This discussion will then take up the short way, or quick selection

Refrigeration Load Sizing For Walk-In
Coolers, Freezers, & Other Boxes
In this Info-Tec, we will show how to calculate the heat load for any
walk-in box. First, well cover the long way. The long way allows market. Shortcut estimating methods can be used for these small
you to calculate the load for any size box, in any location, with any
product load. All the data asked for in Figure 1 must be gathered and
be accurate.
way, for small walk-in boxes. Small will be defined as coolers up to
2,400 Cu. Ft. in size, freezers up to 1,500 Cu. Ft. in size, and no
unusual loads. These small boxes comprise over 90% of the
boxes.
The heat gain through walls, floors, and ceilings, will vary with the type
of construction, the area exposed to a different temperature, the type
of insulation, the thickness of insulation, and the temperature
difference between the refrigerated space and the ambient air.

The basic formula for heat transfer through some heat transfer
barrier is: Q = U x A x TD

Q = Heat transfer, BTU/Hr

U = Overall heat transfer coefficient

BTU/(hour)(Sq.Ft.)(F TD)

A = Area in square feet

TD = Temperature differential between sides of thermal

barrier; for example, between outside design

temperature and the refrigerated space

temperature.

Q is the rate of heat flows through a medium. It can be

determined after finding the thermal resistances of the materials
through which the heat flows.

Certain letter symbols are used to denote heat transfer

factors. K stands for Thermal Conductivity. It is the rate of heat
transfer that occurs through one inch of a material. Different materials
offer different resistances to the flow of heat. K is expressed in units
of BTU/(Hr.)(Sq.Ft. of area)(F TD).

For example, the heat transfer in 24 hours through 2 Sq. Ft. of

Figure 1. material, 3" thick, having a thermal conductivity factor of .25, with an
average temperature difference across the material of 70F would be first find the overall resistance to heat flow, and then find the reciprocal
calculated as follows: of the overall resistance to calculate the U factor.

Q = .25(k) x 2 Sq.Ft. x 24 hours x 70 TD = 280 The basic relation between the U factor and the various
BTU conductivity factors is as follows:

3" thickness R total = 1 + X1 + X2

Since the total heat transferred by conduction varies directly with C k1 k2

time, area, and temperature difference, and varies inversely with the
thickness of the material, it is readily apparent that in order to reduce U = 1 total
heat transfer, the K factor should be as small as possible, and the
material as thick as possible. R

Thermal Resistivity, or r is the reciprocal of K, or Where C is the conductance

1/K. Resistance values can now be added numerically. R total = r1 +
r2 +r3, where r1, r2, and r3 are individual resistances. Individual r- X1 is the thickness of material one
values are used in calculating overall heat transfer coefficients.
X2 is the thickness of material two
C or Conductance is similar to K, except it is an overall heat
transfer factor for a given thickness of material, where K is a factor per k1 is the thermal conductivity of material one
inch.
And k2 is the thermal conductivity of material two
Thermal Resistance R is the reciprocal of Conductance, 1/C,
the same way thermal resistivity was the reciprocal of conductivity. For example, to calculate the U factor of a wall composed of 2"
of material having a k factor of .80, and 2" of insulation having a
The U factor is the overall coefficient of heat transfer. It is conductance of .16, the U value is found as follows:
defined as the rate of heat transfer through a material or compound
R total = 1 + X1
structural member with parallel walls. The U factor is the resulting
heat transfer coefficient after giving effect to thermal conductivity and
C K1
conductance, and is expressed in terms of BTU (Hour)(Sq. Ft. of
area)( F TD). It is usually applied to compound structures, such as = 1 + 2
walls, ceilings, and roofs.
.16 .80
The formula for calculating the U factor is complicated by the fact
that the total resistance to heat flow through a substance of several = 6.25 + 2.5 = 8.75
layers is the sum of the resistance of the various layers. The
resistance to heat flow is the reciprocal of the conductivity. Therefore, U = 1 total = 1
in order to calculate the overall heat transfer factor, it is necessary to
R 8.75
 = .114 BTU/(Hour)(Sq.Ft.)(F TD)

Once the U factor is known, the heat gain by transmission

through a given wall can be calculated by the basic heat transfer
equation.

Assume a wall with a U factor of .114 as calculated in the

previous example. Given an area of 90 square feet with an inside
temperature of 0F and an outside temperature of 80F, the heat
transmission would be:

Q = U x A x TD

= .114 x 90 Sq. Ft. x 80 TD

= 812 BTU/Hr.

The entire heat gain into a given refrigerated space can be found
in a similar manner by determining the U factor for each part of the
structure surrounding the refrigerated space, and calculating as
above. Most good insulating materials have a thermal conductivity (k)
factor of approximately .25 or less, and rigid foam insulations have
been developed with thermal conductivity (k) factors as low as .12 to
.15.

Heat transmission coefficients for many commonly used building

materials are shown in Table 1.

Table 1.

