4-i CHAPTER 4. SCREENING ANALYSIS

TABLE OF CONTENTS

4.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 TECHNOLOGY OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 EMERGING TECHNOLOGIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.1 Electro-Hydrodynamic Enhanced Heat Transfer . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.2 Copper Rotor Motor with Improved Efficiency . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.3.3 Non-HFC/HCFC Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.3.1 Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.3.3.2 Carbon Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.3.3.3 Hydrocarbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4 COMMERCIAL TECHNOLOGIES THAT CAN ENHANCE EER . . . . . . . . . . . . . . 4-8 4.4.1 Evaporator Coil Area (Keeping Coil Rows the Same) . . . . . . . . . . . . . . . . . . . 4-9 4.4.2 Condenser Coil Area (Keeping Coil Rows the Same) . . . . . . . . . . . . . . . . . . . . 4-9 4.4.3 Coil Rows (Keeping Coil Heat Transfer Performance the Same) . . . . . . . . . . 4-10 4.4.4 Coil Rows (Keeping Face Area the Same) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.4.5 Microchannel Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.4.6 Deep Coil Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.4.7 Low Pressure-Loss Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.4.8 High-Efficiency Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.4.9 High-Efficiency Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.4.10 Air-Foil Centrifugal Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.4.11 Backward-Curved Centrifugal Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.4.12 Synchronous (Toothed) Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.4.13 Direct Drive Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.4.14 High-Efficiency Propeller Condenser Fans and Motors . . . . . . . . . . . . . . . . . 4-15 4.4.15 Condenser Fan Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.4.16 Evaporator Fan Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.4.17 Elimination of Air Leakage Paths within Unit . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.5 SCREENING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

LIST OF TABLES

Table 4.5.1 Design Options Not Viable for Consideration in the Engineering Analysis . . 4-18 Table 4.5.2 Design Options Viable for Consideration in the Engineering Analysis . . . . . 4-19a Although the Process Rule specifically applies only to new or revised energy conservation standards for consumer products, the Department applies its procedures to new or revised standards for industrial equipment as well.

4-1 CHAPTER 4. SCREENING ANALYSIS

4.1 INTRODUCTION

The Energy Policy and Conservation Act, as amended (42 U.S.C. 6311-6317) (EPCA or the Act) establishes energy-efficiency standards and test procedures for certain commercial, unitary, air cooled air conditioners and air source heat pumps rated at or greater than 65,000 Btu/h, but less than 240,000 Btu/h. (42 U.S.C. 6313(a)(1) and (2) Further, the Act provides criteria for prescribing new or amended standards which will achieve the maximum improvement in energy efficiency, which the Secretary of Energy determines is technologically feasible and economically justified. (42 U.S.C. 6313(a)(6)(A)) It also establishes guidelines for determining whether a standard is economically justified. (42 U.S.C. 6313(a)(6)(B))

In view of the EPCA requirements for determining whether a standard is technologically feasible and economically justified, Appendix A to subpart C of Title 10 Code of Federal Regulations Part 430 (10 CFR Part 430), “Procedures, Interpretations and Policies for Consideration of New or Revised Energy Cons ervation Standards for Consumer Products” (the Process Rule) sets forth procedures to guide the DOE in the consideration and promulgation of new or revised product efficiency standards under EPCA. a These procedures elaborate on the statutory criteria provided in 42 U.S.C. 6313 and in part eliminate problematic design options early in the process of revising an energy efficiency standard. Under the guidelines, before publishing an advance notice of proposed rulemaking (ANOPR), DOE eliminates from consideration design options that present unacceptable problems with respect to the following four factors:

• technological feasibility; • practicability to manufacture, install and service; • adverse impacts on equipment utility to consumers or availability; and • adverse impacts on health or safety.

The Department will not consider a technology that does not meet any one of the above guidelines. 10 CFR Part 430, subpart C, appendix A, at paragraph 5(b)(1)-(4). Also, the Department understands that there are potential energy savings associated with technologies and techniques that can improve the net annual energy performance of a system, but which generally reduce the energy efficiency ratio (EER) of commercial unitary air-conditioning equipment, orhave no effect on EER. Because the energy-efficiency standards for commercial unitary airconditioning equipment in 42 U.S.C. 6313(a)(1)(C) and (2)(A) are measured and expressed in terms of EER, the Department will not consider those technologies at this time.4-2 This screening analysis evaluates commercial unitary air conditioning and heat pump technologies as possible design options that, inview of the above guidelines, would improve energy efficiency and be technologically feasible and practicable to manufacture, install and service, have no adverse impact on utility or availability to consumers, and have no adverse impact on health or safety. If a particular design option meets all four criteria, DOE will evaluate the design option further for its effect on energy efficiency performance and reveal the results of that evaluation when it publishes a Notice of Proposed Rulemaking (NOPR) in connection with these products.

4.2 TECHNOLOGY OPTIONS

For the commercial unitary equipment covered under this rulemaking, there is a rather long list of design options that can enhance th e equipment’s energy efficiency. Design options fall into one of two categories based on their development status and impact on the equipment’s EER:

• Emerging technologies

• Commercial technologies that enhance EER

4.3 EMERGING TECHNOLOGIES

Emerging technologies are those technologies that are currently unavailable on the commercial market but are being examined in the laboratory as possible means to enhance efficiency. The following technologies withinthis category are further described below:

• Electro-hydrodynamic enhanced heat transfer,

• Copper rotor motor with improved efficiency, and

• Non-hydrofluorocarbon/hydrochlorofluoro carbon (HFC/HCFC) refrigerants (e.g., ammonia, carbon dioxide, and hydrocarbons).

