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This article was published in ASHRAE Journal, August 2010.

Copyright 2010 American Society of Heating, Refrigerating and Air-Conditioning


Engineers, Inc. Posted at www.ashrae.org. This article may not be copied and/or distributed electronically or in paper form without permission
of ASHRAE. For more information about ASHRAE Journal, visit www.ashrae.org.

Refrigeration
Air Cooler
Rating Methods
By Bruce I. Nelson, P.E., Member ASHRAE user whose undersized air coolers cause
lower-than-expected operating suction

R
efrigeration air coolers (evaporators) are widely used to cool and circulate temperatures with associated increased
energy consumption and loss of refrig-
air in cold storage warehouses and food processing facilities. Manufactur- erating capacity.

ers of air coolers publish cooling capacities based on differing assumptions and Air Temperature Change
As air passes across the fins of an evap-
rating methods.1 In Europe, a number of manufacturers of commercial air coolers orator coil, the temperature is reduced
according to the following relationship:4
(i.e., coolers designed for use with R-404a/R-507) subscribe to the Eurovent
q = m C p (Tent Tlvg ) (1)
certification program based on the European test standard EN 328.2 However,
In a room refrigerated by air cooling
no manufacturer is certified for industrial air coolers (i.e., coolers designed for evaporators, the change in air tempera-
ture (reduction) as it passes through the
use with ammonia refrigerant). evaporator coils will equal the change in
air temperature (increase) as it circulates
The U.S. has performance standard though nominal catalog ratings appear to throughout the room. Meaning that in a
AHRI-420,3 but as of yet, no manufactur- satisfy the calculated refrigeration load. well-designed cold room, the air tempera-
ers participate in a certification program The smaller size and lower first cost of ture gradient found in the room is roughly
based on this standard. Therefore, it is air coolers, which are inadvertently un- equal to, and will be determined in large
important for refrigeration design pro- dersized due to misunderstood or misap- part by, the air temperature change in
fessionals to understand the different plied ratings, are seductively attractive to
rating methods being used and to apply contractors and end users. However, the About the Author
them appropriately. In extreme cases, air price difference ultimately will be more Bruce I. Nelson, P.E., is president of Colmac Coil
coolers can be grossly undersized even than paid for by the unsuspecting end Manufacturing in Colville, Wash.

24 ASHRAE Journal ashrae.org August 2010


Variables 6
q = cooling capacity (sensible only), Btu/h (kW)
m = mass flow rate of air, lbm/h (kg/s) 8
Cp = specific heat capacity of moist air,
DT1 = 13.3F
Btu/lbmF (kJ/kgC) 10
Tent = dry-bulb air temperature entering the coil (air

Temperature (F)
on temperature), F (C) 12
Tlvg = dry-bulb air temperature leaving the coil, F (C)
e = effectiveness = (TentTlvg)/(TentTevap) 14
DT1 = DTM = 10F
Tevap = average refrigerant evaporating temperature, F
(C) 16
q DTM = capacity at mean (room) temperature difference, DT1 Air Temperature
Btu/h (kW) DTM Air Temperature
18 p Tevap Air Temperature
q DT1 = capacity at initial (air on) temperature difference,
Btu/h (kW)
20
DT1 = initial temperature difference=air on tem-
perature evaporating temperature, F (C) Figure 1: DT1 versus DTM air temperatures.
DTM = mean (room) temperature difference=average
room temperature evaporating temperature, refrigeration air cooler has a rating of 10 TR at a DT1 of 10F
F (C) (12C). The capacity of the same cooler operating with a new
r = air density, lbm/ft3 (kg/m3) DT1 of 12F (11) will be very close to 1012/10 = 101.2
V = actual volumetric airflow rate, ft3/min (m3/h) = 12 tons (42 kW).

