FORUM

Testing inverter type air conditioners

for field performance
Dr Satya Mavuri (BE MSc PhD), M.AIRAH, Vipac Engineers and Scientists Ltd.

ABSTRACT
Considerable technological advancement in domestic air conditioner (AC) designs over the past few decades has seen recent
developments in variable-speed compressor (inverter) operation. Current test standards allow inverter AC (IAC) manufacturers
to lock the compressor speed for a desired rated capacity. However, it is proposed that rating the inverter under locked mode
is unrealistic, as it does not reflect the way inverters operate in real operation.
In this study, an unlocked mode test method is discussed for testing IAC for field behaviour, and the results are compared
to locked laboratory performance. For almost all inverter units tested, efficiency degradation was recorded in unlocked modes
compared to when tested in locked mode for similar output capacity. It is suggested a new test method be considered for IAC unit
performance in unlocked mode offering an alternative and more realistic field behaviour assessment.

KEY WORDS
Air conditioner, test standard, calorimeter, inverter, performance, locked, unlocked

INTRODUCTION conditioning system to regulate energy required to achieve

IACs
An AC is a mechanism designed to change and control the
air temperature and humidity within an area (in Australia,
these are used primarily for cooling and sometimes heating).
The operation is typically performed by a simple refrigeration
(vapour compression) cycle, shown in Figure 1 below.
the desired indoor space temperature conditions. It functions
like the accelerator of a car, gently increasing or decreasing
power. It maintains the desired temperatures without wild
fluctuations. Figure 2 shows room temperature during the
operation of a fixed-speed AC and IAC unit.
TEMP.

COMPRESSOR OFF
COMPRESSOR COMPRESSOR
INLET OUTLET
COMPRESSOR CONDENSER SET
SUCTON LINE DISCHARGE LINE TEMP.
CONDENSER FAN
WARM AIR
OUT COOLS A ROOM IN COMPRESSOR OFF
AMBIENT (OUTSIDE) AIR LESS TIME SMALL TEMP.
DIFFERENCE
IN
START TIME
DURING COOLING
INVERTER TYPE OPERATION
WARM RETURN AIR LIQUID LINE COMFORTABLE TEMPERATURE TEMPERATURE NON-INVERTER TYPE
IN TEMPERATURE TOO HOT TOO COLD
COOL
SUPPLY AIR REFRIGERANT FLOW Figure 2: Illustration of IAC operation,
OUT EVAPORATOR BLOWER courtesy: www.daikin.com.au

EVAPORATOR METERING DEVICE DRIER
Figure 1: AC operation principle, courtesy:
www.air-conditioning-and-refrigeration-guide.com
A typical refrigeration cycle uses an electric motor to drive
a compressor. The two most common types of compressors are
the fixed-speed type and the variable-speed (inverter) type.
With conventional fixed-speed air conditioners, the compressor
is either on (working to 100% capacity) or off.
An inverter in an air conditioner is used to vary the compressor
motor speed in order to drive variable refrigerant flow in an air
IAC manufacturers claim that IACs are more powerful and
energy-efficient, and provide uninterrupted comfort, significant
savings on running costs, and are also quieter compared to the
fixed-speed unit operation.
IAC and MEPS
ACs sold in Australia must be tested to Australian New Zealand
test standard AS/NZS 3823, comply with the Minimum
Energy Performance Standards (MEPS) and be registered
in a government database1. The Greenhouse and Energy
Minimum Standards determination (GEMS1) regulates
vapour compression-type appliances (ACs and heat pumps).

44 E CO L I B R I U M A P R I L 2 0 1 4
 FORUM

Australian statistics2 suggest that more than 80% of ZONE 3 ZONE 4

the registered AC products are single-phase, non-ducted,
ZONE 1 ZONE 2
reverse-cycle and inverter-type units. Over the years, there is AIR CONDITIONER
a clear domestic market shift from fixed speed units towards COIL REMOVAL
HEAT FLOW
COIL REMOVAL
inverter-type, primarily due to their technological advancement
in operation over the fixed-speed ACs. Realistic test results are
important for the consumers benefit and in estimating and
meeting the overall energy minimum targets. HEATING INPUT HEATING INPUT

Calorimeter test method

LOSSES

LOSSES
OUT SIDE ROOM SIDE
The calorimeter provides a method for determining the
capacity of an AC simultaneously on both the indoor side
and the outdoor side.
Figure 4: Cooling test power balance.

