Converting Traditional Window AC to Heat Pump

for Utilization in Winter

Session 2017-2021
Muhammad Waseem Meladi
2017-BT-MECH-753

Department of Mechanical Engineering

Mechanical Engineering and Technology Program
Muhammad Nawaz Sharif
University of Engineering and Technology, Multan Pakistan
 Declaration
I, Muhammad Waseem Meladi (Reg.# 2017-BT-MECH-753) hereby declare that I
have completed final year project presented in this report, during the scheduled period
of study.

Date: ___________ Signature of the student: ___________________

(Student Name: ________________________ )
(Registration No. :_______________________ )
 CERTIFICATE

It is certified that Muhammad Waseem Meladi (Reg # 2017-BT-MECH-753) has

carried out all the work related to this final year project under my supervision at the
Department of Mechanical Engineering and Technology, Muhammad Nawaz Sharif
University of Engineering & Technology Multan and the work fulfils the
requirements for award of B.Sc. Mechanical Engineering and Technology degree.

Date: _______________________

Supervisor Signature:

Supervisor Name:
Mechanical Engineering Department.

Miss Misbah Niamat

In-charge Tours and Internships,
Mechanical Engineering Department.

Mr. Muhammad Umar Khalidoon

Head of Mechanical Engineering Department
 ABSTRACT

Maximization utilization of an air conditioning unit is vital for the present energy
crisis situation. The objectives of this research are to design and fabricate a portable
air conditioning-heat pump unit for produce cool air and warm water. In other words,
this unit can provide warm water as a by-product of air-conditioning. It is appropriate
for the household section, and some type of commercial buildings and some type of
public buildings that need to use conditioning air and warm water at the same time or
use as pre-heater for water. The unit is designed on wheels to ease mobility, in small
size. It may be used as standalone unit or as a supplement unit to other air
conditioning systems. According to cooling system performance evaluation of the unit
in term of the coefficient of performance ( COP ) and the economic analysis, the
results show that the experimental unit when heat up the water by approximately 10-
16degC at water flow rate of 2.0 l/min will give maximum COP . Waste heat recovery
from the system at the flow rate of 2.0 l/min can reduce water-heating energy
consumption by approximately 4,000 kWh per year. Furthermore, COP improving by
using water cooled condenser of the air conditioning unit can help to reduce the
energy consumption by 1,480 kWh per year. And the unit is economically attractive
also with modification unit that has payback period of 6 months.

KEYWORDS:

COP; AC; Heat Pump; Refrigeration Cycle; Design; Fabrication

iii
 ACKNOWLEDGEMENTS

We consider our self to be fortunate to get this opportunity to be part of a

Project Report on in “CONVERTING TRADITIONAL WINDOW AC TO HEAT
PUMP FOR UTILIZATION IN WINTER” We are sincerely grateful to Engineer
Umar Khalidoon (Head of Mechanical Engineering) for his invaluable guidance,
motivation and support at all stages and creating a flexible and enjoyable environment
to work in.

Special thanks to Engineer Misbah Niamat for the support and help us in
completing this seminar program successfully. Last but not least; We are thankful to
the God, my dearly beloved Parents, all Faculty Members, my Friends and all who
directly or indirectly supported for completion….

iv
 TABLE OF CONTENTS

CERTIFICATE..................................................................................................................i
ABSTRACT.....................................................................................................................iii
ACKNOWLEDGEMENTS.............................................................................................iv
TABLE OF CONTENTS..................................................................................................v
LIST OF FIGURES.........................................................................................................vii
LIST OF TABLES...........................................................................................................ix
LIST OF ABBREVIATIONS...........................................................................................x
Chapter 1 : Introduction.............................................................................................11
1.1 Air Conditioning System.......................................................................................11
1.1.1 Central Chilled Water Air Conditioning Systems - All Air Systems..........11
1.1.2 Central Chilled Water Air Conditioning Systems - Air-And Water Systems
..............................................................................................................................11
1.1.3 Central Chilled Water Air Conditioning Systems - All Water Systems,
Including Cooling Towers Which Can Also Be Applied To Systems 1, 2 Above
..............................................................................................................................12
1.1.4 Direct Expansion Systems [i.e., direct expansion of refrigerant, without the
chilled water-cooling medium]............................................................................12
1.2 Portable Air Conditioner.......................................................................................33
1.2.1 Features of Windows Air Conditioner: (Room AC)..................................34
1.2.2 Components Details....................................................................................35
1.3 Objectives:.............................................................................................................35
To setup a mechanism which use Traditional Window AC as a Heat Pump in winter
for economical heating purpose...................................................................................35
Chapter 2 : LITERATURE REVIEW........................................................................36
2.1 A Short History of Refrigerant-Cycle Air Conditioners.......................................36
2.2 General Air Conditioning System.........................................................................37
2.3 Type of Air Conditioning Systems........................................................................39
2.3.1 Central Air Conditioning Systems..............................................................39
2.3.2 Unitary Air Conditioning Systems..............................................................40
2.3.3 Room Air Conditioning Units.....................................................................40
2.3.4 Split System Air Conditioners....................................................................41
2.4 Air Conditioning System Components..................................................................41
2.5 Outdoor Design Conditions...................................................................................44
2.6 Motion Sensor.......................................................................................................45
Chapter 3 : METHODOLOGY..................................................................................47
3.1 Five Basic Elements of all Cycles.........................................................................48
3.2 Refrigerating Machines.........................................................................................48
3.2.1 A Refrigerating Machine- The Second law of Thermodynamics...............48
3.2.2 Heat engine, Heat pump & Refrigerating Machine.....................................49
3.2.3 Energy Ratios or Coefficients of Performance...........................................50
3.3 Operation...............................................................................................................50

v
 3.3.1 Front Panel..................................................................................................50
3.3.2 Indoor Side Components.............................................................................50
3.3.3 Outdoor Side Components..........................................................................51
3.4 Heat Pump Window Air Conditioner....................................................................51
3.4.1 Four Way Reversing Valve.........................................................................51
3.4.2 Working of Control Valve..........................................................................52
3.4.3 Control Valve in Heating Vs Cooling Cycle...............................................53
3.5 Theoretical Analysis..............................................................................................54
3.5.1 Group Discussion........................................................................................54
3.5.2 Final Year Project Topic.............................................................................54
3.5.3 Time Frame of the Project...........................................................................55
3.5.4 Risk and Analysis of this Project Successfully...........................................56
3.5.5 Internet........................................................................................................56
3.5.6 Design Analysis..........................................................................................56
3.5.7 Visit.............................................................................................................56
3.6 VALIDITY OF THEORITICAL ANALYSIS......................................................57
3.6.1 Manufacturing.............................................................................................57
3.6.2 Product Testing...........................................................................................58
3.7 Bill of Materials.....................................................................................................58
Chapter 4 : Results and Discussion............................................................................59
4.1 Results...................................................................................................................59
4.2 CONCLUSION.....................................................................................................59
Chapter 5 : VALIDATION OF DEVELOPED SYSTEM (COST MODELLING
SYSTEM FOR LEAN PRODUCT AND PROCESS DEVELOPMENT).....................60
5.1 Four Way Reversing Valve...................................................................................60
5.2 TESTING..............................................................................................................60
5.3 Future Development..............................................................................................62
REFERENCES................................................................................................................63

vi
 LIST OF FIGURES

Figure 1: shows the control of chilled cooling coil and fan.........................................15

Figure 2: Single Zone System.....................................................................................16
Figure 3: Reheat System.............................................................................................17
Figure 4: Simple Variable Air Volume (VAV)............................................................17
Figure 5: Variable Air Volume – Reheat.....................................................................18
Figure 6: Dual Duct System.........................................................................................19
Figure 7: Multi-zone System........................................................................................20
Figure 8: Induction System..........................................................................................21
Figure 9: Fan-Coil System (a)......................................................................................23
Figure 10: Fan-Coil System (b)....................................................................................23
Figure 11: Two-pipe Systems......................................................................................24
Figure 12: Three-pipe Systems....................................................................................25
Figure 13: Four pipe Systems (a).................................................................................25
Figure 14: Four pipe Systems (b).................................................................................26
Figure 15: Fan-coil units..............................................................................................27
Figure 16: Fan-coil units..............................................................................................27
Figure 17: Direct Expansion Systems (a).....................................................................29
Figure 18: Window Air Conditioner............................................................................30
Figure 19: Windows AC..............................................................................................35
Figure 20: Minimal Air Conditioning..........................................................................37
Figure 21: Evaporator...................................................................................................41
Figure 22: Condenser...................................................................................................42
Figure 23: Types of Condenser....................................................................................42
Figure 24: Expansion Valve.........................................................................................42
Figure 25: Types of Expansion Valve..........................................................................43
Figure 26: Compressor.................................................................................................43
Figure 27: Types of Compressor..................................................................................44
Figure 28: Methodology...............................................................................................47
Figure 29: 4-Way Valve...............................................................................................51

vii
Figure 30: Working of Control Valve..........................................................................52
Figure 31: Heating Vs Cooling....................................................................................52
Figure 32: Final Product...............................................................................................59
Figure 33: 4-Way Valve...............................................................................................60

viii
 LIST OF TABLES

Table 1: BOM...............................................................................................................58
Table 2 : Results of Test...............................................................................................61
Table 3: Distance the cold air can travel......................................................................61

ix
 LIST OF ABBREVIATIONS

COP Coefficient of Performance

AC Air Conditioner

x
 Chapter 1 : Introduction

1.1 Air Conditioning System

Air conditioning for people is the control of temperature, humidity, air movement and
air cleanliness, heat radiation sometimes [e.g. by chilled ceiling], normally with
mechanical means, to achieve human thermal comfort.

