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INSTRUCTION MANUAL

FOR

AIR CONDITIONER TEST RIG

Manufactured by:

ROORKEE EQUIPMENT & MODELS L PVT TD

Factory : C-18 Ram Nagar Industrial Area, Ram Nagar
Roorkee Distt-Haridwar,
Roorkee-247 667.
Email: rempvtltd@[Link] , remtender007@[Link]
Website: [Link]

AIR CONDITIONER TEST RIG

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OBJECTS:

1. To calculate the C.O.P. of unit

2. To calculate refrigeration capacity
3. To calculate H.P. of unit

APPARATUS:

Window Air Conditioner Test Rig. The unit is equipped with a hermetically sealed compressor
condenser and evaporator, condenser, fan motor, supply duct, various controls such as receiver
with valve fitting, R-22, , pressure gauges, capillary tube, voltmeter, amp meter, and temperature
indicator and Reciprocating Compressor. Capacity : 1.5 Ton

EVAPORATOR:

The liquid refrigerant from the condenser at high pressure is fed through a throttling device to an
evaporator at a low pressure. On absorbing the heat to be extracted from media to be cooled,
the liquid refrigerant boils actively in the evaporator and changes state. The refrigerant gains
latent heat to vaporize at saturation temperature/pressure and further absorbs sensible heat from
media to be cooled and gets fully vaporized and super - heated. The pressure and temperature
in the evaporator can be determined by the “Temperature-Pressure Relation chart” Table 1.

There are different types of evaporators used to different types of evaporators used for different
applications and are accordingly designed. These are at the form of cooling coils coils (fined or
prime surface type) made out of copper or steel or shell and tube coolers (flooded or direct
expansion type), Raceway type of Baudlet Coolers, for Ice Accumulation or Ice Banks etc.

COMPRESSOR:

The compressor is known as the heart of the refrigeration system. It pumps the refrigerant vapour
in refrigeration in refrigeration cycle as the heart pumps blood in the body. The low temperature,
pressure, superheated vapour from the evaporator is conveyed through suction line and
compressed by the compressor to a high pressure, without any change in gaseous state and the
same is discharged into condenser. During this process heat is added to the refrigerant and
known as heat of compression. The compressor should have a compression ratio to raise the
pressure of refrigerant to such a level that the saturation temperature of the discharged refrigerant
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is higher than the temperature of the available cooling medium, to enable the super-heated
refrigerant to condense at normal ambient condition.

Different types of compressors are reciprocating, rotating and centrifugal and are used for
different applications.

CONDENSOR :

The heat added in the evaporator and compressor to the refrigerant is rejected in condenser at
high temperature/high pressure. This super-heated refrigerant vapour enters the condenser to
dissipate its heat in three stages. First on entry the refrigerant losses its super-heat, it then losses
its latent heat at which the refrigerant is liquidified at saturation temperature pressure. These
liquid losses its sensible heat, further and the refrigerant leaves the condensers as a sub-cooled
liquid.
The heat transfer from refrigerant to cooling medium (air or water) takes place in the condenser.
The sub-cooled liquid from condenser is collected in a receiver (wherever provided) and is then
fed through the throttling device by liquid line to the evaporator.

There are several methods of dissipating the rejected heat into the atmosphere by condenser.
Thee are water-cooled, air cooled or evaporative cooled condensers.

In the water cooled condenser there are several types viz. shell and tube, shell and coil, tube in
tube etc. In evaporative cooled condensers both air and water are used. Air -cooled condensers
are prime surface type, finned type or plate type.

The selection of the type depends upon the application and availability of soft water.

THROTTLING DEVICE :

The high-pressure liquid from the condenser is fed to evaporator through a throttling device
which should be designed to pass maximum possible liquid refrigerant to obtain a good
refrigeration effect. The liquid should be properly sized to have minimum pressure drop.

The throttling device is a pressure-reducing device and a regulator for controlling the refrigerant
flow. It also reduces the pressure from the discharge pressure to the evaporator pressure without
any change of state of the liquid refrigerant.

The types of Throttling Devices are :

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 Capillary tubes
 Hand valves

The most commonly used throttling device is the Capillary Tube for applications upto approx. 10
refrigeration tons. The capillary is a copper tube having a small dia-orifice and is selected, based
on the system design, the refrigerant flow rate, the operating parameters (such as suction and
discharge pressures), type of refrigerant, capable of compensating any variations/fluctuations in
load by allowing only liquid refrigerant to flow to the evaporator.

