Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

Main components of central air conditioning

3.1 Refrigeration cycle components

The purpose of the compressor in a

refrigeration system is to raise the
pressure of the refrigerant vapor from
evaporator pressure to condensing
pressure. It delivers the refrigerant vapor
to the condenser at a pressure and
temperature at which the condensing
process can be readily accomplished, at
the temperature of the air or other fluid used for condensing. Fig
3-1 Refrigeration cycle

The pressure–enthalpy (P–h) chart plots

the properties of a refrigerant: refrigerant
pressure (vertical axis) versus enthalpy,
or heat content (horizontal axis). A
diagram of the basic vapor-compression
refrigeration cycle can be superimposed
on a pressure–enthalpy chart to
demonstrate the function of each
component in the system. Refrigerant
Fig 3-2 Basic Refrigeration system

enters the evaporator in the form of a cool, low-pressure mixture of liquid and vapor (A).
Heat is transferred from the relatively warm air or water tobe cooled to the refrigerant,
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causing the liquid refrigerant to boil and in some cases superheat (B). The resulting vapor
(B) is then pumped from the evaporator by the compressor, which increases the pressure and
temperature of the refrigerant vapor. Notice that during the compression process (B to C),
the heat content (enthalpy) of the vapor is increased. The mechanical energy used by the
compressor to increase the pressure of the refrigerant vapor is converted to heat energy,
called the heat of compression. This causes the temperature of the refrigerant to also rise as
the pressure is increased. The resulting hot, high-pressure refrigerant vapor (C) enters the
condenser where heat is transferred to ambient air or water at a lower temperature.

Inside the condenser, the refrigerant desuperheats (C to D), condenses into a liquid (D to E),
and, in some cases, subcools (E to F). The refrigerant pressure inside the ondenser is
determined by the temperature of the air or water that is availableas the condensing media.
This liquid refrigerant (F) then flows from the condenser to the expansion device. The
expansion device creates a pressure drop that reduces the pressure of the refrigerant to that of
the evaporator.

At this low pressure, a small portion of the refrigerant boils (or flashes), cooling the
remaining liquid refrigerant to the desired evaporator temperature (A). The cool mixture of
liquid and vapor refrigerant travels to the evaporator to repeat the cycle.

3.2 Compressor

There are primarily four types of

compressors used in the air-
conditioningindustry reciprocating,
scroll, helical-rotary (or screw), and
centrifugal. The traditional
reciprocating compressor has been used
in the industry for decades. It contains
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

cylinders, pistons, rods, a crankshaft, and valves, similar to an Fig 3-3

Compressor type

automobile engine. Refrigerant is drawn into the cylinders on the downstroke of the piston
and compressed on the upstroke. Scroll and helical-rotary (or screw) compressors have
become more common, replacing the reciprocating compressor in most applications due to
their improved reliability and efficiency. These three types of compressors (reciprocating,
scroll, and helical-rotary) all work on the principle of trapping the refrigerant vapor and
compressing it bygradually shrinking the volume of the refrigerant. Thus, they are called
positive-displacement compressors. In contrast, centrifugal compressors use the principle
of dynamic compression, which involves converting energy from one form to another in
order to increase the pressure and temperature of the refrigerant.

3.2.1 Reciprocating Compressor

The first type of compressor to be discussed

is the reciprocating compressor. The
principles of operation for all reciprocating
compressors are fundamentally the same.
The refrigerant vapor is compressed by a
piston that is located inside a cylinder,
similar to the engine
Fig 3-4 Reciprocating Compressor

in an automobile. A fine layer of oil prevents the

refrigerant vapor from escaping through the
matingsurfaces. The piston is connected

During the intake stroke of the compressor, the

piston travels away from the discharge valve and
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creates a vacuum effect, reducing the pressure

within the cylinder to below suction pressure. Fig 3-5 Compression stroke

Since the pressure within the cylinder is less than the pressure of the refrigerant at the
suction side of the compressor, the suction valve is forced open and the refrigerant vapor is
drawn into the cylinder.

During the compression stroke, the piston reverses

its direction and travels toward the discharge valve,
compressing the refrigerant vapor and increasing the
pressure within the cylinder. When the pressure
inside the cylinder exceeds the suction pressure, the
suction valve is forced closed, trapping the
refrigerant vapor inside the cylinder.
Fig 3-6 intake stroke

3.2.2 Scroll Compressor

Similar to the reciprocating compressor,

the scroll compressor works on the
principle of trapping the refrigerant
vapor and compressing it by gradually
shrinking the volume of the refrigerant.
The scroll compressor uses two scroll
configurations, mated face-to-face, to
perform this compression process. The
tips of the scrolls are fitted with seals
that, Fig 3-5 Scroll
Compressor
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along with a fine layer of oil, prevent the compressed refrigerant vapor from escaping
through the mating surfaces. The upper scroll, called the stationary scroll, contains a
discharge port. The lower scroll, called the driven scroll, is connected to a motor by a shaft
and bearing assembly.. In this example scroll compressor, refrigerant vapor enters through
the suction opening. The refrigerant then passes through a gap in the motor, cooling the
motor, before entering the compressor housing. The refrigerant vapor is drawn into the scroll
assembly where it is compressed, discharged into the dome, and finally discharged out of the
compressor through the discharge opening.