4.3.1 Electro-Hydrodynamic Enhanced Heat Transfer

Electro-hydrodynamic enhancement (EHD) of heat transfer is the result of applying a high-voltage electrostatic potential field across a heat transfer fluid, such as a refrigerant or refrigerant mixture. The applied field destabilizes the thermal boundary layer, thereby producing better mixing of the bulk fluid flow and increasing the net heat transfer coefficient. This procedure appears to be more effective when applied to phase change processes (e.g., boiling and condensation). The Department had initial studies done with several refrigerants, including R-123, R-134a, an R-11/Ethanol mixture, and R-404A. For R-134a, EHD provided dramatic improvements in heat transfer, especially at lower refrigerant qualities (more liquid and less vapor). This technology may allow manufacturers to produce highly compact heat exchangers4-3 with less complicated surfaces without sacrifici ng heat transfer efficiency. Experiments to analyze the heat transfer coefficient for R-123 in pool boiling showed an increment from a baseline of about 1.5 kilowatts per square meter Kelvin (kW/m 2 K) to about 8.5 kW/m 2 K at an applied potential of 1800 volts. This phenomenon is typically used to electronically control the capacity of a heat exchanger by raising the applied voltage to increase the heat transfer. This can lead to improved efficiencies by using smaller capacity equipment, most of the time without EHD, and then utilizing the EHD effect during peak loads. Another potential application is to use continuous EHD enhancement with smaller, less costly heat exchangers. The EHD effect would offset the loss of heat transfer capacity experienced with the smaller heat exchangers. Similarly, EHD can replace, or work in conjunction with, enhanced surface heat exchangers. To use EHD, an electrical voltage (from a few volts to thousands of volts) is applied to the heat transfer device. However, because the heat tr ansfer fluids are typically dielectric (of low electrical conductivity), even high voltages produce very little current. This low current helps keep the power (voltage times current) and the associated energy penalty low. The required electronics also represent an increased mate rial cost. More significantly, applying the electronics would require a more complicated manufacturing process. 1

Because electro-hydrodynamic heat transfer is in the research stage, the Department believes that it would not be practicable to manufacture, install and service this technology on the scale necessary to serve the relevant market at the time of the effective date of an amended standard. Also, because this technology is in the research stage, it is not possible to assess whether it will have any adverse impacts on equipment utility to consumers or equipment availability, or any adverse impacts on consumers' health or safety. Therefore, DOE will not consider electro-hydrodynamic heat transfer as a design option for improving the energy efficiency of commercial unitary air cooled air conditioners and air source heat pumps.

4.3.2 Copper Rotor Motor with Improved Efficiency

Making the critical components of an induction motor's rotor (e.g., conductor bars and end rings) out of copper instead of aluminum improves the energy efficiency of the motor. The greater conductivity of copper results in lower resistance heating losses in the rotor and thus lower losses in the motor. In fact, for the case of similar motor rotors, copper rotors can reduce the electric motor total energy losses by between 15 percent and 23 percent. Further improvements in the design and fabrication of copper motors, such as optimization of the steel laminations, could further increase the efficiency of copper motors over aluminum motors. 2

However, the die casting process for aluminum rotors is well-established, contrary to the die casting for copper. Copper melts at higher temperatures than aluminum, resulting in higher thermal stresses in the die mold, which in turn cause cracks to appear in the mold after short periods of operation. These technical barriers have impeded the manufacture of the copper cast
rotor. 3 Because of these technological issues, the Department believes that it would not be practicable to manufacture, install and service copper rotor motors for use in commercial unitary air cooled air conditioners and air source heat pumps on the scale necessary to serve the relevant market at the time of the standard’s effective date. Also, because copper rotor motors are in the4-4 research stage of development, it is not possible to assess whether this technology will have any adverse impacts on equipment utility to consumers or equipment availability, or any adverse impacts on consumers’ health or safety. Therefore, DOE will not consider copper rotor motor technology as a design option for improving the energy efficiency of commercial unitary air cooled air conditioners and air source heat pumps.

4.3.3 Non-HFC/HCFC Refrigerants

Three non-HFC/HCFC refrigerants, ammonia (NH 3 ), carbon dioxide (CO 2 ), and various hydrocarbons (such as propane and isobutane), are technologically feasible replacements for HFC and HCFC refrigerants used in commercial unitary air-conditioning equipment rated at or greater than 65,000 Btu/h, but less than 240,000 Btu/h. Due to the impending phaseout of HFC/HCFC-based refrigerants, the Department examined each of these three refrigerants as a possible alternative for this rulemaking. Although these alternative refrigerants are technically feasible for use in commercial unitary air-conditioning equipment, they do not necessarily improve energy efficiency.

Typically, the refrigerant, and the design of the air-conditioning system that uses it, must be examined on a case-by-case basis to determine the actual energy efficiency of that system. However, “cycle efficiency” is one metric that can be used to estimate the relative benefit of one refrigerant compared to other refrigerants. (See Chapter 19, “Refrigerants,” in the 2001 ASHRAE Handbook – Fundamentals. 4 ) An ideal cycle efficiency is related to the thermodynamic efficiency of an air conditioner and it is calculated based on (1) the refrigerant properties at each state of the thermodynamic cycle, and (2) the net energy that must be removed or added to the refrigerant to complete the cycle. Of these three refrigerants, only ammonia has an ideal cycle efficiency above those of the HFC refrigerants currently being used for the commercial unitary air-conditioning equipment covered under this rulemaking. While a comparison between the efficiencies of hydrocarbon refrigerants and hydrofluorocarbon refrigerants provides mixed results, in every case CO 2is the least efficient of the alternative refrigerants under consideration. Also see the Alliance for Responsible Atmospheric Policy Report , and the section concerning replacement refrigerants for commercial unitary air conditioners at http://www.arap.org/adlittle/summary.html (March 2004) and Section 1 of the report at http://www.arap.org/adlittle/1.html. (March 2004).

