Guidelines - Installation and Maintenance of Air Conditioners

Guidelines:
Installation and
Maintenance of
Air Conditioners
Guidelines: Installation and Maintenance of Air

Conditioners
FEBRUARY 2022
Guidelines:
Installation and Maintenance
of Air Conditioners
TABLE OF CONTENTS
LIST OF TABLES .................................................................................................................. iv
LIST OF FIGURES.................................................................................................................. v
ACRONYMS AND ABBREVIATIONS .................................................................................. vii
1. AIR CONDITIONING SYSTEM OVERVIEW ....................................................................... 1

1.1 Definition, Operating Principles & Main Components ....................................................... 1
1.2 Different Types of Air Conditioner ...................................................................................... 2
1.2.1 Windows Air Conditioners .............................................................................................................. 3
1.2.2 Split Air Conditioners ...................................................................................................................... 4
1.2.2.1 Non-Inverter Split Air Conditioners ................................................................................................. 6
1.2.2.2 Inverter Split Air Conditioners .......................................................................................................... 6
1.2.3 Multi-Split Air Conditioners ............................................................................................................. 8
1.2.4 Portable Air Conditioners ................................................................................................................ 9
1.2.5 VRV or VRF Heat Pump Air Conditioners .................................................................................... 10
1.3 AC Classification ................................................................................................................ 11
1.4 Summary of Type of Air Conditioners .............................................................................. 12
2. SIZING OF AIR CONDITIONERS ..................................................................................... 15

2.1 Room Conditions & BTUs .................................................................................................. 15
2.2 Cooling load calculation using on line calculator of local supplier................................ 16
2.3 Cooling load calculation using thumb rule approach...................................................... 17
2.4 Detailed Cooling Load calculation .................................................................................... 18
3. AIR CONDITIONING SELECTION ................................................................................... 20

3.1 Efficiency & Cost ................................................................................................................ 20
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3.2 Comfort & Practicality ........................................................................................................ 21

3.3 Taking Control of the AC System ...................................................................................... 24
3.4 Reliability ............................................................................................................................ 25
3.5 Summary............................................................................................................................. 25
4. AIR CONDITIONING INSTALLATION ............................................................................. 27

4.1 The Three Sections of a Split Air Conditioner .................................................................. 27
4.2 Pre-installation ................................................................................................................... 28
4.2.1 Use checklist for pre-Installation ................................................................................................... 28
4.2.2 Energy saving measures before AC installation ........................................................................... 29
4.3 Installation Guidelines ....................................................................................................... 32
4.4 Post Installation Checklist ................................................................................................. 39
5. AIR CONDITIONING SERVICING & MAINTENANCE ..................................................... 40

5.1 Importance of regular AC maintenance and servicing. ................................................... 40
5.2 Basic Maintenance & Servicing of AC Unit ...................................................................... 43
5.3 Good Servicing practice of HCFC/HFC-based Air Conditioners during repairs ............ 47
5.3.1 HFC/HCFC Servicing Steps ......................................................................................................... 47
5.3.2 Leakage ........................................................................................................................................ 52
5.4 Do’s & Don’ts in Air Conditioning Servicing .................................................................... 54
5.4.1 Common Practices that are damaging to Air-conditioning Systems ............................................ 54
5.4.2 Area of focus................................................................................................................................. 54
5.4.3 Good Tools ................................................................................................................................... 54
6. ENERGY EFFICIENT AIR CONDITIONING UNITS ......................................................... 63

6.1 Global & local market development of energy efficient air conditioners ....................... 64
6.2 Efficiency gains from High Efficiency air conditioners ................................................... 66
6.3 Solar air conditioning ........................................................................................................ 67
6.4 Performance Metrics, Energy Efficiency Ratio (EER) & Seasonal EER (SEER) ............. 68
6.5 Mauritius Standard for Energy Efficiency & Labelling of AC (MS 200:2013) .................. 69
6.5.1 Labelling Evolution........................................................................................................................ 69
6.5.2 Labelling Regulations ................................................................................................................... 70
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6.5.3 Labelling details ............................................................................................................................ 70
7. AIR CONDITIONER REFRIGERANTS ............................................................................. 75

7.1 Environmental Impact of Refrigerants .............................................................................. 75
7.1.1 Importance of Ozone .................................................................................................................... 75
7.1.2 Ozone formation ........................................................................................................................... 76
7.1.3 Ozone Depletion ........................................................................................................................... 77
7.1.4 Consequences of Damaging the Ozone layer .............................................................................. 78
7.1.5 Global Warming – Greenhouse effect .......................................................................................... 79
7.1.6 How ACs contribute to Global Warming ....................................................................................... 80
7.2 Commonly used refrigerant ............................................................................................... 81
7.3 Handling of HCFC & HFC gas ............................................................................................ 82
7.4 HCFC Phase out management plan .................................................................................. 83
7.5 Alternative to HCFC gas .................................................................................................... 84
7.6 Energy Efficient Refrigerant gas R32 & R290 ................................................................... 85
7.6.1 Refrigerant gas R32...................................................................................................................... 86
7.6.2 Handling Precautions of R32 ........................................................................................................ 87
7.6.3 Refrigerant gas R290 ................................................................................................................... 89
REFERENCED DOCUMENTS ............................................................................................. 91
ANNEX 1: SPLIT AC MANUFACTURER’S SERVICE MANUAL ........................................ 92
ANNEX 2: SPLIT AC COMMISSIONING CHECKLIST & TEST SHEET ........................... 125
ANNEX 3: SPLIT UNIT AC MAINTENANCE CHECKLIST & SCHEDULE ........................ 128
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LIST OF TABLES
Table 1: Different models of AC IDUs ..................................................................................... 4

Table 2: Summary of Type of Air conditioners ...................................................................... 12
Table 3: AC sizing from local suppliers on line calculator...................................................... 16
Table 4: AC cooling capacity from room size ........................................................................ 17
Table 5: Room AC Cooling load estimator ............................................................................ 19
Table 6: Typical electrical requirement for Split AC units ...................................................... 24
Table 7: Typical Split AC Installation Guide .......................................................................... 32
Table 8: Basic maintenance & servicing steps Split type AC (Indoor & Outdoor units) ......... 43
Table 9: General Servicing Split type AC (Indoor & Outdoor units) ....................................... 45
Table 10: Good servicing practice during repairs .................................................................. 48
Table 11: Good practices in AC Maintenance ....................................................................... 56
Table 12: Energy Efficiency Classes for AC .......................................................................... 73
Table 13: Minimum Efficiency Requirements ........................................................................ 74
Table 14: Requirements for maximum sound power level ..................................................... 74
Table 16: HCFC phase out schedule .................................................................................... 84
Table 17: Basic refrigerants information & alternatives ......................................................... 85
Table 18: Theoretical characteristics of R32 compared with other ref gas ............................ 86
Table 19: Flammability properties of R32 compared with other ref gas ................................ 87
Table 20: Comparison of various thermo-physical properties of selected refrigerants .......... 89
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LIST OF FIGURES
Figure 1: Illustration of the main components of an air conditioner ......................................... 1

Figure 2: Basic air conditioner vapour compression cycle....................................................... 2
Figure 3: Window type AC unit (Front view) ............................................................................ 3
Figure 4: Split type AC attributes ............................................................................................. 8
Figure 5: Multi split air conditioner ........................................................................................... 9
Figure 6: Portable air conditioner ............................................................................................ 9
Figure 7: Air conditioner classification ................................................................................... 11
Figure 8: AC selection dilemma ............................................................................................ 20
Figure 9: AC Noise disturbance ............................................................................................ 22
Figure 10: Air conditioner inspection ..................................................................................... 41
Figure 11: AC indoor unit servicing ....................................................................................... 42
Figure 12: Electronic leak detector ........................................................................................ 53
Figure 13: Residential Energy Use ........................................................................................ 64
Figure 14: Benefits of transitioning the High Efficiency AC ................................................... 66
Figure 15: Efficiency gains for High Efficiency AC ................................................................ 66
Figure 16: Solar AC off grid type ........................................................................................... 67
Figure 17: Hybrid Solar AC using DC & AC power ................................................................ 67
Figure 18: Solar AC with solar collectors............................................................................... 67
Figure 19: Solar Ac with solar collectors ............................................................................... 67
Figure 20: E.g Old label Energy class A to G ........................................................................ 70
Figure 21: EU Old label with Energy Class A to G ................................................................ 70
Figure 22: EU Eco design label with Energy Class range A+++ to D (Reversible type AC) .. 71
Figure 23: E.g Eco Design label for a local supplier (Reversible – 3 climate zone) ............... 71
Figure 24: E.g Eco Design label for a local supplier (Reversible – 1 climate zone) ............... 72
Figure 25: E.g Eco Design label for a local supplier (Cooling only) ....................................... 73
Figure 26: Importance of Ozone ............................................................................................ 76
Figure 27: Stratospheric Ozone Formation ........................................................................... 77
Figure 28: Stratospheric Ozone destruction .......................................................................... 78
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Figure 29: Greenhouse effect ................................................................................................ 79

Figure 30: How ACs contribute to Global warming ................................................................ 80
Figure 31: Commonly used refrigerant in room AC system ................................................... 81
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ACRONYMS AND ABBREVIATIONS
ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers

CO2 Carbon dioxide
EER Energy Efficiency Ratio
GWP Global warming potential
HCFC Hydrochlorofluorocarbons
HFC Hydrofluorocarbon
HFO Hydrofluoroolefins
IEC International Electrotechnical Commission
SEER Seasonal Energy Efficiency Ratio
COP Coefficient of Performance
ISO International Standardisation Organization
KWc Kilowatt Cooling
MEPS Minimum Energy Performance Standards
SEER Seasonal Energy Efficiency Ratio
TWh Terawatt-hour
U4E United for Efficiency
UNEP United Nation Environment Programme
AC Air conditioner
GWP Global warming potential
UV Ultra Violet
BTU British Thermal Unit
EU European Union
MS Mauritius Standards
W Watt
Wc Watt cooling
R value Resistance value
VRV Variable Refrigerant volume
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1. AIR CONDITIONING SYSTEM OVERVIEW
1.1 Definition, Operating Principles & Main Components
Air conditioner means a device capable of cooling or heating, or both, indoor air, using a
vapour compression cycle driven by an electric compressor, including air conditioners
that provide additional functionalities such as dehumidification, air purification, ventilation,
etc.
An air-conditioning system distributes cooled air in an enclosed space. Air conditioning

involves modifying the temperature and humidity of the air supply to make users more
comfortable in a space, subject to heat gains and/or losses and depending on the
product’s use and climatic conditions.
The key components of an air conditioner consist of a compressor, a condenser, an

evaporator. A space is cooled by eliminating heat gains, which are absorbed by the
refrigerant circulating in the indoor evaporator under pressure from a compressor installed
in the outdoor unit. The compressor “compresses” the refrigerant, which, owing to the
changes in its state, can transfer cooling energy in hot weather and heating energy in
cool weather in the case of reverse cycle air conditioning systems.
Indoor unit
Outdoor unit
Figure 1: Illustration of the main components of an air conditioner
The main components of a split air conditioner, the most widely used type, include
an indoor unit installed inside the room to be cooled and an outdoor unit installed outside
the room in open space. In addition, a tubing connects the indoor and outdoor units
carrying the refrigerant.
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Figure 2: Basic air conditioner vapour compression cycle
1.2 Different Types of Air Conditioner
Individual air conditioners systems can be configured in various ways:

• Combined indoor and outdoor units: Windows (monobloc) air conditioners
• Separated indoor and outdoor units: Split air conditioning systems
• Multiple indoor units separated from a single outdoor unit with multiple
refrigerant circuits: Multi-split air conditioners
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• Multiple indoor units separated from a single outdoor unit with one
refrigerant piping: VRF/VRV systems
The scope of this guideline includes the most popular types of residential air conditioners.
These are window type, non-inverter split type, inverter split type, multi-split type, portable
AC and VRV/VRF heat pump air conditioners.
Moreover, this guideline will have main focus on cooling applications since heating
applications from heat pumps have relatively low market shares for the residential sector.
1.2.1 Windows Air Conditioners
In window type air conditioners (also called monobloc or single packaged unit) all the
components, i.e the compressor, condenser, expansion valve and cooling coil; are
enclosed in a single housing. They are relatively easy to install.
Some units may be noisier than other types when operating. They are generally less
efficient, due to size constraints, have fewer options to improve efficiency.
Figure 3: Window type AC unit (Front view)
Advantages of Window Air Conditioners

• Lower purchase price
• Easy to install
Disadvantages of Window Air Conditioners
• Lower efficiency
• Noisier operation
The sales growth of window units has drastically decreased over the past 15 years in the
local context and these type of AC units are no more commercially being sold. Some old
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window units still running but will ultimately disappear. Hence no further consideration is
given to window units in this guideline.
1.2.2 Split Air Conditioners
Split AC is the most common kind. This consists of two distinct units, an internal (indoor
unit) and an external one (outdoor unit), connected by refrigerant piping and electric
cables. The outdoor unit contains the compressor, and is often the noisier of the two.
Due to the blower being the only moving part in the indoor unit, this unit of AC is almost
silent. These can be fit into walls, and with the latest designer looks, can add to the facade
of the room as well.
The indoor units can be of different models such as wall mounted (fixed on wall), ceiling
mounted (fixed on ceiling/floor), cassette (fixed within false ceiling, concealed (requires
air grilles & ducts, generally installed in bulk head).
Table 1: Different models of AC IDUs
1 Wall Mounted
Unit
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2 Conceal Ducted
Unit
3 Cassette type
Unit
Ceiling
Mounted Unit
Floor Mounted
Unit
The split AC dominate air conditioner sales. In addition, they are up to 30% more efficient
given the hot side is separated from the cold side, without heat transmission between
them (unlike windows air conditioners).
These systems may be larger in capacity and generally installed by trained technicians.
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The split Air Conditioners can be of two types:

• Non-inverter type
• Inverter type
1.2.2.1 Non-Inverter Split Air Conditioners
They refer to systems with a fixed speed compressor where the unit turn on & off to
maintain room temperature. Also known as the on-off or conventional air conditioner.
Advantages of Non-Inverter Split Air Conditioner

• Lower purchase price than inverter type air conditioners
• Lower control system than inverter type air conditioners. Highly skilled manpower
not required
• Repair cost is lower inverter type
Disadvantages of Non-Inverter Split Air Conditioner

