Automotive Air Conditioning

Prepared and presented by

DWARKA SECTOR 8 DTC DEPOT TEAM

 Automotive Air Conditioning

Historical development of Air Conditioning

Some of the principles of refrigeration as we know it today were known as long as
ten thousand years before Christ (B.C.).
In Egypt a method was developed for removing the heat from the Pharoah’s
palace. The walls of the palace were constructed of huge stone blocks weighing
over a thousand tons, and every night three thousand slaves dismantled the walls
& moved the heavy stones to the Sahara Desert. Because, the temperature in the
desert is cool during the night, the stones gave up the heat they had absorbed
during the day. Before daybreak the slaves moved the stones back to the site and
reassembled the walls.
It is believed that the Pharoah enjoyed temperatures of about 800 F (26.60 C)
inside the palace while the temperature outside soared to about 1300 F (54.40
C). Three thousand men toiled all night to perform a task that modern
refrigeration now easily handles. Although the work effort is less today, the same
principle of refrigeration is applied to present systems as it was in the Pharaoh’s
time; that is, heat is removed from one space & transferred to another space.
 Laws of refrigeration

Law 1: Illustrated by the refrigeration system of a vehicle. Heat is removed from

the air in the passenger compartment of the vehicle, and thus the temperature of
the air is lowered.
Law 2: Heat is ready to flow or pass to anything that has less heat. Nothing can
stop flow of heat; it can only be slowed down. Heat cannot be contained no
matter how much insulation is used. Law 2 wrt to vehicle refrigerant. Heat is
ready to flow to anything that contains less heat- to the refrigerant in the
evaporator and then to the outside (ambient) air through the tubes and fins of the
condenser.
Law 3: If a change of state to take place there must be a transfer of heat. If a
liquid is to change to a gas; it must take on heat. The heat is carried off in a vapor.
If a vapor is to change to a liquid, then it must give up heat. The heat is given up
to a less hot surface or medium. Law 3 is shown by the liquid refrigerant in the
evaporator. That is, as the refrigerant takes on heat, it changes to a vapor. That
heat is carried off to be expelled outside the vehicle while changing to a liquid in
the condenser.
 Refrigeration Capacity

For many years the cooling capacity of refrigeration units was rated in
horsepower (HP). HP is theoretical unit of energy. One HP is the amount of
energy required to raise 1497 Kg 305 mm in 1 minute. Earlier refrigeration
systems had ratings ¼ HP, ½ HP, ¾ HP, 1 HP and so on. Such a rating is
inaccurate to describe the output of air conditioning because HP value is
generally referred only to compressor size. Another term ton is used to describe
the capacity of air conditioning system.
The value of a ton of refrigeration in Btu/h can be determined if the latent heat of
fusion for water (H2O) is known. The amount of heat required to cause a change
in state of 1 pound of ice at 32 deg F to 1 pound of water (H2O) at 32 deg F is
144 Btu.
In applying this value, a ton of matter , such as water (H2O) contains 2000
pounds . Because 144 Btu are required to change 1 pound of solid water (H2O) or
ICE to a liquid, the equivalent value for 1 ton can be found by multiplying the
amount of energy required to change 1 pound by 2000 pounds.
144 Btu X 2000lb = 288,000Btu
The value 288,000 Btu is the amount of heat energy (in Btu) required to change
the state of 1 ton of ice to 1 ton of liquid in 24 hours. To determine the Btu / h
rating for a ton of refrigeration, divide 288,000 by 24, the number of hours in a
day. 288000/24h=12,000 Btu/h.

One ton of refrigeration is thus equivalent to 12,000 Btu / h.

All air conditioning systems now are rated in Btu. Ex- a ¾ ton air conditioning
system should have a rating of 9000Btu, each quarter ton of refrigeration is
equivalent to 3000 Btu.
288,000Btu x 0.25 ton = 72,000
72,000 / 24h = 3,000 Btu
The actual Btu rating is, by far, a more accurate method of determining the size
of an air conditioning system.
Vehicle air conditioning system are designed and manufactured for particular
make and model of automobiles, the Btu ratings are not as important to the
technician and are not a part of the decision making for purchase.
Most Vehicles are rated over a ton (12,000Btu) of refrigeration.

