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Part - III
AC Manual

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INTRODUTION
 Refrigeration and air conditioning is used to cool products or a building environment.
 AC is the process of alerting the properties of air (Primarily Temperature and Humidity) to
more favorable conditions
 The control of these conditions is desirable to maintain health and comfort of the occupants,
or to meet the requirement of industrial processes.

Systematic Diagram of AC operation

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2. Type of Air - Conditioning

1. Window AC system

2. Split AC system

3. Centralized AC system

4. Package AC system

5. W indows AC system

 The most used and cheapest type AC

 Units are reliable and simple to install solution to keep a room cool while avoiding costly
construction for central AC type
 Installation can be done by making a slot in the wall and there should also some opening
space behind the wall

2.1. Windows AC system

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 It comprises Two parts: the outdoor unit and the Indoor Unit
 The outdoor unit, fitted outside the room, component like compressor, condenser and
expansion valve
 The indoor unit comprises the evaporator or cooling coil and cooling fan. For this uni no need
to make any slot in the wall.
 Now a day split units have aesthetic looks and add to the beauty of the room. It can be used
to cool one or two rooms.

2.2. Split AC System

3. Centralized AC system

 Are used when large buildings, hotels, theaters, airports, shopping malls etc are to be air
conditioned completely.
 If the whole building is to be cooled and conditioned, it is not economical to put windows or
split Ac system.
 Small units might not satisfactorily cool the large halls, auditoriums, receptions areas etc.

2.3. Centralized AC system

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4. Packaged AC system
 Window and split type AC are usually used for small capacities up to 5tons.
 The centralized AC system is used for the cooling loads extended beyond 20 tons
 The packaged Ac are used for the cooling capacities in between these two extremes.
 This units are available in then fixed rate capacity ranged 3, 5,7,10, and 15 tons.
 Usually applied for restaurants, telephone exchanges, homes, small halls etc.…

2.4. Packaged AC system

AC system Major Components

3. Type of Air - Refrigeration

Refrigeration systems: most common one

 Vapor Compression Refrigeration (VCR): uses mechanical energy

 Vapor Absorption Refrigeration (VAR): uses thermal energy

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 Industrial Refrigeration: used in cold storage

1. Vapor Compression Refrigeration

 Highly compressed fluids tend to get colder when allowed to expand

 If pressure high enough
• Compressed air hotter than source of cooling
• Expanded gas cooler than desired cold temperature

3.1. Vapor Compression Refrigeration

Refrigeration cycle

2. Vapor Absorption Refrigeration

 The absorption system differs fundamentally from vapor compression system only in the
method of employed for compressing the refrigerant.
 In the absorption system, the compressor is replaced by an absorber, generator and a pump.

3.2. Vapor Absorption Refrigeration

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3. Industrial Refrigeration

 Industrial refrigeration systems for cold storage, process cooling, water chilling, individual
quick freezing.
 Up to 500 TR capacity using halocarbon or ammonia / environment friendly gas
 Complete with compressors, condensers, all vessels and electrical equipment required

UNIT OF REFRIGERATION

 A ton of refrigeration (TR): 1 TR is a unit of heat extraction capacity of the refrigeration or

cooling equipment. Generally, TR is defined as the amount of heat transferred to freeze or
melt 1 short ton of ice at 0 deg. C in 24 hours.

 1 TR: 12000 BTU

 1 TR: 3024 Kcal/hr of energy/heat load.

: 50Kcal/Min
 A variety of refrigerants are used in vapor compression systems. The choice of fluid is
determined largely by the cooling temperature required.

 Commonly used refrigerants are in the family of chlorinated fluorocarbons, CFCs, also known
as freons: R-11, R-12, R-21, R-22 and R-502.

 Nowadays, the most efficient and environmentally friendly refrigeration technologies are those
that use natural refrigerants. CFCFs refrigerants

 Such as NH3 (ammonia or R717), CO2 (carbon dioxide or R744) and hydrocarbons. In the
case of hydrocarbons, the refrigerant par excellence due to its efficiency is R290, commonly
known as propane.

Industrial Refrigeration Cycle

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4.A STEP-BY-STEP GUIDE FOR

INSTALLATION
General

 Installing an air conditioning unit can be an uphill task, especially if you’re not a specialist in
the field.

 You will need extensive knowledge of air conditioners and how to install them.

 Qualified HVAC technicians need to handle this task

 Various steps to the installation of a new air conditioner.

 Installing an air conditioning unit can be an uphill task, especially if you’re not a specialist in
the field.

 You will need extensive knowledge of air conditioners and how to install them.

 Qualified HVAC technicians need to handle this task

 Various steps to the installation of a new air conditioner.

1. Inspection

 At this stage, the technicians will also identify where they will fit the intended AC system.
 The existing space and location for the selected AC to be decided and prepared in
accordance of installation manual.

2. Site Preparation

 Appropriate pad for outdoor units should be prepared on the right location which has good
access both for installation and maintenance

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 Arrangement for refrigerant line passage should also determine and to be ready.