3.2.2.1 Helical-Rotary (Screw) Compressor

Similar to the scroll compressor, the helical-

rotary compressor traps the refrigerant vapor
and compresses it by gradually shrinking the
volume of the refrigerant. This particular
helical-rotary compressor design uses two
mating screw-like rotors to perform the
compression process. The rotors are meshed
and fit, with very close tolerances, within the
Fig 3-6 Helical Compressor

compressor housing. The gap between the

two rotors is sealed with oil, preventing
the compressed refrigerant vapor from
escaping through the mating surfaces.
Only the male rotor is driven by the
compressor motor. The lobes of the male
rotor engage and drive the female rotor,
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causing the two parts to counterrotate. In this example

Fig 3-7 Helical-Rotary Compressor

helical-rotary compressor, refrigerant vapor is drawn into the compressor through the
suction opening and passes through the motor, cooling it. The refrigerant vapor is drawn into
the compressor rotors where it is compressed and discharged out of the compressor. In the
air-conditioning industry, helical-rotary compressors are most commonly used in water
chillers ranging from 70 to 450 tons [200 to 1,500 kW].

3.2.3 Centrifugal Compressor

The centrifugal compressor uses the principle of

dynamic compression, which involves
converting energy from one form to another, to
increase the pressure and temperature of the
refrigerant. It converts kinetic energy (velocity) to
static energy (pressure). The core component of
a centrifugal compressor is the rotating
impeller. The center, or eye, Fig 3- 8
Centrifugal Compressor

of the impeller is fitted with blades that draw refrigerant vapor into radial passages that are
internal to the impeller body. The rotation of the impeller causes the refrigerant vapor to
accelerate within these passages, increasing
its velocity and kinetic energy. The
accelerated refrigerant vapor leaves the
impeller and enters the diffuser passages.
These passages start out small and become
larger as the refrigerant travels through them.
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As the size of the diffuser passage increases, the velocity, and therefore the kinetic energy,
of the refrigerant decreases. Fig 3-9 Centrifugal Compressor

The first law of thermodynamics states that energy is not destroyed—only converted from
one form to another. Thus, the refrigerant’s kinetic energy (velocity) is converted to static
energy (or static pressure).

In this example centrifugal compressor, refrigerant vapor is drawn into the compressor and
enters the center of impeller. This particular centrifugal

3.2.4 open compressor

In addition to the different methods of

compression, compressors can be
classified as open, hermetic, and
semihermetic. A reciprocating
compressor will be used to explain these
terms. An open compressor is driven by
an external power source, such as an
electric motor, an engine, or a turbine.
The motor is coupled to the compressor
crankshaft by a flexible coupling. Since Fig 3-11 Open Compressor

the shaft protrudes through the compressor housing, a seal is used to prevent refrigerant
from leaking out of the compressor housing. This motor is cooled by air that is drawn in
from the surrounding space..

3.2.5 open compressor

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A hermetic compressor, on the other hand, seals the motor within thcompressor housing.
This motor is cooled by the refrigerant, either by refrigerant vapor that is being drawn into
the compressor from the suction line or by liquid refrigerant that is being drawn from the
liquid line. The heat from the motor is then Fig 3-12 Hermetic Compressor

rejected by thcondenser. Hermetic compressors eliminate the need for the shaft couplings
and external shaft seals that are associated with open motors. The coupling needs
precisealignment, and these seals are a prime source of oil and refrigerant leaks.

3.2.5 semihermetic compressor

Similarly, the motor for a semihermetic

compressor is also contained within the
compressor housing and is cooled by the
refrigerant. The term “semihermetic” means
that the sealed housing is designed to be
opened to repair or overhaul the compressor
or motor.
Fig 3-13 Semihermetic Compressor

3.3Condenser

The first major component to be discussed is the condenser. The condenser is a heat
exchanger that rejects heat from the refrigerant to air, water, or some other fluid. The three
common types of condensers are air-cooled, water-cooled, and evaporative .

3.3.1 Air-Cooled Condensers

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A typical air-cooled condenser uses propeller-type fans to draw outdoor air over a finned-
tube heat transfer surface. The temperature difference between the hot refrigerant vapor that
is flowing through the tubes and the cooler outdoor air induces heat transfer. The resulting
reduction in the heat content of Fig 3-14 Air cooled condenser

the refrigerant vapor causes it to condense into liquid. Within the final few lengths of
condenser tubing (the subcooler), the liquid refrigerant is further cooled below the
temperature at which it was condensed. The air-cooled condenser is very popular in both
residential and commercial applications because of its convenience.

