LAB MANUAL

REFRIGERATION AND CRYOGENICS

(MED 423)

G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD

DEPARTMENT OF MECHANICAL ENGINEERING

INDEX

Sr. Contents Page No.

No.
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

1 Vision & Mission 3

2 Program Educational Objectives 4
3 Program Outcomes 4
4 Program Specific Outcomes 6
5 Course Objectives & Course Outcomes 7
6 University Syllabus 8
7 Lab Instructions 9
8 To study various tools used in refrigeration and Air-conditioning. 10
9 To study construction and working of domestic refrigerator. 25
10 To study construction and working of hermetically sealed 35
compressor.
11 To study leak detection and charging of refrigerant in a vapour 39
compression system
12 To study steam jet refrigeration system 45
13 To study construction and working of water cooler. 46
14 To study working of Electrolux Refrigerator 49
15 To conduct trial on refrigeration test rig. 54
16 To conduct trial on cascade refrigeration system 64
17 To conduct trial on Heat Pump test rig. 69
18 To conduct trial on water cooler test rig. 77
19 To conduct trial on water cooler test rig. 84
20 To conduct trial on window air conditioning system. 91

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Vision of Institute:

MIT aspires to be a leader in Techno-Managerial education at national level by

developing students as technologically superior and ethically strong
multidimensional personalities with a global mindset.

Mission of Institute:

We are committed to provide wholesome education in Technology and

Management to enable aspiring students to utilize their fullest potential and
become professionally competent and ethically strong by providing,

a) Well qualified, experienced and Professionally trained faculty

b) State-of-the-art infrastructural facilities and learning environment

c) Conducive environment for research and development.

d) Delight to all stakeholders.

Vision of Mechanical Engineering Department

To be a center of excellence in the field of Mechanical Engineering where the best of

teaching, learning and research synergize and serve the society through innovation and
excellence in teaching.

Mission of Mechanical Engineering Department

To provide world-class under-graduate and graduate education in Mechanical
Engineering by imparting quality techno-managerial education and training to meet
current and emerging needs of the industry and society at large.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Program Educational Objectives (PEOs):

Graduates will apply the tools and skills acquired during their undergraduate studies
PEO 1
either in advanced studies or as employees in engineering industries.

PEO 2 Graduates of the program will have successful technical and professional career.

Graduates of the program will continue to learn to adopt constantly evolving

PEO 3
technology.

PEO 4 Graduates will demonstrate sensitivity towards societal issues.

Program Outcomes:

POs Description
PO 1 Engineering Apply the knowledge of mathematics, science, engineering
Knowledge fundamentals, and an engineering specialization to the
solution of complex engineering problems.
PO 2 Problem Analysis Identify, formulate, review research literature, and analyze
complex engineering problems reaching substantiated
conclusions using first principles of mathematics, natural
sciences, and engineering sciences.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

PO 3 Design / Design solutions for complex engineering problems and design

Development of system components or processes that meet the specified
Solutions needs with appropriate consideration for the public health and
safety, and the cultural, societal, and environmental
considerations
PO 4 Conduct Use research-based knowledge and search methods including
Investigations of design of experiments, analysis and interpretation of data, and
Complex Problems synthesis of the information to provide valid conclusions.
PO 5 Modern Tool Create, select, and apply appropriate techniques, resources,
Usage and modern engineering and IT tools including prediction and
modeling to complex engineering activities with an
understanding of the limitations.
PO 6 The Engineer Apply reasoning informed by the contextual knowledge to
and Society assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional
engineering practice.
PO 7 Environment and Understand the impact of the professional engineering
Sustainability solutions in societal and environmental contexts, and
demonstrate the knowledge of, and need for sustainable
development.
PO 8 Ethics Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
PO 9 Individual and Function effectively as an individual, and as a member or
Team Work leader in diverse teams, and in multidisciplinary settings.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

PO 10 Communication Communicate effectively on complex engineering activities

with the engineering community and with society at large, such
as, being able to comprehend and write effective reports and
design documentation, make effective presentations, and give
and receive clear instructions.
PO 11 Project Demonstrate knowledge and understanding of the engineering
Management and management principles and apply these to one’s own
and Finance work, as a member and leader in a team, to manage projects
and in multidisciplinary environments.
PO 12 Life-long Recognize the need for, and have the preparation and ability
Learning to engage in independent and life-long learning in the broadest
context of technological change.

Program Specific Outcomes:

PSO 1 Ability to design & analyze components & systems for mechanical performance

PSO 2 Ability to apply and solve the problems of heat power and thermal systems

PSO 3 Ability to solve real life problems with the exposure to manufacturing industries

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Course Objectives:

1. To study understand the fundamental working of various component of

‘Refrigeration systems’
2. To study and understand the working of various compressors, controllers and tools
used in ‘Refrigeration systems’
3. To apply basic concept and analyze the performance of ‘Refrigeration
systems’

Course Outcomes:

CO No. Statement

CO 1 State the basic refrigeration and liquefaction principles with respect to current low
cooling technology.

CO 2 Explain thermodynamics property, processes carried out during refrigeration and

cryogenics.

CO 3 Apply the knowledge for selection of refrigerant and cryogenic fluids for various
refrigeration and cryogenics systems.

CO 4 Analyze various components of refrigeration and cryogenics systems.

CO 5 Evaluate the performance of refrigeration and cryogenics systems.

CO 6 Design the various components of refrigeration systems.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Lab Instructions:

1. All the students must wear college uniform, shoes and college identity card.
2. Make entry in logbook on reporting for the practical in the lab.
3. Don’t sit in the lab by missing theory and practical classes.
4. Don’t touch the lab equipments without permission of practical teacher or lab
assistant.
5. Anemometer, psychrometer or thermometer, if required, will be issued by lab
assistant. Return them after performing the experiment.
6. Before leaving the lab, please keep the stools in proper position.
7. Switch off the lights and fans, if not required.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 1

Objective: To study various tools used in refrigeration and Air-conditioning.

Tube Cutter – It is a refrigeration tool use to cut copper tubing from sizes 1/8” to 1/2” outside
diameter. A larger tube cutter is also available for large tube diameters. Tubes are mark first
before cutting. Slight pressure is applied to the copper tube during cutting. The burr inside the
tube is cleaned with blade reamer.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Flaring Tool – It is a refrigeration tool use to spread the copper end outward until a flare is
formed. File and ream the copper tube before flaring. The copper tube is inserted into the
flaring block with 30% of its diameter protruding. Turn the flaring yoke slowly until the flare
is completed. Remove copper tube and inspect for defects.

Swagging Tool –It is a refrigeration tool use to expand the inside diameter of a copper tube so
that the resulting diameter is the same as the outside diameter. It is used to join two copper
tubes of the same diameter. Clamp the copper tube by the flaring block so that an 'equal to
the outside diameter' of the copper tube length is to be swigged.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Brazing Torch – It is a refrigeration tool use in soldering the joints of two copper tubes
together. 800 degrees Fahrenheit is required to solder copper tubing. Map gas is generally
used in these application, although oxygen-acetylene is also popular except they are bulky and
heavy. It can reach a temperature of 3600 degrees Fahrenheit. When brazing copper tube
joints, do it in a well ventilated area. Prolong inhalation can cause cancer.

Copper Tube Bender – It is a copper tube bending refrigeration tool. It has a three-size molded
half-round wheels. The most common sizes are from 1/4 of an inch diameter, to 5/16, then
3/8. Copper tubes are bent beautifully using this professional bending tool.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Adjustable wrench –It is a wrench with an adjustable jaw. A six inch adjustable wrench is very
useful in the field of refrigeration repair. It can accommodate nuts and bolts' sizes from 1/8 of
an inch to 1 inch. It can fit into the tool box easily.

Flat Edge Screw Driver – It is a screw driver with a flat driving end. An 8 inch screw driver
with a blade width of 1/4" is the most useful size. It is always a good idea to have a 1/8"
blade and a 3/16" blade around with you.

Philip Screw Driver –It is a screw driver with a cross driving end. It is a good idea to have
three sizes of this type also. Buy only good quality philip screw driver because the teeth
easily become blunt very slippery.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Allen Wrench – is an angle hexagonal driving wrench. They are made of hardened steel. You
will need allen key when removing the squirrel caged fan of a window type air conditioner.
The circular fan of an indoor unit is fastened with an allen screw.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Long Nose Plier – is a plier with a long pointed nose. A 7 inch long nose plier is very useful and
is a good addition to your tool box. You will find the many uses of a long nose plier; from hard
to-reach areas like removing a clip from a fan or holding the copper tube when brazing alone.

Electrical Plier – Insulated plier use by electrician. An 8 inch electrical plier is a must have in
your tool box. There are time when it is necessary to remove a live fuse from a fuse box. Or
arranging the stranded wires.

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Pipe Wrench – is a wrench for fastening tubes and pipes. A 12 in pipe wrench must be in your
tool box as well. Sometmes we have to remove a rounded hex nut.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Nut Drivers – Hand held driver to drive or remove hex nuts or bolts. Mostly applicable to deep
down places where our hand is not able to reach. Straight hand grip type and the T-type drivers
are available for you to choose.

Box Wrench – Hand held box type wrenches. They came in from 1/4 of an inch to 1-1/4 inch
size. Usually they are in combination as far as the size is concern. A practical tool for
assembling and disassembling home air conditioner and automotive air conditioner
compressors.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Open Wrench – Open end hand held wrench. Their sizes are from 1/8 of an inch to 1-1/4 of
an inch. It is most useful when you are removing a machine bolt where access is only 50 to 75
percent, or the area is restricted that the wrench can make only one half turn.

