Complete Guide to Air Conditioning Systems

Table of Contents
Part 1: Introduction to Air Conditioning

1. Definition and Importance of Air Conditioning

2. Meaning and Functions of HVAC
3. Thermal Comfort and Human Comfort Parameters

Part 2: Classification of Air Conditioning Systems

1. Based on System Type

a. Window AC
b. Split AC
c. Packaged AC
d. Central AC System
e. VRF/VRV System
2. Based on Application
a. Residential AC
b. Commercial AC
c. Industrial AC
d. Special-Purpose AC
3. Based on Season or Operation Mode
a. Summer AC
b. Winter AC
c. Year-Round AC
4. Based on Working Principle
a. Direct Expansion (DX) System
b. Chilled Water System

Part 3: Basic Thermodynamics & Psychrometrics

1. Refrigeration Cycle (Vapor Compression System)

2. Refrigeration Cycle Variants
a. Vapor Absorption Cycle
b. Reverse Cycle / Heat Pump
3. Psychrometrics: The Science of Moist Air
a. Psychrometric Chart Parameters
b. Uses of Psychrometric Chart
4. Sensible and Latent Heat
5. Heat Load Calculations (Concept Introduction)

Part 4: Major Components of an Air Conditioning System

1. Compressor
2. Condenser
3. Expansion Device
4. Evaporator
 5. Air Handling Unit (AHU)
6. Fan Coil Unit (FCU)
7. Fans and Blowers

Part 5: Supporting Equipment in Air Conditioning Systems

1. Chiller Unit
2. Cooling Tower
3. Chilled Water Pumps
4. Expansion Tank
5. Ducting System
6. Air Filters
7. Dampers and Louvers
8. Sensors and Controls

Part 6: Design Parameters and Heat Load Calculation

1. Purpose of Heat Load Calculation

2. Types of Heat Loads
a. External Heat Load
b. Internal Heat Load
c. Ventilation Load
d. Miscellaneous Loads
3. Heat Load Formula
4. Example Heat Load Calculation for a Room
5. Software Tools for Load Calculation
6. Important Design Parameters

Part 7: Equipment Selection & Sizing

1. Selecting Air Conditioning System Type

2. Compressor Selection
3. Evaporator Coil & Airflow Sizing
4. Air Handling Unit (AHU)/ Fan Coil Unit (FCU) Selection
5. Duct Sizing
6. Fan Selection
7. Pipe Sizing for Refrigerant & Water Lines
8. Pump Selection
9. Safety Factor & Oversizing

Part 8: Control Systems & Automation in Air Conditioning

1. Why Control Systems Matter

2. Basic Control Devices
a. Thermostat
b. Humidistat
c. Timer
3. Advanced Control Devices
a. Temperature Sensors
b. Pressure Sensors
c. Flow Sensors/ Meters
 d. VFD ( Variable Frequency Drive)
4. VAV (Variable Air Volume) Systems
5. BMS (Building Management System)
6. Remote Monitoring & IoT Integration
7. Safety & Efficiency Controls

Part 9: Installation, Commissioning & Testing of Air Conditioning Systems

1. Pre-Installation Checklist
2. Installation Process (System- Wise)
a. Split or Ducted AC
I. Indoor Unit Installation
II. Outdoor Unit Installation
III. Refrigerant Line Connection

b. VRF/VRV System
c. Chiller System with AHU/FCU

I. Chiller Base & Mounting

II. Pipe Setup
III. AHU/FCU Setup
IV. Pump & Cooling Tower Installation

3. Electrical Installation
4. Control & Automation Setup
5. Testing & Commissioning

I. Vacuum & Pressure Testing

II. Refrigerant Charging
III. Functional Testing
IV. Balance Air & Water Flow

6. Performance Verification
7. Documentation & Handover

Part 10: Maintenance, Troubleshooting & Energy Efficiency Tips

1. Importance of Regular Maintenance

2. Types of Maintenance
a. Preventive Maintenance (PM)
b. Corrective Maintenance
c. Predictive Maintenance (using BMS/IoT)
3. Preventive Maintenance Checklist (Monthly/Quarterly)
4. Common Issues & Troubleshooting Guide.
5. Energy Efficiency Tips
6. AMC (Annual Maintenance Contract)

7. Logbook & Documentation.

Part 1: Introduction to Air Conditioning

1. Definition and Importance of Air Conditioning

Definition:
Air conditioning is the process of controlling the temperature, humidity, cleanliness, and air
movement within a specific space to provide human comfort or to meet process requirements.

