SYSTEM DESIGN MANUAL

SUMMARY OF PART 12
This part of the System Design Manual presents data
and engineering procedures to guide the engineer in the practical
designing of water and DX systems.
The text of this Manual is offered as a general guide for
the use of industry and of consulting engineers in designing systems.
Judgment is required for application to specific installation, and
Carrier is not responsible for any uses made of this text.

fan-coil unit system

dx systems

INDEX

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System

CHAPTER 1. FAN-COIL UNIT SYSTEM

The all-water fan-coil unit system is well suited for

many applications. It is particularly applicable to a multiroom building where ductwork costs may be prohibitive.
Where the climate permits, it is equally applicable to the
relatively low temperature hot water characteristics of
central heat pump systems, using an interior zone load as
a heat source. A fan-coil unit system is not recommended
for applications having high latent heat loads.
The system is used in many applications such as
hotels, motels, hospitals, apartments, office buildings,
professional buildings and clinics. Units may be located
under the window, over closets, in dropped ceilings or
furred down spaces.
This chapter discusses the fan-coil unit system
covering the System Description, System Features,
Engineering Procedure and a control arrangement.

TYPE OF SYSTEMS

All-water fan-coil systems may be classified in two

major groups:
1. Single (2-pipe) piping system in which a single
supply of water (cold or hot depending on the
reason) is available at each fan-coil unit and a
single return piping system is utilized.
2. Multi- piping system in which a double supply of
water (cold or hot) is available at each fan-coil
unit and a single (3-pipe) or double (4-pipe)
return piping system is utilized.

SINGLE PIPING SYSTEM

SYSTEM DESCRIPTION
This system (Fig.1) consists of central water heating
and cooling equipment, fan-coil units, controls,
interconnecting piping and wiring as required.
The fan-coil units system is designed to provide
individual space temperature control without utilizing
central station air handling equipment or ductwork. Figure
2 illustrates the basic elements of the unit which include
the air inlet, filter, fan and cooling and heating coil. The
unit may be under-the-window or ceiling mounted.
Either a mixture of outdoor and return air or return air
alone is supplied to the unit. Filters clean the air. The coil

cools and dehumidifies during the summer and heats

during the winter.
In Fig.1 the outdoor air for the under-the-window unit is
shown delivered directly to the unit by low pressure
ductwork. Such a method is preferable to ventilation air
introduced thru a wall opening (Fig.2). The use of a wall
opening to introduce outdoor air to the fan-coil unit is not
generally recommended for multi-story building. Stack
and wind effects may affect adversely the performance of
the units. In some instances air obtained by infiltration
may be sufficient for ventilation, or air obtained from an
interior zone system may be utilized for ventilation. Other
methods of introducing outside air are discussed in Part
11, Primary Air Fan-Coil System.
Temperature control is maintained in two ways:
1. Fan speed adjustment or on-off fan control.
2. Water flow modulation or on-off water flow.
Electric reheat is sometimes installed at each unit to
improve the operation of the fan-coil unit systems during
the intermediate season. Motels particularly are a good
application for electric reheat.
Chilled water from a central refrigeration plant is
circulated thru the unit coils to remove excess moisture
and cool the air during the summer. Hot water from a
water heater is supplied to the same unit coils during the
winter.
SYSTEM FEATURES
Features of the fan-coil unit system are:
1. Individual Room Temperature Control The system
is adaptable to such a control because each unit
has an integral cooling and heating coil designed
for chilled and hot water.
2. Confined Room Air Circulation Each unit
recirculates only room air. Therefore, recirculation
of air between rooms is minimized.
3. Economy of Operation Outdoor air is available
during marginal weather for free cooling. An
outdoor-room air proportioning damper at the unit
provides control.

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System
sufficient heat to temper the outdoor air from the
temperature at which it enters the unit to the room design
temperature (depending on the type of system).

Fig. 1 Two-Pipe Fan-Coil Unit System

4. Minimum Ductwork, Cutting and Patching - Design
costs of ductwork are minimized since supply and
return air ductwork are not normally required.
Cutting and patching in old buildings is normally
confined to requirements for water piping and
ventilation.
5.Under-the-Window Air Distribution - Under-thewindow upward air distribution is superior to other
methods for small rooms, particularly those having a
heating or year-round load.
ENGINEERING PROCEDURE
The following is a design procedure for a fan-coil unit
air conditioning system. As in all design work a survey
and preliminary layout (Part 1) are required. Room loads
and minimum ventilation air quantities are determined by
methods outlined in Part 1.

