Module 4 in IA 109 – DOMESTIC REFRIGERATION AND AIR CONDITIONING

ROOM AIR CONDITIONING SYSTEM

LEARNING OUTCOMES:
1. Discuss air conditioning maintenance and servicing;
2. Appreciate the importance of maintenance and servicing air conditioning; and
3. Perform servicing and maintenance of air conditioning unit.

A room air conditioner is a “comfort-making machine” used to condition rooms for

human comfort. This home air conditioning unit is usually classified according to their design
and method of installation such as window type unit or portable or free-standing type unit. They
are much the same, typically having only one fan motor for the evaporator and the condenser.
The capacity of these units may range from 4000 Btu/hr (1/2 ton) to 24,000 Btu/hr (2 tons).
The purpose of home air conditioning is to lower the temperature of a room, to
dehumidify the air, to filter dirt, fumes, air-borne pollen and irritating industrial dust, to circulate
the air, and for ventilation.

THE REFRIGERATION CYCLE

Refrigeration is the heart of air conditioning. The cycle consists of four major parts: an
evaporator used to absorb heat into the system, a compressor used to pump the heat laden
refrigerant through the system, a condenser used to reject the heat from the system, and an
expansion valve used to control the flow of refrigerant. This is done by maintaining a pressure
difference between the high-pressure side and the low-pressure side of the unit.
Cooling units are considered high temperature refrigeration systems and must operate
above freezing to prevent the condensate from freezing on the evaporator coil. Typically, the
evaporators boil the refrigerant at about 350F.
The evaporator is typically made of copper or aluminium tubing with aluminium fins.
The fins may be straight or spine. All fin types are in close contact with the copper tubing for
the best heat exchange. It operates below the dew-point temperature of the room air for the
purpose of dehumidification. Condensate forming on the evaporator coil is typically drained
back to the condenser section and evaporated.
The compressor for a room air-conditioner is a typical hermetically sealed air
conditioning compressor. The compressor may be rotary or reciprocating.
Condensers are typically copper tubes with fins or aluminium tubes and aluminium fins,
similar to the evaporator. The condenser serves two purposes, it condenses heat-laden vapor
refrigerant inside the tubes and evaporates the condensate from the evaporator section. This is
accomplished by using the heat from the discharge line and a slinger ring on the condenser fan.
Evaporating the condensate serves two purpose, it keeps the unit from dripping and improves
the efficiency of the condenser.
 The capillary tube is a type of metering device used in units. Some manufacturers are
automatic expansion valves with the advantage of controlling the pressure which in turn controls
the temperature. Coil freezing could be prevented by controlling the pressure.
Most room air conditioners are designed to effect the exchange of heat between the
capillary tube and the suction line. this exchange adds superheat conditions to the suction gas
and subcools the refrigerant in the first part of the capillary tube.

COMPRESSOR MOTOR

The compressor motor usually used in air conditioner is the PSC (Permanent Split
Capacitor) motor type This has no relay for starting unlike in household refrigerators. Current
flow through both running winding and the starting winding when the motor is on. A running
capacitor is connected between the running (R) and starting (S) terminals and is in series with
the starting winding.
These motors are sensitive to line voltage. A voltage drop of 5 to percent will cause
starting difficulty and overheating. The starting torque is low. When the pressures are not
balanced, it will overheat and can damaged the motor. To overcome the problem. To overcome
this problem, a starting capacitor and a relay is being used. A recommended rating for add-on
starting capacitors are shown below.

RUNNING CAPACITORS STARTING CAPACITORS

Microfarad Microfarad
20 18
25 18 or 25
30 25
35 25
40 25 to 46
45 45
50 45

Most manufacturers specify Microfarad rating of special start capacitor for each of their
units. Follow manufacturer’s specification.
In installing the start capacitor to a PSC motor compressor for the purpose of increasing
the starting torque, a potential relay is needed to open the starting winding circuit when the PSC
motor reaches 75 percent of rated speed.

MOTOR CAPACITOR

The capacitor is an electrical device that allows electrical energy to be stored for later
use. In alternating current circuit, it changes a single-phase electrical flow to a two phase
electrical flow. The capacitor is usable in both the starting and running windings.
 A simple capacitor is composed of two plates with an insulating material between them.
The capacitor can store a charge of electron on one plate. In an AC circuit, the voltage and
current are continuously changing directions. As electron flow in one direction, the capacitor
plate on one side becomes charged. As the voltage and current changes, the charge of the
capacitor becomes greater than the source voltage, and the capacitor begins to discharge. It is
discharged through the circuit, and the opposite plate becomes charged. This continues through
each AC cycle.
Capacitors can be classified as start capacitor and run capacitor. If used in the starting
winding, it is called the starting capacitor. It is in circuit with starting winding for seconds only.
If the motor is started too often or if the starting winding is used longer than it is designed for,
the capacitor insulation will overheat and the capacitor may fail.
The start capacitor has range of 95 to 400 microfarad. It resembles a cylinder and usually
has a black plastic case. It is physically smaller than the run capacitor. They are the electrolytic
type of capacitors.
When a single-phase motor is operated, phase deviation occurs between current and
voltage due to electric induction and it generates motor waste current. As a result, the motor
does not run at normal rotation. Therefore, a running capacitor is attached to the unit to correct
phase deviation and to normalize motor rotation.
The run capacitor remains in the motor start winding circuit at all times during
compressor operations. It has a range of 5 to 40 microfarad with a metal case, and physically
larger than the start capacitor. Usually, if two run capacitors are wired in parallel, a bleeder
capacitor across the terminals is installed for safety purposes. It is built quite heavy with oil, tar,
or waxed paper.
A 220 volts’ capacitor may be used on a 110 volts’ circuit, but a 110-volt capacitor
cannot be directly connected across a 220-volt circuit. Capacitor has no polarity; you can
interchange the terminals as long as it is the specified capacitor for such motor.

