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Global climate change is a major concern worldwide and most refrigerants which are being used today are Hydro-fluorocarbon (HFC), which are potent green house gases. With the rising popularity of electric vehicles, there has been an increased demand for effective and efficient cooling system, not only for cabin cooling for bus but for battery pack Thermal Management Systems also. This has led to an increase in the refrigerant amount and it is even more in case of commercial electric vehicle. Alternate refrigerant with low global warming potential like R1234yf (GWP = 4), Co2 (GWP = 1), R- 152a (GWP = 124) emerged to cater this challenge; But due to their high cost, risk regarding flammability and relative performance, some researchers found secondary loop cooling system as the next possible solution.

The aim of this paper is to highlight the unique requirement of air conditioning systems for very high ambient temperature and dusty environment. Typical requirement of such applications is needed for off road vehicles, tractors, railway etc. Among them the system requirement for railway has its own challenges in terms of performance, reliability and serviceability. In one of such applications existing design of air conditioning system was facing the issue of frequent tripping during the peak summer condition. One of the reasons was very high dust environment around its condenser area. The level of dust was so high that mesh filter was deployed at condenser front area to prevent choking of condenser fins heat transfer area. The condenser filter cleaning was needed on daily basis to run the Air Conditioning (AC) properly. To solve this problem a newly designed multi-flow wave fin type condenser was deployed in place of regular multi-flow louver fin condenser.