Extensive studies have been made of weather bureau records

for many years to arrive at suitable outdoor design
temperatures. Naturally, the maximum load occurs during the hottest
weather. However, it is neither economical nor practical to design
equipment for the hottest temperature, which might ever occur, since
the peak temperature might occur for only a few hours over the span
of several years. Therefore, the design temperature normally is
selected as a temperature that will not be exceeded more than 1% of conductivity factor of .16. If other insulations are used, the
the hours during the four month summer season. recommended thickness should be adjusted based on relative k
factors.
For Wisconsin, the outdoor design temperatures are 90F dry
bulb, 74F wet bulb. For Minneapolis, Minnesota, they are 92F dry Table 3.
bulb, 75F wet bulb. For Illinois, they are 94F dry bulb, 75F wet bulb.

If the box has any exterior walls or ceiling, an allowance for

radiation from the sun must be taken into consideration. If the walls
of the refrigerated space are exposed to the sun, additional heat will
be added to the heat load. For ease in calculation, an allowance can
be made for the sun load in refrigeration calculations by increasing the
temperature differential by the factors listed in Table 2.

Table 2.

Table 4 lists the approximate heat gain in BTU per 1F

temperature difference per Sq. Ft. of surface per 24 hours for various
thicknesses of commonly used insulations. The thickness of
insulation referred to is the actual thickness of insulation, and not the
overall wall thickness. For example, to find the heat transfer for 24
hours through a 6' x 8' wall insulated with 4 inches of glass fiber, when
the outside is exposed to 95F ambient temperature and the box
temperature is 0F. Calculate as follows: 1.9 factor x 48 Sq. Ft. x
95o TD = 8664 BTU

Insulation thickness must be increased as the storage Table 4.

temperature decreases. Table 3 lists recommended insulation
thickness from the 1981 ASHRAE Handbook of Fundamentals. The
recommendations are based on expanded polyurethane, which has a
 Any outside air entering the refrigerated space must be reduced
to the storage temperature, thus increasing the refrigeration load. In
addition, if the moisture content of the entering air is above that of the
refrigerated space, the excess moisture will condense out of the air,
and the latent heat of condensation will add to the refrigeration load.

Because of the many variables involved, it is difficult to calculate

the additional heat gain due to air infiltration. Various means of
estimating this portion of the refrigeration load have been developed
based primarily on experience, but all of these estimating methods are
subject to the possibility of error, and specific applications may vary in
the actual heat gain encountered.

The traffic in and out of a refrigerator usually varies with its size
or volume. Therefore, the number of times doors are opened will be
related to the volume rather than the number of doors.

Table 5 lists estimated average air changes per 24 hours for

various size refrigerators due to door openings and infiltration for a
refrigerated storage room. Note that these values are subject to major
modification if it is definitely determined that the usage of the storage
room is either heavy or light. Heavy usage is usually defined as four
or more door openings per hour.
Table 5.
Another more accurate means of computing infiltration into a
refrigerated space is by means of the velocity of airflow through an
open door. When the door of a refrigerated storage space is opened,
the difference in density between cold and warm air will create a
pressure differential, causing cold air to flow out the bottom of the
doorway and warm air to flow in the top. Velocities will vary from
maximum at the top and bottom to zero in the center. The estimated
average velocity in either half of the door is 100 feet per minute for a
doorway 7' high at a 60oF TD. The velocity will vary as the square
root of the height of the doorway and as the square root of the
temperature difference.

For example, the rate of infiltration through a door 8' high and 4'
wide, with a 100oF TD between the storage room and the ambient can
be estimated as follows:

Velocity = 100 FPM x 8 x 100

7 x 60

= 100 x 2.83 x 10

2.65 7.74

= 138 FPM

Estimated rate of infiltration 138 FPM x 8 Ft. x 4

Ft. = 2210 Cu. Ft. per min.

Infiltration velocities for various door heights and TDs are plotted
in Table 6.

Table 6.