Importance:
 Maintains comfortable indoor conditions for occupants.
 Essential in industrial processes requiring temperature and humidity control.
 Maintains hygiene and control in hospitals, labs, and clean rooms.
 Protects sensitive equipment like computers, servers, and electronics.

2. Meaning and Functions of HVAC (Heating, Ventilation, Air Conditioning)

HVAC stands for:
 Heating: To supply warm air during cold weather.
 Ventilation: To ensure fresh and clean air circulation.
 Air Conditioning: To cool the air, control humidity, and filter particles
Primary Functions of HVAC Systems:
 Maintain Indoor Air Quality (IAQ).
 Regulate temperature and humidity for human comfort.
 Ensure energy efficiency.
 Manage heat loads in various environments.

3. Thermal Comfort and Human Comfort Parameters

What is Thermal Comfort?

Thermal comfort refers to the condition of mind where a person feels neither too hot nor too
cold. ASHRAE Standard 55 defines thermal comfort using several parameters:

Key Parameters:

 Dry Bulb Temperature (DBT): Ideal range 22°C to 26°C

 Relative Humidity (RH): Optimal range 40% to 60%
 Air Velocity: Typically, between 0.15 - 0.25 m/s
 Mean Radiant Temperature: Temperature of surrounding surfaces.
 Clothing Insulation (Clo) & Metabolic Rate (Met): Depends on clothing and physical
activity level.

Part 2: Classification of Air Conditioning Systems

Air conditioning systems can be classified based on various factors such as system
configuration, application, and operating principle.

1. Based on System Type

a. Window AC

 All components in a single unit

 Suitable for small rooms
 Easy to install but less energy-efficient

b. Split AC

 Indoor (Evaporator) and Outdoor (Compressor + Condenser) units

 Quieter operation and better aesthetics
 Common for residential and small commercial use
c. Packaged AC

 Compact system with higher capacity than window/split

 Often used in medium-sized halls or offices
 Available in air-cooled or water-cooled versions

d. Central AC System

 Used in large buildings, malls, hospitals

 Includes chiller, AHU, ducting system
 Controlled via Building Management Systems (BMS)
 e. VRF/VRV System (Variable Refrigerant Flow/Volume)

 Highly energy-efficient, modular system

 One outdoor unit serves multiple indoor units
 Precise temperature control and zone-wise operation

2. Based on Application

a. Residential AC

 Focused on comfort cooling

 Includes window and split units mostly

b. Commercial AC

 Requires higher cooling loads

 Includes ductable, central, or VRF systems

c. Industrial AC

 Designed for process cooling or clean environment

 Includes chillers, air washers, or precision units

d. Special-Purpose AC

 For server rooms, clean rooms, operation theaters

 Requires constant temperature & humidity
3. Based on Season or Operation Mode

a. Summer AC – Cooling only

b. Winter AC – Heating only

 c. Year-Round AC – Heating + Cooling (via Heat Pumps or Reversible Cycle)

4. Based on Working Principle

a. Direct Expansion (DX) System

 Refrigerant directly cools the air

 Found in split, window, packaged units

b. Chilled Water System

 Uses chilled water produced by a chiller

 Water circulates through AHUs and FCUs
 Common in large commercial and industrial setups
 Part 3: Basic Thermodynamics & Psychrometrics

This section helps engineers understand the scientific principles behind air conditioning systems
— how they work, how heat is transferred, and how air properties are analyzed.

1. Refrigeration Cycle (Vapor Compression System)

This is the most commonly used cooling method in AC systems.

Four Main Components of the Vapor Compression Cycle:

1. Compressor
 Compresses low-pressure refrigerant gas into high-pressure gas.
 Raises temperature and pressure.
2. Condenser
 Rejects heat to the surrounding air or water.
 Gas turns into high-pressure liquid.
3. Expansion Valve (Capillary, TXV, or EEV)
 Reduces pressure of the liquid refrigerant.
 Prepares it for evaporation.
4. Evaporator
 Absorbs heat from the room air.
 Liquid turns into gas (cooling effect).

