CentralAirConditioningPlants

Inourdepartment,theseplants(Aircooledorwatercooled)arecommonlyavailableabove10TR
upto100TR.ThesetypesofplantsaremoresuitableforlargeinstallationssuchasAIRRadioStudio/TV
StudioBuildingsandHighPowerTransmitterBuildings.Inwatercooledplants,externalcoolingtowers/
water spray ponds with water softening plants are the common features. These are invariably provided
withAHU(AirHandlingUnit)andsupply&returnductsforcarryingair.
Thecentralairconditioningplantsorthesystemsareusedwhenlargebuildings,hotels,theaters,airports,
shoppingmallsetcaretobeairconditionedcompletely.Thewindowandsplitairconditionersareusedfor
singleroomsorsmallofficespaces.Ifthewholebuildingistobecooleditisnoteconomicallyviabletoput
window or split air conditioner in each and every room. Further, these small units cannot satisfactorily
coolthelargehalls,auditoriums,receptionsareasetc.
In the central air conditioning systems there is a plant room where large compressor, condenser,
thermostaticexpansionvalveandtheevaporatorarekeptinthelargeplantroom.Theyperformallthe
functionsasusualsimilartoatypicalrefrigerationsystem.However,allthesepartsarelargerinsizeand
havehighercapacities.Thecompressorisofopenreciprocatingtypewithmultiplecylindersandiscooled
by the water just like the automobile engine. The compressor and the condenser are of shell and tube
type.Whileinthesmallairconditioningsystemcapillaryisusedastheexpansionvalve,inthecentralair
conditioningsystemsthermostaticexpansionvalveisused.
Thechilledispassedviatheductstoalltherooms,hallsandotherspacesthataretobeairconditioned.
Thusinalltheroomsthereisonlytheductpassingthechilledairandtherearenoindividualcoolingcoils,
andotherpartsoftherefrigerationsystemintherooms.Whatiswegetineachroomisthecompletely
silent and highly effective air conditions system in the room. Further, the amount of chilled air that is
neededintheroomcanbecontrolledbytheopeningsdependingonthetotalheatloadinsidetheroom.
Thecentralairconditioningsystemsarehighlysophisticatedapplicationsoftheairconditioningsystems
andmanyatimestheytendtobecomplicated.Itisduetothisreasonthatthereareveryfewcompanies
intheworldthatspecializeinthesesystems.Inthemoderneraofcomputerizationanumberofadditional
electronicutilitieshavebeenaddedtothecentralconditioningsystems.
Therearetwotypesofcentralairconditioningplantsorsystems:

1)DirectexpansionorDXcentralairconditioningplant:
Inthissystemthehugecompressor,andthecondenserarehousedintheplantroom,whiletheexpansion
valveandtheevaporatororthecoolingcoilandtheairhandlingunitarehousedinseparateroom.The
coolingcoilisfixedintheairhandlingunit,whichalsohaslargeblowerhousedinit.Theblowersucksthe
hotreturnairfromtheroomviaductsandblowsitoverthecoolingcoil.Thecooledairisthensupplied
throughvariousductsandintothespaceswhicharetobecooled.Thistypeofsystemisusefulforsmall
buildings.

2)Chilledwatercentralairconditioningplant:


Thistypeofsystemismoreusefulforlargebuildingscomprisingofanumberoffloors.Ithasthe
plantroomwherealltheimportantunitslikethecompressor,condenser,throttlingvalveandthe
evaporatorarehoused.Theevaporatorisashellandtube.OnthetubesidetheFreonfluidpassesat
extremelylowtemperature,whileontheshellsidethebrinesolutionispassed.Afterpassingthroughthe
evaporator,thebrinesolutiongetschilledandispumpedtothevariousairhandlingunitsinstalledat
differentfloorsofthebuilding.Theairhandlingunitscomprisethecoolingcoilthroughwhichthechilled
brineflows,andtheblower.