In addition to technological feasibility and energy efficiency concerns, the Department investigated: (1) the practicability to manufacture, install, and service commercial unitary air conditioners that would potentially use ammonia, carbon dioxide, or hydrocarbons; (2) possible adverse impacts on equipment utility and availability to consumers; and (3) potential adverse impacts on health and safety.4-5 4.3.3.1 Ammonia

Ammonia is currently used in large industrial refrigeration systems (e.g., cold storage warehouses) and some laboratory refrigeration systems, and although its use in commercial unitary air-conditioning systems is technologically feasible, ammonia presents significant problems in commercial unitary air-conditioning systems used to cool buildings. Problems include adverse effects on safety and health, as well as on the manufacturing, installation and service of commercial unitary air-conditioning equipment rated at or greater than 65,000 Btu/h, but less than 240,000 Btu/h. It is not likely that the combined effect of all these problems will be overcome before the effective date of an energy efficiency standard.

Large industrial refrigeration systems (as opposed to air-conditioning systems) almost exclusively use ammonia. It is a hazardous substance and service personnel are specially trained, certified, and equipped to work around it. Any transition to the use of ammonia in smaller air-conditioning systems would require significant re-training and re-certification of air conditioning service personnel, more so than a change to any HFC-based alternatives. Although it is technologically feasible to train such service personnel, it is unlikely that there would be a sufficient number of them available with the leve l of expertise needed to work with ammoniabased air-conditioning systems by the effective date of an energy efficiency standard.

In the presence of any amount of water, ammonia exhibits no tolerance to some materials commonly used in the manufacture of air-conditioning equipment. Ammonia is highly corrosive to the copper tubing used in air-conditioning equipment, and would require changing to a different tubing material (e.g., galvanized carbon steel or stainless steel) and method of manufacture of heat-exchanger coils. Further, the higher tensile strength of stainless steel might require new machinery and possibly new manufacturing methods to produce coils in the volume needed to meet demand. Ammonia can also be corrosive to copper wiring and other components used in hermetic compressor motors and would, therefore, require development of entirely newlines of compressors apart from those currently being manufactured for commercial unitary airconditioning equipment. This is already true for existing ammonia-based refrigeration equipment, such as food freezers, where large open compressors, or in some cases semi-hermetic compressors, are used. One manufacturer recently designed a small hermetic scroll compressor for ammonia in which all of the copper in the motor has been replaced with aluminum, but other examples of this are not known. See http://www.mycomj.co.jp/eindex/mycorole.html (March 2004).

Furthermore, because there are few, if any, examples of compression-based ammonia airconditioning systems in the size ranges covered by the rulemaking, any transition to ammoniabased systems would require massive changes in the design and manufacture of the compressors and other components. It is unlikely that such changes would occur by the effective date of an energy-efficiency standard even if no other issues were present with the use of ammonia.

Safety is perhaps the most significant issue with ammonia. Ammonia used in compression-based refrigeration systems is anhydrous (without water) and has very high purity4-6 (>98 percent). It is flammable in concentrations of 16 to 25 percent with air, and presents a potential fire hazard in the event of a leak. The Environmental Protection Agency (EPA) classifies ammonia in this form as an extremely hazardous substance. The U.S. Occupational Safety and Health Administration (OSHA) classifi es ammonia as a material that is hazardous to occupant and worker safety. The AmericanNational Standards Institute (ANSI)/American Society of Heating, Refrigerating and Air-C onditioning Engineers (ASHRAE) Standard 34- 2001, Designation and Classification of Refrigerants, 5 lists ammonia in Safety Group B2 because it is highly toxic, even in low concentrations with air. Further, ANSI/ASHRAE Standard 15- 2001, Safety Code for Mechanical Refrigeration, 6 limits the amount of ammonia in any refrigeration equipment. The National Institute for Occupational Safety and Health (NIOSH) sets the level of exposure for a normal person to ammonia (1⁄2 hour without a respirator and no lasting effects) at 500 parts per million (ppm). The NIOSH considers exposure to 2400 ppm of ammonia for 30 minutes as life threatening. Local safety codes may be more restrictive. An ammonia leak inside a building, including any potential use in commercial unitary air conditioning systems, can adversely effect human health.

For all the reasons outlined above, the Department has screened out the use of ammonia as an alternative refrigerant for this rulemaking.

4.3.3.2 Carbon Dioxide

Carbon dioxide naturally exists in the atmosphere, and it does not have the toxicity or flammability issues that are associated with ammonia or hydrocarbons as refrigerants. In recent years, CO 2has received significant interest due to its good environmental properties. The main focus of this interest has been in automotive air conditioners, where large refrigerant emissions
may occur.
Carbon dioxide was used as a refrigerant prior to the mid 1950s. The use of CO 2in large commercial unitary air-conditioning systems is technologically feasible; however, it presents several problems. The critical temperature of CO 2is 87.8 

### / F; therefore heat rejection occurs above the critical point in a typical comfort cooling application. This means that CO 2does not operate in a typical vapor compression cycle realized by the conventional refrigerants, but in a transcritical cycle. This transcritical cycle offers a lower efficiency than the vapor compression cycle due to the significant irreversibilities in the throttling and CO 2 -to-air heat rejection. Although some of these irreversibilities could be minimized by new heat exchanger designs and work-producing expansion devices, the recovery of heat transfer and throttling irreversibilities can only be accomplished with limited effectiveness. Consequently, it may be expected that the potential for high system efficiency using CO 2is lower than that for refrigerants realizing the conventional vapor compression cycle. 7