The benefit of subcooling on system

performance can be demonstrated by comparing
the performance of a system with and without
subcooling. The change in enthalpy (the line
from A to B) that occurs in the evaporator is
called the refrigeration effect. This is the amount
of heat that each pound [kg] of liquid refrigerant
will absorb when it evaporates. In comparison,
the same system without subcooling produces
less refrigeration effect
Fig 3-15 Effect of subcooling

(the line from A’ to B). The system without subcooling must evaporate substantially more
refrigerant within a larger coil to produce the same capacity as the system with subcooling.
Instead of subcooling in the condenser, some packaged refrigeration equipment, such as
water chillers, may use an economizer or liquid/vapor separator to increase this refrigeration
effect.
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3.3.1.1 centrifugal fan Air-Cooled Condensers

An alternative air-cooled condenser uses a centrifugal fan to draw or blow air over the
condensing coil. The principal advantage of this design is that the centrifugal fan is capable
Fig 3-16 Fan air cooled condenser

of overcoming the higher static-pressure losses associated with ductwork. Therefore, if the
condenser is to be located indoors and uses a duct system to deliver air to and from the
condenser coil, the centrifugal fan air-cooled condenser is probably best suited for this
application.

3.3.2 Evaporative Condensers

A modification of the air-cooled condenser is

the evaporative condenser. Within this device,
the refrigerant flows through tubes and air is
drawn or blown over the tubes by a fan. The
difference is that water is sprayed on the tube
surfaces. As the air passes over the coil, it
causes a small portion of the water to evaporate.
This evaporation process absorbs heat from the
coil, causing the refrigerant vapor within the
tubes to condense. Fig 3-
17 Evaporative condenser

The remaining water then falls to the sump to be recirculated and used again. Subcooling of
the refrigerant can be accomplished by piping the condensed liquid back through another
few rows of coil tubing, located either in the condenser airstream or in the water sump,
where additional heat transfer reduces the temperature of the liquid refrigerant.
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3.3.3 Water-Cooled Condensers

The shell-and-tube is the most common type of

water-cooled condenser. With this design, water is
pumped through the tubes while the refrigerant
vapor fills the shell space surrounding the tubes.
As heat is transferred from the refrigerant to the
water, the refrigerant vapor condenses on the tube
surfaces. The condensed liquid refrigerant then
falls to the bottom of the shell, where it flows
through an enclosure that contains additional
tubes (the subcooler). More heat is transferred from the liquid refrigerant to the water inside
these tubes, subcooling the refrigerant. After the warm water leaves the condenser, it must
either be disposed of (as in the case of using water from a well) or it must be cooled before it
can be reused by the condenser. In this example, the condenser Fig 3-18 Water
cooled condenser

brings in 85°F [29°C] water and warms it up to 95°F [35°C]. Before this water can be used
again, it must be cooled back down to 85°F [29°C].

3.3.4 Water-Cooled Condensers

A cooling tower is a device commonly used to

cool condensing water. In this design, warm water
is sprayed over the fill inside the cooling tower
while apropeller fan draws outdoor air upward
through the fill. The movement of air through the
spray causes some of the water to evaporate, a
process that cools the remaining water. This
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cooled water then falls to the tower sump to be returned to the condenser.
Fig 3-19 Cooling tower

The final temperature of the water leaving the tower is determined, in part, by the humidity
of the outdoor air. If the outdoor air is dry, the final water temperature can be considerably
lower than the ambient dry-bulb temperature. If the outdoor air is humid, however, the final
temperature will be near the ambient dry-bulb temperature. While a cooling tower can
reclaim much of the condensing water, it cannot reclaim it all. The evaporation process uses
up water to dissipate heat contributed by the cooling load plus the heat of compression.

3.4 Evaporators

The second major component to be discussed is the evaporator. The evaporator is a heat
exchanger that transfers heat from air, water, or some other fluid to the cool liquid
refrigerant. Two common types of evaporators are the finned-tube and the shell-and-tube.

3.4.1 Finned-Tube Evaporators

A finned-tube evaporator includes rows of tubes

passing through sheets of formed fins. Cool, liquid
refrigerant flows through the tubes, cooling the
tube and fin surfaces. As air passes through the
coil and comes into contact with the cold fin
surfaces, heat is transferred from the air to the
refrigerant. This heat transfer causes the
refrigerant to boil and leave the evaporator as
vapor. Fig 3-20 Finned-Tube Evaporators
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Inside the final length of tubes—the location

where the temperature difference between the
refrigerant and the air is highest—this larger
temperature difference accelerates the rate of
heat transfer and the refrigerant vapor absorbs
even more heat. When the liquid refrigerant has
completely evaporated, this additional heat gain
to the vapor is called superheating.
Superheating the refrigerant vapor Fig 3-21 Superheat

(the line from B to C) shifts it away from the liquid/vapor region and ensures that the
refrigerant vapor is completely free of liquid prior to traveling to the compressor.