Refrigerants like R-410A, R-32, or R-134a are used to absorb and release heat in the cycle.

2. Refrigeration Cycle Variants

 Vapor Absorption Cycle

 Uses heat source (like gas or hot water) instead of a compressor.
 Used in industrial and solar-powered AC.

 Reverse Cycle / Heat Pump

 Works both as cooler and heater.
 Reverses refrigerant flow direction.

3. Psychrometrics: The Science of Moist Air

Psychrometrics deals with the thermodynamic properties of moist air, essential for proper
HVAC design.

Psychrometric Chart Parameters:

 Dry Bulb Temperature (DBT): Measured using regular thermometer
 Wet Bulb Temperature (WBT): Indicates evaporative cooling potential
 Relative Humidity (RH): % of moisture in air vs maximum it can hold
 Dew Point: Temp where air becomes saturated (100% RH)
 Enthalpy (h): Total heat content (kJ/kg of dry air)
  Specific Volume: Volume of 1 kg of air
 Humidity Ratio / Absolute Humidity: Moisture content in air (g/kg)

Uses of the Psychrometric Chart:

 Determine how much heat & moisture is added or removed
 Calculate latent and sensible heat loads
 Size AHUs, ducts, and dehumidifiers correctly

4. Sensible and Latent Heat

 Sensible Heat: Causes change in temperature (can be measured)
 Latent Heat: Causes change in moisture content (phase change)

Example: If air is cooled from 30°C to 22°C = Sensible Cooling

If moisture is removed = Latent Cooling

5. Heat Load Calculations (Concept Intro)

Before designing an AC system, engineers must calculate:

 External loads: Sunlight, walls, windows
 Internal loads: People, lights, machines
 Ventilation loads: Fresh air introduces heat and moisture

These calculations help determine:

  AC capacity (in TR or BTU/hr)
 Size of ducts, pipes, and equipment
Part 4: Major Components of an Air Conditioning System

This part covers the heart of any AC system — the key components that make it function.
Understanding each of these parts helps engineers in design, maintenance, and
troubleshooting.

1. Compressor

Function:
Compresses low-pressure refrigerant gas to high-pressure gas and pushes it to the
condenser.

Types of Compressors:
 Reciprocating: Piston-type; used in small systems
 Scroll: Quiet, compact, more efficient than reciprocating
 Screw: Used in large commercial/industrial systems
 Centrifugal: For very large HVAC chillers (e.g. shopping malls)

Key Considerations:
 Capacity (TR or kW)
 Power consumption
 Lubrication system

2. Condenser
Function:
Rejects heat from refrigerant gas to the outside medium (air or water), converting it to a
liquid.

Types:
 Air-Cooled Condenser: Uses fans and ambient air (most common)
 Water-Cooled Condenser: Uses cooling water via cooling towers

Location Tip:
Outdoor units or cooling towers are placed in open, ventilated spaces.

3. Expansion Device

Function:
Reduces the pressure of the high-pressure liquid refrigerant before it enters the evaporator.

Types:
 Capillary Tube: Fixed orifice, low cost, less control
 Thermostatic Expansion Valve (TXV): Regulates flow based on cooling demand
 Electronic Expansion Valve (EEV): Smart control, high-efficiency systems

4. Evaporator
Function:
Absorbs heat from indoor air; the refrigerant evaporates (boils) and takes away heat.

Common Forms:
 Copper coils with aluminum fins
 Located in Indoor Unit / Air Handling Unit (AHU)
 Often used with blower fan to circulate air

5. Air Handling Unit (AHU)

Function:
Circulates and conditions air through ducts in a centralized HVAC system.

Components inside AHU:

 Cooling coil (evaporator)
 Filters
 Blower fan
 Dampers & sensors

Used In:
Malls, office buildings, hospitals — large air-conditioned spaces

6. Fan Coil Unit (FCU)

Smaller version of AHU for single zones/rooms

Contains:
 Fan
 Coil (connected to chilled water or refrigerant line)
Common in VRF systems or chilled water networks

7. Fans and Blowers

Purpose:
Move air across coils and through ducts
 Blower: Sucks air from return ducts and pushes it through evaporator coils
 Fan: Outdoor unit fan removes heat from condenser coil
 Part 5: Supporting Equipment in Air Conditioning Systems

This section highlights additional equipment that supports the functioning of larger or
centralized air conditioning systems — especially in commercial and industrial setups.