Theblowersuckshotreturnairfromtheroomviaductsandblowsitoverthecoolingcoil.Thecool
airisthensuppliedtothespacetobecooledthroughtheducts.Thebrinesolutionwhichhasabsorbed
theroomheatcomesbacktotheevaporator,getschilledandisagainpumpedbacktotheairhandling
unit.Tooperateandmaintaincentralairconditioningsystemsweneedtohavegoodoperators,
techniciansandengineers.Properpreventativeandbreakdownmaintenanceoftheseplantsisvital.

Figure5,showingcontrolpanel,compressor,condenserandaccessories

Figure6,ShowingviewofAirConditioningPlantRoom

Figure7,ShowingoveralllayoutofAirConditioningSysteminamultistorybuilding

Aircycle

Figure8,ShowingoveralllayoutofAirConditioningDuctSysteminamultistorybuilding

Indoorairmaybetoocold,toohot,toodry,toowet,toodraftyortoostill.Theseconditionsare
changedbyrotatingtheairandthesetreatmentsareprovidedintheairconditioningaircycle.
Air distribution system directs the treated air from the air conditioning equipment to the space to be
conditionedandthenbacktotheequipment.Themaincomponentsintheaircycleare

(i)Fan

(ii)Supplyduct
(iii)SupplyOutlets
(iv)Returnoutlets
(v)Returnduct

(vi)Filter

(vii)Coolingcoil(orheatingcoilforlowtemperatureareas).

Thetotalresistanceofthesecomponentstotheflowoftheairplusthefrictionresistancecaused
bytheairpassingthroughtheductrunaremajorfactorsindeterminingthesizeofthefanandfanmotor
andtheamountofairpressurethatisrequired.

ForaBroadcastStudiosetupthisresistanceisoftheorderof25mmto50mmofwatergauge.
Centrifugalfanismostcommonlyusedincommercialandresidentialinstallations.Itconsistsofascroll,a
shaftandawheel.Thescrollisactuallyahousingfortheshaftandwheelandtheshaftservesasanaxle
forthewheel.Thewheeliscylindricalinshapeandhasmanyblades.Centrifugalfansareavailablewith
forwardorbackwardcurvedblades.Aforwardcurvedfancandeliverarequiredquantityofairatlowfan
speed.Theairvelocityandspeedofthefanwheel(tipspeed)notonlyplayalargepartindeterminingthe
efficiencyofthefanbutalsoaffectthelevelofnoisegeneratedbythefan.Hightipspeedandhighvelocity
usuallyresultinmorenoise.

Remotelocationofthefanreducesthenoisebutthesystembecomemoreexpensive.Ductsmay
becircular,rectangularorsquareinshape.Fromtheappearanceandpracticalpointofview,rectangular
ductsaregenerallyadopted.Ductsarefabricatedfromawidevarietyofmaterials.Ductsmadeofsheet
metal are very common. The ducts are lined with glass wool or mineral wool slabs of 25 mm thickness
wrappedincoppernaphthanatetreatedcloth.

Outletsareanothermajorpartoftheairdistributionsystem.Theyareimportantfromthepointof
viewofappearance,functionsandperformance.Theprimaryfunctionoftheoutletsistoprovideproperly
controlleddistributionofairtotheroomandremovingtheairfromtheroom.
Ceilingdiffusers,grillesandregistersareusedassupplyoutletandgrillesareusedasreturnoutlets.
Operation
Beforestartingtheplant,ensurethatproperfunctioningofsafetycontrolsincludinginterlockcircuithave
beencheckedandcorrectlyset,andthatallmotorsaremeggertested,directionofrotationverified,all
bearingslubricatedandrefrigerationsystemfullycharged.Thecrankcaseheatermustbeenergisedwell
inadvance.
Proceedstepbystepforoperatingthesystemasfollows:

Starttheairhandlingunit,ensuringthatdampersinthesupplyductarefullyopen.
Openallwatervalvesandstartthewaterpump.Observepressuresatcondenserinletandoutlet.
Open hotgas valve on the condenser and the discharge service valve on the compressor. Open
dischargegaugevalvetoreadthepressure.
Followthesameprocedureandreadthesuctionpressure.
Openliquidlinevalve.Observestandingpressureonthegauges.Thisshouldbeapproximately7.03
2

kg/cm (100psi)forR12and10.5kg/cm (150psi)forR22toindicatethatthesystemistightwith

noleakage.
Open suction service valve and start the compressor. Observe the refrigerant and oil pressures.
Checkthecurrentdrawnbythecompressormotor,observetheoillevelinthecompressorsight
glass.Oilshouldbeclearwithoutfoamafteroperationhasstabilised.

