ENERGY CONSERVATION IN WINDOW AIR CONDITIONERS

[1] Mir Aqueel Ali

Associate professor Mech. Engg. Deptt. B.N.College of Engg.Pusad.India
Email mirakeelali@yahoo.co.in

[2] Avinash Wankhade

Associate professor & Head Mech Engg Deptt B N College of Engg Pusad. India
Email amwankhade@gmail.com [1] Corresponding author

ABSTRACT
Energy savings in a window air conditioner includes correct sizing of AC, purchase, better installation and operation coupled with reduction in cooling loads. The design options for substantial energy saving are related to increase in heat transfer area, heat transfer coefficient, fan, ECM motor and compressor. The cyclic changes should be cared for using variable speed compressors along with electronic expansion valves and fuzzy logic controllers. Replacements of R22, (410a, 407c) already commercialized are less energy efficient compared to R22. The future AC will have better compressor and heat exchangers for improved performance. Keywords Energy, Window, Air conditioner, COP, EER.

SIZING OF ACOne should go for cooling load calculation in order to arrive for appropriate sized AC. A large sized air conditioner penalizes in the following ways 1. It uses more energy. 2. It costs more to purchase than appropriate size AC. 3. The oversized AC cycles (on and off) more frequently reduce its efficiency. Frequent cycling makes indoor temperature to fluctuate more and results in less comfortable climate. It also inhibits dehumidification. It, in addition wears out the compressor and electrical parts more rapidly. [4] The people having misconception of using two half sized AC, so that at least one will run in case of failure of other. It will result in an increase of running and initial cost. PURCHASE Todays AC use 54% less energy to produce same amount of cooling as vintage AC used in mid 1970. Thus replacement is an option for energy saving. Purchase energy star qualified AC which consumes at least 10% less energy than todays conventional models. Its higher cost will be paid during its life span. Purchase an AC with Energy saving features such as i ) Digital readout for thermostat setting, ii) A built in timer, iii) A filter that slides out easily for regular cleaning. [5] INSTALLATION

ENERGY SAVING BENEFITS Window AC accounts for about 50% of room AC market. As on September 2006 the population of single phase AC operating in India was around 5 million units. The industry grew at the rate of 25 %, till the year 2010. The total production in India was around 21.5 million units. These units required around 12000 MW of electrical energy in the year 2006 and 45000 MW of electric energy in the year 2010. If we had improved the energy efficiency of room AC by 5%, we could have saved approximately 2100 MW, which is equivalent to two large size power plants.[1] Indian window AC with an Energy Efficiency Ratio (EER) of 10.5 can improve up to 11.2 used in US.[2,3] The energy saving definitely will have the following advantages. 1. Foreign exchange for import of petroleum products will reduce. 2. The global warming will reduce because of lower amount of pollutants such as CO2, NOx and SO2 . 3. The environmental benefits such as water pollution and erosion of land are viable due to reduction in base load and peak load generation demand

1. Locate the AC in a window or wall near the centre of room on shadiest side of north or east facing wall. Direct sunshine on condenser decreases efficiency by as much as 10%. 2. Minimize air leakage by fitting the AC snugly into its opening and sealing gaps with Caulk (special sealants). 3. Most TXV sensing bulbs are installed with no insulation and improper contact and orientation. In these conditions, hunting may arise (rapid opening and closing of the valve) and harm the compressor while allowing liquid to

enter the compressor in those conditions resulting in increase power consumption. OPERATION

4. Use compact fluorescent lamps (CFL) and fixtures which consume approximately 25% of electricity as compared to similar incandescent lamps and has 8 to 10 times longer life.

