Mobile Air Conditioning

Basic A/C Operation

System Components

All systems contain six major components:

Compressor to circulate the refrigerant
Condenser to transfer heat to ambient air
Receiver dryer or accumulator to store reserve
refrigerant, contain the desiccant, and filter
refrigerant
Expansion device to control amount of
refrigerant entering evaporator
Evaporator to transfer heat from in-vehicle air to
the refrigerant
Lines and hoses to connect these parts together
And the refrigerant
2

Automotive A/C Systems

2 primary systems used to control

evaporator pressure and
temperature:

TXV systems (thermal or thermostatic

expansion valve)
OT systems (orifice tube)

Fixed
Variable
3

Low Side Operation

Goal is to provide constant evaporator

temperature of 32 degrees
Refrigerants have low boiling points

When liquid boils, it absorbs large

amounts of heat
Amount of heat absorbed in evaporator is
proportional to amount of refrigerant
boiled

Low Side Components

Expansion device
Evaporator
Accumulator (if equipped)

Expansion Devices

The expansion device separates the high side

from the low side and provides a restriction
for the compressor to pump against.
There are two styles of expansion devices:
The TXV can open or close to change flow. It
is controlled by the superheat spring, thermal
bulb that senses evaporator outlet
temperature, and evaporator pressure
Most OTs have a fixed diameter orifice

TXV System
A TXV controls the
refrigerant flow from
the high pressure side
to the evaporator. A
receiver dryer is
mounted in the liquid
line of all TXV
systems.

Animation:

OT System
An OT controls the
refrigerant flow from
the high pressure side
to the evaporator. An
accumulator is
mounted in the suction
line of all OT systems.

Animation:

Thermal Expansion Valves, TXVs

The three major types of expansion
valves:
Internally balanced TXVs are the
most common.
Externally balanced TXVs are used
on some larger evaporators.
Block valves route the refrigerant
leaving the evaporator past the thermal
sensing diaphragm so a thermal bulb is
not needed.
Animation: TXV Operation

Internall
y
Balanced

Externall
y
Balanced
Block Valve
9

Thermal Expansion Valves,

TXVs

Variable valve that can change size

of opening in response to system
load
Opens or closes depending on
evaporator pressure and
temperature

10

Orifice Tubes, OTs

The OT used in a modern vehicle
is a tubular, plastic device with a
small metal tube inside. The color
of the OT is used to determine the
diameter of the tube. A plastic
filter screen is used to trap debris
that might plug the tube.
Some older General Motors
vehicles used an OT that
resembled a brass fuel filter.

11

Orifice Tubes, OTs

Fixed diameter orifice

Simple and cheap to produce
Cannot respond or change according
to evaporator temperature
System requires accumulator to
prevent liquid refrigerant from
reaching compressor
12

Evaporator Operation
Hot, liquid refrigerant flows
through the expansion device in
the low side to become a fine
mist.
Refrigerant boils or
evaporates to become a gas
inside the evaporator.
The boiling refrigerant
absorbs heat from the air during
this change of state.
13

Accumulators
Accumulators are used in the suction line of all OT
systems.
The accumulator:
separates liquid refrigerant so only gas flows to the
compressor.

Allows oil in the bottom of the accumulator to return

to the compressor.

provides storage for a refrigerant reserve.

contains the desiccant bag for water removal.

provides a place to mount low pressure switches and

sensors.

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Refrigerant Charge Levels

Low Refrigerant Levels:

Allow refrigerant to vaporize before

evaporator
Prevent proper heat transfer in
evaporator
Causes low system pressures

15

Refrigerant Charge Levels

High Refrigerant Levels:

Prevent refrigerant expansion in

evaporator
Can cause extremely high system
pressures
Prevents heat transfer because of
high pressure in evaporator

16

Evaporator Icing Controls

Cycling Clutch Systems

Evaporator Pressure Controls
Variable Displacement
Compressors

17

Cycling Clutch Systems

Pressure control

Switch mounted on low side

Accumulator
Suction line

Cycles compressor on at 42-49 psi

Cycles compressor off at 22-28 psi

Temperature control

Thermistor senses evaporator temperature

18

Evaporator Pressure
Controls

Devices used to control evaporator

pressure

STVs (suction throttling valves)

POAs (pilot-operated absolute)
EPRs (evaporator pressure regulator)

Usually mounted in evaporator outlet or

compressor inlet
Used to restrict refrigerant flow to
compressor
19

Variable Displacement
Compressors

Provide smooth compressor

operation
Maintain constant evaporator
temperature
Reduces compressor load on
engine when system cooling load
is low
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High Side Operation

Takes low pressure vapor from

evaporator and returns high
pressure liquid to expansion device
Must increase vapor temperature
above ambient temperature for
heat transfer to occur resulting in
change of state from vapor to
liquid
21

High Side Components

High begins at compressor and

ends at expansion device

Compressor
Condenser
Receiver-drier (if equipped)