CompressorPumpDown

It is essential to collect the refrigerant in the condenser with isolation to prevent its loss before
opening the compressor or any other part of the system. This is called pumpdown and the operation
involvesthefollowingprocedure:

Shortthelowpressureswitchwithatemporaryjumperwiresothatthecompressordoesnotstop
beforetherefrigerantfromitisemptied.
Slowlyclosethesuctionvalvewiththecompressorrunning.
2

Whenthesuctionpressuredropstoabout0.15kg/cm (2psi),stopthecompressor.
2

Neverpumpthecompressorbelow0.15kg/cm topreventinfiltrationofmoistureanddirtintothe
crankcase.
Afterafewminutes,thedissolvedrefrigerantwillleavethecrankcaseraisingthesuctionpressure.
Thisadditionalrefrigerantcanbepumpedtothecondenserbyoperatingthecompressoragainfor
ashortwhile.
2

Repeattheaboveproceduretillthesuctionpressuredoesnotriseabove0.15kg/cm afterclosing
theservicevalves.

RemovingRefrigerantfromtheSystem
Itmaybenecessarytoremovetherefrigerantfromthesystemintoacylinderifthereisanexcesscharge
orthereisaleakinthecondenser.Takethefollowingstepsforthisoperation:
(a) Connect a suitable line between the angle valve provided for charging and an empty refrigerant
cylinder.
(b)Purgetheairfromtheconnectionline.
(c) Keep the cylinder cold by immersing it in ice cold waterto ensure afaster refrigerant flow from the
system.
(d) Start the compressor and open the liquid line charging valve, allowing the liquid into the empty
cylinder. If excess refrigerant is to be removed, hold the charging valve open only until the
dischargepressurereachesthenormalreading.Afterthisoperation,removethecharginglineand
closethechargingvalve.

Donotoverchargethecylinderasexcessivepressureisdangerous.
PurgingNonCondensibleGases
Presenceofnoncondensiblesgasessuchasaircauseshighdischargepressure,resultinginreductionof
capacityandhighpowerconsumption.Incasesuchsymptomsarepresent,thefollowingcheckshouldbe
done:
Shutdownthesystemovernight,longenoughforthetemperatureofallcomponentstoleveloff.
Readthestandingpressureandcompareitwiththerefrigerantsaturationpressurecorrespondingto
the temperature of the system. If the standing pressure exceeds the saturation pressure by 0.75
2

kg/cm (10psi)ormore,thenoncondensiblesareexcessiveandmustberemoved.

Forexample,ifR22isusedandthesystemtemperatureis85 F(29.4 C)andstandingpressureis12.8

2

kg/cm (175psi),thenthereisexcessofnoncondensibles.SaturationpressureforR22correspondingtoa
o

temperature85 Fis11kg/cm .Thedifferenceis1.05kg/cm morethan0.75kg/cm ,indicatingcorrective

purging.Forpurging,takethefollowingsteps:
Pumpdownthesystemasdescribedearlier.
Immediatelyafterstoppingthecompressor,closethecompressordischargevalve.
Runthewaterthroughthecondensorforcondensationofrefrigerantvapour.
Crackopenthepurgevalveonthetopofthecondensorforaninstant,shutitagain.
Allow the system to stabilize for a few minutes before reopening and closing the purge valve.
Repeatedpurgingandclosingoperationshouldclearthesystemofnoncondensible.
Restorenormalsystemoperation,checktheimprovementindischargepressure.Checkrefrigerant
chargeandcompressoroilpressure.