3.4.2 Shell-and-Tube Evaporators

Instead of producing cooled air, a shell-and-

tube evaporator is used to produce chilled
water. In this type of evaporator, the cool
liquid refrigerant flows through the tubes and
water fills the shell space surrounding the
tubes. As heat is transferred from the water
to the refrigerant, the refrigerant boils inside
the tubes and the resulting vapor is drawn to
Fig 3-23 Shell-and-Tube Evaporators

the compressor. Water enters the shell at

one end and leaves at the opposite end.
This chilled water is pumped to one or
more heat exchangers to handle the system
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cooling load. These heat exchangers could be coils used to cool air or they could be some
other load that requires chilled water Baffles within the shell direct the water in a rising and
falling flow path over Fig 3-24 Shell-and-Tube Evaporators

3.5 Expansion Devices

An expansion device is used to maintain a pressure difference between the high-pressure

(condenser) and low-pressure (evaporator) sides
of the system established by the compressor.
This pressure difference allows the evaporator
temperature to be low enough to absorb heat
from the air or water to be cooled, while also
allowing the refrigerant to be at a high enough
temperature in the condenser to reject heat to air
or water at normally available temperatures.
There are several types of expansion devices,
including expansion valves (thermostatic or
electronic), capillary tubes, and orifices. This clinic will limit its discussion to thermostatic
expansion valves (TXVs). Fig 3- Expansion Devices

Other expansion devices perform essentially the same function.

3.5.1 Thermostatic expansion

valve

The thermostatic expansion valve

(TEV or TXV) is used for refrigerant
flow control and operates at varying
pressures resulting from varying
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temperatures. This valve maintains constant superheat in the evaporator.Thermal expansion

valve has a sensing bulb, which is connected to TXV by a length of capillary tubing. The
capillary tube transmits sensing bulb pressures to the top of the TXV valve’s diaphragm.
Fig 3-26 Thermostatic expansion valve

3.5.2 Capillary tube metering device

A capillary tube is a refrigerant control; its common types of air conditioner expansion valve. The
capillary is simply a length of tubing with a small inside diameter which acts as a constant throttle
on the refrigerant entering the evaporator. A fine filter or filter drier installed at the inlet of the
capillary prevents
dirt from blocking
the tube.

Fig 3-27 2
Capillary tube

A recent
development in the design of capillary tubes for air conditioning system uses capillary tubes
with a larger insider diameter and a longer tube length. A larger diameter tubes are less
likely to become plugged with dirt and other impurities than a smaller diameter tube. The
long length provides the necessary resistance to create the desired pressure difference across
the metering device. The capillary tube equalizes the pressure in the system when the unit
stops. This pressure equalizing characteristic of the capillary allows a low starting torque
motor to be used with the compressor. Typically, a capillary does not operate as efficiently
over a wide range of conditions as does the thermostatic expansion valve. However, because
of its counterbalance factors in most applications, its performance is generally very good.
Refrigeration systems using a capillary tube doesn’t require the use of a liquid receiver since
all the liquid is stored in the evaporator during the off cycle. However, a suction accumulator
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is often found in the suction line to prevent any non vaporized refrigerant from reaching the
compressor. This will prevents damage to the compressor when excessive liquid refrigerant
enters the evaporator on a low evaporator load condition.

3.6 Accessories

This period discusses several accessories used in comfort-cooling refrigeration systems.

3.6.1 Solenoid Valve

A solenoid valve is used to stop the flow of

refrigerant within the system.These valves are
magnetically operated, and an electric
winding controls the opening and closing of
the valve. The valve is typically a normally-
closed type of valve so that it is closed when
it is deenergized.
Fig 3-28 Solenoid Valve

Another common use of a solenoid valve is

to enable system pump-down and prevent
the refrigerant from migrating through the
system when the compressor is shut off. In
this application, a single solenoid valve is
installed in the liquid line, upstream of all
expnsion valves. When the compressor is
shut off, the evaporator contains a large
quantity of liquid refrigerant.
Fig 3-29 Solenoid Valve
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This can present a problem if some of the refrigerant drains into the suction line and slugs
the compressor when it starts up again. To prevent this from occurring, many systems pump
the refrigerant out of the evaporator and suction line before shutting the compressor off.

3.6.2 Liquid-Line Filter Drier

The next accessory to be discussed, the liquid-

line filter drier, is installed upstream of the
solenoid valve and the expansion valve. It
prevents moisture (water) and foreign matter,
introduced during the installation process, from
entering the expansion valve and the solenoid
valve. Realize, however, that there is no
substitute for cleanliness during system
installation. Moisture and foreign matter can
Fig 3-30 Liquid-Line Filter Drier

cause problems in any refrigeration system. When water is mixed with refrigerant and oil,
and heat is added by the compressor, acids are formed that can damage the valves or
compressor.