1. Chiller Unit

Function:
Removes heat from the water and supplies chilled water to the AHUs or FCUs.

Types of Chillers:

 Air-Cooled Chiller: Uses ambient air and fans to reject heat

 Water-Cooled Chiller: Uses water and cooling towers
 Absorption Chiller: Uses heat (instead of electricity) to chill water, ideal for
cogeneration setups

Components:

 Compressor
 Evaporator
 Condenser
 Expansion Valve
 Controls & Safety Devices

Application:
Used in hotels, malls, hospitals, process industries

2. Cooling Tower

Function:
Removes heat from water used in a water-cooled chiller system by evaporative cooling.

Types:

 Induced Draft Tower: Most common; uses fan to pull air

 Forced Draft Tower: Fan pushes air from the bottom
 Crossflow or Counterflow Design

Important Terms:

 Approach Temperature
  Drift Loss, Blowdown, and Make-up Water

3. Chilled Water Pumps

Purpose:

 Primary Pump: Circulates water between chiller and AHUs/FCUs

 Secondary Pump: Maintains pressure in large systems (variable flow)

Type:
Centrifugal pumps, inline or end-suction types

Considerations:

 Flow rate (GPM or LPM)

 Head (m or ft)
 Efficiency and motor power

4. Expansion Tank

Function:
Absorbs the expansion of chilled water due to temperature change, prevents over-pressure

Location:
In the chilled water loop, usually near pumps

5. Ducting System

Purpose:
Distributes conditioned air to different zones/rooms
Materials:
GI sheet, aluminum, or fabric
Types:

 Supply Duct
 Return Duct
 Fresh Air Intake
 Exhaust Air

Design Considerations:

 Velocity (m/s or fpm)

  Pressure drop
 Duct size (based on CFM)

6. Air Filters

Purpose:
Removes dust, pollen, and other particles from air
Types of Filters:

 Pre-filters: Basic dust removal

 Fine filters (MERV 8–13): Offices, schools
 HEPA filters: Hospitals, cleanrooms
 Activated Carbon: Odor and gas control

7. Dampers and Louvers

Purpose:

 Control air volume and direction

 Maintain pressure zones

Types:

 Volume Control Damper (VCD)

 Motorized Damper
 Fire Damper

8. Sensors and Controls

Used for:

 Temperature Control (Thermostats)

 Humidity Control
 Pressure Differential
 VAV (Variable Air Volume) Boxes

Centralized Monitoring:

 BMS (Building Management System)

 Part 6: Design Parameters and Heat Load Calculation
Designing an effective air conditioning system starts with accurate heat load calculations. This
ensures the system has the right capacity to maintain comfort without over- or under-sizing.

1. Purpose of Heat Load Calculation

 To determine the total cooling capacity (in TR, kW, or BTU/hr) required
 To select the right equipment (compressor, chiller, duct, fan)
 To ensure energy efficiency and comfort
 To avoid system failures or inefficiency

2. Types of Heat Loads

A. External Heat Load
Heat entering the space from outside
 Solar radiation through walls, windows, and roof
 Outdoor air infiltration through doors, windows, and cracks
 Conduction through building envelope
B. Internal Heat Load
Heat generated within the space
 Occupants (people): Depends on activity level
 Lights and electrical appliances
 Office equipment, machinery
C. Ventilation Load
From fresh air intake needed for maintaining indoor air quality
 Outdoor air adds heat and moisture
 Requires sensible + latent cooling
D. Miscellaneous Loads
 Process loads (in industrial AC)
 Server heat, kitchen heat, etc.