RefrigerantCharging

A correct operating charge of refrigerant in the system is essential. Loss due to leakage in the
system has to be made up. It may be necessary to replace the entire charge. An over charge results in
unduly high temperatures, pressures and operating costs and may damage the system components. An
undercharged system leads to insufficient cooling, high operating cost, and, in hermetic system, the
compressormotormayfail.

Refrigerantmaybeaddedtothesystemeitherasavapourorliquiddependinguponthelocation
of charging point and quantity required. Generally, for adding makeup refrigerant, vapour charging
methodismoreconvenient.Fortotalsystemcharge,liquidchargingatthehighsidefollowedbyvapour
chargingatcompressorlowsidewillbequicker.

Under no circumstances should liquid refrigerant be allowed to enter the compressor to avoid
damagetothecompressor.Theprocedureforvapourchargemethodisdescribedbelow:

Openthesuctionanddischargeshutoffvalvesofthecompressor.Installagaugeinthedischarge
gaugeportandopenthegaugelineifagaugeporthasnotbeenprovided.
Connect a refrigerant cylinder and the connection with a compound gauge, to the charging valve
providedoncompressorsuctionline.Purgetheairfromthelinesandtightentheconnections.
Admit the refrigerant by slowly opening the refrigerant cylinder. The cylinder should be kept in
uprightpositiontopreventtherefrigerantfromenteringthecompressorinliquidstate.
Startthecompressor.
As the cylinder gets emptied, its pressure will drop to the same level as the suction pressure. The
remaining refrigerant can be drawn from the cylinder by closing the suction shut off valve and
pullingavacuumonthecylinderwiththecompressorrunning.
Checkthequantityofrefrigerantchargebynotingthedifferenceintheweightofthecylinderand
observingthepressure.

WaterTreatment

Algae/slime scale and corrosion on the water side of the heat transfer equipment retards heat
transfer causing general loss of efficiency and breakdowns. Oxygen, Carbon Dioxide, Sulphur Dioxide
absorbed from the air and dissolved in water cause corrosion, reducing the capacity of lines, increasing
frictionallossesandpumpingcost.Hardwatercausesscalingproblem.Whenheated,themineralsareleft
behind,whichformadepositontheheatexchangersurface.Theheattransferratingofthescaleisvery
much lower than metal. Retarded heat transfer results in increased discharge pressure causing loss in
capacityandincreasedpowerconsumption.

Scalingofthecondensortubesinarecirculatedwatersystemisunavoidable.Descalinghastobe
carriedoutasapreventivemaintenanceonceevery12monthsorearlierdependingonthehardnessof
thewater.Descalingcanbecarriedoutquiteconvenientlybycirculatingmildinhibitedacidsolutionwith
thehelpofasmallpumpconnectedacrossthecondensorinletandthewatervalvesareclosedtoconfine
thecirculationtothecondenseronly.

Chemical compounds are available which suspend minerals of dissolved scale. Algae attach
themselvestothesurfaces,andsincetheyarelivingplants,theygrowuntiltheyclogthepassagesofthe
system. Bacteria forms slime and close the system in much the same way as algae. Algae/Slime is
controlledbyuseoftoxic.Aspecialistshouldbeconsultedtodeterminethealgae/slime.

Thetroubleshouldbediagnosedasaccuratelyaspossiblebeforeanyrepairisattempted.Definite
symptomswillaccompanyafaultyoperationinthesystem.Thefollowingtroubleshootingchartwillhelp
infaultlocationandpromptcorrection:

********

TONNAGE MEASUREMENT OF AC PLANTS

(I) By air-flow method
Tonnage of refrigeration (TR) = A x V x (H1 - H2) {FPS units}
S
200