A full size vehicle may use a 1.75 ton (21,000Btu/h) AC and this is enough to cool
an average 2 bedroom house.
 Human Comfort Control

Five properties of the air must be considered for treatment to

provide a comfortable and healthful environment:-

1. Its temperature; by cooling or heating.

2. Its moisture content; by humidifying or dehumidifying.

3. Its movement; by circulation.

4. Its cleanliness; by filtration.

5. Its ventilation; by introducing fresh outside air to replace

stale air.
Factors of Air Conditioning
Picture on left indicates Evaporation and on right
indicates dehumidification
Basic System layout of MVHVAC
 Basic components of MVHVAC

• Compressors
• Compressor Clutches
• Condensers
• Expansion Devices
• Evaporators
• Receiver-Driers/Accumulators
• Switches and Evap. Temperature Controls
• Rear AC Systems
Positioning of Air Conditioning unit in Low Floor Bus

Positioning of Air Conditioning unit

Understanding Positioning of Air Conditioning unit
Air Conditioning unit mounted on top of low floor bus
Components of Air Conditioning unit
Components of Air Conditioning unit
Control of Air Conditioning unit
 Particular features of Components

• Temperature control system- The temp inside the coach is

controlled by means of control panel. It can be used to
program the temp desired.
• Drive- The compressor is driven by a control of belts from
the coach engine through an electromagnetic clutch of which
the coil is controlled by the control panel of voltage 24V.
• Compressor- Modern design, reduced size, great power and
easy to maintain. Particulars of compressor are:-
1. Absence of oil pump, fewer components liable to wear
2. Clutch pulley turns on shielded bearings which do not require
lubrication.
3. The rollers bearing are mounted and supported by bearings
which prevents overloading.
 Particular features of Components

4. They can rotate in clock wise and CCW direction.

5. Reduced size of the compressor allows quick placement on
chassis.
6. Electromagnetic clutch.
7. Window of level.

• Serpentines of evaporators and condenser- The serpentines

are made with aluminum flaps and copper tubes with internal
grooves expanded mechanically in order to obtain the maximum
performance in the transfer of heat.
• Fans of the evaporator- The centrifugal fans (turbine) are the
double type with a high performance and low noise level.
• Fans of condenser- Axial and direct output fans are used.
Roof top Air Conditioning unit
Labeling of roof top Air Conditioning unit
One portion of the evaporator coil flap opened
 Basic Air Conditioning circuit
Cold air
Evaporator

Thermostat
warm air
Blower motor
expansion valve sight glass

High-pressure gas
High-pressure liquid
Pressure s/w Low-pressure liquid
Low-pressure gas

Compressor Dryer / filter

hot air

Condenser
Receiver
 Power house of Air Conditioning unit

M16 Nut

Tensioner
spring

Engine
pulley
 Positioning of Air Conditioning unit

Compressor

Alternator

Engine Crank pulley

Automotive Air Conditioning
Refrigerant flow cooling dual loop
Refrigerant flow Cooling
Refrigerant flow Heating dual loop
 Automotive Air Conditioning- Heating Cycle

• Includes heater core and solenoid operated heat valves.

• Includes water temperature switch and boost water pump.

• The controller automatically controls the heat valve during the

heating mode to maintain the required temperature. Engine
coolant (glycol sol) is circulated through the heating circuit by
the engine and an auxiliary boost water pump. When the heat
valves solenoids are energized, the valves will open to allow the
engine coolant to flow through the heater coils.

• The valves are normally closed so that if failure occurs the

system will be able to cool.
 Safety devices

• Thermal Switches

Condenser motor overloads- Each condenser motor is equipped

with an internal thermal protector switch, condenser motor
overloads. If excessive motor temperature exists the condenser
motor overload switch will open to de-energize the
corresponding condenser fan.