Flat File – flat hardened steel with cutting ridges. Used for filing a newly cut copper tube ends
to square it. Or to remove burrs from steel brackets. File surface joints so that they can fit
squarely.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Round File – round long hardened steel with cutting ridges. Round file is very useful in
enlarging a hole by filing. Cleaning a rusty steel tube, removing a clogged from a drain hole.
Enlarging a flat washer hole to fit the larger bolt. Or to shape a certain parts through filing.
Making prototype spare parts for hard-to-find spare.

Half Round Files – Half round shaped long hardened steel with cutting ridges. When it is
necessary to make a hole larger where the application of a round file is not practical. The half
round side can finish a curve surface, and the flat side for the flat surface.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Carpenter’s Saw – a hand tool with tooth blade used to cut wood. Fabricating wooden frame
for a window type air conditioner, cutting wooden sticks to be used to elevate an air
conditioner unit. Fabricating elevated stand for a split type stand alone indoor unit.

Tape measure -Steel tape measuring device. Put one in your pocket whenever you are going
out into the field. Either you are going to make measurement for the length of the copper
tubing you will need for a certain project, or measuring the volume of a room.

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Hack Saw – a hand tool with tooth blade used to cut iron pipes or iron bars, maybe you need
to shorten the length of a certain PVC pipe, or fabricating a bracket for a new air conditioner.
Making a new home air conditioner installation. Cutting the window frame so that the new air
conditioner will fit.

Electric Drill Gun –It is also a good refrigeration tool a refrigeration mechanic should have. We
measure the size of a drill gun by the size of the chuck. I have with me a 1/2 inch chuck, and it
is all I need in doing different things, like installing a new compressor and I need to make new
holes for the anchor bolts.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Bench Vise – a refrigeration tool with two jaws for holding works. Most of the time we need
a vise to hold the copper tube so that we can braze the joints correctly. Or we must clamp the
machine bolt so that we can remove the hex nut. Or simply clamp a piece of steel bar so that
we can cut it into the size we need.

Yoke Vise – a pipe vise. It is good to have a yoke vise in your working bench. Yoke vise is a
common refrigeration tool a mechanic should have. Either you are lengthening your water
pipes or removing electrical conduit pipes, a yoke vise clamps the tubing without deforming
them.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Gauge Manifold – refrigeration tool pressure gauges. Whenever you are reprocessing a
refrigerator, or replacing a new compressor for a freezer, or charging refrigerant to your
automotive air conditioner, you need a gauge manifold to tell you if you are doing it right.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Conclusion: Thus we have studied various tools used in refrigeration and Air-conditioning.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 2

Objective: To study construction and working of domestic refrigerator.

Apparatus: Capacity 175 Ltrs, Refrigerator Haier make, storage shelves, shelf of eggs, crisper,
glass shelf, energy meter for compressor, energy meter for heater ,temperature indicator,
refrigerant R-134a.
Theory: Refrigeration is defined as the process of extracting heat from a lower-temperature
heat source, substance, or cooling medium and transferring it to a higher-temperature heat
sink. Refrigeration maintains the temperature of the heat source below that of its
surroundings while transferring the extracted heat, and any required energy input, to a heat
sink, atmospheric air, or surface water. A refrigeration system is a combination of components
and equipment connected in a sequential order to produce the refrigeration effect. The
refrigeration systems commonly used for air conditioning can be classified by the type of input
energy and the refrigeration process as follows: 1. Vapor compression systems. In vapor
compression systems, compressors activate the refrigerant by compressing it to a higher
pressure and higher temperature level after it has produced its refrigeration effect. The
compressed refrigerant transfers its heat to the sink and is condensed to liquid form. This
liquid refrigerant is then throttled to a low-pressure, low temperature vapor to produce
refrigerating effect during evaporation.
 Internal Parts of the Domestic Refrigerator
The internal parts of the refrigerator are ones that carry out actual working of the refrigerator.
Some of the internal parts are located at the back of the refrigerator, and some inside the
main compartment of the refrigerator. Some internal parts of the domestic refrigerator are
(please refer the figure above):

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

1) Refrigerant: The refrigerant flows through all the internal parts of the refrigerator. It is the
refrigerant that carries out the cooling effect in the evaporator. It absorbs the heat from the
substance to be cooled in the evaporator (chiller or freezer) and throws it to the atmosphere
via condenser. The refrigerant keeps on recirculating through all the internal parts of the
refrigerator in cycle.
2) Compressor: The compressor is located at the back of the refrigerator and in the bottom
area. The compressor sucks the refrigerant from the evaporator and discharges it at high
pressure and temperature. The compressor is driven by the electric motor and it is the major
power consuming devise of the refrigerator.
3) Condenser: The condenser is the thin coil of copper tubing located at the back of the
refrigerator. The refrigerant from the compressor enters the condenser where it is cooled by
the atmospheric air thus losing heat absorbed by it in the evaporator and the compressor. To
increase the heat transfer rate of the condenser, it is finned externally.
4) Expansive valve or the capillary: The refrigerant leaving the condenser enters the
expansion devise, which is the capillary tube in case of the domestic refrigerators. The capillary
is the thin copper tubing made up of number of turns of the copper coil. When the refrigerant
is passed through the capillary its pressure and temperature drops down suddenly.
5) Evaporator or chiller or freezer: The refrigerant at very low pressure and temperature
enters the evaporator or the freezer. The evaporator is the heat exchanger made up of several
turns of copper or aluminum tubing. In domestic refrigerators the plate types of evaporator is
used as shown in the figure above. The refrigerant absorbs the heat from the substance to be
cooled in the evaporator, gets evaporated and it then sucked by the compressor. This cycle
keeps on repeating.

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

6) Temperature control devise or thermostat: To control the temperature inside the

refrigerator there is thermostat, whose sensor is connected to the evaporator. The thermostat
setting can be done by the round knob inside the refrigerator compartment. When the set
temperature is reached inside the refrigerator the thermostat stops the electric supply to the
compressor and compressor stops and when the temperature falls below certain level it
restarts the supply to the compressor.
7) Defrost system: The defrost system of the refrigerator helps removing the excess ice from
the surface of the evaporator. The defrost system can be operated manually by the thermostat
button or there is automatic system comprising of the electric heater and the timer.
Those were the some internal parts of the domestic refrigerator; now let us see the external
parts of the refrigerator.
 The external parts of the refrigerator are: freezer compartment, thermostat control,
refrigerator compartment, crisper, refrigerator door compartment, light switch etc.

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

External Visible Parts of the Refrigerator

The external parts of the compressor are the parts that are visible externally and used for the
various purposes. The figure below shows the common parts of the domestic refrigerator and
some them are described below:
1) Freezer compartment: The food items that are to be kept at the freezing temperature are
stored in the freezer compartment. The temperature here is below zero degree Celsius so the
water and many other fluids freeze in this compartment. If you want to make ice cream, ice,
freeze the food etc. they have to be kept in the freezer compartment.
2) Thermostat control: The thermostat control comprises of the round knob with the
temperature scale that help setting the required temperature inside the refrigerator. Proper
setting of the thermostat as per the requirements can help saving lots of refrigerator electricity
bills.
3) Refrigerator compartment: The refrigerator compartment is the biggest part of the
refrigerator. Here all the food items that are to be maintained at temperature above zero
degree Celsius but in cooled condition are kept. The refrigerator compartment can be divided
into number of smaller shelves like meat keeper, and others as per the requirement.
4) Crisper: The highest temperature in the refrigerator compartment is maintained in the
crisper. Here one can keep the food items that can remain fresh even at the medium
temperature like fruits, vegetables, etc.
5) Refrigerator door compartment: There are number of smaller subsections in the
refrigerator main door compartment. Some of these are egg compartment, butter, dairy, etc.

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28
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

6) Switch: This is the small button that operates the small light inside the refrigerator. As soon
the door of the refrigerator opens, this switch supplies electricity to the bulb and it starts,
while when the door is closed the light from the bulb stops. This helps in starting the internal
bulb only when required.

Figure2. Photographic view of domestic refrigerator.

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29
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Conclusion: Thus we have studied the working of domestic refrigerator.

Questions:

1. Explain the on which cycle domestic refrigerator works?

2. What are the main parts of domestic refrigerator?
3. Which refrigerant used in domestic refrigerator?
4. What is the role of compressor in domestic refrigerator?
5. What are the temperature range in different compartment of domestic refrigerator?

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

30
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 3

Objective: To study construction and working of hermetically sealed compressor.

Apparatus: Hermetically sealed compressor cut section.
Theory:
The hermetically sealed compressor is widely used for the refrigeration and air conditioning
applications. You can find it in all the household refrigerators, deep freezers, window air
conditioners, split air conditioners, most of the packaged air conditioners. In hermetically
sealed compressor, the compressor and the motor are enclosed in the welded steel casing and
the two are connected by a common shaft. This makes the whole compressor and the motor
a single compact and portable unit that can be handled easily. The hermetically sealed
compressor is very different from the traditional open type of compressors in which the
compressor and the motor are different entities and the compressor is connected to the motor
by coupling or belt.
Types of Hermetic compressors:
One of the most popular types of hermetically compressors are the reciprocating compressors.
They were the first to be used as the hermetically sealed compressors and still being widely
used. The days the vane type of rotary compressor has become more popular. It is considered
that the rotary type of hermetically compressor consumes less electricity, makes lesser noise,
requires lesser maintenance, and is cheaper than the reciprocating type of compressor. This
is because the rotary compressors has less frictional parts and have only a rotor. The
centrifugal types of hermetically sealed compressors are used for the larger units.

