Overview

Electric cooling equipment is a very mature technology. There are many kinds of equipment in the field that will not
easily fit in the following descriptions that deal with the most common equipment in use today.

Electric cooling equipment can be classified according to the following general categories:

Refrigerant Type/Method:

• DX = Direct expansion

• Water Chiller

• Ammonia Chiller

Method of Heat Rejection:

• Air Cooled

• Water Cooled

DX Chillers are small tonnage (0.5 to 150 tons) equipment where the refrigerant flows through a coil and directly cools the
air that is circulated to the space. Residential and small commercial air conditioners are DX units. Equipment that uses
refrigerant to first cool water and then uses cold water to cool the space or process are typically larger tonnage chillers (over 250
tons) that are a part of a large building central plant. Ammonia chillers are different in that the refrigerant (ammonia) can also be
the circulation medium, but ammonia chillers are not called 'DX'. Ammonia chillers are popular in low-temperature food
processing applications, refrigerated and frozen warehouses and ice arenas. Generally, DX units are called "air conditioners"
and water units are called "chillers".

Air cooled chillers tend to be smaller tonnages (under about 150 tons is typical but units >500 tons are available) and less
efficient than water cooled chillers. Water cooled chillers require a Cooling Tower to cool the water that cools the refrigerant.

The Basics

Cooling is measures in Tons; 1 Ton of cooling = 12,000 BTUs (Removed)

Latent Load = Moisture Removal from air; 1 lb water removed = 970 BTUs

Sensible Load = Temperature Reduction

Small units are called "air conditioners" larger units are called "chillers"

"Split" systems have condensers and evaporators separated by piping; PTAC (Package Terminal Air Conditioners) and
through the wall/window units have all parts combined into one unit/box

Electric Efficiency is rated in EER (Energy Efficiency Ratio)

EER = BTUs Out / Watts In (ie: 10 EER = 12,000 BTUs Out / 1,200 Watts In)

Gas Equipment is rated in COP (Coefficient Of Performance)

COPs vary from 0.5 for single-effect absorption to near 2 for engine drive units.

Space Cooling loads are about 2/3rd Sensible and 1/3 Latent over the average season; during times of high humidity, it
can switch around.

1 Ton Cooling = 12,000 BTUs Removed = 400 CFM Air Movement

10 EER = 3 COP = 1.2 kW/Ton

High efficiency air cooled small tonnage units = 10 EER

 The highest efficiency electric equipment is large tonnage water cooled with EERs of 24; however, large units are NOT
rated in EERs but watts/ton. Therefore, 0.5/kW per Ton. (or 500 watts per ton)

Types of Electric Air Conditioners and Chillers

Air Cooled DX Units

Small DX 2 - 5 Tons Medium DX 5 - 20 Ton Large DX 20 - 150 Tons

Most DX air conditioners use reciprocating or scroll compressor technology; larger units use screw compressors.
Higher efficiency units will use multi-stage controls and/or variable speed compressors to better follow part-load conditions.
Air Cooled Water Chillers

Air cooled water chillers are used in "medium" sized chiller applications where there is a multi-zone chilled water
cooling distribution system, but there is no desire or room for a cooling tower.

Available sizes range all the way from 3 tons to over 500 tons; larger tonnages may be just modules of smaller units
plumbed together.

Air cooled chillers are less efficient than water cooled chillers. The trade-off is no cooling tower is required. Cooling
towers require water to operate, can take up more space, are expensive to maintain and more expensive to install than air
cooled systems. Therefore, TOTAL operating costs can be lower with air cooled equipment (especially in small sizes and
moderate climates). Systems over 500 tons are almost always going to be water cooled.

Water Cooled Chillers

Water cooled chillers dominate the >500 Ton cooling market. Water cooled chillers are the most energy efficient, and in
larger tonnages, allow units to be built that would not be
practical in air cooled models.

Cooling towers are an integral part of the chiller

system. Their efficiency impacts the over all system
efficiency. Therefore, chiller energy management measures
often focus on the cooling tower operation. Variable speed
fans and pumps, improved water treatment systems and
better cleaning practices can dramatically impact the
operating costs of the cooling tower, which can be 10 - 20%
of the total cooling costs.

Water cooled chillers are common in the 500 to

1,500 Ton market; York offers an 8,500 Ton chiller in a single
package. Package units can be plumbed together to form
virtually any sized cooling package needed.

How They Work

The large tonnage chiller in the illustration to the right (York) shows the major components of every chiller system. One
of the long, round tube bundles is the condenser and one is the evaporator - which are actually shell and tube heat exchangers.
The rectangle shaped box is the electric drive motor and the rounded unit being driven is the compressor.

The compressor compresses the refrigerant into the condenser tube, where its temperature raises. Water from the
cooling tower is circulated through the 'other side' of the condenser heat exchanger, cooling the refrigerant and heating the
cooling tower water. The refrigerant then flows to the evaporator where it is allowed to rapidly expand, dropping its temperature;
cooling tower water is pumped to the tower to be cooled. Water from space conditioning coils is circulated on the 'other side' of
the evaporator heat exchanger, which lowers the water temperature and raises the refrigerant temperature. The water is then
pumped to water/air coils located in air handlers that serve the conditioned space; the refrigerant returns to the compressor
where the cycle is repeated.

