Basic Air - conditioning

What is Air-conditioning?

The cooling and dehumidification of indoor air for thermal comfort. In a broader sense, the
term can refer to any form of cooling, heating, ventilating, or disinfection that modifies the
condition of air.

The concept of air conditioning is known to have been applied in Ancient Rome where aqueduct
water was circulated through the walls of certain houses to cool them. Similar techniques in
medieval Persia involved the use of cisterns and wind towers to cool buildings during the hot
season. Modern air conditioning emerged from advances in chemistry during the 19th century,
and the first large-scale electrical air conditioning was invented and used in 1902 by Willis
Haviland Carrier

Description of the vapor-compression refrigeration system

The vapor-compression refrigeration system uses a circulating liquid refrigerant as the medium
which absorbs and removes heat from the space to be cooled and subsequently rejects that
heat elsewhere.

Basic Parts of Airconditioning System

 A air conditioning or heat pump compressor which compresses low pressure
refrigerant gas into a high pressure, high temperature gas. Usually the compressor is in
the outdoor portion of an air conditioning or heat pump system. The compressor is
basically a high pressure pump driven by an electric motor. The air conditioning
compressor is usually packaged in the outdoor compressor/condenser unit illustrated by
our page top drawing.

 A condenser or condensing unit: typically a condensing coil inside which high
temperature high pressure refrigerant gas flows, and over which a fan blows air to cool
the refrigerant gas back to a liquid state (thus transferring heat from the refrigerant gas
to the air being blown by the fan). The condenser unit is basically a coil of finned tubing
and a fan to blow air across the coil. Usually the condenser unit is in the outdoor portion
of an air conditioning system, often packaged along with the compressor motor
discussed above.

 A metering device which dispenses liquid refrigerant into an evaporator coil. The
metering device may be simply a thin section of tubing (a capillary or "cap" tube) or it
may be a bit more sophisticated thermostatic expansion valve (TEV) which includes a
temperature sensing control that can open and shut the device against refrigerant flow.
 An evaporator coil or cooling coil: typically the cooling coil is a section of finned tubing
(it looks a lot like a car radiator) into which liquid refrigerant is metered and permitted
to evaporate from liquid to gas state inside the coil. This state change of the refrigerant,
from liquid to gas, absorbs heat, cooling the evaporator coil surface and thus cooling
indoor air blown across the cooling coil. Usually the cooling coil is located inside the air
handler.

 An air handler and blower unit which provides a fan to blow building air across or
through the evaporator coil. The air handler blower fan unit moves building air across
the evaporator coil surface in order to condition building air by cooling it (and thus also
by removing moisture from the cooled air).

 A duct system which distributes conditioned air from the air handler in to the occupied
space (supply ducts), and which takes air from the occupied space and returns it to the
cooling system air handler.

 Air conditioner controls and features, which include a room thermostat, electrical
switches, fuses or circuit breakers, condensate handling system, and air filters.
 REFRIGERATION CYCLE

1–2. Low-pressure liquid refrigerant in the evaporator absorbs heat from its surroundings,
usually air, water or some other process liquid. During this process it changes its state from a
liquid to a gas, and at the evaporator exit is slightly superheated.
2–3. The superheated vapor enters the compressor where its pressure is raised. The
temperature will also increase, because a proportion of the energy put into the compression
process is transferred to the refrigerant.

3 – 4. The high pressure superheated gas passes from the compressor into the condenser. The
initial part of the cooling process (3-3a) de-superheats the gas before it is then turned back into
liquid (3a-3b). The cooling for this process is usually achieved by using air or water. A further
reduction in temperature happens in the pipe work and liquid receiver (3b - 4), so that the
refrigerant liquid is sub-cooled as it enters the expansion device.

4 - 1 The high-pressure sub-cooled liquid passes through the expansion device, which both
reduces its pressure and controls the flow into the evaporator.

LOW SIDE HIGH SIDE

 BASIC PARTS OF REFRIGERATION AND AIR
CONDITIONING SYSTEMS
( VAPOR-COMPRESSION CYCLE)

BASIC PARTS ARE:

1. COMPRESSOR
2. EVAPORATOR
3. CONDENSER
4. EXPANSION VALVE/DEVICE or METERING DEVICE

COMPRESSOR
 Compresses low pressure refrigerant gas into a high pressure, high temperature gas.
 Heart of air-conditioning system.
 Ideal Suction Pressure is 60psi and Discharge Pressure is 250-260psi.

