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Unitary
Air Conditioning Systems
Unitary
or "packaged" equipment (i.e., air- or water-cooled
direct expansion [DX] systems) are the most widely used air
conditioning and heat pump equipment in the United States.
These systems are often roof-mounted. Packaged air conditioners
provide cooling by a means similar to that employed in the
common household refrigerator-the refrigerant vapor-compression
cycle. The vapor-compression cycle converts a liquid refrigerant
to a gas, and back again, and in the process provides cooling
and produces waste heat. (Packaged heat pump units reverse
the process in the heating mode to provide space heating).
This
equipment includes all the components required to deliver
heating and/or cooling to a space or building in a single
package. It includes a fan for moving air, an indoor cooling
coil (the evaporator), a heating coil or furnace, air filters,
dampers for regulating air flow, refrigeration compressor(s),
an outdoor or condensing coil for rejecting heat, and controls
for automatically regulating space temperature. Smaller packaged
units closely resemble residential air conditioners in using
a single, fixed-output compressor. Multiple compressors become
common in sizes of about 10 tons of cooling capacity (120,000
Btuh) and above. Multiple compressors give stepped output,
particularly when the compressors are of different capacities.
As a hypothetical example, a unit with both a 4-ton and 6-ton
compressor would have output capacities of 4, 6, or 10 tons,
which is very valuable under part-load conditions. At part
loads, these units will be very efficient, since the heat
exchangers are effectively oversized, but humidity control
may suffer with some designs. Roof-top units may include a
non-condensing (lower efficiency) gas furnace section. The
combinations are called "year-round" units.
Larger roof-top units may have very sophisticated controls,
and some are designed for multi-zone variable air volume applications
much like those typical of chiller-based systems.
"Split
systems" are unitary systems designed as two factory-made
assemblies. For example, a typical split system may have the
fan, evaporative coil, filters, and dampers in an indoor unit,
and the compressor and condenser coil in an outdoor cabinet.
For split systems, heating is provided by a furnace section
or heat pump. For smaller units in cold climates, residential-type
condensing (high-efficiency) furnaces are available to about
200,000 Btuh. Split systems require supplemental, field-installed
equipment to provide ventilation air or economizer cycles.
In general, one split system is used for each temperature
zone of the building. Consortium
for Energy Efficiency and National
Building Institute recommendations are given in the table
below.
| Recommended
Efficiency Values for Unitary Air Conditioners
|
| Equipment Type |
Size
Category |
Sub-Category
or
Rating Condition |
Required
Efficiency |
|
Air
Conditioners,
Air Cooled
|
<
65,000 Btuh
|
Split
System
|
13.0
SEER
|
| Single
Package |
|
|
>
65,000 Btuh and
< 135,000 Btuh
|
Split
System and Single Package
|
11.0
EER
11.4 IPLV
|
|
|
>
135,000 Btuh and
< 240,000 Btuh
|
Split System
and Single Package |
10.8
EER
11.2 IPLV
|
|
|
>
240,000 Btuh
|
Split
System and Single Package
|
10.0
EER
10.4 IPLV
|
|
Air
Conditioners, Water and
Evaporatitively Cooled
|
All
Sizes
|
Split
System and
Single Package
|
14.0
EER
|
Source:
Consortium for Energy Efficiency. 2002. "CEE
High-Efficiency Commercial Air Conditioning and Heat Pump
Initiative (HECAC)," p. 1. Boston, Mass.: Consortium
for Energy Efficiency.
The
table below gives recommendations from the same sources
for unitary and applied heat pumps.
| Recommended
Efficiency Values for Unitary and Applied Heat Pumps
|
| Equipment Type |
Size
Category |
Sub-Category
or
Rating Condition |
Required
Efficiency |
|
Air
Cooled
(Cooling Mode)
|
<
65,000 Btuh
|
Split
System
|
13.0
SEER
|
| Single
Package |
13.0
SEER |
|
|
>
65,000 Btuh and
< 135,000 Btuh
|
Split
System and
Single Package
|
11.0
EER
11.4 IPLV
|
|
|
> 135,000 Btuh and
<240,000 Btuh
|
Split System
and Single Package |
10.8
EER
11.2 IPLV
|
|
|
>
240,000 Btuh
|
Split
System and Single Package
|
10.0
EER
10.4 IPLV
|
|
Air
Cooled
(Heating Mode)
|
<
65,000 Btuh
(Cooling Capacity)
|
Split
System
|
8.0
HSPF
|
| Single
Package |
7.7
HSPF |
| |
>
65,000 Btuh and
< 135,000 Btuh
(Cooling Capacity)
|
47oF
db/43oF wb
Outdoor Air
|
3.4
COP |
17oF
db/15oF wb
Outdoor Air |
2.4
COP |
| |
*135,000
Btuh
(Cooling Capacity)
|
47oF
db/43oF wb
Outdoor Air
|
3.3
COP |
17oF
db/15oF wb
Outdoor Air
|
2.2
COP |
|
Water
Source
(Cooling Mode)
|
<
135,000 Btuh
(Cooling Capacity)
|
85oF
Entering Water |
14.0
EER |
|
Water-Source
(Heating Mode)
|
<
135,000 Btuh
(Cooling Capacity)
|
70oF
Entering Water |
4.6
COP |
Source:
Modified by ACEEE from Consortium for Energy Efficiency.
