Case/Duct System (Automobile)

Case/Duct System (Automobile)
33.14.
Case/Duct System
A typical automotive heater/air-conditioner case/duct system is

shown in Fig. 33.57. The purpose of the case/duct system is to
house the heater core and the air-conditioner evaporator, and to
direct the selected mode of air supply through these components
into the passenger compartment of the car. The supply air selected
may be either fresh (outside) and/or re-circulated (in-car) air,
depending upon the system mode. The heated and/or cooled air is
delivered to the floor outlets, dash panel outlets, and/or the defrost
outlets.
Both the independent case and the split case assemblies are used to
house the heater core and air-conditioner evaporator. The
independent case, used on compact and small cars, may have an
upstream blower, shown in Fig. 33.58A, or a downstream blower,
shown in Fig. 33.58B. The independent case system is usually
located under the dash-board, on the inside of the fire-well.
The split case system, which is used on larger cars, is located on
both sides of the engine fire-well. An upstream integral blower (Fig.
33.59) or an independent blower (Fig. 33.60) is used in the split case
system.
For the purpose of understanding, a typical hybrid case/duct system
is taken up for discussion. This system is divided into air intake
section, the heater core and air-conditioning evaporator section, and
the air distribution section (Fig. 33.61). Air-flow is from right to left in
the figure.
Fig. 33.58. Independent case system. A. Upstream blower. B.
Down stream blower.
Fig. 33.59. Split case system with upstream blower.

Fig. 33.60. Split case system with independent (downstream)
blower.
Fig. 33.61. A typical case/duct system split into the three

sections.
33.14.1.
Air Intake
The air intake section or inlet section, shown in Fig. 33.62, consists
of a fresh air inlet, a recirculate (inside) air inlet, a fresh-recirculate
air door, a blower with motor, and an air outlet. The fresh air inlet
provides the system with fresh outside air and the recirculate air inlet
provides recirculated incar air supply. The position of the vacuum
motor operated fresh-recirculate door depends on the system mode,
as shown in Fig. 33.62 in dotted lines, for 100% fresh
Fig. 33.62. Air inlet section.

air and 100% recirculated air conditions. Actually in all modes except
maximum cooling (max A/C), the air supply is from outside. Even in
max A/C mode, some systems provide for up to 20% fresh air, which
increases incar pressure slightly. Normally in max A/C mode inside
air is recirculated.
33.14.2.
Core Section
The core section, more appropriately called the plenum section,

shown in Fig. 33.63, is the centre section of the duct system. It
consists of the heater core, the air-conditioning evaporator, and a
blend door. The blend door, usually Bowden cable operated,
provides full-range control of airflow either through or bypassing the
heater core. All the air passes through the air-conditioning
evaporator. In this section full-range temperature conditions are
achieved for in-car comfort.
Fig. 33.63. Core section.
Heating. The heater water valve allows hot engine coolant to flow
through the heater core. Cool and fresh air from outside is heated as
it passes through the heater core. The air-conditioner is not
operated and hence, it has no effect on the air temperature as the air
first passes through the evaporator. The desired temperature is
achieved by the position of the blend door, which allows a
percentage of the cool outside air to bypass the heater core to
temper the heated air. The heated air and cool air are then blended
in the plenum to provide the desired temperature level before
passing to the air distribution section.
Cooling. In the maximum cooling condition (max A/C), recirculated
air passes through the air conditioner evaporator and is then
directed back into the car. In other than max A/C, fresh outside air
passes through the air-conditioning evaporator and is cooled before
delivery into the car. The desired temperature level is achieved by
the position of the blend door, which allows a percentage of cooled
air to pass through the heater core for reheating. The cooled air
passing through the evaporator and the reheated air passing through
the heater core are blended in the plenum to provide the desired
temperature level and then directed to the air distribution section.
33.14.3.
Air Distribution Section

The air distribution section (Fig. 33.64A) directs conditioned air to
the floor outlets, the defrost outlets, or the dash panel outlets. Also
depending upon the position of the mode doors, conditioned air may
be delivered to any combination of outlets. There are two mode
(blend) doors in the distribution section; the HI/LO door and the
DEF/AC door. The HI/LO door, shown in Fig. 33.64B, provides zero to
100 percent full range outlet control of conditioned air to the HI
(dash panel) and LO (floor) outlets. The DEF/AC door, shown in Fig.
33.64C, provides outlet control of conditioned air either to the
defrost (windshield) outlets or to the dash panel outlets.
Fig. 33.64. Air distribution section.

A. Without diverter door. B. HI/LO diverter door.
C. DEF/AC diverter door.
33.14.4.
Combined Case / Duct System

The combined case / duct system provides full range control of air
circulation through the heater core and air conditioner evaporator.
Figure 33.65A illustrates flow of 100% recirculated air through the air
conditioner evaporator and discharge through the panel eutlets. This
may typically represent mode and blend door positions when
maximum cooling (max A /C) is selected during high in-car
temperature conditions. Figure 33.65 B illustrates 100% fresh air
circulation through the heater core and discharge through the floor
outlets. This may typically represent the mode and blend door
positions when heating is selected during low in-car temperature
conditions and no cooling is provided by the evaporator. A variation
in Fig. 33.65C, shows some of the heated air is diverted to the
defrost outlet. This would be the typical application to clear the
windshield of fog or light icing conditions.

Case/Duct System (Automobile)

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Case/Duct System (Automobile)

A typical automotive heater/air-conditioner case/duct system is

Fig. 33.59. Split case system with upstream blower.

Fig. 33.61. A typical case/duct system split into the three

Fig. 33.62. Air inlet section.

The core section, more appropriately called the plenum section,

Air Distribution Section

Fig. 33.64. Air distribution section.

Combined Case / Duct System

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