ZONE 3 ZONE 4
2 ZONE 1 ZONE 2
2 1
1 AIR CONDITIONER
HEAT FLOW
COIL REMOVAL COIL REMOVAL
4
3

HEATING INPUT HEATING INPUT

3
4

LOSSES

LOSSES
OUT SIDE ROOM SIDE

1 Outer chamber Controlled temperature air space 2 Room reconditioner

3 Air sampler 4 Typical split, non-ducted air-conditioner with connected refrigerant piping Figure 5: Heating test power balance.

Figure 3: Typical balanced ambient calorimeter

chamber courtesy: www.gzlans.com Need for locked mode IAC tests
in a calorimeter with normal RRU controls
The balanced ambient room-type calorimeter, shown
IACs work as fixed capacity units if their operating speed
in Figure 3, is based on the principle of maintaining the
is locked. When the IAC unit is tested without locking its
temperature surrounding the particular compartment equal
compressor speed, inverter controls and normal RRU controls
to the temperature maintained within that compartment,
work against each other. A fluctuating AC power input from a
providing stable room conditions, reduced losses from each
variable-speed compressor and the corresponding fluctuating
room, and achieving lower uncertainties in the test results.
capacity output may have counter-responding RRU controls.
The equipment is installed in a manner similar to a normal This may result in non-stable room temperature conditions.
installation. Each room reconditioning unit (RRU) works on Hence, the compressor speed is locked during the testing and
automatic controls by adjusting the active load to achieve IAC is rated at the corresponding capacity.
the desired room test conditions. Two test conditions are
The current air conditioners test standards requires IAC
shown in Table 1. manufacturers to fix the compressor speed and rate the units
based on locked tests. The locked instructions for fixing
the compressor speed are supplied by the manufacturer. During
Rating Air-on T1 H1 capacity tests, input power is locked and capacity is determined
test conditions Cooling Heating from the calorimeter principles as a typical fixed-speed AC
test. This locked method of testing IAC units is found to be
Indoor Dry-bulb 27C 20C
repeatable to within 3%.
side Wet-bulb 19C 15C
Dry-bulb 35C 7C IAC Laboratory performance
Outdoor
side The capacity of a typical IAC in locked mode is directly
Wet-bulb 24C 6C
proportional to the compressor speed, but its efficiency drops
with capacity as shown in Figure 6.
Table 1: AS/NZS 3823 standard test conditions
An IAC units performance is typically labelled at a desired rated
Figures 4 and Figure 5 show a schematic of the balanced ambient capacity, which is normally lower than the full-load capacity.
calorimeter system and power fluxes during a capacity test. In The regulations also allow inverter units to register by complying
steady-state conditions, the capacity of an AC (indoor or outdoor with 95% MEPS requirements at rated efficiencies and at part-load
side) is measured as power that each chamber has to supply to efficiencies, which need to be between 50100% of rated-load capacities.
the system to keep the same temperature conditions equivalent In most IAC units, the unit controls appear to be optimised for higher
to the power removed or added by the AC in each chamber. efficiencies under test conditions with locking instructions.

A P R I L 2 0 1 4 E CO L I B R I U M 45
 FORUM

5.0 It is also difficult to conduct part-load performances

when no locked instructions are available.
4.5 50% of
Rated-load Inverter Efficiency Locked
Test standards define a circumvention device as any control,
Efficiency (kW/kW)

4.0 control device, software, component or part that alters the

operating characteristics during any test procedures, resulting
3.5 Rated-load in measurements that do not represent an appliances true
characteristics that may occur during normal use under
3.0 Full-load comparable conditions. Generally, circumvention devices save
energy during an energy test, but not during normal use. Hence,
2.5 Part-load
the inverter speed locking instructions can be inferred as
a circumvention device. The standards, however, specify that
2.0
25% 50% 75% 100% 125% 150% any AC shall not contain any circumvention device.
Rated Capacity
(ii) Verification tests
Figure 6: Typical performance of IAC unit in locked
or laboratory mode. Verification (check) tests are likely on registered AC products,
which helps maintain the quality of registered products being
CHOICE3 mentions that the current test standard method of allowing the sold in Australia and New Zealand. In most instances, the
IAC compressor speed to be fixed at a certain rated capacity is unrealistic. GEMS regulator does not have enough information on locked
instructions. Sometimes these instructions are performed
Other Issues through special software/hardware, and may require authorised
(i) Current test standards personnel to operate it. Obtaining information for locking the
When there are no locked instructions from the inverter speed from manufacturers prior to or during check-tests,
manufacturers, current test standards allow a deviation may compromise the veracity of the check tests, delay the process
from the locked method, by testing IAC units at peak cooling and open up other complications. Currently during check tests,
and heating settings. But this method produces full-load there are no requirements to match the compressor speed to
capacities, which may be different to rated-load results. registered value or to measure the compressor speed and report.