Common Compressors being Used:

Reciprocating compressors - uses pistons driven by a crankshaft to deliver gases at high

pressure.
Centrifugal compressors - use a rotating disk or impeller in a shaped housing to force the gas to
the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section
converts the velocity energy to pressure energy

Rotary screw compressors - use two helical screws, known as rotors, to compress the
refrigerant gas.
Scroll compressors - also known as scroll pump and scroll vacuum pump, uses two interleaved
spiral-like vanes to pump or compress the refrigerant.

Hermetic - A hermetic or sealed compressor is one in which both compressor and motor are
confined in a single outer welded steel shell. The motor and compressor are directly coupled on
the same shaft, with the motor inside the refrigeration circuit.
semi-hermetic - A variation of hermetic compressor. Bolted construction offers limited
serviceability.

CONDENSER
 Receives high pressure refrigerant gas from the compressor and cools this refrigerant gas
back to a liquid state.

 high temperature high pressure refrigerant gas flows, and over which a fan blows air to
cool the refrigerant gas back to a liquid state (thus transferring heat from the refrigerant
gas to the air being blown by the fan)
EVAPORATOR
 Absorbs heat from the surrounding air or liquid and moves it outside the refrigerated
area by means of a refrigerant, also known as cooling coil, blower coil, chilling unit or
indoor coil.

EVAPORATOR COIL

EXPANSION VALVE (or metering device)

 It is a component that controls the amount of refrigerant flow and the superheat at the
outlet of the evaporator.

 Dispenses liquid refrigerant into an evaporator coil. The metering device may be simply a
thin section of tubing (a capillary or "cap" tube) or it may be a bit more sophisticated
thermostatic expansion valve (TEV) which includes a temperature sensing control that
can open and shut the device against refrigerant flow.
 Functions Performed by the Throttling Devices in Refrigeration Systems

 When the high pressure refrigerant from the condenser enters the throttling devise the
pressure of the refrigerant drops down suddenly, due to this the temperature of the
refrigerant also drops down suddenly and substantially.
 There are two important functions performed by the throttling devices or the expansion
valves.

1. Reduce the pressure of the refrigerant:

The refrigerant leaving the condenser is at high pressure. The pressure of the refrigerant has to
be reduced so that it can vaporize at the required temperature in the evaporator. The small
opening or the orifice in the throttling valve reduces the pressure of the refrigerant to the level
such that vaporization of the refrigerant occurs. The refrigerant leaving the throttling valve
enters the evaporator at low pressure, low temperature and partially liquid and vapor state.

2. Meet the refrigeration load:

The throttling valve also controls the amount of the refrigerant flowing through it and to the
evaporator. When there is more refrigeration load that means the quantity of the substance
stored in the freezer is more and it is at higher temperature, more amount of heat is to be
removed from it. In such cases the throttling devise allows increased flow of the refrigerant
through it. When the refrigeration load is less that means the quantity of the substance is less
and it is at lower temperature, less amount of heat is to be removed from it. In such cases the
throttling valve allows lesser flow of the refrigerant through it.

Types of Throttling Devices

Some of the most commonly used types of throttling valves are:

 Capillary tube
 Constant pressure or automatic throttling valve
 Thermostatic expansion valve
 Float valve

Capillary tube
 one of the most commonly used throttling devices in the refrigeration and the air
conditioning systems.
 made up of a small copper tubing with hole diameter ranging from 1 mm to 3 mm.
 Their length could be 8 to 12 feet, and it serves as a constant limiting valve to the
refrigerant flow from condenser to the evaporator.
 It is soldered or wrap around the suction copper tube from the outlet of the evaporator
to the compressor. Heat exchange is taking place her
Capillary tube

The automatic expansion type or AEV,

 Keeps the pressure inside the evaporator constant, hence the name. The constant
pressure valve maintains constant pressure inside the evaporator no matter what the
load inside the evaporator is. It does not allow the control of the flow of the refrigerant
through it even when lesser or more refrigerant is required in the evaporator since the
primary function of the constant pressure valve is to maintain constant pressure inside
the evaporator

automatic expansion type

The thermostatic expansion type or TXV or TX,
 is a refrigeration component that controls the amount of refrigerant flow by the signal
sent by the sensing bulb that is attached to the outlet of the evaporator, and give
instructions to opening and closing the valve in the inlet of the evaporator.