Average Room Temperature and DTM Ratings


the evaporator coils. By Equation 1 the magnitude of the air Control of the refrigeration system is normally ac-
temperature change (gradient) in the room will be determined complished by maintaining room air temperature, that is,
by the air mass flow rate through the evaporators. For example, compressors and coolers are cycled on or off depending on
if a relatively small air temperature gradient is desirable in a whether room temperature is rising or falling. Location of
refrigerated room, then air coolers with relatively high airflow the air temperature sensing device relative to the location
rate (i.e., high cfm/ton) for a given capacity must be selected. of evaporators will affect evaporator performance since a
temperature gradient always exists in the room and, as seen
Heat Exchanger Effectiveness previously, evaporator performance is determined by the air
One well-known method used to calculate the sensible cool- on temperature (i.e., by DT1). Evaporators located high in the
ing capacity of evaporators is the effectiveness method.5 Heat room (mounted on the ceiling, for example), will be exposed
exchanger effectiveness is defined as the ratio of the actual to the highest air temperature in the room and operate with
amount of heat transferred to the maximum possible amount of the largest DT1. Conversely, floor mounted evaporators will
heat that could be transferred with an infinite area. This method be exposed to the coldest air in the room and operate with
is extremely useful because cooling capacity can be calculated the smallest DT1.
directly knowing only the dimensional characteristics of the coil For the specific case where air coolers are ceiling mounted
and the initial temperature difference (entering air temperature (i.e., operate at the warmest location in the room); and the
minus the evaporating temperature). This initial temperature system control temperature sensor is mounted at a location
difference is referred to as DT1 (or TD) in the refrigeration where it will sense the average room temperature (i.e., at the
industry. Sensible cooling capacity is calculated as follows: midpoint elevation in the room), manufacturers of air coolers
publish ratings based on mean (average room) temperature dif-
q = m C p (Tent Tevap ) = m C p DT1 (2) ference. This average temperature difference is termed DTM.
DTM ratings for the same air cooler will always be higher than
For a given size of coil operating with constant airflow rate, DT1 ratings since the effective initial temperature difference
the effectiveness can be considered constant over the small op- seen by the evaporator coil is higher by approximately one-
erating temperature ranges typical of refrigeration applications, half of the air temperature change. Figure 1 illustrates how
and therefore, capacity can be considered to be proportional air temperature changes as it passes through an evaporator at
to the ratio of DT1. Hence, if evaporator coil sensible capac- two different operating conditions. Note that airflow is held
ity is known for a given DT1, then capacity at a new initial constant for both operating conditions. The first condition with
temperature difference, DT1, can be found by multiplying DT1 = 10F (12C) is shown in blue. The second condition
the original capacity by the ratio DT1/DT1. For example, a with DTM = 10F (12C) is shown in red. Because the DTM

August 2010 ASHRAE Journal 25


= 10F (12C) condition has a larger initial temperature dif- Room Temperature
ference of DT1 = 13.3F (10C), the cooling capacity and air Sensible Heat Ratio
(F)
temperature change are significantly larger than for the DT1 = 45 0.55
10F (12C) condition. It is interesting how the same evapo-
32 0.66
rator can produce more cooling capacity simply by redefining
temperature difference. 10 0.83
Although DTM ratings may be useful in the specific case of 0 0.89
ceiling mounted air coolers (equipment size and first cost can 10 0.93
be reduced), refrigeration system designers must be careful
30 0.97
to recognize the limitations of this rating system and avoid
the mistake of misapplying DTM ratings. Whenever air cool- Table 1: SHR for 95% RH air on and DT1 = 10F (5.6C) at various
ers are installed at a location in the room where the air on temperatures.
temperature to the coil is less than the highest temperature in
the room, DTM ratings should not be used. This would be the Latent Load and Sensible Heat Ratio (SHR)
case with cooler inlet air ducted from some lower temperature Whenever cooling coil surfaces operate at temperatures
point in the room, or with floor mounted coolers. below the dew point of the air being cooled, water vapor in the
DT1 ratings used with actual anticipated air on tem- airstream is condensed to liquid (at temperatures above 32F
perature will always result in accurate ratings and correct [0C]) or deposited to form frost (below 32F [0C]). The cool-
air cooler selections. This method for air cooler selection is ing effect associated with this dehumidification of the airstream
conservative and recommended whenever air on tempera- is termed latent cooling. The sum of the sensible cooling load
ture to the coil is less than the maximum found in the room and latent cooling load is termed the total load. The ratio of
or process. the sensible cooling load divided by the total cooling load is
called the sensible heat ratio (SHR) and defines the slope of
Converting DT1 to DTM Air Cooler Ratings the air process line on a psychrometric chart.
Equations 1 and 2 were used to derive the relationships shown
Sensible Cooling Load
in Equation 3 that can be used to convert from a known DT1 air SHR = (4)
cooler rating to a new DTM rating for the same cooler. Sensible Cooling Load + Latent Cooling Load