STEPS IN CHECKING THE CONDITION OF A CAPACITOR

1. Get an Ohmmeter and turn the range selector knob to X 1K; zero-in the pointer.
2. Take connecting wire and short circuit the charge that might be on the plates of the capacitor.
Remove the shunt resistor if one is wired across the terminals. Charged capacitor can shock
or damage the meter.
3. After the capacitor has been discharged, remove the connecting wire and put the test prods on
the terminals of the capacitor so as to place dc-charge on the plates.
4. If the pointer of the ohmmeter deflected to direction A and returns to direction B within 10
seconds, the capacitor has taken the charge on the plates and the first half of the test is
successful;
5. If the pointer did not move, the capacitor is defective (Open).
6. If the capacitor has a metal case, check the continuity of the plates of the capacitor and the
metal case. If there is an ohm-resistance reading, the capacitor is defective (Grounded).
7. Test the capacitor if it held a charge; get a voltmeter and turn the selector range knob to 10-
volt scale. It will measure the voltage the capacitor is holding.
8. Put the test prods to the capacitor terminals. Observe the pointer is deflecting from zero to the
left (Off-,Quickly reverse the prods. The polarity is inverted.
9. If the capacitor deflected to a voltage reading or in direction A and returned to direction B, it
means that the capacitor held a charge and is good. If the pointer did not move, the capacitor
is defective. It means that the capacitor is presumed weak and not good.

CAPACITOR RANGE FOR DIFFERENT MOTOR CAPACITY

START CAPACITOR

HORSEPOWER (HP) CAPACITOR RANGE MICROFARAD

(µF)
1/8……………………………………….... 95-200
1/6……………………………………….... 95-200
1/4………………………………………… 200-300
1/3………………………………………… 250-350
1/2…………………………………..……. 300-400
3/4..……………………………………….. 300-400

RUN CAPACITOR

HORSEPOWER (HP) CAPACITOR RANGE MICROFARAD

(µF)
1/8……………………………………….... 4-5
1/6……………………………………….... 4-5
1/4………………………………………… 10
1/3………………………………………… 10-15
1/2………………………………………… 10-15
To 2 HP
3…………………………………………... 20
5…………………………………………... 30

POINTER DEFLECTION FOR CAPACITORS

Start capacitor, run capacitor, or the fan motor capacitor can be distinguished the
deflection of the pointer of the ohmmeter. Since the start capacitor has a higher capacitor than
the run capacitor, its deflection of the pointer is larger than the run capacitor. We know that start
capacitor rangers from 95 to 400 microfarad and the run capacitor ranges from 5 to 40
microfarad, because of its difference in ranges, they also differ in pointer deflection.
 The run capacitor and fan capacitor are usually integrated into one casing, and it is called
“dual capacitor”. When testing a dual-capacitor, the common terminal is usually at the center
and the remaining two terminals can be fan terminal and run terminal.
When testing the dual-capacitor with the ohmmeter, it must be discharged first by using
a connecting wire. If test prods are placed on both sides of the terminals, the pointer will not
deflect. It means that the remaining terminal is the common, C. From the common and to
another terminal, compare the deflection of the pointer. If the pointer deflected longer and
slowly returns, while the other is deflected shorter and also returns, the longer deflection is
considered the run capacitor, and the shorter one is the fan capacitor.
To increase the microfarad value of two capacitors, connect them in parallel and use the
formula:
Mfd = C1 + C2

To decrease the microfarad value of two capacitors, connect them in series and use the
formula

Mfd = C1 x C2
C1 + C 2
EXAMPLE: SOLUTION

CONNECTED IN PARALLEL

GIVEN: C1 = 20 µf Mfd = C1 + C2
C2 = 40 µf Mfd = 20 + 40
Mfd = 60 µf

CONNECTED IN PARALLEL SOLUTION

GIVEN: C1 = 20 µf Mfd = C1 x C2
C2 = 40 µf C 1 + C2
Mfd = 20 x 40
20 + 40
Mfd = 800
60
Mfd = 13.33
FAN MOTOR

The two main purpose of a fan motor in air conditioner is to force the condenser cooling
air through the ducts and over the condenser and condensing units, and to circulate air in the
room. Connected on both ends of the fan motor shaft is the propeller fan and the squirrel cage
fan or sirocco fan.
 The warm room air will be drawn in by the squirrel cage fan, passing through the filter;
the evaporator where heat will be absorbed, and then to the center of the squirrel cage fan and
thrown in to the periphery where it strikes a baffle and then reversed in its directions so that it
blows into the room after passing over the cool tubes and fins.
As a large volume of air will pass through the evaporator, the moisture it carries will be
deposited, thus dehumidification takes place. This moisture will be deposed by simply letting it
drips down into some troughs that directs it to pan under the condenser. The heat and turbulence
of air would evaporate the moisture or it may also be dripped into a lawn.
The atmospheric air will be drawn in by the propeller fan passing through the
compressor where the air will help the motor compressor to lower its temperature, and then
blow it out to the condenser where heat in the high- pressure, high-temperature refrigerant in
the system will be discharge out to the atmosphere. The newer model of a propeller fan has a
slinger ring attached to it. It spatters or “sling” the water onto the hot condenser. The water that
it slings up on the condenser improves the efficiency of the condenser.
The fan motor of air conditioner usually a permanent-star-capacitor (PSC) motor. These
fan motor may be of three speed type. They sometimes have thermal safety controls to protect
them from the high-ampere flow of current.
The fan motor terminals are the common (C), Auxiliary (A), the high (H), and the low
(L) terminals. Others have medium (M) terminals for the three-speed type.

STEPS IN NAMING/FINDING THE TERMINALS OF A FAN MOTOR

FOR THE TWO-SPEED TYPE OF FAN MOTOR

1. Secure an ohmmeter and turn the range selector to x 1 ohm; zero-in the pointer.
2. Get a piece of paper and sketch the terminals for a two speed type motor. Label it 1, 2, 3, and
4, because this motor has common (C), auxiliary (A), high (H), and low (L) only.
3. Get the resistance reading between the terminals.

