Evaporators come in different varieties. We classify them, first with the help of the methods used to control the refrigerant flow through them. Later, we consider the types based on their construction.
I get emails from time to time with questions that stem from the articles or the podcast. This was a great question, but I was not the best person to answer it.![Chiller Evaporator Coil Sizing Chart Chiller Evaporator Coil Sizing Chart](/uploads/1/2/3/7/123742632/155732875.jpg)
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There are two different methods evaporator flow control. They are : (1) dry expansion evaporator, also called direct expansion or D-X-evaporators, and (2) of flooded evaporators. D-X-evaporators are used in the vast majority of comfort air conditioning systems below 100 tons of cooling capacity. They are also used on some refrigeration and industrial process cooling equipment. Flooded evaporators are used to the comfort of air-conditioning systems of more than 100 tons, especially where the centrifugal chillers liquid or absorption chillers are used. Refrigerating and technological tasks also use the flooded evaporators.
The D-X evaporator, the refrigerant flow control, to refrigerant mainly liquid (wet) on the evaporator, but gas (dry) by the time it reaches the evaporator. In the flooded evaporator refrigerant mainly with liquid (water) from the beginning to the end of the process.
D-X evaporator, as shown here, is a continuous tube through which flows the refrigerant. The refrigerant from the dispenser is served at one end of the tube, and suction, compression is connected to the other end. The difference in pressure at the outlet of the evaporator inlet to the outlet causes the refrigerant flow. No recirculation of the gas or liquid refrigerant inside the evaporator. Rather, the refrigerant passes through the whole system before it enters the evaporator again.
Sims 4 mod blind cane. D-X evaporator has a clear point of separation of liquid and gas (steam) forms of refrigerant. The liquid refrigerant, with a small amount of gas, mixed, enters the evaporator, and, gradually, the share of gas increases until the refrigerant is becoming gas near the outlet of the evaporator.
The refrigerant flow in D-X evaporator coil is controlled by a measuring device so that all liquid refrigerant transformed into vapor (gas) at the time of the refrigerant in the evaporator outlet. (Sometimes full conversion occurs just before the refrigerant reaches the outlet.) In fact, most of the D-X-evaporators have metering devices, intended for production of about 10F superheated gas in their outlets.
Unlike D X evaporator, the flooded evaporator provides for the circulation of the refrigerant in the evaporator addition of separation or egalitarian. Liquid refrigerant enters the surge chamber through the dispenser and gravity causes it to flow down to the bottom pipe.
The coil surfaces in contact with the refrigerant at any load. This design produces a very good heat transfer, but requires a larger, more expensive hardware than D-X design. It also requires a large amount of the refrigerant. Steam (or gas)produced in the flooded evaporator separated from the liquid in the surge chamber. Liquid recirculation through the evaporator again, while a pair of exiled compressor suction action.
The flooded evaporator regulates the flow of the refrigerant by means of a float valve, or a similar arrangement. Float valve is used to maintain a given level of liquid in the surge chamber. The couple leaving the surge saturated, not overheat, as in the case of D-X evaporator..
Design Temperature Difference for Chillers
I get emails from time to time with questions that stem from the articles or the podcast. This was a great question, but I was not the best person to answer it.
![Chiller Evaporator Coil Sizing Chart Chiller Evaporator Coil Sizing Chart](/uploads/1/2/3/7/123742632/155732875.jpg)
I reached out to Jeff Neiman, our resident HVAC School chiller tech and he answered it. Here is the question
Hello Bryan,
![Evaporator coils for sale Evaporator coils for sale](/uploads/1/2/3/7/123742632/442107695.jpg)
Thanks for all the good material you provide. I mostly work on the commerical building side of HVAC where chilled water is used as cooling medium and cooling towers provide condenser water. We have chillers as well as heat pump and air cool splits throughout facilities. Most of your diagnostics and troubleshooting methods are for air cooled units. Can they be applied to water cooled evaporators and water cooled condensers? My thinking is yes and no, because with cooling tower 85 supply and return 95 is maintained and 45 supply and 55 return chilled water is provided. Since there is not much change in these temps as opposed to outdoor ambient temperature there won’t be much pressure change in condenser. And as long water is regulated at proper flow to evaporators and condenser then all should hold steady. Do you have any input on this? I’m in NYC. Went to 2 year hvac school and worked almost 3 years in field starting out as a helper in service van as experience and learned as much then got into the building side for about 8 years now. I like listening to your podcast and reading your material as it keeps me refresh with field work as the building side is a little different but the basics and fundamentals are the same. Thanks!
–Anand
–Anand
Hey Anand,
The answer is yes.
Some of the measurements can be applied to chillers as well. Just some of the verbiage is different and the values differ.
The numbers for chilled water (44 out 54 in) and condenser water (85 out 95 in) are industry standard values at full load conditions. Most chillers regardless of manufacturer will have a 10*F delta T on the cond and evap. Machines that operate outside of those ranges are chillers that were ordered specifically to provide a lower temp or larger delta T.
The numbers for chilled water (44 out 54 in) and condenser water (85 out 95 in) are industry standard values at full load conditions. Most chillers regardless of manufacturer will have a 10*F delta T on the cond and evap. Machines that operate outside of those ranges are chillers that were ordered specifically to provide a lower temp or larger delta T.
Many people look at the compressor motor RLA% as the chiller capacity, which is not accurate. Chiller capacity is measured by the evap delta T. If the chiller is designed for 10°F(5.5°K) delta, and is currently providing 44°F(6.66°C)) water and the return water is at 49°F(9.44°C), the delta T is 5°F(2.75°K). So that chiller is currently running at 50% of its total capacity.