DTM Accurate prediction of the refrigeration load, both sensible


qDT1 and latent components, is critical to proper refrigeration system
qDTM = DT1
(3) equipment selection and successful operation. Various types
1 q
DT1
2 60 C V DT1 of sensible cooling loads must be anticipated and included
p in the calculation, such as: lighting, electric motors, forklifts,
Example: product cooling/freezing, transmission of heat through walls,
An air cooler has a DT1 rating of 120,000 Btu/h at DT1 = ceilings and floors, and cooling of infiltration air. Latent cool-
10F and 10F air on temperature. The cooler has a published ing loads are present whenever moisture is added to the air in
airflow rating of 18,850 cfm. Assume the coil is operating with the refrigerated space. Sources of introduced moisture typi-
average air density = 0.0883 lbm/ft3, and average air specific cally include: infiltration air, respiring food products, surface
heat = 0.24 Btu/lbmF. Note this is the same cooler shown in moisture on products, packaging, and other objects entering
Figure 1. the space, human respiration, and humidification equipment
Find the DTM rating for the same cooler with DTM = 10F. (above freezing).
From Equation 3: The SHR determined from the load calculation will come
10 to equilibrium with the SHR of the air passing through the
120, 000 air cooler evaporator coil. In general, as air temperature de-
10
qDTM = = 160,050 Btu/h
120 , 000 creases the amount of water vapor held in the air decreases
1
260 0.24 0.088318, 850 10 by the law of partial pressures, and the minimum possible
SHR increases.
As seen from the example, DTM ratings are typically signifi- Relative humidity of the refrigerated space can be predicted
cantly higher than DT1 ratings for the same air cooler operating by plotting the air process line on a psychrometric chart with
under the same conditions. In the case of the example, the DTM the end point plotted on the saturation curve at the predicted
rating is +33% greater than the DT1 rating! coil surface temperature, and the air process line extending from
Note that the above equations apply only to sensible capacity left to right at a slope equal to the SHR. The intersection of this
calculations and ratings and do not account of the effects of line with a vertical line drawn through the entering air dry-bulb
latent cooling on coil performance and temperature change. temperature indicates the relative humidity of the air entering
The effects of latent load on coil performance and ratings are the coil. Table 1 shows typical sensible heat ratios for various
covered in the following sections. air temperatures at 95% air on relative humidity.

26 ASHRAE Journal ashrae.org August 2010


Advertisement formerly in this space.
Impact of Latent Load (SHR) on Air 1.5
Cooler Ratings
1.45
Evaporator coils are typically con-

Capacity Factor, Qtotal/Qsens Only


1.4
structed of plate fins bonded to tubes. Fins
are referred to as secondary surface 1.35
while tubes are referred to as primary 1.3
surface. For purposes of calculating 1.25
evaporator performance, primary surface 1.2
is considered to be 100% effective in its
1.15
contribution to the total heat transfer sur-
1.1
face area while secondary surface has a
surface effectiveness less than 100% due 1.05

