L 35 ENGINEERING COLLEGE AJMER

AUTOMOBILE ENGINEERING

Chapter 6A: Automotive Air Conditioning:

Introduction, Loads, Air conditioning system Components, Refrigerants,
Fault Diagnosis.

COURSE INSTRUCTOR:
VINOD KUMAR VERMA
ASST. PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
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AUTOMOTIVE AIR CONDITIONING:

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• A CONDITIONING
IR conditioning
Air :
(often referred to as AC, A/C, or air con) is the
process of removing heat and moisture from the interior of an
occupied space to improve the comfort of occupants

• Also Called HVAC – Heating, Ventilation & Air Conditioning

• Human generally feel Comfortable with:

❑Temperatures of 22 °C to 27 °C
❑Relative humidity of 40% to 60%.
❑Air Movement 8–15 m/min (approx. 1Km/hr)
❑Air Quality / Purity
❑Noise Level
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AIR CONDITIONING:
• A liquid like water or alcohol absorbs the heat in its vicinity as it
evaporates.
• When alcohol is put on your skin, you feel chilly.
• This happens because, when the alcohol evaporates, it removes
heat from your skin.
• On the air conditioner cycle, by using the above principle and
refrigerant which is easier to evaporate than alcohol, takes place.
• An application of this principle is refrigeration.
• The higher the vaporizing capacity, the larger the heat absorbing
power and the higher the refrigerating capacity.
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DESIRABLE PROPERTIES OF REFRIGERANT
Physical Properties Environmental Effects of Refrigerants
• Low Boiling Point • Leakage Detection
• Low Specific Heat • Flammability
• Low Freezing Point • ODP
• Low Condensing Pressure
• GWP
• High Evaporator Pressure
• STEL
• High Critical Pressure
• High Vapor Density/Low spc. Vol
• TWA
• High Dielectric strength
• High Latent Heat of Vaporization Chemical Properties
• Toxicity
Economics of Refrigerants • Oil Solubility
• Cost of refrigerants • Low Water Solubility
• Availability • Reactivity
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DESIRABLE PROPERTIES OF REFRIGERANT
• Low Freezing Point: Refrigerants should have low freezing point than the
normal operating conditions. It should not freeze during application. Water for
example cannot be used below 0 Deg C.
• Low Condensing Pressure : The lower the condenser pressure the power
required for compression will be lower. Higher condenser pressure will result
in high operating costs. Refrigerants with low boiling points will have high
condenser pressure and high vapor density. The condenser tubes have to be
designed for higher pressures which also give raise to capital cost of the
equipment.
• If Boiling Point is Low, High Condenser Pressure – Reciprocating Compressor
is used. Eg: Ammonia, R22, R12 etc.
• If Boiling Point is High, Low Condenser Pressure – Centrifugal Compressor is
used. Eg: R11, R13 & R114 etc.
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DESIRABLE PROPERTIES OF REFRIGERANT
• High Evaporator Pressure: This is the most important property of refrigerant.
In a negative pressure evaporator Atmospheric air or Moisture will Leak into the
system. The moisture inside the system will starts freezing at low temperature
zones and clogs and chokes the system.
• Atmospheric air ingression into the system will occupy the heat transfer area
and results in poor heat transfer rates. Presence of air will reduce the partial
pressure of refrigerant and the condensation temperature will rise. It increasers
the condenser pressures and thereby the power consumption for the
compressor will also rise.
• Atmospheric air ingression inside the system may sometime results in
explosions if the flammability values of the refrigerants are in wide range.
• Due to the above disadvantages, Positive evaporator pressure is preferred.
Leak outside the system results in refrigerant loss and it can be identified easily
and refrigerant loss can be topped up. Moderately high evaporator pressure
boosts the compressor suction pressure thus reduces the power costs.
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DESIRABLE PROPERTIES OF REFRIGERANT