3. Heat Load Formula (Simplified)

Total Cooling Load (Q)
Q = Q_sensible + Q_latent
 Where:
 Q_sensible = Heat that raises air temperature
 Q_latent = Heat that adds/removes moisture (humidity)

Units:
 TR (Ton of Refrigeration) → 1 TR = 12,000 BTU/hr ≈ 3.517 kW
 1 TR cools approx. 400–600 sq. ft depending on insulation and load

4. Example Heat Load Calculation for a Room

Let’s say we want to calculate the load for a 5m x 6m office room with 3 people, 4 LED lights,
and 1 window.
Room Volume:
Area = 5m x 6m = 30 m²
Ceiling Height = 3m → Volume = 90 m³
Heat Gains:
 People = 3 x 400 BTU/hr = 1200 BTU/hr
 Lights = 4 x 80W x 3.41 = 1091 BTU/hr
 Equipment = Printer + Laptop = 1000 BTU/hr
 Solar + Wall + Roof gain = approx. 3500 BTU/hr
 Ventilation (fresh air for 3 people) = 800 BTU/hr
Total:
= 1200 + 1091 + 1000 + 3500 + 800
= 7591 BTU/hr → ≈ 0.63 TR
You’d select a 1 TR split AC (closest standard size) for safety margin.

5. Software Tools for Load Calculation

 Carrier HAP (Hourly Analysis Program)
 TRACE 700
 Elite Software RHVAC
 Manual J (for residential loads)

6. Important Design Parameters

 Room orientation (north/south facing)
 Insulation (walls, windows, ceiling)
 Building materials
 Glass type (single, double-glazed, tinted)
 Air changes per hour (ACH)
 Internal activity level
 Part 7: Equipment Selection & Sizing
Once the heat load is calculated, the next crucial step in designing an air conditioning system
is selecting and sizing the equipment accurately to ensure efficient performance and
longevity.

1. Selecting Air Conditioning System Type

Based on the calculated load and building type, choose a suitable AC system:

Load Suitable System Applications

Capacity

< 2 TR Split AC / Window AC Homes, small rooms

2–5 TR Cassette / Ducted Split AC Office rooms, conference halls

5–25 TR VRF/VRV System Commercial floors, buildings

25 TR+ Chiller + AHU/FCU Malls, hospitals, industrial use

2. Compressor Selection
Based on Load:
Use the thumb rule:
 1 TR = 3.517 kW = 12,000 BTU/hr
Match the required TR with compressor specifications from the datasheet.
Selection Criteria:
 Type (Reciprocating, Scroll, Screw, Centrifugal)
 Cooling capacity (TR/kW)
 Coefficient of Performance (COP)
 Power supply (voltage, phase)
 Efficiency (EER, SEER)

3. Evaporator Coil & Airflow Sizing

Coil Selection:
 Match coil size with refrigerant flow rate and room cooling load
 Check fin per inch (FPI) and coil face area
Airflow Rate:
Use CFM = TR × 400
For 5 TR → CFM = 5 × 400 = 2000 CFM

4. Air Handling Unit (AHU) / Fan Coil Unit (FCU) Selection

AHU Selection Parameters:
 Cooling Capacity (TR or kW)
 Airflow Rate (CFM or CMH)
 Coil face velocity: 500–550 FPM typical
 Static pressure loss (for duct sizing)
 Number of rows in cooling coil (3 to 6 rows)
FCU Selection:
 Based on room size and layout
 Horizontal / Vertical type
 With or without ducting

5. Duct Sizing
Use equal friction method or velocity reduction method
Thumb Rule for Duct Velocity:

Air Type Recommended Velocity

Main Supply 1000 – 1600 FPM

Branch Supply 600 – 1000 FPM

Return Air 500 – 900 FPM

Use tools like Ductulator or software (AutoCAD plugins, HAP) to size duct dimensions.

6. Fan Selection
Match CFM and total static pressure (TSP) with system requirements.
Fan types:
 Centrifugal (forward/inclined/backward curved)
 Axial fans (for large volumes, cooling towers)
Fan selection depends on:
 Airflow (CFM)
 TSP (inches of water column)
 Fan efficiency

7. Pipe Sizing for Refrigerant & Water Lines

 Chilled water lines: Based on GPM or LPM
  Refrigerant lines: Based on pipe velocity, pressure drop, and system length
Use manufacturer design manuals or ASHRAE guidelines.

8. Pump Selection (for chilled water system)

Parameters:
 Flow rate (LPM or GPM)
 Head loss (meters or feet)
 Type: End-suction, in-line, vertical multistage
 Motor power (kW or HP)
Use selection software from brands like Grundfos, Wilo, KSB, etc.