Commercial unitary air-conditioning systems that would potentially use CO 2as a refrigerant would need to withstand pressures that are much higher than those employing hydrofluorocarbon-based refrigerants. This w ould require development of new designs for compressors, heat exchangers, service equipment, and other critical components, which are much4-7 more durable than the conventional designs for these devices. Furthermore, the high pressure makes handling and servicing a CO 2 -based system more difficult and would require specially trained personnel. The combination of these problems makes it unlikely that CO 2 -based commercial unitary air-conditioning systems could be manufactured, installed, and serviced to the extent necessary to serve the relevant market by the effective date of a new energy-efficiency standard. For these reasons, the Department has screened out the use of CO 2as an alternative refrigerant for this rulemaking.

4.3.3.3 Hydrocarbons

Hydrocarbons, such as isobutane, propane, propylene and ethane, are technologically feasible for use as refrigerants. However, due to safety concerns, their use has been limited to industrial applications, laboratory applications, and small capacity systems such as refrigerators. Industrial refrigeration applications generally refer to complex customized appliances used in the chemical, pharmaceutical, petrochemical, and manufacturing industries. Industrial refrigeration applications do not include air conditioning, which pipes refrigerated air directly into occupied areas, because hydrocarbon refrigerants are highly flammable gases, even in small concentrations of 1 to 10 percent in solution with air.

The ANSI/ASHRAE Standard 34-2001 classifi es hydrocarbons “A3,” highly flammable. The National Fire Protection Association (NFPA), National Electrical Code Handbook , Article 500-5(a)(4), classifies propane as Class I Group D and describes it, in part, as a flammable gas mixed with air that may burn or explode. Also, building codes in some states and local jurisdictions regulate the use of hydrocarbons as potential refrigerants, including prohibiting the use of hydrocarbons in automobile air conditioners. It follows that these regulations reduce direct risk to human health and safety from the use of hydrocarbons in these applications by restricting access to areas near those systems.

Flammability is the major liability of hydrocarbons. It makes manufacturing, transport,storage, installation, and service of unitary equipment more difficult. Commercial unitary airconditioning equipment that uses a hydrocarbon refrigerant would likely need to include safety features to protect against the possibility of fi re and explosion. New designs would have to be developed and new sensing/control capabilities to be implemented to mitigate the flammability risks. 8 Trained personnel would need to follow speci al safe handling and installation procedures.

Because of the above concerns, the availability of hydrocarbon refrigerants for consumer use is limited, and this situation is unlikely to change by the effective date of an energy efficiency standard. For all these reasons, the Department has screened out hydrocarbons as alternative refrigerants for improving the energy efficiency of commercial unitary air cooled air conditioners and air-source heat pumps.

In summary, because of these technological issues with the ammonia, carbon dioxide, and hydrocarbons, DOE will not consider these three alternative refrigerants as design options for improving the energy efficiency of commercial unitary air cooled air conditioners and air4-8 source heat pumps.

4.4 COMMERCIAL TECHNOLOGIES THAT CAN ENHANCE EER

There are a number of technologies or design options which are currently commercially available for commercial unitary air cooled air conditioners and air source heat pumps and related equipment and which DOE proposes to consider to improve the EER (nominal full load) rating. A typical example is improving compressor efficiency at the nominal rating conditions. Technologies within this category are:

• Evaporator Coil Area (Keeping Coil Rows the Same),

• Condenser Coil Area (Keeping Coil Rows the Same),

• Coil Rows (Keeping Coil Heat Transfer Performance the Same),

• Coil Rows (Keeping Face Area the Same),

• Microchannel Heat Exchangers,

• Deep Coil Heat Exchangers,

• Low Pressure-Loss Filters,

• High-Efficiency Fan Motors,

• High-Efficiency Compressors,

• Backward-Curved Centrifugal Fans,

• Air-Foil Centrifugal Fans,

• Synchronous (Toothed) Belts,

• Direct-Drive Fans,

• High-Efficiency Propeller Condenser Fans,

• Condenser Fan Diameters,

• Evaporator Fan Diameters, and

• Elimination of Air Leakage Paths Within Unit.4-9 4.4.1 Evaporator Coil Area (Keeping Coil Rows the Same)

Increasing the evaporator coil area provides for a greater heat exchange area between the cold refrigerant and the supply air. This increases the heat transfer effectiveness of the coil and the overall efficiency of the air conditioning system. Increasing the evaporator coil area increases the average temperature of refrigerant in the coil and reduces the temperature difference between the refrigerant and the supply air. However, increasing the evaporator coil area also tends to reduce the latent heat removal capability of the evaporator coil.

As a result of its technology options screening assessment, the Department finds that manufacturers already incorporate a wide variation in evaporator coil area in certain commercial unitary air cooled air conditioners and air source heat pumps. The wide variation in evaporator coil area in units currently on the market suggests that further increases in coil area by manufacturers would be technologically feasible. Further, evaporator coils are currently used in all commercial unitary air-cooled air conditioners and air source heat pumps, thus demonstrating that they are practical to manufacture, install and service. Evaporator coils are a necessary component in commercial unitary equipment, and there are a number of coil manufacturers who supply such products to manufacturers. Since evaporator coils are a necessary component of existing equipment and suppliers are numerous, the Department anticipates no adverse impacts on product utility to consumers or product availability from an increase in the evaporator coil area. Finally, the fact that commercial unitary equipment currently uses evaporator coils is evidence that adverse impacts on consumers' health or safety from increasing evaporator coil area are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.2 Condenser Coil Area (Keeping Coil Rows the Same)

Increasing the condenser coil area provides for a greater heat exchange area between the hot refrigerant vapor leaving the compressor and the outside air. A greater area where the heat exchange occurs reduces the temperature of the liquid refrigerant entering the expansion device. This increases the specific refrigeration capacity of the refrigerant and the efficiency of the entire system. In general, increasing the condenser coil face area provides for higher system efficiency, at the expense of more materials and often greater total system size.