Unit Selection
Select the room units to satisfy the following
requirements:
1. Maximum room and ventilation air cooling load,
both sensible and total.
2. Maximum room and ventilation air heating load.
3. External resistance imposed upon the unit by
additional required ductwork. The external
resistance should be considered relative to its
effect on the air volume and the cooling and
heating capacity of the unit.
The unit is normally adequate for zone depths of
approximately 20 feet. Vertical air distribution of the
perimeter unit spreads out in blanketing the exterior wall
and travels along the ceiling for a distance of 15 to 20
feet before falling toward the floor in return air circulation.
Select the fan-coil units so that the smallest units are
used coincident with the highest water temperature.
Water temperatures are usually selected between 45 F
and 50 F. A few trial unit selections give an indication if
the water temperature is acceptable.
The same water flow rate is used for heating as is
used for cooling. System heating capacity is obtained by
an adjustment of entering water temperature.
Convector heating during overnight, weekend or
holiday periods is impractical; only one room heating load
calculation with the unit fan operating is required.

Room Cooling Load

Calculate the load for all typical spaces on east, west,
north and south exposures and for any space that has an
unusual load. It may be necessary to provide flexibility in
these calculations to allow for future partition changes,
depending on the type of application. Eight to sixteen
room load calculations may be required for most multiroom applications. The computations should include both
sensible and latent load requirements.
To determine the total sensible and cooling capacity
required of the unit, ventilation air and room loads must
be combined.
Room Heating Load
Calculate the room heating load in the normal manner.
The computations should include the heating
requirements to offset transmission and infiltration and

Fig. 2 Typical Fan-Coil Unit

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System
Piping Design
Design the piping system in the normal manner. A
single piping system is used to circulate chilled or hot
water to the unit coil. Good design practice should be
followed in system layout (Part 3). A reverse return
system (Fig. 3) is recommended and should be used
whenever it is adaptable to the building layout; this
provides an inherently balanced system. Otherwise a
direct return system may be used.
In buildings with units on more than one exposure a
diversity factor should be applied as outlined in Part 3. In
addition to resulting in smaller piping, headers and
circulating pumps, diversity aids in minimizing sound
problems when the system is operating at low water
quantities. Diversity is not applied to the risers.
If more than one zone of water piping is desired,
secondary circuits can be arranged accordingly.
However, a three- or four-pipe system should be
considered before designing a zoned single piping
system.
The design water flow rate selected for the units can
influence the total system cost. The lower the flow rate,
the lower the first cost of the system piping and pump.
However a check should be made to assure turbulent
flow in the unit coil. The minimum flow per coil circuit to
maintain turbulent flow conditions for a 3/8, 1/2, or 5/8
inch OD tube is approximately 0.5, 0.7 or 0.9 gpm
respectively.
The secondary water pump is operated continuously
and should be selected for an extremely flat head
characteristic (Curve A, Fig. 4). Do not select a pump that
has a steep head characteristic (Curve B, Fig. 4).

Fig. 3 Schematic Water Piping, Two-Pipe

Fan-Coils Unit System

Fig. 4 Pump Head Characteristics

Before the final secondary water pump selection is
made, a check should be made to determine if head
pressure control is required. When the water control valve
(a three-way solenoid valve) in the closed position
permits full water flow bypass around the coil, head
pressure control is not required. If the water velocity in the
runout is less than 10 fps, head pressure control is not
required. Head pressure control requirements are
determined by plotting the head curve of a trial pump
selection (Curve A, Fig. 5). The system pressure drop
curve is added at its various flow rates (Curve B, Fig. 5).
The intersection of Curve A and B is the operating point of
the pump at full load.
The sum of the pressure drops of the unit runout,
fittings, control devices and unit coil are plotted in curve
from (Curve C, Fig. 6). This is the pressure drop of the
system at various water flow rates from the supply riser
thru the unit and back to the return riser. The velocity of

Fig. 5 Pump Selection

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System
amount of condensate is, therefore, a consideration when
sizing drain piping.
Vaporproof insulation is required for water piping and
runouts.
Refrigeration Load
The refrigeration load is established by the peak
building load (or block estimate) of the areas served by
the system. Such an estimate includes all the applicable
items to be found on an Air Conditioning Load Estimate
from shown in Part 1. Provide 5% allowance for
overcooling in the block load estimate.

the water flowing in the runout is also plotted for various

flow rates (Curve D, Fig. 6). Example 1 illustrates the use
of Fig. 5 and 6 in determining the water velocity in the
runout when one unit is operating.