• Less efficient than inverter type air conditioners
• Compressor stop & start, hence compressor does not modulate as inverter type,
wear & tear more
• Does not give accurate cooling temperature as inverter type
1.2.2.2 Inverter Split Air Conditioners
Split air conditioners using a compressor controlled with a variable speed drive (VSD) are
also known as inverter units. The inverter technology (DC) is the latest evolution of
technology concerning electro motors of the compressors. An inverter is used to control
the speed of the compressor motor, so as to continuously regulate the temperature.
The DC inverter units have a variable frequency drive that comprises an adjustable
electrical inverter to control the speed of the electromotor. The drive converts the
incoming AC current to DC and then through a modulation in an electrical inverter
produces current of desired frequency. A microcontroller can sample each ambient air
temperature and adjust accordingly the speed of the compressor.
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The inverter AC units have increased efficiency, extended life of parts and sharp
fluctuations in the load are eliminated. This makes the inverter AC units quieter. The
inverter AC units might be more expensive than constant speed AC units, but this is
balanced by lower energy bills. The sales of inverter AC units have increased
considerably on the local market due to its energy saving attributes, replacing rapidly the
conventional AC units.
The difference between inverter and fix speed air conditioners is that the former can vary
the speed of the compressor, delivering precise cooling as required.
Inverter units are designed to meet cooling conditions occurring rarely, operation at part
load is more frequent, making inverter split air conditioner more efficient than non-inverter
units.
Advantages of Inverter Split Air Conditioners

• More efficient than non-inverter split air conditioners
• Achieves desired temperature quicker and no temperature fluctuations
• Quiet operation as compressor sits in outdoor unit
Disadvantages of Inverter Split Air Conditioners

• Typically, higher purchase price than non-inverter split units
• Highly skilled manpower required due to advanced control system
• Repair cost higher than non-inverter type (for e.g, replacement of faulty electronic
card)
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SPLIT TYPE AIR CONDITIONER ATTRIBUTES
INDOOR UNIT INDOOR UNIT

MODELS LINE UP SMART AC MODELS LINE UP
WALL TYPE WALL TYPE

NON - INVERTER
INVERTER TYPE TYPE
CEILING (ON / OFF TYPE) CEILING
MOUNTED MOUNTED
CASETTE TYPE CASETTE TYPE
FLOOR MOUNTED FLOOR MOUNTED

AIR CONDITIONER
SPLIT UNIT
CONCEALED CONCEALED
DUCTED DUCTED
COOLING ONLY OR
INDOOR UNIT +
REVERSE CYCLE
OUTDOOR UNIT
(COOLING & HEATING)
Figure 4: Split type AC attributes
1.2.3 Multi-Split Air Conditioners
Multi-split air conditioners contain numerous indoor units (typically up to four units)
connected to a single outdoor unit. They are used to multiple rooms.
Advantages of Multi-Split Air Conditioners

• Multiple indoor units using one outdoor unit
• Can be installed in various rooms
• Separate controls for different rooms
Disadvantages of Multi-Split Air Conditioners

• No redundancy since all indoor units rely on one outdoor unit
• High purchase price
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Figure 5: Multi split air conditioner
1.2.4 Portable Air Conditioners
A portable air conditioner is a self-contained unit, similar to a window air conditioner. It is

typically designed with wheels to allow it to be moved. Water condensed from the portable
air conditioner may be collected in a bucket for manual removal, drained through gravity
hose, or evaporated and exhausted with the condenser process air.
Figure 6: Portable air conditioner
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Advantages of portable air conditioners

• Lower purchase price
• Can be moved from room to room
• Easy to install
Disadvantages of portable air conditioners

• Typically, less efficient: lower efficiency at hot climate/better efficiency if outdoor
air temperature is low
• Noisier operation
• Water need to be removed manually
1.2.5 VRV or VRF Heat Pump Air Conditioners
A VRF (Variable Refrigerant Flow) or VRV (Variable Refrigerant Volume) air conditioning
system is a particular type of heat pump air conditioning system in which one outdoor unit
can be connected to multiple indoor units. Each indoor unit is individually controllable by
its user and a variety of indoor unit models can be mixed and matched to suit individual
indoor requirement (wall mounted, cassette, ducted, ceiling, etc)
The outdoor unit can be made up of a number of modules to create the required capacity.
The compressors can be operated at varying speeds, so the VRF units work at only the
rate needed to meet the prevailing heating or cooling requirements, considerably
enhancing the efficiency.
Advantages of VRF air conditioning system
• Energy efficiency
• Installation flexibility
• Heat & cool simultaneously
• Quiet operation
• State of the art smart technology controls
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Disadvantages of VRF air conditioning system

• High purchase price
• Complex refrigerant piping installation make standard of initial installation a
crucial factor on life expectancy. Highly skilled manpower resources required.
• Leak detection trouble shooting very difficult
• Being a centralised system, shut down of the outdoor unit for troubleshooting
entail shutting down of all indoor units
1.3 AC Classification
Air conditioners are generally classified of several criteria: the most common of these are
presented below.
AC CLASSIFICATION
Figure 7: Air conditioner classification
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1.4 Summary of Type of Air Conditioners
Table 2: Summary of Type of Air conditioners
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Source AC & comfort fans: review of Regulation 206/2012 & 626/2011 – Final report – EU, HAL – 2018
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2. SIZING OF AIR CONDITIONERS
Air Conditioners are designed to accomplish three tasks:

• Reduce the air temperature
• Remove excess moisture
• Filter/Clean the air
2.1 Room Conditions & BTUs
To accomplish these tasks, the right air conditioner must be sized based on the conditions
of the room. However, the sizing of an air conditioner is a very complex calculation as it
involves various parameters and differs from region to region.
In Mauritius, the sizing of domestic AC is mostly based on the area of the room, and the
region. The sizing of the air conditioners should depend on how much cooling capacity
will be required to keep the occupant at a comfortable temperature.
This load will be partly dependent upon the home’s square footage (square metre).
Also more accurate load determination will include: -

(a) building construction, orientation to the sun, “R” value of the insulation;
(b) number, size, and placement of rooms;
(c) number, size, and placement of windows and doors;
(d) types of windows and doors (thermal efficiency);
(e) number and arrangement of floors;
(f) the climate
Room temperature: The typical temperature of the room will help determine how powerful
the air conditioner needs to be in order to keep the room cool. This vary through-out the
year.
The temperature normally ranges from 20 °C to 26 °C (CEB recommends range 24 °C to

26 °C in order to save energy)
British Thermal Units or BTUs are used to measure thermal energy.
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When choosing an air conditioner, the BTU/hr rating refers to the amount of heat that the
unit can remove from the air over a certain period of time. An air conditioner with a higher
BTU/hr rating will be able to remove more heat than an air conditioner with lower BTU/hr
rating.
An air conditioner that is too large for a room will cool that room too quickly and then shut
off without removing the humidity, giving the air a damp and uncomfortable feel.
So the first step, when sizing the air conditioner, is to measure the room or space that it
will be cooling. This will provide the necessary information needed, in order to choose an
appropriately-sized unit.
To do this, determine the square footage (square metre) of the room by multiplying the
length by the width.
Air conditioners cooling capacity are also designated in Kilowatt cooling (KWc).
1 Watt cooling= 3.412 BTU/hr

1 Kilowatt cooling = 3412 BTU/hr
1 BTU/hr = 0.3 Watt cooling
1 BTU/hr/ft2 = 3.15 W/m2
2.2 Cooling load calculation using online calculator of local supplier
The table below shows some cooling requirement rate in sizing the residential air
conditioners capacity among different local AC suppliers and the CEB.
Table 3: AC sizing from local suppliers on line calculator
J Kalachand
CEB King Bros Dragon Electronics
(AC
(Authority) (AC Supplier) (AC supplier)
Supplier)
BTU/hr/ft2 64 75 74-83 64-74
Wc/m2 202 237 233-262 202-233

(SI Unit)
Except for the CEB which do not have an interactive web site, the values above are
available through the on-line calculator from the local AC supplier websites which give
the user a first estimate on the selection of air conditioner capacity based on the room
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areas by inputting the room dimensions and the location of the site (coastal or non-coastal
region).
The cooling rates vary from supplier to supplier and even with the CEB.
2.3 Cooling load calculation using thumb rule approach
There is a general consensus among various actors of the air conditioning industry such
as the consultants, contractors & the Energy Services Division of a thumb rule approach
for a cooling rate of 60 BTU/hr/ft2 in the domestic sector as a quick estimate to calculate
the AC capacity based on the room dimensions on construction projects.
The table below shows the sizing of the AC based on the commonly built room
dimensions in typical residential projects.
For e.g., for a standard house having a room size of 10 m 2 floor area, the quick cooling
load estimate from the table will indicate the choice of an AC of capacity 9,000 BTU/hr.
Table 4: AC cooling capacity from room size
Room Dimensions AC cooling capacity

Sqm (ft²) - BTU/hr (kWc)
9.4 - 14
9,000 (2.6)
(100 - 150)
14.1 – 18.7
12,000 (3.5)
(151 - 200)
18.8 – 28
18,000 (5.2)
(201 - 300)
28 – 37.4
24,000 (7)
(301 - 400).
~46.7 (~500) 30,000 (8.7)
~56 (~600) 36,000 (10.5)
~65.4 (~700) 41,000 (12)
Note: Quick reference guide for domestic sector construction projects
(Based on 60 BTU/hr/ft2 or 0.19 kWc/m2). Conversion factor 1 m² = 10.7 ft²
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A trained AC technician chosen to install the new system should be able to perform these
calculations. Having the wrong-size heating-cooling system can lead to multiple
problems. Over-sizing your cooling system is not a good thing.
Determining the load by using rules of thumb may lead to an over-sized cooling system,
resulting in an increased initial cost, increased monthly utility bills, increased
maintenance, and shortened equipment life because the equipment cycles off and on too
frequently.
An underpowered unit will struggle to cool a room effectively, running constantly and
using excess energy. To avoid this, many people will simply buy the most powerful air
conditioner that they can afford, but that will also have unwanted effects. Air conditioners
are designed to remove both heat and humidity from a room.
A big cooling system cools down the temperature very quickly, but it does not run long
enough to remove sufficient moisture or “humidity” from the air.
Many people then turn down the thermostat to make the air conditioner run longer,
increasing the utility bill.
In some cases, the insufficient moisture removal resulting from over-sized cooling
equipment can lead to mould growth and other types of moisture-related damage.
2.4 Detailed Cooling Load calculation
There are a few things that must be consider for the detailed Cooling load calculation.
The cooling load consists of two parts:

1. The temperature of the air, called the sensible load
2. Moisture or “humidity” in the air, called the latent load
In order to have a more accurate load calculation, the following adjustments are to be
considered: -
• Heavy Sun Exposure to walls & roof
• No. of people occupying the space
• Lights, air infiltration
• Windows orientation & shades
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The chart below represents more detailed parameters for the cooling load estimation for
room air conditioner.
Table 5: Room AC Cooling load estimator
Room Air Conditioner Cooling Load Estimator

Heat Source (A)Floor Cooling Load (A) x (B)
area m2 (B) Mu ltiplying factor Wc/m2 Watt (Wc)
Exposed to sun
Area of Windows No awnings No awnings or Awnings Fully shaded
No Curtains cuiains of curtains
South No Blinds
120 blinds
95 blinds
65 60
South East 380 260 130 60
East 430 300 145 60
North East 370 260 130 60
North 270 190 100 60
North West 370 260 130 60
West 430 300 145 60
South West 380 260 130 60
Exposed to Brick,brick veneer.weather 35
Outside wall area the sun board fibro 40
less glass Not Brick,brick veneer.weather 15
exposed board fibro 15
lnternal wall area 8
Ceiling area Uninsulated 50 Insulated 8
Suspended floor Uncarpeted 12 Carpeted 6
area
Door area Closed when not in use 100
Sitting or sleeping 120 W/person
People
Active 250 W/person
Lights Appliances Power I lights 20W/m2
Sensible Cooing loat (Watt Wc)
Required thermal coolng capacity = Sensible cooling load x 1.3
Source AC supplier GREE Aust/NZ – website www.greenonline.com/calculator
Note: Heat generated by electrical equipment such as personal computers, laptops, server, printers have minimal incidence for
rooms in residential premise but more relevant for office building projects.
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3. AIR CONDITIONING SELECTION
Once the base BTU/hr (KWc) requirement is known, the selection of the air conditioner
becomes a daunting task since the market is flooded with different types and different air
conditioning brands having several features.
Figure 8: AC selection dilemma
The following factors that need to be considered when selecting residential air
conditioners.
3.1 Efficiency & Cost
One of the most important things to remember when purchasing an AC system is that it’s
an investment for the family and home. So although the cheaper option is the more
attractive option, remember, generally, it’s the less expensive systems that will be costing
more down the track, both through increased running costs and also increased
maintenance costs.
Conversely, the higher quality systems tend to have higher efficiencies, which make them
less expensive to operate and more likely to pay for themselves over time.
The current demand for energy efficient air conditioner has also seen a rise in in-house
technologies that lead to further savings.
Energy Efficient Ratio (EER) and Star rating system on the labelling are now significant
parameters that have to be considered for the usage of an AC. EER is the ratio of cooling
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capacity (in watts) to power consumption (in watts). The higher the star rating, better is
the efficiency of the system.
The effectiveness of an air conditioning system can be appropriately judged by the

amount of cooling per unit of power consumed. Higher the amount of heat removed per
hour per unit of power consumed, higher is the efficiency of air conditioner. Also, higher
the EER, better is the air conditioner.
Energy efficient air conditioners have been elaborated in more details as a separate
chapter in this report.
3.2 Comfort & Practicality
When choosing an air conditioner it is important to know the different types and models
of AC systems available on the market. The different type of the air conditioners has
already been elaborated in Chapter 1 above. Out of these, the split type units represent
the lion’s share of the sales in the domestic sector. The latest trend in the split type air
conditioner segment can basically be classified as:
• Reverse Cycle: An air conditioner with both heating and cooling capabilities.
• Inverter: An air conditioner that delivers a constant airflow and adjusts the
intensity of the outdoor unit (compressor) to achieve the desired temperature
set-point. Inverter systems are more energy efficient than the traditional fixed-
speed air conditioning units.
• Smart AC: An air conditioner that connects to home network in order to control
and monitor its output through an app on compatible tablet or mobile devices.
Once the appropriate system has been selected, some other important features are also
to be considered such as the noise level and available electrical connection.
Noise level
Noise from air conditioners can be a source of disturbance to the occupant and also the
neighborhood by disrupting their sleep and interfering with their normal daily activities
(listening to the TV, talking to the phone, studying). Air conditioner noise can range from
being a nuisance to actually damaging people’s health and is a common cause of noise
related complaints.
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Noise by definition is unwanted or unpleasant sound. Due to the range of noise that can
be heard by the human ear, a scale was developed called the decibel scale [dB(A)] which
is used to represent how loud a particular noise. The higher the air conditioner capacity
the higher is the decibel level.
The siting of the air conditioner is the most important factor in ensuring noise is not going
to intrusive. Placing the unit close to the neighbour’s house is likely to create excessive
noise, as the noise is trapped and reflected between the walls and the eaves of the house.
Placing the air conditioner on the rear or facing the street on placing on the roof reduces
the noise reaching the neighbor. Barriers can be introduced to reduce the noise level.
Figure 9: AC Noise disturbance
For the split type air conditioner, the decibel level of both the indoor unit and the outdoor
unit are specified in the technical literature. When comparing air conditioners, check the
sound pressure level of the unit. The smaller the number of dB(A) on the label, the quieter
the air conditioner. Comparing noise level on units help to choose a quieter unit.
Environment Protection Act (Mauritius)