If the average time the door is opened each hour can be

determined, the average hourly infiltration can be calculated, and the
heat gain can be determined as above. (If positive ventilation is
provided for a space by means of supply or exhaust fans, the
ventilation load will replace the infiltration load if greater) and the heat
gain may be calculated on the basis of the ventilating air volume. This
situation is very unusual (most walk-ins are not ventilated).
Once the rate of infiltration has been determined, the heat load
can then be calculated from the heat gain per Cu. Ft. of infiltration as
given in Table 7. The product load is composed of all the heat gain
occurring due to the product in the refrigerated space. The load may
arise from a product placed in the refrigerator at a temperature higher
than the storage temperature, from a chilling or freezing process, or
from the heat of respiration of perishable products. The total product
load is the sum of the various types of product load, which may apply
to the particular application.
Table 7.
Fruits and vegetables are living organisms. Their life processes
continue for some time after being harvested, and as a result they give
off heat. Certain other food products also undergo continuing
chemical reactions, which produce heat. This is called heat of
respiration. Meats and fish have no further life processes and do not
generate any heat. The amount of heat given off is dependent on the
specific product and its storage temperature. The heat of respiration
varies with the storage temperature.
Many engineering manuals are available with the entire product
data needed to calculate product load. (These manuals have been
well circulated throughout Climatic Control Company. The Heatcraft
Engineering Manual H-ENG-1 dated June 1990 is used for this Info-
Tec.)
Most products are at a higher temperature than the storage
temperature when placed in a refrigerator. Since many foods have a
high percentage of water content, their reaction to a loss of heat is
quite different above and below the freezing point. Above the freezing
point, the water exists in liquid form, while below the freezing point;
the water has changed to ice. The specific heat of a product is defined
as the BTUs required to raise the temperature of one pound of the
substance 1F.
Specific heats of products are listed in the manuals. Note that
the specific heat above freezing is different than the specific heat
below freezing. Also note that freezing points vary.
The heat to be removed from a product to reduce its temperature
above freezing may be calculated as follows:
Q = W x c x (T1 - T2)
Where Q is the number of BTUs to be removed
W is the weight of the product in pounds
c is the specific heat above freezing
T1 is the initial temperature, F
And T2 is the final temperature, F (freezing or above)
 For example, the heat to be removed in order to cool 1,000
pounds of veal (whose freezing point is 29F) from 42F to 29F can cooling again can occur in the same manner as that above freezing,
be calculated as follows:
Q = W x c x (T1 - T2)
= 1000 pounds x .71 specific heat x (42 - 29)
= 1000 x .71 x 13
= 9,230 BTU
Food products have a high percentage of water content. In order
to calculate the heat removal required to freeze the product, only the
water need be considered. Since the latent heat of fusion or freezing
of water is 144 BTU/Lb., the latent heat of fusion for the product can
be calculated by multiplying 144 BTU/Lb. by the percentage of water
content. To illustrate, veal has a water percentage of 63%, and the
latent heat of fusion for veal is 91 BTU/Lb. 63% x 144 BTU/Lb. = 91
BTU/Lb.
The heat to be removed from a product for the latent heat of
freezing may be calculated as follows:
Q = W x h if
Q is the number of BTUs to be removed
W is the weight of product in pounds
h if is the latent heat of fusion, BTU/lb.
The latent heat of freezing of 1,000 pounds of veal at 29F is:
Q = W x h if
= 1000 lbs. x 91 BTU/lb.
= 91,000 BTU
Once the water content of a product has been frozen, sensible
with the exception that the ice in the product causes the specific heat
to change. The specific heat of veal above freezing is .71, while the
specific heat below freezing is .39.
The heat to be removed from a product to reduce its temperature
below freezing may be calculated as follows:
Q = W x ci x (Tf - T3)
Q is the number of BTUs to be removed
W is weight of product in pounds
ci is specific heat below freezing
Tf is freezing temperature
T3 is final temperature
For example, the heat to be removed in order to cool 1,000
pounds of veal from 29F to 0F can be calculated as follows:
Q = W x ci x (Tf - T3)
= 1,000 lbs. x .39 specific heat x (29-0)
= 1,000 x .39 x .29
= 11,310 BTU
The total product load is the sum of the individual calculations for
the sensible heat above freezing, the latent heat of freezing, and the
sensible heat below freezing.
From the foregoing example, if 1,000 pounds of veal were to be
cooled from 42F to 0F, the total would be:
Sensible Heat above freezing 9,230 BTU
 Latent Heat of freezing 91,000 BTU approximations, the actual electric power input in watts is the only
accurate measure of the energy input.
Sensible Heat below freezing 11,310 BTU
Table 8.
Total product load 111,540 BTU

Note that as of now, no time limit has been imposed. The

product load of 111,540 BTU is not BTU/Hr! Eventually a time factor
must be taken into consideration. As an example, if the 1,000 Lbs. of
veal was the only load and the specifications are to have the veal get
to 0F in 8 hours, the hourly load is the total load divided by the number
of hours to get to 0F. 111,540 8 = 13,942.5 BTU/Hr.

In addition to the heat transmitted into the refrigerated space

through the walls, air infiltration, product load, and any heat gain from
other sources must be included in the total cooling load estimate.

Any electric energy directly dissipated in the refrigerated space

such as lights, heaters, etc. is converted to heat and must be included
in the heat load. One-watt hour equals 3.41 BTU, and this conversion
ratio is accurate for any amount of electric power.

Any electrical energy transmitted to motors inside a refrigerated

space must undergo a transformation. Any motor losses due to
friction and inefficiency are immediately changed to heat energy. That
portion of the electrical energy converted into useful work, for example
in driving a fan or pump, exists only briefly as mechanical energy, is
transferred to the fluid medium in the form of increased velocity, and
as the fluid loses its velocity due to friction, eventually becomes
entirely converted into heat energy.