The mycoolingtower.com.au website has been developed by AIRAH as part of a collaboration between industry groups, water corporations
46 E CO L I B R I U M A P R I L 2 0 1 4
and the Victorian government providing best practice information and tools to help businesses operate cooling towers water and energy efficiently.
 FORUM

Test method for field behaviour IAC unit 2

Under current laboratory test conditions, the IAC unit is
operated at a locked compressor speed (hence fixed power input), Cooling capacity Registered Lab test Field test
but in field conditions (i.e. the consumers home/office), the unit T1 test-rated load value locked unlocked
operates to match the room load. This field performance can be
different to the laboratory operation. Hence the locked rating Cooling capacity (kW) 410 - 0.8% + 0.6%
can mislead consumers, as the test results reflect laboratory Power input (kW) <3 + 0.5% + 10.1%
performance rather than field performance. AEER (kW/kW) >3 - 1.0% - 8.2%
Currently, there is no accepted test method available in the Compliance to MEPS PASS PASS FAIL
public domain to test the IAC units under field behaviour.
In this study, a new method for unlocked mode tests on Table 3: IAC-2 cooling: laboratory vs field behaviour.
IACs is discussed and the associated efficiency was evaluated.
This study highlights the findings from various inverter products
tested at Vipac using an unlocked mode and compares the IAC unit 3
results to the traditional locked mode.
When tested in an unlocked mode, the indoor test room Cooling capacity Registered Lab test Field test
is given an almost fixed thermal load, and the inverter unit T1 test-rated load value locked unlocked
under test adjusts its speed or the power input to meet the
load. Because the RRU generated a fixed effective heating or Cooling capacity (kW) <4 - 0.9% + 0.6%
cooling capacity, the indoor room temperatures can fluctuate Power input (kW) <1 - 1.8% + 56.9%
depending on operation of the test IAC. The IAC test operation AEER (kW/kW) >4 + 1.0% - 35.7%
is adjusted with the remote controller to achieve a close match
to the indoor-unit room temperatures required by the test Compliance to MEPS PASS PASS FAIL
standard. Temperature resolution on remote (usually 1C)
Table 4: IAC-3 cooling: laboratory vs field behaviour.
could affect the stability of the final indoor room conditions.
The final remote temperature setting may show a different value
to the actual room condition. Outdoor room conditions are
maintained at the same as the standard test conditions. Heating capacity
Registered Lab test Field test
For example, when 50% of the rated-load cooling experiment H1 test-rated
value locked unlocked
in unlocked mode was conducted using a rated 4kW IAC unit, vs full load
with RRU controls first, both the indoor-unit room as well as Heating capacity (kW) <4 - 0.1% + 24.4%
the outdoor-unit room were set to the desired test conditions.
Power input (kW) <1 - 0.7% + 70.4%
After the temperatures of the indoor-unit room and outdoor-
unit room were stabilised, IAC was operated at the set room ACOP (kW / kW) >3 + 0.7% - 26.8%
temperatures. The RRU in the indoor-unit room was locked Compliance to MEPS PASS PASS FAIL
to produce effective heating output of 2kW (50% of the rated
cooling capacity) to obtain the designated 50% of rated load. Table 5: IAC-3 heating: laboratory vs field behaviour.
The AC unit would tend to make the indoor room temperature
lower or higher than the required temperature conditions. Then,
the remote controller would need to be reset in order to keep the
Rated COOLING Test T1 Conditions - Unlocked Mode
indoor room at the required condition as per the test standard. Indoor & Outdoor Temperature, Relative Humidity and Power Input
Once stable operation was obtained, the IAC unit capacity was 100
1400
calculated from the Calorimeter principles. 90
80 1200
IAC Unit 1 70
Temperature (C) and RH (%)