to the change in surface temperature from 1


0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1
the root to the tip of the fin.
Sensible Heat Ratio
The capacity of the evaporator sur-
faces to transfer mass (condense water Figure 2: Total cooling capacity factor versus sensible heat ratio.
or deposit frost, from the airstream) is
a function of the difference in water vapor pressure between and 95% relative humidity would be 0.89. From Figure 2, an air
the coil surface and air stream and the surface mass transfer cooler rated on a total cooling basis at +0F (17.8C) and 95%
coefficient. The mass transfer process is much more thermally air on relative humidity would show a nominal capacity +11%
effective than the sensible heat transfer process, that is, the heat greater (capacity factor = 1.11) than a sensible only rating. In
flux through the evaporator surfaces during the mass transfer this case, therefore, air coolers selected using ratings based 95%
process is extremely high.6 Consequently, if the surface ef- air on relative humidity would be significantly undersized.
fectiveness of the coil were to remain constant, the increase in
the evaporator cooling capacity during combined sensible and Conclusions
latent cooling would be equal to the sensible cooling capacity U.S. air cooler manufacturers have traditionally published
divided by the SHR, as follows: capacity ratings based on SHR = 1.0 (all sensible) and DT1.
European manufacturers typically include latent cooling in their
Sensible Cooling Load
Total Cooling CapacityIdeal = (5) air cooler ratings, indicated by an air on relative humidity
SHR typically between 85% and 95%. European manufacturers also
However, the increase in heat flux through the fin surfaces publish ratings based on either DT1 or DTM, or both. The dis-
has the effect of decreasing fin efficiency and overall surface cussion above illustrates the differences in these rating methods
effectiveness due to an increase in the fin surface temperature and highlights the importance of selecting air coolers using rat-
gradient.7 The result is a slightly lower total cooling capacity ings suited to the operating conditions. Misapplication of DTM
than that predicted by Equation 5. Using a computer model and/or total cooling ratings can result in severely undersized air
developed to accurately calculate fin efficiency and surface coolers and the consequent failure of the refrigeration system to
effectiveness for both sensible and combined sensible and perform to energy efficiency and cooling capacity expectations.
latent heat transfer, a prediction of the increase in evaporator
coil performance as a function of SHR was made. Results of References
the predicted capacity increase as a function of SHR for an 1. Nelson, B. 2010. Comparing air cooler ratings. Technical Bul-
ammonia refrigeration evaporator coil operating over a wide letin. Colmac Coil Manufacturing, Inc.
range of room temperatures (+35F to 30F [2C to 34C]) 2. EN. 2002. Standard EN 328, EN 328Heat exchangersTest
procedures for establishing the performance of forced convection unit
and having typical fin spacings and geometry with DT1 = 10F
air coolers for refrigeration. European Norm.
(5.6C) are shown in Figure 2. 3. AHRI. 2008. Standard 420, Performance Rating of Forced-Circu-
Air cooler ratings, which include latent cooling will appear lation Free-Delivery Unit Coolers for Refrigeration. Air-Conditioning
higher (in some cases significantly higher) than all sensible Heating & Refrigeration Institute.
ratings. Care must be taken to correctly predict the cooling 4. 2009 ASHRAE HandbookFundamentals, Chap. 4, p. 4.18.
load SHR and the resulting relative humidity in the refrigerated 5. Kays, W.M., A.L. London. 1964. Compact Heat Exchangers,
space. Selecting an air cooler with a rating based on a high room Second Edition, Chap. 2, pp. 1524. McGraw-Hill Book Company.
relative humidity (SHR less than 1.0) for a room with an actual 6. AHRI 2001. Standard 410, Forced-Circulation Air-Cooling
and Air-Heating Coils, Section 6.2.1. Air-Conditioning Heating &
SHR equal to or close to 1.0 will result in undersized air coolers.
Refrigeration Institute.
For example, a long-term cold storage warehouse is designed 7. Xia, Y., A.M. Jacobi. 2005. Air-side data interpretation and
for +0F (17.8C) room temperature with a calculated SHR performance analysis for heat exchangers with simultaneous heat and
nearly equal to 1.0 (i.e., packaged products and minimal infiltra- mass transfer: wet and frosted surfaces. International Journal of Heat
tion). From Table 1, the SHR for +0F (17.8C) air temperature and Mass Transfer 48:50895102.

28 ASHRAE Journal ashrae.org August 2010

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