Experiment: Study of Air Cooler
1. Aim
To study the construction, working principle, components, and performance characteristics of an air
cooler.
2. Objectives
• To understand the basic working of an evaporative air cooler.
• To identify and study the components: pump, blower, cooling pads, water distribution system,
thermostat (if any), and air-flow mechanism.
• To understand factors affecting cooling efficiency.
3. Theory
An air cooler (evaporative cooler) works on the principle of evaporative cooling.
When hot and dry air passes through wet cooling pads, water evaporates and absorbs latent heat from
the air, reducing its temperature.
4. Main Components
1. Cooling Pads (Honeycomb / Aspen): High-surface area material to hold water.
2. Water Pump: Circulates water from the sump to the top of cooling pads.
3. Blower/Fan: Draws outside hot air and forces it through wet pads.
4. Water Distribution System: Ensures uniform wetting of pads.
5. Sump Tank: Stores water for circulation.
6. Float Valve: Maintains water level.
7. Speed Control Switch: For blower motor.
8. Louvers: Direct the flow of cooled air.
9. Speed Control Switch / Regulator.
10. Body Casing.
1. Cooling Pads (Honeycomb / Aspen Pads)
Definition:
Cooling pads are porous materials that hold water and allow air to pass through them.
Proper Working:
• Pads must remain uniformly wet.
• No dry spots should be present.
• Pads should be clean and free from dust or algae.
2. Water Pump
Definition:
A small electric pump that lifts water from the tank (sump) to the top of the cooling pads.
Proper Working:
• Should supply water continuously and uniformly to the pads.
• No noise or irregular flow.
• Water flow should be steady, not too slow or too heavy.
3. Water Distribution System (Water Tray + Pipes)
Definition:
Pipes or a channel that distributes water from the pump to the top of cooling pads.
Proper Working:
• Water should be spread evenly across the pads.
• No leakage or blockage in holes.
• Tray should not overflow.
4. Blower/Fan
Definition:
The blower pushes cooled air into the room, while the fan draws hot air through the pads.
Proper Working:
• Should rotate smoothly without vibration.
• Speed control must function (Low/Medium/High).
• No rubbing or scratching sound from blades.
5. Sump Tank (Water Tank)
Definition:
Bottom area of the cooler that stores water for circulation.
Proper Working:
• Water level must be within the marked range.
• Tank must be clean (no dirt, algae, or foul smell).
• No leakage.
6. Float Valve
Definition:
A small valve that controls the water level automatically when water is supplied through a pipe.
Proper Working:
• Should stop water flow when the tank is full.
• Should allow water when the tank level is low.
7. Motor (Blower Motor)
Definition:
The electric motor that drives the blower or fan.
Proper Working:
• Smooth rotation without overheating.
• Should respond to speed control settings.
• No burning smell or unusual noise.
8. Louvers (Front Grills)
Definition:
Adjustable slats used to direct the airflow (up–down or left–right).
Proper Working:
• Should move freely and hold position.
• Allow proper airflow without obstruction.
9. Speed Control Switch / Regulator
Definition:
Electrical switch that controls motor speed.
Proper Working:
• All speed levels should work properly.
• Switch should not spark or heat.
• Should provide smooth change in airflow.
10. Body Casing
Definition:
Outer structure that holds all parts of the air cooler.
Proper Working:
• Should be free from cracks or loose fittings.
• Should provide proper ventilation for the motor.
Working Principle
• Hot air enters the cooler.
• Air passes through wetted pads.
• Water evaporates → absorbs heat → reduces air temperature.
• Blower pushes cool air into the room.
Factors Affecting Cooling Efficiency of an Air Cooler
Cooling efficiency of an air cooler depends on several important factors.
The major factors are:
1. Dryness of Air (Ambient Humidity)
• Air coolers work best in hot and dry climates.
• When humidity is high, the air cannot absorb more moisture → less evaporation → poor
cooling.
Lower humidity = higher cooling efficiency
2. Quality and Wetness of Cooling Pads
• Cooling pads must be clean, thick, and fully wet.
• Good quality pads (Honeycomb pads) increase surface area → more evaporation.
Uniformly wet pads = better cooling
3. Air Flow Rate (Blower/Fan Speed)
• Air must pass slowly enough through the pads to allow time for evaporation.
• Too high fan speed → air passes quickly → less cooling.
• Too low speed → insufficient airflow.
Balanced airflow gives maximum cooling
4. Water Circulation Rate
• Adequate water flow ensures pads remain wet.
• Insufficient water → dry pad area → low cooling.
Proper water supply = effective evaporation
5. Temperature of Air Entering the Cooler
• Higher outside temperature increases evaporation rate → more cooling.
• Moderate or low temperature reduces cooling efficiency.
Hotter air improves efficiency
6. Cleanliness of Air and Pads
• Dusty pads block airflow and reduce evaporation.
• Clean pads allow better contact between air and water.
Clean pads = improved performance
7. Air Leakage
• If room windows/doors are fully closed, humidity increases rapidly → cooling decreases.
• Proper ventilation is necessary for continuous cooling.
Cross-ventilation maintains high cooling efficiency
8. Water Quality
• Hard water causes scaling on pads and pump blockage.
• This reduces water absorption and evaporation.
Soft/clean water improves efficiency
9. Condition of Blower and Motor
• Weak motor or damaged blower reduces air delivery.
• This directly reduces cooling performance.
10. Size and Type of Cooler
• Desert coolers provide higher airflow for large rooms.
• Small room coolers have less cooling capacity.
Correct cooler size = higher efficiency
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