Air conditioning systems can be categorized according to the means by which the
controllable cooling is accomplished in the conditioned space. They are further
segregated to accomplish specific purposes by special equipment arrangement.

 In selecting a suitable air conditioning system for a particular application,

consideration should also vent to the following: -

 System Constraints: Cooling load, Zoning requirements, Heating and

ventilation
 Architectural Constraints: Size and appearance of terminal devices,
acceptable noise level, Space available to house equipment and its location
relative to the conditioned space, acceptability of components obtruding
into the conditioned space
 Financial Constraints: Capital cost, Operating cost, Maintenance cost

There are four basic system categories:

1.1.1 Central Chilled Water Air Conditioning Systems - All Air Systems
 Single zone

 Reheat

 Variable Air Volume

 Dual Duct

 Multizone

11
1.1.2  Central Chilled Water Air Conditioning Systems - Air-And Water
Systems
 Induction

 Fan Coil

 Two-pipe

 Three-pipe

1.1.3  Central Chilled Water Air Conditioning Systems - All Water

Systems, Including Cooling Towers Which Can Also Be Applied To
Systems 1, 2 Above

 Fan-coil units
 Central chilled water air conditioning system with fan coils and other
devices
 Water cooling tower

1.1.4 Direct Expansion Systems [i.e., direct expansion of refrigerant,

without the chilled water-cooling medium]

 Window air conditioners

 Unitary and Rooftop Air Conditioners
 Split type and package air conditioning systems
 Heat pumps

1.1.1. Central Chilled Water Air Conditioning Systems - All Air

Systems

An all-air system provides complete sensible and latent cooling capacity in the cold
air supplied by the system. Heating can be accomplished by the same air stream,
either in the central system or at a particular zone. All-air systems can be classified
into 2 categories: - 

-Single duct systems

-Dual duct systems

12
 System Advantages

1. The central plant is located in unoccupied areas, hence facilitating operating

and maintenance, noise control and choice of suitable equipment.
2. No piping, electrical wiring and filters are located inside the conditioned
space.
3. Allows the use of the greatest numbers of potential cooling seasons house with
outside air in place of mechanical refrigeration.
4. Seasonal changeover is simple and readily adaptable to climatic control.
5. Gives a wide choice of zoomability, flexibility, and humidity control under all
operating conditions.
6. Heat recovery system may be readily incorporated.
7. Allows good design flexibility for optimum air distribution, draft control, and
local requirements.
8. Well suited to applications requiring unusual exhaust makeup.
9. Infringes least on perimeter floor space.
10. Adapts to winter humidification.

System Disadvantages

1. Requires additional duct clearance which can reduce the usable floor space.
2. Air-balancing is difficult and requires great care.
3. Accessibility to terminals demands close cooperation between architectural,
mechanical and structural engineers.

Distribution systems have a number of important components:

The Air Handling Unit is a cabinet that includes or houses the central furnace, air
conditioner, or heat pump and the plenum and blower assembly that forces air through
the ductwork.

1. The Supply Ductwork carries air from the air handler to the rooms in a house.
Typically, each room has at least one supply duct and larger rooms may have
several.
2. The Return Ductwork carries air from the conditioned space back to the air
handler. Most houses have only one or two main return ducts located in a
central area.

13
3. Supply and Return Plenums are boxes made of duct board, metal, drywall or
wood that distribute air to individual ducts or registers.
4. The Ductwork is a branching network of round or rectangular tubes generally
constructed of sheet metal, fiberglass board, or a flexible plastic and wire
composite material located within the walls, floors, and ceilings. The three
most common types of duct material used in home construction are metal,
fiberglass duct board, and flex-duct.
5. Flex-duct is installed between the register and plenum box, or plenum box
and air handler, usually in a single, continuous piece. While flex-duct has
fewer seams, the inner lining and outer insulated covering can tear or be
pinched closed. Also longer flex-duct runs can restrict the flow of air; proper
design and installation is very important.
6. Both metal and fiberglass duct board are rigid and installed in pieces.
Fiberglass duct board, like flex-duct, is made of an insulation material. Ducts
are built of sections of the duct board. The seams in the duct board should be
carefully sealed with mastic or high-quality duct tape.
7. Rectangular metal duct, especially the kind used for plenums and larger
trunk runs, is often insulated on the inside with fiberglass duct liner. If it is not
insulated on the inside, metal ducts should be insulated on the outside using a
fiberglass batt with an attached metal foil vapor retarder. The insulation should
be at least two inches thick, and the vapor barrier installed on the outside of
the insulation facing away from the duct.
8. The seams in the insulation are usually stapled together around the duct and
then taped. All of the seams should be sealed before insulation is installed. All
return and supply ducts located outside the conditioned space, in attics,
crawlspaces, or basements, for example, should be sealed and insulated.
a. Ductwork Joints join pieces of ductwork.
b. Elbows are manufactured pieces of duct used for turns.
c. Boots connect ductwork to registers.
d. Registers and Grilles are the coverings for duct openings into the
conditioned space.

14
 Chapter 01 Figure 1: shows the control of chilled cooling coil and fan 

These are components will bring about: -

a) Heat Balance:

The amount of heat extracted out of the air conditioned room (by the cooling system,
exhaust air systems, building leakage, must be equal to the amount of heat generated
inside the room (by human being, electrical appliances, etc.) and transferred into the
room (by conduction through the building envelope, radiation via the glass, hot air
leakage into the room through gaps in windows, doors, fresh air introduced into the
room, etc.) i.e. Total kW going into room = Total kW going out of the room.

b) Air Balance:

The mass flow rate of the air going into the room = The mass flow rate of air going
out of the room. Fresh air coming into the room : 2.5 l/s per person, non-smoking, 5
l/s per person for smoking accommodation, good indoor air quality (IAQ) is
important.

15
c) Single Zone System

The all-air single-zone air conditioning system is the basic central system which can
supply a constant air volume or a variable air volume at low, medium or high
pressure. Normally, the equipment is located outside the conditioned space but can
also be installed within the conditioned are if conditions permit. Typical applications
include:

- -Space with uniform loads

- -Small spaces requiring precision control
- -Multiple systems for large areas

Chapter 01 Figure 2: Single Zone System

 Reheat System

- The reheat system is a modification of the single-zone system. It provides:-

- Zone or space control for areas of unequal loading.
- Heating or cooling of perimeter areas with different exposures.
- Close control for process or comfort applications. In the reheat system, heat is
added as a secondary process to either preconditioned primary air or
recirculated room air. The heating medium can be hot water, steam or
electricity.

Advantages: Closely controls space conditions

Disadvantages: Expensive to operate

16
 Chapter 01 Figure 3: Reheat System 

Variable Air Volume System

The variable air volume system compensates for varying cooling loads by regulating
the volume of cooling air supplied through a single duct.

Simple Variable Air Volume (VAV)

Simple VAV systems typically cools only and have no requirement for simultaneous
heating and cooling in various zones.

Chapter 01 Figure 4: Simple Variable Air Volume (VAV)

17
(b) Variable Air Volume – Reheat

It integrates heating at or near the terminal units. It is applied to systems requiring

full heating and cooling flexibility in interior and exterior zones. Heating is turned on
when the air flow reaches a predetermined minimum.