CONTROLS
A typical control arrangement for the fan-coil unit and
secondary water coil circuit is shown in Fig. 7and 8
respectively. Figure 7 is a schematic of a control package
consisting of a solenoid valve operated from a room
thermostat in conjunction with a manual multi-speed fan
switch.

Example 1 Runout Water Velocity

Given:
Figure 5 and 6
Unit design water quantity 1 gpm

Unit Control
Sensible and latent cooling capacity when the
performed by a single element cannot be adjusted to the
wide range of coil sensible heat ratios which occur in
comfort cooling. Maintenance within acceptable limits of

Fig. 6 Runout Characteristics

Find:
Water velocity in runout
Solution:
Enter Fig. 5 at water flow gpm = 1.
Read head from Curve A = 45 ft water.
Enter Fig. 6 at 45 ft water.
Read water flow from Curve C = 8.4 gpm
thru the unit.
Enter Fig. 6 at water flow = 8.4 gpm.
Read velocity from Curve D = 9.0 ft/sec in
runout.
If the water velocity is above 10 fps, two courses of
action are open:
1. Add head pressure control at the pump, or
2. Redesign the piping for a lower pressure drop so
that the pump with a lower head at shutoff can be
selected.
Optimum design of drain piping considers the type of
ventilation air supply provided. When the fan-coil unit
system handles the entire dehumidification of outdoor
and recirculated air, there is a substantial amount of
condensate from the units. However if the system draws
ventilation air from an interior zone (conditioned by a
separate system), very little condensate collects. The

Fig. 7 Control Package, Manual Three-Speed

Fan Control with Automatic On-Off
Water Flow

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System
room relative humidity is specified in order to provide
desired dry-bulb temperature. Room conditions may be
controlled by fan speed adjustment for cooling or by onoff fan control for heating. It may also be controlled by a
combination of fan speed adjustment and on-off water
flow to the heat transfer coil within the unit (or water flow
modulation).
Basic control at the unit is accomplished by a multispeed fan switch. Control of the water flow thru the unit
coil may be manual, electric or pneumatic.
Continuous design flow of chilled water thru the
cooling coil provides better maintenance of room
humidity levels. However even with multi-speed fan
control for loads below that equivalent to the minimum fan
speed, the room temperature cannot be maintained and
the fan must be shut down. Typical room temperature and
humidity conditions for a fan-coil unit with manual, threespeed fan control are illustrated in Fig. 9.
When unit fans are shut down, the chilled water to the
coils should be shut off, preferably automatically, to
prevent damage from condensation. If the chilled water is
permitted to flow, the entire unit may approach the
temperature of the chilled water, including the
condensate pan and drain line. This can lead to
condensation problems, such as water spotting and
mildew.

Fig. 8 Control Diagram, Pneumatic, Two-Pipe

Fan-Coil Unit System

Fig. 9 Room Temperature and Humidity

Conditions, Manual Three-Speed Fan Control
Modulated control of chilled water thru the cooling coil
allows the room humidity level to rise as the room
sensible load falls. Typical room temperature and
humidity conditions for such a control are shown in Fig.
10.
Typical room temperature and humidity conditions for
manual, on-off fan control are illustrated in Fig.11.
When selecting a control system, it is recommended
that:
1. The room thermostat should be located on the
room wall and not at the unit when outdoor air is
admitted directly to the unit.
2. Means should be available to shut off the flow of
outdoor air to the unit to prevent coil freeze-up in
winter when the unit is shut down. This provision
should be made when ventilation air is admitted to
the unit thru a wall opening.

Fig. 10 Room Temperature and Humidity

Conditions, Automatic Modulated Water Control

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System
The thermostat is reset by a master outdoor air thermostat
to maintain a scheduled hot water temperature relative to
the outdoors.
Automatic summer-winner change-over control (Fig. 7)
senses the hot water temperature at the unit and reverses
the action of the room or unit thermostat for winter
operation. The thermostat opens or closes the solenoid
valve in the water line to the unit coil. The manual multispeed fan switch is adjusted by the occupant as desired.