9. Safety Factor and Oversizing

Never oversize by more than 10–15% unless future expansion is considered. Oversizing leads
to:
 Short cycling
 Increased energy cost
 Poor humidity control

Summary Checklist for Equipment Selection:

Component Key Sizing Parameter

Compressor TR/kW, COP, power supply

Evaporator TR, FPI, airflow rate

AHU/FCU CFM, coil size, pressure drop

Duct Velocity, pressure drop, material

Fan CFM & static pressure

Pipes Flow rate, velocity, pressure drop

Pump Flow rate, head, efficiency

 Part 8: Control Systems & Automation in Air Conditioning

Modern air conditioning systems go far beyond just cooling — they are smart, responsive,
and energy-efficient thanks to advanced control systems and automation. This part is crucial
for engineers designing intelligent and sustainable HVAC setups.

1. Why Control Systems Matter

 Ensure desired temperature and humidity.
 Reduce energy consumption.
 Improve user comfort and safety.
 Enable monitoring and remote access.
 Extend system life via predictive maintenance.

2. Basic Control Devices

A. Thermostat
 Senses room temperature
 Sends signal to AC system to turn ON/OFF
 Can be:
 Manual (analog)
 Programmable
 Smart Wi-Fi-based
B. Humidistat
 Controls humidity level (esp. in precision cooling)
C. Timer
 Schedules AC operation (e.g. daily ON/OFF)

3. Advanced Control Devices

A. Temperature Sensors
 Placed in different zones
 Feedback to central controller or BMS
B. Pressure Sensors
 Monitor refrigerant or water pressure in compressors, chillers, pumps
C. Flow Sensors / Meters
 Measure chilled water or refrigerant flow
D. VFD (Variable Frequency Drive)
 Adjusts fan or pump motor speed based on demand
 Saves energy in variable load systems (e.g. VRF, AHUs)
4. VAV (Variable Air Volume) Systems
 Adjust airflow to each zone based on its cooling demand
 Use VAV boxes with dampers, sensors, and actuators
 Maintains constant temperature with varying airflow
Benefits:
 Energy savings
 Zonal control
 Reduced fan power

5. BMS (Building Management System)

A centralized system that monitors & controls HVAC, lighting, power, fire safety, and security.

Features:
 Live status of AC operation
 Room-wise temperature & humidity monitoring
 Scheduling and automation
 Alarm system for faults or anomalies
 Energy analytics and reporting

Protocols Used:
 BACnet
 Modbus
 KNX

6. Remote Monitoring & IoT Integration

Modern systems can be integrated with mobile apps or cloud dashboards, especially in
smart buildings.
 Remote ON/OFF
 Fault alerts via SMS/email
 Energy consumption reports
 AI-based predictive maintenance

7. Safety & Efficiency Controls

 High/Low pressure cut-off switches

 Anti-freeze protection
 Overload protection for compressors
 Economizers for free cooling
 Night setback settings to reduce cooling load at night
Summary: Key Automation Tools in AC Systems

Control Element Purpose

Thermostat Basic temperature control

Sensor Real-time feedback to controllers

(Temp/Pressure)
VFD Variable speed for energy saving

VAV Box Zonal air volume control

BMS Centralized system control & monitoring

IoT / Smart Apps Remote monitoring & automation

 Part 8: Control Systems & Automation in Air Conditioning

Modern air conditioning systems go far beyond just cooling — they are smart, responsive,
and energy-efficient thanks to advanced control systems and automation. This part is crucial
for engineers designing intelligent and sustainable HVAC setups.

1. Why Control Systems Matter

 Ensure desired temperature and humidity
 Reduce energy consumption
 Improve user comfort and safety
 Enable monitoring and remote access
 Extend system life via predictive maintenance

2. Basic Control Devices

A. Thermostat
 Senses room temperature
 Sends signal to AC system to turn ON/OFF
 Can be:
 Manual (analog)
 Programmable
 Smart Wi-Fi-based
B. Humidistat
 Controls humidity level (esp. in precision cooling)
C. Timer
 Schedules AC operation (e.g. daily ON/OFF)