Noise Exposure limits
Neighbourhood Noise
07.00 -18.00hrs : 60 dB(A)
18.00 - 21.00 hrs : 55 dB(A)
21.00 – 07.00 hrs : 50 dB(A)
+5 dB(A) adjustment possibility
dB(A) – Equivalent A-weighted sound pressure level
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It may be found that the sound pressure level label of an air conditioner is 56 dB(A) or
more and wonder how it could comply to with a legal limit of 55 dB(A).
This can be explained by the following comparison. A light bulb with a power rating of
60W has a certain intensity of light at the actual bulb, but with distance this intensity
decreases, although the power of the globe remains 60W. Similarly, the noise level of a
air conditioner with a sound pressure level of 56 dB(A) will decrease as the distance from
the unit increases.
Noise can also affect our performance, learning and stress levels. The level of annoyance
experienced from the noise depends on the level of noise, type of noise, how often it
occurs, how long it goes, time of day or night and the individual’s own tolerance.
Electrical safety connections
• Avoid using any kind of extension cords to power an air conditioner. These can
cause fires and are unreliable.
• Get the proper power supply and required protecting device (RCDs, DP switch)
to the AC unit. This will reduce fire risk and stress on the electrical system of
the house.
• Do visual inspections to ensure that all the electrical cords are working properly
and are not damaged by rodents.
• Once the AC unit is plugged for use ensure that there is sufficient access and
lighting to power off the unit.
• Avoid putting the AC units where water could get into it. Also don’t put plant or
other things on top of the unit.
• Keep the Ac unit electrical wires from hot items. Hot surfaces can damage the
units.
• Grounding of the AC unit is compulsory.
• Ensure a single length of electrical wires between Indoor Unit (IDU) & Outdoor
Unit (ODU). Ensure no breaks on wires and hence no connections in PVC
trunking or cable tray.
• Consult the Service manual of a typical AC unit about the safety aspects of
electrical connections (refer to Annex 1).
• Typical electrical requirement for Split AC units.
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Table 6: Typical electrical requirement for Split AC units
Anti-corrosion coating for the ODU
Corrosion attack on the ODU casing and condenser fins are common problems
encountered in coastal region and also in wet region which result in high degree of
degradation of the ODU to such extent that the life time of the equipment is shortened.
The standard manufacturer’s specification does not allow for Ac units meant for
tropicalized climate like ours. These anti corrosion coating are factory mounted from
manufacturers are available on special order.
Some local suppliers import AC units which already has the anti-corrosion casing and
the blue or gold or black condenser fins protection. Some local suppliers also have the
facility to undertake in-situ special anti-corrosion treatment on the ODU of the AC units.
3.3 Taking Control of the AC System
With the leaps and bounds in technology in recent years, especially for the home, there
are a wide range of new possibilities now available to the homeowner. One of these new
possibilities is the opportunity to take control of the home products thanks to the
introduction of smart devices.
When it comes to choosing an AC system, make sure to keep in mind the functions that
matter most. If its total control over the AC system that is required, consider installing a
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smart air conditioning system, which gives the ability to control the entire AC system from
anywhere in the world at the touch of the fingertips.
Simply install the required applications to the tablet or mobile device and have complete
comfort and control.
This translates into energy savings whereby the air conditioner.

i) can be turned off or adjusted at the set temperature to reduce demand when the
user is not at home, and into comfort when the user is at home.
ii) turn the air conditioner on or off, or adjust the temperature to improve the comfort
level without getting up.
iii) give complete insight on technical nature such as watts, voltages, current, units
consumed.
3.4 Reliability
Another key consideration when choosing an air conditioner system that will serve the
home for decades is reliability. When it comes to picking a pricier model, it pays to stick
with a reputable company with extensive experience and great after-sales service.
Purchasing an air conditioner is a family investment.
Famous brands which have been in the market for decades offer the more reliable
choice.
3.5 Summary
A checklist for selection of an air conditioner is as follows: -
(a) Capacity: Calculate required cooling capacity from room size (described in
Chapter 2).
(b) Make a first selection of AC unit from available range (described in Chapter 1).
Inverter split AC units are the most in demand nowadays due to its energy
saving capacity. Ensure selection of unit is equal or a little more than the
required capacity.
(c) Locate position of indoor and outdoor units such that horizontal & vertical
distance between them is minimum.
(d) Ensure the AC unit has the best Energy rating. The higher the better.
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(e) Check manufacturer’s reputation & reliability for lifetime of the AC unit.
(f) Check local supplier’s credentials for installation charges done by trained
technicians, after sales service, servicing, commissioning sheet, etc.
(g) Check noise level of indoor & outdoor units to compare with other
manufacturers.
(h) Check warranty available for AC unit in general and for compressor in
particular (one year or multiple years).
(i) Check features associated with the AC unit on remote controller (timer, turbo
boost, Wifi, smart, etc) and aesthetic look of indoor unit.
(j) Check monthly power consumption (from supplier)
(k) Check for anti-corrosion coating for coastal climate and rainy region.
(l) Check and ensure stabilised electrical supply is available. Or make provision
for same (as advised by professionals).
(m) Check the refrigerant gas used. Mostly R410a available on the local market
nowadays.
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4. AIR CONDITIONING INSTALLATION
No matter what type of air conditioner that’s chosen to be installed for residential
application, there is one hurdle that needs to be faced, the installation.
Air conditioning installation is an important part of the process and in essence that help
in deciding between which type of system could go in the living quarters. Here are some
of the processes that are involved for the split type and window type air conditioner setup
For many consumers a split air conditioner offers the best of all worlds in the air
conditioning department.
The term split means that half of the system is on the outside while the rest is on the
inside. In this case the compressor unit and many of the loud running features are outside
while the indoor unit rests comfortably inside - without taking up window space.
Installing a split air conditioner is a more advanced process.
What absolutely needs to be present, though, is a hole between the inside and outside of
a home so that refrigeration lines can be run to the indoor unit. The first step in installing
a split air conditioner is deciding where it's going to be mounted and cutting a hole for
those lines.
4.1 The Three Sections of a Split Air Conditioner
There are obvious some pretty detailed steps to installing a split air conditioner with an
outside condenser coil and indoor unit. To better understand the basics of the install it's
easier to break them down in three areas:
• Outside Condenser - The condenser is placed outside so that the noise of it

running doesn't bother people inside and so that there's more ventilation for the
hard-working coils. The condenser is placed on a slab or fixed on bracket near
the home.
• Indoor Evaporator - The indoor evaporator is the brains of the operation where
the temperature is controlled and the cool air is delivered. The vent is the
messenger so to speak, the condenser does all the hard work outside and the
evaporator brings the good news inside.
• The Connectors (Piping & Wiring) - Of course lines are needed to connect
the two devices with copper wire delivering refrigerant, wires carrying
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electricity, and tubes dispensing the water that is formed in the cooling process
outside.
4.2 Pre-installation
4.2.1 Use checklist for pre-Installation
The pre-installation check list ensures that there is a mutual agreement on the installation
of both the Indoor unit (IDU) and the Outdoor unit (ODU).
Indoor unit:
(a) Obtain user approval on final best location after pros & cons of different options
considered
(b) The restrictions on installation specified in the IDU installation drawings are met
as per Installation manual
(c) IDU should be sited where both air inlet and air outlet have clear paths
(d) IDU is not in the path of direct sunlight.
(e) IDU is away from the source of heat or steam
(f) Cool air is circulated throughout the room without obstruction
(g) The IDU is away from the from electronic ignition type fluorescent lamps as this
may shorten the remote controller range
(h) The IDU is at least 1m away from any television or radio set
(i) IDU is installed at recommended height of 2.1m
(j) Position of window or door in the room does not cause short circuiting of cooled
air from the IDU to the outside/corridor, as this leads to wastage of energy.
(k) Position of bed or study table do not blow directly on the head of the occupant
and wardrobe position does not represent an obstacle in the air flow distribution.
Outdoor unit:
(a) Obtain user approval on final best location after pros & cons of different options
considered
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(b) The restrictions on installation specified in the ODU installation drawings are met
as per Installation manual.
(c) ODU should be sited where both air intake oo the condenser coil have required
clearance and hot air outlet have no obstruction such as bushes, trees, etc.
(d) The ODU is not in the path of direct sunlight.
(e) The ODU noise level is not a source of disturbance for the neighbours.
(f) The ODU is installed in such location where it is easily accessible for servicing and
intervention.
(g) The ODU has the shortest pipe runs to ensure better efficiency.
(h) Installation accessories (not provided by the manufacturer), where required, such
as concrete slab, L-support brackets, additional refrigerant, condensate pipes,
power sockets, sealing of hole, etc are brought to the knowledge of the user.
(i) Additional run of pipes are well protected and not exposed to UV rays of the sun
4.2.2 Energy saving measures before AC installation
The following energy saving measures are worth taken into consideration before
installation of the split AC unit.
Planning ahead
Location of the IDU & ODU is very important as mentioned above. Excessive pipe runs
between ODU & IDU should be avoided as drop off in performance can be experienced,
resulting in more energy consumption. Also, always provide suitable service access for
technicians to carry out effective system maintenance, and follow up on energy
consumption, in accordance with the manufacturer’s recommendations.
Selection/sizing
As described in Chapter 2 & 3, correct sizing and selection of air-conditioning equipment

is key to achieving optimum energy efficiency. Over-sizing in itself doesn’t render the
system operationally inefficient. However, increased power consumption over the lifetime
of the system can prove otherwise. Alternatively, under-sizing the system can result in
excessive operation during normal system lifetime and can cause premature failure. Of
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course, where possible, select Energy A, A* or above rated equipment with the latest in
DC inverter technology. It is also important to adhere to the manufacturers’ recommended
pipe sizes and maximum pipe lengths as system capacity will reduce significantly if these
are exceeded.
Control/set point
The most energy-efficient air conditioning systems installed in any application can be
rendered energy inefficient if not controlled in the correct manner. Most of today’s control
options can greatly increase the efficiency of an air-conditioning system. Control of
operation times and set-point temperatures are the most basic and fundamental of control
functions that will enhance system efficiency. Also consider options available on air
conditioning systems, such as Energy Saving and Economy modes.
Refrigerant charge
Paying attention to refrigerant charge is important for any air-conditioning system.

Undercharging will result in the starvation of refrigerant within the system, in turn reducing
the ability of the refrigerant to absorb the required amount of energy to satisfy the heating
or cooling demand of the conditioned space. Operation times will subsequently increase,
increasing energy consumption and also creating higher risk of system failure. If a system
is undercharged, always check for leaks within the pipe work and equipment and repair
or replace as necessary before re-charging.
Insulation
Poorly insulated and/or damaged insulation on pipe work breaks the vapour seal allowing
condensation to form on the pipe. This condensation can soak into the insulation
destroying the thermal insulation properties. The resulting exposed pipes will decrease
the system’s efficiency. Many split system expansion devices are located in the outdoor
unit and poorly insulated pipe work can affect the efficiency of the air conditioning system.
Exposed pipes will act like a heat exchanger and absorb or reject energy before the
refrigerant reaches the indoor or outdoor unit reducing the performance of the air
conditioning system. Always ensure pipe work insulation is of the correct quality and
standard as recommended by the manufacture and/or in line with good refrigeration
installation practice.
Servicing and access
Too often, system maintenance is neglected – and even the most efficient air-conditioning
systems will not fulfil their operating potential if not serviced regularly. Regular
maintenance checks will ensure that the air-conditioning system operates as efficiently
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as possible. Energy consumption can increase substantially as a result of replacing poorly

maintained or dirty components. Simple routine maintenance such as checking and
cleaning fans, filters, coils/heat exchangers, etc will maintain system efficiency.
Frequently, poor planning with regards to system location makes it impossible for service
engineers to gain safe and suitable access to units on routine maintenance visits. If the
filter or coils cannot be inspected or cleaned, the system’s efficiency will be dramatically
reduced as the airflow across the coils becomes restricted. Over time this will result in
costly repairs to the condenser as the compressor will inevitably fail.
Reference should always be made to the manufacturer’s recommendations to location

and service space requirements as detailed within installation and maintenance manuals.
Air distribution
Good air distribution is key to an effective and efficient air-conditioning system. Consider
the distribution of air into the conditioned space. Avoid ‘dead zones’ and draughts as they
may lead to the occupants using the controls erratically. Always consider the usage of the
space and the furnishing within the space to avoid any possible ‘short circuiting’ of airflow.
Short circuiting lead to wastage of energy.
Usage & the people factor
Understanding how and when to use the airconditioner is also a pre-requisite for energy
efficiency. Basic functions such as fan speed and louvre angle can be adjusted to improve
efficiency. Use external shading to reduce the amount of light/ heat entering a space, and
louvres can be retrofitted to buildings to provide shade during summer whilst allowing
lower winter sun to penetrate the area. Blinds can also be angled to reduce solar heat
gains whilst reflecting light onto walls and ceilings to reduce demand for electric lighting.
While these are all things that can be done to boost efficiency, all this work can be undone
by the ‘human factor’ – i.e if occupants leave doors and windows open. The answer is not
usually to issue a set of rules, but to encourage staff involvement by demonstrating how
they can be more in control of their own environment. Explain how thermostats operate
and give guidance on recommended operating temperatures and on how to set heating
or cooling units correctly. This is more a people issue than a technical one, but vital to the
overall performance and efficiency of a system.
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4.3 Installation Guidelines
Table 7: Typical Split AC Installation Guide
Part 1 - Setting up the Indoor Unit
1 • Select an unobstructed location on your interior wall to mount the indoor unit.
• Choose a spot away from direct sunlight and heat sources for the best results.
• Choose a location with studs to ensure the wall is strong enough to hold the weight of the
unit.
• Mount the unit 7 feet (2.1 m) off the floor and ensure there’s at least 6–12 inches (15–30
cm) of open space on every side of the unit to allow for proper airflow.
• Install the unit at least 3.3 feet (1.0 m) away from antennas and power or connecting lines
that are used for television, radio, home security systems, intercoms, or telephones. The
electrical noise from these sources could cause operational problems for the air
conditioner.
• Avoid locations where gas may leak or where oil mist or sulfur exists
2 • Secure the mounting plate to the interior wall.