EXAMPLE:

1 – 2 = 130 ohms
1 – 3 = 95 0hms
1 – 4 = 110 ohms
2 – 3 = 35 ohms
2 – 4 = 50 ohms
3 – 5 = 15 ohms

4. Get the three highest reading and they are;

1 – 2 = 130 ohms
1 – 3 = 95 ohms
1 – 4 = 110 ohms

5. Terminal with the same number (common) among the three pairs with highest reading is the
auxiliary (A). Therefore no. 1 is Auxiliary (A).
6. The highest reading between terminals 1 – 2 = 130 ohms, is between the auxiliary (A) and
common (C) terminals. Since no. 1 is auxiliary, therefore no.2 is common (C).
7. The second highest reading is between terminals 1 – 4 = 110 ohms, is between the auxiliary
(A) and the low (L). Since no. 1 is auxiliary, therefore no. 4 is low (L).
8. The 3rd highest reading is between terminals 1 – 3 = 95 ohms, is between the auxiliary (A) and
the high (H). Since no. 1 auxiliary (A) therefore no. 3 is (H).
9. Therefore, no. 1 is auxiliary (A)
no. 2 is common (C)
no. 3 is high (H)
no. 4 is low (L)

FOR THE THREE-SPEED TYPE OF FAN MOTOR

1. Secure an ohmmeter and turn the selector range knob to x 1 ohm; zero-in the pointer.
2. Get a piece of paper and sketch the terminals of a three-speed fan motor. Label it 1, 2, 3, 4,
1nd 5 because fan motor has auxiliary (A), common (C), high (H), medium (M), and low (L).
3. Get the resistance reading between the terminals.

EXAMPLE:

1 – 2 = 170 ohms
1 - 3 = 105 ohms
1 – 4 = 130 ohms
1 – 5 = 140 ohms
2 – 3 = 65 ohms
2 – 4 = 90 ohms
2 – 5 = 100 ohms
3 – 4 = 25 ohms
3 – 5 = 35 ohms
4 – 5 = 10 ohms

4. Get the four highest reading, and they are:

1 – 2 = 170 ohms
1 – 5 = 140 ohms
1 – 4 = 130 ohms
1 – 3 = 105 ohms
5. Terminal with the same number (common) among the four pairs is the Auxiliary (A).
6. The highest reading, 1 – 2 = 170 ohms, is between the auxiliary and common (C). Since no. 1
is auxiliary (A), therefore no. 2 is common (C).
7. The second highest reading, 1 – 5 = 140 ohms, is between the auxiliary (A) and low (L).
Since no. 1 is auxiliary (A), therefore no. 5 is low (L).
8. The third highest reading, 1 – 4 = 130 ohms, is between the auxiliary (A) and Medium (M).
Since no. 1 is auxiliary (A), therefore no. 4 is medium (M).
9. The fourth highest reading, 1 – 3 = 105 ohms, is between the auxiliary (A) and high (H).
Since no. 1 is auxiliary (A), therefore no. 3 is the high (H).
10. Therefore, no. 1 is auxiliary (A)
no. 2 is common (C)
no. 3 is high (H)
no. 4 is medium (M)
no. 5 is Low (L)

AIR SWING MOTOR

Some manufacturers of air conditioners connected the air swing motor in the grill of the
panel frame of the air conditioner. The grill is swinging to distribute the cool air blowing
from inside the air conditioner to the in-door room. Air swing motor is in series with switch
to control the motor.

TROUBLES OF FAN AND AIR SWING MOTORS

1. If one or two combination terminals have not resistance reading, example: 1 – 2 = 45 ohms, 1
– 3 = no reading, 1 - 4 = no reading, the motor is open or burned out.

2. If one or two combination terminals have the same reading, example 1 – 2 = 45 ohms, 1 – 3 =
45 ohms, 1 – 4 = 90 ohms, the motor is short circuited.

3. If one or two terminals have continuity with the body of the motor, the motor is grounded.

4. If the combination terminals are good but the motor is humming, its bushing is defective

INSTALLATION METHOD

Most of the claims raised by users criticizing the inefficient cooling of the units are due
to the inappropriate selection of the installation sites. Once it is installed it is difficult to change
its location. It is therefore very important to select the proper place for the installation of any
particular unit.
Air conditioner should be installed at the place from where cold air can effectively
circulate to all parts of the room. The ideal set up is to install it as close a possible to the center
of the room at the elevation of 75 – 150 cm. above floor level, and at the position where there is
no obstacle in front of the outlet of cold air. If it is installed near the wall, floor or ceiling,
circulation of cold air is hampered and the room will not cool down evenly nor effectively.
Typically, the airflow should be directed upward as cold air tends to move downwards.
This will also keep the supply air from mixing with the return warm-room air to the evaporator.
The outdoor unit of the air conditioner must be clear from any obstacle so that the
discharging of heat from the condenser can be effective. Provide a space for at least 80 cm. from
the back of the air conditioner to the wall or other obstacles and space of 60 cm. at both sides.
The window where-in the air conditioner will be installed must be shaded or not exposed
to the sun especially during afternoon. If this is not possible, some shading must be used for
greater efficiency. Awning are most effective since they shade the unit and the window at the
same time, but it must not restrict the free flow of air to and from the unit. Venetian blinds or
shades are the second choice to cut down great amount of sun’s heat transmitted to the room
through the windows.
Within the vicinity of air conditioner, there should be no sources of toxic gas, corrosive
gas or obnoxious shell. It should also be far away from toilet.
Hot air discharging from kitchen, boiler room etc., should not directly hit the back or
sides of an air conditioner.
The unit must not be installed near the door or entrance because the cold air can escape
every time the door is opened, thus reducing the cooling efficiency of the unit.
Before installing the unit, it should be determined first if it is the correct specification or
size for the room to be air conditioned. The proper electrical outlet must be located within the
length of the cord furnished with the unit. Extension cord is not allowed, for it will cause
damage to the unit as well as the electrical circuit. The unit must have its own fuse box or circuit
breaker for its protection from high amperage or overload of power.
Installing the air conditioner must be balanced. The center of gravity in the unit is near
its center. In other units, the center of gravity is near the compressor and it tendency it all out of
the window, unless half of the unit is protruded into the room or there is a brace kit which is
usually provided by the manufacturer to support the back of the unit. The unit is slanted so that
the condensate will flow down outside the unit.
The condensate should drain to the proper place, such as a flower bed, on the grass or in
a gutter, or a hose is connected from the unit to the canal. Condensate must not drip on the side
walk for it can slick the side walk and sometimes algae may form because of this dripping
condensate.
Usually a foam trip provided by the manufacturer is place on the space between the
window and the air conditioner. Cold Air cannot escape through this space; thus a foam rubber
is installed.