1000
The Annual Energy Efficiency Ratios (AEER) or Annual Coefficient 60
Power (Watts)

800
of Performance (ACOP) was calculated from measured capacity 50
and electrical energy consumption including the non-operating 40 600
power. MEPS compliance in accordance with AS/NZS 3823 was 30
400
evaluated from the calculated AEER and ACOP values. 20
200
10
0 0
Cooling capacity Registered Lab test Field test 8:52 a 9:07 a 9:21 a 9:36 a 9:50 a 10:04 a 10:19 a 10:33 a 10:48 a
T1 test-rated load value locked unlocked Indoor Drybulb Outdoor Drybulb
Time
Indoor RH Outdoor RH Unit power input
Cooling capacity (kW) 410 - 6.7% - 0.1%
Figure7: IAC-3 cooling: rated-load unlocked mode
Power input (kW) >2 + 3.7% + 25.4%
AEER (kW/kW) >3 - 10.0% - 20.3%
Compliance to MEPS PASS FAIL FAIL
A final 21C remote setting produced 26.7C of room
Table 2: IAC-1 cooling: laboratory vs field behaviour. air-on temperature (27C is required, see Table 1, T1).

A P R I L 2 0 1 4 E CO L I B R I U M 47
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COOLING Test T1 Conditions - Part-load Unlocked Mode a matching load) and the corresponding efficiency under
Indoor & Outdoor Temperature, Relative Humidity and Power Input
100 350
simulated field conditions were measured.
90
300 Some IAC units have produced fluctuating behaviour in
80 unlocked tests, but they ran with a very stable power input,
250
70 and provided stable room conditions under locked mode
Temperature (C) and RH (%)

60 200 operation.

Power (Watts)
50
40
150 In general, IAC units used much higher electric power than
30 100
the rated or locked value when subjected to a thermal
20 load equivalent to the rated capacities under field behavior.
50 Some units also failed to meet MEPS under unlocked mode
10
0 0 operation.
2:52 p 3:21 p 3:50 p 4:19 p 4:48 p 5:16 p Time
5
Indoor Drybulb Outdoor Drybulb Indoor RH Outdoor RH Unit power input

4.5 50% of
Rated-load Inverter Efficiency Locked
Figure 8: IAC-3 cooling: part-load unlocked mode.

Efficiency (kW/kW)
Inverter Efficiency Unlocked
A final 26C remote setting produced 27.4C of room air-on 4.0
temperature (27C is required, see Table 1, T1).
3.5 Rated-load
HEATING Test H1 Conditions Unlocked Mode
Indoor & Outdoor Temperature, Relative Humidity and Power Input
100 1400 3.0 Full-load
90
1200 Part-load
80 2.5
1000
Temperature (C) and RH (%)

70
60 800 2
Power (Watts)

50 25% 50% 75% 100% 125% 150%

600 Rated Capacity
40
30 400
Figure 11: Observed IAC performance locked vs unlocked tests.
20
200
10 As displayed, at the maximum compressor speed, the full-load
0 0 capacity and efficiency would be the same in either locked
10:33 a 11:02 a 11:31 a 12:00 p 12:28 p 12:57 p TIme
or unlocked modes. However, the gap was noticed to widen
Indoor Drybulb Outdoor Drybulb Indoor RH Outdoor RH Unit power input towards the lower capacity range.

Figure 9: IAC-3 heating: full-load unlocked mode. When the compressors were varying their speed repeatedly
at a certain interval, energy consumption is high compared
A final 23C remote setting produced 20C of room air-on to the locked mode operation. In some inverters, inefficient
temperature (20C is required, see Table 1, H1). and faulty hot-gas bypass controls may have resulted in lower
HEATING Test H1 Conditions Part-load Unlocked Mode efficiencies in field behaviour.
Indoor & Outdoor Temperature, Relative Humidity and Power Input
100 800 Thus, the efficiencies of the IACs will fit to a lower curve relative
90 to the locked mode condition.
700
80
600 Advantages of proposed test method
Temperature (C) and RH (%)

70
500
60 There are distinct advantages to the proposed unlocked
Power (Watts)

50 400 mode of testing the IAC units compared to the existing

40 300 locked mode test method:
30
200 Any calorimeter laboratory can adopt the unlocked
20
100 test method to conduct the performance tests on IAC units
10
0 0 for field behaviour. This can also be applied to psychometric
9:36 a 2:24 p 7:12 p 12:00 a 4:48 a 9:36 a Time 2:24 p or air-enthalpy type (AS/NZS 3823) test methods.
Indoor Drybulb Outdoor Drybulb Indoor RH Outdoor RH Unit power input
There is no need for locked instructions from the
Figure 10: IAC-3 heating: part-load unlocked mode. manufacturer or any special assistance during the tests.