Construction of Hermetically sealed reciprocating compressor:

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31
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

In hermetically sealed compressor, in one side of the enclosed casing the various parts of the
compressor like cylinder, piston, connecting rod , and the crank shaft are located. If it is multi-
cylinder compressor, there are more than two cylinders inside the casing. On the other side of
the casing is the electric winding inside which the shaft of the motor rotates. This motor can
be single speed or multi-speed motor. In hermetically sealed compressor the crank shaft of
the reciprocating compressor and the rotating shaft of the motor are common. The rotating
shaft of the motor extends beyond the motor and forms the crankshaft of the hermetically
reciprocating compressor.
All these parts of the hermetically sealed compressor are assembled and enclosed in a strong
and rigid casing made up of welded steel shell. The steel shell comprises of two half rounded
steel bodies that are welded together to form the casing for the hermetically sealed
compressor. In some cases the two halves of the shell can be bolted together instead of
welding, which permits easy opening of the casing in case of compressor burnout.
The hermetically sealed compressors have inbuilt lubrication system for the lubrication of the
piston and cylinder and crank shaft. The lubricant also acts as the coolant for the piston and
cylinder. Additionally, the cool suction refrigerant also offers cooling effect.
Externally , the casing has refrigerant suction and discharge connections that are connected
to the evaporator and condenser respectively. There is also socket for the electrical
connection. The typical condenser unit with the hermetically sealed compressor is shown in
fig. Such condenser units are called s hermetic condenser units.
Working of Hermetically sealed compressor:
In hermetically sealed compressor, the motor and the compressor are enclosed in the same
housing to prevent leakage. The housing has welded connections for refrigerant inlet and
outlet and for power input socket as shown in figure 1. As a result of this there is virtually no

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32
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

possibility of refrigerant leakage from compressor. All motors reject a part of the power
supplied to it due to eddy current and friction. Similarly, compressor also gets heated up due
to friction and due to temperature rise of the refrigerant during compression. In open type
both the compressor and the motor reject heat to the surrounding air for efficient operation.
In hermetic compressor heat cannot be rejected to the surrounding air since both are enclosed
in a shell. Hence, the cold suction gas is made to flow over the motor and compressor before
entering the compressor. This keeps the motor cool. The motor winding is in direct contact
with the refrigerant, hence only those refrigerants which have dielectric strength, can be used
in hermetically sealed compressor.

Figure1. Hermetically sealed compressor

The cooling rate depends upon the flow rate of the refrigerant, its temperature and the
thermal properties of the refrigerant. If flow rate is not sufficient of if the temperature is not
low enough the insulation on the winding of the motor can burn out and short circuiting may
occur. Hence, hermetically sealed compressor give satisfactory and safe performance over a
very narrow range of design temperature and should not be used for off-design conditions.
The COP of the hermetically sealed compressor based systems is lower than that of the pen
compressor based systems since a part of the refrigeration effect is lost in cooling the motor

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33
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

and the compressor. However hermetically sealed compressor are almost universally used in
small systems such as domestic refrigerators, water coolers, air conditioners, etc where
efficiency is not as important as customer convenience. In addition to this the use of
hermetically sealed compressors is ideal in the systems which uses capillary tube as expansion
devices. Hermetically sealed compressors are normally not serviceable.
Application:
The hermetically sealed compressor is widely used for the refrigeration and air conditioning
applications because of several advantages like:
1) The hermetically sealed compressor can be moved easily from one place to the other place,
they are highly portable. One does not have to dissemble the compressor form the motor and
no coupling, belt and pulley arrangement is involved.
2) The whole condenser unit of the refrigeration and air conditioning unit comprising of the
condenser and the compressor can be moved easily from one place to the other.
3) Since no coupling, belt or pulley is involved, the maintenance is lesser.
4) The lubrication system of the hermetically sealed compressor is inherent and no external
lubrication is required, unless the fresh gas charge is done.
5) The installation of the hermetically sealed compressor is very easy. The suction and
discharge connections and the electrical connections are available externally.
6) Hermetically sealed compressor have very long life , the companies offer warranty period
upto seven years for these compressors.
Conclusion: Thus we have studied the working of hermetically compressor.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

34
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 4

Objective: To study varies controllers in refrigeration.

1. Refrigerant controls:
Refrigerant controls are devices used to control the flow of refrigerant at varies points
throughout the refrigeration cycle. Following are some points where refrigerant
controls are used in a system.
I. Expansion valves used to regulate the flow of refrigerant liquid to the
evaporator.
II. Suction line regulators used to control the flow of refrigerant gas from the
evaporator coil.
2. Hand Expansion Valve
It is hand operated needle valve as shown in figure 1. The rate of liquid flow through
the valve depends upon the pressure differential across the valve orifice and the
degree of valve opening, he latter being manually adjustable.

Figure 1. Hand Expansion valve

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35
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

3. Automatic Expansion Valve

It is activated by evaporator pressure and which keeps constant since the pressure of
the refrigerant in the evaporator determines evaporator temperature. Figure2 shows
the schematic diagram of an automatic expansion valve.

Figure 2. Automatic Expansion Valve

4. Thermostatic Expansion Valve

It is throttling device which works automatically, maintaining proper and correct liquid
flow as per the requirements of the load on evaporator as shown in figure3.

Figure 3. Thermostatic Expansion Valve

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36
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

5. Capillary Tube:
A capillary tube is a fixed restriction-type device. It is the simplest of the refrigerant
flow controls, consisting merely of fixed length (from 0.5 m to 5 m) of diameter (0.5
mm to 2.25 mm) tubing installed between the condenser and evaporator.
6. Low Side Float Valve
Low-side float valve is essentially a hallow ball, pan or inverted bucket connected
through linkages and pivots to open or close needle valve as shown in figure 4. It
maintains a predetermined liquid level in an evaporator.

Figure 4. Low Side Float Valve

7. High Side Float valve
It is the same element as a low-side float: a hallow ball, linkages, and a needle valve. It
differs from the low-side float in that it is on the high side of the system and that rising
liquid level opens the valve as shown in figure 5.

Figure 5. High Side Float Valve

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37
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

8. Pressure Relief Valve

These are the safety valves designed to relieve the pressure in the system to the
atmosphere, or to outdoors through a vent line, in the event that the pressure in the
system rises to unsafe level for any reason.
9. Fusible Plug
A fusible plug is sometimes substituted for the pressure relief valve. A fusible plug is
simply a pipe plug which has been drilled and filled with a mental alloy designed to
melt at some pressure determined fixed temperatures.

10. Oil Safety Switches

In large compressors forced lubrication is done for which an oil pump is employed. If
the pump does not work due to some reason the parts will not be lubricated and these
parts will get damaged. Therefore, some means must be provided to stop the
compressor in case the pressure of lubricating oil falls below a pre-determined
minimum level. This is achieved by using an oil pressure failure control in the control
circuit of refrigeration equipment.

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38
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 5

Objective: To study leak detection and charging of refrigerant in a vapour compression system.
Apparatus: Vacuum pump, four-way manifold guage,90 degree shut off valve, process stub
Schrader valve, dye-drier with Schrader valve, 134a recovery cylinder, 134a charging cylinder
and charging hose.
Refrigerant Charging Procedure:
A: Operation
Caution:
• During operation, be sure to wear safety goggles and protective gloves.
• Before charging the refrigerant, evacuate the system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely evacuated only under the minimum vacuum
level. The minimum vacuum level affects the temperature in the system.
• The list below shows the vacuum values necessary to boil water in various temperatures. In
addition, the vacuum levels indicated on the gauge are approx. 3.3 kPa (25 mmHg, 0.98 in Hg)
lower than those measured at 304.8 m (1,000 ft) above sea level.

Temperature Vacuum

1.7°C (35°F) 100.9 kPa (757 mmHg, 29.8 inHg)

7.2°C (45°F) 100.5 kPa (754 mmHg, 29.7 inHg)

12.8°C (55°F) 99.8 kPa (749 mmHg, 29.5 inHg)

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39
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

18.3°C (65°F) 99.2 kPa (744 mmHg, 29.3 inHg)

23.9°C (75°F) 98.5 kPa (739 mmHg, 29.1 inHg)

29.4°C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg)

35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg)

Vacuum level required to boil water (at sea level)

1) Close the valves on low-/high-pressure sides of the manifold gauge.

A) Low-pressure gauge (Compound pressure gauge)

B) High-pressure gauge
C) Close

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40
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

2)Install the low-/high-pressure hoses to the corresponding service ports on the vehicle
respectively.
3)Connect the center hose of the manifold gauge set with the vacuum pump.
4) Carefully open the valves on the low-/high-pres-sure sides to activate the vacuum pum

(A) Low-pressure gauge (Compound pressure gauge)

(B) High-pressure gauge
(C) Slowly open
(D) Vacuum pump turn on
5) After the low-pressure gauge reaches 100.0 kPa (750 mmHg, 29.5 inHg) or higher, evacuate
the system for approx. 15 minutes (Continue evacuation)
6) After 15 minutes of evacuation, if the reading shows 100.0 kPa (750 mmHg,
29.5 inHg) or higher, close the valves on the both sides to stop the vacuum pump.

