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Figure 1
Figure 2
required. The approximate conditions where injection pressor protection control much as the oil failure con-
occurs are shown in Figure 2. At the conditions trol protects the compressor during periods of low oil
where Demand Cooling is operating, the performance pressure. Demand Cooling will be called to operate
values are time averages of the instantaneous values, only during those periods when condensing tempera-
since small fluctuations in suction and discharge tures and return gas temperatures are high or in peri-
conditions occur as the Demand Cooling injection ods where a system failure (such as an iced
valve cycles. evaporator, an expansion valve which does not con-
trol superheat, blocked condenser, or a failed con-
While the refrigerant injection concept has been denser fan) raises condensing temperatures or return
widely recognized for some time, its application has gas temperatures to abnormally high levels or lowers
not been widely used since the early 1960’s because suction pressure to abnormally low levels.
of the widespread availability of CFC-502, reduction
of capacity and efficiency, and poor reliability of injection Operating Range
systems.
Demand Cooling is designed to protect the com-
The Copeland Demand Cooling system addresses pressor from high discharge temperatures over the
the capacity and efficiency issues by limiting injection evaporating and condensing temperature ranges
to those times when it is required to control discharge shown in Figure 2 at a maximum return gas tempera-
temperatures to safe levels. For most applications this ture of 65ºF.
will only be during periods of high condensing tem-
peratures, high return gas temperatures, or abnormally Demand Cooling System Design
low suction pressure. The Demand Cooling system When Demand Cooling operates, it “diverts” refrig-
has been designed to meet the same high reliability eration capacity in the form of injected saturated
standards as Discus compressors. refrigerant from the evaporator to the compressor
In most cases, with floating head systems where (See Figure 3 for a typical single system schematic).
condensing temperatures are low during most of the The effect of this diversion on evaporator capacity is
year. Demand Cooling will operate primarily as a com- minimal because the diverted capacity is used to cool
the gas entering the compressor. As the gas is 3) Suction pressure: Evaporator design and sys-
cooled, it naturally becomes more dense, increasing tem control settings should provide the maxi-
the mass flow through the compressor, which partly mum suction pressure consistent with the ap-
compensates for the capacity diverted from the plication in order to have as low a compression
evaporator. ratio as possible.
If there is substantial heat gain along the suction Demand Cooling Compressors
line, injection may result in a substantial loss in
evaporator capacity during Demand Cooling opera- No new compressor models have been introduced
tion. In order to minimize this loss, good practice indi- for Demand Cooling. Instead, existing low tempera-
cates Demand Cooling operation be kept to a mini- ture Discus CFC-502 compressors have been
mum through proper system design and installation modified and rerated for use with HCFC-22 and
practices. There are three areas which can be ad- Demand Cooling. The modifications are the addition
dressed to minimize the impact of Demand Cooling of an injection port on the compressor body and a
operation on performance. temperature sensor port in the head of the compres-
sor. The locations of these ports are critical and were
1) Compressor Return Gas Temperature: Suction determined through an extensive development pro-
lines should be well insulated to reduce suction gram.
line heat gain. Return gas superheat should be
as low as possible consistent with safe com- The HCFC-22 rating data includes the effects of
pressor operation. Demand Cooling injection when operating conditions
require it.
2) Condensing Temperatures: It is important when
using HCFC-22 as a low temperature Condenser Sizing
refrigerant that condensing temperatures be Condensers should be sized using conventional
minimized to reduce compression ratios and methods. Demand Cooling has virtually no effect on
compressor discharge temperature. system heat of rejection.
Figure 3
Demand Cooling System Components In order to avoid nuisance trips, a one minute
time delay is provided before alarm after a continu-
The Demand Cooling System (see Figure 1) con-
ous high or low resistance reading or over tempera-
sists of: The Demand Cooling Temperature Sensor
ture condition.