A typical liquid-line filter drier includes

a molded, porous core. The core has
ahigh affinity for moisture and removes
foreign matter from the refrigerant. The
two common types of filter driers are
replaceable core and sealed. The
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replaceable core type allows the core to be easily replaced. The sealed type is completely
closed, reducing the Fig 3-31 Liquid-Line Filter Drier

chances of refrigerant leaks. Ball-type shutoff valves are typically installed just upstream and
downstream to allow the filter drier to be isolated and the core (or unit) replaced.

3.6.3 Moisture-Indicating Sight Glass

A moisture-indicating sight glass is installed in

the liquid line, upstream of the expansion valve,
and permits the operator to observe the condition
of the refrigerant prior to entering the expansion
valve. The value of the sight glass is in its
moisture indication ability—the sight glass
should not be used to determine system
refrigerant charge or subcooling. Actual
temperature and pressure measurements
Fig 3-32

are required to determine proper charge and subcooling. With the sight glass installed
directly ahead of the expansion valve, it can also be used to detect the presence of bubbles in
the liquid line. This would indicate that some of the liquid refrigerant has flashed into vapor
upstream of the expansion valve. Since the expansion valve is designed to control the flow
of liquid refrigerant only, the presence of refrigerant vapor results in a reduction in the
quantity of liquid refrigerant being fed to the evaporator. There are many potential causes of
liquid refrigerant flashing. The sight glass can alert the operator to the conditio
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3.6.4 Suction Line Filte

Similar to the liquid-line filter drier, the

suction line filter performs the task of
removing foreign matter from the
refrigeration system. It is installed in the
suction line, just upstream of the
compressor. The suction filter contains
filter media to remove copper filings,
Fig 3-33 Suction Line Filte

flux, dirt, and other foreign matter that may

have been introduced during the installation
process or as the result of a compressor
failure. It protects the compressor parts
from the abrasive action that could result if
these materials enter the compressor. Dirt
can obstruct oil passages, robbing the
compressor bearings of lubrication.
Fig 3-34 Suction Line Filte

Similar to the liquid-line filter drier, the two common types of suction line filtersare
replaceable core and sealed. The replaceable core type allows the core to beeasily replaced.
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The sealed type is completely closed, reducing the chances ofrefrigerant leaks.Replaceable
core suction filters are commonly installed after a compressorfailure has occurred. The core
is replaced after the foreign matter or acid hasbeen

3.6.5 Hot Gas Muffler

The purpose of the hot gas muffler is

to smooth out the pulsations
associated with the refrigerant vapor
being discharged from a reciprocating
compressor, reducing noise and
vibration. The pressure of the
refrigerant vapor leaving
reciprocating compressor fluctuates
rapidly because of the manner in
which it is compressed by the
Fig 3-35 Hot Gas Muffler

reciprocating pistons. The muffler contains a perforated tube inside a shell. The pressure
peaks cause some of the refrigerant vapor to pass from the perforated tube into the muffler
shell. This shell is divided into chambers that allow it to absorb these peaks. In essence, the
muffler shaves off the peaks of these pulsations and fills in the valleys,

3.6.6 Shutoff Valve

Shutoff valves are used to isolate one part of

the refrigeration system from the rest.
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Additionally, they can be used to trap the refrigerant charge in one component of the system,
the condenser for example, to permit service or repair to another part of the system.
Common uses of shutoff valves include: Isolating the liquid-line filter drier and suction filter
to allow easier core (or unit) Fig 3-36 Shutoff Valve

replacement Isolating the compressor from the rest of the system to allow for repair or
replacement Isolating the charge within the condenser or a receiver to allow access to the
rest of the system

3.6.6 Access Port

An access port is used to add refrigerant to the

system or for measurement. An access port is
typically installed in the liquid line in a
convenient location and is used to charge the
system with liquid refrigerant. It is also
Fig 3-37 Access Port

used to measure subcooling. The suction line typically includes two access ports. One is
installed near the compressor and is used to measure suction pressure. The other is located
near the external equalizer-line connection for the expansion valve, and is used to measure
superheat when checking or adjusting the expansion valve setting.

3.7 Chiller and types

A chiller is a machine that removes heat from a

liquid via a vapor-compression or absorption
refrigeration cycle. Most often water is chilled, but
this water may also contain 20% glycol and
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corrosion inhibitors; other fluids such as thin oils can be chilled as well.Chilled water is used
to cool and dehumidify air in mid- to large-size commercial, industrial, and institutional

facilities. Fig 3-38 Chiller

Most chillers are designed for indoor operation, but a few are weather-resistant. Chillers are
precision machines that are very expensive to purchase and operate,

3.7.1 According to compressor type

There are basically four different types of chillers: [Reciprocating compressor]

Reciprocating compression, [scroll compressor] scroll compression, [Rotary screw
compressor] screw driven compression, and [centrifugal compressor] centrifugal
compression.

Reciprocating Chiller Scroll Chiller

Rotary screw Chiller Centrifugal Chiller

Fig 3-39 Chiller types

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3.7.2 According To Cooling Medium

Chillers can be air-cooled or water-cooled.