3. Fix Indoor Unit

 Indoor unit should fix near to the outdoor unit which has been predetermined before
installation.

 Maintenance access also be in consideration

4. Setting Up the outside Unit

 The technicians will then set up the air conditioner condenser on the setup pad earlier.

 Inspect for any damages that may have occurred in transit and transportation.

 If it’s in perfect shape, then fit the line and service valve of the unit.
 Once fitted in the valve, then melt the copper line set, service rod, and a filler rod used to join
the two together, forming a leak-free connection.

5. Laying of Refrigerant Lines

 The refrigerant line comprises two copper lines through which the refrigerant travels to the
outside condenser and back into the evaporator coil.

 HVAC technicians should install hangers around the area the refrigerator lines pass through
to ensure they stay in place.

 They will then roll out the lines and push them close enough to reach the valve of the outside
unit.

 They will also install a small low-voltage control wire connecting the thermostat to the room
and the outside unit.

 This will allow you to turn the air conditioner on and off.

6. Installation of Filter Dryer

 A filter dryer is installed in the air conditioner condenser as it absorbs moisture and provides
physical filtration.

 Many manufactures recommend that the filter dryer installation remains close to the
expansion valve at the indoor coil.

 This helps protect the filter dryer from bad weather that could cause it to rust.

7. Electrical Cable Installation

 Proper type and standard power cable with power controlling circuit should be installed.

 Controlling circuit can be fuse or ACB type for breaker or overcurrent protection listed by the
air conditioner manufacturers.

8. Condensat Drain Line Installation

 Moisture produced during the cooling process travels down a PVC pipe that connects to the
evaporator coil.

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 The evaporator has a primary and secondary drain, with the primary condensate drain
traveling from the coil to an appropriate drain or condensate pump.

 A condensate pump if the house does not have a floor drain.

9. Testing

• The final step involves testing the installed system.

• AC should Our turn on the air conditioner for 15 to 20 minutes. This is enough time for the
refrigerant to flow through the system and start the air conditioning process.

• Then commission will carry out and, it ensuring everything is in great shape.
• Commissioning the unit also ensures the manufacturer’s warranty is in full effect.

General

 Regular air conditioning maintenance pays off in two ways.

 While your AC runs smooth and keeps you cool without breaking down, it also saves you
money on energy bills.

 When an AC is put through regular maintenance, its efficiency is kept high and in turn, it uses
lesser energy.

Key Parts of an AC to be Maintained

5. Maintenance and Repair

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General

Safety Rules During AC Maintenance

1. Turn Power off

2. Wear Personal Protective Equipment (PPE)

3. Follow lock out / Tag out procedures

4. Handel refrigerant correctly

5. Use Material Safety data sheets (MSDA sheets)

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6. Keep tools & Equipment in good working order

1.Turn of Power

2. Wear Personal Protective Equipment (PPE)

HVAC personal protective equipment not only safeguards your health but preserves the senses so
that your eight hours on the job don’t rob you of a lifetime off of it. That’s why it is of paramount
importance to plug your ears, shield your eyes, cover your skin and otherwise protect yourself with the
best HVAC PPE the market has to offer.

3. Follow lock out / Tag out procedures

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4. Handel refrigerant correctly

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5. Use Material Safety data sheets (MSDA sheets)

Material safety data sheets (MSDS) are a type of document that provides information about the
composition and health hazards of a chemical. MSDS are used by manufacturers, distributors, and
users of chemicals to ensure safe handling practices. MSDS provide information about handling and
storing chemicals safely, as well as what first aid measures to take in case of exposure to hazardous
chemicals.

6. Keep tools & Equipment in good working order

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Air Conditioner Maintenance Tips

1. Clear/Replace air filter

 One of the most important AC maintenance tasks is to keep the air filter clean or replace it
when necessary.

 Clean the filter if AC comes with the reusable kind and if not, just replace it altogether.

 The frequency with which you need to do this depends upon where you live.

2. Check all wiring

 Before you perform this step, make sure to cut power supply to the air conditioner.

 Now remove your condensing units access panel and check if there are any melted
insulations or burned and broken wires.

 Locate the contactor switch and see if it shows too much pitting. If so, replace it.

 Check for any loose electrical connections throughout.

Measure the Input Voltage

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3. Check the thermostat

 One of the most important items in any air conditioner maintenance checklist, the thermostat
is used to maintain an ideal temperature.

 In case you are using an old-style mechanical thermostat, know that investing in a
programmable thermostat is absolutely worth it.


4. Check the Condensers Fan
 The fan of the condenser unit is very important for its proper functioning.
 To check if it is working properly, turn off the power to your wall mounted air conditioner and
examine the fans blades for any signs of chips or cracks.

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5. Clean The outer Body

 Since a part of your air conditioner is left exposed to outside elements, it tends to accumulate
a lot of debris like dirt, leaves, dead insects and even grass clippings.

 If not paid attention to, this build-up can reduce the air conditioners capacity and decrease the
air flow.

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