1. Some units also use sophisticated sensors to detect the DESIGN OPTIONS presence of persons in the room to be cooled or heated and to direct the airflow in their direction. In correlation, a INCREASE HEAT TRANSFER SURFACE AREA mode sometimes called Economic can be associated: 1. Increase Frontal Coil Area, 2.Increase Depth of Coil, when nobody is in the room, the cooling or heating 3.Increase fin density, 4.Add sub cooler to condenser coil. operation is stopped. 2. Set AC thermostat settings properly, AC uses 3to5 percent INCREASE HEAT TRANSFER COEFFICIENTS less energy for each degree set above 22C, therefore set 1. Improve fin design, 2. Improve tube design, 3.Spray 1. the thermostat as high as is comfortably possible in condensate on the condenser coil,4.Hydrophilic film coating summer (25-27c) [6 ] on fins,5.Improve fan and fan motor efficiency 3. Fan speeds are available in 2 or 3 options. Set the fan speed on high, except on very humid days. When humidity MICRO CHANNEL HEAT EXCHANGERS is high set the fan speed on low for more comfort. Consider an interior fan in conjunction with AC to spread IMPROVE COMPRESSOR EFFICIENCY the cooled air more effectively through the room without greatly increasing electricity use. Using fan allows you to CYCLIC CHANGES set the thermostat temperature higher and thus reduces the energy consumption. 1. Variable speed compressor, 2.Alternative refrigerants, 3. 4. Dont place lamps or Television near AC thermostat. This Electronic Expansion valves, 4.Thermostatic cyclic controls. may cause the AC to run longer. 5. Use a voltage stabilizer to narrow the voltage variation. OTHER LOSSES For each 1% voltage variation outside the narrow band around rating point causes energy consumption variation 1.Side louver, 2. Divider wall heat loss, 3.Discharge air by 0.5 to 1% at normal conditions and 1 to 1.5 % under recirculation heat loss, 4.Suction heat gain, 5. Reversing adverse condition in a hermetic compressor. valve, 6. Evaporative cooling, 7. Thermal Bridging MAINTENANCE 1. The air filter, condenser and evaporator coils should be regularly cleaned with a blower. Some units also control the air flow passage of the indoor unit by measuring the pressure loss to warn end-users when it is necessary to clean the filter. 2. Use a fin comb to straighten the bent fins on evaporator and condenser coil. 3. In case of refrigerant leak evacuation should be done by vacuum pump instead of compressor, used by mechanics. Use of vacuum pump ensures dehydration and removal of non condensable gases which may otherwise increase condenser and evaporator temperature. This is in turn increases energy consumption. 4. Refrigerant charge should be optimum. Both under charging and overcharging increase energy consumption. COOLING LOAD REDUCTION 1. If possible go for passive cooling in the building before construction. 2. Install window sun shade, storm windows, blinds or drapes in front of glass, storm door, double or triple pane windows. 3. The cool roof, attic, floor and wall insulation will reduce the cooling load by 15%. INCREASE FRONTAL COIL AREA Enhancing frontal area in either of the coil results in increased efficiency of the entire system. In order to have adequate dehumidification at least 25% of the capacity should be allotted for dehumidification. The increase in frontal coil area improves evaporator performance thereby increasing evaporating temperature. The increased evaporating temperature results in inadequate dehumidification. The frontal area of coil cannot be increased beyond a limit because it increases cabinet size. INCREASE DEPTH OF COIL Vertical tube rows may be at the most 3 or 4 because each successive row in a coil is only 70% effective as preceding row. For systems working with R-410A, the trend is to use number of rows to 2 or 3 rows and for R-407C, it is possible to take advantage of the temperature glide by using a configuration with more than 3 rows . Addition of horizontal row is limited by chassis size, issue of weight and refrigerant charge. FIN DENSITY OPTIMIZATION Dominant heat transfer resistance is usually on the air-side. Fin density should be optimized with regards to improvement