Water-cooled chillers incorporate the use of
[cooling towers] which improves the chillers'
thermodynamic effectiveness as compared to
air-cooled chillers. This is due to heat
rejection at or near the air's wet-bulb
temperature rather than the higher, sometimes
much higher, dry-bulb temperature.

Where available, cold water readily available Fig 3-40 Water-cooled chillers

in nearby water bodies might be used directly for cooling, or to replace or supplement
cooling towers It dispensed with the need for cooling towers, with a significant cut in
[[carbon emissions]] and energy consumption. It uses cold lake water to cool the chillers,
which in turn are used to cool city buildings
via a [[district heating district cooling]]
system.

The return water is used to warm the city's

drinking water supply which is desirable in
this cold climate. Whenever a chiller's heat
rejection can be used for a productive purpose,
Fig 3-41 Airr-cooled chillers

3.8 Air Handling Unit (AHU)

3.8.1 Introduction
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Air handling unit and often abbreviated to AHU, is a device used as part of a heating,
ventilating, and air-conditioning (HVAC) system. Usually, an air handler is a large metal
box containing a blower, heating and cooling elements filter racks or chambers, sound
attenuators, and dampers. Air handlers usually connect to ductwork that distributes the
conditioned air through the building, and returns it to the AHU.

Sometimes AHUs discharge (supply) and admit

(return) air directly to and from the space served,
without ductwork. Small air handlers, for local
use, are called terminal units, and may only
include an air filter, coil, and blower; these simple
terminal units are called blower coils or fan coil
units. Larger air handlers that condition 100%
outside air, and no recalculated air, are known as
makeup air units (MAUs).
Fig 3-42 (AHU)

Air handlers commonly also provide

provisions to allow the introduction of
outside air into, and the exhausting of air
from, the building. A heat recovery heat
exchanger, of many types, may be fitted to
the air handler for energy savings and
increasing capacity

Fig 3-43 model (AHU)

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3.8.2 Air handling unit Components

Fig 3-44 Air

handling unit components

3.8.2.1 Mixing box

A mixing box is the section of an air

handling unit used to mix the return air flow
with the outside air flow. It consists of
three sets of dampers whose operation is
coordinated to control the fraction of the
outside air in the supply air while
maintaining the supply air-flow rate
approximately constant. Figure below is a
simplified diagram of the mixing
Fig 3-45 Mixing box

box simulated in the model. A variant of this design has a separate outside air damper
that is adjusted to provide the minimum outside air flow required during occupancy.
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

3.8.2.2 Dampers

All dampers are made with rigid aluminum frame

with air foil aluminum blades so as to reduce
pressure drop and sound generated when air passes
through the blades. An opposed blades
arrangement is used with virtually no air leakage.
Dampers blade's rotation is achieved by the PCV
gear's rotation.
Fig 3-46 Dampers

3.8.2.3 Filters

Filters types can be selected

to meet any filtration
requirements and so wide
variety of filter types are
available, including flat
filters, V-filters, bag filters,
HEPA filters, carbon filters
Fig 3-47 filters type

and other filters. Selection of filters depends on the indoor air quality requirements.

3.8.2.4 Coils

A variety of coils chilled water coil,

hot water coil, steam coils and DX
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coils are available to suit the client needs. Coils are manufacturing from seamless copper
tubes expanded in aluminum Fig 3-48 coils

fins and they are provided with manual air vent accessible from out side casing for quick
venting. Coils are available from 1-12 rows for both chilled water and DX-systems and
from 1-4 rows for heating coils. Finally coils are Anti-corrosion coating.

3.8.2.5 Fans

Supply & return /exhaust fans are centrifugal fans and all fans are selected for optimum
outlet velocities and low sound level. Fans are supplied with flexible connection between
fan discharge outlet and the unit casing. The fan shaft is made of steel machined and the
bearing is ball bearing.

Fig 3-49 fan

3.9 Air Distribution Systems

3.9.1 Introduction

A basic air-distribution system includes supply air and return air. An air-distribution
system should be zoned to deliver an adequate amount of supply air to the cooling air
intake vents of the server equipment cabinets. Supply air temperature should be
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

maintained within the following parameters: The following three types of air distribution
systems are listed in order of recommendation

1) Under floor air distribution system—down flow air-conditioning equipment located

on the raised floor of the computer room uses the cavity beneath the raised floor as
plenum for the supply air.

2) Ceiling plenum air distribution system—Supply air is ducted into the ceiling plenum
from up flow air-conditioning equipment located in the computer room or from an air
handling unit (remote).

3) Above ceiling ducted air-distribution system—Supply air is ducted into a ceiling

diffuser system from up flow air-conditioning equipment located in the computer
room or from an air handling unit (remote).

3.9.2 Air distribution systems Components

1) Air distribution system comprising various inlets for recalculated air and outlets for
supply air.

2) The duct system including supply duct and return duct.

3) The fan which provides the necessary energy to move air.

