Experimental investigation of

D. Y. Goswami Performance of a Residential Air

G. D. Mathur
S. M. Kulkarni
Solar Energy and
Energy Conversion Laboratory,
Mechanical Engineering Department,
University of Florida,
Gainesville, FL 32611
Conditioning System with an
Evaporatiyely Cooled Condenser
This paper presents an experimental investigation of the use of indirect evaporative cool-
ing process to increase the performance of an air-to-air vapor compression refrigeration
system. The condenser of an existing 2.5 ton (8.8 kW) air conditioning system at the
University of Florida's Energy Park in Gainesville was retrofitted with a media pad type
evaporative cooler, a water source, and a pump. The system performance was moni-
tored without and with the evaporative cooler on the condenser. The data show that
electric energy savings of 20 percent can be achieved by using an evaporatively cooled
air condenser. The energy savings can pay for the cost associated with retrofitting the
condenser in as little as two years.

Introduction
The concept of using evaporative cooling is widely employed
in cooling towers for air conditioning systems for large facili-
ties and to provide cooling for agricultural greenhouses. It is a
proven concept (ASHRAE, 1989) but is used on a very limited
basis for the residential and small commercial air conditioning
systems, which are usually air-to-air compression-type systems.
The performance of such systems can be improved by employing
indirect evaporative cooling such that no moisture is added to the
supply air stream. This can be achieved by evaporative cooling
of the outside air before it passes over the condenser coil, re-
sulting in a larger overall temperature difference across the heat
exchanger and thus greater cooling effect. The process requires
very little additional energy input for the condenser fan and for
water pumping, resulting in higher coefficient of performance.
Increased cooling effect allows the equipment to be downsized
resulting in lower peak demand and energy usage. This can result
in significant energy and demand savings overall since there are
millions of air conditioners in the residential sector that can be
easily retrofitted. A simple retrofit on the condenser of an air
conditioning unit can save enough energy to pay for itself in as
little as one to two years. Indirect evaporative cooling has rarely
been used for the residential and small commercial air-to-air va-
por compression air conditioning systems due to the following
reasons:
(1) spray of water on the coil causes mineral deposits on the heat
transfer surfaces which decreases the performance of the system
and
(2) spray of water on the coil makes it essential to have an ex-
pensive water treatment system to prevent scale buildup on the
heat transfer surfaces.
Contributed by the Solar Energy Division of THE AMERICAN SOCIETY OF
MECHANICAL ENGINEERS for publication in the ASME JOURNAL OF SOLAR ENERGY
ENGINEERING. Manuscript received by the ASME Solar Energy Division, Jan. 1993;
final revision, Mar. 1993. Associate Technical Editor: J. Mitchell.
The above problem can be eliminated if an alternative system,
e.g., media pad evaporative cooler is used. Media pads are cellu-
lose bound cardboard structures which are cross-fluted to increase
the transfer area. The average life expectancy of the media pad
evaporative cooler is of the order of five years. With clean water,
it may last up to ten years (Munters, 1986). With this system,
air is allowed to pass through the wetted medium (media pad)
before entering the condenser. Hence water droplets do not reach
the heat transfer surfaces of the condenser coil, thus avoiding
mineral deposits on the coil. The mineral deposits occur on the
inexpensive media pads, which can be replaced periodically as
needed. The present investigation was conducted to demonstrate
the practicality of this concept for new air conditioning units as
well as retrofits of existing units and to evaluate the actual savings
by employing this concept. This paper presents the results of per-
formance improvement of a residential air conditioner retrofitted
with a media pad evaporative cooler.
Literature Review
Evaporative cooling has been investigated by a number of in-
vestigators in many different combinations and configurations
(Brown, 1990; Meckler, 1990). Different types of heat ex-
change systems have been investigated by integrating the evapora-
tive coolers: heat-pipe heat exchangers (Scofield, 1986; Scofield
and Taylor, 1984; Mathur, 1990a); plate-type heat exchangers
(Scofield and DesChamp, 1984; Wu and Yellott, 1987); rotary
regenerative heat exchangers (Woolridge et al., 1976); and two-
phase thermosiphon loop heat exchangers (Mathur, 1990b), etc.
Because of the importance of evaporative cooling in reducing the
energy needs for cooling, the U.S. Department of Energy's (DOE)
major computer program for building energy analysis (DOE 2.1d)
has been modified to model and analyze a variety of direct, indi-