 TEV valve maintains the pressure difference (high and low) at the entry point to the
cooling coil, thus assuring that as the high-pressure refrigerant enters the low pressure
space of the cooling coil, it can "evaporate" from a refrigerant liquid to a gaseous form,
thus producing the temperature drop that cools the cooling coil itself.

 Uses a temperature sensing bulb filled with a similar gas as in the system that causes the
valve to open against the spring pressure in the valve body as the temperature on the
bulb increases. As temperatures in the evaporator decrease, so does the pressure in the
bulb and therefore on the spring causing the valve to close.
Float valve
Float valve is used as the throttling device in the large industrial refrigeration plants that fulfill
the cooling requirements of the entire process.

There are two types of float valves as discussed below: Low Side Float Valves and High Side
Float Valve

Low Side Float Valves

 The low side float type of the throttling valve is usually used in the flooded type of the
refrigeration plants. In industrial refrigeration plants the evaporators are of shell and
tube type. In the plants with medium capacity the refrigerant is filled in the tube side
and the substance to be chilled is filled in shell side such as in the water chilling plants.
But when very low temperature is required for large quantity of the substance the
refrigerant is filled in the shell side and the substance to be chilled is on tube side. Such
types of evaporators are called as the flooded evaporators.
 The float valve maintains the constant level of the liquid in the flooded evaporator
irrespective of the pressure and the temperature inside it. The float of the low side float
valve is placed in the evaporator, which is at low pressure. The construction and the
working of the low side refrigeration float valve are similar to the float valve used in the
water tank used for maintaining the level of the liquid.

Difference Between “High” Side and “Low” Side

High Side Float Valve

 While in the low side float valve the float chamber is placed in the evaporator on low
pressure side, in the high pressure side float valve and the float chamber is placed on
the high pressure side between the condenser and the evaporator. In low side float
valve the valve opens as the level of the refrigerant drops in the evaporator, but in high
side float valve the valve opens when the level of the refrigerant increases in the
chamber.
 The refrigerant condensed in the condenser moves to the chamber of the high pressure
float valve. As the level of the refrigerant rises the float ball moves up and opens the
float valve that allows for the passage of the refrigerant through needle valve. The level
of the refrigerant would rise in float chamber when more refrigerant is coming from the
condenser that means there is more load on the plant. Thus when there is higher load
on the plant there is increase in the flow of the refrigerant through the float valve (refer
the image below).
Difference Between “High” Side and “Low” Side

The high pressure region is called the "high side". It includes the compressor discharge, hot gas
line, condenser, liquid line, and metering device inlet.

The low pressure region is called the "low side". It includes the metering device outlet,
evaporator, suction line and compressor suction.

What Are Refrigerants

Any substance, which absorbs heat through vaporization or expansion, is called a refrigerant. In
broader sense, the term refrigerant is also applied to such cooling systems as cold water or
brine solutions. As commonly interpreted, refrigerants include those working mediums that
pass through the cycle of evaporation, recovery, compression and condensation. Thus,
circulating cold mediums are not primary refrigerants, nor are cooling systems such as ice and
solid carbon dioxide.

Desirable Properties Of Refrigerants

Desirable refrigerants are those which possess chemical, physical, and thermodynamic
properties that permit their efficient application and service, in practical designs of refrigerating
equipment. In addition, if the volume of charge is large, there should be no danger to health
and property in case of its escape. A great variety of substances, such as butane, carbon
tetrachloride, ethane, and hexane have been applied to refrigeration systems, but found to
have little practical use. These materials are either highly explosive or flammable, or possess
other combinations of undesirable properties.

Different Refrigerants
Air

Air is one of the earliest refrigerants and was widely used in World War I whenever a
completely nontoxic material was required. Although air is free of cost and completely safe, its
low coefficient of performance makes it unable to compete with the modern nontoxic
refrigerants.

Ammonia

Ammonia is one of the oldest and widely used of all refrigerants. It is flammable and highly
toxic. It is widely used in commercial and large industrial reciprocating compression systems
where high toxicity is secondary.
Carbon Dioxide

It is a colorless and odorless gas, which is heavier than air. It is nontoxic and nonflammable but
has extremely high operating pressures. In former years it was used for marine refrigeration,
theatre air conditioning systems, and for hotel refrigeration systems.

Freon Refrigerants

These refrigerants use ethane and methane as bases, and are the most important group of
refrigerants being used in modern technology. These are used in a variety of applications, such
as reciprocating compression refrigeration, and rotary compressors.