MULTI-PIPING SYSTEM

Fig. 11 Room Temperature and Humidity

Conditions, Manual On-Off Fan Control
Secondary Water Coil Circuit Controls
Either electric or pneumatic controls may be used for
control of the water temperature to the fan-coil units. The
sequence of operation is the same regardless of which is
used.
Summer Operation
Outdoor air damper control may be either manual or
automatic when ventilation is obtained thru an outside
wall opening at the unit. If automatic control is used, the
damper may be operated from the unit fan motor control
to open when the fan is started. If outdoor air is supplied
by a separate fan system thru low pressure ductwork, the
fan may be started manually. With the primary chilled
water pump running, the secondary water thermostat at
the secondary water pump discharge controls a threeway mixing valve (Fig. 8). It maintains a constant
secondary water temperature to the fan-coil units.
The room or unit thermostat (Fig. 7)controls the
solenoid valve in the water line to the unit coil. A manual
multi-speed fan switch is adjusted by the room occupant
as required.
Winter Operation
The outdoor air damper operates as in summer. With
no need for chilled water the primary chilled water pump
is shut down. The three-way mixing valve is positioned to
channel the secondary water from the fan-coil units thru
the water heater, to the secondary water pump, and then
to the units. The water heater stream valve is controlled
by a thermostat at the leaving side of the water heater.

SYSTEM DESCRIPTION
Figure 12 is a sketch of a 3-pipe system and Figure 13
shows a 4-pipe system.
The ability of a single piping system to satisfy the
constantly changing heating and cooling requirements of
individual perimeter spaces increases with the number of
zones provided. A multi-piping system provides hot and
chilled water at each fan-coil unit the year round. In effect
each unit then is a separate zone and functions
independently. Its control valve selects either hot or
chilled water for the unit coil depending on whether the
module it serves requires heating or cooling. Simple,
nonreversing thermostats may be utilized and changeover controls are not required. Design water quantities for
the heating load may be minimized.
Certain aspects of the three-pipe system should be
investigated before deciding on a system design since
three-pipe systems are covered by one or more patents.
Although the system permits substantial first cost savings
by using a common return, the operating costs are
somewhat higher than those of a four-pipe system
because of the mixing in the common return of water from
the units operating on heating with water from the units
operating on cooling.
The four-pipe system provides isolation of the hot and
cold water circuits to minimize hydraulic problems. A
single or split coil may be used at the unit. A split coil
simplifies unit piping
Two methods of operation are commonly used for
multi-piping systems. The first method gives complete
year-round temperature control in the room. Hot and cold
water are necessaryat the room until at all times of the
year. If the room temperature is too cold, hot water flows
thru the fan-coil unit. If the room temperature is too warm,
cold water flows thru the fan-coil unit. The second method
of operation has hot and cold water available at the room
unit only during the intermediate seasons. It is used when
economy of operation is paramount and adequate room
temperature control is desired. The sequence of
equipment operation is shown in Chart 1. The
temperatures at which the cooling and heating equipment
is started and stopped vary from building to building.

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System

Fig. 12 Three-Pipe Fan-Coil Unit System

SYSTEM FEATURES
In addition to the features of the fan-coil unit system as
itemized under Single Piping System, additional features
of the multi-piping system are:
1. Quick Response to Thermostat Settings A
change in thermostat setting is immediately
apparent because hot and cold water are
available at each unit. Quick response is
psychologically advantageous
2. Elimination of Zoning by Exposure Multiple
pumps, zoned piping and allied controls are
eliminated because each space is a zone in itself
as compared to the single piping system.
3. Elimination of Operational Difficulties of Changeover When the system is properly designed,
change-over is not required and operation is
simplified.
4. Year-round Room Temperature Control Tenant
complaints during the intermediate season are
eliminated because of the availability of both
heating and cooling.
CHART 1 OPERATING SCHEDULE
OPERATING SCHEDULE
OUTDOOR
REFRIGERATION
TEMPERATURE
EQUIPMENT
BOILER
95 70
ON
OFF
70 50
ON
ON
50 0
OFF
ON