• High Critical Pressure: Critical pressure of the refrigerant should be higher than
the condenser pressures. Otherwise the zone of condensation decreases and the
heat rejection occurs.
• High Vapor Density: Refrigerants with High vapor density/ Low specific volume
will require a smaller compressors and velocity can be kept small and so the
condenser tubes used will also be in smaller diameter.
• High Dielectric strength: In hermetically sealed compressors refrigerant vapor
contacts with motor windings and may cause short circuits. Therefore dielectric
strength should be high to avoid short circuits.
• High Latent Heat of Vaporization: Higher latent heat of vaporization of the
refrigerant will result in lower mass flow rates according to the Heat transfer
equation. If the mass flow is very small it is difficult to control the flow rates.
Therefore ammonia cannot be used for small refrigeration systems.
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DESIRABLE PROPERTIES OF REFRIGERANT
• High Heat Transfer Coefficient: Higher heat transfer coefficient requires
smaller area and lower pressure drop. This makes the equipment compact
and reduced the operating cost.
• Toxicity: Toxicity is the important properties of refrigerants. The refrigerants
should be non poisonous to humans and food stuff. The toxicity depends upon
the concentration and exposure limits.
• Oil Solubility: The lubricating oils must be soluble in Refrigerants. If the oil is
not miscible in the refrigerant used and it is heavier it will settle down in the
evaporator and reduces the heat transfer. Therefore oil separators are to be
employed. If the oil density is less than the refrigerant used and it if it is
immiscible, the oil will float on the surface of the refrigerant. Therefore
overflow drain is to be provided to remove oil. If the refrigerant velocity is not
sufficient, then it cannot carry all oil back into the compressor. It may
accumulate in evaporator. This phenomenon is called Oil logging.
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DESIRABLE PROPERTIES OF REFRIGERANT
• Low Water Solubility: Most of the refrigerants form acids or bases in the
presence of water. This will cause corrosion and deteriorates valves, Seals
and Metallic parts. Insulation of windings in hermetic compressors will also get
damaged. The free water apart from the dissolved water in refrigerant freezes
below 0 Deg C and chokes the narrow orifice of expansion valve. This may
also cause bursting of the tubes.
• Reactivity: The refrigerants should not react with the materials used in
refrigeration cycle like evaporators, condenser tubes, compressors, control
valves etc. Ammonia reacts with Copper and Cuprous alloys and forms
copper complexes. CH3Cl reacts with Aluminium. Most of the refrigerants
form acids with water. CCl2F2, CH4Cl can form HCL with water which
dissolves the copper from condenser tubes and deposits them on compressor
pistons and deteriorates the life of the machinery.
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DESIRABLE PROPERTIES OF REFRIGERANT
• Leakage Detection: Ammonia and SO2 can be detected by their
characteristic smell. Strong smelling chemicals like acrolein may be added to
refrigerant for easy leak detection.
• Freon leak can be detected by a halide torch. It consists of an alcohol lamp
that emits a blue flame. If Freon is present blue flame turns into green. This
test is based on Beilstein Test for Chlorine.
• Ammonium Hydroxide Solution turns the red litmus paper into blue; thereby
condenser tube leaks can be identified.
• SO2 can be detected with NH3 H2O Solution. It makes white fumes of
ammonium sulfide.
• Electronic detectors, Ultrasonic leak detectors may also be used to detect the
leaks.
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DESIRABLE PROPERTIES OF REFRIGERANT
• Flammability: The refrigerant should not make combustion mixture in Air.
Freon, Carbon Dioxide, SO2 are non flammable. Methane, butane and other
hydrocarbons are flammable. Ammonia will form explosive mixture when the
concentration in air is between 16 to 25 %.
• ODP: The ozone depletion potential (ODP) of a refrigerant is the relative
amount of depletion to the ozone layer it can cause. ODP of R11 is fixed as
the maximum value of 1.0. R-22 for example, has an ODP of 0.055.
• GWP: Global Warming Potential (GWP) is a relative measure of how much
heat a refrigerant traps in the atmosphere. GWP of Carbon Dioxide is 1.0. For
Methane GWP is 72, it means that if the same mass of CH4 and CO2 were
introduced into the atmosphere, that methane will trap 72 times more heat
than the carbon dioxide. It is normally mentioned as 20 years or 100 years
period.
• STEL: Short Term Exposure Limit is the maximum concentration to which one
can be exposed up to maximum of 15 minutes.
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DESIRABLE PROPERTIES OF REFRIGERANT
• TWA: Time weighted Average is the concentration to which repeated eight
hour exposures for five days in a week which is considered to be safe.
• Cost of refrigerants: The quantity of refrigerant used in any industry is very
small. Therefore cost of the refrigerants is normally high when compared to
other chemicals. Similarly if it is very low industry professional will not take
necessary action to control the leaks.
• Availability: Refrigerants should be readily available near the usage point. It
must be sourced and procured within a short span of time to enable the user
in case of leaks, maintenance schedules etc.
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TYPES OF REFRIGERANTS
• Primary Refrigerants- The Old and Busted One (It was effective and cheap. However,
scientists quickly discovered its sinister secret: It was partially responsible for the rapidly-
depleting ozone layer. In 1994, it was banned from all new cars sold in the US)
• Secondary Refrigerants- - In most cars that are on the road today, R134a refrigerant
makes the A/C system blow cold on hot days. Selected for its low flammability and safety, as
well as because it's kinder to the environment, almost every car built since 1994 is equipped
with R134 refrigerant.
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EXAMPLES OF COMMON AUTOMOTIVE REFRIGERANT