in heat transfer, effect on fan power; water drainage and dirt build up. The fin density is a function of type of coil (evaporator or condenser), fin type (wavy, louvered, enhanced), number of tube rows and tube diameter. SUB COOLER A sub cooler can be added between condenser outlet and capillary inlet and may be submerged near the condenser in the condensate produced by evaporator. The addition of sub cooler will increase the size of condenser coil. The addition of sub cooler may be possible if adequate area is available otherwise the size of window air conditioner will increase thereby resulting in increased initial cost. The increase in EER may be 1.4 to 3 % for various capacities. IMPROVE FIN DESIGN Enhancements to the fin design have the effect of improving coils air side heat transfer coefficient thereby improvement in overall heat transfer capability of coil. The improvements are partly due to increased air turbulence over coil caused by enhanced fin design. The fin improvement can be achieved by using a corrugated or wavy fin pattern or a louvered or lanced fin pattern. Recent progress also includes decrease of the fin thickness . IMPROVED TUBE DESIGN The refrigerant side heat transfer coefficient with grooved tubing is greater than that for smooth tubing. Improvement of refrigerant heat transfer coefficient with grooved tubing is a function of width, height and spacing of grooves as well as oil concentration within the refrigerant. The effect of refrigerant pressure drop should be optimized. In order for the heat exchange increase not to be too detrimental to the refrigerant pressure loss in the heat exchangers, the diameter of the copper tube is adapted to the refrigerant conditions, with larger diameters for the gas state and lower diameters for liquid or two phase conditions. These measures also enable to decrease the refrigerant charge resulting in lower power consumption. The system performance due to different heat exchanger fin and tube designs data from Chinese texts on air conditioner technology is given in Table 1 which summarizes the heat transfer and pressure drop enhancement factors. The enhancement factors are relative to flat fins and smooth tubing (i.e., flat fins and smooth tubing have heat transfer and pressure drop enhancement factors of 1.0). The value used for the heat transfer enhancement factor is the multiplication factor for air-side heat-transfer coefficient of the coil. [7]

Table 1
Design Heat Transfer Enhancement Factor 1.12 1.5 1.8 1.11 1.44 1.57 2.4 2.2 Pressure drop Enhancement Factor 1.05 1.2 1.2 1.05 1.25 1.25 1.5 1.4

Evap Wavy Fin (s mooth tube) Evap Slit Fin (s mooth tube) Evap Slit Fin (g roove tube) Cond Wavy Fin (smooth tube) Cond Slit Fin (groove tube) Cond Slit Fin (groove tube) Evaporator Groove Tube Condenser Groove Tube

SPRAY CONDENSATE ON CONDENSER COIL There is a slinger ring at the condenser fan blade tips which collects and sprays small amount of condensate on condenser coil during fan rotation. Spraying condensate improves air side heat transfer coefficient but should be optimized for dirt built up due to water accumulation. Typically, only a small percentage less than 25% of the condenser coil is actually wetted by the spray because the fan can only sling water on the first few rows of the heat exchanger HYDROPHILIC FILM COATING ON FINS Fins with hydrophilic coatings have an affinity for water causing condensed water to film the fin surface in a thin layer. The strong affinity for water results in less retention of bridge shaped water drops between fin surfaces. According to research it causes the water drops to fall of the fin surface quickly resulting in reduced air side pressure drops and increased air flow rates across the heat exchanger. The aluminum fins will not corrode due to separation of water droplets. Under dehumidifying conditions, hydrophilic type fin surfaces are reported to reduce air side pressure drop. Therefore cooling capacity is improved as compared to air conditioning systems using untreated fins. FAN & FAN MOTOR The air delivery side of room air conditioner consists of one motor driving two fans, one on evaporator side and the other on condenser side. The evaporator fan is usually a blower wheel (centrifugal forward curved fan) while condenser fan is propeller typed. The evaporator and condenser fan motor consume 5% and 7 respectively of total energy consumption of room AC. Propeller fans previously made of processed metals, are now made of plastics. The shape of blade must be such that it should increase the volumetric efficiency and decrease the noise level. Opportunities for conserving energy are also available by improving the efficiency of air delivery system and fan motor. In addition, improving fan motor efficiency results in additional compressor energy saving. This is due to lower heat removed by the heat exchangers because less heat is rejected by the fan motor. Earlier fan motors were of low efficiency shaded pole typed but now permanent split