Fig. 13 Four-Pipe Fan-Coil Unit System

ENGINEERING PROCEDURE
The design procedure for a multi-piping system is
similar to the design of a single piping system. The few
differences in design procedure are created by the
piping system and involve piping design, controls and hot
water quantities.
Unit Selection
Water quantities for the design heating load should be
selected to give as high a rise as possible while matching
the required heating load coincident with turbulent flow.
Piping Design
A multi-piping system is used to circulate chilled and
hot water to the fan-coil unit.
The cold water supply and the common return line on
a three-pipe system are sized first. Both headers are
designed using a diversity factor. Several pumping
arrangements can be used with this system. With a
separate hot water pump (Fig. 14), the hot water piping is
designed in accordance with normal practice.
A four-pipe system completely isolates the cold and
hot water systems (Fig. 15) so that the piping for each
system may be designed independently using a diversity
factor on the chilled water supply and return
headers.
The secondary and hot water pumps are selected for
an extremely flat head characteristic (Fig. 4). Head
pressure control requirements, if any, should be
determined as in Example 1.
Heating Load
The heating load is established from a summation of
the room heating loads plus 20% for quick warm-up.
Heating equipment can be either a stream

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System

Fig. 14 Schematic Water Piping, Three-Pipe Fan-Coil Unit System

Fig. 15 Schematic Water Piping, Four-Pipe Fan-Coil Unit System

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System

Fig. 16 Wiring Diagram, Three-Pipe and

Four-Pipe Fan-Coil Unit System Using
Multi-speed Motor
converter or a hot water boiler. The design water
temperature is that which is determined from the unit
selection. The water quantity is that determined from the
sum of the individual room requirements.
CONTROLS
Control arrangements are many and varied.
Pneumatic, electric or manual are used. Unit controls are
often electric and may be automatic or partially
automatic.
Typical control arrangements for the fan-coil unit and
secondary chilled and hot water coil circuits are
illustrated in Fig. 16, 17 and 18 respectively. The control
is fully automatic at the unit.
Unit Control
On a three- or four-pipe system two control valve
actions are required, one to control hot water and a
second to control cold water. In addition, fan speed
adjustment and/or on-off air flow may be accomplished.
The control valve action may be modulating or twoposition. Manual control valves should not be used with
any multi-piping system.

Fig. 17 Wiring Diagram, Single Speed Motor

Fig. 18 Control Diagram, Pneumatic, Three-Pipe

Or Four-Pipe Fan-Coil Unit System
The sequence of operation for fully automatic control
is shown graphically in Fig. 19.
Secondary Chilled Water and Hot Water controls
Either electric or pneumatic controls may be used for
control of the water temperature to the fan-coil units. The
sequence of operation is the same regardless of which is
used.
With the primary chilled water pump running, the
chilled water thermostat at the secondary chilled water
pump discharge controls a three-way mixing valve (Fig.
18). It maintains a constant chilled water temperature to
the fan-coil units. With the hot water pump running, the
hot water thermostat at the leaving side of the water
heater controls the water heater stream valve. The
thermostat is adjusted by a master outdoor air thermostat
to maintain a scheduled hot water temperature relative to
the outdoors.
Referring to Fig. 19, on a rise in room temperature the
unit fan is started on low speed and the cold water
solenoid valve is opened. On a further rise in room
temperature, the fan is automatically changed to high
speed. As the room temperature approaches the

Part 12. Water and DX System | Chapter 1. Fan- Coil Unit System
thermostat setting, the fan returns to the low speed
setting; when the thermostat is satisfied, the fan and cold
water solenoid are shut off. On a drop in temperature the
fan is started on low speed and the hot water solenoid
valve is opened. On a further drop in room temperature
the fan is automatically changed to high speed.
This control arrangement offers the advantage of
longer operation at minimum sound level with close
temperature regulation. For a few hours of peak load the
fan is automatically changed to high rpm to give
maximum heating or cooling capacity.

Fig. 19 Unit Control Operation

Part 12. Water and DX System | Chapter 2. DX Systems

CHAPTER 2. DX SYSTEMS

DX systems are confined to the smaller and

intermediate tonnage air conditioning and refrigeration
applications. Packaged centrifugal and absorption
machine liquid chillers are used for the higher tonnages.
DX systems for air conditioning or liquid chilling are
those employing field-fabricated refrigerant piping.
Condensing units and remote condenser (reciprocating)
liquid chilling packages may be utilized in such systems.
The piping interconnects reciprocating compressors,
condensers and cooling coils or liquid chillers.
Refrigerant piping becomes economically less
attractive as the amount of piping and distance between
compressor, evaporator and condenser increases. The
use of a cooling tower and/or reciprocating liquid chiller
may then be more economical.
This chapter includes System Description, System
Features and Engineering Procedure.