A common misunderstanding is the belief that no heat is
transmitted into the refrigerated space if an electric motor is located
outside the space, and a fan inside the space is driven by means of a
shaft. All of the electrical energy converted to mechanical energy
actually becomes a part of the load in the refrigerated space.
People give off heat and moisture, and the resulting refrigeration
load will vary depending on the duration of occupancy of the
refrigerated space, temperature, type of work, and other
factors. Table 9 lists the average heat load due to occupancy, but for
stays of short duration, the heat gain will be somewhat higher.

Because the motor efficiency varies with size, the heat load per Table 9.
horsepower as shown in Table 8 has different values for varying size
motors. While the values in the table represent useful
 Outside Dimensions: height 8', width 10', length 40', inside
volume 3,000 Cu. Ft.

Floor area (outside dimensions) 400 Sq. Ft. on insulated slab

in contact with ground

Ambient temperature 100F, 50% relative humidity

Ground temperature 55F

Refrigerator temperature 40F

1/2 H.P. fan motor running continuously

Two 100 watt lights, in use 12 hours per day

Occupancy, 2 men for 2 hours per day

The total supplementary load is the sum of the individual factors
In storage:
contributing to it. For example, the total supplementary load in a
refrigerated storeroom maintained at 0F in which there are 400 watts 500 Lbs. of bacon at 50F
of electric lights, a 3 H.P. motor driving a fan, and 2 people working
continuously would be as follows: 1000 Lbs. of string beans
400 Watts x 3.41 BTU/Hr. = 1364 BTU/Hr. Entering product:
3 HP motor x 2,950 BTU/Hr. = 8,850 BTU/Hr. 500 Lbs. of bacon at 50F
2 People x 1300 BTU/Hr. = 2,600 BTU/Hr.
15,000 pounds of beer at 80F
Total supplementary load = 12,814 BTU/Hr.
To be reduced to storage temperature in 24 hours
The most accurate means of estimating a refrigeration load is by
Heavy door usage
considering each factor separately. The following example will
illustrate a typical selection procedure. The load has been chosen to It makes no difference in what sequence each factor that
demonstrate calculations and does not represent a normal loading. comprises the load is calculated, just so all factors are considered. It
is best to keep the same sequence so one will remember all of the
SPECIFICATIONS
factors. In this example, well do the box itself, or heat transmission
load, air infiltration, product load, and then supplementary loads.
Walk-in cooler with 4" of glass fiber insulation, outside
location, but shaded
Sidewalls:

As1 = 40' x 8' x 2 = 640 Ft2

Qs1 = 640 Ft2 x 60TD x 1.9 (Table 4) = 72,960 BTU

As2 = 10' x 8' x 2 = 160 Ft2

Qs2 = 160 Ft x 60TD x 1.9 = 18,240 BTU

Ceiling:

Ac = 40' x 10' = 400 Ft2

Qc = 400 Ft2 x 60TD x 1.9 = 45,600 BTU

Floor:

Af = 40' x 10' = 400 Ft2

Qf = 400 Ft2 x 15TD x 1.9 = 11,400 BTU

 Q total for a 24 hour transmission load = 148,200 BTU (cooler alone, no other loads)

Air infiltration:

3000 Ft3 x 9.5 air changes (Table 5) x 2 usage factor x 2.11 factor (Table 7) = 120,270 BTU

Product load factors were taken from the Heatcraft Engineering
Manual H-ENG-1.
Many products have a range shown for their specific heats, such
as bacon or pork. The specific heat is shown as .46 to .55 BTU/LB/F
above freezing. When a range for specific heat is given, average the
low and high of the range to calculate the load. The average is (.46 +
.55) 2 = .505. There is no reason to use three decimal places or
more in calculating, so round off to two decimal places.
 Q bacon = 500 Lbs. bacon x .50 sp. ht. x 10TD = 2500 BTU.

Q beer = 15,000 lbs. beer x .92 sp. ht. x 40TD = 552,000 BTU.

Q beans = 1,000 Lbs. beans x .5 = 5000 BTU.