Chapter 01 Figure 5: Variable Air Volume – Reheat

Advantages

1. When combined with a perimeter heating system, it offers inexpensive

temperature control for multiple zoning and a high degree of simultaneous
heating-cooling flexibility.
2. Capital cost is lower since diversities of loads from lights, occupancy, solar
and equipment of as much as 30% are permitted.
3. Virtually self-balancing.
4. It is easy and inexpensive to subdivide into new zones and to handle increased
loads with new tenancy or usage if load does not exceed the original design
simultaneous peak.
5. No zoning is required in central equipment.
6. Lower operating cost because
7. Fans run long hours at reduced volume
8. Refrigeration, heating and pumping matches diversity of loads
9. Unoccupied areas may be fully cut-off
10. Reduced noise level when the system is running at off-peak loads.
11. Allows simultaneous heating and cooling without seasonal changeover.

18
Dual Duct System

The dual-duct system employs two air ducts to supply cold air and warm air to a
mixing terminal unit which proportions the cold and warm air in response to a
thermostat located in the conditioned space. The system is well suited to provide
temperature control for individual spaces or zones.

Chapter 01 Figure 6: Dual Duct System

Advantages (in addition to those common to all air systems)

1. Systems with terminal volume regulation are self-balancing.

2. Zoning of central equipment is not required.
3. Instant temperature response is achieved because of simultaneous availability
of cold and warm air at each terminal unit.
4. No seasonal changeover is necessary.

Disadvantages

1. Initial cost is usually higher than other VAV systems.

2. Does not operate as economically as other VAV systems.

19
1.5 Multi-zone System

The multi-zone system applies to a relatively small number of zones served by a

single, central air-handling unit. Different zone requirements are met by mixing cold
and warm air through zone dampers at the central air handler in response to zone
thermostats. 

Chapter 01 Figure 7: Multi-zone System

Advantages (in addition to those common to all-air systems)

1. Easy to balance.
2. Air transmission and distribution is simplified.

1.1.2. Central Chilled Water A/C Systems - Air-and-Water Systems

An air-and-water system is one in which both air and water (cooled or heated in
central plant room) are distributed to room terminals to perform cooling or heating
function. The air side is comprised of central air conditioning equipment, a duct
distribution system, and a room terminal. The supply air, called primary air, usually
has a constant volume which is determined by:

1. The ventilation requirement.

2. The required sensible cooling capacity at maximum cooling load.
3. The maximum sensible cooling capacity following changeover to the winter
cycle when chilled water is no longer circulated to the room terminal. 

20
The water side consists of a pump and piping to convey water to heat transfer surfaces
within each conditioned space. The water is commonly cooled by the introduction of
chilled water from the primary cooling system and is refereed to as the secondary
water loop. Individual room temperature control is by regulation of either the water
flow through it or the air flow over it.

Induction System

The inducting system is designed for use in perimeter rooms of multi-storey, multi-
room building that may have reversing sensible heat characteristics. It is especially
adapted to handle the loads of skyscrapers with minimum space requirements for
mechanical equipment.

In the induction system, ducted primary air is fed into a small plenum chamber where
its pressure is reduced by means of a suitable damper to the level required at the
nozzles. The plenum is acoustically treated to attenuate part of the noise generated in
the duct system and in the unit. The primary air is then delivered through nozzles as
high velocity jets which induce secondary air from the room and over the secondary
coil.

Induction units are usually installed at a perimeter wall under a window. Some hotel
rooms are provide with induction coils.

Chapter 01 Figure 8: Induction System

21
The induction system employs air ducts to convey treated air with higher pressure
levels and of the right adjustable quantities to various cooling/heating coil units.
These coil units are built in with induction nozzles such that when high pressure air
goes through them, air room the room is inducted across the fin surface of the water-
circulated coils. This inducted air stream is either cooled or heated after passing
through the coil, and then mixed with the air coming out of the nozzle. The right
quantity of high-pressure air is adjusted automatically in response to a thermostat
located in the conditioned space. The system is well suited to provide temperature
control for individual spaces or zones.

Advantages

1. Individual room temperature control.

2. Separate sources of heating and cooling for each space available as needed to
satisfy a wide range of load variations.
3. Low distribution system space required as a result of reducing the air supply
by use of secondary water for cooling and high velocity air design.
4. Reduced size of central air handling equipment.
5. Dehumidification & filtration performed in a central plant room remote from
conditioned space.
6. Outdoor air supply is positive.
7. Minimal maintenance required for individual induction units which have no
moving parts, i.e. no fans
8. Air duct dimensions are smaller than VAV systems or CAV systems
9. Zoning of central equipment is not required.
10. No fan comes together with the coil, making the conditioned space quiet.

Disadvantages

1. Limited to perimeter space.

2. The primary air supply is usually constant with no provision for shutoff.
3. Not applicable to spaces with high exhaust requirement.
4. Higher energy consumption due to increased power required by the primary
pressure drop in the terminal units.
5. Controls tend to be more complex than for all-air systems.

22
 6. A low chilled water temperature is needed to control space humidity
adequately.
7. Seasonal changeover is necessary.
8. Initial cost is usually higher than fan coil systems.

Fan-Coil System

The fan-coil system is similar to the inducting system, with the induction unit
replaced by the fan-coil unit. The basic elements of the fan-coil units are a finned-
tube coil and a fan section. The fan section recirculates air continuously from within
the perimeter space through the coil which is supplied with either hot or chilled water.
Auxiliary air may be delivered to the conditioned space for dehumidification and
ventilation purposes.

Chapter 01 Figure 9: Fan-Coil System (a)

Chapter 01 Figure 10: Fan-Coil System (b)

23
Advantages (in addition to those for induction units)

1. System can be operated with the primary air turned off.

2. The air velocity is fairly constant regardless of the primary air quantity.
3. Primary air can either connect directly to fan-coil unit or supply the room
separately.

Two-pipe Systems

In two-pipe systems for induction coil, fan-coil or radiant panel systems, the water
distribution circuit consists of one supply and one return pipe. The secondary water is
cold in summer and intermediate seasons and warm in winter. The primary air
quantity is fixed, and the primary air temperature is varied in reverse proportion to
outside temperature to provide the necessary amount of heating during summer and
intermediate seasons. During winter cycle operation, the primary air is preheated and
supplied at about 10°C to provide a source of cooling.

Chapter 01 Figure 11: Two-pipe Systems

Advantages

Usually less expensive to install than four pipe systems.

Disadvantages

1. Less capable of handling widely varying loads or providing widely varying

choice of room temperature than four-pipe systems.
2. Cumbersome to change over.
3. More costly to operate than four-pipe systems.

24
Three-pipe Systems

Three-pipe systems for induction coil, fan-coil and radiant panel systems have three
pipes to each terminal unit, a cold water pipe, a warm water pipe and a common
return. These systems are rarely used today because they consume excess energy.

Chapter 01 Figure 12: Three-pipe Systems

Four pipe Systems

Four-pipe systems have a cold-water supply, cold water return, warm water supply
and warm water return. The terminal unit usually has two independent secondary
water coils, one served by hot water, the other by cold water. The primary air is cold
and remains at the same temperature year-round.

Chapter 01 Figure 13: Four pipe Systems (a)

25
 Chapter 01 Figure 14: Four pipe Systems (b)

Advantages (as compared with two-pipe systems)

1. More flexible and adaptable to widely varying loads.

2. Simpler to operate (No summer-winter changeover and primary air reheat
schedule).
3. Higher efficiency due to lower operating costs.

Disadvantages

 Higher initial cost.

1.1.3. Central Chilled Water Air Conditioning Systems - All-water

Systems

All-water systems are those with fan-coil, unit ventilator, or valance type room
terminals with unconditioned ventilation air supplied by an opening through the wall
or by infiltration. Cooling and dehumidification is provided by circulating chilled
water through a finned coil in the unit. Heating is provided by supplying hot water
through the same or a separate coil.

System Advantages

1. Flexible and readily adaptable to many building module requirements.

2. Provides individual room control. 

System Disadvantages

1. No positive ventilation is provided unless wall openings are used.

2. No humidification is provided.

26
 3. Seasonal change over is required.
4. Maintenance and service work has to be done in the occupied areas.

Fan-coil units

A fan-coil unit basically consists of a finned tube coil, a filter and a fan section. The
fan recirculates air continuously from the space through the coil, which contains
either hot or chilled water.