Where
A = Cross sectional area of duct through which air is passing in sq. ft.
V = Air velocity per minute, in Ft. per minute, measured by anemometer in
ft./min
S = Specific volume of (return) air
H1 = Enthalpy for return air, in Btu/lb
H2 = Enthalpy for supply air, in Btu/lb
Note:
Both H1 and H2 are determined from the psychometric chart with help of Dry bulb
temperature (Tdb in deg F.) and Wet bulb temperature (Twb in deg F.) Similarly
Specific volume (S) is determined from the psychometric chart
Example 1:
Calculate Tonnage of AC Plant having the following measurement figures:
A = 30.25 sq. ft.
V = 293 Ft. per minute
S = Specific volume of return air = 13.7 cubic Ft./ Lb.
For Return duct,
For Supply duct,

Tdb = 73 0F and Twb = 670 F. ------------- (X)

Tdb = 53 0F and Twb = 490 F. ------------- (Y)

Calculations:
H1 = Enthalpy for return air, in Btu/ Lb, determined from psychometric chart in r/o
(X)
= 31.8 Btu/Lb.
H2 = Enthalpy for supply air, in Btu/ Lb, determined from psychometric chart in r/o
(Y)
= 19.8 Btu/Lb.
S = Specific volume of return air = 13.7 cubic Ft./ Lb.
Therefore Tonnage = Tonnage of refrigeration = A x V x (H1 -H2)TR
S
200
= Tonnage of refrigeration = 30.25x293 x (31.8 19.8) TR
13.7
200
= 38.8 TR (Answer)

(II)

By Water-flow method

Points to be remembered:

1Watt

0.86 k Cal / Hr** (unit of power i.e. rate of energy)

1 Watt

3.412 Btu / Hr*

or [1 Btu = 1 3.412 Watts]

1 k Watt =

3412 Btu / Hr

or [1 Btu = 1 3412 k Watts] #

1 Btu

0.252 k Cal

1 Ton

12000 Btu / Hr

200 Btu / Min

50 k Cal / Min

[200 Btu x 0.252 k Cal]

3024 k Cal / Hr

[200 Btu x 0.252 k Cal x 60 Min]

3.561 kW

# [12000 3412 = 3.561]

Heat gained by water = { Q x Sp. Heat x (Th Tc) x 60} Btu/Hr ---- (A)
= heat rejected by the refrigerant in the condenser
Heat developed due to work done by compressor = {

3 V x I x Cos } Watts
= { 3 V x I x Cos x 3.412}*Btu/Hr ----- (B)
Or = { 3 V x I x Cos x 0.86} ** k Cal /Hr

Refrigeration capacity in TR =
[Heat gained by water in Btu/Hr] [Heat developed due to work done by compressor in Btu/Hr]
12000
= (A) - (B)

12000

= { Q x Sp. Heat x (Th Tc) x 60} { 3 V x I x Cos x 3.412}

12000
Where

Q = Quantity of water flowing through the water cooled condenser in Ltr/ Min
Th
= Temperature after condenser in0 F
Tc
= Temperature before condenser in 0 F

Sample measurements
Q = Quantity of water flowing through the water cooled condenser = 620 Ltr/ Min
Th
= Temperature at condenser outlet = 990 F

Tc
= Temperature at condenser inlet = 920 F
V
= compressor Voltage = 390 Volts
I
= compressor Current = 60 Amp
Cos = Power Factor = 0.85
Calculations:
(A) = Heat rejected by the refrigerant in the condenser
=Qx
= 620

Sp. Heat x (Th Tc) x 60 Btu/Hr

x 2.204 x (99 92) x 60 = 57,3922 Btu/Hr

(B) = Heat developed due to work done by compressor

= { 3 V x I x Cos x 3.412} Btu / Hr
= { 3 x 390 x 60 x .85 x 3.412} Btu / Hr = 11, 7476 Btu / Hr

Refrigeration capacity in TR =

(A) - (B) = (57,3922) - (11,7476)

12000
12000

= 38 TR, ANSWER

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HVACAirConditioningTroubleshootingandRepair