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41
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

(A) Low-pressure gauge (Compound pressure gauge)

(B) High-pressure gauge
(C) Close
(D) Vacuum pump turn off
7) Note the low-pressure gauge reading.
8) Leave it at least 5 minutes, and then check the low-pressure gauge reading for any
changes. When a gauge indicator shows near to zero point, this is a sign of leakage. Check
pipe connector points, repair them, and make sure there is no leakage by air bleeding.

9) Following the can tap operation manual instructions, install it to the refrigerant can.

(A) Tap valve

(B) Center manifold hose
10) Disconnect the center manifold hose from the vacuum pump, and connect the hose to the
tap valve.
11) When a 13.6 kg (30 lb) refrigerant container is used, measure the refrigerant amount in
use using a weighting scale.
12) Confirm that all the 3 hoses are tightly connect-ed to the manifold gauge set.
13) Open the valve on the HFC-134a source.
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

14) Loosen the center hose connection on the manifold gauge set (if applicable, press a purge
valve on the manifold gauge set) only for a couple of seconds to allow the air in the center
hose to es-cape by the refrigerant.
15) Carefully open the high-pressure valve with the engine stopping.
CAUTION:
Do not open the low-pressure valve.
16) Close the high-pressure valve when the low-pressure gauge reaches 98 kPa (1 kg/cm2, 14
psi).
Using a leak tester, check the system for leaks.
17) If any leakage is found after the refrigerant recovery is completed, repair the applicable
area.
17) After confirming that there are no leaks with the leak test, charge the required amount
of refrigerant.
18) Close the high-pressure valve when; the readings of low-/high-pressure gauges become
almost equal, after the charging speed is reduced,

the HFC-134a source becomes empty, or the system is filled with the gas
19) If the HFC-134a source is empty, close the high-pressure valve, close the valve on the can
tap, and replace the HFC-134a source with a new one to restart the operation.
20) Confirm that both the low-/high-pressure valves can be closed. Start the engine with the
A/C switch OFF.
21) Quickly repeat ON-OFF cycles a few times to prevent initial compressor damage.
22) Set up the system to on condition.

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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

23) While reading the low-pressure gauge, careful-ly open the low-pressure valve with the
refrigerant source connected and the service hose purged.
24) Adjust the refrigerant flow to maintain the pres-sure on the low-pressure side at 276 kPa
(2.81 kg/ cm2, 40 psi) max.
25) After the system is fully charged, close the low –pressure valve.
26) Close the valve on the refrigerant source.
27) Disconnect the hose from the service port, and install the service port cap.

Conclusion: Thus we have studied the charging of refrigerant in a vapour compression

refrigeration system.

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44
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 6

Objective: To study steam jet refrigeration system

Steam jet or Ejector refrigeration system uses water as refrigerant. It uses the basic principle
of boiling of liquid at lower temperature by reducing pressure on its surface.

This system employs a steam ejector or booster instead of mechanical compressor. The main
components as shown in figure are flash chamber or evaporator, steam nozzles, ejector and
condenser.

The flash chamber is heavily insulated and is fitted with perforated pipes which spray warm
water coming out of refrigerated space. Some of this water is converted into vapours after
absorbing latent heat from the rest of the water, thereby cooling it. Loss of water through
vapours is made up from make-up water line.

High pressure steam from boiler is passed through steam nozzle thereby increasing its velocity.
This entrains water vapours from flash chamber and results in further formation of vapours.

The mixture of steam and water vapour passes through venturi-tube of ejector and gets
compressed. This leads to rise in temperature and pressure of the mixture and then it is fed
to the water cooled condenser as shown in figure1.

The condensate is again fed to boiler as feed [Link] jet refrigeration system is widely
used in paper mills, breweries, food processing plants, gas plants etc. Since water is the
refrigerant, it cannot be used for applications below 0°C.

Figure1. Steam Jet Refrigeration System

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45
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 7

Objective: To study construction and working of water cooler.

Theory:
In 1906 Halsey Willard Taylor and Luther Haws invented the first drinking water fountain, with
the primary motivation being to provide safer drinking water and avoid the risk of typhoid
fever caused by contaminated water. (Luther Haws' father had died of typhoid fever
precipitated by contaminated water. Early drinking fountains provided room temperature
drinking water, but demand led to the development of fountains that could provide cooler
water thereby killing the micro-organisms responsible for pollution and disease. But early
water coolers did not have a discrete water treatment method for purifying the dispensed
[Link] the years went by, water coolers further evolved into smaller, lighter, and more
efficient units. They also varied in shape and size, depending on the needs of the consuming.
Water cooler is one piece of equipment that we find in our day to day life. Water coolers are
used to reduce the temperature of drinking water and to maintain the temperature of the
water in a particular range. In this article we will discuss the working and most common types
of water coolers made by us. The purpose of water cooler is to make water available at a
constant temperature respective of room temperature.
WORKING PRINCIPLE
The process of refrigeration occurs in a system which encompasses of a compressor, a
condenser, expansion device and an evaporator. VCR system functions based on reversed
Brayton cycle. The VCR system consists of four main components which are compressor,
condenser, expansion device and evaporator. Compressor is used to compress the low
temperature and pressure refrigerant from the evaporator to high temperature and pressure.
After compression the high temperature and pressure refrigerant is discharged into the

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46
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

condenser though the delivery or discharge. The Condenser consists of coils of pipe in which
the high temperature and pressure refrigerant is cooled and condensed. There refrigerant,
which passing through the condenser, gives up its latent heat to the surrounding condensing
medium which is normally air or water. The condensed liquid refrigerant from the condenser
is stored in the vessel known as receiver from where it is supplied to evaporator through the
expansion valve (i.e. capillary) or refrigerant control valve. The function of the expansion valve
is to allow the liquid refrigerant under high temperature and pressure to pass at a controlled
rate after reducing its temperature and pressure. Some of the liquid refrigerant evaporates as
it passes though the expansion valve, but the greater portion is vaporized anthem evaporator
at low temperature and pressure. Next it travels to the evaporator. An Evaporator consists of
coils of pipes in which the liquid vapour refrigerant at low temperature and pressure is
evaporated and changed into vapour refrigerant at low pressure and temperature. In
evaporating, the liquid vapour refrigerant absorbs its latent heat of vaporization from the
medium (water) which is to be cooled. The performance of the water cooler system is to be
evaluated by using experimental methods which is carried out by using the specially developed
test rig. The test rig can be modified and upgraded if required. The work explains some of the
technical modification and evaluation of the refrigeration system under varying load
condition. The refrigeration system used to test the concept has a low pressure with single
hermetically sealed compressor.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

47
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Conclusion: Thus we have studied construction and working of water cooler.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

48
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

EXPERIMENT NO. 8

Objective: To study working of Electrolux Refrigerator.

Apparatus: Gross volume 41 litres , refrigerant water, ammonia, hydrogen , electrically heated
generator, natural convection type condenser, natural evaporator, energy consumption
1.07KWH per 24 Hrs.
Theory:
Absorption refrigerators are often used for food storage in recreational vehicles. The principle
can also be used to air-condition buildings using the waste heat from a gas turbine or water
heater. Using waste heat from a gas turbine makes the turbine very efficient because it first
produces electricity, then hot water, and finally, air-conditioning
(called cogeneration/trigeneration). Absorption refrigerators are a popular alternative to
regular compressor refrigerators where electricity is unreliable, costly, or unavailable, where
noise from the compressor is problematic, or where surplus heat is available.
The domestic absorption type refrigerator was developed from an invention by Carl Munters
and Baltzer Von Platen. This system is often called “Munters Platen System”.
This type of refrigerator is also called “Three-fluid absorption system”. The three fluids
used in this system are ammonia, hydrogen and water.
- The “ammonia” is used as a refrigerant because it possesses most of the desirable
properties.
Though it is toxic, and not otherwise preferred in domestic appliances, it is very safe in
this system due to absence of any moving parts in the system and , therefore, there is
the least chance of any leakage.
- The “hydrogen” being the lightest gas, is used to increase the rate of evaporation (the
lighter the gas, faster is the evaporation) of the liquid ammonia passing through the

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49
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

evaporator. The hydrogen is also non-corrosive and insoluble in water. This is used in
the low-pressure side of the system.
- The “water” is used as a solvent because it has the ability to absorb ammonia readily.

Principle and Working of Electrolux Refrigerators.

Figure drawn below shows a schematic diagram of an „Electrolux refrigerator‟. It is a domestic

refrigerator and is the best known absorption type of refrigerator. Here pump is dispensed
with. The small energy supply is by means of a heater which may be electric or gas as shown
figure1.