Chapter 01 Figure 15: Fan-coil units 

Chapter 01 Figure 16: Fan-coil units 

27
1.1.4. Central chilled water air conditioning system with fan coils
and other devices

In this system, the following circuits do not mix with each other, and heat exchange is
performed via various metal surfaces: -

-the chilled water circuit – nominally 12 deg .C entering water chiller, 7 deg. C
leaving chiller, i.e. nominally 7 deg .C entering fan coil units [FCU] /air handling
unit[AHU] /primary handling unit[PAU]- for treating fresh air, 12 deg. C leaving
these devices – chilled water pumps move water through this circuit – CH. W. F-
chilled water flow ;

- CH. W. R- chilled water flow return.

- -refrigerant circuit – refrigerant compressors move the refrigerant through this
circuit
- -cooling water circuit - nominally 35 deg .C entering water cooling tower , 30
deg. C leaving cooling tower, i.e. nominally 30 deg .C entering condenser of
chiller assembly, 35 deg. C leaving condenser of chiller assembly – Condenser
water pumps move condenser water through this circuit.

a) Water cooling tower

A water cooling tower cools the water entering it from 35 deg. C to 30 deg. C
nominally. The warmer water is sprayed inside the cooling tower amidst the stream of
an upward air flow produced by the fan at the top of the tower. The air stream going
out carries water particles. These water particles should not be taken into buildings, to
avoid Legionnaire disease to occur. Condenser water pumps move condenser water
through this circuit. Water in this circuit has to be treated. There is water loss to
atmosphere in using cooling towers.

b) Direct expansion Systems

[i.e. direct expansion of refrigerant, without the chilled water-cooling medium]

1.1.5. Direct Expansion Systems

28
 [i.e. Direct Expansion of Refrigerant, Without The Chilled
Water Cooling Medium] -Window Air Conditioners

A window unit is an encased assembly designed primarily for mounting in a window,

through a wall, or as a console. These units are designed for comfort cooling and to
provide delivery of conditioned air to a room either without ducts or with very short
ducts. They include a prime source of refrigeration, dehumidification, means for
circulating and cleaning air, and may also include means for ventilating, and/or
exhausting and heating.

Chapter 01 Figure 17: Direct Expansion Systems (a)

 In a window air conditioner, the indoor unit and outdoor unit of the split system is put
into one single unit. The refrigerant compressor now is part of the machine locating at
the window area. Since this compressor gives out most noise, among other
components, the window unit will make the room acoustically inferior to other air
conditioning systems. Fresh air exchange for the room can be provided by:-

1) Setting the “ventilator” switch of the window air conditioner to “open”

position

29
 2) Installing a ventilating extract fan in the room to extract room air to outside –
caution- not to oversize the fan
3) Naturally leaking of air in and out of the room

Chapter 01 Figure 18: Window Air Conditioner

These are commonly air-cooled units.

 The units are the floor – standing type designed for installation outdoors or on
the roof.
 A supply air duct and a return air duct are to be connected to the cooling unit.
 Application: For general air conditioning of stores, residences, schools,
offices, etc. particularly suitable for single flat building with extensive floor
areas.
 A remote controller should be installed on an easily accessible wall,
incorporating a temperature selection switch & thermostat.

The Basic Concepts of A Split Air Conditioning System [ Small

System]

a. A split air conditioning system consists of an indoor unit and an outdoor unit
connected together by refrigerant pipes. The refrigerant circulates between these 2
units [i.e. 2 parts of the system] to take heat from indoor to outdoor, by firstly having

30
heat of the room air absorbed into the refrigerant via an air-refrigerant heat exchanger
which is the indoor unit, then conveying the heat to the outdoor unit for disposal.

b. The indoor unit comprises a finned coil and a fan which is driven by an electric
motor. Refrigerant is circulated inside the finned coil to the outside unit and then back
to the indoor unit. The fan pulls or pushes air around the outer surfaces of the coil
inside the indoor unit, taking warm air from the room and injecting cooled air into the
room in summer. The refrigerant has no direct contact with air. So the heat of the
room air is transferred into the refrigerant in the indoor unit. Inside the coil,
refrigerant evaporates, and the indoor unit is therefore commonly called an evaporator
by the engineers. The indoor unit is wall-mount or ceiling mount unit. 

c. The outdoor unit

The refrigerant then takes the heat from the indoor unit to the outdoor unit, which is
commonly called a condensing unit. [ i.e. a unit for refrigerant to condense] In an air-
cooled outdoor unit, heat exchange occurs in the same way as the indoor unit.
However, the outdoor unit contains a refrigerant compressor, in addition to having a
finned coil and motor-driven fan. The refrigerant does not have direct contact with air.
Refrigerant going through this outdoor coil is losing its energy across the metal
surface of the coil to the atmosphere, as outside air is drawn pass the surface of the
finned coil by the fan. By passing through this finned coil, the outside air is heated up,
by normally about 5 deg. rise in temperature. The outside air passing through the
outdoor unit is an open circuit. That is, air path is not recirculated. 

The refrigerant compressor, which usually is installed inside the outdoor unit, is
pumping the refrigerant through the indoor unit and the outdoor unit. [ In the split
system therefore the compressor – generating noise when pumping refrigerant- is
located outdoor, inside the outdoor unit] The refrigerant takes up energy as it goes
through the indoor unit, and rejects energy to the outside atmosphere as it goes
through the outdoor unit. Energy rejected is the sum of the energy taken indoor plus
the energy consumed by the compressor in pumping the refrigerant through the
refrigerant circuit. This refrigerant circuit is a closed circuit, and if pipe joints are well
installed, no leakage of refrigerant should occur.

31
 

d. Air circuits for the indoor environment. The air passing through the indoor unit
is cooled, say to 15 deg. C, before recirculated back to the room. A large part of air
heated up in the room, say to 25 deg. [ Note : Design room temperature is 23 deg C in
general for human comfort ] then goes back to the indoor unit for cooling. A small
part of room air is extracted to outside by an exhaust fan, with an amount of fresh
outside air coming in to replenish this amount exhausted. Now this make up air can be
supplied by connecting a small air duct from an external opening to the indoor unit.

e. Single splits and multiple splits

 -single split – one indoor unit is connected to one outdoor unit by insulated
copper refrigerant pipes
 -multiple splits– several indoor units are connected to one outdoor unit by
insulated copper refrigerant pipes 

f. Energy saving options

If heat rejection in the outdoor unit is taken care by cooling water, there would be a
saving of 30% of energy. In urban areas,. cooling water can be provided by freshwater
cooling towers. The water-cooling tower can be placed at the top of a building, with a
pump drawing water from it to circulate the condensing water to the outdoor units of
the split system. After taking up heat from the outdoor unit, with an increase of
unusually 5 deg. C, condensing water is circulated back to the cooling tower for
cooling again. Of course the finned coil f the outdoor unit has to be replaced by a
water –cooled condenser. See “water cooling tower” below.

Another efficient option is to have a few additional valves and controls added to the
basic split system to make it to serve as a heat pump system in winter. That is, the
refrigerant will do a reverse job in taking heat from outside , and rejecting it to the
indoor environment. Thus the refrigerant goes through a reversed cycle by taking heat
from outside and rejecting heat to the room. One unit of energy for pumping the
refrigerant will cause 4 units of energy to be taken from outside, i.e. ,totally 5 units of
energy, into the room.

32
g. A variant of split air conditioning system - A packaged system

If the refrigerant compressor of the outdoor unit of the split air conditioning system is
installed together with the indoor unit, it is called a packaged system. The
compressor now is put indoor, making the machine less quite than the split system.
However this will allow a larger cooling capacity for the indoor unit, which then will
be floor-mount usually. A packaged system is needed if the outdoor unit, now called a
condenser, is put on the roof top, with the indoor unit a few floors below.

h. Direct expansion air conditioning equipment consist of factory-matched

refrigeration cycle components for inclusion is air-conditioning systems which are
field designed to meet the needs of the user. The following list of variations is
indicative of the vast number of types of unitary air conditioners presently available.

1. Arrangement: single or split.

2. Heat rejection: air-cooled, evaporative condenser, water-cooled.
3. Unit exterior: decorative for in-space applications, functional for equipment
room and ducts, weatherproofed for outdoors.
4. Placement: floor standing, wall-mounted, ceiling suspended, roof-mounted.
5. Indoor air: vertical up flow, counterflow, horizontal, 90° and 180° degree
turns, with fan, or for use with forced air furnace.
6. Locations: Indoor - Exposed with plenums or furred in ductwork; concealed in
closets, attic, crawl spaces, basements, garages or equipment room.

Wall - Built-in, window, transom.

Outdoor -Rooftop, wall-mounted or on ground.