MAINTAINING AN AIR CONDITIONER

Maintaining room air conditioner unit basically involves keeping the filters and
evaporators coil clean. If the filter is not maintained, the evaporator coil will become dirty and
cause low suction pressure. It is known that the room unit evaporator operates at about 35 0F. If
the coil temperature drops, air will begin to form in the evaporator coil. Filter must be cleaned at
least every month. If the dirt of the filter contaminated the evaporator coil, its efficiency to
absorb heat inside the room will be lessened.
All units have thermostat that control the temperature of the coil. It is usually installed
below the evaporator coil.
Service may involve problems usually mechanical or electrical in nature. In mechanical
problems, the fan motor and bearing problems or refrigerant circuits are the most often
encountered ones. It can also be electrical in nature especially today when brownouts are
rampant. Usually the compressor will burnout or be damaged due to low power or high power
supply. If the compressor is not defective, trouble may be on the capacitors, overload protector
of the switch.

TROUBLE CHARTS

The common operating problems of an air conditioner are listed including the causes
below for quick reference including causes and correction of a specific fault.

SYMPTOMS AND POSSIBLE CAUSES POSSIBLE REMEDIES

UNIT WILL NOT RUN
a. Broken fuse or contacts a. Check power supply, switch or plug and
b. Defective starting switch measure the voltage.
c. Low voltage b. Replace fuses, contacts or switches
c. Voltage should be within 10% plus or
minus
the 220 V.

FAN MOTOR RUNS BUT THE COMPRESSOR IS NOT OPERATING

a. Defective thermostat
b. Faulty starting capacitor
c. Faulty running capacitor
d. faulty relay
e. Low voltage
f. Faulty wiring
a. Turn the thermostat to the coldest setting,
if
the motor does not run while the room
temperature is above 750F, change the
thermostat.
b. Check the start and run capacitors and
relay
If these are defective, replace them
c. Check the voltage
d. Check the electrical wiring connection

COMPRESSOR CYCLE OFF AND ON

a. Low voltage a. Check the voltage and motor amperage
b. Dirty or restricted air across the condenser b. Check the condenser fan, the condenser

c. Faulty overload or incorrect size
d. High ampere compressor
UNIT NOT COOLING PROPERLY
a. Dirty filter
b. Outside air entering the unit
c. Dirty or restricted condenser
d. Lack of refrigerant
e. Defective compressor
f. Defective fan motor
EVAPORATOR FULL OF ICE
a. Clogged or dirty filter
b. Evaporator fan tripping or defective
c. Room temperature is low
d. Outside temperature is low
e. Lack of refrigerant
UNIT VIBRATES OR RATTLES
a. Loosened bolt
b. Tubing striking metal surface
c. Loose fan blades
d. Misaligned fan motor
e. Improper installation of unit
WATER DRIPS INSIDE THE ROOM
a. Unit not properly levelled
b. Condensate pan clogs
c. Evaporator drip pan, leaking
d. Condenser fan slinger out of position
CHARGING AN AIR CONDITIONER WITH THE REFRIGERANT
and
anything that causes the restriction
c. Check the overload specification
d. Check the thermostat and it sensing valve
position on the evaporator
a. Check filter and clean or replace it
b. Check for any opening from outside door
or
window
c. Check the condenser air circulation
d. Check any leak; re-charge the system
e. Check for the suction and discharging of
compressor, replace if defective
f. Check the fan motor, repair or replace it.
a. Clean of replace filter
b. Check for a fan temperature or terminal
resistance; repair replace
c. If room temperature drops below 700F, the
evaporator may have over frost
d. Check the outside room temperature
e. Check leak; re-charge the system
a. Check for loosed volts and tighten them
b. Make tube clearance between the metal
case and tubes.
c. Check fan blades, tighten loosen screw
d. Check the alignment of fan motor; re-align
e. Check the installation of the unit; re-align
a. Level the unit. The unit must be tipped
slightly towards outside.
b. Clean condensate drainage
c. Check the evaporator drip pan; repair leak
d. Check the slinger position; re-align
 Charging an air conditioner is the same as charging the refrigerator. The only difference
is that, instead of using R-12, R-22 is utilized. R-22 boils at -41.4 0F comparing with -21.60F of
R-12. The pressure on the low-pressure side when charging an air conditioner is 65-69 psig and
275-296psig on the high-pressure side. The charging pressure on both sides must accompany the
compressor amperage. The usual horsepower ratings of the compressor for a room air
conditioner are 1-ph, 1.5-hp and 2-hp motor. The 1-hp compressor has a running amperage of 6
to 7 amp., and the 1.5-hp compressor has 8 to 10 amp., while the 2-hp has 10 to 14 amp. The
compressor running amperage differs from one manufacturer to another. The herein example is
the average running amperage of a common compressor motor.
When charging the system, always place the ammeter on one-line source. Observe the
amperage reading when the charging the system. If the amperage rating of the compressor is 7
while pressure is 55 psig on the compound gage, do not hesitate to add motor up to 69 psig, it
can damage the compressor if the pressure is too high.
Always make a testing for leak. Be sure that the filter, the evaporator and the condenser
are clean from dirt. The fan motor must be on its normal operations. Likewise, the room
temperature as well as the outside room temperature should be within the normal range.
Remember that in charging, evacuation of the system must be done first. The system
must be free from moisture, dirt, or any tiny particle that can cause damage to the unit.