Figure1. Electrolux Refrigerator

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50
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Principle. The principle involved makes use of the properties of gas-vapor mixtures. If a liquid
is exposed to an inert atmosphere, it will evaporate until the atmosphere is saturated with the
vapor of the liquid. This evaporation requires heat which is taken from the surroundings in
which the evaporation takes place. A cooling effect is thus produced. The partial pressures of
the refrigerant vapor (in this case ammonia) must be low in the evaporator, and higher in the
condenser. The total pressure throughout the circuit must be constant so that the only
movement of the working fluid is by convection currents. The partial pressure of ammonia is
kept low in requisite parts of the circuit by concentrating hydrogen in those parts.
Working:
The ammonia liquid leaving the condenser enters the evaporator and evaporates into the
hydrogen at the low temperature corresponding to its low partial pressure. The mixture of
ammonia and hydrogen passes to the absorber into which is also admitted water from the
separator. The water absorbs the ammonia and the hydrogen returns to the evaporator. In
the absorber the ammonia therefore passes from the ammonia circuit into water circuit as
ammonia in water solution. This strong solution passes to the generator where it is heated
and the vapor given off rises to the separator. The water with the vapor is separated out and
a weak solution of ammonia is passed back to the absorber, thus completing the water circuit.
The ammonia vapor rises from the separator to the condenser where it is condensed and then
returned to the evaporator. The photographic view shown in figure2.

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51
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure2. Photographic view of vapour absorption refrigerator

The actual plant includes refinements and practical modifications (which are not included
here). The following points are worth noting:
1. The complete cycle is carried out entirely by gravity flow of the refrigerant.
2. The hydrogen gas circulates only from the absorber to the evaporator and back.
3. With this type of machine efficiency is not important since the energy input is small.
4. It has not been used for industrial applications as the C.O.P. of the system is very low.
Role of Hydrogen. By the presence of hydrogen it is possible to maintain uniform total
pressure throughout the system and at the same time permit the refrigerant to evaporate at
low temperature in the evaporator corresponding to its partial pressure. Thus the condenser
and evaporator pressures of the refrigerant are maintained as below
(ii) In the condenser only ammonia is present, and the total pressure is the condensing
pressure.

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52
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

(iii) In the evaporator hydrogen and ammonia are present; their relative masses are
adjusted such that the partial pressure of ammonia is the required evaporator
pressure.

These are achieved without the use of pumps or valves.

Advantages and Disadvantages of Electrolux Refrigerator over Conventional Refrigerators:
Advantages:
1. No pump or compressor is required.
2. No mechanical troubles, maintenance cost is low.
3. No lubrication problem; no wear and tear.
4. Completely leak proof.
5. Noiseless.
6. No chance of pressure unbalancing and no need of valves.
7. System may be designed to use any available source of thermal energy-process steam,
exhaust from engines or turbines, solar energy etc.
8. Easy control, simply by controlling heat input.

Disadvantages:
1. More complicated in construction and working.
2. C.O.P. very low.
3. The major disadvantages of this type of refrigerator are that if it is spoiled once, it
cannot be repaired and has to be replaced fully.

Conclusion: Thus we have studied the working of a vapour absorption refrigeration system
(Electrolux Refrigerator).

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53
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

B. To conduct Trial on Following Refrigeration Systems

Experiment No.09

Name of Experiment: To conduct trial on refrigeration test rig.

Objectives;
1. To understand principle of operation and working of vapour compression system.
2. To calculate theoretical, actual and relative C.O.P. of the system
Working:
The refrigeration system works on vapour compression cycle. The refrigeration is the process
of (maintaining a closed space temperature below the surrounding temperature) is
accomplished continuously circulating, evaporating and condensing a fixed supply of
refrigerant in a closed system. Evaporation occurs at a low temperature and low pressure
while condensation occurs at a high temperature and pressure. Thus it is possible to transfer
heat from an area of low temperature to an area of high temperature. (the surrounding).
The compressor pumps the low pressure vapour refrigerant from evaporator, increases
pressure and discharge high pressure vapour refrigerant to the condenser. In the condenser
heat rejected to the surrounding by passing air over it.

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54
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure1. Schematic diagram of refrigeration system.

At that pressure refrigerant losses its latent heat and liquefies. Then the refrigerant passes
through the drier/filter where any residual moisture or foreign particles present, these are
plugged the flow rate of refrigerant into the evaporator is controlled by the expansion device.
Where its pressure and consequently temperature is lowered to the saturation temperature
at the corresponding pressure. The low temperature vapour enters evaporator where it
absorbs heat from the surrounding medium and evaporators. The compressor draws the cold
vapour and the cycle repeats. The schematic diagram of experimental setup is shown in figure1
and photographic view in figure 2.
Operating Instructions:
 Place the machine in the proper positon where its level is horizontal and it is well
ventilated.
 Give 230 volts, 50 Hz and single phase electric supply to the unit.
 Fill the colorimeter or isothermal bath with clean water.

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55
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

 Start the compressor by putting the switch ON

 The pump in the calorimeter will equalize the temperature in the tank.
 Put ON the supply of heater.
 Refrigerant circulated through the tube absorb heat from the water and equal amount
of heat supplied from the heater to maintain the temperature of the bath practically
constant.
 Load = Refrigeration effect.
 Record all the readings as per the observation table
 Allow at least ½ hours running time for the correct results
 Calculate the results as per the procedure mentioned.

CAUTION:
 Always start the machine only after ensuring adequate water level in the tank.
 Do-not switch on the heater in the dry tank
 Do-not tamper with the temperature as well as the pressure settings.

Technical Specifications:
Component Specifications
Compressor Hermetically sealed. Emerson make
Capacity 500 watts @ rated test condition
Condenser Forced convection air cooled
Drier/Filter Molecular sleeve type
Expansion Device Capillary tube and Thermostatic expansion valve
Evaporator Shell and coil type
HP/LP cut out Provided
Pressure gauges 2 numbers, (Bourdon tube)
Temperature indicator Provided ( As well as wells are provided to measure
temperature at varies point using ordinary
thermometer)
Energy meter Provided for compressor and heater
Refrigerant R-134 a

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56
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure2. Photographic view of refrigeration system

Standard Values and Formulas:
Standard Barometric = 1.013 bar = 1.013 x 105 N /m2
Pressure
Density of Water = 1000 kg / m3 = 1 kg / liter
Specific heat of water = 4.18 kJ/kg K
Gas Constant for Air = 287 J / kg K
Specific Gravity of R-134a at = 1.2
400 C
1 Ton of Refrigeration effect = 3500 Watts = 3.5 kJ / s
0
Density of air at 25 C = 1.1 kg/m3
1 kWHr (kilowatt-hour) = 3600 kJ
1 bar = 14.5 psig

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57
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Observation Table
(Note-Take first reading when heater starts.)

Refrigerant Pressure

Refrigerant flow lph

(kWhr) compressor.

(kWhr) heater.
Energy meter

Energy meter

Psig
Water temperature oC

Refrigerant temp.
(oC)
Time

E1 – time for 10 pulses

E2 – time for 10 pulses

Discharge
Suction

P1 P2 Vr
After compressor - 2
After evaporator - 1

After condenser - 3

After Expansion - 4

5
Hrs

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58
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Calculations:

1. To calculate actual C.O.P. of the system:

A. Method:1
Actual refrigeration effect = Heater load
= Energy meter reading
Time for 20 pulses
Energy meter constant = 3200 pulses per kWhr.
Number of pulses  3600
N
t Heater  Energy meter constant(Heater)

Actual refrigeration effect =

Actual Compressor work w = Time for 20 pulses

Energy meter constant= 3200 pulses per kWhr.
Number of pulses  3600
W
t compressor  Energy meter constant(compressor)
Actual Compressor work w =

Actual coefficient of performance = Actual refrigeration effect/ Actual compressor work

= N/W
=

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59
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

B. Method:2

Actual refrigeration effect = Mass of Water in tank*Specific heat of water* (Final temperature
(N) of water- intimal temperature of water)/ Duration of trail
=

Actual refrigeration effect

(N)

Actual coefficient of performance = Actual refrigeration effect/ Actual compressor work

= N/W
=
2. To calculate theoretical C.O.P. of the system:

We have
Average suction pressure (Pscution gauge) = bar

Average discharge pressure (Pdischarge gauge) = bar

Absolute suction pressure

Suction gauge pressure+ barometric pressure = bar
Absolute discharge pressure
discharge gauge pressure+ barometric pressure = bar
Accordingly,
Enthalpies of refrigerant at salient points are

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MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure3 P-h chart

Accordingly,
Enthalpy of refrigerant at inlet of compressor h1 =_____________ kJ/ kg
Enthalpy of refrigerant at outlet of compressor h2 =_____________ kJ/ kg
Enthalpy of refrigerant after condensation h3 =_____________ kJ/ kg
Enthalpy of refrigerant after expansion h4 =_____________ kJ/ kg

Theoretical refrigeration effect = N = h1-h4= ____________ kJ/kg

Theoretical compressor work = W = h2-h1 = ___________kJ/kg

Coefficient of performance = C.O.P. = N/W =__________________

(Note: These valves of enthalpies can be calculated with the help of P-h chart of R-
134a)

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61
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

3. To calculate Carnot C.O.P. of the system:

TL
Carnot C.O.P. 
TH  TL

= ---------------------

TL= Saturation temperature to corresponding evaporator pressure (bar)

TH=Saturation temperature to corresponding condenser pressure (bar).

4. To calculate Relative C.O.P. of the system:

Actual C.O.P. ............

Relative C.O.P.   
Therotical C.O.P. .............

Conclusions:
1. Understand the working of vapour compression cycle and function of each component.
2. It is observed that Carnot C.O.P. > theoretical C.O.P. > actual C.O.P. due to the losses
at varies points.