2002
Almost
all commercial unitary equipment is air-cooled, but
the exception, water-cooled heat pump systems, can even
serve large multi-zone buildings. Small, packaged water-cooled
air conditioners/heat pumps provide an easy way to get
multiple temperature control zones in minimum space.
Because most designs put all of the heat pumps on a
single water "loop," these systems can efficiently
serve where some zones require heating while others
need cooling. Such cases are very common and include
heat needed on the northern side while the southern
exposure requires cooling or simultaneous core cooling
and perimeter heating. The heat that some heat pumps
reject in cooling mode is carried automatically to those
needing to heat their zones. Ultimately, when the building
is either predominantly in cooling or in heating mode,
the water "loop" will drift out of pre-set
temperature bounds, and heat pump efficiency will drop.
To maintain loop temperature when the building wants
more heat, a central boiler can be provided. When additional
loop cooling is required, a cooling tower is employed
(the chiller of customary central systems is replaced
by the compressors of the heat pumps). Alternatively,
ground water or a ground source heat exchanger can be
used to support more constant loop temperature.
The
primary disadvantage of this approach is that separate
arrangements are required to meet ventilation requirements
(see section on Ventilation Air and Energy Efficiency).
These arrangements are often a supplemental duct system
or a "dedicated outdoor air system" that brings
in and exhausts conditioned air. These systems have
limited or no ability to work as economizers. Instead,
a "water-side" economizer can be employed,
using a cooling tower to cool the loop temperature.
The cooler the temperature, the more efficiently the
heat pumps work in cooling mode. This allows overnight
pre-cooling, for example.
Heating
with Unitary Equipment
As
suggested in the section on cooling with packaged systems,
unitary equipment offers several options for heating.
A gas or oil furnace is commonly integrated into the
smaller, single-zone, constant volume, roof-top unit,
making it a "year-round." When the thermostat
calls for heat, the furnace is activated.
Packaged units are also available with electric heat.
It is almost always cost-effective to use a heat pump
as a first stage of heat and electric resistance as
the second stage or back-up source. Before selecting
electric heat, check your local utility rates. In most
areas of the United States, electricity for heating
costs two to three times more than natural gas. With
typical gas and electric rates, heat pumps cost roughly
the same as natural gas furnaces to operate. However,
heat pumps do not function well at very low outdoor
temperatures; therefore, in cold climates (e.g., New
England & other Northern states), consider another
source of heat.
Alternatively,
most packaged units are also available with either hot
water or steam coils as a source of heat. Roof-mounted
coils and piping are subject to freezing and therefore
not recommended. Some heating systems will locate hot
water or electric coils in the ductwork downstream of
the packaged unit. In other cases, heating is supplied
by baseboard radiation. In these cases, the packaged
air conditioning unit may not require any heat at all.
If the minimum quantity of outdoor air for ventilation
is low (usually 25 percent of the supply or less), no
heat in the unit is required. Units that serve strictly
interior zones also may not need a heating coil unless
the ventilation load is high.
For
smaller commercial buildings (such as apartment buildings
and wings of schools), the use of "trains"
of residential boilers is common, particularly when
the boiler system provides service hot water by employing
an indirect water heater. Residential-size units, up
to 225,000 Btuh, are relatively inexpensive since they
are made in relatively large quantities. For low-load
conditions, if the "lead" boiler is a condensing
unit, very high efficiencies are feasible. "Follower"
units, dispatched in sequence as the load rises, need
not be condensing units-if an appropriate control system
is used. Such controls should always include an "outdoor
reset" that reduces the output temperature when
conditions outside are mild. Even though this increases
circulating pump energy modestly, it improves overall
efficiency.
Energy
Efficiency of Packaged Equipment
In
the cooling mode, packaged air conditioning and heat
pump equipment is rated by its energy efficiency ratio
(EER). This is the net cooling capacity (Btuh) divided
by the electricity consumed (watts) at peak operating
conditions. Another important measure of the cooling
efficiency of this equipment is the integrated part-load
value (IPLV), which is a single number based on the
weighted average of EER for operation at various load
levels. Manufacturers rate smaller equipment (less than
65,000 Btuh) on the basis of seasonal energy efficiency
ratio (SEER), which is similar to EER except the rating
takes into account the range of conditions during the
cooling season. For these small units, the difference
between listed "commercial" and "residential"
units is that the former use three-phase equipment instead
of single-phase.
In
the heating mode, the rating depends on the type of
heating equipment used. Small furnaces must be rated
according to annual fuel utilization efficiency (AFUE)
while larger furnaces are rated by either thermal efficiency
or combustion efficiency (see section on Central Heating
Plants: Boilers and Furnaces). Small packaged heat pumps
must be rated according to heating season performance
factor (HSPF) while larger heat pumps and hydronic systems
are often compared by their coefficient of performance
(COP, watts/watt), the ratio of their performance at
high and low outside air (or entering water) temperatures.
The higher the EER, IPLV, SEER, HSPF, or COP, the more
energy efficient the equipment.
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