• R12 (Dichlorodifluoromethane / Freon)- The Old and Busted One (It was effective
and cheap. However, scientists quickly discovered its sinister secret: It was partially responsible
for the rapidly-depleting ozone layer. In 1994, it was banned from all new cars sold in the US)
• R134a (Hydrofluorocarbon / HFC) - In most cars that are on the road today,
R134a refrigerant makes the A/C system blow cold on hot days. Selected for its low
flammability and safety, as well as because it's kinder to the environment, almost every car
built since 1994 is equipped with R134 refrigerant.
• R1234yf (Hydrofluoroolefin / HFO) - R1234yf was chosen to replace R134a in all
new cars by 2021. Some manufacturers have already made the switch, or the switch is in
progress. In fact, as of 2018, 70% of new Kia cars already come equipped with R1234yf!
• This new refrigerant performs similarly to R134a, but with one important difference: it
breaks down much faster in the upper atmosphere. That means it'll contribute less to global
warming. It's also easy to upgrade a car's A/C system from R134a to make it compatible
with R1234yf.
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LOADS ON AIR CONDITIONING IN AUTOMOBILE

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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• Metabolic Load - The metabolic activities inside human body constantly create heat and
humidity (i.e. perspiration). This heat passes through the body tissues and is finally released to
the cabin air. This amount is considered as a heat gain by the cabin air and is called the
metabolic load. The metabolic load can be calculated by

• Where M is the passenger metabolic heat production rate. It is found from the tabulated values in
ISO 8996 TABLE based on various criteria such as occupation and activity levels. For a driver
and a sitting passenger, the values can be estimated as 85 W/m2 and 55 W/m2, respectively. The
Dubois area ADu, which is an estimation of the body surface area as a function of height and
weight, is calculated by

• where W and H are the passenger weight and height respectively.

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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• Radiation Load - The heat gain due to solar radiation is a significant part of the cooling
loads encountered in vehicles. According to ASHRAE, solar radiation heat load can be
categorized into direct, diffuse, and reflected radiation loads. Direct radiation is that part of the
incident solar radiation which directly strikes a surface of the vehicle body, which is calculated
from

• Where IDir is the direct radiation heat gain per unit area and θ is the angle between the surface
normal and the position of sun in the sky. τ is the surface element transmissivity and S is the
surface area, respectively. Before local sunrise and after local sunset, simply no radiation loads
are considered.
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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• Ambient Load - The ambient load is the contribution of the thermal load transferred to the
cabin air due to temperature difference between the ambient and cabin air. Exterior convection,
conduction through body panels, and interior convection are involved in the total heat transfer
between the ambient and the cabin. Below equation shows the general form of the ambient load
model.

• where U is the overall heat transfer coefficient of the surface element. Ts and Ti are the average
surface temperature and average cabin temperature, respectively. U has different components
consisting of the inside convection, conduction through the surface, and outside convection.
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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• Exhaust Load - Conventional and hybrid electric vehicles have an Internal Combustion
Engine (ICE) that creates exhaust gases. The Exhaust Gas Temperature (EGT) can reach as
high as 1000°C. Because of the high temperature of the exhaust gas, some of its heat can be
transferred to the cabin through the cabin floor. Considering SExh as the area of the bottom
surface in contact with the exhaust pipe, the exhaust heat load entering the cabin can be written
as

• where U is the overall heat transfer coefficient of the surface element in contact with the exhaust
pipe and it should be calculated separately by assuming no external convection since the
exhaust temperature is measured at the outer side of the bottom surface. SExh is the surface area
exposed to the exhaust pipe temperature and TExh is the exhaust gas temperature.
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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• Engine Load - Similar to the exhaust load above, the high temperature engine of a
conventional or hybrid car can also contribute to the thermal gain of the cabin. Below Equation
shows the formulation used for calculating the engine thermal load.

• where U is the overall heat transfer coefficient of the surface element in contact with the engine
and SEng is the surface area exposed to the engine temperature.
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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• Ventilation Load - Fresh air is allowed to enter the vehicle cabin to maintain the air quality
for passengers. As the passengers breathe, the amount of CO2 concentration linearly increases
over time. Thus, a minimum flow of fresh air should be supplied into the cabin to maintain the
passengers comfort. The minimum fresh air requirements for different numbers of passengers in
a typical vehicle, for instance, a minimum of 13% fresh air is needed for a single passenger.