As a result of this technology options screening assessment, the Department finds that manufacturers already incorporate a wide variation in condenser coil area in certain commercial unitary air-cooled air conditioners and air-source heat pumps. The wide variation in condenser coil area in units currently on the market suggests that further increases in coil area by manufacturers would be technologically feasible. Further, condenser coils are currently used in all commercial unitary air-cooled air conditioners and air-source heat pumps, thus demonstrating that they are practical to manufacture, install and service. Condenser coils are a necessary component in commercial unitary equipment, and there are a number of coil manufacturers who supply such products to manufacturers. Since condenser coils are a necessary component of4-10 existing equipment and suppliers are numerous, the Department anticipates no adverse impacts on product utility to consumers or product availability from an increase in the condenser coil area. Finally, the fact that commercial unitary equipment currently uses condenser coils is evidence that adverse impacts on health or safety to consumers from increasing condenser coil area are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.3 Coil Rows (Keeping Coil Heat Transfer Performance the Same)

Decreasing the number of coil rows (in the evaporator or condenser) decreases the static pressure drop over the coil, resulting in less work for the supply fan. However, as the number of rows decreases, the heat exchange capacity of the coil decreases. This option is typically combined with other design options that increase capacity, such as increasing the coil face area, to maintain the desired rate of heat transfer across the coil surface. The difficulty here is primarily finding space for the additional coil area.

Notwithstanding the possibility of fewer rows of coils and corresponding decreases in heat exchange capacity, the Department finds that manufacturers already reduce the number of rows of coils in combination with other design options to maintain constant heat transfer in certain commercial unitary air-cooled air conditioners and air-source heat pumps. The wide variation in the number of rows of coils in units currently on the market suggests that changes in the number of rows of coils in particular desi gns would be not only technologically feasible, but also practical to manufacture, install and service. Coils are a necessary component in commercial unitary equipment and there are a number of coil manufacturers who supply such products to unitary equipment manufacturers. Since coils are a necessary component of existing equipment and since suppliers are numerous, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that coils are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from changing the number of rows of coils are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.4 Coil Rows (Keeping Face Area the Same)

Increasing the number of coil rows increases the heat exchange capacity of a coil, but also results in an increase in the static pressure drop over the coil, causing the fan to work harder. In addition, most of the heat exchange in a multi-row coil takes place in the first rows in contact with the incoming air, with each subsequent row providing less heat exchange than the preceding row. There are diminishing returns from adding more coil rows. However, this may be the only viable option to increasing heat transfer rates in systems with space constraints. Another concern for unitary package equipment used in a commercial building is that the supply fan also operates for heating and for ventilation whenever the building is occupied. Therefore, the supply fan typically operates many more hours than the cooling system. This presents a problem for design options that increase supply fan energy because an increase in overall energy use would result in a reduction in the EER.4-11 Notwithstanding possible diminishing returns to improvements in EER as well as increases in fan energy use, the Department finds that manufacturers already increase the number of rows of heat exchanger coils while keeping the face area constant, combined with other design options to maintain constant heat transfer, in certain commercial unitary air-cooled air conditioners and air-source heat pumps. The wide variation in the number of rows of coils in units currently on the market suggests that changes in the number of rows of coils in particular designs would be not only technologically feasible, but also practical to manufacture, install and service. Coils are a necessary component in commercial unitary equipment, and there are a number of coil manufacturers who supply such products to unitary equipment manufacturers. Since coils are a necessary component of existing equipment and suppliers are numerous, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that coils are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from changing the number of rows of coils are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.5 Microchannel Heat Exchangers

Microchannel heat exchangers, unlike a conventional coil tube with an attached plate fin, have a rectangular aluminum cross-section containing several small channels through which refrigerant passes. Aluminum fins are brazed between the rectangular tubes. All components are aluminum. Microchannel designs provide more heat transfer per unit of face area than a conventional coil design, while creating a lower pressure drop than a similarly performing conventional coil. The small size and lower air-side pressure drop that results from microchannel heat exchangers provide opportunities to reduce the size and weight of the heat exchanger. That is why they are used in automobile air conditioners. However, the microchannel heat exchanger has not penetrated building air conditioning markets, where size and weight constraints are not as critical. In particular, the microchannel construction hinders condensate removal, which makes its application for evaporator coils in unitary air conditioners (and in heat pumps, both coils) difficult. However, this limitation would not prevent it from being used for the condenser coils, where no condensate removal is required.

The Department finds that microchannel heat exchangers are already incorporated in certain types of air conditioners. The wide variation in condenser coil area in units currently on the market suggests that further changes in coil area by manufacturers would be technologically feasible. Further, microchannel heat exchangers are being used in greater numbers of air conditioners, thus demonstrating that they are practical to manufacture, install and service. Since condenser coils are a necessary component of existing equipment and suppliers are numerous, the Department anticipates no adverse impacts on product utility to consumers or product availability from the use of microchannel heat exchangers in those condenser coils. Finally, the fact that condenser coils are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from changing the condenser coil area are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.4-12 4.4.6 Deep Coil Heat Exchangers

The deep coil design option changes the typical evaporator coil design to one that uses more rows of coil tubing with fewer fins per inch. The goal of the deep coil design is to provide the advantages of a multi-row coil, which are compactness, good heat transfer, and good dehumidification capability, while minimizing the static pressure impact.