• Hold the mounting plate against the wall where the indoor unit is to be installed.
• Use a level to make sure it is both horizontally and vertically level.
• Use a pencil to mark the locations of the screw holes, remove the plate, then drill a hole
into the wall where each screw will go.
• Position the plate so it matches up with the holes, insert plastic anchors into the holes,
and secure the plate to the wall with tapping screws
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3 • Drill a 3 in (7.6 cm) hole through the wall to feed the pipes outside.
• Make a mark in the center of the hole in the mounting plate.
• Use a keyhole saw or a drill with a hole-cutting attachment to create a circular 3 in (7.6 cm)
opening through the wall that slopes slightly downward toward the ground to ensure
adequate drainage.
• Make sure there are no pipes or wires behind the wall before drilling or cutting the hole.
4 • Check the electrical connections on the indoor unit.

• Lift the A/C unit’s front panel and remove the cover.
• Make sure the cable wires are connected to the screw terminals and that the wiring
matches the diagram that came with the unit.
5 • Run the pipes and cables through the hole in the wall, then connect them to the unit.
• Secure the included copper pipes of the unit and additional copper pipe run, power cable,
and drain pipe together with electrical tape. Place the drain pipe on the bottom to ensure
a free flow of water.
• Ensure the additional copper pipe runs and interconnecting wires are as specified in the
instruction manual.
• Run the pipes and cable through the hole in the wall, then secure them to the designated
spots on the indoor unit as directed by the instruction manual.
• Minimize how much the pipes and cable bend to ensure that the unit performs well.
• Make sure that the drainage pipe allows water to drain in an appropriate place. See the
instruction manual included with the kit for more information.
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6 • Secure the indoor unit to the mounting plate.

• To attach the air conditioner to the wall, simply align the female connections on the back
of the unit with the male connections on the mounting plate.
• Press firmly to secure the unit in place.

• Make sure the unit tilts backward 2-3 degrees so that water can flow out of the drain pipe.
• Refer to typical manufacturer’s instruction manual for installation detail
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Part 2 - Installing the Outdoor Condenser (on Ground level)
1 Position the outdoor unit away from any heavily trafficked, dusty, or hot areas.
Find the hole drilled through the mounting plate for the interior unit and position the exterior unit
within 50 feet (15 m) depending on unit capacity or as specified in the instruction manual, so the
piping and cable can easily be attached.
Choose a location with at least 12 inches (30 cm) of space surrounding its perimeter to ensure
proper functioning. If possible, select a shady location that’s sheltered from the wind in addition
to dust and traffic to keep your unit functioning at its best.
Make sure that no antenna of a radio or television is within 10 feet (3.0 m) of the outdoor
condenser.
Note: Outdoor unit is also commonly installed on wall using galvanised L-support brackets or
installed on roof.
2 • Lay a concrete pad on the ground.
• Don’t place the outdoor unit directly on the ground, as it’s heavy and can shift around on
dirt or rocks. It’s necessary to install the condenser on a concrete pad.
• Position the pad where identified to install the unit and use a level to make sure it’s flat
and even.
• Situate the concrete pad so that it’s high enough to keep the unit out of any water that
may puddle on the ground due to rain.
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3 • Secure the outdoor unit on top of the concrete pad.

• Lay a rubber cushion on top of the pad to minimize vibration,
• Set the outdoor condenser unit on top of the pad.
• Secure the unit to the concrete with anchor bolt.
4 • Check the electrical wiring in the outdoor unit.

• Remove the cover on the condenser. Refer to the unit’s wiring diagram in the instruction
manual and make sure the wires are connected as the diagram suggests.
• Make any adjustments as necessary.
• Fasten the cables with a cable clamp and replace the cover.
5 • Connect the piping and cable to the outdoor unit.

• Use flare nuts to secure the 2 copper pipes from the indoor unit to the outdoor unit as per
the instruction manual.
• Connect the power cable that runs from the indoor unit to the outdoor unit as well.
• Finally, connect the power supply to a designated outlet.
• Refer to typical manufacturer’s instruction manual for installation detail
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Part 3 - Completing the Project
1 • Bleed the air and humidity from the refrigerant circuit.

• Remove the caps from the 2-way and 3-way valves and from the service port and connect
a vacuum pump hose to the service port.
• Turn the vacuum on until it reaches an absolute vacuum of 10mm Hg. Close the low
pressure knob and then turn off the vacuum.
• Test all of the valves and joints for leaks, then disconnect the vacuum. Replace the service
port and caps.
• Note: When vacuumising, low pressure valve in open position & high pressure valve in
closed position. Before running the AC high pressure valve in open position.
2 • Affix the piping (or trunking/cable tray) to the wall with clamps.
• To ensure the pipes and cables don’t move around or become disconnected.
• Attach them to the exterior wall of your home using the clamps that came with the kit.
• Follow the directions in the manual to ensure the clamps are spaced adequately.
3 • Seal up the hole in the wall using expanding polyurethane foam.

• Spray expanding polyurethane foam into the hole you drilled to feed the cable and piping
through the wall.
• Make sure the hole is completely sealed to prevent hot air or insects from getting through.
• Let the foam dry as per the instructions on the label before turning on your air conditioning.
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4 • Turn on the unit, commissioning and enjoy the cool air!

• All that’s left to do is to start the air conditioner, which can be done from the indoor unit.
It should only take a minute or 2 for cool air to start blowing into the home.
• Commissioning procedures (Refer to Annex 2 Check list) .
Typical Split Air Conditioner Installation as per Manufacturer’s Instruction Manual (Refer Annex 1)
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4.4 Post Installation Checklist
The post-installation check list ensures the user to check the final installation of both the
Indoor unit (IDU) and the Outdoor unit (ODU).
(a) IDU & ODU are installed on solid bases.

(b) Check the refrigerant lines are properly installed with appropriate bending
radius and thermally insulated. Ensure insulation not exposed to UV rays of
the sun.
(c) Condensate pipe is properly installed.
(d) The AC unit is earthed.
(e) Batteries are inserted in the remote-control.
(f) The hole in the wall for refrigerant pipes is properly sealed.
(g) Installation manual recommendation has been followed on restrictions.
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5. AIR CONDITIONING SERVICING & MAINTENANCE
An effective air conditioning system is an important feature within a property as it promote

a comfortable stay at home and also create a conducive working environment. Many
property owners invest in quality and expensive systems but don’t ensure that the AC
units are regularly serviced.
Aircon systems parts are susceptible to regular wear and tear, depending on the hours of
operation. This wear and tear cause the units to lose some of their efficiency every year.
A poorly maintained aircon unit consumes more energy in order to function normally.
Regular air conditioning helps the AC unit to run at almost optimum efficiency and serve
the property for an extended period.
5.1 Importance of regular AC maintenance and servicing.
Improves efficiency & save electricity
AC servicing helps to improve its efficiency so that it can work the way it is supposes to
and also help to save on electricity bills as it will not be using extra energy to work. An
efficiently running AC unit consumes less power than a poorly maintained air conditioning
unit. This means that by failing to have the AC unit inspected and serviced regularly, this
end up in incurring high energy bills
Prolong lifespan
AC servicing is vital as it helps to prolong the lifespan of the unit. This is because it is well
taken care meaning that any defects are taken care of on time to ensure that it runs the
way it is supposed to without any problem. Failure in some parts of your unit compromises
the entire unit and this reduces the lifespan of the unit. Investing the small amount needed
to schedule regularly servicing helps saves on long-term costs.
Reduces Emergency Repairs
Poorly maintained ac units are bound to experience numerous and unexpected

breakdowns. This is due to the fact that minor damages that you may not easily notice
tend to grow into major problems which may require costly repairs. However, by having
your unit regularly inspected, minor issues are able to detected early enough and fixed.
If there are any parts that have suffered wear and are damaged, they can be repaired or
replaced.
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Improves the air quality
Air conditioners help purify the air we breathe in through filters. These filters trap dust and
dirt particles. It is, therefore, essential to ensure that these filters are regularly cleaned or
replaced. Failure to clean and replace these filters causes the trapped pollutants and
allergens to find their way back into the air. It is important to make sure that the occupant
is breathing clean and healthy air at all times. Most people like to switch on the aircon at
night hence it is important to ensure the unit is serviced so that only quality air circulate
in the house which is fee from germs and other types of bacteria. This will definitely reduce
the trips made to the doctor which and help save money and time.
Prevent water leakage
When the air conditioner is filled up with dirt and fungus, it will definitely not function in
the proper way. This usually leads to water leakage which can cause material damaged.
Servicing the unit corrects this problem on time to ensure the air con is used without this
problem.
Hence, there are clearly considerable benefits of having the air conditioning unit regularly
serviced and maintained. Not only are there financial gains but also one can enjoy an
efficiently working air conditioner.
Air conditioner should be serviced regularly especially before the start of the warmer
weather. A technician will come out to inspect and service the air conditioner. This will
keep things in running order and helps spot potential trouble.
The technician will give the unit an overall inspection, looking for any signs of trouble.
They will test the voltage, inspect the overall condition of the unit, check the refrigerant,
and examine the drainage lines.
Figure 10: Air conditioner inspection
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They will inspect the blower motor and test the thermostat to ensure proper operation. A
motor that is drawing too many amps may be about ready to fail completely. A thermostat
that doesn’t engage the unit when it’s supposed to could need adjustment or replacing.
The air filter will need to be checked every month. The technician will check it as part of
the servicing. They should also clean various parts like the compressor, condenser,
evaporator coils, and drainage line.
Figure 11: AC indoor unit servicing
Finally, they should test refrigerant levels and observe the air conditioner function through
a complete cycle. If any problems are still present, they should report and recommend
repairs.
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5.2 Basic Maintenance & Servicing of AC Unit
• Turn off the power to the unit by switching off the DP switch.
• Switch off the circuit breaker at the electrical panel.
• Follow the steps as detailed below.
Table 8: Basic maintenance & servicing steps Split type AC (Indoor & Outdoor units)
1 Step 1: Clean filter.
• The simplest and most effective way to keep the air conditioner running smoothly is
cleaning the filter regularly (on monthly or quarterly basis).
• By regularly cleaning the filter, a lot of the burden on the system is reduced. A dirty or
clogged filter makes the air conditioner work much harder than does a clean filter.
• Cleaning the filters regularly is easy on the budget and easy on the system as well. This
will lower the utility bill and will extend the life of the air conditioner.
2 Step 2: Keep coils clean.

• The air conditioner coils and fins on the outside of the unit need to be kept clean and
clear of obstructions. Leaves and other debris sometimes accumulate around the unit.
If obstructions are present, the unit must work harder to function than it should. The unit
can be cleaned with a regular garden hose and a broom. Splashing of water on electrical
components is to be avoided.
• Pressure washer is to be avoided, as the strong spray could cause harm to the system.
A little bit of housekeeping in this regard goes far toward keeping the air conditioner
working optimally.
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3 Step 3: Keep surrounding shrubbery trimmed.

• If shrubbery around the unit have been planted to hide it from view, be sure adequate
space is maintained around the unit so that it function without obstruction.
• A quick trim will do the trick.
4 Step 4: Adjust the thermostat.

• The thermostat settings on the remote control is to be checked regularly as the season
varies. This will lessen the amount of time the unit has to work each day and will
lengthen its life cycle.
• An additional benefit will be a lower utility bill each month. Pre-programming the
thermostat to match the schedule so that the room can be pre-cool is also possible.
5 Step 5: Check the seal.

• Ensure all doors & windows are properly sealed to help keep the home/room cool. The
less cool air that escapes from the room, the less the unit will have to work.
• A trained HVAC technician can detect most problems before they become major ones.
A typical tune-up will include various tests to ensure that the unit’s internal parts are
functioning correctly, as well as a filter check, and a refrigerant charge if needed.
• The technician will likely also clear the drain, and clean the unit thoroughly inside and
outside.
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Table 9: General Servicing Split type AC (Indoor & Outdoor units)
1. Clean the evaporator coils.

• Open the cover and use the soft paint brush to dust off the coil.
• Next, spray the coil with coil cleaner, letting it drip into the drain pan.
• Afterwards, clean the drain pan with soap and hot water.
• Make sure the drain flows freely. If it does, skip the next step.
2 Clean the evaporator drain.

• This is usually a 1-inch PVC pipe coming off the evaporator enclosure. Follow it to where
it drains out.
• Attach the wet/dry vacuum to this end, sealing it with duct tape or with a rag.
• Remove the vacuum’s filter to avoid damaging it and turn the vacuum on for 2-3 minutes
to clear out any blockage.
3 Clean the filter.

• This should be done on a monthly or quarterly basis.
4 • Turn the power back on and let it go through a full cycle. If it’s not cooling like it used to,
diagnose the cause and inform of the repairs.
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5 Clean the condenser.
• If it’s at ground level, it is more likely to have debris than at the roof.
• Remove the grate over the fan and vacuum any debris found inside.
• With a garden hose, spray the fins from the inside out. (Never use a pressure
washer. The fins are very thin and can damage easily.)
• All rusty parts are to be treated with anti-corrosion products and final coat of
paint to match condenser.
6 Inspect the fins.
• They are very thin and bend easily. If damaged spots are noticed, like where the
fins are flattened, straighten them gently with the butter knife or fin tool.
• Be careful not to damage the tubing within the fins.
7 Good housekeeping
• Rake any ground-level debris away from the condenser and prune any branches
or bushes away at least two feet.
A maintenance checklist is provided at Annex 3.
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5.3 Good Servicing practice of HCFC/HFC-based Air Conditioners during repairs
In domestic air-conditioning appliances, HFCs are the most commonly used replacement
for HCFC refrigerant. Step-by-step procedures for good servicing practices for both HCFC
and HFC-based appliances
5.3.1 HFC/HCFC Servicing Steps
1) Recover the HCFC or HFC into a cylinder using a recovery machine for split air-
conditioners.
2) Flush and clean the refrigeration system with nitrogen.
3) Do the necessary repair work on the appliance, as required. The system should
stay open for as little time as possible. In case required for HCFC/HFC-based
appliances, change the filter drier.
4) Flush using oxygen-free dry nitrogen to ensure that nitrogen flows freely.
5) Leak test with dry nitrogen or an electronic leak detector. Release nitrogen into
atmosphere (charge a small quantity of refrigerant and remaining nitrogen into the
system, while using electronic leak detector).
6) Evacuate to lowest pressure, check if vacuum holds.
7) Charge HCFC/HFC or HFC blend.
8) Run unit and check its performance.
These steps are elaborated in detail in the table below.
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Table 10: Good servicing practice during repairs
1 Step 1: Recovery of HCFC/HFC Refrigerant

Both HCFCs and HFCs are greenhouse gases, and HCFC have ODP as well. It is recommended to recover the pure
or azeotropic refrigerant in a cylinder rather than venting it out in the atmosphere.
To recover the HCFC or HFC, the following tools are needed:
• A good recovery machine (preferably an oil-less compressor) and

• A recovery cylinder
2 Step 2: Cleaning and Flushing
• Cleaning and flushing are important steps. Synthetic and hygroscopic oils must not be exposed to ambient
conditions for extended periods of time. The HFC and POE combination is very sensitive to contamination,
therefore, proper cleaning and flushing of system is required. Once the old filter is removed, the system needs
to be properly flushed and cleaned of micro particles.
• The following good practices are advised for cleaning and flushing the system:
• Always use dry nitrogen at about 5-10 bar (70-140 psig). The nitrogen cylinder must be fitted with a two-stage
regulator. It must have a proper regulator.
• ODS ref gas, should not be used. Use ODS-free substances when chemical cleaning is required. There should
be no traces of liquid chemical after the cleaning is done. Technicians must be aware that exposure to any of
the chemicals by inhalation, eye and skin contact or ingestion is toxic to humans.
• Technicians must wear personal protective equipment (PPE) while handling chemicals.
• Atmospheric air contains moisture, which is detrimental to the RAC system. Use of air should be totally avoided,
especially with HFCs or HCFCs.
3 Step 3: Repair the System
• Carry out all necessary repairs.
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4 Step 5: Pressure Testing and Leak Detection
• Pressure testing to check for leakage in the circuit should be done after repairs using oxygen free dry nitrogen
(OFDN).
• The test pressure can be 1.5 times the working pressure. In case of air conditioners, it may be about 20 bars.
Test pressure varies depending on the refrigerant.
• For instance, R-410 around 43 bars for test pressure.
• The given pressure is to be monitored over a period of time (may be 15 to 20 minutes) in order to check for a
fall in pressure.
• Use electronic leak detector and look for leakage if any.