Summary:

The working pressures, temperatures and states of the refrigerant in different parts of the
refrigeration cycle are shown in Figure.
There are mainly two pressures operating in the refrigeration cycle, commonly known as the high
side and the low side. The “high-side as referred to high pressure prevailing from compressor
onward right up to the inlet of the throttling device and from the throttling device up to the suction
of the compressor is called the “low side”.

VAPOUR COMPRESSION REFRIGERATION CYCLE DIAGRAM (Mollier Diagram)

Earlier the state of the refrigerant in various parts of the refrigeration system, along with the
pressure, temperatures etc. have been covered. It is now necessary to understand the individual
thermodynamic processes that make up the cycle and also understand the effect of change in a
particular part of the cycle on the overall complete cycle. These aspects are greatly simplified by
the use of proper charts and diagrams, in which the process, and the complete cycle can be
graphically represented for different conditions.

There are two types of representation in use which are:

1. The pressure-enthalpy (Ph) diagram – also known as the Mollier Diagram.

2. The temperature-entropy diagram

Of these the pressure-enthalpy (Ph) diagram is more commonly used and is explained
hereunder.

Mollier Diagram :
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The Mollier of pressure-enthalpy (Ph) diagram for a refrigerant is a graph with a number of
curves from which various properties of the refrigerant under different conditions or phases
can be read.
The curves are drawn by using the values taken from thermodynamic tables of the
refrigerant, both at saturation and super-heated conditions. The pressure are represented
on the ordinate (left vertical line) and the enthalpy (total heat content) in Btu/lb. are taken
on abscissa (bottom horizontal line).
Since pressure and temperature have definite relation at saturation, the horizontal

pressure lines can also represent constant temperatures and the diagrams are also

termed as temperature-enthalpy diagram. The charts include a curve which indicates

saturation line showing different states of refrigerants.

The chart is divided into three areas, which are separated from each other:

(a) Saturated liquid

(b) Saturated vapour
(c) The area in between the two having a mixture of liquid and vapour.

Processes

1. Points falling on the left side of saturated liquid curve represent sub-cooling.

2. Points on the right side of saturated vapour curve represent super-heating.

3. The horizontal distance between the two curves represent difference in enthalpy
level between saturated vapour and liquid at specific pressure and is equal to
Latent Heat of Vapourisation at the saturation pressure/temperature.

For known values of saturation pressures on high side and low side (Ph) diagram or
Mollier Diagram is shown in Figure.

For simplification only saturated pressures are assumed. Four processes in refrigeration
cycle are explained below:

(a) Compression: In compressor (vertical 1,2 on diagram) the compression is

assumed as adiabatic (constant enthalpy). No heat is added or subtracted to the
refrigerant vapour from outside. The vapour is saturated at the beginning and end
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of compression. In actual practice, the vapour are super-heated at beginning and

end of compression – shown in dotted line 1’-2’.
The temperature and pressure of refrigerant vapour is raised during compression.

(b) Condenser: In condenser (horizontal line 2-3 on diagram)- the condensation of

refrigeration takes place at constant pressure. The drop in enthalpy (total heat
content) is equal to latent heat of condensation (or vapourisation) at saturation
pressure. The process is shown by line 2-3 on diagram. The liquid at point 3 is
saturated. In actual practice, the vapour is super-heated at beginning of
condensation and sub-cooled at end of condensation. The process is shown by
line 2’2-2’2. The refrigerant change its state from vapour to liquid in this process.

(c) Throttling: In Throttling Device (shown by line 3-4 in diagram) this is an adiabatic
process, the pressure drop occurs is refrigerant at constant enthalpy i.e. no heat
transfer occurs between refrigerant and outside. The refrigerant is saturated liquid
point 3 and mixture of vapour and liquid at point 4. For sub-cooled liquid the
process is shown by dotted line 3’4’.

(d) Evaporation: In Evaporator (shown by line 4-1 in diagram) the evaporation of

liquid refrigerant takes place at constant pressure. The refrigerant gains latent heat
from surrounding medium to be cooled. The refrigerant is saturated vapour at end
of evaporation at point 1. The net refrigerating effect is obtained by projection of 1
and 4 on line 0-x i.e. 91-04. In actual cycle, taking sub-cooling of liquid refrigerant
in condenser and super-heating of refrigerant vapour in evaporator, the net
refrigerating effect would be 01-04’. It is seen to obtain better refrigerating effect,
sub-cooling in condenser and super-heating in evaporator is essential.