capacitor (PSC) motors having efficiency in the range of 50% to 60 are used. Electronically commutated motors (ECM) have the efficiency in range of 70 to 80%. In an ECM power is pulsed on and off electronically. By varying the timing and duration of pulses, the electronic controller can accomplish speed control as well as maintain high torque at the start and over a broad speed range. [8] The cost of ECM is 2.5 to 5 times more and increases by 0.4 as compared to PSC motors. In a conventional AC, since there is a single motor, it runs both the indoor and the outdoor fans. Hence, when the fan speed inside reduces, even the outside fan speed decreases. This reduces the machine's ability to throw hot air outside and impacts the overall efficiency of the AC. If there are two independent fan motors one for the indoor fan and the other for the outdoor fan. The inside fan speed is independent of the outside fan speed, and thus the ability of the machine to throw hot air outside remains unaffected. Energy saving is achieved due to better cooling of condenser. [9] MICRO CHANNEL HEAT EXCHANGERS Micro channel heat exchangers (MCHX) use has been recommended in Energy star product specification for room AC draft 1 version 3[10]. MCHX transfer heat through multiple flat fluid filled tubes containing small channels while air travels perpendicular to fluid flow. Compared to fin tube heat exchangers the air passing over the heat exchanger has longer dwell time, increasing both the efficiency and rate of heat transfer. This advancement in heat exchanger technology allows the MCHX to be smaller and yet have the same performance as a conventional heat exchanger, in other words improved performance in same volume as that of conventional heat exchanger. The smaller size of the exchanger reduces refrigerant pressure drop, improving overall compressor performance. However, micro channels also have weaknesses, such as large pressure drop, high cost of manufacture, dirt clogging, and flow mal-distribution, especially for two-phase flows. A study of performance evaluation of a window room AC with micro channel condensers by Man-Hoe Kim and Clark reveals that refrigerant charge requirements can be decreased by 35%,which in turn reduces global warming (due to higher GWP of R410 a). The condenser core volume and weight can be reduced by 55% and 35%. [20]. T his technology is already adopted by the car industry for more than 9 years it has been recently adapted to mini chillers by Carrier. IMPROVED COMPRESSOR EFFICIENCY Compressors are the heart of refrigeration system. Energy consumed by the compressor is 80 % of window air conditioners total energy. System efficiency can be improved simply by utilizing more efficient compressors. Compressor efficiency is improved through the use of high efficiency motors, high grade materials in the pumping mechanism combined with advance production methods and equipment. Progresses have been made to reduce friction losses in rotary

compressors. The Swing compressor manufactured by Daikin has the roller solidarized with the blade; this avoids leakages between high and low pressure sides. The compressor has 15 % higher global efficiency, but it also uses an improved DC motor. Other manufacturers (Toshiba, Fujitsu, Sanyo) have adopted a rotary compressor with two stages or twin rotary compressor that enables to improve the efficiency by 10 %. [11] Advantages of scroll over reciprocating are 1 Highest volumetric efficiency- approximately 100%, 10% to 20 higher EER, 2 Low sound characteristics- approximately 5 decibels lower than reciprocating , Smoother and continuous compared to rapid piston movement which ensures low vibration and lower discharge pulse 3 Outstanding reliability with regards to lower failure rate and tolerance to liquid refrigerant as well as debris.[12] Scroll compressors with three dimensional compression are also experimented. They are (i) 35% smaller in size, (ii) 26% lighter in weight, (iii) 5.5% more efficient and (iv) The noise generated is lowered by 6 DB as compared to conventional one. [13] VARIABLE SPEED COMPRESSORS Power consumed by a motor varies as the cube of its speed. A compressor working with variable speed motor and its speed modulated to match the load offers the advantage of substantial reduction in power consumption and increase in EER by 1.2.Variable speed compressor matches the load in a room. Rather than having only on off control, modulating the cooling capacity can better match the required load. Advantages of variable speed compressors are i. Quieter Operation at low speeds. ii. Enhanced comfort by eliminating large fluctuations in room temperature. The control of variable speed compressors is accomplished through the use of electronic ASD at the motor. Because electronic ASD are compact and do not have to be mechanically coupled to motor, they can be applied to fractional size motors of room ACs. Inverter based ASD are common for induction motors while converter based ASDs are used for ECM motors. ASD perform well both with rotary and scroll compressors. A savings of 10% is possible with variable speed compressor. A digital scroll modulates capacity from 10% to 100% significantly lowering energy consumption with the help of electronically controlled solenoid which loads and unloads scroll members. [14] Although more efficient than single speed systems at full load conditions. Because of parasitic losses associated with the electronics required to operate variable speed compressor, they may actually draw more power at full load conditions. Thus, variable speed systems may exacerbate peak power concerns for electric utilities. ALTERNATIVE REFRIGERANTS EPA will ban the use of R22 after 2020 and production by 2010. In addition to ODP, GWP and energy efficiency,