SYSTEM DESCRIPTION

Field-fabricated refrigerant piping is required for an air

conditioning system using direct expansion coils and for
a liquid chiller with a remote condenser. It is also required
between the coils, the reciprocating compressor and the
condenser when using direct expansion coils in either a
built-up apparatus, fan-coil equipment or both. The
minimum piping required for a liquid chiller (unless closecoupled) is that needed to connect the compressor and
the condenser.

DIRECT EXPANSION AIR COOLING

Figure 20 is an isometric of a typical basic
refrigeration system serving fan-coil equipment and
utilizing direct expansion coils. Two compressors in
parallel using an evaporative condenser and a subcooling coil provide refrigeration for direct expansion
coils in each of three fan-coil units. A liquid suction
interchanger in the liquid line from the sub-cooling coil
increases the refrigerant cycle efficiency.
Capacity control at the compressors maintains a
relatively stable suction pressure at the direct expansion
coils. Solenoid valves in the liquid line to each coil are deenergized to shut off the flow of liquid refrigerant when its
respective fan-coil unit is shut down.
LIQUID CHILLING
Figure 21 is an isometric of a typical DX system for
water chilling. A packaged water chiller utilizes an
evaporative condenser for condensing. The water chiller
illustrated is a dry expansion cooler and is dual circuited.
Chilled water temperature is controlled by compressor
capacity and cooler circuit control.
Although dry expansion coolers are used on most
applications, flooded coolers are available (Fig.22). Dry
expansion coolers are desirable because of:
1. Low first cost
2. Smaller space requirements
3. Minimum refrigerant requirements
4. Minimum freeze-up possibilities
5. Minimum oil return problems

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 20 Refrigeration System Supplying Direct Expansion Coils

SYSTEM FEATURES

Features of the DX system are:

1. Flexibility Physical layout and matching of
equipment is more flexible.
2. Low First Cost Reciprocating machines provide
the lowest capital expenditure for refrigeration
applications below approximately 100 tons.
3. Suitability The trend towards air-cooled
condensers makes the system suitable for many
refrigeration applications. In addition the system
can be used with an existing air handling
apparatus which includes direct expansion
cooling coils.

ENGINEERING PROCEDURE

The following procedure is offered to assure a

practical basic refrigeration system. As in all design work
a survey and preliminary layout are required as covered
in Part 1. Refrigeration load is determined by using the

method applicable to the particular type of air

conditioning system (Part 1).
The utilization of a single compressor and condenser
is desirable when designing a DX system because of
lower first cost, smaller space requirements and
minimized hydraulic problems.
However multiple compressors and condensers are
commonly used. Factory packages consisting of liquid
chiller, multiple compressors and condensers are
satisfactory because of low mass production costs and
single controlled design.
When a single compressor or condenser of adequate
size is unavailable to match load requirements, it may be
advisable to design several systems each having its own
evaporator, compressor and condenser. This is done with
the understanding that the load may be readily divided
into smaller portions which can be physically and more
conveniently located apart.

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 21 Dry Expansion Reciprocating Liquid Chilling Package with Evaporative Condenser

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 22 Flooded Liquid Chiller and Reciprocating Compressors with Evaporative Condenser

EQUIPMENT SELECTION
When selecting equipment, primary considerations
involve the evaporator, condensing media and
component balancing.
Evaporator selection is logically the first step in the
selection of equipment for a basic refrigeration system,
whether direct expansion or chilled water. In order to
satisfy the established conditions of air quantity and
entering and leaving wet- and dry-bulb temperatures, a
specific coils surface is required. Direct expansion air
cooling coils may therefore be selected without having to
consider the refrigeration machine or condenser. The
selection of the refrigeration machine requires the
determination of the refrigerant temperature from the
cooling coil selection. This invariably proves more
economical than the completely arbitrary choice of an
initial refrigerant temperature.
Chilled water quantity and temperature are predetermined for air conditioning or process work. The

chiller of a liquid chilling plant should therefore be

selected prior to the compressor. An adjustment of chiller
size may prove desirable when balancing the
components.
The selection of a condensing media is an economic
consideration. In some cases it is a matter of preference.
Air cooling, water cooling and evaporative cooling
methods of condensing are available. The greater the
distance between refrigeration and heat rejection
equipment, the more economically favorable is the
cooling tower (water cooling method of condensing). In
other circumstances, despite higher power costs an aircooled condenser is selected because of scarcity of
water, less maintenance, nonicing features and simplicity.
Some components of the system such as the
evaporator can be selected individually based on
operating requirements and without particular regard to
other components in the system. However most
components should be selected so that when operated