3. Advanced Control Devices

A. Temperature Sensors
 Placed in different zones
 Feedback to central controller or BMS
B. Pressure Sensors
 Monitor refrigerant or water pressure in compressors, chillers, pumps
C. Flow Sensors / Meters
 Measure chilled water or refrigerant flow
D. VFD (Variable Frequency Drive)
 Adjusts fan or pump motor speed based on demand
 Saves energy in variable load systems (e.g. VRF, AHUs)
4. VAV (Variable Air Volume) Systems
 Adjust airflow to each zone based on its cooling demand
 Use VAV boxes with dampers, sensors, and actuators
 Maintains constant temperature with varying airflow
Benefits:
 Energy savings
 Zonal control
 Reduced fan power

5. BMS (Building Management System)

A centralized system that monitors & controls HVAC, lighting, power, fire safety, and security.
Features:
 Live status of AC operation
 Room-wise temperature & humidity monitoring
 Scheduling and automation
 Alarm system for faults or anomalies
 Energy analytics and reporting

Protocols Used:
 BACnet
 Modbus
 KNX

6. Remote Monitoring & IoT Integration

Modern systems can be integrated with mobile apps or cloud dashboards, especially in
smart buildings.
 Remote ON/OFF
 Fault alerts via SMS/email
 Energy consumption reports
 AI-based predictive maintenance

7. Safety & Efficiency Controls

 High/Low pressure cut-off switches

 Anti-freeze protection
 Overload protection for compressors
 Economizers for free cooling
 Night setback settings to reduce cooling load at night
Summary: Key Automation Tools in AC Systems
Control Element Purpose
Thermostat Basic temperature control
Sensor (Temp/Pressure) Real-time feedback to controllers

VFD Variable speed for energy saving

VAV Box Zonal air volume control
BMS Centralized system control & monitoring
IoT / Smart Apps Remote monitoring & automation
 Part 9: Installation, Commissioning & Testing of Air Conditioning Systems

A well-designed air conditioning system will only perform as intended if it is properly installed,
tested, and commissioned. This phase is critical and must be executed under engineering
supervision.

1. Pre-Installation Checklist
 Confirm site readiness (civil, electrical, ducting, etc.)
 Ensure all equipment is delivered and undamaged
 Review shop drawings, layout plans, and BOQ
 Check proper tools, safety equipment, and manpower availability
 Verify power supply capacity and phase connection

2. Installation Process (System-Wise)

A. Split or Ducted AC
 Indoor Unit Installation
 Level and fix on wall/ceiling
 Connect condensate drain (ensure slope for gravity drainage)
 Install insulation on suction pipe
 Outdoor Unit Installation
 Fix on vibration-absorbing pads
 Ensure proper clearance for air circulation
 Connect refrigerant piping and electrical wiring
 Refrigerant Line Connection
 Use flaring tool for leak-free joints
 Apply vacuum before charging
 Insulate both suction and liquid lines

B. VRF/VRV System
 Follow manufacturer guidelines strictly
 Use copper piping as per length and height limitations
 Connect communication cables and data wiring
 Pressure test, vacuum, and refrigerant charging carefully

C. Chiller System with AHU/FCU

 Chiller Base & Mounting
 Foundation bolts, vibration isolators
 Pipe Installation
 Chilled water and condenser water loop
  Install valves, strainers, gauges, and flow meters
 AHU/FCU Setup
 Mount on vibration pads
 Connect chilled water lines and control cables
 Pump & Cooling Tower Installation
 Align pump and motor
 Install make-up water and drain lines in towers

3. Electrical Installation
 Follow wiring diagram of manufacturer
 Install proper MCBs, contactors, and isolators
 Ground all equipment properly
 Separate wiring for compressors, fans, controls

4. Control & Automation Setup

 Install sensors, thermostats, actuators as per layout
 Connect VFDs (if used) and test signal response
 Interface BMS (if applicable) for central control
 Calibrate all set points (temperature, humidity)

5. Testing & Commissioning

A. Vacuum & Pressure Testing

 Pull vacuum to -500 to -700 mmHg
 Hold for 30 minutes to confirm no leaks
 Nitrogen pressure test (typically 300 psi)

B. Refrigerant Charging
 Charge refrigerant as per system design
 Use charging cylinder or weighing scale
 Monitor subcooling/superheat levels