In the diagram below (York literature) the 'Condenser Water Pump' is to/from the Cooling Tower and the 'Chilled Water
Pump' is to/from the conditioned space water/air coils.
Operating Costs

Operating costs for cooling equipment is highly variable with the size and type of equipment. The most expensive
equipment to operate is small, air-cooled unit air conditioners. The most efficient are the large water cooled centrifugal chillers.
Small equipment is rated in EER (Energy Efficiency Ratio) and large equipment is generally rated in kW per Ton. The higher the
EER the more efficient the equipment, the lower the kW per Ton the more efficient.

Air cooled equipment with a 10 EER costs 1.2 kW/Ton per hour to operate
Currently the best water cooled equipment is rated for 0.5 kW/Ton per hour to operate

(York states a 0.2 kW/Ton at part load with variable speed drive)

Typically operating cost ratings for small equipment includes the condenser fan; the operating cost ratings for large
equipment is for the compressor ONLY; it does NOT include the cost for circulation pumps or to run the cooling tower.

Chiller Plant First Costs

Chiller plants get less expensive per ton as the size of the unit increases. Larger systems are generally more efficient
also. Facilities with critical air conditioning requirements will require redundant equipment. However, several pieces of small
equipment will be both more expensive to purchase, operate and maintain. Facilities that have been expanded over time will
likely have several chiller units from different vintages. A good energy management practice is to determine the most energy
efficient way to operate the plant and control the various units accordingly.

The following Table is from the Trane Corporation on the relative costs of central chiller systems by type:

The 5S Process for Getting Organized

The 5S Process, or simply "5S", is a structured program to systematically achieve total organization, cleanliness, and
standardization in the workplace. A well-organized workplace results in a safer, more efficient, and more productive operation.
It boosts the morale of the workers, promoting a sense of pride in their work and ownership of their responsibilities.

"5S" was invented in Japan, and stands for five (5) Japanese words that start with the letter 'S': Seiri, Seiton, Seiso, Seiketsu,
and Shitsuke. Table 1 shows what these individual words mean. An equivalent set of five 'S' words in English have likewise
been adopted by many, to preserve the "5S" acronym in English usage. These are: Sort, Set (in place), Shine, Standardize, and
Sustain. Some purists do not agree with these English words -
they argue that these words have lost the essence of the original 5 Japanese words.

Table 1. 5 s Definitions

Japanese Term English Equivalent Meaning in Japanese Context

Throw away all rubbish and unrelated materials
Seiri Tidiness
in the workplace
Set everything in proper place for quick
Seiton Orderliness
retrieval and storage
Clean the workplace; everyone should be a
Seiso Cleanliness
janitor
Seiketsu Standardization Standardize the way of maintaining cleanliness
Practice 'Five S' daily - make it a way of life;
Shitsuke Discipline
this also means 'commitment'
Seiri
The first step of the "5S" process, seiri, refers to the act of throwing away all unwanted, unnecessary, and unrelated
materials in the workplace. People involved in Seiri must not feel sorry about having to throw away things. The idea is to
ensure that everything left in the workplace is related to work. Even the number of necessary items in the workplace must be
kept to its absolute minimum. Because of seiri, simplification of tasks, effective use of space, and careful purchase of items
follow.

Seiton
Seiton, or orderliness, is all about efficiency. This step consists of putting everything in an assigned place so that it can be
accessed or retrieved quickly, as well as returned in that same place quickly. If everyone has quick access to an item or
materials, work flow becomes efficient, and the worker becomes productive. The correct place, position, or holder for every
tool, item, or material must be chosen carefully in relation to how the work will be performed and who will use them. Every
single item must be allocated its own place for safekeeping, and each location must be labeled for easy identification of what it's
for.

Seiso
Seiso, the third step in "5S", says that 'everyone is a janitor.' Seiso consists of cleaning up the workplace and giving it a
'shine'. Cleaning must be done by everyone in the organization, from operators to managers. It would be a good idea to have
every area of the workplace assigned to a person or group of persons for cleaning. No area should be left uncleaned. Everyone
should see the 'workplace' through the eyes of a visitor - always thinking if it is clean enough to make a good impression.

Seiketsu
The fourth step of "5S", or seiketsu, more or less translates to 'standardized clean-up'. It consists of defining the standards
by which personnel must measure and maintain 'cleanliness'. Seiketsu encompasses both personal and environmental
cleanliness. Personnel must therefore practice 'seiketsu' starting with their personal tidiness. Visual management is an
important ingredient of seiketsu. Color-coding and standardized coloration of surroundings are used
for easier visual identification of anomalies in the surroundings. Personnel are trained to detect abnormalities using their five
senses and to correct such abnormalities immediately.

Shitsuke
The last step of "5S", Shitsuke, means 'Discipline.' It denotes commitment to maintain orderliness and to practice the first
4 S as a way of life. The emphasis of shitsuke is elimination of bad habits and constant practice of good ones. Once true
shitsuke is achieved, personnel voluntarily observe cleanliness and orderliness at all times, without having to be reminded by
management.

Maximum Ceiling Temperature Temperature Color Code (with

Glass Bulb Color
Temperature Rating Classification Fusible Link)
135-170°F / 57- Orange (135°F) or
100°F / 38°C Ordinary Uncolored or Black
77°C Red (155°F)
175-225°F / 79- Yellow (175°F) or
150°F / 66°C Intermediate White
107°C Green (200°F)
250-300°F / 121-
225°F / 107°C High Blue Blue
149°C
325-375°F / 163-
300°F / 149°C Extra High Red Purple
191°C
400-475°F / 204-
375°F / 191°C Very Extra High Green Black
246°C
500-575°F / 260-
475°F / 246°C Ultra High Orange Black
302°C
625°F / 329°C 650°F / 343°C Ultra High Orange Black

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