Others

Other refrigerants are methyl chloride, sulphur dioxide, hydrocarbon refrigerants, methyl
chloride, and azeotropes.

Selection Of Refrigerants
No substance has proved to be the ideal working medium, under all operating conditions. The
characteristics of some refrigerants make them desirable for use with reciprocating
compressors. In some applications toxicity is of negligible importance, whereas in others, such
as comfort cooling, a nontoxic and nonflammable refrigerant is essential. Therefore, in selecting
the correct refrigerant, it is necessary to determine those properties which are most suitable,
and to choose the most closely approaching ideal for the particular application.
 COOLING TOWER
What are cooling towers?

Cooling towers are heat exchangers that use water and air to transfer heat from air-conditioning
systems to the outdoor environment. Most commonly, they are used to remove heat from
the condenser water leaving a chiller

COOLING TOWER

Purpose of Cooling Tower

 It is the heat removal device 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 to near the wet-bulb air temperature or rely solely on air to cool
the working fluid to near the dry-bulb air temperature.

Types of Cooling Towers

 Open (Direct) Cooling Towers
 Closed (Indirect) Cooling Towers
Open (Direct) Cooling Towers
Open cooling towers expose the condenser water coming from the chiller plant directly to the
atmosphere. This warm water is sprayed over a fill in the cooling tower to increase the contact
area, and air passes through the fill. Most of the heat is removed by evaporation. The cooled
water remaining after evaporation drops into the collection basin and is returned to the chiller’s
condenser.

Note: Fill - The portion of a cooling tower that provides a large air-water interface area for heat
transfer allowing a small amount of water to evaporates into the airstream, cooling the
remaining water.
Closed (Indirect) Cooling Towers
A closed cooling tower circulates warm water from the chiller plant through tubes located in the
tower. In a closed tower, the cooling water does not come in contact with the outside air. Water
that circulates only within the cooling tower is sprayed over the tubes and a fan blows air across
the tubes. This cools the condenser water within the tubes, which is then recirculated to the
chiller plant.
Best Practices for Maintenance of Cooling Towers
 Effective water treatment
 Prevent scale deposits
 Prevent or clean clogged spray nozzles
 Ensure Adequate Airflow
 Ensure Adequate Pump Performance

Effective water treatment

Effective water treatment eliminates harmful bacteria and bio-film and controls scale, solids,
and corrosion. Bleed or blow down-the continuous flow of a small portion of the recirculating
water to a drain to eliminate dissolved solids-is insufficient by itself to control scale and
corrosion and is always ineffective in controlling biological contamination. A regular chemical-
treatment program is always recommended for controlling biological organisms, scale, and
corrosion.

Prevent scale deposits

When water evaporates from the cooling tower, the minerals that were dissolved in it are left
behind as scale deposits on the surface of the fill. Scale build-up inhibits heat transfer from the
water to the air, which reduces the fill’s effectiveness. Excessive scale build-up is a sign of
inadequate water treatment.

Algae and sediment that collect in the water basin as well as excessive solids that get into the
cooling water can clog the spray nozzles. This causes uneven water distribution over the fill and
uneven airflow through the fill, which reduces evaporation. These problems indicate improper
water treatment and clogged strainers. Kits are available to replace older, smaller distribution
nozzles or troughs with large-orifice, clog-free designs.

Ensure Adequate Airflow

Poor airflow through the tower reduces the transfer of heat from the water to the air. Poor
airflow can be caused by debris at the inlets or outlets of the tower or in the fill, loose fan and
motor mountings, poor motor and fan alignment, poor gearbox maintenance, improper fan
pitch, damage to fan blades, or excessive vibration. Reduced airflow due to poor fan
performance can ultimately lead to motor or fan failure.
Ensure Adequate Pump Performance

A closed-loop cooling tower uses a pump to transport water over the tubes for evaporative
cooling. Proper water flow is important to achieve optimum heat transfer. Loose connections,
failing bearings, cavitation, clogged strainers, excessive vibration, and operating outside of
design conditions result in reduced water flow, reduced efficiency, and premature equipment
failure.