Note we had all 24 hours to reduce the temperature of the bacon 200 watts x 12 hours x 3.41 BTU/Hr. = 8,184 BTU
from 50F to 40F.
1/2 H.P. x 4250 BTU/Hr-Hr (Table 8) x 24 = 51,000 BTU
Note that we have to deal only with the heat of respiration for the
beans. They were specified in long-term storage and no temperature 2 People x 2 hrs/day x 840 BTU/Hr. (Table 9) = 3,360 BTU
reduction was required. (In the real world, there probably would have
been a temperature reduction, but remember we are demonstrating Total 24 hour supplementary Load = 62,544 BTU
calculations.) The heat of respiration for beans is shown as 4.6 to 5.7
BTU/Lb./24 hrs. at 40F. Again, averaging and rounding off .5 We can now total all the loads to arrive at a 24-hour load.
BTU/Lb./24 hrs.
Transmission load = 148,200 BTU
The total product load is:
Air infiltration = 120,270 BTU
500 lbs. bacon = 2500 BTU
Product = 559,500 BTU
15,000 lbs. beer = 552,000 BTU
Supplementary = 62,544 BTU
1000 lbs. beans = 5,000 BTU
Total 24 hour load = 890,514 BTU
Total 24 Hr. product load = 559,500 BTU
Often a 5% to 10% safety factor is added to the load calculations,
The supplementary loads are: to be sure the equipment is big enough.
 If, as in the example, all the data concerning the load is gathered,
no safety factor need be added. In fact, additional safety factor load
may be detrimental. The equipment may end up very oversized and
cause low load problems. Also, safety factors result in higher
equipment costs.
In general, the fact that the compressor is sized on the basis of
16 to 18 hours operation in itself provides a large safety factor. The
load is calculated on the basis of the peak demand at design
Tech Tip: Hourly load for compressor sizing is simply the 24-hour load divided by the selected run
time.
For example, if 18 hours run time is selected: 890,514 BTU 18
hr = 49,473 BTU/hr.
In order to complete the equipment selection, a split must now
be determined. Split is the temperature difference (TD) between the
refrigerant and air. The split is selected based on the relative humidity
to be maintained in the refrigerated space. The smaller the split, the
higher the humidity.
Relative humidity in a storage space is affected by many
variables, such as system running time, moisture infiltration, condition
Recommended splits for the most common applications are:
Type Split oF RH %
Wet Produce Walk-In 10
Dry Produce Walk-In 13
Service Meat Case 15
conditions, and the design conditions are selected on the basis that
they will occur no more than 1% of the hours during the summer
months. The design criterion provides plenty of safety factors if the
data is complete and accurate. More and more designers are picking
18 hour run times rather than 16 hours, due to equipment cost. Even
20 to 22 hours are used when the temperature difference between box
temperature and refrigerant temperature results in evaporator coils
running close to or above freezing. For freezers, 18 hour run time is
usually acceptable.
and amount of product surface exposed, air motion, outside air
conditions, type of system control, etc. Perishable products differ in
their requirements for an optimum relative humidity for storage, and
recommended storage conditions for various products are shown in
the product tables. Satisfactory control of relative humidity in a given
application can be achieved by selecting the compressor and
evaporator for the proper operating temperature difference or TD
between the desired room temperature and the refrigerant
evaporating temperature.
90
85
80
 Meat Walk-In 18
All Freezers 10
For a cooler with mixed product in storage, the product
requiring the highest humidity will determine the split. To pick a
split for our example consider the storage requirements for each
product. Beer would be in cans, bottles, or kegs, and is unaffected by
humidity. Pork requires 85% to 90% R.H. and beans 90% to 95%
RH. In order to prevent moisture loss and consequently ruining the
bacon and beans, the split selected should be 10F to maintain high
humidity. Once the split has been determined, major equipment
selections can proceed.
The load divided by the split will equal the evaporator size
at 1F TD. Using our example:
49,473 10 = 4947 BTU at 1TD.
To find the right condensing unit: Box temperature minus
split equals suction temperature. In our example, 40F - 10F =
30F. The unit we want would be shown in a catalog rated at 49,473
BTU/Hr. at 30F suction temperature.
Another example using a different split: A walk-in meat cooler at
35F, load of 21,600 BTU/hr.
The calculation is as follows:
21,600 18 = 1200 BTU at 1 TD or 12,000 BTU @ 10 TD
75
--
The right evaporator for this job would be listed in a catalog
as 12,000 BTU at 10 TD. Box temperature minus split equals
suction temperature. 35F - 18F = 17F. The right condensing
unit would be rated 21,600 BTU/hr. at 17F suction temperature.
If the two components match, they should drop the suction to just
the right pressure every time it runs. Then, if the load calculation was
accurate, the compressor will run 45 minutes and be off 15 minutes
(18 hour run time). If the load is heavier than calculated, it will run
more and be off less. If the load is less than calculated, the
compressor will stay off longer. As long as the load stays somewhere
close to calculated load, the RH will be close to the requirement.
Selecting a condensing unit depends on the type of condensing
medium to be used, air or water, the design ambient temperature or
water temperature, and the capacity of the condenser selected. Air-
cooled condensers are commonly selected to operate on temperature
differences (TD) from 10F to 30F, the lower to be used for low
temperature applications where the compression ratio is less critical,