The Department finds that deep coil heat exchangers are already incorporated in certain commercial unitary air cooled air conditioners and air source heat pumps. Because this is a design variation in typical evaporator coil design, the technological feasibility, and practicability to manufacture, install and service these types of coils have already been discussed in Section 4.4.1. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.7 Low Pressure-Loss Filters

The purpose of low pressure-loss filter designs is the reduction of total system fan power requirements. This is principally achieved by increasing the total face area of the filter design, including modifications to the filter rack as well as the use of pleated filters. This allows for a reduction in the average air velocity over the filter face and subsequent reduction in fan power.

The Department finds manufacturers already incorporate low pressure-loss filters in certain commercial unitary air-cooled air conditioners and air-source heat pumps. Widespread application of this simple technique to reduce fan power makes it not only technologically feasible, but also practical to manufacture, service and install. Thus, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that filters are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety from improving the pressure loss in the filters are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.8 High-Efficiency Fan Motors

High-efficiency electric motors that drive supply fans and condenser fans can increase efficiency and reduce overall energy use in commercial air conditioning equipment and heat pumps. From an energy conservation standpoint, th is is particularly important for supply fans because they also provide commercial building ventilation and typically operate for several times the total operating hours of the air conditioning compressor. Further, both condenser and supply fan motor efficiency improvements can increase full- and part-load efficiency for unitary equipment. Typical supply fan motors for unitary package equipment in this size range (65,000 Btu/h to 240,000 Btu/h cooling capacity) are between 1.5 and 5 horsepower (hp) in size, with motor efficiencies regulated under EPCA. (42 U.S.C. 6311 et seq ., as amended) However, motor efficiencies of four percentage points higher than EPCA levels are available throughout this size range, and their use results in increased overall system efficiency. 94-13 The Department finds that high-efficiency fan motors are readily available and are already incorporated in certain commercial unitary air-cooled air conditioners and air-source heat pumps. Widespread application of high-efficiency fan motors to increase the system efficiency not only makes them technologically feasible, but also practical to manufacture, service and install. Thus, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that motors are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from improving the motor efficiency are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.9 High-Efficiency Compressors

Motors drive compressors and fans in heating, ventilating and air conditioning (HVAC) equipment. Because virtually all such compressors are hermetic designs, the overall compressor efficiency includes motor-efficiency. Higher efficiency compressor designs are an ongoing industry challenge, and there have been substantial gains in compressor efficiency, which translate into more-efficient air conditioning systems. Any further gains in compressor efficiency will be more difficult to achieve. Previous DOE reviews of improvements in compressor efficiency suggest that compressor manufacturers anticipate no more than a three percent improvement by 2007 in compressor efficiency, based on design changes. 10

The Department finds that high-efficiency compressors are already incorporated in certain commercial unitary air-cooled air conditioners and air-source heat pumps. Widespread application of high-efficiency compressors to increase the system efficiency not only makes them technologically feasible, but also practical to manufacture, service and install. Thus, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that high-efficiency compressors are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from further improvements to the compressor efficiency are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.10 Air-Foil Centrifugal Fans

Air-foil centrifugal fans can operate at efficiencies near 90 percent, but because of the need to shape each fan blade and the need for greater detail in the inlet scroll design, these fans are more technically complicated than either backward-curved or forward-curved fans. 11

Although this particular design feature of fan blade designs may be more complicated to manufacture, as a result of this technology options screening assessment, the Department finds that air-foil centrifugal fans can be incorporated in certain commercial unitary air-cooled air conditioners and air-source heat pumps. Further, widespread application of this technology to increase fan system efficiency not only makes it technologically feasible, but also practical to manufacture, service and install. Thus, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that certain air conditioning4-14 and ventilating applications currently use air-foil centrifugal fans is evidence adverse impacts on health or safety to consumers from improving the fan efficiency are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.11 Backward-Curved Centrifugal Fans

A backward-curved centrifugal fan has the tips of its blades inclined away from thedirection of the airflow (backwards), enabling it to move air at higher pressures. The backwardcurved blade fan is most efficient when it is built with blades that are made in an air-foil shape. 12 Backward-curved fan designs have typical effici encies near 80 percent, compared to the 65-70 percent efficiency common for forward-curved fan designs used for supply air fans in most unitary HVAC equipment. However, backward-curved fans are larger than forward-curved fansproviding the same pressure and air flow. In addition, the higher tip speed of the backwardcurved fans can increase fan noise.

Even though issues with increased fan dimensions and noise exist, as a result of this technology options screening assessment, the Department finds that backward-curved centrifugalfans are available on the market and already incorporated in certain commercial unitary aircooled air conditioners and air-source heat pumps. Widespread application of this technology to increase fan system efficiency not only makes it technologically feasible, but also practical to manufacture, service and install. Thus, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that certain applications currently use backward-curved centrifugal fans is evidence adverse impacts on health or safety to consumers from improving the fan efficiency are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.12 Synchronous (Toothed) Belt

Synchronous belts (also called timing, positive-drive, or high-torque drive belts) are toothed, require the installation of engaging toothed-drive sprockets, and can be applied to supply-air fan drives. Synchronous belts offer about 98 percent efficiency and maintain that high efficiency over a wide load range. 12The automotive industry uses them in various applications. The HVAC equipment industry recognizes the higher efficiency of this type of belt, but has elected not to use it in its equipment due to the additional complexity of design and manufacturing.