(TS), The Demand Cooling Module (CM), and the
Injection Valve (lV). The alarm relay uses a single-pole-double-throw
contact. The contact terminals are “L”, “M”, and
The TS uses a precision Negative Temperature
“A”:
Coefficient (NTC) Thermistor (thermistor resistance
drops on temperature rise) to provide temperature “L” - Common (to “A” and “M”)
signals to the CM.
“L - M” - Normally Closed (compressor run. open on
The IV meters refrigerant flow from the liquid line alarm)
to the compressor. The IV solenoid receives on-off
signals from the CM. When compressor cooling is “L - A” - Normally Open (alarm signal, close on
required the solenoid is energized and opens the IV alarm)
orifice to deliver saturated refrigerant to the compres-
The Normally Closed (NC) contact of the alarm
sor for cooling. The valve orifice is carefully sized to
relay (“L” to “M”) should be wired in the compres-
meet the requirements of each body style of Discus
sor contactor control circuit so that opening this
compressors.
contact removes the compressor from the line and
The CM has three functional groups: removes power to the CM. See Figure 4A, B, C, & D.
A) The Input signal and calculator circuits Figures 4A & B also shows a current sensing relay
compare the temperature sensor input signal to (which must be used with compressors employ-
an internal set-point and decide whether to ing internal overcurrent protection) and Sentronic
energize the IV solenoid or, in the case of a oil pressure switch. The control circuit is purposely
problem. The CM alarm relay. arranged so that an internal overload protector trip
removes power to both the Sentronic and the Demand
B) The output signal to the IV is controlled by Cooling module. This precaution prevents the oil
an electronic switch connected to the IV sole- pressure switch from timing out and the Demand
noid so that, when required, refrigerant vapor Cooling solenoid from injecting when the compressor
can be metered to the compressor to prevent is not operating.
compressor overheating. One side of the elec-
tronic switch is connected internally to “L1” and The alarm relay requires a manual reset in order to
the other side to output terminal “S” (see call attention to a system problem.
Figure 4)
System Information
C) The alarm signal for local or remote control.
1) Demand Cooling is designed to work on all
The alarm relay is energized, after a one minute
Copeland Discus compressors equipped with
delay, by a continuous, low or high TS tempera-
injection ports. A different kit is required for
ture signal. An alarm signal can indicate the
each compressor body style and control volt-
following:
age. See Table 2 for a listing of Demand Cool-
1) Compressor discharge temperature has ing Kit part numbers.
risen above the level designed to be
2) The system must be clean. A dirty system may
controlled by Demand Cooling.
have foreign material that can lodge in the
2) A shorted sensor. solenoid orifice. Always install a liquid line filter
dryer in the injection valve inlet line capable of
3) An open sensor. removing particles as small as 25 microns.
5
Figure 4A Figure 4B
AE4-1287
Figure 4C Figure 4D
Table 1
Attached is the Demand Cooling Diagnostic Troubleshooting Guide (form number 92-91).
Table 2
Table 3A
Table 3B
2) Connect the temperature sensor probe to the compressor Discus, R-22 Demand Cooling
discharge line 6" from the discharge valve. The probe Areas of Expected Injection
must be tightly secured to the discharge line, and must (See page 3 for chart usage)
be well insulated so that moving air will not produce a
false reading (a poorly insulated probe may cause errors
of more than 30°F!).
3) Use Table 2 to select the family of the test compressor:
2D, 3D, 4D or 6D.
4) Use Table 2 to select the room temperature and
condensing temperature closest to yours. (The
evaporator temperature chosen for the data of Table 2
was 25°F).
5) Because of system variations, there will be deviations
from Table 2. A measurement of +5% or 10% of the
selected Table 2 discharge pressure may be considered
satisfactory.
6) When operating under published conditions, the
discharge temperature should never be more than 280°F
or less than 200°F. If successful, the test is ended.
Otherwise go to the next step.
7) If the measured discharge temperature is lower by more
than 10% of the discharge temperature of Table 2,
perform Steps 5-8 of the “If The Injection Valve Is
Continually Injecting” test.
Copeland Corporation
1675 W. Campbell Rd.
Form No. 92-91 R1 (7/03) Sidney, OH 45365-0669
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