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 PIPING FOR WATER
DISTRIBUTION
Fig. 1 Schematic diagram of the condenser retrofit
rect, and multiple-stage evaporative cooling systems (McDonald
et al., 1990). Evaporative cooling with a mechanical refrigera-
tion system as a backup has been designed (Scofield and Sterling,
1992) for the arid areas.
All of the work reported above on evaporative cooling primar-
ily deals with commercial and industrial applications where the
system capacities are very large. However, the same principle
can be applied to the residential air conditioners also.
System Set-Up and Instrumentation
The outdoor condensing unit of an existing 2.5 ton (8.8 kW)
Trane Heat Pump was retrofitted with a media pad evaporative
cooler. The heat pump is being used for air conditioning of an
occupied test house at the University of Florida Energy Research
and Education Park. The manufacturer's specifications of the heat
pump are:
Condenser fan: 1/4 h.p. (187 W), Full load Amps = 2.7, 230
Volts
Evaporator fan: 1/2 h.p. (373 W), Full load Amps = 3.3, 230
Volts
Cooling Capacity = 29,800 Btu/hr (8.73 kW)
SEER = 9.0.
The condenser coil is rectangular in shape and is placed outside
the building. It is a single row deep coil. The ambient air is drawn
into it from all four sides and the hot air is exhausted from the
top of the condenser unit. The retrofit consisted of constructing a
sheetmetal structure around the condenser coil to hold the media
pad, a pan at the bottom of the media pad holder, a spray bar at
the top of the media pad and a small pump to pump the water
from the pan to the spraybar, as shown in Fig. 1. At each side
of the condenser coil, the opening (26 in. x 21 in.) was divided
into 16 equal elements. The air velocity was measured at the
center of the individual elements. The face velocity at the side
of the condenser coil ranges between 280 to 700 fpm (1.42 to
3.6 m/s). The total air flow rate over the condenser coil was
measured to be 2430 cfm (1.15 m3/s). The condenser fan has a
1/4 hp (187 W) motor installed. The condenser coil was retrofitted
with 8-in. (20.32-cm) thick media pad (Munters, 1986), and a
Nomenclature
COP coefficient of performance
CFM air volumetric flow rate, SCFM
E effectiveness of the system, percent
Ec cooling equipment efficiency (0.95 kW/ton)
EER energy efficiency ratio
GPM water flow rate, gallons per minute
Ha air pressure drop, inches W.C.
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recirculating pump. The face area of the media pad is larger than
the opening on the sides of the condenser coil. This resulted in
face velocities between 195 to 212 fpm (0.99 to 1.08 m/s) over
the media pads.
The face velocity over the evaporator coil was also measured.
Air flow measurements were done at nine points close to the
evaporator coil that resulted in an average air flow rate of 930
cfm (0.44 m3/s). Dry and wet bulb temperatures were recorded
upstream and downstream of the evaporator coil.
Individual power meters were used to monitor the power con-
sumption of the compressor, fans (evaporator and condenser),
and the recirculating pump. The pressure drop across the media
pad was measured with an inclined manometer. A hygrometer
was used to record the outside relative humidity during the day-
time. The conditioned space temperature was recorded from the
thermostat inside the building. A hygro-thermograph was used
inside the building to record the temperature and relative humid-
ity of the conditioned space. The pressure around the loop was
recorded with the help of Mamac transducers and the temperatures
were measured with T-type (Copper-Constantan) thermocouples.
A strip chart recorder was used for recording all the variables for
analysis. Table 1 shows the summary of the instruments used in
this investigation. Figure 2 shows the schematic view of the sys-
tem. It also shows the locations of the temperature and pressure
taps. The performance of the system was recorded without and
with the media pad evaporative cooler on the condenser.
Results and Discussions
The air conditioning system was first monitored for four weeks
without the media pad evaporative cooler on the condenser coil.
The condenser was then retrofitted and the system performance
was monitored for another four weeks. Figures 3 to 6 show the
data without the evaporative cooler while Figs. 7 to 9 show the
data with the condenser retrofitted with the evaporative cooler.
Figure 10 shows the psychromatic process of the condenser per-
formance with and without evaporative cooler on the condenser
coil.
Hw = water pressure drop, feet W.C.
P = peak demand charges (dollars kW)
SE = saturation efficiency, percent
Subscripts
e = evaporator
c = condenser
NOVEMBER 1993, Vol. 115/207
 Table 1 Details of the instruments

Instrument for Make, Model and Other

Variable Measurement Specifications

Power consumption of Power computers Haltronics, Range 0-12 kW,

various components Accuracy ± 3 percent

Pressure drop across Inclined tube manometer Dwyer,

media pads Range 0.05 to 3 inches of W.C.,
Accuracy 0.01 inches W.C.