6 Step 6: Evacuation – HCFC/HFC
• Evacuation is very important to remove non-condensable gases and moisture from HCFC/HFC refrigerants.
• HFC systems need deeper vacuum than HCFCs (500 microns or lower) because of hygroscopic nature of
polyol ester oil.
• A two-stage vacuum pump, capable of pulling vacuum between 20 to 50 microns at blank off is required. A
micron gauge capable of reading between 5 to 5000 microns is required to make accurate measurement of the
vacuum.
6a Evacuation – 1st step
• First make proper connection to the vacuum pump (or the manifold) connecting an appropriate hose to the
access valve. Then switch on the vacuum pump and open the valves. Run the pump and evacuate till the
gauge shows the lowest vacuum at which it holds steady. This level should be around 500 microns or preferably
lower.
• Next, close the valve to isolate the vacuum pump from the manifold and observe the rise in pressure (vacuum
holding). The pressure should not rise beyond 1,500 microns (the lower the better) in 5 to 10 minutes. This is
an indication that most of the moisture is expelled. Of course, lower readings like 500 microns or so are even
better and welcome.
• In case the pressure increase is greater, the system should be evacuated once again and the vacuum holding
repeated.
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6b Evacuation – 2nd step
• After the vacuum gauge shows the vacuum, close the valve and remove the micron gauge.
• Then attach the charging cylinder with valve in close position.
• Again run the vacuum pump for two minutes with side valve in open position to remove the non-gases from the
charging hose. By doing this there will be no need to purge the refrigerant from the charging hose.
Recommended Evacuation – R-410A
• With R-410A, technicians need to follow good practices, including deep vacuum. The following is the
methodology for performing a vacuum for R-410A air conditioners:
• Step 1: Evacuate the system to 1,000 microns from both service valves. To measure the vacuum, a vacuum
gauge must be used at all times—do not use a system manifold gauge.
• Step 2: Break the vacuum with oxygen free dry nitrogen to 14 psig (1 bar approx).
• Step 3: Evacuate to 500 microns.
Step 4: Repeat Step 2.
Step 5: Evacuate to the lowest pressure that pump will achieve (200 microns for a minimum of 1 hr).
7a Step 7a: Charging by weight
• Following charging method should be followed:

• Charge always in a well-evacuated system.
• Charging should be done slowly and gradually, so that no liquid goes into the compressor.
• Charging should be done by weighing accurate mass of charge; this is essential for good appliance
performance.
• In case excess refrigerant is charged by mistake, the excess refrigerant charge should not be vented out. It is
better to release the full refrigerant and recharge the recommended weight after evacuation.
• Charge the exact same weight of refrigerant in the system as recommended by the appliance manufacturer
instead of charging by feel (To ensure good cooling performance and low energy consumption
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7b Step 7b: Avoid Overcharging!
• Undercharging an air-conditioner results in a relatively low condensing pressure. But when a technician charges
by feel, once the refrigerant is charged, the condensing pressure rises until a given liquid level is obtained in
the condenser/receiver.
• While the condenser/receiver is being filled, the pressure remains constant.
• Once the condenser/receiver is full, refrigerant backs up into the condenser, the useable condenser area is
reduced and the condensing pressure rises further.
• The caution is “Avoid Overcharging.

8 Step 8: Checking Proper Operation
• As a final step, the air-conditioner should be switched on and the following parameters verified to ensure that
it is operating correctly:
• Grill temperature—the return air temperature and grill temperature difference must be between 10°C to 15°C,
depending upon wet bulb temperature; compressor current and extraneous vibrations.
• If there are vibrations, remove them with anti-vibration pads.
Source: Good servicing practices-Phasing out of HCFC in the RAC servicing sector – UNEP: 2015
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5.3.2 Leakage
Why does leakage occur?
1. Refrigerant leaks are caused by material failure. The material failure is normally
attributable to one or more of the following factors:
2. Vibration – Vibration is a significant factor in material failure and is responsible for

“work hardening” of copper, misalignment of seals, loosening of securing bolts to
flanges, etc.
3. Frictional wear – There are many cases of frictional wear causing material failure,
and they vary from poorly-fixed pipe work to malfunctioning shaft seals.
4. Incorrect material selection – In a number of cases, the use of inappropriate

materials leads to leaks. For example, certain types of flexible hoses are known
to leak, while other materials cannot hold up to vibration, transient pressure
and/or temperature changes.
5. Poor quality control – Unless the materials used in the refrigeration system are of
a high and consistent standard, changes in vibration, pressure and temperature
will cause failure.
6. Poor connections – Poorly made connections, such as brazed joints, flare

connections, or valves without caps, can allow refrigerant to escape.
7. Corrosion – Exposure to a variety of chemicals or harsh weather can result in a

variety of different types of corrosion, which decay the construction material and
result in pitting on pipes.
8. Accidental damage – Accidental mechanical impacts to refrigerant-containing

parts can happen under many circumstances, therefore it is important to ensure
that all parts of the system are protected against external impacts.
9. Air conditioning systems are designed to operate correctly with a fixed charge of
refrigerant. If it has been determined that a system has insufficient refrigerant, the
system must be checked for leaks, then repaired and recharged.
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Different Methods – Leak detection
- Leak Detection by Oil Stains
A trained service technician can identify a leaking system by observing the presence of
oil stains on the outside of the equipment. If refrigerant leaks out, lubricant oil leaks out
as well, but it does not evaporate rapidly and remains on the outside of the equipment
and pipes, indicating the leak area.
- Leak detection with Electronic Leak Detector
Electronic refrigerant detectors contain an element sensitive to a particular chemical

component in a refrigerant. The device may be battery or AC-powered and often has a
pump to suck in the gas and air mixture. Often, an audible “ticking” signal, and/or flashing
indicator lamp increases in frequency and intensity as the sensor finds higher
concentrations of refrigerant, which in turn leads to the source of the leak.
Figure 12: Electronic leak detector
Many refrigerant detection devices also have varying sensitivity ranges that can be
adjusted. Many modern refrigerant detectors have selector switches for switching
between refrigerant types, e.g., HCFCs, HFCs, or HCs.
When using electronic refrigerant detectors in a workshop, always ensure good ventilation
since sometimes it gives false signals due to other refrigerants being present in the
surrounding area.
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5.4 Do’s & Don’ts in Air Conditioning Servicing
5.4.1 Common Practices that are damaging to Air-conditioning Systems

• Flushing with air / refrigerant
• Use of petrol for cleaning
• Leak testing using air/refrigerant
• Self-evacuation using system compressor or a used compressor as vacuum
pump
• Improper assessment of vacuum achieved
• Charging by feel
• Contamination/Cross contamination of refrigerants
5.4.2 Area of focus
• Good tools • Cleaning & Flushing

• Tube cutting, Deburring • Leak Testing
• Flare fitting • Evacuation
• Swaging • Measurement & Holding of vacuum
• Bending • Charging of refrigerant
• Brazing • Cross contamination
5.4.3 Good Tools
Using proper tools and equipment leads to accuracy, reliability, responsiveness and
credibility - the essential elements of quality service. In order for a refrigeration and air-
conditioning system to be properly evacuated and dried, a technician needs to use the
correct vacuum pump.
Tools like flaring tools and torque wrenches are required for more recently developed
refrigerants, and these need to be of good quality. In order to properly handle and service
these new refrigerants, facilities need to be upgraded in terms of tools and equipment.
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Many cheap tools and equipment are available on the open market, but they are not
always accurate and their quality is uncertain. It is essential to have the right tools for the
right job.
In order to have a good set of tools and equipment, technicians must understand the
importance and benefits derived from each of them.
Since HCFC refrigerants are being phased-out, many alternatives are being
commercialised. The level of accuracy required by these new alternatives is relatively
high, making it that much more important to understand the use of each tool and
equipment.
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Table 11: Good practices in AC Maintenance
1. Tube Cutting and Deburring

• Tube cutting, a basic technical operation, is a good place to start with good practices. In the
same way that if the base of a building is strong, you can construct a multi-storey building,
proper tube cutting is an essential first step for a strong RAC system.
• The technician must cut the tube by slowly rotating the wheel, adding pressure on every two
rounds to cut the tube perfectly. After cutting, the pipe should be deburred from the inside
and outside.
2 Flare Fitting
• As new refrigerants enter the market and technicians need to work on increasingly high
pressures, they need to be able to prepare the right kind of flare fittings to tolerate these
pressures.
• A suitable flaring tool needs to be used so that the integrity of the copper is not compromised
when it is flared.
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3 Swaging
• After the tube is properly cut and cleaned, it is ready to be swaged.
• Many technicians use the hammer and swaging tool. After insertion, they try to give the tool
a soft blow to enhance the gap of the swage.
• This method results in a lot of play in both the pipes, which ultimately leads to poor brazing.
• The new tool available on the market. It is like a flaring tool, but the technician changes the
flaring cone with the swaging bit, which comes in a set of different sizes.
• Remember to rotate the handle twice to loosen it, and then rotate and tighten again.
• Repeat the process until the desired swaging is reached.

4 Bending
• Often, when a tube is small, technicians bend it by hand.
• The problem with this practice is that it is impossible to see any wrinkles on the inside of the
tube with the naked eye, and if there is a wrinkle, it will restrict the flow of refrigerant.
• Always use a pulley type tube bender so the tube will be correctly bent.
• In some countries there are still a few technicians who use a spring-type bender but they
should be encouraged to change to the pulley type bender for greater accuracy.
5 Essentials of Brazing: The key aspects of brazing:

• In brazing, the base metals to be joined, copper (Cu) andiron (Fe) are never melted, but are
heated to a temperature below their melting point (above 650°C but below the Cu melting
point, 1,083°C). The filler rod, made of a special alloy, melts at these temperatures when it
contacts the heated metals.
• The brazing rod should melt on contact with the heated Cu tubes and should never be heated
directly by the torch flame and melted onto the joint. This can happen only if the Cu tubes
have been heated to the appropriate temperatures.
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• The filler rod that has melted on contacting the heated base metals (Cu tubes) flows into the
clearance between the overlapping Cu tubes by capillary action. This capillary action will take
place only when the clearances are maintained within certain limits.
• The figure shows a cross-section of the inner and outer tubes being brazed, along with the
molten filler material. The melted filler rod, now liquid, coats the surface of the Cu tubes and
penetrates superficially into their surface.
• This process forms a strong metallurgical bond between the outer surface of one tube and
the inner surface of the other tube where this overlap is formed. The boundary-locking layers
in the diagram show the metallurgical bond.
5a Good Brazed Joints: Prerequisites
(a) The first thing to be done before starting to braze is to ensure that the joints are correctly
prepared. This involves a thorough cleaning of the surfaces to be joined, using emery or wire
brush to leave a clean and bright surface. This will ensure removal of all dirt, grease, oil and
other impurities that might be present on the surfaces and can prevent proper coating of the
surfaces.
The second thing is to ensure that the clearances between the two tubes to be joined are
maintained correctly. The ideal clearance would be between 0.05 mm to 0.200 mm. If the
tubes are the same diameter, this can be achieved using good swaging tools.
(b) The next important aspect is the brazing temperature, which is a result of the right
combination of fuel, torch and flame. The best results can be had using oxy- acetylene
(c) It is also essential to use the right brazing filler rods. For Cu to Cu brazing, filler rods consisting
of 7.5% phosphorus and the rest Cu (known as Phos Cu) can be used without a flux, as
phosphorus itself acts as a good flux. Brazing rods with 2% silver (Ag) can also be used,
preferably with a flux, as Ag lowers the melting temperature.
For brazing copper to a different metal (Cu to Fe), filler rods containing phosphorus must be
strictly avoided. For Cu to Fe brazing,rods containing at least 35% Ag must be used with a
flux, the balance composition of the rods being Cadmium and Zinc (Cd and Zn).
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(d) Finally, brazing operation with a torch must be done in a way that ensures that the base
metals (the tubes) are heated in a manner that facilitates the flow of the molten filler rod into
the clearances.
7 Cleaning and Flushing:
(a) Compressed air should never be used for flushing, particularly when a hermetic compressor
is used to generate the compressed air. This is because the compressed air contains
moisture and other gases and the lubricant from the compressor will contaminate the system.
Instead, use only dry nitrogen. It is inert and will also absorb some of the moisture in the
system.
(b) Oxygen in the air can react with the compressor oil, while moisture in the air can be absorbed
by the compressor oil. This is particularly critical for compressors running on HFCs.and POE
lubricants.
(c) Whenever chemical cleaning is needed to clean contaminated systems and use ODS-free
alternatives, technicians must be aware of the toxic effects of these chemicals on human
health (technicians should read the Material Safety Data Sheet on each chemical before use).
These effects can occur after inhalation, eye or skin contact, or ingestion. Technicians must
wear personal protective equipment (PPE) while handling these chemicals. Any chemical
poured inside the RAC system for cleaning must be vaporised out of the system.
(d) Though not at all recommended, petrol is sometimes used as a cleaning agent. This is not a
good idea since commercial petrol contains all sorts of impurities that will contaminate the
system.
8 Leak Testing
(a) Leak testing should always be done using dry nitrogen because it is inert. Dry nitrogen also
absorbs moisture inside the system. Compressed air or oxygen should never be used for this
purpose.
(b) The same reasons that prohibit using air for flushing, mentioned earlier slide, hold for leak
testing.
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(c) The advantage of dry nitrogen is that it absorbs a good bit of the moisture present in the
system and reduces the moisture removal load of the vacuum pump during the next step of
evacuation.
(d) When using an electronic leak detector, a small quantity of the refrigerant is introduced as a
tracer gas and mixed with nitrogen, since the electronic leak detector never senses Nitrogen.
9 Equipment for Evacuation
(a) Using the appliance’s compressor for evacuation (‘self-vacuuming’) is a common practice in
the field. It is a bad practice, as not only does not evacuate all the moisture and other gases
out of the system, but it also damages the compressor.
(b) Reciprocating refrigeration compressors cannot produce the vacuum necessary to evacuate
all the moisture. Further, using the appliance compressor as a vacuum pump can deposit
moisture in the discharge chamber and valves, resulting in compressor deterioration. It can
also pump out lubricant oil, which can lead to compressor failure.
(c) The same reasons hold for separate reciprocating compressors being used as vacuum
pumps. The vacuum created will be just as inadequate to boil out all the moisture in the
system.
(d) Moisture is present in the system as tiny droplets of condensed liquid, usually water. It can
be removed only by boiling, which can be done either by heating or by creating a deep
vacuum. On site, the most practical way to remove moisture is create a vacuum in the system
deep enough to boil off the water. Water boils at 25°C at a vacuum of about 1” Hg or 25,000
microns. To ensure complete and rapid boiling off, a vacuum of at least 500 microns has to
be reached.
(e) Reciprocating refrigeration compressors generate vacuum of about 76,000 microns. Single
stage rotary vacuum pumps are normally used for vacuum levels of about 76,000 microns. It
is therefore essential to use a two-stage rotary vacuum pump to reach levels of 100 to 200
microns at a fairly good speed of pumping, particularly for refrigerants like HFCs and HCs.
This will ensure that most of the water in the system will have boiled off.
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10a Equipment for Evacuation (Two stage)