Useful Formulas

 1Hp = 0.7456999kW
 1TR or 1 Tons of Refrigeration =kW/3.516
 1 kWH = 3415.179 BTU/hr
 Heating Btu/hr = GPM x 500 x ΔT
 1 GPM at 20° T = 10,000 Btu/hr
 Btu/hr / 10,000 = 1 GPM (@20° ΔT )
 Cooling 1 ton (CHW) = GPM x 500 x ΔT/12,000
 = 2.4 GPM (@10° ΔT)
 Latent heat Btu/hr = .68 x CFM x grains
 To cool air Btu/hr = CFM x 4.5 x enthalpy
 (enthalpy from psych chart)
 GPM = Btu/hr / (500 x T)
 To heat air Btu/hr = CFM x 1.08 x T
 To humidify air #/hr H2O = CFM x 4.5 x grains/7,000
 Pump horsepower HP = GPM x ft Head x .0002525/eff
 Fan horsepower HP = CFM x static pressure ("H2 O) .000157/eff
 Basic Aircon Troubleshooting

UNDERCHARGING OF REFRIGERATION SYSTEM

Indication:

 Compressor is running hot and performance of the compressor falls off due to high
superheat temperature at the suction side of compressor.

 Suction and discharge pressure of the compressor is low.

 Large vapor bubbles in the liquid sight glass.

 Low gauge readings in the condenser.

 Ammeter reading for the compressor motor is lower than normal.

 Rise in room temperature which is to be cooled.

 Compressor is running for extended period of time.

Causes:

 Leakage of refrigerant at the shaft seal, flange couplings, valve gland etc.

 Expansion valve may be blocked at the strainer.

 Partial blockage of refrigerant at the filter or drier may cause undercharging.

Action:

 Identify and rectify the leakage of refrigerant from the system.

 Clean the filter and drier.

 Charge the system with fresh refrigerant if required.

OVERCHARGE OF REFRIGERATION SYSTEM

Indication:

 The liquid level in the condenser is too high (high condenser gauge reading). This will
reduce the available condensing surface, with corresponding increase in the saturation
temperature and pressure.

 High pressure switch of the refrigerant compressor activates and stops the compressor.

 There is possibility of excessive liquid refrigerant getting to the evaporating, giving icing
at the compressor suction, and a pressure drop across the expansion valve. The cold
room temperature may rise, if the evaporator is flooded.

Causes:

 It may be due to the reason that excessive refrigerant has been charged in the system.

 Air in the system may also cause over charging indication.

 It may also be due to the formation office on the regulator.

Action:

 Remove the refrigerant from the system. This is done by connecting a cylinder to the
liquid line charging valve, starting the compressor, and then operating the charging
valve.

 Purge the air from the system and maintain effective cooling.

 Remove ice from the regulator by using any of the defrosting methods.

MOISTURE IN THE SYSTEM

This normally comes with the ingress of air in the system. Moisture may freeze at the expansion
valve, giving some of the indication of under charging. It will contribute to the corrosion in the
system. It may cause lubrication problems and breakdown of the lubricating oil in the
refrigerant compressor.
AIR IN THE SYSTEM

Indication:

 This may cause the refrigeration compressor to overheat, with a high discharge pressure
and normal condensing temperature.

 There are possibilities of small air bubbles in the liquid sight glass of the condenser.

 Condensing pressure of the refrigerant in the condenser may be high.

 If there is excessive air, it may reduce the cooling capacity of the system, making the
compressor to run for the extended period of time.

 It may cause the gauge pointer of the condenser to jump indefinitely.

Causes:

 During charging, air may enter in to the system.

 If Freon-12 is used air may leaks in to the suction line because the working pressure of
the Freon-12 refrigerant is less than the atmospheric pressure.

Action:

 Air in the system can be removed by collecting the system gas in the condenser, leaving
the condenser cooling water on and venting out the air from the top of the condenser
because air will not be condensed in the condenser but remains on top of the condenser
above the liquid refrigerant.

 Connect the collecting cylinder to the purging line of the condenser, open the valve, and
collect air in the cylinder.

 After purging the air from the system don’t forget to shut the purging valve.

 Check the level of the refrigerant in the system. If required, charge the system with
fresh refrigerant.

 Restart the compressor with all safety precautions.

FREEZING OF EXPANSION VALVE DUE TO MOSTURE AND AIR IN THE SYSTEM

OIL IN THE REFRIGERATION SYSTEM

Indication:

 Temperature is not dropping in the cold rooms as normal, due to fact that oil act as
insulation in the evaporator.

 It may cause excessive frost on the suction line.

 Refrigerant compressor runs for the extended period of time.

 Lubricating oil level in the compressor will drop.

Causes:

 This may happen if the oil separator is not working properly.

 Oil my carry over from the compressor and may not come back to the compressor due
to blockage in the system.