Questions:
1. Explain working of vapour compression cycle with the help of block diagram
2. What is role of compressor in vapour compression cycle? What type of compressor is
preferred in applications of vapour compression cycle? (List out with specifications at
least any two)
3. What is refrigeration effect and how it is calculated in present experiment?
4. What are the practical applications of vapour compression cycle? List out at least five
of them with specifications.
5. What is function of expansion device in vapour compression cycle? What is the
difference of capillary tube and thermostatic expansion valve?
6. What are different steps carried for trouble shooting of vapour compression cycle
applications. (mention few of them any one application)

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62
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

(Reference: Tecquipment)

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63
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Experiment No.10

Name of Experiment: To conduct trial on cascade refrigeration system

Objectives:
1. To understand the working of cascade refrigeration system.
A cascade system is a multistage application in which two separate refrigerant systems are
interconnected in such a manner that one provides the means of heat rejection (condenser)
for the [Link] lower system may, therefore may operate at a much lower temperature.
Cascade system has the additional feature, over compound systems of permitting the use of
different refrigerants in each cycle of the cascade.
Working:
Initially, when the compressor is started, the refrigerant is compressed at high pressure, and
then it enters into the shell and coil type condenser, where the flowing water absorbs all the
heat. Then it enters into the drier/filter, flow meter and it goes into the expansion device
where its expansion takes place and pressure drops. Then it enters into the cascade condenser
where it takes heat from the low side refrigerant (R-23) as shown in figure1.

Figure1. Schematic diagram of cascade refrigeration system

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64
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

In the low side system compressor discharges refrigerant at high pressure, then it enters into
the oil separator where compressor oil gets separated from the refrigerant. Then refrigerant
goes into de-super heater where its heat gets absorbed by flowing water, then it goes into
cascade condenser (i.e., high side evaporator) where its heat is rejected and it becomes in
liquid form. After passing through drier /filter, expansion device it goes into low side
evaporator where it absorbs heat from chamber. It converts into low-pressure vapour state.
Then it goes into the compressor as shown in figure 2.

Figure2. Photographic view of cascade refrigeration system

R-23 is having high standing pressure so it becomes trouble for compressor starting. So to
avoid it refrigerant is stored in the expansion chamber where the pressure takes place. It is
connected in series with the compressor inlet line.

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65
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Specifications:
A. High-side
Components High side
Compressor Hermetically sealed ,Emerson make
Accumulator Dry all
Condenser Forced convection air cooled
Drier/filter Provided
Expansion device Provided
Flow-meter Provided
Evaporator Coil in coil type
De-super heater Not required
Expansion chamber Not required
Oil-seperator Not required
Hp/lp cut-out Provided
Pressure gauges Provided
Energy meter Provided
[Link] Provided
Temp. Controller Sub zero
Insulation Puf
Temperature attained at the evaporator - 15 deg celsius
Refrigerant R-22
Supply 230 volts, 50 hz, 1 phase

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66
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

B. Low-side

Components Low side

Compressor Hermetically sealed, Emerson make
Accumulator Dry all
Condenser Coil in coil type
Drier/filter Provided
Expansion device Provided
Evaporator Natural convection type
De-super heater Shell and coil type
Expansion chamber Provided
Oil-seperator Danfoss make
Hp/lp cut-out Provided
Pressure gauges Provided
Energy meter Provided
[Link] Es point
Temp. Controller Selectron
Heater Provided
Dimmer for heater Provided
Insulation Puf
Observation Table:

Part1: High Side System Refrigerant: R-22

Sr. Time Refrigerant temperatures

Suction pressure psig

Energy meter heater

Discharge pressure

After compression
After evaporation

After expansion
condensation

Energy meter
temperature

compressor
Evaporator
After
Psig

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67
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Part2: Low side system Refrigerant: R13

Sr Time Refigerant
. temperatures

Energy meter compressor

Evaporator temperature
Suction pressure psig

Energy meter heater

After condensation
Discharge pressure

After compression
After evaporation

After expansion
Psig

Calculations & Results

Refrigeration effect at low side n2 = Heater load

= Time for 10 pulses
= 11.25/t
Compressor work at low side w2 = Time for 10 pulses
= 11.25/t
C.O.P. On low side = N2 / w2
=
Now refrigeration effect on high side n1 = Condenser heat rejection on low side
= Compressor work on low side + refrigeration
effect on low side
=
Compressor work on high side w1 =
=
C.O.P. =
Results: = Actual Theoretical
C.o.p. On low side =
C.o.p. On high side =
Overall c.o.p. =

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68
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Experiment No.11

Name of Experiment: To conduct trial on Heat Pump test rig.

Objectives;
1. To understand principle of operation and working of heat pump system.
2. To calculate theoretical, actual and relative C.O.P. of the system
Working:
The apparatus consists of refrigeration system with water-cooled shell coil type evaporator
and condenser. A hermetically sealed compressor using R-134a refrigerant,
Compresses the refrigerant and sends to the condenser. Liquid refrigerant from the condenser
passes through flow meter and drier/filter to capillary tube, where it is throttled to low
pressure and temperature. The low temperature refrigerant passes to evaporator, boils in
evaporator while absorbing heat from the water surrounding the coil and this low pressure
superheated refrigerant returns to compressor.
The condenser and evaporator are shell and coil type with continuous water flow. Flow rates
of condenser and evaporator can be changed to obtain different working temperatures for
condenser and evaporator. Heat collected in evaporator, heat rejected to condenser and input
to the system can be measured and performance of the system can be evaluated as
refrigeration cycle or as a heat pump. The schematic diagram of mechanical heat pump is
shown in figure 1.

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69
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure 1. Schematic diagram of mechanical heat pump system.

Specifications:
1. Compressor - Hermetically sealed Emerson Climate Tech compressor,
2. Refrigerant -R-134a
3. Condenser - Shell and coil type condenser.
4. Evaporator - Shell and coil type evaporator.
5. Expansion device – capillary tube.
6. Measurements -
A. Pressure gauges for condensing and evaporating pressure - 2-nos.
B. Wattmeter for compressor input measurement.
7. Controls - Overload protector for compressor.
8. Necessary switches and fuse.

Experimental Procedure:

1. Connect the water supply to the unit.

2. Fill both the tanks to 10 liters of clean potable quality of water.
3. Record initial temperature of water in both the tanks

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70
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

4. Water inlet temperature should be taken before switching on the compressor

5. Switch ‘ON” the main supply. Switch ‘ON’ the compressor.
6. The temperature on the hot side will start steadily increasing and that from the cold side
shall be reducing.
7. When the hot side (condenser side) reaches about 50o C, stop the machine.
8. Record the time between initial and final readings.
9. Note down all the readings and complete the observation table.
10. May you need conduct another set of readings, drain the water completely with the
help of drain valves provided at the bottom and refill the tanks with fresh water and repeat
the procedure.
Standard Values and Formulas:

Standard Barometric = 1.013 bar = 1.013 x 105 N /m2

Pressure
Density of Water = 1000 kg / m3 = 1 kg / liter
Specific heat of water = 4.18 kJ/kg K
Gas Constant for Air = 287 J / kg K
Specific Gravity of R-134a at = 1.2
400 C
1 Ton of Refrigeration effect = 3500 Watts = 3.5 kJ / s
Density of air at 250 C = 1.1 kg/m3
1 kWHr (kilowatt-hour) = 3600 kJ
1 bar = 14.5 psig

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

71
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Observation Table:

[Link]. Observations Readings Unit

1 Start time Sec
2 End time Sec
3 Cond. water quantity Liters
4 Evaporator water quantity _liters
5 Condensing pressure Pc ( psig)
6 Evaporating pressure Pe ( psig)
7 Compressor input time for 10 pulses sec
8 Temperature after compression oC

9 Temperature after condensation oC

10 Temperature after expansion oC
11 Temperature after evaporation oC
12 Condenser/ evaporator initial temp o C oC
13 Condenser water final temperature o C (5) oC
14 Evaporator water final temperature o C (6) oC

CAUTION:
 Do not exceed the condenser side temperature beyond 50o C
 Always use fresh water for new set of trials.
 Keep the tanks clean and dry when not in use.
 Do not tamper with any of the settings.
 Keep the unit at least 300 mm away from walls.

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72
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure 2: Photographic view of mechanical heat pump

Calculations:

1. To calculate Theoretical C.O.P.

Accordingly,

1. Enthalpy of refrigerant at inlet of compressor h1 =_____________ kJ/ kg

2. Enthalpy of refrigerant at outlet of compressor h2 =_____________ kJ/ kg
3. Enthalpy of refrigerant after condensation h3 =_____________ kJ/ kg
4. Enthalpy of refrigerant after expansion h4 =_____________ kJ/ kg

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73
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure3.P-h chart

5. Theoretical refrigeration effect = N = h1-h4= __________kJ/kg

6. Theoretical compressor work = W = h2-h1 = _________kJ/kg

7. Coefficient of performance = C.O.P. = N/W = _____________

(Note: These valves of enthalpies can be calculated with the help of P-h chart of R-
134a)

A. c
2. To calculate Actual C.O.P. of the system

Heat aborbed in evporator

Actual C.O.P. 
Work supplied to compressor

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74
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

1. Heat absorbed in the evaporator from water: m w  Cpw  (TW1  Tw2 )

Where,
mw = mass of water in evaporator tank (m3)
Cpw = specific heat of water (kJ/kg K)
Tw1 = Initial temperature of water (oC)
Tw2 = Final temperature of water (oC)

Number of pulses  3600

2. Work supplied to the compressor W 
Tcompressor  Energy meter constant(compressor)

B. condenser side
C. Heat rejected by the condenser to water: m w  Cpw  (TW2  Tw1 )

Where,
mw = mass of water in condenser tank (m3)
Cpw = specific heat of water (kJ/kg K)
Tw1 = Initial temperature of water (oC)
Tw2 = Final temperature of water (oC)

Number of pulses  3600

Work supplied to the compressor W 
t compressor  Energy meter constant(compressor)

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75
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

3. To calculate Carnot C.O.P. of the system:

TL
Carnot C.O.P. 
TH  TL

= ---------------------

TL= Saturation temperature to corresponding evaporator pressure (bar)

TH=Saturation temperature to corresponding condenser pressure (bar).