(a) The reasons for using two-stage rotary vacuum pumps have been outlined previously.
Evacuation is necessary for all HFC refrigerants, which, along with their lubricating oils, are
highly hygroscopic. Moisture, if present, leads to other problems like sludge formation and
capillary choking.
(b) The two-stage rotary vacuum pumps are able to pull vacuum to about 100 microns because
of their construction (a rotary multi-vane pump) and the excellent sealing done by the vacuum
pump oil, which serves as both lubricant and sealant.
(c) Reciprocating refrigeration compressors cannot produce such deep levels of vacuum
because of the clearance volume in the pumping chamber or cylinder, and also because the
sealing is not as good as in rotary vacuum pumps.
11 Charging
(a) The performance of capillary-fitted air-conditioning systems, both in terms of cooling as well
as energy consumption, is optimum at a particular charge weight, which is normally defined
by the appliance manufacturer on the nameplate.
(b) It has been shown that energy consumption (kWh/day) increases sharply if the charge is
lower or higher than the optimum weight.
(c) The most sensitive appliances are those fitted with HCs, where the charge weight is less than
50% of the equivalent HCFC-22 system.
(d) Thus, after carrying out any air-conditioning system repair or servicing, it is best to recharge
the system with the amount of refrigerant specified by the manufacturer.
12 Contamination and Cross-Contamination
• Contaminants: If sufficient care is not taken during servicing, refrigerant systems can be
contaminated by moisture, non-condensable air (particularly if evacuation is not done
thoroughly), chemical residues, dirt or dust.
• Cross-Contamination: In addition to the above sources of contamination, there is also the risk
of cross-contamination, which is the introduction or contaminants into an AC system from
another system or equipment used during servicing.
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• This can happen when the same refrigerants recovery cylinders are used for refilling different
refrigerants.
• This will seriously affect appliance performance
13 Likely Sites for Refrigerant Cross-Contamination
1. The most common sites for substantial refrigerant residues are the evacuation & charging (E&C)
units and the recovery and recycling (R&R) machine condensers. In both of these cases, where an
E&C unit or a R&R machine is used for more than one refrigerant, there is the potential for cross
contamination.
In order to avoid this, the following action Is recommended:
(a) Empty out the residual refrigerant completely before using a different refrigerant and evacuate
the E&C unit or R&R machine, preferably to 1,000 microns, before reuse. This ensures
removal of almost all traces of residual refrigerant.
(b) It is better however, if separate machines are used for separate refrigerants.
2. Other potential sources of contamination are recovery cylinders. It is absolutely essential to use a
separate cylinder for each and every type of refrigerant.
3. When retrofitting old systems with substitute refrigerants, it is necessary to remove all traces of old
refrigerant oil through deep evacuation and changing of refrigeration oil is recommended.
14 How to Avoid Cross-Contamination
• Perform a deep vacuum up to 1,000 microns or less before switching to a new refrigerant.
• And if possible, use separate E&C and recovery machines for each type of refrigerant.
• Make sure that separate recovery cylinders are used for each refrigerant.
Source: Good servicing practices-Phasing out of HCFC in the RAC servicing sector – UNEP: 2015
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6. ENERGY EFFICIENT AIR CONDITIONING UNITS
The demand for air conditioners is increasing rapidly across the world, especially with hot
climates.
The sales of air conditioners are growing significantly in emerging economies such as
Brazil, India and Mexico as the standard of living improves. The same trend is being
witnessed in Mauritius with the growing number of residential projects.
The global air conditioner stock is expected to increase from 660 million units in 2015 to
more than 1.5 billion units by 2030, significantly increasing CO2 emissions from this
sector. Additionally, the peak power demand from air conditioners can threaten the
stability of electrical grids.
In 2015, room air conditioners accounted for approximately 20 per cent of the residential
electricity demand in 150 developing and emerging countries.
Air conditioning makes up a significant portion of household energy demand in particular

in regions with hot climates where periods of high use correlate with peak power demand
in hot summer days, since many AC units operate at the same time and therefore
increasing the electricity demand.
They are, thus, key driver of growing GHG emissions. This is because air conditioner
refrigerants have a significant climate impact, and their electricity consumption increases
GHG emissions from fossil fuel power.
Meeting the growing electricity demand from air conditioners is a national & global
challenge to policy makers. However, it also presents a unique opportunity for energy
savings and GHG reductions through well designed regulations to transform the markets
and find cost effective, energy saving measures to respond to consumer demand.
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Figure 13: Residential Energy Use
Source CEB Guide
This chapter focus on the transition to energy efficient air conditioners for the household
market.
6.1 Global & local market development of energy efficient air conditioners
• Air conditioning stock – AC demand on the rise & expected to accelerate in next
decade; AC stock estimated to reach 1.5 billion units in 2030.
• Air conditioning sales & growth – Global annual AC sales over 60M units in 2014
and expected to reach 300M in 2030
• The air conditioner markets worldwide are growing at an average pace of 10% per
year.
The market for split air conditioners is growing the fastest, representing 88% of worldwide
room air conditioner sales. The market for window air conditioners is declining or
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disappearing in some countries. Window air conditioners are still very popular in the US,
where they accounted for more than 90% of room air conditioner sales in 2014. (Source
U4E 2017)
From the survey carried out during this assignment, installation of the window units the
last five years has not been recorded by any local AC suppliers.
Inverter split air conditioners are widely available in markets such as EU, Japan, China,
India & other developing economies.
From the survey carried out during this assignment the sales volume of inverter split units
is increasing every year among the AC suppliers
Benefits of transitioning to high efficiency air conditioners
The benefits of transitioning to high efficiency AC and low GWP developed for 150
developing countries and emerging countries are as follows:
Annual Energy Savings (electricity consumption):
An estimated 620 TWh/year of electricity can be saved in 2030 if the best currently
available technology for air conditioning is adopted.
Lower Emissions:
Improving room air conditioning efficiently (~30% more efficient than current technology)
in parallel with low GWP refrigerants in these products could avoid up to 480
megatonnes of CO2 in 2030.
Financial Savings:
Up to $56 billion ($ 17 billion only for India) can be saved cumulatively for consumers
through 2030 by improving air conditioner energy efficiency policies. (Source U4E 2017)
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Figure 14: Benefits of transitioning the High Efficiency AC
6.2 Efficiency gains from High Efficiency air conditioners
There are multiple options to improve energy efficiency of air conditioners. These include
the use of more efficient technologies and components such as inverter/variable speed
compressors, fans, heat exchangers, expansion devices and refrigerant fluids.
If applied altogether, these improvement options could save between 60-72% of energy
compared to a base case model (defined as a non-inverter split AC unit. In general, higher
costs and size constraints are some of the barriers to include more efficient components
in air conditioners.
Figure 15: Efficiency gains for High Efficiency AC
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6.3 Solar air conditioning
Solar air conditioning refers to any air conditioning (cooling) system that uses solar power.
This can be done through solar thermal energy conversion and photovoltaic conversion
(sunlight into electricity).
The solar air conditioner with photovoltaic conversion can be off grid type which uses DC
batteries or the hybrid air conditioner which have dual purpose DC power & AC power
through the inverter.
Figure 16: Solar AC off grid type Figure 17: Hybrid Solar AC using DC & AC power
Figure 18: Solar AC with solar collectors Figure 19: Solar Ac with solar collectors
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The solar air conditioner which has the solar thermal energy conversion uses solar plate
collectors mostly the evacuated tubes.
Solar air conditioning has not yet been gathering momentum in the local market since the
few prototypes installed on a pilot basis has not reaped the required success.
Moreover, from the survey carried out during this assignment, not a single local supplier
(among 17 suppliers interviewed) have installed a solar air conditioner the last five years.
Hence not much first-hand information is currently available on the type of solar air
conditioners which best suit our climatic conditions & which can become the future in the
energy efficient AC units.
6.4 Performance Metrics, Energy Efficiency Ratio (EER) & Seasonal EER (SEER)
The ISO 5151 has been adopted by most countries as a reference test standard for
measuring air conditioners’ cooling capacity and efficiency. However, not all economies
are aligned with ISO 5151, and some differences remain between test methods. North
American (and some South American countries) follow standards set by ASHRAE.
The EER and SEER are the two main types of metrics in use internationally to rate energy
efficiency of air conditioners.
The energy efficiency of an air conditioner is generally expressed by its coefficient of

performance, also called Energy Efficiency Ratio (EER).
The EER is the ratio of the cooling capacity and the power consumed when measured at
full load (i.e., at the maximum deliverable cooling capacity of the air conditioner). This
EER has been the basic parameter used to indicate the energy performance of air
conditioners in Minimum Energy Performance Standards (MEPS) and energy efficiency
labelling regulations.
Given that air conditioners typically operate at full load for only a small number of hours
in the cooling season, EER is often not the best representation of air conditioner
performance especially for variable speed systems since it does not take into account
performance at part-load. Many countries (China, EU, India, Japan, Republic of Korea,
US) have transitioned to the Seasonal Energy Efficiency Ratio (SEER) as a metric to rate
performance and capture part-load performance.
The SEER represents the expected overall performance of an air conditioner for a typical
year’s weather in a given location. Instead of being evaluated at a single operating
condition, the SEER is calculated with the same indoor temperature, but over a range of
outside temperatures over the course of the cooling season.
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6.5 Mauritius Standard for Energy Efficiency & Labelling of AC (MS 200:2013)
An EER metric can be a first step in countries where MEPS are implemented for the first
time, while an SEER (considered a more complicated metric) could be adopted in
countries where standards are already in place and a metric that considers seasonal
performance would achieve higher energy savings.
6.5.1 Labelling Evolution
Product labelling is one of the most direct and effective means of delivering information
about energy efficiency to consumers.
When implemented well, labelling is one of the most cost-effective energy-efficient policy
measures.
The EU Energy labeling is long known & appreciated tool for consumers, advising them
on the energy efficiency and other functional performance qualities of models which are
to be considered for their purchase.
The purpose of Energy Labels is to rank all models of certain type of products within
certain energy class range, typically from A to G or A+++ to D and show the ranking at
the points of sale.
The old labelling classified energy class range from A to G.
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Figure 20: E.g Old label Energy class A to G Figure 21: EU Old label with Energy Class A to G
The new Eco Design label measures are another set of the EU legislation that regulates
the energy consumption and functional performance aspects of products, through setting
of the minimum requirements for the placing on the market. They are based on the
Seasonal Energy Efficiency indicators (SEER) and SCOP (heating function) which
considers the efficiency of the part load condition.
In practice (at the point of sale) these type of products are displayed showing the full
range of energy classes (A+++ to D) but at the same time the eco design legislation
prohibits the market entry of some models below a certain minimum energy class.
6.5.2 Labelling Regulations
The EU Regulations establishes requirements for the labelling and the provision of
supplementary product information for electric mains-operated air conditioners with a
rated capacity of ≤ 12 KW output power for cooling or heating.
6.5.3 Labelling details
The new energy label refers to all Eco Design air conditioning units and is required for
giving useful information of energy consumption and energy classification.
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A comparison has been done between the Eco Design label as ratified by the EU to
explain the information portrayed on the Eco Design label for an Air conditioner currently
available on the local market.
Figure 22: EU Eco design label with Energy Figure 23: E.g Eco Design label for a local
Class range A+++ to D (Reversible type AC) supplier (Reversible – 3 climate zone)
1. Brand name – [ XXX ]

2. Energy classification in cooling mode, A+++ the most efficient [ A++ ]
3. Design load cooling (KW) [ 4.6 ]
4. SEER: Seasonal Efficiency Ratio (for cooling mode), is the cooling season energy
efficiency performance, expressed as the ratio between the reference seasonal cooling
demand in KWh/a and the seasonal electricity consumption for cooling for cooling KWh/a
[ 6.1 ]
5. Annual power consumption in cooling mode. [ 264 ]
6. Sound power level (dB) indoor unit. [ 58 ]
7. Sound power level (dB) outdoor unit.[ 63 ]
8. Indoor’s & Outdoor’s units model name. [ XXX ]
9. Energy classification in heating mode. [ A+++, A+, B ]
10. Design load heating (KW). [ 3.3, 3.3, 5.0 ]
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11. SCOP: Seasonal Coefficient of Performance (for heating mode) is the heating season
efficiency performance, expressed as the ratio between the reference seasonal heating
energy demand in KWh/a and the seasonal electricity consumption for heating which may
vary according to the climate profile chosen in KWh/a. [ 5.1, 4.0, 3.3 ]
12. Annual power consumption in heating mode. [ 906, 1155, 3182 ]
13. European map divided into 3 climate zones.
Below is an Eco Design label for a reversible type Air conditioner (make XXX).
Figure 24: E.g Eco Design label for a local supplier (Reversible – 1 climate zone)
The energy label for air conditioners referred to the Energy Efficiency Ratio (EER,
cooling function) and Coefficient Of Performance (COP, heating function) to express
the energy efficiency of all air conditioners. These indicators are measured at full load
operation only.
For some cooling only units, EER and COP is still applied.
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Figure 25: E.g Eco Design label for a local supplier (Cooling only)
The energy efficiency classes are dependent on the type of air conditioner and the related
SEER/SCOP.
The Energy efficiency classes as defined by EU Regulation 626/2011 Table 21 is

tabulated below. Also, EU Regulation 626/2012 Table 21 which shows the minimum
efficiency requirements and Table 23 which shows the requirements for maximum sound
power level for air conditioners are reproduced below.
Table 12: Energy Efficiency Classes for AC
Energy Efficiency Class SEER SCOP