1.2 Portable Air Conditioner

Portable air conditioner is an innovation product originally from standard air

conditioner that is limited to be used in room or inside building. Then, it is design to
make it easier to move from one place to another. This product is design looks like a
decoration tree which people mostly use it as a decoration in outdoor event such as
wedding and talk.

33
As we all notice that Pakistan has a tropical rainforest climate due to its proximity to
the equator. It is hot and humid country all year round, with an average temperature of
27 °C (80.6 °F) and almost no variability in the yearly temperature. Mostly Pakistani
are finding a way to get comfort especially during day event. This portable air
conditioner can help them to produce comfortable environment in the hot day.
Besides, they do not have to depend to conventional fan that still producing warm air
but this portable will give cold air same as normal air conditioner that in close room.

This portable air conditioner is equipped with photo sensor that can sense the
existence of people in front of it and it will automatically switch off if there is no
people and it will turn on back if it detects people crossing or standing in front of it.
This will make people easier rather than switching on or off manually especially in
the busy event. It is also economizing the electricity when the usage is continuously
without people using it which lead to waste the energy.

The present of air conditioner is difficult to install specially to fit in outdoor

environment. This product is design with wheel which make it easier to move and
install. With the simplest installation procedure, anyone can easily install the air
conditioner to wherever they are desired.

1.2.1 Features of Windows Air Conditioner: (Room AC)

• Simplest form of an air conditioning system.

• Mounted on windows or walls.

• Single unit that is assembled in a casing where all the components are located.

• It has a double shaft fan motor with fans mounted on both sides of the motor.
One at the evaporator side and the other at the condenser side.

• The evaporator side is located facing the room for cooling of the space and the
condenser side outdoor for heat rejection.

34
 Chapter 01 Figure 19: Windows AC

1.2.2 Components Details

Major Parts of the AC

• Evaporator

• Compressor

• Condenser

• Expansion Valve

1.3 Objectives:

To setup a mechanism which use Traditional Window AC as a Heat Pump in winter

for economical heating purpose.

35
 Chapter 2 : LITERATURE REVIEW

2.1 A Short History of Refrigerant-Cycle Air Conditioners

Remarkably, one of our founding fathers, Ben Franklin, had a hand in the
underlying science of air conditioning. In 1758, Ben Franklin and a colleague in
England, chemist John Hadley, conducted an experiment on the cooling
properties of evaporation. By using a bellows to evaporate highly volatile liquids
like alcohol and ether, they were able to drop the temperature to 7°F, building up
a thick layer of ice on their mercury thermometer—while the ambient temperature
was 64°F (Energy Solution, 2012)

In 1820, another of history‘s greatest scientists, the British inventor Michael

Faraday, showed that by mechanically compressing ammonia to liquefy
(condense) it and then allowing the ammonia to expand and evaporate, he could
cool air. And in 1842, a Florida physician, John Gorrie, wanting to keep patients
cool, was able to use this principal to make ice in an Apalachicola hospital. Gorrie
patented his system in 1851 and hoped to commercialize it to cool buildings, but
his financial backer died and with it, Gorrie‘s path to success. Air conditioning
would not reappear for 50 years (Energy Solution, 2012).

In 1902, Willis Carrier of Syracuse, New York perfected a system for

dehumidifying a commercial printing plant. The goal was to stabilize the paper,
but the invention also kept the plant‘s temperature more comfortable and the
workers more productive. He formed The Carrier Air Conditioning Company of
America to produce these systems, eventually extending beyond commercial
buildings to homes. With 32,000 employees in 170 countries, Carrier
Corporation(now a subsidiary of United Technologies Corporation) is today the
world leader in high-technology heating, air conditioning, and refrigeration
systems (Energy Solution, 2012).

Air conditioning has in the past been used where the climate is too hot for
comfort. Cooling will increase the relative humidity of the air, so humidification
is not usually built into these systems. If it is necessary, the usual method is to

36
inject steam from electrically boiled water. That is all there is to the part of the
system in the room, which is sketched on the left in figure The bit that is more
difficult to understand, or at least unfamiliar to most people, is how the cooling
fluid is produced and controlled. That is the part on the right of the diagram.

2.2 General Air Conditioning System

Chapter 02 Figure 20: Minimal Air Conditioning.

A fan draws air from the room first through a cooling device, consisting of metal fins
extending from a pipe through which cooling fluid circulates, at a rate determined by
the thermostat or by the humidistat. The air next passes over a heater, usually
electrical, which is energised on instructions from the room thermostat.

The part of the system in the room, on the left, pulls airfirst over a cool surface and
then over a warming surface. The part of the system on the right recirculates the
cooling fluid. The fluid passes from the reservoir through a valve B into the lower
pressure within the cooling unit in the room. There the liquid boils, removing heat
from the air. The boiling point is fixed by the constant pressure set by valve A. The
vapour is then compressed and condensed back into a liquid which collects in the
reservoir ready for another cycle

37
The cooling fluid used to be a chlorofluorocarbon compound, and often still is, though
they all more or less ravage the earth's ozone layer. The essential characteristics of
these fluids is that they have quite a low boiling point at atmospheric pressure and that
they can stay in the pipes for a long time without decomposing either themselves or
the pipes. Finally they need to have some lubricating ability, or the ability to carry a
lubricant, because the fluid has to be compressed and pumped round the system. This
rare set of necessary properties has proved difficult to combine with friendliness to
the earth's atmosphere. The liquid is let into the cooling unit through a valve marked
B on the diagram. It evaporates while it passes through the pipe, taking heat from the
air just as water evaporating from a towel laid on your fevered brow cools you when
on holiday in the Mediterranean.

The temperature in the cooling coil depends partly on the amount of fluid let in by
the valve, which is controlled by the thermostat or the humidistat. But now comes a
crucial difference from your Mediterranean experience: the minimum temperature at
the cold surface can be fixed by controlling the pressure in the cooling coil, with the
valve marked A on the diagram. The boiling point of any liquid depends on the
pressure. One could use water in the cooling coil, if the pressure is kept low enough.
At 1000 Pa pressure, which seems a lot but is just 1% of atmospheric pressure, water
boils at 7 degrees. It isn't used in cooling coils of this evaporative type because it has
practical disadvantages.

The reason for wanting to limit the minimum temperature is to stop ice clogging the
air passage. There are clever systems which notice when ice has formed and hold a
melting pause, but that adds to the cost. The pressure controller is therefore set to
make the cooling fluid boil at the lowest temperature that is likely to be needed to
control the humidity, but always over zero degrees. The temperature needed for
cooling is nearly always higher than that needed for dehumidification, so it is the RH
setting that is decisive.

This brings me to the first point that conservators need to understand: it is expensive
to produce air at a dew point below about 4 degrees in this type of equipment. This
dewpoint corresponds to 50% RH at 15°C. This sort of air conditioning is entirely
suitable for keeping people comfortable, but it is not good for specialised stores, for
films or for furs, for example, where one needs a temperature below 15 degrees. Such

38
equipment is, however, often used for such places. A better solution is to use an
absorption dehumidifier, which will be described in a later article

Now back to the main story: The vapour that emerges through the pressure controller
is gathered up by a compressor. The compression also heats the gas, as will be
understood by anyone who has pumped up a cycle tyre. The hot gas is then led away
from the room, to be cooled down. This is often done on the roof or in a small
enclosure which vibrates to the roar of the fan blowing air over the fins of a
condenser. The cooled, now liquid coolant is piped back to the reservoir, ready for its
next tour through the room air conditioner.

The entire process described above is inefficient and uses electricity, which is itself
produced by inefficient conversion of heat energy. Such systems are therefore
confined to small places where the inefficiency is compensated by the generally high
reliability and freedom from maintenance. Air-Conditioning Processes

An air-conditioning process (Wang, S.K. and Lavan, Z, 2009) describes the change in
thermodynamic properties of moist air between the initial and final stages of
conditioning as well as the corresponding energy and mass transfers between the
moist air and a medium, such as water, refrigerant, absorbent or adsorbent, or moist
air itself. The energy balance and conservation of mass are the two principles used for
the analysis and the calculation of the thermodynamic properties of the moist air.

Generally, for a single air-conditioning process, heat transfer or mass transfer is

positive. However, for calculations that involve several air-conditioning processes,
heat supplied to the moist air is taken as positive and heat rejected is negative.