Subcooling is still measured the same, although the reading that you get will change as chiller capacity changes. At low loads your subcooling will be lower and will increase as capacity increases.
Suction superheat is a value that I really don’t look at because the reading on a flooded type of system will usually be very low or even 0. Rather discharge superheat (discharge temp – cond sat temp) is a more accurate reading and will be a direct result of you suction superheat. High suct SH, there will be high dis SH and vice versa. Again, this value will change as chiller capacity changes.
However if the chiller is a DX type, the suction superheat is just as valid as on a residential system
However if the chiller is a DX type, the suction superheat is just as valid as on a residential system
One of the values that was described in the podcast was temperature difference (supply air temp – coil temp).
In regards to air handlers with chilled water coils you can do the same thing. Measure your supply air temp minus the coil leaving water temp. This will tell you how well the heat is transferring to the water from the air going across the coil.
In regards to air handlers with chilled water coils you can do the same thing. Measure your supply air temp minus the coil leaving water temp. This will tell you how well the heat is transferring to the water from the air going across the coil.
In chiller lingo this measurement is called approach
There are two different approach temps that i look at on a chiller:
Condenser approach (cond sat temp – lvg cond water temp)
Evaporator approach (lvg water temp – evap sat temp)
Evaporator approach (lvg water temp – evap sat temp)
Approach values should range in 0 – 3°f(0°K – 1.65°K), given that your flows are correct.
Just like on air cooled units where proper airflow is needed across the evaporator and condenser, you need to verify that you have proper water flows.
Just like on air cooled units where proper airflow is needed across the evaporator and condenser, you need to verify that you have proper water flows.
In air to air applications you are measuring static to identify airflow issues. In water applications, I’m measuring pressure differential across each barrel. If I know my design pressure drop on the evap and cond, I can compare to my actual to know if my flows are proper. Keep in mind though that most chiller manufacturers will give the the design pressure drop in ft/hd. You will need to convert your real time reading to ft/hd to have an accurate comparison if you are using a gauge with a psi scale.
Even if your water temps stay pretty constant while in operation, your pressures will veer off as problems arise and your approach values will increase.
The chiller will always try to maintain at 44°f(6.66°C) chilled water out (or whatever the setpoint is) as long as it can do so.
The chiller will always try to maintain at 44°f(6.66°C) chilled water out (or whatever the setpoint is) as long as it can do so.
The refrigeration cycle doesn’t change, stick to the basics and don’t over think it
When running building, try to get your condenser water as low as possible when running. But stay above 65°F(18.33°C).
Anytime you can provide condenser water lower than the design of 85°F(29.44°C) you will lower your condenser pressure and lower the lift (cond pressure – evap pressure). This will result in less work the compressor has to do and lower KW. This is a common method called condenser relief.
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— Jeff Neiman
Bryan Orr is a lifelong learner, proud technician and advocate for the HVAC/R Trade
To size your production machine cooling load use the following information: Calculate the total lbs/hour of material your machine uses and divide it by the lbs/ton listed below for your specific process. This will give you the tons of cooling required at 50° Fleaving water temperature.
When operating below 50° F you must decrease the rated chiller cooling capacity by 2% for every one degree F you operate below 50° F.
To correct for 45° F operation you would divide the chiller rated cooling load by 0.9. See calculation: 100% – (2% x 5° F below 50° F) = 90% or 0.9.
Chiller Evaporator Coil Sizing Chart Conversion
INJECTION MOLDING = 1 LBS/TON | EXTRUSION = 1 LBS/TON |
30 lbs/hour HDPE 35 lbs/hour LDPE 35 lbs/hour Acrylic 35 lbs/hour PP 40 lbs/hour Nylon 40 lbs/hour Derlin 40 lbs/hour Urethane 45 lbs/hour PET 50 lbs/hour PS 50 lbs/hour ABS 50 lbs/hour PC 50 lbs/hour Acetal 70 lbs/hour PVC | SHEET CALENDERING 35 lbs/hour PE 60 lbs/hour ABS 60 lbs/hour PS PROFILE 50 – 60 lbs/hour HDPE 50 – 60 lbs/hour LDPE 50 – 60 lbs/hour PP 50 – 60 lbs/hour PET 60 – 75 lbs/hour ABS 60 – 75 lbs/hour PVC |
FEED THROAT: 1/2 ton up to 400 ton injection. 1 ton over 400 ton injection. | Barrel = 1 ton/” screw dia Screw = 2 tons Throat = 1/2 ton up to 3″ Throat = 1 ton 4″ to 6″ Gear drive = 100 hp/ton (oil cooling) |
BLOW HOLDING = 1 TON | VACUUM FORMING = 1 TON |
40 lbs/hour HDPE 40 lbs/hour PET 40 lbs/hour PVC | 70 lbs/hour HDPE & LDPE 70 lbs/hour PP 200 lbs/hour PS 250 lbs/hour PVC |
HOT RUNNER MOLDS convert heater watts to btu’s and divide by 2. (watts x 3.414 divide by 24,000 Btu’s)MOTOR COOLING LOAD FOR PORTABLE CHILLERS | |
Hydraulic cooling: | 8 hp = 1 ton |
Vacuum pumps: | 8 hp = 1 ton |
Air compressors: | 8 hp = 1 ton (internal oil cooling). |
8 hp = 1 ton (after cooler cooling). | |
Chilled water flow rate is 2.4 gpm/ton. | |
Chiller ton is 12,000 Btu’s | |
Chiller operating temperature range with water is from 45° F. to 60° F. leaving water temperature. | |
Chiller operating temperature range with glycol/water is from 25 F. to 45° F. leaving water temperature. |