 Defective piston rings or worn out liner of the compressor may cause the oil to carry
over along with the refrigerant.

 Compressor may take high capacity current during starting.

Action:

 Check the oil separator for proper functioning.

 Check the drier for proper cleaning and if its require cleaning clean it

 Evaporator coil should be drained to remove any trace of oil.

 If there is oil in the cooling coils, increase the condenser and evaporator temperature
differentials and remove excess frost on the suction pipe.
FLOODING OF REFRIGERANT IN THE SYSTEM

This is seen as liquid getting back to the suction of the refrigerant compressor. It may be due to
a faulty or incorrectly adjusted expansion valve and also due to solenoid valve leakage. It may
also result from overcharging of the refrigeration system. Flooding may lead to an iced up
evaporator.

For Chiller Systems

CHILLER SYSTEM DOES NOT START:

1. Have all voltages and fuses checked (if system is not operating) If fuses are blown-check
for shorts or grounds before new fuses are installed. There was a reason for the fuses
blowing-find it first.
2. Make sure chiller has water in the closed loop reservoir tank. This can cause the flow
switch to chatter or the system to ice up.
3. Check the thermostat set point and make sure the water in the closed loop reservoir is
above that setting. If the water is cool the chiller may not need to run.
4. Keep all air, water filters and coils clean and clear for proper air flow.
5. Make sure any belts have been checked and spares are on hand.
6. Make sure that there is at least 1 piping line with open water circulation. This can be
also obtained by the use of a water bypass at the end of the process water loop.
7. If there are water leaks: Make sure that all condensate trap lines are clear. If blocked,
ceiling tiles may show water marks. If system is " Split" check the indoor evaporator
section where the air filters are located, or the main unit if it is a "Package" system.
8. If a conditioned area is hot: Check all zone damper controls, thermostats or water
solenoid valves, to confirm water flow through the cooling coils.
9. Safeties: Reset them 2-3 times maximum. If the system continues to trip the safety then
call a chiller service technician.

CHILLER-START UPS AND SHUT DOWNS:

1. Do not shut off chiller by main power disconnects. Use control power switches provided
on the chiller control panel.
2. First time start ups should be done by a qualified chiller service technician. Serious
damage can occur if certain steps are not taken from the beginning.
3. Start ups (Daily): make sure the chiller recirculation pump is on and running before the
compressors are started.
 4. In some of the cases the HVAC system runs 365 days/year: If this is the case the controls
for the conditioned areas (start up and shut down) are the thermostats in those
particular areas. There would be no need to shut the system down where the unit is
located.
1. 5.Shutting down for several months: If this is done due to seasonal weather changes,
make sure that the chilled water loop has proper chemical treatment to reduce rust and
piping damage.

Operating Adjustments: (HVAC)

1. Temperature ranges: HVAC chiller systems run relatively cold 40-50F and must use
freeze protection in the circulation water loop.
2. Seasonal temperature shifts (inside conditioned areas) : Even though the chiller
temperature is pre-set; changes in ambient temperatures can make a conditioned area
feel cooler or warmer. Adjust the zoned thermostats to combat these seasonal changes.
Don't change the temperature of the chiller- a room thermostat is much easier.
3. Stagnant air or musty smells: Make sure that the indoor air filters are changed monthly
or at least quarterly. Dust and dirt reduce the efficiency of the system, increase
operating costs and cause poor air quality for those who work in those areas.
4. Room's) too cold or too hot: First check the zone thermostat and adjust as needed.
NOTE: If the HVAC system is not a chiller but cooled by refrigeration; generally do not
set the thermostat below 68-70F. The unit may ice up and cause damage to the
compressor. If the system is chiller water cooled; it does not matter what the zone
thermostat is set for, only the personal comfort level of those in the rooms.
Other Troubleshooting Methods:
Symptom Possible Causes
Insufficient airflow
1. Unit discharge obstructed
from ventilation
2. Blocked air filter
system
1. Cooled air being dumped directly
onto occupants by diffuser
Cold draughts felt in 2. Air conditioned space is under
certain areas within negative pressure causing cooler
an air conditioned outside air leakage
space 3. Blocked air filter
4. Cold air being drawn in from
outside
1. Broken or inaccurate space air 1. Adjust and set temperature
Air conditioned room thermostat
overheating 2. Incorrect setpoint temperature on 2. Replace faulty thermostat
thermostat
1. Fan and/or motor bearings have
worn
Ventilation system 2. Fan impeller is out of balance
has become noisy 3. Air damper adjustment has
moved causing excessive wind
velocity noise
1. Duct system has become blocked,
reducing air flow
Ventilated space has 2. Fan is failing to operate
become stuffy 3. Air damper adjustment has
altered restricting air flow
4. Blocked air filter
Solution
1. Clear blockage
2. Clean air filter
1. Set air diffusers so as to give
even air distribution
2. Balance air system to provide
a positive or even pressure
3. Clean air filter
4. Balance ventilation for neutral
or positive internal building
pressure.
setting on thermostat
1. Replace or repair worn bearing
2. Re-balance or replace impeller
3. Reset air damper
1. Clear blockage from within
ducting
2. Re-commission fan
3. Reset air damper to required
air volume
4. Clean air filter
 1. Faulty or inaccurate space air
thermostat 1. Replace or repair thermostat
Inconsistent space air
2. On/Off band too wide on space 2. Reduce band width on
temperature in air
air thermostat thermostat
conditioned room
3. Thermostat is being affected by 3. Move thermostat
another source