3.9.3 Selected and located of diffusers

A diffuser is the mechanical device that is designed to control the characteristics of a

fluid at the entrance to a thermodynamic open system. Flow through nozzles and
diffusers may or may not be assumed to be adiabatic.

Frictional effects may sometimes be important, but usually they are neglected. However, the
external work transfer is always assumed to be zero. It is also assumed that changes in
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

thermal energy are significantly greater than changes in potential energy and therefore the
latter can usually be neglected for the purpose of analysis.

3.9.3.1 Types of Diffusers

Square
ceiling

diffuser floor diffuser round ceiling diffuser

stampaire diffuser drum diffuser baseboard diffuser

Fig 3-50 Types of Diffusers

3.9.3.2 Consideration must be known

1- Consideration Selected and located of diffusers

 The amount of air delivered by outlet should be proportional to the load of the
part of space for which it installed.
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

 The selection of the type of outlet is governed by the ceiling high, nature of
room, occupancy, etc.

 The location of the outlet should be governed by the condition of uniform air
distribution and rapid temperature equalization.

 The selection of size of the outlet can be made from the manufacture's catalog
data according to the air delivery.

2- Consideration Selected and located of return air opening

 There should not be any short-circuiting of air between the supply outlet and
return inlet.

 The return air which is either too cool in winter or too warm in summer or
contains dirt, gasses or odors should be removed without causing any drafts in
conditioned space by making the undesirable product to move in its natural
direction.

 The velocity of air decreases rapidly as one move away from the inlet.

 The consideration of noise is a little more in the case of return inlets as they are
normally located near the ear-level. In this case the velocity in the return inlets
should not exceed 75 % of the velocity in the supply air outlets.

3- General procedure for select the diffusers

 Determine the air flow requirements and space size.

 Select the diffuser to be used.

 Determine the space characteristic length.

 Select recommended throw-to-length ratio

 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

 Calculate the throw.

 Select appropriate diffusers from catalog data

 Make sure any other specification are met (noise, total pressure. Etc,).

3.10 Ducts

used in heating, ventilation, and air conditioning (HVAC) to deliver and remove air. These
needed airflows include, for example,
supply air, return air, and exhaust air.[1]
Ducts also deliver, most commonly as
part of the supply air, ventilation air. As
such, air ducts are one method of
ensuring acceptable indoor air quality as
well as thermal comfort. A duct system
is often called ductwork. Planning
('laying out'), sizing, optimizing,
detailing, and finding the pressure losses
through a duct system is called duct
design
Fig 3-51 Duct

3.10.1 Materials

3.10.1.1Polyurethane and Phenolic insulation panels (pre-insulated air

ducts)

Traditionally, air ductwork is made of sheet metal which is installed first and then lagged
with insulation as a secondary operation. Ductwork manufactured from rigid insulation
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

panels does not need any further insulation and is installed in a single fix. Light weight and
installation speed are among the features of preinsulated aluminium ductwork, also custom
or special shapes of ducts can be eas ily fabricated in the shop or on site.

The ductwork construction starts with the tracing of

the duct outline onto the aluminium preinsulated panel,
then the parts are typically cut at 45 degree, bent if
required to obtain the different fittings (i.e. elbows,
tapers) and finally assembled with glue. Aluminium
tape is applied to all seams where the external surface
of the aluminium foil has been cut. A variety of flanges
are available to suit various installation requirements.
All internal joints are sealed with sealant.
Fig 3-52 Polyurethane

Among the various types of rigid polyurethane foam panels available, a new water
formulated panel stands out. In this particular panel, the foaming process is obtained through
the use of water instead of the CFC, HCFC, HFC and HC gasses. And most manufacturers of
rigid polyurethane foam panels use normal pentane as foaming agent instead of the CFC,
HCFC, HFC and HC gasses, so dose manufacturers of rigid phenolic foam panels.

3.10.1.2 Fiberglass duct board (preinsulated non metallic ductwork)

Also the fiberglass panels provide built-in

thermal insulation and the interior surface
absorbs sound, helping to provide quiet operation
of the HVAC system. The duct board is formed
by sliding a specially-designed knife along the
board using a straightedge as a guide; the knife
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automatically trims out a "valley" with 45° sides; the valley does not quite penetrate the
entire depth of the duct board, providing a thin Fig 3-53 Fiberglass

section that acts as a hinge. The duct board can then be folded along the valleys to produce
90° folds, making the rectangular duct shape in the fabricator's desired size. The duct is then
closed with staples and special aluminum or similar 'metal-backed' tape. Commonly
available duct tape should not be used on air ducts, metal, fiberglass, or otherwise, that are
intended for long-term use; the adhesive on so called 'duct tape' dries and releases with time.