Reference: Refrigeration and Air Conditioning: repair and Troubleshooting Guide, reprinted
2010, by Joy Job A. Cabangon.

Self-Check on Module 4 - Room Air Conditioning System

I Multiple Choice
Direction: Write the letter of the correct answer on the space provided.
__1. Short circuit in the hermetic compressor can be identified easily because of the following,
except…a) Common-Run and Common Start terminals have the same resistance value b)

A room air conditioner is a “comfort-making machine” used to condition rooms for human
comfort. This home air conditioning unit is usually classified according to their design and
method of installation such as window type unit or portable or free-standing type unit. They are
much the same, typically having only one fan motor for the evaporator and the condenser. The
capacity of these units may range from 4000 Btu/hr (1/2 ton) to 24,000 Btu/hr (2 tons).
The purpose of home air conditioning is to lower the temperature of a room, to
dehumidify the air, to filter dirt, fumes, air-borne pollen and irritating industrial dust, to circulate
the air, and for ventilation.

THE REFRIGERATION CYCLE

 Refrigeration is the heart of air conditioning. The cycle consists of four major parts: an
evaporator used to absorb heat into the system, a compressor used to pump the heat laden
refrigerant through the system, a condenser used to reject the heat from the system, and an
expansion valve used to control the flow of refrigerant. This is done by maintaining a pressure
difference between the high-pressure side and the low-pressure side of the unit.
Cooling units are considered high temperature refrigeration systems and must operate
above freezing to prevent the condensate from freezing on the evaporator coil. Typically, the
evaporators boil the refrigerant at about 350F.
The evaporator is typically made of copper or aluminium tubing with aluminium fins.
The fins may be straight or spine. All fin types are in close contact with the copper tubing for
the best heat exchange. It operates below the dew-point temperature of the room air for the
purpose of dehumidification. Condensate forming on the evaporator coil is typically drained
back to the condenser section and evaporated.
The compressor for a room air-conditioner is a typical hermetically sealed air
conditioning compressor. The compressor may be rotary or reciprocating.
Condensers are typically copper tubes with fins or aluminium tubes and aluminium fins,
similar to the evaporator. The condenser serves two purposes, it condenses heat-laden vapor
refrigerant inside the tubes and evaporates the condensate from the evaporator section. This is
accomplished by using the heat from the discharge line and a slinger ring on the condenser fan.
Evaporating the condensate serves two purpose, it keeps the unit from dripping and improves
the efficiency of the condenser.
The capillary tube is a type of metering device used in units. Some manufacturers are
automatic expansion valves with the advantage of controlling the pressure which in turn controls
the temperature. Coil freezing could be prevented by controlling the pressure.
Most room air conditioners are designed to effect the exchange of heat between the
capillary tube and the suction line. this exchange adds superheat conditions to the suction gas
and subcools the refrigerant in the first part of the capillary tube.

COMPRESSOR MOTOR

The compressor motor usually used in air conditioner is the PSC (Permanent Split
Capacitor) motor type This has no relay for starting unlike in household refrigerators. Current
flow through both running winding and the starting winding when the motor is on. A running
capacitor is connected between the running (R) and starting (S) terminals and is in series with
the starting winding.
These motors are sensitive to line voltage. A voltage drop of 5 to percent will cause
starting difficulty and overheating. The starting torque is low. When the pressures are not
balanced, it will overheat and can damaged the motor. To overcome the problem. To overcome
this problem, a starting capacitor and a relay is being used. A recommended rating for add-on
starting capacitors are shown below.

RUNNING CAPACITORS STARTING CAPACITORS

 Microfarad Microfarad
20 18
25 18 or 25
30 25
35 25
40 25 to 46
45 45
50 45

Most manufacturers specify Microfarad rating of special start capacitor for each of their
units. Follow manufacturer’s specification.
In installing the start capacitor to a PSC motor compressor for the purpose of increasing
the starting torque, a potential relay is needed to open the starting winding circuit when the PSC
motor reaches 75 percent of rated speed.

MOTOR CAPACITOR

The capacitor is an electrical device that allows electrical energy to be stored for later
use. In alternating current circuit, it changes a single-phase electrical flow to a two phase
electrical flow. The capacitor is usable in both the starting and running windings.
A simple capacitor is composed of two plates with an insulating material between them.
The capacitor can store a charge of electron on one plate. In an AC circuit, the voltage and
current are continuously changing directions. As electron flow in one direction, the capacitor
plate on one side becomes charged. As the voltage and current changes, the charge of the
capacitor becomes greater than the source voltage, and the capacitor begins to discharge. It is
discharged through the circuit, and the opposite plate becomes charged. This continues through
each AC cycle.
Capacitors can be classified as start capacitor and run capacitor. If used in the starting
winding, it is called the starting capacitor. It is in circuit with starting winding for seconds only.
If the motor is started too often or if the starting winding is used longer than it is designed for,
the capacitor insulation will overheat and the capacitor may fail.
The start capacitor has range of 95 to 400 microfarad. It resembles a cylinder and usually
has a black plastic case. It is physically smaller than the run capacitor. They are the electrolytic
type of capacitors.
When a single-phase motor is operated, phase deviation occurs between current and
voltage due to electric induction and it generates motor waste current. As a result, the motor
does not run at normal rotation. Therefore, a running capacitor is attached to the unit to correct
phase deviation and to normalize motor rotation.
The run capacitor remains in the motor start winding circuit at all times during
compressor operations. It has a range of 5 to 40 microfarad with a metal case, and physically
larger than the start capacitor. Usually, if two run capacitors are wired in parallel, a bleeder
capacitor across the terminals is installed for safety purposes. It is built quite heavy with oil, tar,
or waxed paper.
A 220 volts’ capacitor may be used on a 110 volts’ circuit, but a 110-volt capacitor
cannot be directly connected across a 220-volt circuit. Capacitor has no polarity; you can
interchange the terminals as long as it is the specified capacitor for such motor.