Outside conditions Hygrothermo-graph Bendix model 594,

Range 0-110°F,
Accuracy 1° F

Refrigerant pressure at Pressure transducers Mamac PR 262, Range ± 20

various locations inches of W.C,
Accuracy ± 0.05 inches of W.C.

Refrigerant temperature Thermocouples T type, Copper-constantan

and air temperature Range 260° C to 400° C,
Accuracy 0.01 °C

Air velocity Velometer Solomat, MPM 500e,

Range 40 to 20000 fpm,
Accuracy 0.001 fmp

Fig. 2 Refrigeration system showing the location of the pressure, temperature, and power measurements

System Performance Without Evaporatively Cooled Con-

12- denser. Figure 3 shows the coefficient of performance (COP),
11- energy efficiency ratio (EER), ambient air temperature (°F), and
10-
relative humidity, kW/ton, and compressor power (kW) during
the day on July 11, 1992. On this particular day (7/11/92), the
9-
AMBIENT weather was sunny all day long. In the early hours of the day
8- TEMP (X10) when the ambient air temperatures were lower, the performance
7- of the system (COP and EER) was higher since the condenser
6- was operating at lower pressure heads. As the day progressed,
5-
the ambient air temperature increased which resulted in lower
«COP performance due to increased condenser pressure head. Higher
4-
__—x RH(xlO)
condenser pressure resulted in an increase in power consumption
s~— COMP. POWER
by the compressor. The performance of the system increased
2 in the late afternoon when the ambient air temperature dropped.
x - * kW/1 UN
Data recorded on other sunny days showed similar results (Figs.
4 and 5).
0-
8.00 9.00 _,
10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00
i i t
n 19.00 20.00 21.00 22.00
TIME ( hrs) Figure 6 shows the results from the data recorded on a day
(7/14/92) when a thunderstorm passed through Gainesville. At
Fig. 3 System performance without evaporative cooler (date 7/11/92)
14.00 hours, the ambient temperature was 95°F (35°C) and as

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 EER AMBIENT TEMP (F)
AMBIENT TEMP <F> (X10)
(X10)
RH (XiO)

COMPRESSOR COMPRESSOR
POWER ( kW) POWER ( kW)

—* kW/TON

8.00 9.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00
TIME ( hrs ) TIME ( hrs )

Fig. 4 System performance without evaporative cooler (date 7/13/92) Fig. 6 System performance without evaporative cooler (date 7/14/92)

12-

11-
1 * EER
10-
AMBIENT TEMP (F)
(X10) 9- H AMBIENT TEMP (F)
EER (X 10)
8

7-

6- j*. RH (X 10)

5-

m COP

3-
COMPRESSOR
POWER ( kW) 2- (kW)

1-

13.50 14.50 15.50 17.50 18.50

0-
.
12.00 .
13.00 14.00. I I I

TIME (hrs ) TIME (hrs )

Fig. 5 System performance without evaporative cooler (date 7/20/92) Fig. 7 System performance with evaporative cooler (date 8/19/92)