3.10.1.2 Flexible Ducting

Flexible ducts, known as flex, have a

variety of configurations, but for
HVAC applications, they are typically
flexible plastic over a metal wire coil to
make round, flexible duct. In the
United States, the insulation is usually
glass wool, but other markets such as
Australia, use both polyester fibre and
glass wool for thermal insulation. A
protective layer surrounds the
insulation, Fig 3-54 Flexible

and is usually composed of polyethylene or metalised PET. Flexible duct is very convenient
for attaching supply air outlets to the rigid ductwork. However, the pressure loss through
flex is higher than for most other types of ducts. As such, designers and installers attempt to
keep their installed lengths (runs) short, e.g., less than 15 feet or so, and to minimize turns.
Kinks in flex must be avoided. Some flexible duct markets prefer to avoid using flexible
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

duct on the return air portions of HVAC systems, however flexible duct can tolerate
moderate negative pressures - the UL181 test requires a negative pressure of 200 Pa.

3.10.1.3 Fabric

Fabric ducting, also known as air

socks, duct socks or textile ducts, are
designed for even air distribution
throughout the entire length. Usually
made of special permeable polyester
material, fabric ducts act like a
conventional system with much
more diffusers. Fabric ducts are
normally used where even air
distribution is essential.
to the nature or the air distribution,
Fig 3-56 Fabric

extile ducts are not usually concealed within false ceilings, because of this, they are
manufactured in various colours to coordinate with the interior. Fabric ducts fitted above a
ceiling will need to be pvc coated so that no maintenance is required to maintain
performance.

3.10.2 Duct system components

3.10.2.1 Vibration isolators

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A duct system often begins at an air handler. The blowers in the air handlers can create
substantial vibration and the large area of the duct system would transmit this noise and
vibration to the inhabitants of the building. To avoid this, Fig 3-57 Vibration
isolators

vibration isolators (flexible sections) are normally inserted into the duct immediately before
and after the air handler. The rubberized canvas-like material of these sections allow the air
handler to vibrate without transmitting much vibration to the attached ducts.

3.10.2.2 Take-offs

Downstream of the air handler,

the supply air trunk duct will
commonly fork, providing air to
many individual air outlets such
as diffusers, grilles, and
registers. When the system is
designed with a main duct
branching into many subsidiary
branch ducts, fittings called
take-offs allow a small portion
of the flow in the main duct to
be diverted into each branch
duct. Fig 3-58 Take-offs

Take-offs may be fitted into round or rectangular openings cut into the wall of the main duct.
The take-off commonly has many small metal tabs that are then bent to retain the take-off on
the main duct; round versions are called spin-in fittings. Other take-off designs use a snap-in
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

attachment method, sometimes coupled with an adhesive foam gasket to provide improved
sealing.

3.10.2.3 Stacks, boots, and heads

Ducts, especially in homes, must often allow air to

travel vertically within relatively thin walls. These
vertical ducts are called stacks and are formed with
either very wide and relatively thin rectangular
sections or oval sections. At the bottom of the stack, a
stack boot provides a transition from an ordinary large
round or rectangular duct to the thin wall-mounted
duct. At the top, a stack head can provide a transition
back to ordinary ducting while a register head allows
Fig 3-59 Stack and boot

the transition to a wall-mounted air register.

3.10.2.4 Volume Control Dampers

Ducting systems must often provide a method of

adjusting the volume of air flow to various parts of the
system. VCD's (Volume Control Dampers - Not To Be
confused with Smoke/Fire Dampers) provide this
function. Besides the regulation provided at the
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

registers or diffusers that spread air into individual rooms, dampers can be fitted within the
ducts themselves. These dampers may be manual or automatic.
Fig 3-60 Volume Control Dampers

3.10.2.5 Smoke/Fire Dampers

Smoke and Fire dampers are found in

ductwork, where the duct passes through a
firewall or firecurtain. Smoke dampers are
automated with the use of a mechanical motor
often referred to as an Actuator. A probe
connected to the motor is installed in the run
of duct, and detects smoke within the duct
system which has been extracted from a
room, or which is being supplied from the
Fig 3-61 Smoke/Fire Dampers

AHU (Air Handling Unit) or elsewhere within the run. Once smoke is detected within the
duct, the Actuator triggers the motor release and the smoke damper will automatically close
until manually re-opened. You will also find Fire dampers in the same places as smoke
dampers, depending on the application of the area after the firewall.

3.10.2.6 Plenums

Plenums are the central distribution and collection units

for an HVAC system. The return plenum carries the air
from several large return grills (vents) to a central air
 Chapter 3 [MAIN COMPONENTS OF CENTRAL AIR CONDITIONING]

handler. The supply plenum directs air from the central unit to the rooms which the system is
designed to heat or cool.

1 Fig 3-62 Plenums

3.10.2.7 Terminal units

While single-zone constant air volume

systems typically don't have them, other
types of air distribution systems often have
terminal units in the branch ducts. Usually
there is one terminal unit per thermal zone.
Some types of terminal units are VAV
'boxes' of either single or dual duct, fan-
powered mixing boxes of either parallel or
series arrangement, and induction terminal
units. Terminal units may also include
either, or both, a heating or cooling coil.

Fig 3-63 Terminal units