STEPS IN CHECKING THE CONDITION OF A CAPACITOR

1. Get an Ohmmeter and turn the range selector knob to X 1K; zero-in the pointer.
2. Take connecting wire and short circuit the charge that might be on the plates of the capacitor.
Remove the shunt resistor if one is wired across the terminals. Charged capacitor can shock
or damage the meter.
3. After the capacitor has been discharged, remove the connecting wire and put the test prods on
the terminals of the capacitor so as to place dc-charge on the plates.
4. If the pointer of the ohmmeter deflected to direction A and returns to direction B within 10
seconds, the capacitor has taken the charge on the plates and the first half of the test is
successful;
5. If the pointer did not move, the capacitor is defective (Open).
6. If the capacitor has a metal case, check the continuity of the plates of the capacitor and the
metal case. If there is an ohm-resistance reading, the capacitor is defective (Grounded).
7. Test the capacitor if it held a charge; get a voltmeter and turn the selector range knob to 10-
volt scale. It will measure the voltage the capacitor is holding.
8. Put the test prods to the capacitor terminals. Observe the pointer is deflecting from zero to the
left (Off-,Quickly reverse the prods. The polarity is inverted.
9. If the capacitor deflected to a voltage reading or in direction A and returned to direction B, it
means that the capacitor held a charge and is good. If the pointer did not move, the capacitor
is defective. It means that the capacitor is presumed weak and not good.

CAPACITOR RANGE FOR DIFFERENT MOTOR CAPACITY

START CAPACITOR

HORSEPOWER (HP) CAPACITOR RANGE MICROFARAD

(µF)
1/8……………………………………….... 95-200
1/6……………………………………….... 95-200
1/4………………………………………… 200-300
1/3………………………………………… 250-350
1/2…………………………………..……. 300-400
3/4..……………………………………….. 300-400
RUN CAPACITOR

HORSEPOWER (HP) CAPACITOR RANGE MICROFARAD

(µF)
1/8……………………………………….... 4-5
1/6……………………………………….... 4-5
1/4………………………………………… 10
1/3………………………………………… 10-15
1/2………………………………………… 10-15
To 2 HP
3…………………………………………... 20
5…………………………………………... 30

POINTER DEFLECTION FOR CAPACITORS

Start capacitor, run capacitor, or the fan motor capacitor can be distinguished the
deflection of the pointer of the ohmmeter. Since the start capacitor has a higher capacitor than
the run capacitor, its deflection of the pointer is larger than the run capacitor. We know that start
capacitor rangers from 95 to 400 microfarad and the run capacitor ranges from 5 to 40
microfarad, because of its difference in ranges, they also differ in pointer deflection.
The run capacitor and fan capacitor are usually integrated into one casing, and it is called
“dual capacitor”. When testing a dual-capacitor, the common terminal is usually at the center
and the remaining two terminals can be fan terminal and run terminal.
When testing the dual-capacitor with the ohmmeter, it must be discharged first by using
a connecting wire. If test prods are placed on both sides of the terminals, the pointer will not
deflect. It means that the remaining terminal is the common, C. From the common and to
another terminal, compare the deflection of the pointer. If the pointer deflected longer and
slowly returns, while the other is deflected shorter and also returns, the longer deflection is
considered the run capacitor, and the shorter one is the fan capacitor.
To increase the microfarad value of two capacitors, connect them in parallel and use the
formula:
Mfd = C1 + C2

To decrease the microfarad value of two capacitors, connect them in series and use the
formula

Mfd = C1 x C2
C1 + C 2
EXAMPLE: SOLUTION

CONNECTED IN PARALLEL
GIVEN: C1 = 20 µf Mfd = C1 + C2
C2 = 40 µf Mfd = 20 + 40
Mfd = 60 µf

CONNECTED IN PARALLEL SOLUTION

GIVEN: C1 = 20 µf Mfd = C1 x C2
C2 = 40 µf C 1 + C2
Mfd = 20 x 40
20 + 40
Mfd = 800
60
Mfd = 13.33
FAN MOTOR

The two main purpose of a fan motor in air conditioner is to force the condenser cooling
air through the ducts and over the condenser and condensing units, and to circulate air in the
room. Connected on both ends of the fan motor shaft is the propeller fan and the squirrel cage
fan or sirocco fan.
The warm room air will be drawn in by the squirrel cage fan, passing through the filter;
the evaporator where heat will be absorbed, and then to the center of the squirrel cage fan and
thrown in to the periphery where it strikes a baffle and then reversed in its directions so that it
blows into the room after passing over the cool tubes and fins.
As a large volume of air will pass through the evaporator, the moisture it carries will be
deposited, thus dehumidification takes place. This moisture will be deposed by simply letting it
drips down into some troughs that directs it to pan under the condenser. The heat and turbulence
of air would evaporate the moisture or it may also be dripped into a lawn.
The atmospheric air will be drawn in by the propeller fan passing through the
compressor where the air will help the motor compressor to lower its temperature, and then
blow it out to the condenser where heat in the high- pressure, high-temperature refrigerant in
the system will be discharge out to the atmosphere. The newer model of a propeller fan has a
slinger ring attached to it. It spatters or “sling” the water onto the hot condenser. The water that
it slings up on the condenser improves the efficiency of the condenser.
The fan motor of air conditioner usually a permanent-star-capacitor (PSC) motor. These
fan motor may be of three speed type. They sometimes have thermal safety controls to protect
them from the high-ampere flow of current.
The fan motor terminals are the common (C), Auxiliary (A), the high (H), and the low
(L) terminals. Others have medium (M) terminals for the three-speed type.

STEPS IN NAMING/FINDING THE TERMINALS OF A FAN MOTOR

FOR THE TWO-SPEED TYPE OF FAN MOTOR

1. Secure an ohmmeter and turn the range selector to x 1 ohm; zero-in the pointer.
2. Get a piece of paper and sketch the terminals for a two speed type motor. Label it 1, 2, 3, and
4, because this motor has common (C), auxiliary (A), high (H), and low (L) only.
3. Get the resistance reading between the terminals.