2.3 Type of Air Conditioning Systems

There are several type of air conditionings systems (J. Paul Guyer, 2009)) that are
commonly used to build up an air conditioner which are:

2.3.1 Central Air Conditioning Systems.

Use these systems for applications where several spaces with uniform loads will be
served by a single apparatus and where precision control of the environment is
required. Cooling coils can be direct expansion or chilled water. Select air cooled or
evaporative condensers, cooling towers, and ground-loop systems based on life cycle

39
economics considering operating efficiencies and maintenance costs associated with
outdoor design conditions and environment, e.g., high ambient temperatures and dusty
conditions could adversely impact the operation of air cooled condensers. Consider
temperature rise of chilled water supply when selecting chilled water coils, especially
for applications requiring precision humidity control.

2.3.2 Unitary Air Conditioning Systems.

These systems should generally be limited to loads less than 100 tons. Unitary
systems are packaged in self-contained or split configurations. Self-contained
units incorporate components for cooling or cooling and heating in one
apparatus. Thermostatic expansion valves are preferred over capillary tubes and
orifices for refrigerant control when available as a manufacturer's option since
expansion valves provide better superheat control over a wide range of operating
conditions. Split systems may include the following configurations:
a) Direct expansion coil and supply fan combined with a remote compressor
and condensing coil; or
b) Direct expansion coil, supply fan, and compressor combined with a
remote condenser, cooling tower, or ground-loop system.

These systems generally have lower first cost than central systems but may have
higher life cycle costs. If part load operation is anticipated for a majority of
equipment operating life, consider multiple unitary equipment for superior
operating efficiencies and added reliability. Refer to ASHRAE Handbook,
Equipment for size and selection criteria.

2.3.3 Room Air Conditioning Units.

These units are self-contained units serving only one space. These units are typically
referred to as window or through-the-wall type air conditioners. Rooms served by
these units should have a separate HVAC unit to provide ventilation air for a group of
rooms. Use them when they are life cycle cost effective, and in accordance with MIL-
HDBK-1190. Refer to ASHRAE Equipment Handbook. Built-up Systems.

These systems consist of individual components assembled at the building site.

Generally, use them when a large volume of air is handled. These systems may be

40
used as remote air handling systems with a central cooling plant. unitary air handling
units. Determine the number of air handling units by an economic division of the load,
considering: (a) the value of space occupied by equipment; (b) the extent of ductwork
and piping; (c) the multiplicity of control, maintenance, and operating points; and (d)
energy conservation factors.

2.3.4 Split System Air Conditioners

The more common of the two types of central air conditioners, split system air
conditioners have the compressor / condenser housed in a unit outdoors and the
evaporator indoors. The primary benefit of split system air conditioners is that they
keep the noisy part outside. Split system air conditioners connect into your existing
ductwork, cooling your home evenly and quietly

2.4 Air Conditioning System Components

These are major parts of an air conditioner that can be use to build up the portable air-
conditioned which is to manage refrigerant and move air in two directions: indoors
and outside:
1. Evaporator – to receives the liquid refrigerant
• These are heat exchangers where liquid refrigerant is evaporated for the
purpose of removing heat from the refrigerated space or product.
a) Direct (Dry Expansion) or
b) Recirculating (flooded /liquid overflow) System.

Chapter 02 Figure 21: Evaporator

41
2. Condenser - Facilitates Heat Transfer

Condensers are special heat exchangers that remove the heat of vaporization
from steam. A condenser is a vessel or stage which turns a vapor into a liquid

Chapter 02 Figure 22: Condenser

42
 Chapter 02 Figure 21: Types of Condenser

3. Expansion Valve – To Regulates Refrigerant flow into the evaporator

Expansion valves are devices used to control the refrigerant flow in a

refrigeration system. They help to facilitate the change of higher pressure of
liquid refrigerant in the condensing unit to lower pressure gas refrigerant in the
evaporator.

Chapter 02 Figure 24: Expansion Valve



4.

43
Compressor - A Pump that02Pressurizes
Chapter the Refrigerant
Figure 25: Types of Expansion Valve
 The compressor is the heart of the machine.
 The principal function of the compressor is to draw the cool, low-
pressure refrigerant gas and compress to increasing its temperature
and pressure.

Chapter 02 Figure 26:

Compressor

Chapter 02 Figure 22: Types of Compressor

44
2.5 Outdoor Design Conditions

In principle, the capacity of air-conditioning equipment should be selected to

offset or compensate for the space load so that indoor design criteria can be
maintained if the outdoor weather does not exceed the design values. Outdoor
and indoor design conditions are used to calculate the design space loads. In
energy use calculations, hour-by-hour outdoor climate data of a design day
should be adopted instead of summer and winter design values. ASHRAE
Handbook 1993 Fundamentals (Chapter 24 and 27) and Wang’s Handbook of
Air Conditioning and Refrigeration (Chapter 7) both list tables of climate
conditions for the U.S. and Canada (Wang‘s Handbook of Air Conditioning and
Refrigeration - Chapter 7) based on the data from the National Climate Data
Centre (NCDC), U.S. Air Force, U.S. Navy, and Canadian Atmospheric
Environment Service(ASHRAE Handbook 1993).

In these tables: Summer design dry bulb temperature in a specific location To.s, in
F, is the rounded higher integral number of the statistically determined summer
outdoor design dry bulb temperature To.ss so that the average number of hours of
occurrence of outdoor dry bulb temperature To higher than To.ss during June, July,
August, and September is less than 1, 2.5, or 5% of the total number of hours in
these summer months (2928 hr). The data are an average of 15 years. An
occurrence of less than 2.5% of 2928 hr of summer months, that is, 0.025  2928
= 73 hr, is most widely used.
 Summer outdoor mean coincident wet bulb temperature in F, is the mean of
all the wet bulb temperatures at the specific summer outdoor design dry bulb
temperature To.s during the summer months.

 Summer outdoor 2.5% design wet bulb temperature is the design wet bulb
temperature that has an average annual occurrence of less than 73 hr. This
design value is often used for evaporative cooling design.

 Mean daily range, in F, is the difference between the average daily maximum
and the average daily minimum temperature during the warmest month.

45
 In ASHRAE Handbook 1993 Fundamentals, solar heat gain factors (SHGFs),
in Btu/h.ft2, are the average solar heat gain per hour during cloudless days
through double-strength sheet (DSA) glass. The maximum SHGFs are the
maximum values of SHGFs on the 21st of each month for a specific latitude.

 Winter outdoor design dry bulb temperature To.w, in F, is the rounded lower
integral value of the statically determined winter outdoor design temperature
To.ws, so that the annual average number of hours of occurrence of outdoor
temperature To > To.ws is equal to or exceeds 99%, or 97.5% of the total number
of hours in December, January, and February (2160 hr).

A degree day is the difference between a base temperature and the mean daily
outdoor air temperature To.m for any one day, in F. The total numbers of heating
degree days HDD65 and cooling degree days CDD65 referring to a base
temperature of 65F per annum are (J. Paul Guyer, 2009)

Equation 4:

2.6 Motion Sensor

Motion detection is a process of confirming a change in position of an object relative

to its surroundings or the change in the surroundings relative to an object. This
detection can be achieved by both mechanical and electronic methods. In
addition to discrete, on or off motion detection, it can also consist of magnitude
detection that can measure and quantify the strength or speed of this motion or the

46
object that created it. When motion detection is accomplished by natural organisms, it
is called motion perception.

Motion can be detected by: sound (acoustic sensors), opacity (optical and infrared
sensors and video image processors), geomagnetism (magnetic sensors,
magnetometers), reflection of transmitted energy (infrared laser radar, ultrasonic
sensors, and microwave radar sensors), electromagnetic induction (inductive-loop
detectors), and vibration (triboelectric, seismic, and inertia-switch sensors). Acoustic
sensors are based on: electret effect, inductive coupling, capacitive
coupling, triboelectric effect, piezoelectric effect, and fibre optic transmission.
Intrusion sensors have the lowest rate of false alarms.

Motion sensor is a device for motion detection. That is, it is a device that contains a
physical mechanism or electronic sensor that quantifies motion that can be either
integrated with or connected to other devices that alert the user of the presence of a
moving object within the field of view. They form a vital component of
comprehensive security systems, for both homes and businesses.

Motion sensor that transforms the detection of motion into an electric signal. This can
be achieved by measuring optical changes in the field of view. Most motion detectors
can detect up to 15 – 25 meters (50–80ft).