Although the synchronous belt design and manufacturing may be more complicated, as a result of this technology options screening assessment, the Department finds that synchronousbelts could be incorporated in certain commercial unitary air-cooled air conditioners and airsource heat pumps. Since the automotive industry uses the synchronous belts, they are not only technologically feasible but also practical to manufacture, install, and service. More widespread application within the heating, ventilating, and air conditioning industry would likely encourage simpler designs and standardize manufacturing practices. With additional suppliers of these belts, the Department anticipates no adverse impacts on product utility to consumers or product4-15 availability. Since the belts are currently used in competing industries, adverse impacts on health or safety to consumers are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.13 Direct Drive Fans

In a direct-drive fan, the fan wheel connects directly to the motor. Direct drive fans prevent the sharp reduction in efficiency caused by belt drive slippage.

The Department finds that certain commercial unitary air-cooled air conditioners and airsource heat pumps already incorporate direct driv e fans. Widespread application of this simple technique to increase fan system efficiency not only makes it technologically feasible, but also practical to manufacture, service and install. Thus, the Department anticipates no adverse impacts on product utility to consumers or product availability. Finally, the fact that direct-drive fans are currently used in certain applications is evidence that adverse impacts on health or safety to consumers from wider use of direct drive fans are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.14 High-Efficiency Propeller Condenser Fans and Motors

The condenser section of a commercial unitary air conditioner typically uses a propeller fan to provide high air flow rates for this typi cally low-pressure application. Because propeller fans are inherently low-pressure devices, they achieve maximum efficiency results even in cases of zero external pressure. 13 Unitary air conditioning equipment designs that minimize pressure drop across the outdoor condensing coil can maximize fan efficiency. In addition, commercial HVAC equipment typically uses multiple propelle r-type, fractional-horsepower-motor fans, and there is significant potential for increasing the efficiency of these small fan motors. Currently, there is a wide range of energy-efficiency levels for such small motors on the market, and there are no energy-efficiency standards. Use of a dvanced motor technologies, such as electronic commutation and copper rotors, can improve the efficiency of a condenser fan from a range of 40-60 percent to a range of 85-90 percent .14

The Department finds that high-efficiency propeller condenser fans and high-efficiencymotors are already incorporated in certain commercial unitary air-cooled air conditioners and airsource heat pumps. Widespread application of hi gh-efficiency fans and motors to increase fan system efficiency not only makes them tec hnologically feasible, but also practical to manufacture, service and install. Finally, the fact that condenser fans are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from improving the efficiencies of these components are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.4-16 4.4.15 Condenser Fan Diameters

Increasing condenser fan diameters would increase the amount of air passing through the condenser coils per unit of fan energy, thereby increasing the fan system efficiency. Generally,the biggest problem is finding space for these larger fan units within an already spaceconstrained cabinet.

Even with possible space constraints, the Department finds that increased diameters for condenser fans are already incorporated in certain commercial unitary air-cooled air conditioners and air-source heat pumps. Widespread application of this simple technique to increase fan system efficiency not only makes it technologically feasible, but also practical to manufacture, service and install as long as space is available. Finally, the fact that evaporator fans are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from increasing the fan diameter are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.16 Evaporator Fan Diameters

Increasing evaporator fan diameters would increase the amount of air passing through the evaporator coils per unit of fan energy, thereby increasing the efficiency of the fan system.Generally, the biggest problem is finding space for these larger fan units within an already spaceconstrained cabinet.

Although there are possible space constraints, the Department finds that increased diameters for evaporator fans are already incorporated in certain commercial unitary air-cooled air conditioners and air-source heat pumps. Widespread application of this simple technique to increase fan system efficiency not only makes it technologically feasible, but also practical to manufacture, service and install as long as space is available. Finally, the fact that evaporator fans are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from increasing the fan diameter are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.4.17 Elimination of Air Leakage Paths within Unit

The Department’s engineering analysis of through-the-wall air conditioners found small air leakage paths between the evaporator and condenser sections which, because of the pressure differentials, can result in air passing between these sections and loss of efficiency. It appears that eliminating these air leakage paths in through-the-wall air conditioners, through design or manufacturing changes, is one of the more cost-effective ways to improve the efficiency of these units. If similar air leakage paths occur regularly in commercial unitary air conditioners, design or manufacturing changes to eliminate these leaks may represent a cost-effective way to increase EER and annual energy performance.

The Department finds that where significant air leakage paths occur in certain unitary air4-17 conditioners and heat pumps, design and manufacturing practices to reduce the air leakage existand are already incorporated in certain commercial unitary air-cooled air conditioners and airsource heat pumps. These practices are, therefore, technologically feasible. Also, because these practices are widely applicable across different sizes of commercial unitary air conditioning equipment, they are also practical and cost-e ffective ways to increase EER and would not have any adverse impacts on product utility to consumers or on product availability. Finally, the fact that these design practices are currently used in commercial unitary equipment is evidence that adverse impacts on health or safety to consumers from eliminating more air leakage paths are unlikely. Therefore, the Department believes this design option is viable for consideration in the engineering analysis.