refrigerant should be non toxic, non flammable, chemically stable, inert etc. Even though, the ODP and GWP of refrigerant may be less still it may contribute to global warming due to reduced energy efficiency. R410 A (HFC 410A) is a binary blend of 50/50 by weight of HFC 32 and HFC 125 and is an alternative to meet the montreol protocol in the long term because of zero ODP. It has negligible temperature glide (less than 0.2 K over its operating range), but has GWP- 2000, AEL-1000ppm. [15] Commercialization is complete. If used as a drop in substitute capacity reduction and power increase are significant [16].when used in new systems there is a very marginal decrease in energy efficiency. An advantage of R-410A is the lower liquid density of the refrigerant (approximately 12% lower than for R-22). The refrigerant charge is then approximately 25 to 30% lower than the required charge of a R-22 system for comparable duty and efficiency. Another Alternative R 407 C (HFC 407C) is a ternary blend of HFC 32/HFC-125/HFC-134a with composition of 23/25/52 % by weight. The temperature glide is (7.4 0) as well as GWP-1700, AEL-1000ppm. This temperature glide leads to an impact on boiling heat transfer. The pool boiling heat transfer coefficient decreases as temperature glide increases. This cycle of events decreases the heat rate transfer and the overall performance. Moreover, since it is a non-azeotropic refrigerant mixture, fractionation may occur in case of the leak in the system. Hence when leaks occur, the entire refrigerant must be removed and new R407C fluid with the right composition must be used. Inclusion of liquid to suction heat exchanger in R407 c retrofitted system has improved performance of window air conditioner in terms of refrigerating capacity, mass flow rate and COP, but has reduced power consumption and pressure ratio. [17] ELECTRONIC EXPANSION VALVES As compared to capillary the thermostatic expansion valves (TXV) can adapt better to changes in operating conditions such as those due to variation in ambient temperatures, which affect the condensing temperature. Electronic expansion valves (EXV) are controlled by either digital or electronic circuits, they give additional flexibility to consider control schemes that are impossible for conventional TXV .In air conditioners which have inverter driven variable speed compressors, EXV can improve performance beyond that of TXVs. EXV measures and controls the superheat of suction gas as it leaves the evaporator (at saturated condition ) and enters compressor, compared to the standard TXV which controls the superheat of suction gas only up to the location of thermal bulb of valve mounted on suction line. Adopting EXVs in air conditioners enables an appreciable energy saving with respect to the same installations equipped with traditional TXVs. Another advantage of TXV and EXV over the capillary is the ability to block refrigerant migration when the unit is OFF or cycling ON-OFF, thus in power consumption reduces at the start.

THERMOSTATIC CYCLIC CONTROL Remote thermostatic cyclic controls accurately monitor room temperature than earlier built in thermostats. Fuzzy logic controller offers better comfort requirements. Efficiency gains require coupling it with an improved air flow discharge and distribution system. OTHER LOSSES I. SIDE LOUVERS Side louvers have a significant impact on unit performance. Side louvers separate the airstreams to and from the condenser and reduce recirculation and enhance the movement of air over the outdoor coil. Units without side louvers operate at a lower efficiency due to additional compressor power (around 4%) required for compensating the decreased air flow over the condenser coil. II. DIVIDER WALL HEAT LOSSES Divider wall heat losses are composed of heat leakage (due to temperature difference) and air leakage losses. Heat leakages are controlled by Styrofoam insulation; they can be further reduced with better insulation which has higher sound blankets. Air leakage in indoor section takes place through cracks and open spaces in divider wall. They should be tried to reduce with better damper arrangements. III. DISCHARGE AIR RECIRCULATION HEAT LOSS Short circuiting of discharge air into the AC reduces heat content of the mixture, thereby reducing capacity (around 6%). The EER decreases since the energy input is same. They can be reduced with better air delivery such as side delivery. IV. REVERSING VALVE A reversing valve allows a room AC to operate as a heat pump and provide space heating in addition to cooling. The reversing valve adds an additional load to the system that increases the units power requirement by an estimated 5% V. SUCTION LINE HEAT GAIN It takes places due to motion of refrigerant from indoor to outdoor section and hence capacity decreases. The heat gain can be reduced by better insulation on suction line. VI. EVAPORATIVE COOLING A problem related with application of air condenser in hot weather conditions (about 50oc) is related to the high storeyed buildings. In these buildings the hot air from air conditioners of lower story rises up and provides a hot flow field around the air conditioners of higher storeyed. Sometimes, the increase in the air temperature is so high that the air