There are four types of sensors used in motion detectors spectrum:

 Passive infrared sensors (Passive)-Senses body heat. No energy is emitted

from the sensor.
 Ultrasonic (active)-Sends out pulses of ultrasonic waves and measures the
reflection off a moving object.
 Microwave (active)-Sensor sends out microwave pulses and measures the
reflection off a moving object. Similar to a police radar gun.
 Tomographic Detector (active)-Senses disturbances to radio waves as they
travel through an area surrounded by mesh network nodes. Has the ability to
detect through walls and obstructions.

47
 Chapter 3 : METHODOLOGY

Methodology can properly refer to the theoretical analysis of the methods appropriate to a
field of study or to the body of methods and principles particular to a branch of knowledge. In
this chapter, it talks about the methods used to gather information in order to finish the
research. It was involving the process flow of every step-in archive the objective of this
project. There are many methods use in this project such as internet references, interviewing
lecturers and technicians and the most important is group discussion.

Chapter 03 Figure 23: Methodology

48
3.1 Five Basic Elements of all Cycles

Working substance: transports energy within system

Heat source: supplies heat to the working medium

Engine: device that converts the thermal energy of the medium into work

Heated: heat added in engine itself.

Unheated: heat received in some device separate from engine.

Heat sink/receiver: absorbs heat from the working medium.

Pump: moves the working medium from the low-pressure side to the high-pressure
side of the cycle.

3.2 Refrigerating Machines

There are essentially two categories of thermal plants. These are:

 Thermal power plant or work producing plants

 Refrigerating /heat pump plats or work consuming plants

The work producing plants or heat engines lead to the conversion of heat to work. The
work consuming plants (refrigerators or heat pumps) are not those which are in any
way related to the conversion of work into heat. The objective of the work consuming
plants, actually, is to lead to the flow of heat from a low temperature body to a high
temperature body. The work is required to achieve this. Examples of work consuming
plants refrigerators ( Cold storages, Domestic refrigerators, ice plants and food
freezing plants.

3.2.1 A Refrigerating Machine- The Second law of Thermodynamics

A refrigerating machine is device which will either cool or maintain a body at a
temperature below that of surroundings. Hence, heat must be made to flow from a
body at low temperature to the surroundings at high temperatures. However, this is
not possible on its own. We see in nature that heat flows from a high temperature
body to a low temperature body. Therefore, work is done to flow the heat from low

49
temperature to a high temperature. The vapor compression refrigeration cycle is a
common method for transferring heat from a low temperature to a high temperature.

3.2.2 Heat engine, Heat pump & Refrigerating Machine.

Reversible heat engine may be converted into a refrigerating machine by running it in
reverse direction.

• For a Heat Pump, there is no difference in the cycle of operation between a

Refrigerator and a Heat pump. The same machine can be utilized either

• To absorb heat from a cold body and reject it to the surroundings

(Refrigerating Machine)

• To absorb heat from the surroundings and reject it to a hot body (Heat Pump)

The main difference between the refrigerating machine and heat pump is in their
operating temperatures.

• The Refrigerating Machine operates between the ambient temperature and a

low temperature.

• A Heat Pump operates between the ambient temperature and high

temperature.

Another essential difference in their useful function.

• In a Refrigerating Machine, the heat exchanger that absorbs heat is

connected to the conditioned space.

• In a Heat Pump, instead, the heat exchangers that rejects heat is connected to
the conditioned space.

The other heat exchanger in each case is connected to the surroundings. Thus if a
refrigerating machine, that is used for cooling in summer, is to be used as a heat pump
for heating in winter, it will be necessary either

• To rotate the machine by 180˚ to interchange the positions of the two heat
exchangers between the space and surroundings. Or

50
 • To exchange the he functions of the two heat exchangers by the operations of
the of the valves

3.2.3 Energy Ratios or Coefficients of Performance

The performance of a heat engine is described by its thermal efficiency.

The performance of a refrigerating machine or a heat pump is expressed by the ratio

of useful heat to work, called the energy ratio or Coefficient of Performance
(COP).

For a refrigerating machine, Cooling energy ratio or COP for cooling. For a heat
pump, Heating energy ratio or COP for heating

3.3 Operation

3.3.1 Front Panel

Older unit usually are of mechanical control with rotary knobs to control the
temperature and fan speed of the air conditioner.

The newer units come with electronic control system where the functions are
controlled using remote control and touch panel with digital display. The front panel
has adjustable horizontal and vertical(some models) louvers where the direction of air
flow are adjustable to suit the comfort of the users.

The fresh intake of air called VENT (ventilation) is provided at the panel in the event
that user would like to have a certain amount of fresh air from the outside.

3.3.2 Indoor Side Components

Cooling Coil with a air filter mounted on it. The cooling coil is where the heat
exchange happen between the refrigerant in the system and the air in the room.

Fan Blower is a centrifugal evaporator blower to discharge the cool air to the room.

Capillary Tube is used as an expansion device. It can be noisy during operation if

installed too near the evaporator.

Indoor Side Components

51
Operation Panel is used to control the temperature and speed of the blower fan. A
thermostat is used to sense the return air temperature and another one to monitor the
temperature of the coil. Type of control can be mechanical or electronic type.

Filter Drier is used to remove the moisture from the refrigerant.

Drain Pan is used to contain the water that condensate from the cooling coil and is
discharged out to the outdoor by gravity.

3.3.3 Outdoor Side Components

Compressor is used to compress the refrigerant.

Condenser Coil is used to reject heat from the refrigeration to the outside air.

Propeller Fan is used in air-cooled condenser to help move the air molecules over the
surface of the condensing coil.

Fan Motor is located outside. It has a double shaft where the indoor blower and
outdoor propeller fan are connected together.

3.4 Heat Pump Window Air Conditioner

In low temperate countries, heating of the room is required. A heat pump window air
conditioner unit can cool the room during summer and heat the room during winter.

A reversing valve (also known as 4-Way-Valve) is used to accomplish this.

During heating operation, it reverses the flow of the refrigerant which results in the
evaporator to act as a condenser and the condenser as evaporator.

3.4.1 Four Way Reversing Valve

It changes the direction of refrigerant flow. By reversing the flow of refrigerant, the
heat pump refrigeration cycle is changed from cooling to heating or vice versa.

This allows a residence or facility to be heated and cooled by a single piece of

equipment, by the same means, and with the same hardware.

52
 Chapter 03 Figure 24: 4-Way Valve

3.4.2 Working of Control Valve

Chapter 03 Figure 25: Working of Control Valve

53
3.4.3 Control Valve in Heating Vs Cooling Cycle

Chapter 03 Figure 26: Heating Vs Cooling

Operation

The reversing valve has two states, relaxed (inactivated) and energized. The
energized state is typically achieved by applying 24 volts AC, which is commonly
used in HVAC equipment.

The heat pump can be designed by the manufacturer to produce either cooling or
heating with the reversing valve in the relaxed state. When the reversing valve is
energized, it will produce the opposite transfer of heat from its relaxed state. For
example, a reversing valve installed in such a way as to produce cooling when relaxed
will produce heating when energized. Likewise, a reversing valve installed to produce
heating when relaxed will produce cooling when energized.

Control

Depending on the construction and use of the heat pump, the reversing valve may be
driven by the heat pump through the use of a defrost control board, or it may be
driven directly by a thermostat (typically from the "O" terminal of the thermostat).

Replacement

54
Reversing valves are built into the heat pump by the manufacturer and must be
replaced by an HVAC technician if they fail.

Since the valve is an integral part of the sealed refrigerant circuit, proper procedures
for recovering and then later refilling the refrigerant must be followed, to prevent its
loss into the atmosphere.

Utilization

 Drying processes
 Washing process
 Heating of process water waste heat from a refrigerant system
 Pasteurization

Other applications

Industrial plants provide a wide variety of heat sources and potential users.

The heat pump is a promising technique with numerous applications in the industry.

3.5 Theoretical Analysis

3.5.1 Group Discussion

There are 2 more students with same that are doing research on the same type of
project which is air conditioner but 2 of them are doing in different part. So, we
are also gathering together to discuss about this project, By discussing among the
group, we help each other to solve problem. By doing group discussion we
manage to come out with a few solutions of the problem statement. These are the
discussion that we were discussed:

3.5.2 Final Year Project Topic.

To complete the requirement of this final year project, I need to choose three topic
to be our own project and we have come out with few topics which need further
discussion to select which topic are the suitable. The 3 topics are compressor

55
study, refrigerant study and I have finally decided to choose new generation of
portable air conditioner as the topic of my final year project. We have concluded
that they will do their test also in my project. This is because the new generation
of portable air conditioner has full fill all the final year project requirement that
are application, realistic, modification and innovation.