1. Short circuiting between intake 1. Relocate either the intake or

Unpleasant smells
and discharge louvres the discharge louvre
coming from the
2. Burnt windings on fan motor 2. Replace fan motor
ventilation system
3. Subjected to outside pollution 3. Fit odour removal filter

1. Water system is out of balance 1. Balance water system

Excessive noise from 2. Pump bearings have become 2. Repair or replace pump
heating or chilled worn 3. Change or balance impeller
water system 3. Pump impeller is out of balance 4. Raise water pressure on
4. Pump cavitation system

1. Heating or cooling loads have

altered due to renovations 1. Alter system to suit load
Air conditioning 2. Systems are not balanced 2. Balance complete system
system in one area of correctly 3. Alter or balance to match
the building reacts 3. Intended use of that part of the loads
differently to others building has changed since initial 4. Upgrade system to match
design existing loads
4. Outside air temperate is beyond
the design capabilities
Room space
temperature is not 1. There is insufficient warm up time 1. Adjust time clock so that
adequate first thing in the morning system starts earlier
in the morning
 1. Reset timeclock
2. Time clock setting prohibits start 3. Replace fuse
Air conditioning 3. Blown fuse 4. Energise system
system fails to start 4. Power supply down 5. Check all system safety devices
5. Safety devices prohibiting start-up for failure

Split system heat

pump operates but 1. Refrigerant gas has leaked and 1. Repair gas leak and recharge
does not produce any depleted. refrigerant pipework.
cooling or heating

Split system heat 2. Refrigerant gas has leaked but not 1. Repair gas leak and recharge
pump operates but fully depleted refrigerant pipework
does not meet the 3. Outside air temperate is beyond 2. Upgrade system to match
required load the design capabilities existing loads
REFRIGERANT LEAK DETECTION METTHODS
Method 1: Soap test:

Soap test is the easiest way of detecting refrigerant leak.

However this test can only be performed on a positive gauge pressure system, i.e. the system
has higher pressure than ambient.

Systems, operating under vacuum, may draw in moisture, and cause refrigerant contamination,
and parts failure.

We can use this test on current air conditioning systems, using chlorine and fluorine based
refrigerant.

The steps are,

1. switch on the system with cooling, or heating mode,

2. make a soap solution using dishwasher liquid and water,
3. pour it into a container.
4. Use a mist spray to spray onto hard-to-reach areas,
5. cover the test area from wind,
6. clean the area to be tested using a clean, dry cloth,
7. apply (or spray) the solution onto the test area,
8. spread the solution along the test area using leather (or non absorbing) cloth,
9. watch for bubble formation

If there is no bubble formation, then there is no leak at the test area. You may repeat the test
on other areas on the system.

Leak presence on the system will cause the soap bubble to expand. Such occurrence will
require tube repair, and/or parts replacement.

Wipe dry the area after the test.

Method 2: UV light refrigerant leak detection:

A phenomenon that will normally occur on refrigerant leak is that, lubrication oil leak into the
atmosphere.

This happens as the oil is well mixed with the refrigerant. Hence, refrigerant leak will also mean
oil leak.
Processed lubrication oil, will have an ultraviolet (UV) component in it. Air conditioning
lubrication oil is not left out.

This UV component is easily detectible by UV light, or famously known as Black light.