EXAMPLE:

1 – 2 = 130 ohms
1 – 3 = 95 0hms
1 – 4 = 110 ohms
2 – 3 = 35 ohms
2 – 4 = 50 ohms
3 – 5 = 15 ohms

4. Get the three highest reading and they are;

1 – 2 = 130 ohms
1 – 3 = 95 ohms
1 – 4 = 110 ohms

5. Terminal with the same number (common) among the three pairs with highest reading is the
auxiliary (A). Therefore no. 1 is Auxiliary (A).
6. The highest reading between terminals 1 – 2 = 130 ohms, is between the auxiliary (A) and
common (C) terminals. Since no. 1 is auxiliary, therefore no.2 is common (C).
7. The second highest reading is between terminals 1 – 4 = 110 ohms, is between the auxiliary
(A) and the low (L). Since no. 1 is auxiliary, therefore no. 4 is low (L).
8. The 3rd highest reading is between terminals 1 – 3 = 95 ohms, is between the auxiliary (A) and
the high (H). Since no. 1 auxiliary (A) therefore no. 3 is (H).
9. Therefore, no. 1 is auxiliary (A)
no. 2 is common (C)
no. 3 is high (H)
no. 4 is low (L)

FOR THE THREE-SPEED TYPE OF FAN MOTOR

1. Secure an ohmmeter and turn the selector range knob to x 1 ohm; zero-in the pointer.
2. Get a piece of paper and sketch the terminals of a three-speed fan motor. Label it 1, 2, 3, 4,
1nd 5 because fan motor has auxiliary (A), common (C), high (H), medium (M), and low (L).
3. Get the resistance reading between the terminals.

EXAMPLE:
1 – 2 = 170 ohms
1 - 3 = 105 ohms
1 – 4 = 130 ohms
1 – 5 = 140 ohms
2 – 3 = 65 ohms
2 – 4 = 90 ohms
2 – 5 = 100 ohms
3 – 4 = 25 ohms
3 – 5 = 35 ohms
4 – 5 = 10 ohms

4. Get the four highest reading, and they are:

1 – 2 = 170 ohms
1 – 5 = 140 ohms
1 – 4 = 130 ohms
1 – 3 = 105 ohms

5. Terminal with the same number (common) among the four pairs is the Auxiliary (A).
6. The highest reading, 1 – 2 = 170 ohms, is between the auxiliary and common (C). Since no. 1
is auxiliary (A), therefore no. 2 is common (C).
7. The second highest reading, 1 – 5 = 140 ohms, is between the auxiliary (A) and low (L).
Since no. 1 is auxiliary (A), therefore no. 5 is low (L).
8. The third highest reading, 1 – 4 = 130 ohms, is between the auxiliary (A) and Medium (M).
Since no. 1 is auxiliary (A), therefore no. 4 is medium (M).
9. The fourth highest reading, 1 – 3 = 105 ohms, is between the auxiliary (A) and high (H).
Since no. 1 is auxiliary (A), therefore no. 3 is the high (H).
10. Therefore, no. 1 is auxiliary (A)
no. 2 is common (C)
no. 3 is high (H)
no. 4 is medium (M)
no. 5 is Low (L)

AIR SWING MOTOR

Some manufacturers of air conditioners connected the air swing motor in the grill of the
panel frame of the air conditioner. The grill is swinging to distribute the cool air blowing
from inside the air conditioner to the in-door room. Air swing motor is in series with switch
to control the motor.

TROUBLES OF FAN AND AIR SWING MOTORS

1. If one or two combination terminals have not resistance reading, example: 1 – 2 = 45 ohms, 1
– 3 = no reading, 1 - 4 = no reading, the motor is open or burned out.

2. If one or two combination terminals have the same reading, example 1 – 2 = 45 ohms, 1 – 3 =
45 ohms, 1 – 4 = 90 ohms, the motor is short circuited.

3. If one or two terminals have continuity with the body of the motor, the motor is grounded.

4. If the combination terminals are good but the motor is humming, its bushing is defective

INSTALLATION METHOD

Most of the claims raised by users criticizing the inefficient cooling of the units are due
to the inappropriate selection of the installation sites. Once it is installed it is difficult to change
its location. It is therefore very important to select the proper place for the installation of any
particular unit.
Air conditioner should be installed at the place from where cold air can effectively
circulate to all parts of the room. The ideal set up is to install it as close a possible to the center
of the room at the elevation of 75 – 150 cm. above floor level, and at the position where there is
no obstacle in front of the outlet of cold air. If it is installed near the wall, floor or ceiling,
circulation of cold air is hampered and the room will not cool down evenly nor effectively.
Typically, the airflow should be directed upward as cold air tends to move downwards.
This will also keep the supply air from mixing with the return warm-room air to the evaporator.
The outdoor unit of the air conditioner must be clear from any obstacle so that the
discharging of heat from the condenser can be effective. Provide a space for at least 80 cm. from
the back of the air conditioner to the wall or other obstacles and space of 60 cm. at both sides.
The window where-in the air conditioner will be installed must be shaded or not exposed
to the sun especially during afternoon. If this is not possible, some shading must be used for
greater efficiency. Awning are most effective since they shade the unit and the window at the
same time, but it must not restrict the free flow of air to and from the unit. Venetian blinds or
shades are the second choice to cut down great amount of sun’s heat transmitted to the room
through the windows.
Within the vicinity of air conditioner, there should be no sources of toxic gas, corrosive
gas or obnoxious shell. It should also be far away from toilet.
Hot air discharging from kitchen, boiler room etc., should not directly hit the back or
sides of an air conditioner.
The unit must not be installed near the door or entrance because the cold air can escape
every time the door is opened, thus reducing the cooling efficiency of the unit.
Before installing the unit, it should be determined first if it is the correct specification or
size for the room to be air conditioned. The proper electrical outlet must be located within the
length of the cord furnished with the unit. Extension cord is not allowed, for it will cause
damage to the unit as well as the electrical circuit. The unit must have its own fuse box or circuit
breaker for its protection from high amperage or overload of power.
Installing the air conditioner must be balanced. The center of gravity in the unit is near
its center. In other units, the center of gravity is near the compressor and it tendency it all out of
the window, unless half of the unit is protruded into the room or there is a brace kit which is
usually provided by the manufacturer to support the back of the unit. The unit is slanted so that
the condensate will flow down outside the unit.
The condensate should drain to the proper place, such as a flower bed, on the grass or in
a gutter, or a hose is connected from the unit to the canal. Condensate must not drip on the side
walk for it can slick the side walk and sometimes algae may form because of this dripping
condensate.
Usually a foam trip provided by the manufacturer is place on the space between the
window and the air conditioner. Cold Air cannot escape through this space; thus a foam rubber
is installed.

