How to Choose The Right Air-cooled Condenser

When selecting a refrigeration unit for a new installation, select the unit to provide the desired cooling effect to reduce and/or maintain the temperature of the product. This capacity is typically expressed in Btuh. Unit coolers (evaporators), compressors and metering devices are all selected based on the Btuh requirement of the refrigerant selected. The only major component not selected based on this Btuh requirement is the condenser.

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The condenser must be selected for the total heat rejection (THR) of the system, which is the sum of the heat energy absorbed by the evaporator and the additional heat energy added to the refrigerant by the compressor. This additional heat energy is called the heat of compression. The heat of compression varies depending on the compressor design, so the compressor manufacturer's information should be used whenever possible. If this information is not available, many condenser manufacturers will provide a reference table to determine this value.

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It is not always necessary to select an air-cooled condenser; many times, condensing units are selected for installation. Condensing units are selected based on the required Btuh capacity, and their condensers are selected by the condensing unit manufacturer. However, systems that use remote air-cooled condensers require a separate condenser selection.

To begin the selection process, first, determine the THR of the system by adding the heat of compression of the compressor (obtained from the compressor manufacturer's or condenser manufacturer's table.) If the condenser is installed above sea level, a correction factor needs to be applied to the THR. The condenser manufacturer will usually provide a table with the required correction factors.

Next, calculate the design temperature difference (TD), which is the design condensing temperature minus the design ambient temperature.

Design TD = condensing temperature - ambient temperature

Next, for the type of refrigerant in the system, use the condenser manufacturer's selection chart to choose a condenser based on THR and design temperature differences. Some manufacturers' charts may show the capacity of their condensers at a 1°F temperature differential. If necessary, you can determine the TD required at 1°F by dividing the THR by the design condenser TD as follows.

THR/°TD = THR ÷ calculated design condenser TD

If the required THR is between the two condenser capacities on the selection table, select the higher of the two. For example, you are selecting a remote air-cooled condenser for a system with a net cooling demand of 225,000 Btuh. The condenser will be installed at sea level, so there is no need for a height correction factor. It is a low-temperature system with an R-404A semi-hermetic suction cooling compressor with a design evaporative temperature of -20°F, an ambient outdoor temperature of 90°F, and a design condensing temperature of 110°F.

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Using this factor, the THR would be 348,750 Btuh (225,000 Btuh x 1.55). Design the condenser TD to be 20°F (110°F - 90°F).

Selecting the correct air-cooled condenser for the installation is an important part of ensuring the system operates properly and at maximum efficiency.

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When installing walk-in coolers and freezers, the installing contractor will need to select the proper location of the condensing unit. Location is an important consideration for the overall success of the installation. There are several items to consider when selecting the location.

First, the location should be discussed with the customer. Be sure the customer is in agreement with the placement of the condensing unit. The customer may have a plan for the location different from where the installing contractor decides to place the unit. As retail space becomes more expensive, customers will want to take advantage of all their indoor space and may want the condensing unit located outdoors or in an indoor location that will not interfere with their operation.

If the condensing unit is to be placed indoors, make sure the location has adequate ventilation. Low-temperature condensing units will require approximately 200 cubic feet per minute (cfm) per 1,000 Btu, and medium-temperature units will require approximately 165 cfm per 1,000 Btu. Always check with the condensing unit manufacturer for ventilation requirements, as they may differ from these approximate values. Another consideration with air-cooled units located indoors is the heat they may add to the space. This additional heat may be objectionable to the equipment owner.

OUTDOOR CONSIDERATIONS

An alternative to locating the condensing unit indoors is to place it outdoors. When installed outdoors there are several components that should be added with the condensing unit. Some of these components may be ordered as installed options.

The condensing unit should have a crankcase heater installed. This will help to prevent refrigerant migration during the off-cycle when the condensing unit is exposed to temperatures that are colder than the evaporator. The condensing unit will also need some means of keeping the high side pressure above a minimum value during low outdoor temperatures. This is normally accomplished with either a fan-cycling control or a head-pressure controller.

The method of controlling the case temperature may also need to be modified. The system should use a pumpdown method to control the operation of the condensing unit. A standard air-sensing temperature controller should be used to control the operation of a liquid line solenoid. When the temperature controller is satisfied, it will close the liquid line solenoid, causing the refrigerant to be trapped in the condenser and receiver.

This will cause the low-side pressure to drop. The system's low-pressure control will then shut down the condensing unit as the low side pressure drops to an appropriate value. A defrost timer will also need to be added to the control system to ensure that the evaporator defrosts properly.

The outdoor unit should be covered to protect it from the outdoor environment. If the condensing unit is ordered for an outdoor application, it will normally come with some type of enclosure. When moving an indoor condensing unit to the outdoors, make sure an adequate enclosure is constructed to properly protect the unit.

One last consideration when installing either an indoor or outdoor condensing unit is to make sure the system can be easily serviced. Too often, service technicians encounter systems in which the condensing unit is located in an area where it is extremely difficult to access. Also, make sure there is an electrical disconnect available to shut off the electrical supply when needed.

Publication date: 09/04/

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