• the air leakage from different vehicle types. They showed that for typical vehicles, leakage
occurs as a function of the pressure difference between the cabin and the surroundings as well
as the vehicle velocity. For a small sedan car at a pressure difference of 10 Pa, a leakage of 0.02
m3/s
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LOADS ON AIR CONDITIONING IN AUTOMOBILE

• AC Load - The duty of the air conditioning system is to compensate for other thermal loads so
that the cabin temperature remains within the acceptable comfort range. In cold weather
conditions, positive AC load (heating) is required for the cabin. Inversely, in warm conditions,
negative AC load (cooling) is needed for maintaining the comfort conditions. The actual load
created by the AC system depends on the system parameters and working conditions. In this
work, it is assumed that an AC (or heat pump) cycle is providing the thermal load calculated by
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CALCULATION OF AIR CONDITIONING CAPACITY REQUIRED

• What is a TON?
• A ton, as used in the HVAC field, is a term that describes how much heat the AC
unit can remove from a home in one hour. The measurement for heat is the
British thermal unit (BTU). One ton of air conditioning can remove 12,000 BTUs of
air per hour or or 3517 watts
• So for 1.5 tons, this will turn out to be 18000 BTU/hr or 5275.5 watts.
• And for 1 tons, as mentioned above; 12000 BTU/hr or 3517 watts.
• Now the term EER is important for calculating actual power consumption of AC.
• The input wattage to AC is dependent on Energy Efficiency Ratio & star rating.
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CALCULATION OF AIR CONDITIONING CAPACITY REQUIRED

• (Note: calculations are done assuming 8hr/day for 5months)

• So here, if we consider a 5 star ac, then its input power is 1677 watt. EER =
cooling capacity of ac/power consumed by ac=5275.5/1677 =3.14
• And, 5275.5/3.1=1701.77 Watt this will be power consumption for 1 hr.
• For 8 hours, energy consumption will turn out to be; 1.702 * 8 = 13.616 kWhr
• Hence if you run 1.5 ton, 5 star ac for 8 hours a day, it will consume 13.616 units.
So for a month (30 days) it will consume, 13.616*30=408.48 units.
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CALCULATION OF AIR CONDITIONING CAPACITY REQUIRED

• What is a BTU?
• The British Thermal Unit, or BTU, is an energy unit. It is approximately the energy
needed to heat one pound of water by 1 degree Fahrenheit. 1 BTU = 1,055 joules,
252 calories, 0.293 watt-hour or the energy released by burning one match. 1 watt
is approximately 3.412 BTU per hour.

• BTU is often used as a point of reference for comparing different fuels. Even
though they're physical commodities and quantified accordingly, such as by volume
or barrels, they can be converted to BTUs depending on the energy or heat
content inherent in each quantity. BTU as a unit of measurement is more useful
than physical quantity because of fuel's intrinsic value as an energy source. This
allows many different commodities with intrinsic energy properties to be compared
and contrasted; for instance, one of the most popular is natural gas to oil.
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CALCULATION OF AIR CONDITIONING CAPACITY REQUIRED

• BTU can also be used pragmatically as a point of reference for the amount of
heat that an appliance generates; the higher the BTU rating of an appliance, the
greater the heating capacity. As for air conditioning in homes, even though ACs
are meant to cool homes, BTUs on the technical label refer to how much heat
the air conditioner can remove from their respective surrounding air.
• Cooling capacity for a room is defined as the heat load in a room that have to be removed in
order to achieve a certain room temperature and humidity. The typical design is set to 24°C
temperature and 55% Relative Humidity.
• Study shows that this combination of temperature and RH is the most conducive for the
human body. The unit used to measure heat load is BTU/hr. 1 BTU/hr is the heat energy
needed to increase 1 pound of water by 1°F.
• When choosing an air conditioner, usually a 1 HP (horse power) equipment is able to
remove 9,000 BTU/hr of heat. With better technology, some machines are able to remove
10,000 BTU/hr of heat with the same capacity. The higher the listed BTU/hr, the greater the
cooling capacity.
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OVER VIEW OF AIR CONDITIONING IN AUTOMOBILE

Charge air
Fan / Motor cooler
Evaporator
/Shroud
Heater Hoses

Radiator

Inside Sensor Radiator

Hoses
Control
Pannel Compressor
TXV &
Orifice tube Refrigerant lines
Custom Duct Accumulator
Design Dehydrator
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AIR CONDITIONING IN AUTOMOBILE