MAINTAINING AN AIR CONDITIONER

Maintaining room air conditioner unit basically involves keeping the filters and
evaporators coil clean. If the filter is not maintained, the evaporator coil will become dirty and
cause low suction pressure. It is known that the room unit evaporator operates at about 35 0F. If
the coil temperature drops, air will begin to form in the evaporator coil. Filter must be cleaned at
least every month. If the dirt of the filter contaminated the evaporator coil, its efficiency to
absorb heat inside the room will be lessened.
All units have thermostat that control the temperature of the coil. It is usually installed
below the evaporator coil.
Service may involve problems usually mechanical or electrical in nature. In mechanical
problems, the fan motor and bearing problems or refrigerant circuits are the most often
encountered ones. It can also be electrical in nature especially today when brownouts are
rampant. Usually the compressor will burnout or be damaged due to low power or high power
supply. If the compressor is not defective, trouble may be on the capacitors, overload protector
of the switch.

TROUBLE CHARTS

The common operating problems of an air conditioner are listed including the causes
below for quick reference including causes and correction of a specific fault.

SYMPTOMS AND POSSIBLE CAUSES POSSIBLE REMEDIES

UNIT WILL NOT RUN
a. Broken fuse or contacts a. Check power supply, switch or plug and
b. Defective starting switch measure the voltage.
c. Low voltage b. Replace fuses, contacts or switches
 c. Voltage should be within 10% plus or
minus
the 220 V.

FAN MOTOR RUNS BUT THE COMPRESSOR IS NOT OPERATING

a. Defective thermostat
b. Faulty starting capacitor
c. Faulty running capacitor
d. faulty relay
e. Low voltage
f. Faulty wiring
a. Turn the thermostat to the coldest setting,
if
the motor does not run while the room
temperature is above 750F, change the
thermostat.
b. Check the start and run capacitors and
relay
If these are defective, replace them
c. Check the voltage
d. Check the electrical wiring connection

COMPRESSOR CYCLE OFF AND ON

a. Low voltage
b. Dirty or restricted air across the condenser
c. Faulty overload or incorrect size
d. High ampere compressor
a. Check the voltage and motor amperage
b. Check the condenser fan, the condenser
and
anything that causes the restriction
c. Check the overload specification
d. Check the thermostat and it sensing valve
position on the evaporator

UNIT NOT COOLING PROPERLY

a. Dirty filter a. Check filter and clean or replace it
b. Outside air entering the unit b. Check for any opening from outside door
or
c. Dirty or restricted condenser window
d. Lack of refrigerant c. Check the condenser air circulation
e. Defective compressor d. Check any leak; re-charge the system
f. Defective fan motor e. Check for the suction and discharging of
compressor, replace if defective
f. Check the fan motor, repair or replace it.

EVAPORATOR FULL OF ICE

a. Clogged or dirty filter
b. Evaporator fan tripping or defective
c. Room temperature is low
d. Outside temperature is low
e. Lack of refrigerant
a. Clean of replace filter
b. Check for a fan temperature or terminal
resistance; repair replace
c. If room temperature drops below 700F, the
evaporator may have over frost
 d. Check the outside room temperature
e. Check leak; re-charge the system

UNIT VIBRATES OR RATTLES

a. Loosened bolt a. Check for loosed volts and tighten them
b. Tubing striking metal surface b. Make tube clearance between the metal
c. Loose fan blades case and tubes.
d. Misaligned fan motor c. Check fan blades, tighten loosen screw
e. Improper installation of unit d. Check the alignment of fan motor; re-align
e. Check the installation of the unit; re-align

WATER DRIPS INSIDE THE ROOM

a. Unit not properly levelled
b. Condensate pan clogs
c. Evaporator drip pan, leaking
d. Condenser fan slinger out of position
a. Level the unit. The unit must be tipped
slightly towards outside.
b. Clean condensate drainage
c. Check the evaporator drip pan; repair leak
d. Check the slinger position; re-align

CHARGING AN AIR CONDITIONER WITH THE REFRIGERANT

Charging an air conditioner is the same as charging the refrigerator. The only difference
is that, instead of using R-12, R-22 is utilized. R-22 boils at -41.4 0F comparing with -21.60F of
R-12. The pressure on the low-pressure side when charging an air conditioner is 65-69 psig and
275-296psig on the high-pressure side. The charging pressure on both sides must accompany the
compressor amperage. The usual horsepower ratings of the compressor for a room air
conditioner are 1-ph, 1.5-hp and 2-hp motor. The 1-hp compressor has a running amperage of 6
to 7 amp., and the 1.5-hp compressor has 8 to 10 amp., while the 2-hp has 10 to 14 amp. The
compressor running amperage differs from one manufacturer to another. The herein example is
the average running amperage of a common compressor motor.
When charging the system, always place the ammeter on one-line source. Observe the
amperage reading when the charging the system. If the amperage rating of the compressor is 7
while pressure is 55 psig on the compound gage, do not hesitate to add motor up to 69 psig, it
can damage the compressor if the pressure is too high.
Always make a testing for leak. Be sure that the filter, the evaporator and the condenser
are clean from dirt. The fan motor must be on its normal operations. Likewise, the room
temperature as well as the outside room temperature should be within the normal range.
Remember that in charging, evacuation of the system must be done first. The system
must be free from moisture, dirt, or any tiny particle that can cause damage to the unit.