4. To calculate Relative C.O.P. of the system:

Actual C.O.P. ............

Relative C.O.P.   
Therotical C.O.P. .............

Conclusions:

1. Understand the working of vapour compression cycle and function of each component.
2. It is observed that Carnot C.O.P. > theoretical C.O.P. > actual C.O.P. due to the losses
at varies points.

Applications:
Hot water generation for commercial and industrial uses, concentration of juices, milk and
sugar syrups, concentration of dyes and chemicals, for recovery of valuable solvents from
different manufacturing processes
Questions:
1. How Do Heat Pumps Work?
2. Is a heat pump better than an air conditioner?
3. Is a heat pump environmentally friendly?
4. Differentiate between ‘Heat engine’, ‘Refrigerator’ and ‘Heat pump’.

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76
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Experiment No.12

Name of Experiment: To conduct trial on water cooler test rig.

Objectives;
1. To understand principle of operation and working of a Water Cooling System.
2. To determine Coefficient of Performance of the system.
Working:
The Water Cooler test set up enables students to study and understand vapour compression
cycle, its components, principle and working. All the components are mounted on rigid steel
frame. The trainer consists of a hermetically sealed compressor, forced convection air-cooled
condenser, filter / drier, expansion device and coil wound type evaporator. Separate pressure
gauges are provided to record suction and discharge pressures and digital temperature
indicators for various temperatures.
The refrigerant used is R-134a which is environment friendly.
The water cooler consists of an insulated stainless steel tank around which evaporator tubes
are wound and soldered. The tubes are made of refrigerated grade annealed copper tubes.
This is a direct expansion type evaporator. The heat absorbed by the refrigerant is passed
through water which is stored in the tank as shown in figure1.

Figure1. Schematic diagram of water cooler test rig

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)
77
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Specifications
A. Refrigeration System
Parameter Description
Capacity 20 Liters water storage
Compressor Hermetically sealed
Condenser Forced convection air cooled.
Condenser fan Axial flow type
Evaporator Direct expansion type
Expansion device Capillary Tube
Accumulator Copper / M.S. shell suction line accumulator provided.
Insulation Polyurethane Foam (PUF)
Refrigerant R-134 a.

B. Controls & Indications

Temperature Thermostat with Indication & 6 channel digital display
Pressure Pressure gauges 2 Nos. provided

C. Electrical System
Supply 230 Volts, 50 Hz, 1 phase.
Input power 500 Watts.
Rated current 2.8 Amps.
Energy-meters Provided for compressor

D. Construction
Water Tank Stainless Steel
Outer body Stainless steel / or powder coated.
Size 1000 x 1200 x 450 ( L X H X D ) mm

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78
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Operating Instructions:
1. Place the machine in the proper position where its level is horizontal and it is well
ventilated.
2. Give 230 volts, 50Hz, and 1 phase supply to the unit.
3. Fill water in the tank up to over flow level.
4. Switch ON the main switch.
5. Connect the water supply to the feeding.
6. Start the compressor by putting the switch ON.
7. The tank temperature will start dropping down.
8. Record all the readings as per the observation table.
9. Calculate the results as mentioned in the manual

Figure2. Photographic view of water cooler test rig.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

79
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Standard Values and Formulas:

Standard Barometric = 1.013 bar = 1.013 x 105 N /m2

Pressure
Density of Water = 1000 kg / m3 = 1 kg / liter
Specific heat of water = 4.18 kJ/kg K
Gas Constant for Air = 287 J / kg K
Specific Gravity of R-134a at = 1.2
400 C
1 Ton of Refrigeration effect = 3500 Watts = 3.5 kJ / s
Density of air at 250 C = 1.1 kg/m3
1 kWHr (kilowatt-hour) = 3600 kJ
1 bar = 14.5 psig
Observation Table:

[Link]. Observations Readings Unit

1 Start time Sec
2 End time Sec
3 Water quantity in water tank Liters
4 Condensing pressure Pc ( psig)
5 Evaporating pressure Pe ( psig)
6 Compressor input time for 10 pulses sec
7 Temperature after compression oC

8 Temperature after condensation oC

Calculations:
1. To calculate Theoretical C.O.P.
8. Enthalpy of refrigerant at inlet of compressor h1 =_____________ kJ/ kg
9. Enthalpy of refrigerant at outlet of compressor h2 =_____________ kJ/ kg
10. Enthalpy of refrigerant after condensation h3 =_____________ kJ/ kg
11. Enthalpy of refrigerant after expansion h4 =_____________ kJ/ kg

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80
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure3.P-h chart

12. Theoretical refrigeration effect = N = h1-h4= __________kJ/kg

13. Theoretical compressor work = W = h2-h1 = _________kJ/kg
14. Coefficient of performance = C.O.P. = N/W = _____________

(Note: These valves of enthalpies can be calculated with the help of P-h chart of R-134a)

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81
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

2. To calculate Actual C.O.P. of the system

Heat aborbed in evporator

Actual C.O.P. 
Work supplied to compressor

5. Heat absorbed in the evaporator from water: m w  Cpw  (TW1  Tw2 )

Where,
mw = mass of water in evaporator tank (m3)
Cpw = specific heat of water (kJ/kg K)
Tw1 = Initial temperature of water (oC)
Tw2 = Final temperature of water (oC)
Number of pulses  3600
6. Work supplied to the compressor W 
Tcompressor  Energy meter constant(compressor)

3. To calculate Carnot C.O.P. of the system:

TL
Carnot C.O.P. 
TH  TL

= ---------------------

TL= Saturation temperature to corresponding evaporator pressure (bar)

TH=Saturation temperature to corresponding condenser pressure (bar).

4. To calculate Relative C.O.P. of the system:

Actual C.O.P. ............

Relative C.O.P.   
Therotical C.O.P. .............

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82
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Conclusions:

3. Understand the working of vapour compression cycle and function of each component.
4. It is observed that Carnot C.O.P. > theoretical C.O.P. > actual C.O.P. due to the losses
at varies points.

Applications
As water is palatable at 12 to 15o C, it used in offices, schools, colleges, restaurants, factories
for drinking water storage and cooling.

Questions:
A. What are different components and controllers used in water cooler?
B. What is the temperature range of drinking water?
C. What are the benefits of drinking of cold water?
D. List out leading manufacturer of water cooler in the India (at least three)
E. Write the technical specifications of water coolers (leading manufactures in India at
least three)

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83
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Experiment No.13

Name of Experiment: To conduct trial on air conditioning test rig.

Objectives:
1. To evaluate the tonnage capacity of the air conditioning system by enthalpy difference
method.
2. To evaluate actual and theoretical C.O.P. of the system.
3. To plot the refrigeration cycle on P-H & T-S charts.
4. To plot the psychometric processes on psychometric charts.
Working:
The Air Conditioning system is works on Vapour compression Refrigeration cycle using
R 22 as a refrigerant. It has hermetically sealed compressor, which sucks vapour refrigerant
from the evaporator. The vapour is compressed to higher pressure and consequently to higher
temperature in the compressor. The high pressure and high temperature refrigerant then
enters the condenser, where its latent heat is removed by rejecting the heat to the air passing
over the forced convection condenser.

Figure1. Experimental setup of air conditioning test rig.

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84
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

The liquefied refrigerant passes through drier (where any residual moisture is absorbed) and
through rotameter (where flow is measured) and enters the expansion device. In the
expansion device, (either a capillary tube or expansion valve) the refrigerant is throttled to a
lower pressure and as a result, the temperature of the refrigerant also reduced.
This low temperature wet vapour flows through the evaporator, which is a forced convection
air-cooled evaporator. Here, the refrigerant picks up heat from air passing over it and gains
heat; it evaporates and enters the compressor. This cycle repeats. The schematic diagram of
experimental set-up shown in figure 1.
In addition to basic system components, many controls such as overload protector,
thermostat, HP/LP cut-out are provided to safeguard the system against any malfunctioning.
To accomplish psychometric processes, heating elements and humidification arrangement is
provided. To vary the airflow, air dampers are provided. For measurement of pressures dial
type pressure gauges are fitted and to record temperatures digital temperature scanner is
incorporated. The photographic view of air conditioning test rig is shown in figure2.
Specifications:
Capacity : 0.75 tr @ rated test conditions
Compressor : Hermetically sealed. Make: emerson climate [Link]
any equivalent make.
Condenser : Forced convection air cooled.
Condenser fan : Axial flow.
Drier/ filter : Provided.
Expansion device : Capillary tube.
Evaporator : Direct expansion, shell & coil type
Water in shell & refrigerant in coil
Evaporator fan : Centrifugal / axial flow type
Dehumidifier : finned type air heater.
Humidifier : Provided
Refrigerant : R-22
Hp / lp cut-out : Alco/ or danfoss / or indfoss or any equivalent make.
Temperature : 6 channel facility with digital display.
Pressure : 2 nos.; dial type pressure gauges.
Refrigerant flow : Glass tube rotameter provided.

