INSTRUCTIONAL MANUAL FOR

AIR CONDITIONING TEST RIG

OBJECTIVE:-

1. Study of vapour compression cycle for conditioner.

2. To calculate actual COP.
3. To study different air conditioning processes:
a) Heating
b) Cooling
c) Humidification
d) Heating and Dehumidification
e) Cooling and Humidification
f) Cooling and Dehumidification

INTRODUCTION:-
Air conditioning is the simultaneous control of the temperature, humidity, motion
and purity of the atmosphere in a confined space. Air conditioning applies in the
heating season as well as in the cooling season. The air conditioning has wide
applications in submarine ships, aircrafts and rockets. Air conditioning is associated
with the human comfort and controlling the humidity ratio.

THEORY:-
Air conditioning may be defined as the process of removing heat from a
substance under controlled conditions. It also includes the process of reducing and
maintains the temperature of a body below the general temperature of its
surroundings. This is widely used for cooling of storage chambers in which perishable
foods, drinks, and medicines are stored.
Simple Vapour Compression

Figure shows the schematic diagram of simple vapour compression refrigeration

system.

It consists of following parts:

COMPRESSOR:
The low pressure and temperature of refrigerant from the evaporator is drawn into
the compressor through the inlet and suction valve as it is compressed to high
temperature and pressure. This high temperature and pressure vapour refrigerant is
discharged into the condenser through the delivery pipe.

CONDENSER:
The condenser or cooler consists of pipe in which the high pressure and temperature
refrigerant is cooled and condensed. The refrigerant while passing through the
condenser gives up heat to the surrounding which consists of condensing medium
which is normally air or water.

CAPILLARY TUBE:
It expends the liquid refrigerant at high pressure to the liquid refrigerant at low
pressure so that a measured quantity of the liquid refrigerant is passed into the
evaporator.

EVAPORATOR:
It consists of coils of pipe in which the liquid vapour refrigerant at low pressure and
temperature is evaporated and changed to the vapour refrigerant at low temperature
and pressure. In evaporating the liquid vapour refrigerant absorbs the latent heat of
vaporization from the medium which is to be cooled. Evaporator the liquid refrigerant
by absorbing the heat into vapor refrigerant and sends back in to the compressor.
VAPOUR COMPRESSOR:
The refrigerant start at some initial state or condition passes through a series of
processes in a definite sequence and return to the initial condition. This series of
processes is called cycle.

The standard vapor compressor cycle (SVCC) consists of the following processes:
1. Reversible adiabatic compression from the saturation vapor to a super heated
condition.
2. Reversible heat rejection at constant pressure (sub cooling liquid and
condensation of the refrigeration)
3. Irreversible is enthalpy expansion from saturated liquid to a low-pressure sub
cool liquid.
4. Reversible heat addition at constant pressure.

DESCRIPTION:
The air conditioning test rig unit is required to conduct experiments and
demonstrate the process cooling of atmospheric air. The unit consists of a
compressor. Both evaporator and the air cooled condenser are mounted on board
with separate fans. Air is sucked from the room and is supplied to the room after
cooling. The system is provided with voltmeter and ammeter, a digital temperature
indicator. The unit will be fitted with all instruments facilities so that temperature and
pressure can be measured at different points in the air conditioning system.
TECHNICAL SPECIFICATION: -
Compressor : ISI Kirloskar Hermetically sealed compressor
Condenser : Fined Tube type air cooled condenser with fan
Evaporator : Suitable for above compressor immersed in duct.
Fins and Copper tube type cooling coil
Refrigeration : Freon R 134a
Fan Blower Set : Standard make.
Refrigeration : a) Glass tube Rotameter
b) Capillary tube expression devices.
c) Filter cum Drier
d) Suction & Discharge pressure gauge
e) LP/HP cut-off
Control Panel : a) Main Switch
b) Digital Voltmeter
c) Digital Amp. Meter
d) Energy Meter
e) Blower ON/OFF Switch
f) Compressor ON/OFF Switch
g) Heater ON/OFF Switch
h) Boiler (Humidity) ON/OFF Switch
Digital Temp : RTD thermocouple for various temperature Indicator
Air Velocity : Digital Air Anemometer

The whole Set-up is mounted on a sturdy frame and base plate.

UTILITIES REQURIED:-
Electricity Supply: Single Phase, 220 VAC, 50Hz, 5-15Amp socket with earth
connection.

TEMPERATURE SENSOR & ENTHALPY DETAILS: -

T1 = Temperature Of Compressor Inlet

T2 = Temperature Of Compressor Outlet (Condenser Inlet)
T3 = Temperature Of Condenser Outlet
T4 = Temperature Of Evaporator Inlet
T5 = Temperature Of Air Duct

H1 = Enthalpy of refrigeration effects at Compressor Inlet, kJ/kg.

H2 = Enthalpy of compressor work at Compressor Inlet, kJ/kg.
H3 = Enthalpy of sub cooling at the outlet of Condenser, kJ/kg.
H4 = Enthalpy of refrigerant Inlet of Evaporator, kJ/kg.
P1 = Pressure at Compressor Suction, kJ/cm2.
P2 = Pressure at Compressor Discharge, kJ/cm2

Inlet DBT = F = (F -32)/1.8 C = ..C

 Outlet DBT = ..F = (F -32)/1.8 C = .. C
PRECAUTIONS:

1. Before taking the readings ensure that the sensing bulb of wet bulb
thermometer is properly wetted by soft cloth.
2. Do not start the heater while conducting the experiment for calculating COP.
3. Keep the heater ON during dehumidification process.