3.5.3 Time Frame of the Project.

At first stage, we have discussed the timeline of this project. After the topic was
selected, we were writing the topic proposal for one week. We had divided into
four phases of the time frame. For the first phases, we had searched as many as
information that could for about two months. The second phases are we start
writing the progress report. The progress report included introduction, literature
review and methodology. We spent time for this phase about two months. Phase
three and four will be next semester which the manufacturing process and result.

56
3.5.4 Risk and Analysis of this Project Successfully.

In our project, i have found few risks that can jeopardise my result. So i discuss
with them. The risks that we face are the process of manufacturing needs highly
skill. Manufacturing the portable air conditioner involve process such as safety,
assembling, and painting. If there are mistake happen, the functionality of this air
conditioner will be reduced. Other than that, to develop the portable air
conditioner we need to spend a lot of money to make this project success. So, we
have set up a few limitations on our project to get good result.

3.5.5 Internet

By using the internet, I manage to get useful information about components to

construct the portable air conditioner that I can choose which the suitable
components can be equipped to the portable air conditioner. From the internet I
have found the common decoration that people are using.

3.5.6 Design Analysis

After gather all information, I need to design portable air conditioner. At the early
stage I only do drawing and sketching on the paper. I have drawn as many designs as
possible. After completing the drawing, we have chosen one drawing that is the best
design and the latest. The next step is to get the measurement of the design that can be
suit into air conditioning system.

3.5.7 Visit
We had made a visit in Punjab Refrigeration Pvt. Limited to buy spare parts as
decided and We used Hamza Workshop for fabrication. We filled the refrigerant from
local market. We finalize the project in Workshop and arranged a test run to check
and validate our project. All the price details are mentioned in results section.

57
3.6 VALIDITY OF THEORITICAL ANALYSIS

3.6.1 Manufacturing
Before starts the manufacturing process, there are some materials are needed to
prepared to manufact this smart portable air conditioner which are:-

1. Hose
2. Fiber
3. Resin
4. Wheels
5. Paint
6. Decoration stuff
7. Refrigerant (R22 and Co2)

Besides that, the list equipment needed on this project are:-

1. Spanner set
2. Solder and welder
3. Filler
4. Brush
5. Thermometer
6. Drill
7. Vacuum pump
8. Pressure gauge

In the manufacturing process, I have chosen all the suitable components to use in the
system then assemble all of it to be a air conditioning system. The decoration of the
portable air conditioner will be making as housing of the conditioner. There are
several steps in manufacturing process which are: -

1. Finding unused components whether already damaged or still working but it

should be repairable. The main components should find is compressor and
blower.
2. The next step is repairing the components. There are several steps of repairing
process such as placing parts, welding, soldering, and wiring. The problem
that usually occur on the unused compressor and blower is leakage at the
pipes.

59
 3. The air conditioner is design raptly and it should be fitted with the components
then do the scaling to get the exact size of the air conditioner body.
4. Then it is proceeded with molding the air conditioner body by using composite
materials. The materials used to build the air conditioner body are fiber, resin
and catalyst.
5. After the building the body is finished, it is proceeded with the painting
process. The body is paint by using varnish to make it look like a real tree.
then it will add some decorations like leaf.
6. The last stage of the process is testing. The product is tested by assembling all
the components and connect with the power source.

3.6.2 Product Testing

After the product has been finalized, this product will be tested in workshop. it will
test the portable air conditioner to use inside the workshop whether it can operate or
not. If not, some modification should do to make sure it functions properly.

3.7 Bill of Materials

Table 1: BOM

Sr.No Items Name Quantity Cost per Unit Cost

1 Window AC 1 4000 4000

2 4-Way-Valve 1 1750 1750

3 Refrigerant R22 1 kg 1500 1500

4 Fabrication Per Joint 100 400

Total 7650

60
 Chapter 4 : Results and Discussion

4.1 Results

To create smart air conditioner, the components of the air conditioner that will be
used has been identified to suit with the design. It has been done by finding unused
components of air conditioner such as blower and compressor. The data was collected

Chapter 04 Figure 27: Final Product

4.2 CONCLUSION

As a conclusion, we can conclude that a cheap portable air conditioner is achievable

and can be marketable. The portable air conditioner made satisfies the basic air
conditioner functions for cooling purpose. The air conditioner has been tested to its
functions and reliability of its design. Human factor taught us that human may feel
comfortable because of several factors. One of the factors is the temperature, as we all
noticed that some of the country especially country with equatorial climate such as
South East Asia have hot temperature climate. Because of that, air conditioner
become one of the important things that help people to feel comfortable with reducing
temperature in their surroundings. We can conclude that this smart portable air is
marketable. It is because it has very limited space to place air conditioner. So, this
smart portable air conditioner is possible to reduce space for air conditioner with
placing in decorations space which is near to the user. The smart portable air
conditioner is also proved that it is making people easier to move the air conditioner
with the wheels and simple assembling system. It could make user faster to move and
setup the air conditioner.

61
Chapter 5 : VALIDATION OF DEVELOPED SYSTEM
(COST MODELLING SYSTEM FOR LEAN PRODUCT
AND PROCESS DEVELOPMENT)

5.1 Four Way Reversing Valve

It changes the direction of refrigerant flow. By reversing the flow of refrigerant, the

heat pump refrigeration cycle is changed from cooling to heating or vice versa.

This allows a residence or facility to be heated and cooled by a single piece of

equipment, by the same means, and with the same hardware.

Chapter 04 Figure 28: 4-Way Valve

5.2 TESTING

The testing of this smart portable air conditioner has been tested at two type of place
which are in small, confined place at outdoor. The thermometer has been used to
measure the temperature. It was put 1meter in front of the air conditioner direct to the
air out. This test is done to measure the effectiveness of the air conditioner to cool the
environment.

62
 Table 2 : Results of Test

Time (Minute) Temperature (Degree Temperature (Degree

Celcius) atoutdoor in
1 34 36

2 32 36

3 30 35

5 28 33

10 25 32

20 25 32

As we can see from the result, the air conditioner is easier to cool in the small,
confined room because of the closed area. But in the open area, this is very difficult to
cool because of some reason which are it was placed in open air and the blower was
not strong for cooled air to reach longer distance. The blower should be strong as a
big fan to cool larger area.

Table 3: Distance the cold air can travel

Temperature (Degree Celcius) in

Distance (feet)
small confined room

0 25

0.5 25

1 25

1.5 27

2 28

2.5 29

3 30

63
Based on the result above, the maximum distance of the cold air can travel is 2 feet
which is the optimum distance effectiveness of the portable air conditioner. It is still
not reaching the target in the beginning of the project. This should be improved in the
future with adding a stronger blower which can increase the distance of the cold air
travel.

5.3 Future Development

As this is the first stage of development. Some of the ideas is still cannot be applied
on this project because of some problems and time limitation. So that, I will leave it
for the other stage of development either for my own project or other student. There
are a few things that can be improvised this portable air conditioner in the future
development. The electrical energy consumed can be reduced by setting the smart
portable air conditioner to operate automatically. This can be simply done by placing
motion sensor that can sense the motion of people and turn the power on then it will
of when there are no people in that area. Besides that, other improvement that can be
made on this project is to increase the strength of the cold air flow with creating a new
design with adding more or replace high power of blower. The high power of blower
can produce strong air flow which can increase the length distance.

64
 REFERENCES

• https://www.airconditioning-systems.com/window-air-conditioner.html

• https://www.brighthubengineering.com/hvac/55241-how-the-window-air-
conditioner-works/

• 2018 TOC Refrigeration, A/C and Heat Pumps Assessment Report

• “Heating and Cooling With a Heat Pump” Produced by Natural Resources

Canada’s Office of Energy Efficiency

• Energy Solution,buildinggreen.com,

• http://www2.buildinggreen.com/blogs/chilling-out-air-conditioners

• Wang, S.K. and Lavan, Z. ―Air-Conditioning and Refrigeration‖ Mechanical

• Engineering Handbook, 2009

• J. Paul Guyer, 2009,Introduction to Air Conditioning Systems

• Wang‘s Handbook of Air Conditioning and Refrigeration (Chapter 7)

• ASHRAE Handbook 1993 Fundamentals (Chapter 24 and 27)

• Wikipedia, the free encyclopedia,

• http://en.wikipedia.org/wiki/Motion_detection

• http://aweddingplannermalaysia.blogspot.com/2012/09/tree-branches-
weddingdecoration-idea.html

• http://www.answers.com/topic/methodology

65