A+++ SEER ≥ 8.50 SCOP ≥ 5.10
A++ 6.10 ≤ SEER < 8.50 4.60 ≤ SCOP < 5.10
A+ 5.60 ≤ SEER < 6.10 4.00 ≤ SCOP < 4.60
A 5.10 ≤ SEER < 5.60 3.40 ≤ SCOP < 4.00
B 4.60 ≤ SEER < 5.10 3.10 ≤ SCOP < 3.40
C 4.10 ≤ SEER < 4.60 2.80 ≤ SCOP < 3.10
D 3.60 ≤ SEER < 4.10 2.50 ≤ SCOP < 2.80
E 3.10 ≤ SEER < 3.60 2.20 ≤ SCOP < 2.50
F 2.60 ≤ SEER < 3.10 1.90 ≤ SCOP < 2.20
G SEER < 2.60 SCOP < 1.90
Source: EU Regulation 626/2011 (Table 27)
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Table 13: Minimum Efficiency Requirements
Air conditioners, except

Double and single duct
Air conditioners
SEER SCOP
(heating
Season average)
If GWP of refrigerant 4.60 3.80
> 150 for < 6 kW
≤ 150 for < 6 kW
> 150 for 6-12 kW
≤ 150 for 6-12 kW
Source : EU Regulation 626/2012 (Table 21) Minimum efficiency requirements
Table 14: Requirements for maximum sound power level
Rated capacity ≤ 6 kW 6 < Rated capacity ≤12 kW

Indoor sound power Outdoor sound power Indoor sound power Outdoor sound power
level in dB (A) level in dB(A) level in dB (A) level in dB(A)
60 65 65 70
Source: EU Regulation 626/2011 (Table 23)
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7. AIR CONDITIONER REFRIGERANTS
Refrigerants used in air conditioners have changed over the years as they have become
controlled substances under the Montreal Protocol due to damage they cause to the
ozone layer and the climate system. HCFCs, the last-generation refrigerants commonly
used in air conditioners, are scheduled to be totally phased out in developed countries by
2030 and in developing countries by 2040.
Non-ozone depleting HFCs are commercially available alternatives to HCFCs. While they
do not deplete the ozone layer, HFCs are potent GHGs, hundreds to thousands of times
more powerful in trapping heat in the atmosphere than CO2. Since the HCFC phase-out
was agreed, annual HFC consumption has increased at a rate of 10 – 15 per cent per
year, raising alarm to their potential contribution to rising global temperatures.
Avoiding production and use of HFCs by using technologically feasible low-GWP

substitutes could avoid as much as 0.5 °C warming by the end of the century.
In order to reduce production and consumption of these powerful greenhouse gases, the
parties to the Montreal Protocol unanimously adopted the Kigali Amendment in October
2016, agreeing to add HFCs to the list of controlled substances and approving a timeline
for their gradual reduction by 80 – 85 per cent by the late 2040s.
7.1 Environmental Impact of Refrigerants
7.1.1 Importance of Ozone
Life on Earth has been safeguarded against harmful ultraviolet radiation due to the
protective ozone layer in the atmosphere.
While the sun’s rays help sustain life on Earth, they also contain harmful ultraviolet (UV)
rays.
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Figure 26: Importance of Ozone
Located in the Stratosphere, the ozone layer efficiently screens out almost all the Sun’s
harmful UV rays, absorbing them and preventing them from causing damage on the
Earth’s surface.
7.1.2 Ozone formation
Ozone is a tri-atomic molecule of Oxygen which join together to form the ozone molecule
(O3). Through natural atmospheric processes, ozone molecules are created and
destroyed continuously.
In the Stratosphere zone (the layer found between 11 – 36 km above earth’s surface, that
contains the ozone layer), UV rays from the sun react with the existing oxygen molecules
(O2) and break them down into oxygen atoms. In the reaction that follows, three oxygen
atoms join together to form ozone molecules. Thus oxygen is continually converted into
ozone.
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Figure 27: Stratospheric Ozone Formation
The reverse reaction also take place where some ozone molecules decomposed into
three oxygen atoms, which join together in twos to become oxygen molecules. In this
way, a continuous equilibrium is maintained between ozone and oxygen in the
stratosphere.
7.1.3 Ozone Depletion
Ozone is not a stable gas and is particularly vulnerable to destruction by natural

compounds containing hydrogen, nitrogen and chlorine. A chain reaction is triggered
when the HCFC molecules come close to the ozone layer. The HCFC molecule
decomposes and releases a Chlorine radical when it comes into contact with the sun’s
rays. This chlorine radical reacts with an oxygen atom from an ozone molecule, yielding
an oxygen and a chloromono-oxide molecule. The chloromono-oxide molecule is
unstable and breaks again, releasing a free chlorine radical. This chlorine radical now
starts a similar reaction with another ozone molecule. These repetitive cycles deplete the
ozone layer.
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Figure 28: Stratospheric Ozone destruction
The presence of chlorine atoms in ODSs is the cause of ozone depletion. Reactions by
manmade, ozone depleting chemicals upset the natural ozone balance in the
stratosphere, raising serious concerns.
7.1.4 Consequences of Damaging the Ozone layer
Ultra Violet radiation (UV) is classified in three ranges: UV-A, UV-B, UV-C. Of these, UV-
A is the least energetic and harmful.
The component of UV-C in the solar spectrum itself is small, and that reaching the earth
is practically nil. UV-B, however is energetic enough to cause biological interactions. With
the loss of the natural ozone shield, the Earth’s living organisms are exposed to the
harmful effects of UV-B radiation.
Among other effects, UV-B radiation can increase in the probability of skin cancer among
human beings. It can also induce eye injury, damaging the cornea and lens of the eye,
which can lead to cataracts. UV radiation can also suppress the human immune system,
making it prone to a number of infectious diseases. Fish and other ocean animals are
affected by this radiation, since it adversely influences aquatic life, leading to decreased
reproductive capacity and impaired development. Materials are also harmed by increased
UV radiation, which has adverse effects on synthetic polymers, naturally occurring
biopolymers and other materials of commercial interest. Material used in buildings, paints,
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packaging and countless other substances can be degraded by UV-B rays, which
accelerate photodegradation rates. Typical damage ranges from discoloration to loss of
mechanical integrity. Increased UV-B radiation may also cause decreased crop yields
and damage to forests, as well as increased cancer rates in humans.
7.1.5 Global Warming – Greenhouse effect
Another important environmental impact of refrigerants relates to the phenomenon of

Global Warming.
The Greenhouse Effect is:
The solar radiation interacts with Earth’s surface in several ways. Out of the total solar
radiation, nearly 20% is reflected from the Earth’s atmosphere, 20% is dispersed into the
atmosphere and 9% is reflected from earth’s surface or dust. The remaining, nearly 51%,
penetrates the atmosphere and reaches earth’s surface.
Most of the solar radiation reaching the earth’s surface are reradiated to the atmosphere.
As the reradiated radiation leaves the earth, it once again interacts with the atmosphere.
Some of this manages to escape (about 17%), but the majority of radiation is returned
back to the earth’s surface by the presence of greenhouse gases. This reflected energy
further warms the surface of the earth, leading to what is called the Green House effect.
Figure 29: Greenhouse effect
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Nature made the greenhouse effect which is necessary to sustain life on earth. Absence
of greenhouse effect would have rendered the earth temperatures so low that human life
would not have existed.
However, some of the greenhouse gases, such as carbon dioxide (CO2), methane (CH4),
nitrous oxide (N2O), Sulphur hexafluorides (SF6), Halocarbons (HFCs), Perfluorocarbons
(PFCs) & Nitrogen Trifluoride (NF3) essentially emitted through human activities, cause
an increase in the level of greenhouse effect and thus, high global warming and this is
harmful to mankind and the living beings on earth.
7.1.6 How ACs contribute to Global Warming
• Refrigerant emissions over the working life of AC (Direct emissions)
• Consumption of electricity over the entire working life of AC
• Electricity use contributes almost 90% of the CO2 emissions. Emissions can be
around 1 kg of CO2 per kWh
1 kg R410A = 2,068 kg CO2; 1 kg R134a = 1,430 kg CO2
1 kg R404A = 3,922 kg CO2
Figure 30: How ACs contribute to Global warming
Air Conditioners contribute to global warming in two ways, called the direct and indirect
contribution. Direct contribution is due to the direct emission of refrigerant used in air
conditioners. Refrigerant emits during installation and servicing, due to leakage, failure
and at the end of life of ACs. As HCFCs and HFCs are having high global warming
potential (e.g GWP of HCFC-22 is 1820) small emission to environment contributes high
global warming.
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Indirect contribution is the energy-related contribution that is represented by the

emissions of Greenhouse gases (mainly CO2) that arise from the production of electricity.
Over the entire life cycle of air conditioning equipment, considerable amount of electricity
is consumed. In most countries, electricity generation is by fossil fuel.
Various experiments and calculations have shown that the indirect contribution of ACs to
the greenhouse effect is significantly higher than the direct contribution associated with
the emission of HCFCs.
7.2 Commonly used refrigerant
Commonly used refrigerant in air conditioning sector are shown below.
Figure 31: Commonly used refrigerant in room AC system
The refrigerants used are divided into three categories – HCFC, HFCs and HCs.
HCFCs, including HCFC-22 are ozone depleting substances which are being phased out
under the HPMP of Montreal Protocol, in accelerated phase-out schedule. These are also
having high global warming potential.
The next category refrigerants are HFCs and blend of HFCs. At present, HFC-32 and
blends like R410A, R404A and R407C are commercially available and used as refrigerant
in room air conditioning sector. These chemicals are not having ozone depleting
potential, but they are having high global warming potential. The Montreal Protocole has
been amended to phase down HFCs as these chemicals have high GWP values.
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The 3rd category refrigerant, HCs, like R-290 and R-600a are commercially available
refrigerant which are not having ozone depleting potential and having negligible global
warming potential compared to the other two categories of refrigerants.
7.3 Handling of HCFC & HFC gas
Handling Precautions
The following points need to be considered for the safe handling of HFCs
(a) HFCs are heavier than air, so they displace air.

(b) HFCs have no smell.
(c) Since they are heavier than air, HFCs collect in lower positions like the bottom of
an appliance or the basement of a building.
(d) HFCs can be toxic; a person may suffocate if a high concentration of HFC is
inhaled.
Storage of Cylinder / Can
HFC cylinders should be stored in dry, well-ventilated areas, away from direct sunlight.
Make sure there are no sources of direct heat near the storage. No flame or torch must
be ignited near the cylinder. The best practice is to work in a well-ventilated area.
Cylinder Valve
The cylinder and cylinder valves should not be modified, as they are specifically designed
for HFC use. It is advised never to refill disposable cylinders, as they are not designed for
refilling.
Safety: Decomposition
HFCs decompose on heating and form hydrofluoric acid. It is therefore advised that
appliances should not be heated by flame, electrical heating elements, or smoke. The
work area must be well ventilated. If the cylinder becomes cold or some frost forms on
the outside of the cylinder while charging, do not heat it with a flame, just put the cylinder
in hot water (40°C) and then charge the refrigerant. In case of any decomposition,
ventilate the work area and make sure no one smokes.
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Safety: Do not overfill cylinder
It is important for not overfilling a cylinder. A refillable or recovery cylinder should not be
refilled more than 75% of volume and at a temperature of 21°C, as the temperature is
directly proportional to the space covered by the refrigerant.
When the cylinder is refilled to 85% of its volume and exposed to direct sunlight, and if
the temperature reaches 54°C, the cylinder can explode. This is because if atmospheric
temperature increases, the refrigerant volume also increases. This can lead to explosion.
Safely: POE Oils
Polyolester oils (POE), Polyalpha olefin oils (PAO) and Polyalkyl glycol oils (PAG) are
used with HFCs. The oils cause ski problems. Technicians should wear gloves when
handling the oil or oil-filled components. Technicians must take special precautions when
handling burnt-out systems, as burnt-out compressors form undesirable gases,
specifically acids. The best option is to wear personal protective equipment (PPE) while
handling burnt out systems and when working with mineral oils.
Safe Disposal of Refrigerants
In determining the proper management of waste refrigerants, the recovery, recycling and
reclamation of refrigerant gases is normally considered wherever these facilities are
available in other countries. The recovery process in refrigerant gas cylinders is followed
in our local context.
Once a decision has been taken to discard a recovered refrigerant (i.e. where there is no
further certain use for it by the end-user or by the contractor), it is considered a hazardous
waste and must therefore be managed in accordance with the relevant waste legislation.
Waste refrigerant gases must be brought to an appropriately authorised waste facility

when taken from an end-user site by the licensed contractor in safe transportation. The
storage of waste refrigerant gases is not permitted on any site.
7.4 HCFC Phase out management plan
Article 5 Developing countries POMP
Montreal Protocol successfully phasing out the production and consumption of ODSs. All
197 countries of the world are working together to phase out ODSs.
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In Kigali, Montreal Protocol made amendment to phase down the use of HFcs in 2016
called Kigali amendment. It is a dedicated effort to reduce GHG emission through phase
down of HFCs and improve energy efficiency.
The HCFC Phase-Out Schedule – Article 5 (Developing) countries is shown below.
Table 15: HCFC phase out schedule
Schedule Year
Average of 2009
Baseline
and 2010
Freeze 2013
90% (reduction of 10%) 2015
65% (reduction of 35%) 2020
32.5% (reduction of 67.5%) 2025
Annual average of 2.5% 2030 to 2040
0% (reduction of 100 %) 2040
7.5 Alternative to HCFC gas
Refrigerant options
Manufacturers are considering alternatives to transition to climate-friendly refrigerants in

room air conditioners (i.e. substances with zero ozone depleting potential and low GWP).
These alternatives, including propane (R-290), HFC-32 (R-32), and HFC/hydrofluoro

olefins (HFO) blends; pose a lower climate burden.
They display different characteristics affecting their environmental performance, energy

efficiency, safety and cost. The table illustrates the properties of various refrigerant
classes such as GWP, ODP and alternative refrigerant.
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Table 16: Basic refrigerants information & alternatives
Source: Safe use of HCFC alternatives in RAC – UNEP 2015
7.6 Energy Efficient Refrigerant gas R32 & R290
A particular attention is being given in this section to the energy efficient refrigerant gas
R32 & R290 (propane).
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7.6.1 Refrigerant gas R32
R32 refrigerant is also known as difluoromethane and belongs to the HFC family of
refrigerant. It is chlorine free and ozone-safe fluorocarbon and it is a component of
R410A. This gas is poised to replace the other gaseous such as R410A as the preferred
gas due to its lower GWP. Its chemical formula is CH2F2.
R32 has a GWP about one third that of R410A and it has excellent properties as a
refrigerant. Therefore, the technology has been developed to use it by itself as an
alternative refrigerant to replace R410A especially in the air conditioning sector. R32
delivers superior performance in both cooling/heating capacity and energy efficiency,
compared to R410A, volumetric capacity of R32 is about 15% higher and its COP is about
6% higher. Hence it can contribute to reduce equipment’s indirect impact on CO 2
emission.
Table 17: Theoretical characteristics of R32 compared with other ref gas
Source: Daikin R32 Instructions for use and handling
R32 is flammable, but its flammability is extremely low compared with that of hydrocarbon
refrigerants such as propane. Therefore, R32 is positioned as a slightly flammable
refrigerant.
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Table 18: Flammability properties of R32 compared with other ref gas
Source: Daikin R32 Instructions for use and handling
7.6.2 Handling Precautions of R32
Laws & Regulations
R32 is a high-pressure liquefied gas and is classified as slightly flammable refrigerant.