the storm moved into the test area, the ambient air temperature The following uncertainties were obtained:
dropped to 77°F (25°C) at 15.30 hours. A sudden reduction of compressor power 1.6 percent
the ambient air temperature resulted in a decrease of the con- COP 1.6 percent
denser pressure thus reducing the compressor power which in EER = 2.4 percent.
turn resulted in an increase of the COP and EER. The system
performance decreased again when the ambient air temperature
increased in the late afternoon. Savings Analysis
System Performance With Evaporatively Cooled Con- This section gives an analysis of the savings due to an evap-
denser. Figures 7 to 9 show the variation of COP, EER, ambient orative cooler. The following data for 7/11/92 (11.30 a.m.) are
air temperature (°F) and relative humidity, kW/ton, and compres- used for the analysis:
sor power (kW) during the day with evaporatively cooled con- Ambient dry bulb temperature 92°F (33.3°C)
denser. The compressor power in this case, on the average, was Ambient wet bulb temperature 75°F (23.9°C)
approximately 2.4 kW in comparison to approximately 2.9 to 3.0 Conditioned space dry bulb
kW without evaporative cooling. This represents a decrease in temperature 75°F (23.9°C)
the compressor power by approximately 17 to 20 percent. Fig- Conditioned space wet bulb
ures also reveal that the EER of the system has gone up from an temperature 62.5°F (16.9°C)
average value of 9 (without evaporative cooling, Figs. 3, 4, 5, 6) Saturation efficiency of media pad 88 percent
to approximately 11 with evaporative cooling. This is an increase
[8 inches (20.32 cm) @ 200 fpm
of the system performance by approximately 22 percent.
(1.02 m/s)]
Figures 7 to 9 also show the variation of the kW/ton. This Pressure drop for the media pad 0.025" W.C. (6.2 Pa)
shows how the evaporative cooler has caused a reduction of the Evaporator air flow rate 930 scfm (0.44 m3/s)
electrical input to produce a ton of cooling. The value of kW/ton Condenser air flow rate 2430 scfm (1.15 m3/s)
went down to 0.8 from an average value of 0.95 for the system
kW/ton the system 0.95
without the evaporative cooling.
Condenser effectiveness (measured) 21 percent
Evaporator effectiveness (measured) 47 percent
Error Analysis. Error analysis for estimating uncertainty in
experimental results was done (Kline and McClintock, 1953). The dry bulb temperature of the air leaving the media pad evap-
Test data for 7/11/92 (11:30 a.m.) were used for the analysis. orative cooler (before entering the condenser) may be determined

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 AMBIENT TEMP (F)
(X 10)

STATE DBT(F)/WBT(F)
1 92/75
* COMPRESSOR
POWER (kW)
2 77/75
Dry Bulb Temperature 3 84.4/77
4 104.6/78
9.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 Process 1-2-3 C With evaporative Cooler)
TIME { hrs ) Process 1-4 < Without evaporative cooler)

Fig. 8 System performance with evaporative cooler (date 8/20/92) Fig. 10 Psychrometric process diagram

Savings in equipment = tons saved * Equipment cost/ton

costs ($) = 0.69 * 650=448.5
EER Power savings = tons saved * kW/ton for the system
= 0.69 * 0.95
AMBIENT TEMP (F)
(X 10) = 0.66 kW.

Assuming the fan and motor efficiencies of 75 and 90 percent,

13,00 14.00 15.00
TIME (hrs)
Fig. 9 System performance with evaporative cooler (date 8/22/92)
by
= 92 - 0.88(92 - 75)
= 77.0°F (25°C).
Hence, with the use of an evaporative cooler, the air tem-
perature drops by 15°F (8.3°C) (difference between 92°F and
77.0°F). This results in an increased recovery on the supply side
(evaporator) causing the airstream to have additional temperature
drop. This temperature drop is calculated as
= 92 - 0.47(92 - 77.0)
= 84.95°F (29.4°C).
the additional condenser fan power requirements can be calculated
from the following equation (Mathur, 1990b):
Power = CFMc Ha/(6346 * 0.75 * 0.90)
= 2430 * 0.025/(6346 * 0.75 * 0.90) * 0.746
COMPRESSOR
POWER (kW)
= 0.011 kW.
From the manufacturer's catalog of media pad evaporative
cooler (Munters, 1986), a water flow rate of 13.5 gpm (0.00085
16.00 17.00 18.00 19.00
m3/s) is needed for an 8-in. thick media pad (Munters recom-
mends 1.5 gpm per square foot of horizontal area of the media
pad). For 13.5 gpm (0.00085 m3/s) of water flow rate inside a
3/4 in. (1.91 cm) PVC pipe, the total head loss (frictional, hy-
drostatic, and minor losses) is 10.8 ft (3.3 m) of water column.
The power requirements for the recirculating water pump with
an efficiency of 90 percent may be calculated from the following
equation (Mathur, 1990b):
Power = GPM Hw/(3965 * 0.9)
= 13.5* 10.8/(3965* 0.9) "0.746
= 0.031 kW.
Net Power Savings = 0.660 - 0.011 - 0.031 = 0.618 kW
In many areas of the country, there are peak demand charges,
applied to monthly electric utility bills. Assuming a peak demand
charge of $7.5/kW for Gainesville area, the peak demand savings
per year may be calculated from the following equation:

Assuming the supply air to be made up of 100 percent out-
side air, the supply-side temperature drop across the evaporator
is increased by 7.05°F (3.9°C) (difference between 92°F and
84.95°F). This additional recovery on the evaporator side re-
sults in a decrease of the cooling load by 0.28 tons (0.99 kW)
[1.08 * 930 * 0.47 * 7.05/12000]. Figure 10 shows the process on
the psychrometric chart.
Cooling Savings. In order to calculate the energy and the
equipment savings for cooling, a cooling equipment efficiency of
0.95 kW/ton, and a cooling equipment cost of $650/ton (Mathur,
1990b) are used. The reduction in cooling equipment cost may
be determined by the following equation:
Tons saved = 1.08 * 2430 * 0.21 (92-77.0)/12000
= 0.69 tons (2.43 kW)
Peak demand savings/year= tons saved * Ec * P * 12
= 0.69 * 0.95 * 7.5 * 12
= $59.00.
The above analysis shows that if a media pad evaporative
cooler is used with a 2.5 ton (8.8 kW) air conditioning unit,
the cooling load reduces by 0.28 tons (0.99 kW) and the con-
denser load goes down by 0.69 tons (2.43 kW). This reduction in
the cooling tonnage results in a lower initial cost of the system
by $448.50, net power savings of 0.618 kW, and peak demand
savings of $59.00/year.
Retrofit Payback Calculations. The following section gives
the details of the retrofit payback analysis:
2.5 ton unit: 14.8 Amps @ 230 Volts
Operation 12/day for 7 months

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 Table 2 Savings and payback data
Summer Design Cond. Savings
City (DBT°F/WBT°F) Power (kW) Payback (yrs)

Miami 90/77 0.45 1.55

Oriando 94/76 0.63 1.47

Jacksonville 96/77 0.66 1.69

Key West 90/78 0.42 1.50

Panama City 92/78 0.49 2.15

Fort Meyers 93/78 0.52 1.49

Tampa 92/77 0.52 1.61

Cost of retrofitting the condenser = $200 Conclusions

Total operational time (210 day/year* 12 hrs/day) = 2520 h/yr
Cost of electricity = 0.085 ($kW-h)
Cost of water in Gainesville = $0.70/1000 gal
Average precooling of the air = 14°F
Water evaporation rate (worst case for Gainesville for the
month of May) = 8.74 (gal/li).
Cost of water per year = 8.74*2520* (0.70/1000) = 15.42
($/yr)
Cost of running the pump = 0.031 * 0.085 * 2520 = 6.64 ($/yr)
Cost of additional fan power = 0.011 * 0.085* 2520 = 2.36
($/yr)
Reduction in the compressor amperage (measured) = 20 percent
Service Factor =1.0
The decrease of the amperage will result in the following sav-
ings per year:
2520h x 230V x 14.8A x 1.0S.F. x 20% X 0.085$
yr x 1000 W-h/kW-h x kW-h
= $145.82/year.
Hence
payback period = Cost of Retrofit/[Net Savings/year]
= 200/(145.82-15.42-6.64-2.36)
= 1.64 years.
Simulation Program. A computer program has been devel-
oped for predicting the performance of air conditioning systems
with evaporatively cooled air condensers. The program uses BIN
weather (Weather data, 1978) data for a detailed analysis. The
computer program was run for estimating the savings for various
cities with an evaporatively cooled air condenser. Assuming the
existing airconditioning system to operate in seven different cities
in Florida, a comparison has been made for the energy savings
and the payback period. Table 2 shows the comparison of the
performance of the system at various locations in Florida.
As can be seen from Table 2, incorporating an evaporative
cooler with the condenser improves the system performance. The
payback period for the cost associated with retrofitting, in most
cases, is less than two years.
The performance of a 2.5-ton (8.8 kW) refrigeration system
was investigated with and without media pad evaporative cooled
air condenser. The experimental investigation revealed that with
evaporative cooling, the supply air was further cooled to a lower
temperature. The evaporatively cooled condenser resulted in de-
crease in the power consumption by the compressor and conse-
quently saved enough energy to pay for the retrofit in less than
two years.
Acknowledgments
The authors would like to thank the Florida Energy Extension
Service for the financial support for this project. The authors
wish to thank Dr. Michael K. West, the technical monitor for this
project, for his valuable advice thoughout the project.
References
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Kline, S. J., and McClintock, F. A., 1953, "Describing Uncertainties in single
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