Heating and Air-Conditioning Testing II. Climatic Test Bench

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John Haynes
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1 Heating and Air-Conditioning Testing II Climatic Test Bench

3 Heating and Air-Conditioning Testing II Climatic Test Bench Content IAV's Climatic Test Benches 4 Mobile Coolant Circuit 6 Evaporator Air Treatment System 8 Condenser Chamber 10 Contact Tanja Vogel

5 IAV's Climatic Test Benches The percentage of new vehicles equipped with an air-conditioning system has risen dramatically in recent years. Additional demands, e.g. for fuel-efficient engines and weightoptimized components with unchanged cooling performance, have given rise to a constant growth in development input for air-conditioning systems. In response to this situation, IAV has installed a climatic test bench for developing and designing air-conditioning systems. In addition to designing and determining the performance of individual air-conditioning components, the test bench in particular provides the means for conducting measurements on the: u overall system with OEM lines and components u front-end section with radiator/fan package u heating/air-conditioner u overall vehicle at idle. 4 5

6 Condenser chamber Collector I Collector II Evaporator air treatment system Expansion valve External vehicle condenser (test component) Internal condenser Internal evaporator External vehicle evaporator (test component) Oil separator Vehicle air-conditioner compressor

7 Mobile Coolant Circuit Technical Specifications u Features 1 Internal evaporator 12 kw max. 1 Internal condenser 20 kw max. 1 Electrical compressor drive u Control Variables 1 Compressor speed 500 to 9000 rpm 1 Evaporation pressure 2.5 to 5 bar 1 Overheating 0 to 20 K 1 Undercooling 0 to 20 K 1 Hot gas temperature control 60 to 150 C Configuration Capabilities u Connection of vehicle evaporators and/or vehicle condensers u Integration of different air-conditioner compressors Scope of Testing u Performance measurement on vehicle air-conditioner compressors u Torque measurement u Determination of performance characteristic of vehicle air-conditioner compressors u Measurement Variables 1 Torque 1 Coolant mass flow 1 Temperature and pressure recording 1 Throughout the mobile coolant circuit u Power Output for Compressor 1 0 to 30 V; 0 to 10 A Cooling capacity Ps1 Ps2 u Safety Features 1 Low-pressure shut-off < 2 bar 1 High-pressure shut-off > 35 bar 1 Hot gas temperature shut-off > 150 C Speed [rpm] Mobile Coolant Circuit Compressor speed Condensation pressure control Evaporation pressure control Overheating, controllable between Undercooling, controllable between 500 to 9000 rpm 5 to 30 bar 2.5 to 5 bar 0 and 20 K 0 and 20 K Hot gas temperature control 60 to 150 C Capacity of internal evaporator Capacity of internal condenser Torque measurement Mass flow measurement Pressure and temperature measurement 12 kw 20 kw at the drive motor on Coriolis measurement system upstream and down stream of each component in the cooling circuit 6 7

8 Dehumidifying Cooling Heating Lateral air discharge into shop Steam humidifier Orifice plate flowmeters Air discharge at front; Connection for air conditioner or frame Shop air intake Lateral air discharge into condenser chamber

9 Evaporator Air Treatment Systems Technical Specifications u Temperature and Humidity 1 Temperature range: -20 to 60 C 1 Rate of change: 1 K/min 1 Relative humidity: 10 to 95 % u Air Flow 1 Air volume flow: 80 to 800 m 3 /h 1 Small-diameter orifice plate flowmeter: 80 to 200 m 3 /h 1 Large-diameter orifice plate flowmeter: 100 to 800 m 3 /h 1 Air discharge cross section 600 x 400 mm 1 Air discharge cross section 150 mm Ø 1 Air volume flow is adjustable by regulating volume flow or differential pressure u Sensors 1 45 thermocouples 1 1 humidity sensor 1 1 differential pressure sensor 1 1 pressure capsule for ambient pressure u Power Supply Unit Output (e.g. for air-conditioning system) 1 0 to 35 V; 0 to 40 A u Other Features 1 Discharge flange into condenser chamber and at side into shop, with connection for insulated hose Configuration Capabilities u Heating/air-conditioning system on a test rack u Evaporator in a test frame u Vehicle or empty body in the condenser chamber or next to evaporator air treatment system u Measurement of two evaporator systems Scope of Testing u Performance measurements at the evaporator coolant and air side u Air-side pressure loss measurements at the evaporator u Absence-of-water measurements at the air-conditioner u Measurements at the expansion valve u Blower characteristic u Control curve u Heating performance Evaporator Air Treatment System Temperature range -20 to +60 C Rate of temperature change 1 K/min Relative air humidity 10 to 95% Air volume flow 80 to 800 m 3 /h Outlet size at front approx. 300 x 400 mm Lateral air outlet 2 x 150 mm Ø 8 9

10 Volume flow measurement Air recirculation system for chamber temperature control Condenser air outlet

11 Condenser Chamber Technical Specifications u Air Recirculation System 1 Temperature range: C 1 Rate of change: 1 K/min u Condenser Air Duct 1 Air volume flow: 200 to 8000 m 3 /h 1 Discharge outlet size approx. 700 x 900 mm u Compressor Drive 1 Speed: 500 to 9000 rpm u Sensors 1 52 thermocouples 1 5 pressure sensors 1 2 humidity sensors 1 1 pressure pick-up (air side) 1 1 differential-pressure capsule u Power Supply Unit Output (e.g. for Radiator Fan) V; A u Other Features 1 Exhaust gas extraction/fresh-air intake 1 Discharge flange for evaporator air treatment system Configuration Capabilities u Vehicle, front vehicle or front end with air flowing through condenser air duct u Complete vehicle coolant circuit in test rack u Radiator/fan package u Condenser in test frame in the condenser air duct Scope of Testing u Performance measurements on condensers, coolant and air side u Pressure loss measurements on condensers, coolant and air side u Tests on the entire coolant circuit or entire vehicle u Filling quantity optimization u Cooling behavior in passenger compartment Condenser Chamber Temperature range -20 to +60 C Rate of temperature change 1 K/min Air volume flow 200 to 8000 m 3 /h Size of air-circulation duct outlet approx. 700 x 900 mm Speed range of compressor drive motor 500 to 9000 rpm Connection to evaporator air treatment system 150 mm Ø 10 11

12 IAV GmbH Carnotstrasse BERLIN GERMANY Tel Fax Excellence in Automotive Research & Development

Summary of Comments (Washington Revisions November 7, 2000) Update November 27, 2000

SAE Alternate Refrigerant Cooperative Research Program Summary of Comments (Washington Revisions November 7, 2000) Update November 27, 2000 To: Alternate Refrigerant Task Force Members From: Ward Atkinson