and high TDs for high temperature applications. Most manufacturers
catalogs list air-cooled condensing units by ambient temperature,
90F or 95F being the most common. The condenser TD has
therefore been taken into consideration and condensing unit selection
can be based on the ambient temperature.
Commercially available components seldom will exactly match
the design requirements of a given system, and since system design
is normally based on estimated peak loads, the system may often
have to operate at conditions other than design conditions. More than
one combination of components may meet the performance
requirements, the efficiency of the system normally being dependent
on the point at which the system reaches stabilized conditions or
balances under operating conditions.
Most manufacturers of commercial and low temperature coils
publish only ratings based on the temperature difference between
entering dry bulb temperature and the evaporating refrigerant
temperature. Although frost accumulation involving latent heat will
occur, unless the latent load is unusually large, the dry bulb ratings
may be used without appreciable error.
The most accurate means of determining the refrigeration load is
by calculating each of the factors contributing to the load as was done
in the previous example. However, for small walk-in coolers, various
types of shortcut estimating methods are frequently used.
As was mentioned at the beginning of this Info-Tec, 90% of walk-
in coolers and freezers can be defined as small. By limiting small
coolers to a maximum of 2,500 Cu. Ft., and freezers to 1,500 Cu. Ft.
in size, errors made in calculations, or assumptions made due to
incomplete data, will be small.
Every attempt should be made to gather all the data listed
in Figure 1. Even if a small box, calculating the load the long way
will produce the best results. The short way or quick selection
process should be used only when time restraints prevent accurate
calculations, and/or data is incomplete, forcing certain assumptions to
be made regarding load calculations.
There is certain minimum data required to be able to use the
quick selection tables. See Figure 1. You need to know the answers
to 1, 2, 3, 7, and 13 to arrive at a load figure. (Of course, youll need
to know answers to 10, 11, and 12 to properly complete equipment
selection, but not to find the load.)
Tables are attached for walk-in coolers and walk-in
freezers. The capacities given are for average applications. If the
load is unusual, these tables should not be used. The low
temperature tables do not include any allowance for a freezing load,
and if a product is to be frozen, additional capacity will be
required. You would need to know how much of what is going in at
what temperature and how long you have to pull down to box
temperature.
Note all the small print. The BTUs shown are the per hour load,
including the 16 - 18 hour run time safety factor.
Some typical examples: A customer calls for a quote on the
equipment for a walk-in cooler, 14' long by 10' wide by 8' high. The
box will be located in an air-conditioned store. He wants the box
temperature about 36F to 38F. He doesnt have the slightest idea
of how much of what is going to be in the box, but does know it is all
long-term storage. There is nothing else unusual about the box, like
beer shafts or glass doors. Its a good box with an insulated floor.
This is a very typical example of all the information you will get to
size the load for a small box. While not perfect, it will suffice, and
heres why:
The 14' x 10' x 8' dimensions can be inside or outside
dimensions; it wont matter. The difference between inside and
outside dimensions in load will be next to nothing in the small
box. The normal temperatures for walk-in coolers will range from
34F to 40F. While the chart was prepared for 34F, again, because
the box is a small box, no significant difference will exist in load
between a 34F box and a 40F box. Since you will probably never
be able to exactly match the load to the equipment selected, if the box
temperature is toward the high end of the range, 38F to 40F, select
the equipment capacity closest to the load, less than the load. If box
temperature is near the low end of range, 34- 36F select equipment
closest to the actual load. This box is in an air-conditioned store, so
the ambient temperature selected will be 80F. Had the box been in
an un-air-conditioned building, 90F would be selected as the
ambient. An outside box, forming its own structure, or three walls,
ceiling, and floor outside of a main structure should be considered an
unusual condition. Which way the box faces, the color of the walls
and ceiling, etc. (see previous section on sun load calculation) have
to be considered and calculations made. Avoid using the 100F
ambient temperature column for outside boxes, except very small
boxes, up to 1,200 Cu. Ft.
The customer stated it was a good box, meaning it is well built
and not leaking excessively. Our chart specification of 3" of fiberglass
insulation needs no adjustment. No amount for any product is given,
but there is always some product loading. Product loading cannot be
ignored! Long-term storage is defined as at least 24 hours to get
whatever product is put into the box down to box temperature. The
average product load column is based on extensive studies of small
boxes to determine the BTU/Hr. loads. Besides, how much product
can be crammed into a small box that would significantly affect the
average load figure?
The customer has told us there is nothing unusual about the load,
so no further load calculations are necessary or adjustments made to
the quick selection chart.
Taking the loads from the chart, we find:
Wall/Infiltration = 6880 BTU/Hr.
Ave. Product Load = 2790 BTU/Hr.
Total = 9670 BTU/Hr.