4.5 SCREENING PROCESS

For the purpose of this rulemaking, the Department screened out certain technologies as design options. These technologies and the principal rationale for screening them out are summarized in Table 4.5.1.4-18 Table 4.5.1 Design Options Not Viable for Consideration in the Engineering Analysis

EMERGING TECHNOLOGIES
Electro-Hydrodynamic Enhanced Heat Transfer — This is currently in the design stage. Practical use of this technology is unlikely in the time frame established in the final rule.
Copper Rotor Motor with Improved Efficiency — Given current manufacturing issues and small existing product volume for this technology, it is highly unlikely that enough copper rotor motors will be available in the market in the time frame established in the final rule.
Non-Hydro-Fluorocarbon/Hydro-Chlorofl uorocarbon (HFC/HCFC) Refrigerants (e.g., Ammonia, Hydrocarbons, CO 2 ) — Long-running safety concerns with ammonia and hydrocarbons are likely to preclude their use in any commercial systems developed within the next few years in the United States. High pre ssures and low critical temperatures make design of commercially viable CO 2air conditioning systems unlikely to occur in time for the final rule.4-19 While many of the technologies discussed in this report show promise, only certain design options can improve the EER (nominal full-load) rating under DOE’s test procedures and, therefore, are viable for consideration in the engineering analysis. These technologies are listed in Table 4.5.2.

Table 4.5.2 Design Options Viable for Consideration in the Engineering Analysis
COMMERCIAL TECHNOLOGIES THAT CAN ENHANCE EER

(1) Evaporator Coil Area (Keeping Coil Rows the Same)

(2) Condenser Coil Area (Keeping Coil Rows the Same)

(3) Coil Rows (Keeping Coil Heat Transfer Performance the Same)

(4) Coil Rows (Keeping Face Area the Same)

(5) Microchannel Heat Exchangers

(6) Deep Coil Heat Exchangers

(7) Low Pressure Loss Filters

(8) High-Efficiency Fan Motors

(9) High-Efficiency Compressors

(10) Air-Foil Centrifugal Fans

(11) Backward-Curved Centrifugal Fans

(12) Synchronous (Toothed) Belts

(13) Direct Drive Fans

(14) High-Efficiency Propeller Condenser Fans

(15) Condenser Fan Diameters

(16) Evaporator Fan Diameters

(17) Elimination of Air Leakage Paths Within Unit4-20 1. Air-Conditioning and Refrigeration Institute. June 2, 2002. Electrohydrodynamic Heat Transfer [Online]. Available URL: http://www.ari.org/rt/tu/1996/9601b.html

2. Cowie J. and E. Brush. June 4, 2002. Electrical Energy Efficiency Results of Die-Cast Copper Rotors , Copper Development Association, Inc. [Online Report]. Available URL: http://www.copper-motor-rotor.org/pdf/eeresults.pdf

3. Copper Development Association, Incorporated. June 1, 2002. Application of High Temperature Mold Materials To Die Cast the Copper Motor [Online Report]. Available URL: http://www.copper-motor-rotor.org/pdf/project_description.pdf

4. American Society of Heating, Refriger ating and Air-Conditioning Engineers, Inc. (ASHRAE) 2001. Refrigerants , Chapter 19, ASHRAE Handbook of Fundamentals, Atlanta, Georgia.

5. American National Standards Institute/American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (ANSI/ASHRAE). 2001. Standard 34-2001, Designation and Classification of Refrigerants, ASHRAE, Atlanta, Georgia.

6. American National Standards Institute/American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (ANSI/ASHRAE). 2001. Standard 15-2001, Safety Code for Mechanical Refrigeration , ASHRAE, Atlanta, Georgia.

7. Zhao Y., M.M. Ohade, and Radermacher R. June 5, 2002. Microchannels Heat Exchangers with Carbon Dioxide: Final Report September 2001 [Online Report]. Center for Environmental Energy Engineering, University of Maryland, College Park, Maryland. Available URL: http://www.arti-21cr.org/research/com pleted/finalreports/10020-final.pdf

8. Keller, F.J., Liang, H., Farzad, M., 1997. “Assessment of Propane as a Refrigerant in Residential Air-Conditioning and Heat Pump Applications.” ASHRAE/NIST Refrigerants Conference; Refrigerants for the 21 st Century. October 6-7, 1997, Gaithersburg, MD.

9. United States Department of Energy. July 2, 2002 . How to buy a premium energy efficient motor , Federal Energy Management Program, Energy Efficiency and Renewable Energy Network [Online Report]. Available URL: http://www.eren.doe.gov/femp/procurement/pdfs/motors.pdf

10. United States Department of Energy. July 2, 2002. CAC TSD Technical Support Document: Energy Efficiency Standards for Consumer Products: Residential Central Air Conditioners and Heat Pumps , October 2000, Energy Efficiency and Renewable Energy Network [Online Report]. Available URL: REFERENCES4-21 http://www.eren.doe.gov/buildings/codes_standards/reports/cac_hp_tsd/index.html

11. United States Department of Energy. June 3, 2002. Energy Tips: Replace V-Belts with Cogged or Synchronous Belt Drives . Office of Industrial Technologies [Online Report]. Available URL: http://www.oit.doe.gov/bestpractices/pdfs/motor3.pdf

12. United States Army. June 4, 2002. Maintenance of Mechanical And Electrical Equipment At Command, Control, Communications, Computers, Intelligence, Surveillance, And Reconnaissance (C4isr) Facilities , HQUSACE/OCE Army Technical Manuals [Online Report]. Available URL: http://www.usace.army.mil/inet/usace-docs/armytm/tm5-692-2/chap14VOL-2.pdf

13. American Society of Heating, Refrig erating, and Air Conditioning Engineers Incorporated. 2000. 2000 ASHRAE AVAC Applications , Atlanta, Georgia

14. Arthur D. Little, Incorporated. April 6, 2003. Opportunities for Energy Savings in the Residential and Commercial Sectors with High-Efficiency Electric Motors [Online] Available URL http://www.eere.energy.gov/buildings/documents/pdfs/doemotor2_2_00.pdf