The working principle of black light

Ultraviolet lights are not visible to human eyes, and hence, we need a UV light, to reflect the UV
component on a surface.

UV lights will do exactly that.

UV surfaces that are exposed to UV light will reflect this light, and make it visible to our eyes.

In our case the UV surface is refrigerant and oil leak.

The steps are,

1. shade the test area,

2. direct the light onto test area of the air conditioning system, and look for
fluorescent mark

This method can detect small amounts of refrigerant leaks.

Method 3: Refrigerant leak detection using electronic device:

Electronic leak detector is most widely used and very accurate refrigerant leak testing method,

It is also known as the halogen leak detector, as refrigerant used in air conditioners are of
chlorine and fluorine based material.

These are halogen gases.

How it works?

Leaking refrigerant will be drawn into the unit by a small pump.

The refrigerant will pass through a proportional halogen detector, and it will be translated into
electrical signal.

This signal will be amplified and read out will be provided, together with audible sound.
Testing steps are,

1. switch on the unit,

2. cover the test area from direct draft,
3. pass the detection probe near test area and wait for audible and visible signals

Which Electronic Refrigerant Leak Detector to Buy?

For the most part, there are just two types of electronic leak detectors. There are those that
use a heated diode, and those that rely on corona discharge. On the corona discharge type,
anything that breaks that corona barrier will set off the detector. You name it - dust, moisture,
refrigerant (sometimes), solvents, etc.

Then you have the heated diode type detectors. They are less prone to false alarms from
moisture and shop chemicals. More importantly, heated diode leak detectors are also much
more sensitive to R-134a. Other leak detectors are suitable for finding R-12 and R-22 leaks, but
we've found that leaks in R-134a systems are best located using the heated diode detectors. In
fact, right after R-134a came out, most of our electronic leak detectors became obsolete. Leak
detectors which once worked well with R-12 and R-22 just weren't doing the job. It's not that
electronic leak detectors don't work with R-134a, it's just most don't work well enough.

Here's our recommendation. Look for a leak detector that uses a heated sensor.
Years ago there were few models that incorporated the heated diode. Today, there are many
heated sensor units to choose from, and most are very economical to own. When researching
which detector to buy, consider sensor life expectancy, and unit sensitivity during comparison.
These specifications should be mentioned in sales literature.

Other factors to consider when choosing a leak detector:

 sensor replacement cost

 warm-up time

 power supply
 Example of a heated sensor leak detector

Alternative refrigerant leak detection method:

Another way of detecting refrigerant leak is by checking oil leak, as refrigerant leak will also
expel a small amount of oil.

Wipe a cloth over test area of an air conditioner part, and feel with your finger for presence of
oil on the cloth.

Safety in refrigerant leak detection:

Please,

1. do not use bare hands to sense for leak, to avoid frost bite
2. do leak detection in well ventilated area
3. evacuate the area, if you smell pungent odour
4. call for repair as soon as possible, if you have detected pungent smell
 COOLING LOAD CALCULATIONS

In calculating the cooling load, the following must be considered:

 Total floor area of the conditioned space

 Outdoor Design Temperature is 35°C
 Desired Indoor Condition is 23°C
 Sensible Heat gain from thermal transmission, Qst
 Sensible Heat gain through solar radiation, Qsr
 Sensible Heat gain through infiltration, Qsi
 Sensible Heat emission from occupants, Qso
 Sensible Heat gain from electric lights, Qse
 Sensible Heat gain from motors, Qem
 Latent Heat emission from occupants, Qlo

Shortcut Method according to ENERGY STAR:

Energy Star is an international standard for energy efficient consumer products originated in the
United States of America.

 Determine the square footage of the area to be cooled using the following formulas:

 For square and rectangular rooms, multiply the length of the area by its width

 For a triangular area, multiply the length of the area by the width and divide by 2
• Most rooms can be further divided into these basic shapes to determine the square
footage.

• Using the square footage and the chart below, determine the correct cooling capacity.
Cooling capacity is measured in British thermal units (BTUs) per hour.

• Make any adjustments for the following circumstances:

• If the room is heavily shaded, reduce capacity by 10 percent.

• If the room is very sunny, increase capacity by 10 percent.

• If more than two people regularly occupy the room, add 600 BTUs for each additional
person.

• If the unit is used in a kitchen, increase capacity by 4,000 BTUs.

• Consider where you install the unit. If you are mounting an air conditioner near the
corner of a room, look for a unit that can send the airflow in the right direction.