To handle the refrigerant R32 safely, local laws & regulations have to be observed.
Handling of containers
R32 is a high-pressure gas and kept in high-pressure containers. Although these

containers are of safe design, they may crack when handled roughly and this can cause
accidents. Be very careful not to drop, hit or roll the containers or to let them fall over.
Storage
Like all other high-pressure gases, store R32 in a cool, dark and well-ventilated place. If
R32 gas is leaked it tends to sink to a lower level and remain there since R32 is heavier
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than air. If R32 gas accumulates to high concentrations in some area, symptons of oxygen
deficiency may occur to the person who gets into the area, accidental combustion of the
gas may result. All containers for high-pressure gases including R32 have a safety device
fitted. If the storage temperature or pressure rises above certain level, the safety device
is actioned so that the gas escapes.
Precautions about decomposed gas
Keep R32 away from heat or open flame. If R32 is combusted or thermally decomposed
as a result of exposure to flame or heat source, hazardous will be generated.
Health Precautions
Like other liquefied high-pressure gases, R32 should be prevented from coming into
direct contact with the skin or eyes and from being inhaled.
Emergency treatment methods are as follows.
• If gas is inhaled
- Move the person to airy place to rest in a relaxed position

- Keep the person warm with a blanket
- If breathing is weak loosen the clothing artificial respiration can be given
• If liquefied gas gets into the eye
- Wash the eyes out with water for 15 minutes or more. Try to avoid rubbing the
eyes and blinking.
- When needed seek medical assistance immediately.
- To prevent such accidents, always wear protective goggles when handling R32.
• If liquefied gas comes into direct contact with the skin
- When liquid R32 evaporates, its temperature drops dramatically.

- Direct contact with the skin in this state may cause frostbite.
- If a large quantity of evaporating liquid R32 comes into direct contact with the
skin, it will cause frostbite, so seek medical assistance immediately.
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7.6.3 Refrigerant gas R290
The hydrocarbon propane C3H8 is a naturally occurring gas found in the depth of earth.
Propane can be separated from other petrochemicals and refined for commercial use. As
a Liquefied Petroleum Gas (LPG), propane can be converted to liquid under low
pressures.
In general, the thermodynamic properties of propane help to reduce pressure losses and
improve heat transfer. These favourable properties like high latent heat, high liquid
specific heat, etc, makes it an energy efficient refrigerant.
It can be seen from the table below, R290 exhibits the most desirable properties as
compared to common refrigerants.
Table 19: Comparison of various thermo-physical properties of selected refrigerants
Advantages of R290
• Zero ozone depletion potential

• Very low global warming potential compared to common refrigerants
• Excellent thermodynamic properties leading to high energy efficiency
• Good compatibility with system components
• Low charges allowing smaller heat exchangers and piping dimension
Safety aspect of R290
The safety aspect of propane like its high flammability, being odourless & hence not
detected by smell and being heavier than air therefore it accumulates at ground level in
case of leakage represent key challenges for its introduction in the local market.
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Therefore, the use and handling of R290 requires adequate safety measures such as fire
and explosion provision, safe storage requirement, emergency procedures, personnel
protection, etc
The survey conducted for this assignment has not registered any local suppliers importing
AC units which are using these refrigerant gases.
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REFERENCED DOCUMENTS
1. International Standards in Refrigeration & Air Conditioning – UNEP - 2014
2. Energy Efficient AC – A case study of the Maghreb – World Bank Gp – 2016
3. Use of ventilation & AC – Australian Standards AS 1668.2 – 2016
4. Promoting Higher Efficiency AC in ASEAN – A regional policy roadmap – UNEP, EU, ASEAN SHINE -2015
5. CEB Guide Book – Helping you to save energy & money
6. AC & comfort fans: review of Regulation 206/2012 & 626/2011 – Final report – EU, HAL – 2018
7. Refrigerant system & heat pump – ISO 5149 -1: 2014
8. Future of HVAC in a Net Zero World – AIRAH: 2018
9. Accelerating the global adoption of Energy Efficient & Climate friendly AC – U4E, UN for Environment – 2017
10 Installation procedure of air conditioner Window & Split – UNEP – 2014
11. Good servicing practices-Phasing out of HCFC in the RAC servicing sector – UNEP: 2015
12. AC Residential Best Practice Guideline – AIRAH – 2003
13. Guide to Buying AC – Brisbane City
14. Installation manual of various AC manufacturers-
15. Energy Efficiency Act 2015
16. Energy Efficiency Regulations 2017
17. Internet
18. Safe use of HCFC alternatives in RAC – UNEP 2015
19.Daikin R 32 – Instruction for use & handling
20. R290 – Split AC resource guide - Proklima
21. R290 refrigerant grade propane – Linde Group
22. Service product training – Split Inverter Course Daikin Europe
23. Good service practices & installation of room AC – Trainers Handbook – GIZ
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ANNEX 1: SPLIT AC MANUFACTURER’S SERVICE MANUAL
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Split Air
Conditioner
Wall Mounted Type
Service Manual
MUP 09-HI
MUP-12HI
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ANNEX 2: SPLIT AC COMMISSIONING CHECKLIST & TEST SHEET
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Company's name Date
Address Client's Name
Email/Tel: Address
Make/Model/Capacity of Air Conditioning Unit
Procedure for Comissioning:=

A items to be checked prior to comissioning Remarks (Tick as appropriate)
Indoor and outdoor units are insta1led properly on solld

bases.
No refrigerant gas leaks.
Refregerant gas and liquid pipes and indoor drain hose extension
are thermally insulated.
Draining line is properly installed.
System is properly earthed.
The specified wires are used for interconnecting wire connections.
Indoor and outdoor unit's air intake or exhaust has clear path of air.
Shut- off valves are opened.
Indoor unit properly receives remote control commands.
B Commissioning
1 Measure the supply voltage and make sure that it falls in the
specified range.
2 Make sure the swing flap opens and closes smoothly when putting
power to the unit.
3 Check that all shut- off valves are open
4 Trial operation should be carried out in either cooling or heating

mode
4a In cooling mode,select the lowest programmable temperature; in
heating mode
4b In heating mode select the highest programmable temperature
5 Trial operation may be disable in either mode depending on the

room temperature
Use the remote control trial operation as described below
6 After trial operation is completed, set the temperature to a normal

level(23°C to 25 °C in heating mode).
7 For protection,the system disables restart operation for 3 minutes
after it is turned off.
8 Carry out the test operation in accordance with the Operation in
accordance with the operation manual to ensure that all functions
and parts, such as louver movement, are working properly.
9 The air conditioner requires a small amount of power in its standby
mode. If the system is not used for some time after installation, shut
off the circuit breaker to eliminate unecessary power consumption.
10 If the circuit breaker trips to shut off the power to the air conditioner,
the system will restore the original operation mode when the circuit
breaker is restored again.
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ANNEX 3: SPLIT UNIT AC MAINTENANCE CHECKLIST & SCHEDULE
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Maintenance
Introduction To ensure an optimal operation it is required to maintain the

installation on a regular base by a skilled AC technician.
List of all critical items which should be checked in basic installation maintenance.
Maintenance to
the indoor unit
Step Item Frequency

1 Cleaning the air filter Once every 3 months
2 Cleaning the heat-exchanger Only required if
The cleaning can be done with a mixture of heat-exchanger is
water and neutral soap dirty
3 Check the functioning of the thermostat Once a year
4 Measure the suction and discharge air of Once a year
the indoor unit and compare with previous
measuring data.
5 Check if the drain piping is not blocked Once a year
6 Check if the electrical connections on the Once a year
terminal are all still tight.
Check if all other connections on the PCB
are still OK
Maintenance to
outdoor unit
Step Item Frequency

1 Cleaning of the heat exchanger. Once every 4 months
The cleaning should be done with
low-pressure fresh tap water.
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2 Removing the corrosion from the casing. Once a year

Before adding new paint, all the
corrosion should be removed with a
steel brush or rough sandpaper.
Maintenance to outdoor unit (continued)
3 Removing the corrosion from the Once a year

fan-motor.
Same remark as for step 2
4 Check the condition of the screws. Once a year
All rusted screws should be replaced
5 Remove all the dust from the PCB 3 times a year
boards. PCB boards, which have
indication of corrosion, should be
cleaned and protected with a layer.
The cleaning liquid and protection
layer, which is currently used, can be
used in the future.
6 Check if the electrical connections on Once a year

the terminal are all still tight.
Check if all other connections on the
PCB are still OK
General items
Step Item Frequency

1 Repair or replace the Once a year
interconnection insulation if required
2 Check for oil traces at the flair Once a year
connections. This is an indication for
possible leaks.
3 Measure the high and low pressure Once a year
and compare with the previous
measuring data
4 Measure the current of the Once a year
operating compressor and fan motor
and compare with previous measuring
data.
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Checklist
Checklist Split
Complaint / error code
General information
Service Technician
Company name Visit date
Installation ID Service ID
Installation conditions
Installation date
Level difference
Piping length
Measurements
Outdoor unit Indoor unit
Type
Serial number
Compressor current (A)

Input current (A)
Compressor frequency (only
(Hz) inverter)
Refrigerant charge (Kg)
Low pressure (bar)
Suction pipe temperature (°C)
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High pressure (bar)

Discharge pipe temperature (°C)
Liquid temperature (°C)
Intake air temperature (°C)
Outlet air temperature (°C)
Room humidity (%RH)
Heat exchanger (°C)
temperature
Checklist, continued
Actions taken
Refrigerant taken out

Refrigerant put in
Leak test done
Heat exchanger cleaned
Replaced parts
Others
Remarks
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DISCLAIMER
These guidelines relate to the sizing, selection, installation and maintenance of domestic type air conditioners of cooling
capacity less than 12 kW. The contents of this Guideline should not be copied or reproduced by any third party or otherwise
quoted or referred to, in whole or in part, without the prior permission of the recipient in writing.
The EEMO disclaims any responsibility or liability for any loss or damage suffered by any third party by taking reliance of
these guidelines.
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Guidelines: Installation and Maintenance of Air

LIST OF TABLES .................................................................................................................. iv

ACRONYMS AND ABBREVIATIONS .................................................................................. vii

1. AIR CONDITIONING SYSTEM OVERVIEW ....................................................................... 1

2. SIZING OF AIR CONDITIONERS ..................................................................................... 15

3. AIR CONDITIONING SELECTION ................................................................................... 20

3.2 Comfort & Practicality ........................................................................................................ 21

4. AIR CONDITIONING INSTALLATION ............................................................................. 27

5. AIR CONDITIONING SERVICING & MAINTENANCE ..................................................... 40

6. ENERGY EFFICIENT AIR CONDITIONING UNITS ......................................................... 63

6.5.3 Labelling details ............................................................................................................................ 70

7. AIR CONDITIONER REFRIGERANTS ............................................................................. 75

REFERENCED DOCUMENTS ............................................................................................. 91

ANNEX 1: SPLIT AC MANUFACTURER’S SERVICE MANUAL ........................................ 92

ANNEX 2: SPLIT AC COMMISSIONING CHECKLIST & TEST SHEET ........................... 125

ANNEX 3: SPLIT UNIT AC MAINTENANCE CHECKLIST & SCHEDULE ........................ 128

Table 1: Different models of AC IDUs ..................................................................................... 4

Figure 1: Illustration of the main components of an air conditioner ......................................... 1

Figure 29: Greenhouse effect ................................................................................................ 79

ACRONYMS AND ABBREVIATIONS

ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers

VRV Variable Refrigerant volume

1. AIR CONDITIONING SYSTEM OVERVIEW

1.1 Definition, Operating Principles & Main Components

An air-conditioning system distributes cooled air in an enclosed space. Air conditioning

The key components of an air conditioner consist of a compressor, a condenser, an

Figure 1: Illustration of the main components of an air conditioner

Figure 2: Basic air conditioner vapour compression cycle

1.2 Different Types of Air Conditioner

Individual air conditioners systems can be configured in various ways:

1.2.1 Windows Air Conditioners

Figure 3: Window type AC unit (Front view)

Advantages of Window Air Conditioners

1.2.2 Split Air Conditioners

Table 1: Different models of AC IDUs

The split Air Conditioners can be of two types:

1.2.2.1 Non-Inverter Split Air Conditioners

Advantages of Non-Inverter Split Air Conditioner

Disadvantages of Non-Inverter Split Air Conditioner

1.2.2.2 Inverter Split Air Conditioners

Advantages of Inverter Split Air Conditioners

• Achieves desired temperature quicker and no temperature fluctuations

• Quiet operation as compressor sits in outdoor unit

Disadvantages of Inverter Split Air Conditioners

• Highly skilled manpower required due to advanced control system

SPLIT TYPE AIR CONDITIONER ATTRIBUTES

INDOOR UNIT INDOOR UNIT

WALL TYPE WALL TYPE

CASETTE TYPE CASETTE TYPE

FLOOR MOUNTED FLOOR MOUNTED

Figure 4: Split type AC attributes

1.2.3 Multi-Split Air Conditioners

Advantages of Multi-Split Air Conditioners

Disadvantages of Multi-Split Air Conditioners

Figure 5: Multi split air conditioner

1.2.4 Portable Air Conditioners

A portable air conditioner is a self-contained unit, similar to a window air conditioner. It is

Figure 6: Portable air conditioner

Advantages of portable air conditioners