DEVELOPMENT OF AN AIR CONDITIONING TRAINER UNIT

(Project Study)

Virne B. Dalisay, RME

Jude Michael A. Guardian, RME
Mechanical Engineering Department
College of Engineering and Technology
virne_dalisay@yahoo.com

Abstract

The goal of teaching process is enabling students in mastering the subjects

through application of concepts into real performances. One of the best way to achieve
teaching-learning is to equip them with more core knowledge and skills that will enable
them to adapt successfully in the future to changing jobs and environment that might
require different skills with the aid of equipment or apparatus. For many years the
mechanical engineering department has been facing the problem of insufficient
instructional materials and facilities, and one of the required laboratory equipment and
apparatus for the ME Laboratory subject is the air-conditioning trainer unit. This project
aimed to develop a functional and convenient trainer unit to facilitate the transfer of
learning and related activities of the students. Vapor compression window type air
conditioning unit was modified and arranged to suit as trainer unit with glass box
simulation cooling area. Control metering devices as well as electrical port connections
were also added for parameter readings and experiment activities. Based on the
experiments conducted it showed that the trainer unit can be used as demonstration and
diagnostic unit of air conditioning components at the same time provides data for the
determination of theoretical and actual coefficient of performance (COP). This
performance can be used to determine the efficiency of a specific air-conditioning unit.
 INTRODUCTION

Air conditioning technology is a key topic in building services engineering. For this
reason air conditioning technology plays an important role in instruction used by,
instructors/professors to train students acquire skills in air-conditioning.
For many years the university, has been facing the problem of insufficient and
inadequate instructional materials and facilities, especially those that could help in the
development of the student’s manipulative skills.
As stipulated in CHED Memorandum Order (CMO) No.09 series of 2008 the
policies and standards (PS) for the program of Bachelor of Science in Mechanical
Engineering (BSME), one of the required laboratory equipment and apparatus for the ME
laboratory is the refrigeration and air-conditioning trainer unit. The ME laboratory subject
is one of the major subjects of the Mechanical Engineering course.
For now the university is undergoing on Level III Accreditation. It is the requirement
of Commission on Higher Education (CHED) for the schools, institute and colleges to be
qualified and meet the level of being a university. It will be the way so that our university
can provide additional equipment and facilities for the benefits of students and faculty
members. But still it is undergoing a process, that’s why our university still experiencing
insufficient knowledge when it comes to technical situation.
The researchers believe that one of the best way to help minimize the problem of
inadequate equipment is to come up with a trainer that will help facilitate the teaching
learning process in the Refrigeration and Air conditioning. Today, numerous company
offered a laboratory instructional model in the market that caters different test
performance which are very important for improvement of fast learning-comprehension
of the students in refrigeration and air-conditioning topics. However, unit existing in the
market are considerably high price to purchase gives constraints to institution to provide
such required unit for instructional purpose laboratory. By designing and developing this
demonstration and simulation unit, this could help the institution to provide a laboratory
unit enhancing the knowledge on air-conditioning system.
 The idea of developing an air-conditioner trainer unit was initiated to facilitate the
transfer of learning and also to assist the learning activities of the students, particularly in
the Refrigeration and Air conditioning subjects. Lecture alone do not satisfy the need of
the learners .Therefore, technical knowledge and skills are always supplied with actual
performances.

OBJECTIVES OF THE PROJECT

The project was conducted to initiate the realization and adaptation of the air
conditioning trainer unit. Specifically, the objectives of the project are:
1. Developed a window type air conditioning demonstration and simulation unit;
2. Perform readings and conduct test to determine the;
a. temperatures before and after cooling process
b. pressures at low and high side during the cooling process
c. theoretical and actual coefficient of performance (COP)
3. Perform air conditioning components procedure operations and diagnostic
maintenance operations.

The study was focused on the, development and performance evaluation of the
air-conditioning trainer unit including conceptualization, construction and testing. Locally
available materials are to be used in the development of the Air-Conditioning Trainer Unit.
The developed trainer unit delimited to a window type air-conditioner unit, provided
with wiring installation rated at ½ hp compressor, fan motor, capacitor, selector switch
and thermostat. Include also the dimension of 2.0 ft x 1.8 ft x 1.6 ft room area for testing.
It limits only on the performance testing of the coefficient of performance (COP) and
power consumption of the unit and cooling capacity of the unit at different given
parameters.
 METHODOLOGY

The study was then conceptualized by looking into existing designs of air-
conditioning trainer unit used in the training course program at TESDA-ANTS and the
existing commercial trainer units in the market that could make as basis for the design of
the frame and assembly of the components. Based from the gathered designs,
information and specifications, good features of the existing model were considered for
adoption, adaptation and simplification to come up with the modified, simplified and
economical air-conditioning trainer unit. Based on the design requirements and design
data, a design drawing was prepared. The developed trainer unit was subjected to an
evaluation to determine its operating characteristics.

THE WORKING DRAWING

Figure 1. The main frame of the trainer unit

Figure 2. Design plan and its components

Figure 3. Front view of the unit

 Figure 4. Rear view of the unit

Figure 5. The developed demonstration and simulation air conditioning unit

PERFORMANCE EVALUATION
Testing procedure
1. Preliminary Preparation

a. Prepare the trainer unit

2. Actual Testing

a. Install the machine on a flat and level surface.

b. Prepare all the tools to be used for testing such as timer, pocket thermometer,
ball pen and paper.

c. Install the small room at the evaporator side.

d. Check if the connections are properly connected.

e. Plug in the machine on AC power supply.

f. Rotate the selector switch one turn right to start the fan.

g. Rotate the selector switch one turn right to start the fan.

h. Another one turn to the right to start the compressor.

i. To set the fan at medium running state, add another one turn to the right in the
selector switch.

j. To set the fan at high running state just add another turn to the right in the
selector switch.

k. Measure the initial temperature of the room.

l. Record the temperature reading at low, medium and high operation state after
ten minutes.

m. Interpret the collected data.