22

Compressors
There is a large variety of
compressors. Some of variations are:
The compressor manufacturer
Piston, vane, or scroll type
The piston and cylinder arrangement
How the compressor is mounted
Style and position of ports
Type and number of drive belts
Compressor displacement
Fixed or variable displacement
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Compressor Operation
In/Suction:
Low Pressure,
about 30 psi &
Low
Temperature,
close to freezing

Out/Discharge:
High Pressure,
about 200 psi &
High
Temperature,
above ambient

The compressor increases the

refrigerant pressure about five
to ten times. This increases the
temperature so heat can leave
the refrigerant in the condenser.
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Reed Valve
Plate

Piston Compressors
Piston
This two-cylinder
compressor uses aConnecting
Rod
crankshaft to move
the pistons up and Crankshaft
down. Refrigerant flow
is controlled by the
suction and discharge
reeds in the valve
plate.

Animation:

Shaft
Seal

25

Scotch Yoke Compressors

Discharge
Reed
Suction Reed

A Scotch yoke compressor

has two pairs of pistons
that are driven by a slider
block on the crankshaft.
The pistons are connected
by a yoke.

Pistons

Animation: Scotch Yoke Compressor

Yoke

26

Scroll Compressors
The orbiting scroll is
driven by the
crankshaft and moves
in a small circular
orbit. The fixed scroll
remains stationary

Fixed
Scroll

Shaft
Seal

Animation: Scroll Compressor

Orbitin
g Scroll

Clutch
Assembly
27

Swash Plate Compressors

Pistons
Reed Plate

The swash plate is

mounted at an angle
onto the drive shaft. It
drives three doubleended pistons. Two
sets of reeds control
the refrigerant flow in
and out of the
cylinders,

Swash
Plate
Shaft Seal
Clutch Assembly
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Animation: Swash Plate Compressor

Vane Compressors
Rotor

The rotor is driven by

the clutch and
driveshaft. The vanes
move in and out of the
rotor to follow the outer
wall to pump refrigerant.

Vane

Discharg
e Reed
Animation: Vane Compressor

Shaft Seal

29

Wobble Plate Compressors

Pisto
n

Wobble Plate Bearing

Plate
Animation: Wobble Plate Compressor

Angle/Drive
30

Wobble Plate Compressors

The wobble plate does not rotate; it just wobbles,
being driven by the angled drive plate that does
rotate. Variable displacement, wobble plate
compressors can change the angle of the drive
plate, and this changes piston stroke and
compressor displacement. Most wobble plate
compressors have 5 to 7 pistons.

31

Variable Displacement
Wobble Plate Compressors
Low Angle
Minimum
Stroke

The evaporator pressure

has dropped, and the
control valve has
increased crankcase
High Angle, pressure
Maximum
Stroke

Control Valve

Normal operation when

cooling is required.
Crankcase pressure is low.
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Condenser Operation

Hot, high pressure gas is pumped from the compressor to enter the
condenser.
The gas gives up its heat to the air passing through the condenser.
Removing heat from the hot gas causes it to change state and
become liquid.
33

Condenser Types
Condensers A and C are
round tube, serpentine
condensers.
Condenser B is an
oval/flat tube, serpentine
condenser.
Condenser D is an
oval/flat tube, parallel
flow condenser.
Flat tube condensers are
more efficient.
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Serpentine Condenser
Refrigerant flows
from the upper
inlet to the
bottom outlet
through two
tubes. These
tubes wind back
and forth though
the condenser.
35

Parallel Flow Condenser

Refrigerant flows from the
upper inlet to the bottom
outlet through groups of
parallel tubes. Some carry
refrigerant from the right to
the left, and others move it
back to the right side.

36

Heat Exchangers

Condensers have to move heat from the refrigerant to

the air.
Evaporators must move heat from air to the refrigerant.
Both require a lot of contact area for both air and
refrigerant.
Both require free movement of air and refrigerant.

37

Receiver Dryers
A receiver dryer is mounted in the liquid
line of a TXV system. It is used to:

Barb
Connection
s, Note
Sight Glass

Male Flare
Connection
s

to store a reserve of refrigerant.

hold the desiccant bag that removes water

from the refrigerant.

filter the refrigerant and remove debris

particles.

provide a sight glass so refrigerant flow can

be observed.

Male O-ring
Connections,
Note Switch

provide a location for switch mounting.

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High Pressure Controls

High pressure cutoff

Switches designed to open

compressor clutch circuit at high
pressures

High pressure release

Designed to release refrigerant at

high pressures

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Pressure Release
A/C systems can include a
pressure release valve that is
usually mounted at the compressor
or a fuse plug mounted on the
receiver dryer. The relief valve can
open at a preset pressure and then
reclose. The center of the fuse plug
melts to let pressure escape.

Pressure
Relief
Valve

Fuse
Plug

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