A final 18C remote setting produced 19.9C of room air-on Field performance can be obtained for any suitable thermal
temperature (20C is required, see Table 1, H1). load and corresponding unit behaviour (power input and
efficiency) in meeting that load.
DISCUSSION Use of any circumvention device in the air
conditioner system can be more easily identified.
Tested cooling or heating capacity, within 1% of registered
(or desired) values was obtained during the unlocked tests. Rating will show performance in field
IAC power input (which was responded by the unit to obtain conditions, which will greatly benefit consumers.

48 E CO L I B R I U M A P R I L 2 0 1 4

Creative IAC units receive the credit
they deserve and the poor designs
would be eliminated.
Check testing can be quicker,
independent and with more veracity.
The field performance results obtained
with this method could be applied
to check MEPS compliance ratings.
This method will encourage IAC
manufacturers to focus on real
performance rather than the
laboratory performance.
Suggested considerations
in the current test standards
and regulations
Remove the locked operation
allowance when testing IAC units.
Adopt the proposed unlocked test
method and account for the possible
transient behaviour.
Include a method of proportioning
the calculated results when the
achieved indoor room temperatures
are different to the required standard
test conditions.
In most of the IAC units, the
rated-load is lower than the full-
load capacities. It is recommended
to consider performance of IAC
units at full-load, part-load and
also at a desired rated-load when
determining the MEPS compliance.
CONCLUSIONS
There has been significant technological
advancement in domestic AC designs
over the past few decades, such as variable
speed compressor operation. Current
test standards allow IAC manufacturers
to fix the compressor speed for a certain
rated capacity. However, we believe
rating the inverter under locked method
is unrealistic, as it does not reflect the way
inverters operate in real life.
In this study, the IAC unlocked field
testing method was discussed. Vipac
testing shows that IAC units under
unlocked conditions used much higher
electric power than the rated values
when subjected to a similar thermal load
equivalent to the rated or locked
capacities. Some units failed to meet
MEPS under the new proposed test
methodology.
Using proposed unlocked test method,
IAC units can now be tested for field
FORUM
Backward curved centrifugal fans
behaviour in a laboratory environment.
Impeller diameter: 190 to 710 mm
Correct field test rating and labelling
Max. Capacity: up to 6,500 l/s
results would benefit consumers. It is
Max. Static: up to 1,800 Pa
suggested that the AS/NZS Standards
High power density with most
be revised for testing inverter units by
optimized sound level
considering the possible performance
100% speed controllable
deterioration in unlocked conditions.
EC-option available
Easy installation and maintenance
REFERENCES Requires up to 50% less input power
1) Australian/New Zealand Standards AS/ than comparable AC fans
NZS 3823, Performance
of electrical appliances
Airconditioners and heat pumps
2) www.energyrating.gov.au;
3) www.choice.com.au
http://www.choice.com.au/reviews-and-
tests/household/heating-and-cooling/
home-cooling/small-air-conditioners-
review-2009/page/results.aspx
http://www.choice.com.au/reviews-and-
tests/household/heating-and-cooling/
home-cooling/large-air-conditioners-
2008-review/page/results.aspx
4) Air conditioner test facilities
at VIPAC, Melbourne: Vipac is NATA
accredited for testing various AC
products, having six environmental
chambers up to 540m. The balanced
ambient calorimeter is rated to 18kW.
Lab circuits are of 1MW heating and
1MW cooling using recirculated water
loops and dedicated glycol and DX
systems to multiple chambers.
www.vipac.com.au
About the Author
Dr Satya Mavuri, M.AIRAH, is a senior
testing and numerical modelling
engineer at Vipac. His role includes
testing, design and development of
457
air conditioners, heat pump hot water
systems, heat exchangers, numerical Meet us at Stand
modelling and R&D consulting for a
range of thermodynamic systems.
Satya has had more than 12 technical
papers published in journals and for
conferences.
Email: satyam@vipac.com.au
A P R I L 2 0 1 4 E CO L I B R I U M 49