 RESULTS AND DISCUSSIONS

THE AIR-CONDITIONING TRAINER UNIT

The developed air-conditioning trainer was composed of 8 components such as:

control panel board, frame, compressor, evaporator, condenser, pressure gauges, fan
motor and testing room.

1. Control Panel Board. The control panel was made up of 36 inches x 16

inches ply-board that is attached to the upper part of the frame. The panel board
was made of ¼ -inches ply-board which composed of fan motor terminals,
selector switch terminals, selector switch, ammeter, thermostat, compressor
terminals, and capacitor terminals.
2. Frame. The frame of the trainer unit serves as support to the components of
the unit. It is made of an aluminum 2.0-in x 2.0-in tube. It has a dimension of
36 in x 24 in x 24 in. The joints were riveted to insure strength of the joints.
3. Compressor. The hermetic compressor with ½ horsepower capacity is the
main component of the trainer that pumps refrigerant (R-22) throughout the
system.
4. Evaporator. Made of copper tubing with aluminum fins. It is where heat is
being absorbed, thus changing liquid refrigerant into gas refrigerant.
5. Condenser. Made of copper tubing with aluminum fins similar to the
evaporator. It is where heat absorbed by evaporator discharged into the
atmosphere.
6. Pressure Gauge. The trainer unit has two pressure gauges; low pressure
gauge installed at the low side and high pressure gauge installed at the high
side of the system.
7. Fan Motor. The fan motor is operated at 0.38 amperage and 45 watts
capacity and is thermally protected. It is a three-speed type motor used to run
the propeller and the sirocco fan.
8. Testing Room. The testing room that measures 24 in x 23.5 in x 13 in, is a
detachable room installed at the front of the evaporator. The room is made of
 ¼-in. ply-board, (1.0 in x 1.0 in) wood and two pieces of ¼-in. clear glass with
a dimension of 12.0 in x 12.5 in.

PRESENTATION OF THE OUTPUT AND TESTING RESULT

The study was conducted to developed and evaluate the coefficient of

performance and power consumption of the trainer unit as well as cooling capacity of the
unit. Locally available materials were used for the development and fabrication of the
trainer unit.
The trainer unit was designed as an interactive learning model. It means that the
students are able to touch, operate and have visual observation of the components during
running condition.
Students can also perform and recognize the components of an air-conditioner
through practice on the wiring installation of different parts of the unit.

Table 1. Result of testing for temperature reading and COP before and after cooling
of the room.

Table 1 showed that the developed trainer unit can give a different temperature
reading and cool the controlled area at specific time. Coefficient of performance (COP)
also revealed that a value of 3.2 for indoor temperature of 24 degrees Celsius and 31.5
degrees Celsius ambient temperature gives the highest value among the conducted trials.
This value can be used to determine the efficiency of a specific air-conditioning unit. The
higher the value of COP the higher the efficiency of an air-conditioning unit.

Table 2. Results of testing for pressure reading before and after cooling

Table 2 showed that the developed trainer unit was operated and gave values for
pressure at low and high side at different temperature conditions of the controlled area
being cooled.

Table 3. Trainer unit comparison

Model Cost Performance determination
 Actual COP
Window Air Conditioner  Theoretical COP
P 48,500.00
Trainer unit  Components operation
simulator
 Cooling effect
Window Heat Pump Air
 Work input
Conditioner & Refrigerator P 500,000.00
 Actual COP
Trainer a
 Theoretical COP
 Components operation
simulator
 Actual COP
Mechanical Window Air-
P 1,200,000.00  Theoretical COP
Conditioner Trainer b
 plot the different states
of air on the
psychometric chart
Note: ahttp://www.yalong.com
bhttp:www.legionbrothers.com/products-detail-print.php
 The demonstration and simulation unit entailed an investment cost of P 48, 500.00
which was considered as low cost type compared to the existing air-conditioning trainer
unit in market and used by other institutions.

The Power Consumption

The compressor rated power was 0.5 hp equivalent to 0.373 KW and the fan motor
with 45 watts equivalent to .045 KW. As per information gathered from the Tablas Island
Electric Cooperative (TIELCO), the prevailing price of the electric power is P 12.50/KW-
hr. The air-conditioning trainer unit has a power consumption of P 5.24/hr. With the
amount of the prevailing price of electricity, the price of the computed power is P
125.76/day.

SUMMARY AND CONCLUSIONS

This study was conducted to develop a low-cost yet operational air-conditioning

trainer unit for mechanical and agricultural engineering students of Romblon State
University. It could also cater students who would like to broaden knowledge in operating
principles of a window type air-conditioning unit. It aimed to determine the reading of
temperature and pressure before and after cooling of the controlled area, evaluate the
performance through coefficient of performance (COP), and power consumption (kW-hr)
of the trainer unit by simulating the actual conditions into the prepared controlled area for
evaluation. Results of the performance test showed that the developed unit can be used
as model and simulate the actual cooling environment of a window type air-conditioning
unit; hence it can be used a tool to improve classroom learning process of the students.
The demonstration and simulation unit entailed an investment cost of P 48, 500.00
which was considered as low cost type compared to the existing air-conditioning trainer
unit in market and used by other institutions.