STARTING PROCEDURE:-

1. Clean the apparatus and make it free from dust.

2. Ensure that all ON/OFF switches given on the panel are at OFF position.
3. Switch on the main supply.
4. Start the condenser fan motor.
5. Start the blower fan motor of the cooling coil (Evaporator).
6. Start the compressor.
7. Note down the readings of ampmeter, voltmeter, and energy meter.
8. Note down the readings of the various pressure gauges.
9. Note down the reading of DBT and WBT.
10. Take down the readings of Anemometer.
11. Take down the readings of various temperatures.
12. Note down the readings of Mass Flow rate of refrigerant through the
Rotameter.
13. Switch ON the heater fitted in supply duct and note down readings.
14. Please note down that when the compressor should be OFF when the heater is
ON.
15. Take readings.
16. Switch on the boiler to provide steam for humidification as required.
17. Note down the observations and calculate the COP.
18. While switching off the machine, first switch off the heaters off in services,
switch off the compressor, condenser fan motor, blower fan motor, then
switch off the main and then switch off the main board.
 STANDARD DATA:-
1. Air velocity = m/s
2. Inlet air duct area = 228x228mm = 0.05198 m2
3. Density of air = 1.162 kg/ m3
4. 1 Bar = 1 psi / 14.5
5. Energy meter constant = 3200 Pulses/KWH

OBSERVATION & CALCULATION TABLE

Sr. Compressor Temperature of Refrigerant oC Temperature of Time taken Velocity

No. Pressure (PSI) Air (DBT) oC for 10 of air
P1 P2 T1 T2 T3 T4 T5 Inlet Outlet Rev./ Sec. m/s
Suction Discharge
1.

2.

3.

Sr. PROCES INLET INLET OUTLET OUTLET REMARKS

No. SYSTEM DBT WBT DBT WBT
1. Heating Only Heater ON
2. Cooling Only Compressor ON
3. Humidification Humidification (Boiler)
and Blower ON
4. Heating and Humidification (Boiler)
Dehumidification and Heater ON
5. Cooling and Humidification (Boiler)
Humidification and Compressor ON
6. Cooling and Dehumidification
Dehumidification (Heater) and
Compressor ON
CALCULATION:-

1. Refrigeration effect = ma Cp (Tai - Tao)

ma = mass flow rate of air in kg/s

= velocity of air x Inlet air Duct area x density of air
Cp = Specific heat of air (1.005)
Tai = Inlet temperature of air (DBT)
Tao = Outlet temperature of air (DBT)

No of revolutions x 3600
2. Compressor Input = -------------------------------------
Time x Energy meter constant
 Refrigeration effect
3. Actual C.O.P. = --------------------------
Compressor Input

H1 - H3
4. Theoretical C.O.P. = -----------
H2 - H1

Mark points 1, 2, 3 using (P1, T2), (P2, T3), (P2, T4) respectively on P-h diagram from
refrigeration chart and read H1, H2 and H3 (where H3 = H4) to calculate COP.

Actual C.O.P
6. Relative C.O.P = ----------------------
Theoretical C.O.P

Note that the COP of a heat pump depends on its duty the heat rejected to the hot
sink is greater than the heat absorbed from the cold source, so the heating COP is 1
greater than the cooling COP. The maximum achievable COP would be 8.8. Test
results of the best systems are around 4.5. When measuring installed units over a
whole season and accounting for the energy needed to pump water through the
piping systems, seasonal COP's are around 3.5 or less. This indicates room for
improvement.

PRECAUTION & MAINTENANCE INSTRUCTIONS:-

1. Check the voltage. It should not less than 180 volt and more than 230 volts
single phase 50Hz Ac supply.
2. Do not run the compressor without switch on the fan motor.
3. Do not switch on the heater without switch on the blower fan motor.
4. Whenever the compressor is switched off. Do not switch on the compressor
before five minute of interval.
5. Mount Rotameter vertically and maintain upwards flow run.
6. Avoid sudden opening/closing of the Hand shut off valve in the line to
Prevent float hunting and possible glass tube breakage.

TROUBLESHOOTING:-
1. If electric panel is not showing the input on the mains light. Check the main
supply.
2. If temperature of any sensor is not displays in D.T.I. check the connection and
rectify that.
REFERENCES:-
1. Arora C P, Refrigeration and Air Conditioning, 19th Edition, Tata McGraw
Hill, Delhi (1985).
2. Pradad M, Refrigeration and Air Conditioning, 2nd Edition, New Age
International Private Limited, Delhi (2002).
3. Dossat, R J, Principles of Refrigeration, 4th Edition, Pearson Education
(Singapore), India, (2002).
4. Mcquiston F G, Parker J D and Spilter J D, Heating, Ventilating, and Air
Conditioning, 5th Edition, John Wiley and Sons Inc, New York (2001).