OPERATING PROCEDURE

1. Switch on the main board. Check voltage. It should be less than 190 Volts.
2. Start the unit stepwise starting with condenser fan motor and then compressor.
3. Note down the readings of ammeter, voltmeter, energy meter for compressor,
condenser cooling fan motor etc.
4. Check down the readings of the various pressure gauges. Absence of any reading
will indicate the blockage of pipeline or leakage of gas.
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5. Runt he unit for half an hour and note following readings :

(a) Suction pressure i.e. compressor inlet
(b) Discharge pressure i.e. compressor outlet
(c) Compressor inlet temperature
(d) Compressor outlet temperature
(e) Condenser outlet temperature
(f) Air outlet temperature
(g) Ambient temperature
6. While switching off the machine, first switch off the compressor, then condenser
fan motor and then switch off the main board.

Important Cautions
1. Check the voltage. It should not be less than 200/240 Volts. Single Phase 5d0 Hz.
AC supply.
2. Do not run the compressor without switch on the fan motor.
3. Whenever the compressor is switched off, do not switch on the compressor before
five minutes of interval.
4. Avoid sudden open/closing of the hand shut off valve in the line to prevent float
hunting and possible glass tube or leakage breakage.

PUMP DOWN THE GAS

To collect the gas in receiver tank to replace any part:

1. Start the unit and run for 15 to 20 minutes.

2. Close the outlet of receiver tank and see all the controls should be open.
3. Run the unit at least 15 to 20 minutes and see the pressure gauges if there is 0 in
the gauge. Than close all the valves and also the inlet of tank.
4. Now you can replace any part of the unit.
OBSERVATIONS AND CALCULATIONS
Temperature before compression
i.e. suction temperature T1 =
Temperature after compression
i.e. discharge temperature T2 =
Temperature after condenser T3 =
Temperature of Air coming out T4 =
Gauge pressure before compression P1’ = PSI
i.e. suction pressure
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P1’ PSI

Absolute suction pressure P1 = ---------- = kg/cm2

14.22

Gauge pressure after compression P2’ = PSI

i.e. Discharge pressure

P2’ PSI
Absolute Discharge pressure = ---------- = kg/cm2
14.22

Mass of refrigerant flow m = 1.5 kg/min.

From PH chart of F-22

Take P1 T1 calculate = H1 = KJ/kg

Take P2 T2 calculate = H2 = KJ/kg

Draw P2 T3 calculate = H3 = KJ/kg

As evaporation is constant enthalpy process

So H3 = H4

Refrigerating effect = H1 – H4 KJ/kg

Work done by compressor = H2 – H1 KJ/kg

Refrigerating effect
COP = -----------------------------------
Work done by compressor

H1 – H 4
= -----------
H2 – H 1

(H2 – H1) x m x 427

H.P. of unit = -------------------------- H.P.
4500 x 4.18

(H1 – H4) x m
Refrigerating cap in Ton = ------------------ Tons
50 x 4.18

Sample Redding not for actual reading

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AC TEST RIG (Calculations)

 Temp Before Compression [Section temp] T1=10C

 Temp after Compression [Discharge temp] T2=86C
P 1’ PSI
 Absolute Suction Pressure P1 = ---------- kg/cm2
14.22
68
P1 = ---------- = 4.78 kg/cm2
14.22

P 1’ PSI
 Absolute Discharge Pressure P1 = ---------- kg/cm2
14.22
260
P2 = ---------- = 18.28 kg/cm2
14.22

 Mass of Refrigerant Flow M = 1.5kg/min

 From PH chart of R-22 Taken Pressure & Temp

H1= 258 Kj/kg
H2= 300 Kj/kg
H3= H4= 66.7 Kj/kg

Refrigerating effect
1. COP = -----------------------------------
Work done by compressor

H1 – H 4 258.18 – 66.7
= ----------- = ----------------- = 4.5
H2 – H 1 300 – 258.18

(H2 – H1) x m x 427

2. H.P. of unit = ------------------------------ HP
4500 x 4.18

(300 – 258.18) x 1.5 x 427

= ------------------------------ = 1.5 HP
4500 x 4.18

(H1 – H4) x m
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3. Refrigerating cap in Ton = --------------------- Tons

50 x 4.18

(258.18 – 66.7) x 1.5

= ------------------------- = 1.45 Tons
50 x 4.18

TABELS

DISCHARGE DISCHARGE
SECTION TEMP AFTER COND. COLD AIR SUCTION PR.
TEMP PR.
[Link].
T1 T2 T3 T4 P1 P2

EXP. 10 86 18 22 68 260

1
2
3

REF.
H.P. OF
[Link]. H1 H2 H3 = H4 C.O.P. CAPACITY
UNIT
(IN TON)

EXP. 258.18 300 66.7 4.5 1.5 1.45

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2

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