air conditioner is not operational, it has no effect on the air temperature as the air first passes
through evaporator.
3. The desired temperature level is achieved by the position of the blend door.
4. This allows a percentage of the cool outside air to bypass the heater core.
5. The heated air and cool air are then blended in plenum to provide desired temperature level before
passing on to the air distribution section.
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6. This tempered air is then directed to the air distribution section Depending upon the position of mode
door conditioned air may be delivered to the floor outlets, the defrost outlets, or the dash panel outlets,
or any combination of outlets.
Application : Used in Heavy passenger Vehicle

 Hybrid Case System

1. A typical hybrid case/duct system is shown in figure.

2. This system is divided into air intake section, the heater core and air-conditioning evaporator section,
and the air distribution section Air-flow is from right to left in the figure.

Air Intake -
1. The air intake section or inlet section consists of a fresh air inlet, a recirculate (inside) air inlet, a fresh-
recirculate air door, a blower with motor, and an air outlet.
2. The fresh air inlet provides the system with fresh outside air and the recirculate air inlet provides
recirculated in car air supply.
3. Normally in max A/C mode inside air is recirculated.
Core Section
1. The core section, more appropriately called the plenum section is the centre section of the duct system.
2. It consists of the heater core, the air-conditioning evaporator, and a blend door.
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3. The blend door, usually Bowden cable operated, provides full-range control of airflow either through or
bypassing the heater core.
4. All the air passes through the air-conditioning evaporator.
5. In this section full-range temperature conditions are achieved for in-car comfort.
Heating:
1. The heater water valve allows hot engine coolant to flow through the heater core.
2. Cool and fresh air from outside is heated as it passes through the heater core.
3. The air-conditioner is not operated and hence, it has no effect on the air temperature as the air first
passes through the evaporator.
4. The desired temperature is achieved by the position of the blend door, which allows a percentage of the
cool outside air to bypass the heater core to temper the heated air.
5. The heated air and cool air are then blended in the plenum to provide the desired temperature level
before passing to the air distribution section.
Cooling:

1. In the maximum cooling condition (max A/C), recirculated air passes through the air conditioner
evaporator and is then directed back into the car.
2. In other than max A/C, fresh outside air passes through the air-conditioning evaporator and is cooled
before delivery into the car.
3. The desired temperature level is achieved by the position of the blend door, which allows a percentage
of cooled air to pass through the heater core for reheating.
4. The cooled air passing through the evaporator and the reheated air passing through the heater core are
blended in the plenum to provide the desired temperature level and then directed to the air distribution
section.

 Air Distribution Section

1. The air distribution section directs conditioned air to the floor outlets, the defrost outlets, or the dash
panel outlets.
2. Also depending upon the position of the mode doors, conditioned air may be delivered to any
combination of outlets.

 Rear Heating System.

Construction :

1. Some trucks and vans are equipped with rear air distribution system to provide rear heating.
2. A schematic sketch of rear heating system is as shown in figure.
3. Depending on design it may have major components;

a. blower and motor, d. heater core with flow control,

b. temperature door, e. outlet mode door,
c. evaporator core with metering f. control panel, and
device, g. controller.

4. In this system second heater core is located at the rear of passenger compartment.
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Working :

1. Driver controls overall operation.

2. Some systems allows the rear passenger to control the temperature.
3. For control of rear blower switch is provided at the front or at rear or sometimes at both places.
4. In this system rear blower forces the air into the second heater core from where heated air enters into the
distribution section and finally delivered to the rear compartment.

Function: To maintain the required warm temperature at rear compartment of vehicle during winter season.

 Rear Cooling System :

1. Some trucks and vans are equipped with rear air distribution system to provide rear cooling.
2. A schematic sketch of rear cooling system is as shown in following figure.
3. Depending on design it may have following major components;
a. blower and motor, d. heater core with flow control,
b. temperature door, e. outlet mode door,
c. evaporator core with metering f. control panel, and
device, g. controller.
4. In this system second evaporator core is located at the rear of passenger compartment.
5. Driver controls overall operation.
6. Some systems allow the rear passenger to control the temperature.
7. For control of rear blower switch is provided at the front or at rear or sometimes at both places.
8. In this system rear blower forces the air into the second evaporator core from where cooled air enters
into the distribution section and finally delivered to the rear compartment.
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 Rear Heating And Cooling.