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 23 Reciprocating Liquid Chilling Package with Air-Cooled Condensers, Three Compressors
together as a system, performance requirements are
satisfied.
Balancing of the components of a basic refrigeration
system is covered in Part 7. In general more than one
combination of components meets the performance
required of the system. Examination of several such
combinations should be made to determine the optimum
design.
The selection and balancing of system components
influences the initial operating cost of the system. If
optimum first cost is desired, compressor design, suction
and head pressures are secondary; if optimum operating
cost is desired, pressures are of primary importance.

Accessories such as liquid subcooling equipment and

liquid suction interchangers should be considered when
balancing components of the systems. These
accessories are covered in Parts 3, 4 and 7.
Utilization of liquid subcooling increases the capacity
of both the compressor and the condenser by the same
amount. The evaporator is not affected.
The use of liquid subcooling:
1. Provides an increase in system capacity.
2. Subcools the liquid to offset the effect of moderate
lifts.

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 24 Reciprocating Liquid Chilling Package with Air-Cooled Condensers, Four ,Compressors
3. Reduces horsepower per ton of refrigeration.
When the balanced capacity of a combination of
compressor and evaporative condenser is slightly
undersize, it is normally more economical to add a
subcooling coil than to select the next larger combination.
The capacity of the condenser and compressor is
increased by the same amount because with subcooled
liquid each pound of refrigerant evaporated does more
work. While increasing the capacity of the system,
subcooling does not require any additional horsepower.
Therefore the horsepower per ton of refrigeration is
reduced.

Compressor ratings for Refrigerants 12 and 500 are

generally based on 65 F actual suction gas temperatures.
When this suction gas temperature is not obtained at the
compressor, its rating must be lowered by an appropriate
multiplier. To develop the full rating the required
superheat over and above that available at the evaporator
outlet may be obtained by means of a liquid suction
interchanger. The effect of a liquid suction interchanger
on the refrigeration cycle is discussed in Part 4.
PIPING DESIGN
Piping design (Part 3) should be followed when

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 25 Typical Wiring Diagram for Evaporative Condenser Installation, 208-220 Volts, with
Single Pumpout Compressor Control and Crankcase Heater
multiple or single compressors, condensers and
evaporators are selected for a system.
Remote condenser type reciprocating liquid chiller
packages require field-fabricated refrigerant piping
between the compressors and condensers. Piping design
and condenser selection should be made as
recommended in Part 3.
Figures 23 and 24 illustrate a layout for a
reciprocating water chiller package utilizing air-cooled

condensers. In Fig. 23 the water chiller package consists

of three compressors and a dual circuited cooler. Two
compressors, two condensers and one cooler circuit are
joined while the remaining compressor, condenser and
cooler circuit are similarly connected. The condensers
utilized in this instance are air-cooled with integral
subcooling coils. Receivers are not used with this type of
condenser because of the liquid seal maintained and the

Part 12. Water and DX System | Chapter 2. DX Systems

Fig. 26 Typical Wiring Diagram for Evaporative Condenser Installation, 208-220 Volts, with
Pumpdown Compressor Control

storage capacity afforded by the subcooling coil. The

liquid refrigerant is piped directly from the liquid
connection at the condenser to the chiller.
In Fig. 24 the water chiller package consists of four
compressors, four condensers and a dual circuited
cooler. Two compressors, two condensers and one
cooler circuit are connected while the remaining
compressors, condensers and cooler circuit are similarity
joined.