Low Temp
Low Pressure
Gas

Low Temp
Low Pressure

Compressor Evaporator Gas

High Temp
High Pressure
Gas

Low Temp
Low Pressure
Liquid

Condenser Expansion Valve

Low Temp
High Pressure Low Temp
Liquid High Pressure
Liquid
Receiver Dryer
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PARTS OF AIR CONDITIONER SYSTEM

Refrigerant
• Refrigerant (also known as coolant or by its brand name Freon®) is a special fluid
that is vital to cooling and freezing technology. It operates on a closed loop and
carries heat from the inside of your building to the outside. You can think of the
refrigerant as the messenger/traveler. We use refrigerant because it changes
states from liquid to vapor at convenient temperatures for the refrigeration cycle.
• Refrigerant moves through an air conditioner’s cooling tubes and copper coils,
connecting the inside unit to the outside unit. It absorbs heat from your indoor air,
changing states from gas to liquid. After absorbing heat from the inside air, the
refrigerant travels to the outdoor unit where the heat is pushed outdoors.
• Once the refrigerant has dispersed its heat outdoors, it changes back to its
gaseous state and travels back indoors. After the refrigerant gets cold again, an
indoor fan blows air over the cold coils and then circulates cold air through the
home. This cycle repeats every time your air conditioner is on.
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PARTS OF AIR CONDITIONER SYSTEM

Compressor
• The job of the compressor is to pressurize the refrigerant, thus raising its
temperature. Due to the combined gas law (a combination of Boyle’s Law,
Charles’ Law, and Gay-Lussac’s Law), which states that if pressure increases so
does its temperature, when you compress the refrigerant, it will heat up. It does
this by squeezing the gas very tightly together.

• We heat up the refrigerant in order to get its temperature higher than the outdoor
temperature. Since heat naturally flows from a hotter to colder bodies, in order to
dispense heat outdoors, the refrigerant must be hotter than the air outdoors. This
is why we need the compressor to increase its pressure and thus its
temperature.
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PARTS OF AIR CONDITIONER SYSTEM

Condenser Coil
• The condenser coil is in the outdoor air conditioning unit. It receives the high
pressure, high temperature refrigerant from the compressor. You can think of it
as the opposite of the evaporator coil. Whereas the evaporator coils contain cold
refrigerant, the condenser coils contain hot refrigerant.

• The condenser coils are designed to facilitate heat transfer to the outdoor air.
The refrigerant releases heat energy with the aid of the condenser fan, which
blows air over the coils. As the heat leaves the refrigerant to the outside
environment, it turns back into a liquid where it then flows to the expansion
valve, which depressurizes the refrigerant and cools it down.
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PARTS OF AIR CONDITIONER SYSTEM

Expansion Valve
• When the refrigerant leaves the condenser in its liquid state, it has dispersed
heat, but it is still too hot to enter the evaporator coils. Before the refrigerant
passes to the evaporator coils, it must be cooled down. This is where the
expansion valve (also known as a metering device) comes in, normally a
thermostatic expansion valve.
• Again using the principles behind the combined gas law, which states that when
pressure decreases so does its temperature, the expansion valve depressurizes
the refrigerant and cools it down.
• An expansion valve removes pressure from liquid refrigerant allowing for the
refrigerant to change from a liquid to a vapor/gas in the evaporator. It also
controls the amount of refrigerant/voltage flow entering the evaporator.
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PARTS OF AIR CONDITIONER SYSTEM

Evaporator Coil
• Evaporator coils are very important to an air conditioner. It’s where the air
conditioner actually picks up the heat from inside your home.
• The copper tubes receive the depressurized, liquid refrigerant from the
expansion valve. When your indoor air blows over the cold coils, the heat from
inside the home gets absorbed. This is because of the 2nd law of
thermodynamics which states that heat flows naturally from hot to cold.
• Just like the condenser coils need the help of the condenser fan to facilitate heat
transfer, the evaporator coils rely on the indoor air handler’s fan (aka the blower)
to blow air over the coils.
• As the refrigerant absorbs heat from the indoor air, it starts to evaporate to form
a vapor.
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HOW THE REFRIGERATION CYCLE WORKS

• The return vents, located inside your home, suck in hot air from inside the room.
The refrigerant picks up heat as air flows over the evaporator coils, which are
very cold.
• Once the refrigerant absorbs a certain amount of heat from the indoor air, it then
discharges it to the compressor, which pressurizes and heats up the refrigerant.
After passing through the compressor, it flows through the condenser coils. A big,
often loud condenser fan helps to push air over the condenser coils to facilitate
heat transfer outdoors.
• Refrigerant then cycles back over an expansion valve, depressurizing it and
cooling it down. It then performs the same heat absorption process over and
over again.
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FOR ANY QUIRES ASK IN COMMENT SECTION