ThefollowingisangeneralA/Csystemtroubleshootingguide.Realizethatitisgenericandmanyofthe
thingslistedheremaynotapplytothe944.
Symptom/PossibleCause
LowCompressorDischargePressure
1.Leakinsystem
2.Defectiveexpansionvalve
3.Suctionvalveclosed
4.Freonshortage
5.Pluggedreceiverdrier

Solutions
Repair
1.Repairleakinsystem
2.Replacevalve
3.Openvalve
4.Addfreon
5.Replacedrier

6.Compressorsuctionvalveleaking
7.Badreedvalvesincompressor

6.Replacevalve
7.Replacereedvalves

HighCompressorDischargePressure
Repair
1.Airinsystem
1.Rechargesystem
2.Cloggedcondenser
2.Cleancondenser
3.Dischargevalveclosed
3.Openvalve
4.Overchargedsystem
4.Removesomerefrigerant
5.Insufficientcondenserair
5.Installlargefan
6.Loosefanbelt
6.Tightenfanbelt
7.Condensernotcenteredonfanortoofarfrom
7.Centerandcheckdistance
radiator
LowSuctionPressure
1.Refrigerantshortage
2.Worncompressorpiston
3.Compressorheadgasketleaking
4.Kinkedorflattenedhose
5.Compressorsuctionvalveleaking
6.Moistureinsystem
7.Trashinexpansionvalveorscreen

Repair
1.Addrefrigerant
2.Replacecompressor
3.Replaceheadgasket
4.Replacehose
5.Changevalveplate
6.Replacedrier
7.Replacedrier

HighSuctionPressure
1.Looseexpansionvalve
2.Overchargedsystem
3.Expansionvalvestuckopen
4.Compressorreedvalves
5.Leakingheadgasketoncompressor

Repair

CompressorNotWorking
1.Brokenbelt
2.Brokenclutchwireorno12vpower
3.Brokencompressorpiston
4.Badthermostat
5.Badclutchcoil
6.LowRefrigerantlowpressureswitchhascut
offclutchpower
EvaporatorNotCooling
1.Frozencoil,switchsettoohigh
2.Drivebeltslipping
3.Hotairleaksintocar
4.Pluggedreceiverdrier
5.Capillarytubebroken
6.Shortageofrefrigerant
7.Highheadpressure
8.Lowsuctionpressure
9.Highsuctionpressure

1.Tightenvalve
2.Removesomerefrigerant
3.Replaceexpansionvalve
4.Replacereedvalves
5.Replaceheadgasket
Repair
1.Replacebelt
2.Repairwireorcheckforpower
3.Replacecompressor
4.Replacethermostat
5.Replaceclutchcoil
6.Addrefrigerant
Repair
1.Turnthermostatswitchback
2.Tightenbelt
3.Checkforholesoropenvents
4.Replacedrier
5.Replaceexpansionvalve
6.Addrefrigerant
7.Seeproblem#2
8.Seeproblem#3
9.Seeproblem#4

10.Defectiveexpansionvalve
11.Frozenexpansionvalve

10.Replaceexpansionvalve
11.Evacuateandreplacedrier
Repair
1.Replacethermostat
2.Settodrivingcondition
3.Checkforexcessiveducthoselength,
kinkorbend.

FrozenEvaporatorCoil
1.Faultythermostat
2.Thermostatnotsetproperly
3.Insufficientevaporatorair
ACSystemGaugeReadings

ThefollowingtableisageneralguidelineforA/Csystempressuresandtemperaturesbasedonambient
outsidetemperature.Rememberthattheseareaguidelineandyouractualtemperaturesandpressures
willvarydependingonhumidityintheairandtheconditionofyoursystem.
A/CSystemPressureReadings
AmbientTemperature

LowSidePressure

HighSidePressure

CenterVentTemperature

60F

2838psi

130190psi

4446F

70F

3040psi

190220psi

4448F

80F

3040psi

190220psi

4348F

90F

3540psi

190225psi

4450F

100F

4050psi

200250psi

5260F

110F

5060psi

250300psi

6874F

120F

5565psi

320350psi

7075F

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