conditioner trip down. It is generally believed that the COP of an air conditioner decreases about 2% to 4 by increasing each o C in condenser temperature and the COP of an air conditioner could drop down as much as 40% in hot weather condition. Energy conservation can be done by putting two cooling pads on both sides of the air conditioner and injecting water on them in order to cool down the air before it passing over the condenser. The experimental results show that thermodynamic characteristics of new system are considerably improved and power consumption decreases by about 16% and the COP increases by about 55%.[18 ] VII THERMAL BRIDGING Thermal bridging occurs when insulating material is bridged by a conductive material; for example by a AC with a metallic chassis that extends from the exterior to the interior of the home. The AC forms a thermal bridge that conducts heat from the home in the wintertime and into the home in the summertime. Energy conservation can be done by minimizing this loss by using plastics instead of metallic sheets. CONCLUSION The various methods of energy conservation are discussed. The design adoption depends upon modification cost and energy saved. Improvement in compressor EER may be the first priority followed by use of better heat exchangers. MCHX are not yet commercialized for window AC. Government of India has taken a welcome step by making BEE star label for room AC compulsory from January 2010. REFERENCES [1] Bhambure J M , Room ACs with Star Ratings ISHRAE Journal July sept
2006 [2] Most efficient air conditioner. American council for energy efficient economy as on 24/1/2011. [3] BEE labeled air conditioner version 2 august 2010

[4] Consumer energy informat ion Energy efficiency and renewable energy network fact sheet. [5] Room air conditioner energy efficiency and renewable energy. [6]Gu ide on energy efficient Roo m air conditioner [7]. Technical and economic analysis of energy efficiency of Chinese roo m air conditioner, February 2001 LBNL 4555O pp (29) [8] Electronically co mmutated motors Washington state university extension energy program [9]. www.h itachi.co mHo me>Products> HomeA ir Conditioners > W indow Air Conditioners > Quadricool TM [10] Energy star product specification for room AC draft 1 version3

[11] ASHRA E handbook- systems and equipment 2008 (S I) Chapter 49 room air conditioners pp (49.1 49.5) [12] Scroll co mpressors presented by kirloskar Copeland ltd. at national conference on RAC, Chennai. [13] High efficiency and large capacity 3D scroll co mpressors. GU series .Mitsubishi heavy industries Ltd. Technical Review Vol .43 no. 2 (June 2006). [14]. Liebert DS model with optional digital scroll co mpressor [15] J,M.Calm and P.A.Do manski, R22 Rep lacement status ASHRA E Journal 46 (8):29-39,August 2004 [16]. Performance assessment of HCFC-22 window air conditioner retrofitted with R-407C S. Devotta a, A.S. Padalkar, N.K. Sane Applied Thermal Eng ineering Vo lu me 25, Issues,17-18 December 2005, Pages 29372949 [17] R.Vijayan and P S S Srinivasan influence of internal heat exchanger on performance of window A C retrofitted with R 407C Journal of scientific and industrial research ol.68, Febraury2009, pp 153156 [18] Ebrahim Hajidavalloo Applicat ion of evaporative cooling on the condenser of window-air-conditioner Applied Thermal Engineering 27 (2007) 19371943 [19] Development of a linear comp ressor for air conditioners and heat pumps. Warren D .Waldron (EPA .Pro ject Su mmary). [20] Man- Hoe- Kim and Clark, Performance Evaluation of window Room ac with micro channel condensers.