Lets completely finish the equipment selection for this box. We
will have to select a split. Not knowing anything about product in the
box, it is best to use a TD of 10F as the split. This will result in high
humidity, beneficial for most products and cant harm any packaged
goods. A 15F split could also be used. As we will see when selecting
the equipment, we can determine which split is more economical to
use. A higher split will result in a smaller evaporator, but may
necessitate a larger condensing unit negating any dollar savings of the
smaller, less expensive evaporator with a larger, more expensive
condensing unit.
Using a 10F split, our suction temperature will be 26F. Box
temperature was given as 36 - 38F. If a range of desired box
temperature is given, always use the lowest temperature.
Before equipment selection can continue, we need the answers
to Figure 1, 11, 12, and 13. The customer has told us the condensing
unit will be outdoors, either 115 VAC or 230 VAC single phase is
available, and to quote pump down as an option. (All equipment
selected will be equipment Climatic Control Company is handling as
of this date.)
First, we select the unit cooler. A Chandler RLC092F1 is rated
9200 BTU at 20F suction, 10F TD. At 26F suction, the RLC092F1
will be about 9300 BTU, 10F TD, as close as we can get to the
calculated load. Next, select the condensing unit. Some designers
will take a 2 or 3F temperature penalty for suction line loss when
selecting a condensing unit. It is deducted from the temperature
found after determining the split. With all the built-in safety factors, it
isnt really necessary. It is convenient to use those 2 or 3F to adjust
the suction temperature to correspond to BTU ratings shown on
manufacturers tables for condensing units. In our example, using
25F will be convenient.
A Tecumseh AJ9486EC condensing unit is rated 9500 BTU/Hr.
at 25F suction, 90F ambient temperature. It is single phase 208/230
Volt. It meets all the specifications and is a good match for the
RLC092F1 unit cooler. After selecting the condensing unit, look at the
detailed specification sheet(s) for the unit. We will need to know the
liquid line size to be able to select the liquid line components. We
need to find out if the unit has a low-pressure control, needed for pump
down control or the primary control if no thermostat is used. It is at
this point we can compare the cost of the major components to see if
using a 15split will make any difference in price. Using the 15 TD,
the RLC067F1 will be the unit cooler. The AJ9486EC at 20F suction
will be 8600 BTU/Hr., a little small, but the next larger unit is far too
big. It is still a close enough match to use the AJ9486EC with the
RLC067F1. In this case, there is a significant savings using a 15F
split.
If this condensing unit was going to be inside a heated building,
nothing more would be added to it, but the customer has told us it is
going outdoors. This requires the addition of an appropriate RDM,
outdoor enclosure, crankcase heater, and head pressure control valve
(see Info-Tec 10). A larger receiver will be needed because of the HP
valve. The rest of the liquid line components should be selected,
dryer, and sight glass, based on the liquid line size and tonnage of the
condensing unit. Select the TXV based on the load in tons. The
customer asked for pump down control as an option. Pump down
should be on all refrigeration systems, so should be quoted all the time
even if the customer doesnt request it. If not asked for, include pump
down as an option. To complete a pump down system, a low-pressure
control, liquid line solenoid valve, and thermostat are needed. A high-
pressure control or dual pressure control should also always be
quoted as options. Check the condensing unit specifications sheets
to see what may or may not be included with the unit. For instance,
as of this date, Tecumseh does not include low-pressure controls on
units up to and including one H.P., but does include them on units with
a rating of 1.5 horsepower and up. Some units have crankcase
heaters included, etc. Chandlers units vary considerably as to the
included devices. The point is, check the catalogs and specification
sheets for what is or is not included.
Quick load selection for small walk-in freezers is very similar to
walk-in coolers. Using the walk-in freezers chart, find the box size
closest to size youre given, pick the ambient temperature that is
appropriate, and then use the column closest to the box temperature
shown, 0, -10, or -20F. Use the 0F column for boxes up to
+10F. Any freezer over a box temperature of +10F will have to be
calculated the long way.
To the BTU/Hr. figure for the transmission load, add the figure for
average product load BTU/Hr.
Example: a freezer with the following dimensions: 10 x 10' x 9 It
is also in a building without air-conditioning. The box temperature is -
20F.
Box = 8,760 BTU/Hr.
Average load = 2,520 BTU/Hr.
Total load = 11,280 BTU/Hr.
All freezers use a split of 10F TD, so the suction temperature
will be -30F. Pick equipment rated for the load at -30 F suction
temperature. Dont forget we are now dealing with unit coolers that
will need some method of defrost other than air temperature during
the off cycle. Electric defrost is 99% of the method chosen to defrost
for small boxes. Hot gas defrost is used with supermarket rack
systems and in some large boxes. The 11,280 BTU/Hr. load at -
30 would use a Chandler ELC 122F2. A defrost timer needs to be
added to the equipment list, an 8145-20 Paragon. Pump down is not
an option; it must be used! An accumulator is highly recommended
on any job, but is a must on low temperature jobs. Always quote the
condensing unit with an accumulator and note that to the customer. If