1.Rear heating system:

1. Some trucks and vans are equipped with rear air distribution system to provide rear heating.
2. A schematic sketch of rear heating system is as shown in figure.
3. Depending on design it may have major components; blower and motor, temperature door, evaporator
core with metering device, heater core with flow control, outlet mode door, control panel, and controller.
4. In this system second heater core is located at the rear of passenger compartment.
5. Driver controls overall operation.
6. Some systems allow the rear passenger to control the temperature.
7. For control of rear blower switch is provided at the front or at rear or sometimes at both places.
8. In this system rear blower forces the air into the second heater core from where heated air enters into the
distribution section and finally delivered to the rear compartment.

2. Rear Cooling system:

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1. Some trucks and vans are equipped with rear air distribution system to provide rear cooling.
2. A schematic sketch of rear cooling system is as shown in following figure.
3. Depending on design it may have following major components; blower and motor, temperature door,
evaporator core with metering device, heater core with flow control, outlet mode door, control panel,
and controller.
4. In this system second evaporator core is located at the rear of passenger compartment. Driver controls
overall operation.
5. Some systems allow the rear passenger to control the temperature.
6. For control of rear blower switch is provided at the front or at rear or sometimes at both places.
7. In this system rear blower forces the air into the second evaporator core from where cooled air enters
into the distribution section and finally delivered to the rear compartment

 General Faults And Their Remedies In Comfort Heating System.

1. Little or no heat:

Causes: Remedies:

a. Air circulation not enough. a. Blower motor or switch is at fault. Temperature

door or cable may be adjusted. Leakage of air from
b. Air in the heater core. heater housing may be stopped.
c. Heat core is clogged b. Bleed air out.
d. Thermostat of engine cooling system is stuck c. Core should be repaired or replaced.
open.
d. Replace the thermostat.

2. Defrosting insufficient:

Causes: Remedies:

a. Control cable of defrost door is out of a. Cable should be readjusted.

adjustment.
b. Remove the obstructions
b. Defrost outlets blocked.

 ‘Comfort Heating System’ :

1. The comfort heating system in vehicle is able to provide desired air temperature inside the vehicle.
2. It operates with ventilating system.
3. Figure shows comfort heating system in a vehicle.
4. It consists of heater core which is a small radiator as like engine radiator.
5. Hot coolant from the engine is circulating through this heater core by using engine water pump.
6. This heats the heater core. Air from the outside flows through the heater core air passages.
7. This heats the air.
8. This heating system has three doors-
a. Temperature door- It is used to permit more or less air to flow through heater corer.
b. Air door- It can be operated to allow full air flow or no air flow or any position in between.
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c. Defroster door- It can be used to supply the heated air on the inside of the windshield or to the
outlet of the heater in the car.
9. All these doors are operated manually by control levers or knobs on the instrument panel.

Functions of Comfort Heating System:

1.To provide the desired air temperature inside the passenger compartment.
2.To circulate the hot water from an engine.
3.To heat the air coming from outside atmosphere.
4.To control the temperature by using temperature door.
5.To control the airflow by using air door.
6.To supply heated air on the inside of windshield by using defroster door.

Application : If atmospheric temperature is too low then this system is used.(Generally in Winter Season)

 Rotary Vane Air Cycle System :

1. The compressor of ROVAC system is called circulator.

2. The condenser is called primary heat exchanger.
3. The collector in the system serves in similar manner as an accumulator in conventional system.
4. It separates liquid (hydrocarbon) from vapour (air).
5. Unlike accumulator however the liquid is retained in the collector & is not metered back into the system.
6. A small amount of oil circulates in the system at all times to provide lubrication for the circulator.
7. Other liquid comprised of & hydrocarbons are vaporized in secondary heat exchanger as it pick up heat.
8. Conversely this vapour changed back to the liquid in primary heat exchanger as its heat is given up to
the outside air.
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ductsystem withupstream ductsystem.

Summer 2019