C. Functional Testing
 Start system and monitor:
 Compressor operation
 Suction/discharge pressure
 Air outlet temperature
 Fan speed and airflow
 Condensate drainage
D. Balance Air & Water Flow
 Use anemometer for airflow (CFM)
 Use flow meters for chilled water GPM
 Adjust dampers, valves for proper distribution
6. Performance Verification
 Check if system maintains desired temperature
 Measure power consumption vs design
 Ensure even air distribution
 Monitor for noise, vibration, leakage
 Confirm controls respond properly (ON/OFF, modulate, alarms)

7. Documentation & Handover

 Prepare as-built drawing
 Submit testing and commissioning report
 Provide operation manual to client
 Train end users on basic operation and maintenance
 Record refrigerant and equipment serial numbers

Installation Best Practices

Task Tip

Refrigerant Avoid sharp bends, use correct slope, ensure insulation

Piping
Drain Maintain gravity slope or use pump, insulate to avoid sweating
Piping
Ducting Seal joints with mastic, avoid leakage

Electrical Use separate circuits, proper earthing, and cable sizing

Work
Anchor Use vibration isolators for rotating equipment
Bolts
 Part 10: Maintenance, Troubleshooting & Energy Efficiency Tips

After a system is installed and commissioned, proper maintenance is essential for consistent
performance, energy savings, and longevity. This section covers all the essential practices and
skills an engineer needs to keep air conditioning systems running optimally.

1. Importance of Regular Maintenance

 Prevents system failure
 Ensures consistent cooling/heating
 Reduces electricity bills
 Increases equipment life
 Ensures indoor air quality

2. Types of Maintenance
A. Preventive Maintenance (PM)
 Scheduled servicing at regular intervals
 Prevents problems before they occur
B. Corrective Maintenance
 Fixing issues after a fault has occurred
 Includes part replacement, repairs
C. Predictive Maintenance (using BMS/IoT)
 Monitoring system performance via sensors
 Predicting faults using analytics

3. Preventive Maintenance Checklist (Monthly/Quarterly)

Component Task

Air Filters Clean/replace to ensure airflow

Condenser Clean to prevent high pressure & heat buildup

Coils
Evaporator Coil Clean to maintain efficient heat transfer
Fan/Blower Check alignment, balance, and belt tension

Refrigerant Check pressure & top-up if required

Electrical Panel Tighten terminals, check MCBs, relays

Drain Lines Clear blockages to avoid overflow

Sensors Calibrate for accuracy

Ducts Inspect for leakage or insulation damage

4. Common Issues & Troubleshooting Guide

Problem Possible Cause Solution

AC not cooling Low refrigerant / dirty coil / Check charge, clean coils, test
thermostat sensor
Water dripping indoors Clogged drain / improper slope Clean drain, correct slope
High electricity bill Dirty filters / oversizing / VFD Maintenance, recheck system
off size
Compressor not Faulty capacitor / overload / Replace component, check
starting wiring wiring
Noise or vibration Fan imbalance / loose parts / Align fan, tighten, use isolators
mounting
Uneven cooling across Damper issue / low airflow Check duct damper, measure
zones CFM

5. Energy Efficiency Tips

 Use VFDs on pumps, fans to reduce power at part load

 Install programmable thermostats
 Seal ducts to avoid conditioned air leakage
 Clean filters monthly
 Upgrade to inverter-based or VRF systems
 Zone-wise control with VAVs
 Use energy recovery ventilators (ERVs) in large systems

6. AMC (Annual Maintenance Contract)

 Offer AMC to clients post-installation
 Covers regular service, priority breakdown support
 Includes periodic inspection, documentation
 Ensures customer satisfaction and long-term relationships

7. Logbook & Documentation

Maintain a maintenance logbook including:
 Date of service
 Observations
 Parts replaced
 Refrigerant added
 Performance reading (amps, volts, pressure, temperature)
This helps in tracking trends and planning proactive servicing.
Summary: Golden Rules for AC Maintenance

Rule Why It Matters

Clean coils & filters Maintains airflow and efficiency

Check refrigerant charge Prevents underperformance

Tighten electricals Avoids overheating & fire risk

Clear drain pipes Prevents water leakage

Keep system records Improves reliability & analysis

Service before peak Ensures readiness for summer/winter

seasons