CONTROLS
A basic electric control arrangement is shown in Fig.
25 and 26. An electric control is particularly suited to this
type of application because of the number of
interconnections required between the controls and motor
starters.
Single pumpout compressor control with crankcase
heater is shown. It minimizes the accumulation of liquid
refrigerant in the compressor crankcase during system

Part 12. Water and DX System | Chapter 2. DX Systems

shutdown. Single pumpout and automatic pumpdown
control is covered in Part 3 and 7.
The liquid line solenoid valve and crankcase heaters
are interconnected with the fan starter and room
thermostat. When the fan is running and the thermostat
demands cooling, the liquid line solenoid valve opens,
the compressor crankcase heaters are deenergized, and
the single-pole double throw (SPDT) relay starts the

evaporative condenser fan and pump motors. The

compressor starts and continues to run if within a short
period of time the oil pressure has built up sufficiently. Oil
pressure is sensed at the differential oil pressure switch.
The low and high pressure switches can shut down the
compressor and evaporative condenser.

A
Applications
DX systems
fan-coil unit system
C
Controls
DX systems
fan-coil unit system
four-pipe
three-pipe
two-pipe
Cooling load, room
fan-coil unit system
D
DX systems
engineering procedure
equipment selection
piping design
system description
system features
E
Engineering procedure
DX systems
fan-coil unit system
four-pipe
three-pipe
two-pipe
Equipment selection
DX system
F
Fan-coil unit system
controls

engineering procedure
piping design
refrigeration load
room cooling load
room heating load
unit selection
system description
system features
type
multi-piping
single-piping
H
Heating load
Multi-piping fan-coil unit
system
Heating load, room
fan-coil unit system
L
Liquid chillers, description
dry expansion coolers
flooded cooler
P
Piping design
DX system
fan-coil unit system
four-pipe
three-pipe
two-pipe
R
Refrigeration load
fan-coil unit system

Room cooling load

fan-coil unit system
Room hearing load
fan-coil unit system
S
Secondary water control
fan-coil unit system
summer operation
winter operation
System dwaption
direct expansion air
cooling
four-pipe fan-coil unit
system
liquid chilling
three-pipe fan-coil unit
system
two-pipe fan-coil unit
system
System features
DX system
four-pipe fan-coil unit
system
three-pipe fan-coil unit
system
two-pipe fan-coil unit
system
U
Unit control
fan-coil unit system
four-pipe
three-pipe
two-pipe
Unit selection
fan-coil unit system

Fig. 1 - Two- Pipe Fan-Coil Unit System

Fig. 2 - Typical Fan-Coil Unit
Fig. 3 - Schematic Water Piping, Two-Pipe
Fan-Coil Unit System
Fig. 4 - Pump Head Characteristics
Fig. 5 - Pump Selection
Fig. 6 - Runout Characteristics
Fig. 7 - Control Package, Manual Three-Speed Fan
Control with Automatic On-Off Water Flow
Fig. 8 - Control Diagram, Pneumatic, Two-Pipe
Fan-Coil Unit System
Fig. 9 - Room Temperature and Humidity Conditions,
Manual Three-Speed Fan Control
Fig.10 - Room Temperature and Humidity Conditions,
Automatic Modulated Water Control
Fig.11 -Room Temperature and Humidity Conditions,
Manual On-Off Fan Control
Fig.12 - Three-Pipe Fan- Coil Unit System
Fig.13 - Four-Pipe Fan-Coil Unit System
Fig.14 -Schematic Water Piping, Three-Pipe Fan-Coil
Unit System (12-8)
Fig.15- Schematic Water Piping,
Three-Pipe Fan-Coil Unit System

Fig.16 - Wiring Diagram, Three- Pipe and FourPipe

Fan-Coil Unit System Using Multi-Speed Motor
Fig. 17 - Wiring Diagram, Single Speed Motor
Fig. 18 - Control Diagram, Pneumatic, Three-Pipe or
Four-Pipe Fan-Coil Unit System
Fig. 19 - Unit Control Operation
Fig. 20 - Refrigeration System Supplying Direct
Expansion Coils
Fig. 21 - Dry Expansion Reciprocating Liquid
Chilling Package with Evaporative Condenser
Fig. 22 - Flooded Liquid Chiller and Reciprocating
Compressors with Evaporative Condenser
Fig. 23 - Reciprocating Liquid Chilling Package
With Air Cooled Condensers, The Compressors
Fig. 24 - Reciprocating Liquid Chilling Package
With Air Cooled Condensers, Four Compressors
Fig. 25 -Typical Wiring Diagram for Evaporative
Condenser Installation, 208-220 Volts, with
Single PumpoutCompressor Control and Crankcase
Heater
Fig. 26 Typical Wiring Diagram for Evaporative
Condenser Installation, 208-220 Volts, withPumpout
Compressor Control