the defrost heater load connected to the defrost timer exceeds the
timers electrical load rating, use a contactor to carry the heaters
load. The rest of the equipment selection is the same as for coolers -
- dryer, sight glass, TXV, thermostat, etc.
There are many other loads that will be encountered that have to
be added to the load found through long way calculations or through
using quick selection tables.
Some of the more common loads and the loads to be added:
Beer shafts
1500 BTU/Hr. for one. Any additional shafts, add 1000 BTU/Hr.
per shaft.
Walk-in coolers with glass doors
1 to 4 doors - 1,200 BTU/Hr. per door
5 to 7 doors - 1,100 BTU/Hr. per door
8 doors and up - 1,000 BTU/Hr. per door
Walk-in freezers with glass doors
Freezers at 90TD (Box to ambient)
1 to 4 doors - 2,000 BTU/Hr. per door
 5 to 7 doors - 1,600 BTU/Hr. per door
8 doors and up - 1,500 BTU/Hr. per door
Freezers at 110 TD (Box to ambient)
1 to 4 doors - 2500 BTU/Hr. per door
5 to 7 doors - 2100 BTU/Hr. per door
8 doors and up - 2000 BTU/Hr. per door
Glass doors are assumed to be double pane for coolers, triple
pane for freezers.
Back bars are usually constructed with 2" of fiberglass insulation
or its equivalent. Based on a 50F TD and 16 hour run time, the load
for back bars can be expressed in BTU/Hr. for specific lengths:
Up to 6' long------------ 1100 BTU/Hr.
7' - 8' long -------------- 1400 BTU/Hr.
9' - 10' long ------------- 1800 BTU/Hr.
11' - 12' long ----------- 2100 BTU/Hr.
13' - 15' long ----------- 2700 BTU/Hr.
10' - 20' long ----------- 3500 BTU/Hr.
Loads for open display cases in supermarkets and convenience
stores can be figured in BTU/Hr. per foot of case. The stores are
assumed to be air-conditioned. Open freezers are 700
BTU/FT/Hr. Open coolers are 500 BTU/FT/Hr.
Floors for all walk-in coolers and freezers should be insulated,
but often the box is build around a concrete floor poured on
grade. Amateurs that build the box will usually do a good job
insulating the walls and ceiling, but forget that cold air falls and neglect
to insulate the floor. Special problems are encountered in these
situations. Many studies have been done, and are still being done, on
determining the load for uninsulated concrete on grade walk-in
floors. When the box is first put into operation, the transmission load
through the floor will be large, but as time goes by, the transmission
load will decrease. How much and how fast is dependent on so many
variables, too many to even list here, that there is no formula that can
be used to accurately predict the load changes. The load would have
to be constantly monitored, and this is certainly not practical.
Many guidelines have been proposed to deal with uninsulated
concrete floors on grade. The old McQuay Co. (Now Heatcraft), after
extensive research and testing over a long period of time, came up
with a formula to add some load for uninsulated concrete on grade
floors. It is 5 BTUs per Sq. Ft. per 24 Hrs. times DT between summer
ground temperature and box temperature. It does not matter if the
floor is concrete on ground or concrete on cinder fill. The concrete
can be any thickness from 4" to 10".
A freezer should never be built with an uninsulated concrete on
grade floor. Eventually, the moisture in the ground under the floor
would freeze and heave the entire box.
Example: Walk-in cooler at 35F box temperature with 6" thick
uninsulated concrete on grade floor in Wisconsin 10' wide x 14'
long. (Ground temperature for Wisconsin = 55F, Illinois = 60F,
Minnesota = 55F) Therefore, 5 x 140 x 20 = 14,000 BTU load for 24
hours. Factoring in an 18 hour run time results in a 780 BTU/Hr. load
to be added. How to figure the concrete on grade floor loading
controversy still goes on. Obviously, the best way to avoid this
problem is to have an insulated floor.
In larger boxes where the load requires approximately 10
horsepower or more, it is recommended the load be divided into
multiple units. While initial cost will be higher, the advantages gained
will justify the higher costs. Remember, everything has been sized for
maximum load, which seldom occurs. Multiple units can be staged,
giving capacity control, and reducing electrical costs. Staging also
cuts demand charges by utilities. Nothing lasts forever, so when one
unit fails and needs service, the other unit(s) can prevent expensive
product loss. Once pull down of a product load has been
accomplished, the box probably can be maintained at temperature by
a fraction of the horsepower needed for full load, thereby saving
operating and maintenance costs. In the 10 horsepower range,
recovery (payback) of the initial higher cost of equipment will typically
occur in 2 to 3 years. Smaller boxes would also benefit by using
multiple units, but payback will take longer.
While having nothing to do with load calculating, it may be of
interest to some why cold preserves food.
Spoiling of food is actually the growth of bacteria in it. Cold slows
the movement of molecules and makes all organisms sluggish. Cold
slows the growth of bacteria, thus foods to not spoil as fast. By
keeping bacteria from growing, food will be edible longer.
Most foods contain a lot of water. Food, therefore, should be
kept slightly above freezing. The correct refrigerator temperature for
fresh food is 34F to 44F.
Freezing food extends the storage time considerably. If food is
frozen slowly, large ice crystals are formed and their size breaks down
the food tissues. When defrosted for use, the food spoils rapidly and
taste is ruined. Fast freezing at 0F to -15F, forms small ice crystals
which do not damage the food tissues. That is why food freezers
should be maintained at least at 0F. Food placed in them will freeze
quickly, and when defrosted for use, even after long storage, will still
be tasty.