Evaporator motor overloads- The evaporator motor is equipped

with internal thermal protector switch. If excessive motor
temperature exists the switch will open to de-energize the
corresponding evaporator fan. This will prevent the affected
evaporator motor from operating.
 Safety devices

• Pressure Switches

High Pressure Switch- During the A/C mode HVAC system

operation will automatically stop if the HP Switch contacts open
due to an unsafe operation. Opening HPS contacts de-energizes
through the controller, the A/C Compressor clutch and condenser
fan motor relays shutting down the system. For R-134a systems
the switch is factory set to open at 300±10 psig and close at
200±10 psig.

Low Pressure Switch- Installed on the compressor opens on a

pressure drop to shut down the system when the low pressure
condition occurs. For R-134a systems the switch is factory set to
open at 6±3 psig. In addition if the control monitors a pressure
less than 10 psig by the suction pressure transducer mounted on
the evaporator section the system will shut down for at least one
minute.
Switches in the system mounted on compressor proximity

High Pressure Switch Low Pressure Switch

Safety devices- Fuse and breakers and ambient lockout

• Fuse and Breakers- All output from the relay board are
protected against the high current by circuit breakers.
Independent 15 A circuit breakers protects the motors. Either
breaker or fuse blows off to protect the circuit.

• Ambient lockout- Ambient temperature sensor is located at the

condenser section measures the condenser air temperature.
When the temperature is less than 45ºF, the compressor is
locked out until the temperature increases above 50ºF to
prevent compressor damage.
 Danger about moisture in the system

• Moisture in conc. Greater than 20 ppm may cause serious

damage.

• Refrigerant reacts chemically with water (H2O) to form HCL

(Hydrochloric acid). The heat generated in the air conditioning
system speeds up the acid forming process.

• The HCL corrodes all of the metallic parts of the system

particularly those made of steel. Iron, Copper and Aluminum are
damaged by the acid as well.

• Moisture in the system causes icing and results in air condition

ineffectiveness.
 Three sensors in the system

This is internal temperature sensor located in the air return

air conditioning system
 This is duct sensor and it
This is external temperature
is located in the duct just
sensor located outside the
above the presumed
air conditioning system.
conductor seat.
 GLW 210 Controller

• When the ignition key is turned on the display will show the
controller’s version after that the internal temperature of the
vehicle. Before start the display will show initials AL. Controller
monitors the three sensors :- Internal temperature sensor,
Outside temperature sensor and Duct sensor.
• This panel works with supply voltage of 12 & 24 VDC.
• It is protected against reverse polarity.
• The system allows 32 VDC up to 5 minutes without
any problem.
• Programmed data will be stored in memory.
• The panel will operate 10 to 95 % humidity with out
any condensation.
The Dash controller only works when engine is in operation.

23
3rd touch turns off the equipment
Failure Codes in Controller
Each bus have two numbers of return air
grille
Receiver drier fitted at the top of the
vehicle
Sight glass to view the quality of the
refrigerant
Receiver / accumulator -
Thermal expansion valve (TXV)-
 Automotive Air Conditioning VENT

VENT- The highlighted is the vent of the system with controller motor. In
Vent mode only the evaporator fans operate. Once the temperature is
satisfied there is a window when the unit will go into vent mode. Vent
mode is 2ºC from the set point. The compressor clutch is disengaged at
this time.
ELECTRONIC WATER VALVE BODY
 Clutch Assembly

Pulley

Coil
Drive Plate
Clutch Assembly
 Pulley

Current is sent to the clutch Coil

coil to energize the magnet
and apply the clutch. Shutting
off the current flow releases
the clutch and stops
compressor operation.

Clutch Hub/Plate
Most compressors use a three-part
clutch: the hub, rotor, and coil.
The hub is attached to the
compressor drive shaft. It has a
plate that is pulled against the rotor
when the clutch is applied.
The rotor is driven by the
accessory drive belt; it is mounted
over the front of the compressor
using a bearing so it can rotate.
The coil becomes an electromagnet
when current is sent through it.
Hub Pulley/ Magnetic
Rotor Coil
Automotive Air Conditioning manifold gauge
Trouble shoorting