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85
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Air temperature : DBT & WBT measurement by sling psychrometer.

Air flow measurement : By inclined tube manometer.
Supply : 220-240 volts, 50 hz, 1 phase.
Input power : 1.2 kw.
Rated current : 5 amps.
Indicating lamps : Provided for compressor and heater.
Energy-meter : Range 0-20 a; provided for compressor
Material : Panel: 1.2 mm thick
Outer finish : Powder coating
Procedure:
1) Connect the supply cable to regulated / stabilized power supply.
2) Switch ON the main switch.
3) Put ON the AHU fan.
4) Record the DBT & WBT at the inlet and at the outlet of the duct. (Ensure that the well
of WBT is filled with water.) Use psychrometer.
5) Switch ON the compressor.
6) Allow the system to reach steady state.
7) Record the air temperatures at inlet and outlet (DBT & WBT) Use [Link]
the Energy-meter reading.
9) Record suction and discharge pressures.
10) Record Rotameter reading, refrigerant temperatures at various locations viz: before
&after compression and before & after expansion.
11) Measure velocity head with the help of manometer at inlet of the ducting.
12) Take minimum 6 to 8 numbers of readings in 15 minutes of intervals each.

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86
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure 2. Photographic view of air conditioning test rig.

Standard Values and Formulae

 Standard Barometric Pressure = 1.013 bar = 1.013 x 105 N /m2

 Density of Water = 1000 kg / m3
 Gas Constant for Air = 287 kg / kJ K
 Specific Gravity of R-22 at 400 C = 1.2
 1 Ton of Refrigeration effect = 3500 Watts = 3.5 kJ / s
 Density of Air at 250 C = 1.1 kg/m3

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87
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Observation table:
Discharge pressure (hp)psig

reading mm of
Inlet air Outlet Refrigerant
Suction pressure ( lp) psig

Sectional area of the duct

temp. air temp. Temperatures

Energy meter kwhr

Refrigerant flow
0c 0c 0c
Time hrs

After compression
After evaporation
[Link].

After expansion

ManometerLph
wg
condensation
After
WBT

WBT
DBT

DBT

Calculations:
To determine
1. Tonnage capacity of the A.C. system:
Inlet conditions : oC
DBT oC WBT

Outlet conditions : oC DBT oC WBT

Inlet air enthalpy h1 = kJ/kg

Outlet air enthalpy h2 = kJ/kg
Enthalpy difference = h1-h2 kJ/kg
Velocity head, h = mm of liquid column
Velocity of air = m /s
Air outlet sectional area, A = m2
Volume flow rate of air, Q = Vxa= m3/s
Mass flow rate of air m = Volume flow rate x density of air
= Q x 1.1 kg /sec
Refrigeration effect (actual) N = Mass flow rate x enthalpy difference
= m x (h1-h2) kJ/ sec
Tonnage capacity TR = N/ 3.5 TR

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88
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

2. Actual C.O.P. of the system

Refrigeration effect (actual) N = mass flow rate x enthalpy difference
m x (h1-h2) kj / sec
compressor work, W = energy meter reading/ time in hrs.
= kw or kJ/ s
Actual C.O.P. = N/ W
=

3. Theoretical C.O.P. of the system:

To evaluate theoretical C.O.P. of the system, carry out following procedure.
1. For any set of readings at a particular time, note suction and discharge pressures in psig.
2. Divide these pressures by 14.5 to convert them into bar.
3. Add barometric pressure of the present location to obtain absolute pressures in bar.
4. Locate these pressures on “Y” axis of P-h chart. Draw two horizontal lines, one for low
pressure and one for high pressure.
5. Locate particular temperatures on these lines and mark 1,2,3,4.
6. Find out enthalpies at salient points by referring to “X’’ axis of P-H chart.
h 1= kJ/kg

h 2= kJ/kg

h 3= kJ/kg

h 4= kJ/kg

7. N= refrigeration effect= h1-h4= kJ/kg

8. W= compressor work = h2-h1= kJ/kg
9. Theoretical C.O.P. =N/W = (h1-h4) / (h2-h1)
Conclusions

1. Understand the working of air conditioning system and effect on varies psychometric
properties and its processes.
2. Calculated theoretical and actual C.O.P. of the systems.
3. The cooling capacity of the plant = ---------------kW i.e.-----------TR
4. The Actual C.O.P. of the system is --------------------------
5. The theoretical C.O.P. of the system is -------------------

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89
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Questions:
1. Define and explain an ‘air-conditioning system with neat sketch. Name its basic elements.
2. Explain with neat sketch explain the main components of central air-conditioning system.
3. Explain the difference between summer air-conditioning and winter air conditioning.
4. Define room sensible heat factor. How room sensible heat factor line is drawn on the
psychometric chart?
5. List the application of air-conditioning & Define room sensible heat factor and effective room
sensible heat factor.
6. State the factor which should be taken into consideration while selecting a system of air
conditioning

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

90
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Experiment No.14

Name of Experiment: To conduct trial on window air conditioning system.

Objectives:
1. To calculate.
a) Actual C. O. P
b) Theoretical C. O. P of the cycle.
2. To determine tonnage capacity of the window type air conditioner.
3. To plot operating cycle on p-h chart.
Working:
The window conditioning system works on vapour compression Refrigeration cycle using R-22
as a refrigerant.
This system is having a hermetically sealed compressor, which sucks refrigerant vapour from
the evaporator. The vapour is compressed to higher pressure and consequently to higher
temperature in the compressor. The high pressure and high temperature refrigerant then
enters the condenser, where its latent heat is removed by rejecting the heat to the air passing
over the forced convection condenser. The liquefied refrigerant passes through drier (where
any residual moisture is absorbed) and through rotameter (where flow is measured) and
enters the expansion device. In the expansion device, (either a capillary tube or expansion
valve) the refrigerant is throttled to a lower pressure and as a result, the temperature of the
refrigerant also reduced. This low temperature wet vapour flows through the evaporator,
which is a forced convection air cooled evaporator. Here, the refrigerant picks up heat from
air passing over it and gains heat; it evaporates and enters the compressor. This cycle repeats.
For measurement of pressures dial type pressure gauges are fitted and to record temperatures
digital temperature scanner is incorporated. The schematic diagram of window air-
conditioning system is shown in figure1 and 2.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

91
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure1. Window air conditioning unit.

Figure 2. Schematic diagram of window air-conditioning system

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

92
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Figure2. Photographic view of window air conditioning system

Specifications:

Nominal capacity : 3350 watts at rated test conditions

Make : Blue star ltd.
Compressor : Hermetically sealed, rotary
Condenser : Forced convection air cooled
Evaporator : Forced convection air cooled
Expansion device : Capillary tube
Thermostat : On panel
Energy meter : For compressor provided
Pressure gauges : 1 no for suction pressure
1 no for discharge pressure
Temperature indicator : Digital temperature indicator

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

93
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

Dry bulb temperature and wet bulb : By sling psychrometer

temperature measurement
Air flow measurement : By inclined tube manometer

1. To calculate actual C.O.P. of the system:

C.O.P. = Refrigeration effect/ work input

N/w
Now, N = Cooling effect
= Enthalpy difference of air at inlet and
outlet.
To calculate enthalpy at inlet we
have h1 = Enthalpy of air at inlet condition
= Enthalpy of air corresponding to its
wet bulb temperature

Similarly, enthalpy of air at outlet = kj/kg

condition h2

Enthalpy difference = H1 – h2 kJ/kg

=
= KJ/kg
Refrigeration effect = m (h2- h1 ) kJ/ s
Where m = Mass flow rate of air which can be
computed with the help of inclined
tube manometer
To find out work input to the = Final reading – initial reading
system, we have
Energy meter reading difference
= unit = 1 kwhr = 3600 kJ

Time elapsed = seconds

Work input per unit time = kW
(input power)
2. Theoretical C.O.P. of the system

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

94
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF LABORATORY : Refrigeration and Air Conditioning

LABORATORY MANUAL
COURSE CODE :MED 423
CLASS: B Tech. PART: I

NAME OF COURSE : REFRIGERATION AND CRYOGENICS

To evaluate theoretical C.O.P. of the system, carry out following procedure.

1. For any set of readings at a particular time, note suction and discharge pressures in
psig.
2. Divide these pressures by 14.5 to convert them into bar.
3. Add barometric pressure of the present location to obtain absolute pressures in bar.
4. Locate these pressures on “Y” axis of P-H chart. Draw two horizontal lines, one for low
pressure and one for high pressure.
5. Locate particular temperatures on these lines and mark 1,2,3,4.
6. Find out enthalpies at salient points by referring to “X’’ axis of P-H chart.
h 1=

h 2=

h 3=

h 4=

7. N= Refrigeration Effect= h1-h4 = KJ/kg

8. W= Compressor Work = h2-h1 = KJ/Kg
9. Theoretical C.O.P. =N/W = ( h1- h4) / (h2- h1)

[Link] the psychometric processes on hand drawn and actual psychometric chart such
cooling, humidification, heating etc.

Results:

The capacity of the air conditioner kW TR

The actual C.O.P. Of the system :
The theoretical C.O.P. of the system :
Conclusions:

1. Understand working of window air conditioner and its components.

PREPARED BY:[Link] APPROVED BY: Dr., A. J. Keche (HMED)

95