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Automatic Controls
for Industrial Refrigeration Systems
REFRIGERATION &
aIR CONDITIONING DIVISION Application Handbook
Application Handbook Automatic Controls for Industrial Refrigeration Systems
Contents Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1Compressor Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Discharge TemperatureControl with Liquid Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Crankcase Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Reverse Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. Condenser Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Air Cooled Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Evaporative Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Water Cooled Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. Liquid Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 High Pressure Liquid LevelControl System (HP LLRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Low Pressure Liquid Level Control System (LPLLRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5. Evaporator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Direct Expansion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Pumped Liquid Circulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 Hot Gas Defrost for DX Air Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 Hot Gas Defrost for Pumped Liquid Circulation Air Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5 Multi TemperatureChangeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6 Media Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6. Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1 Oil cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Oil Differential Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.3 Oil Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.5 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7. Safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2 Pressure and TemperatureLimiting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.3 Liquid Level Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.5 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8. Refrigerant Pump Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1 Pump Protection withDifferential Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2 Pump Bypass Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3 Pump Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.5 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.1 Filter Driers in Fluorinated Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.2 Filter Driers in CO2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.3 Water Removal for Ammonia Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.4 Air purging systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.5 Heat Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.6 Reference Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1 Typical RefrigerationSystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2 ON/OFF and modulating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Foreword This Danfoss application guide is designed In this application guide, the pilot-operated servo
to be used as a reference document by all valve ICS is recommended as a pressure and
those involved in the workings of industrial temperature regulator. Please note that the well
refrigeration systems. established PM valve could also be applied where
ICS is used.
This guide aims to provide answers to the various
questions relating to industrial refrigeration For the final design of the installation it is
system control: - Why a type of control method necessary to use other tools, such as the
is necessary for the refrigeration system? Why manufacturer’s catalogues and calculation
should it be designed in this way? What type of software (e.g. Danfoss Industrial Refrigeration
components can be used? How to select control catalogue and DIRcalc software).
methods for different refrigeration systems? In
answering these questions, the principles of the DIRcalc is the software for calculation and
different control methods are introduce followed selection of Danfoss Industrial Refrigeration
by same control examples, comprising Danfoss valves. DIRcalc is delivered free of charge.
Industrial Refrigeration products. Please contact your local Danfoss sales company.
The main technical data of the components is Please do not hesitate to contact Danfoss, if
also provided. Finally, comparisons between you have questions about control methods,
different solutions for each control method are application and controls described in this
made, so that the reader should know how to application guide.
select a solution.
Tapp_0015_02
1 3
Danfoss
04-2006
Compressor
Oil
separator
Condenser
Oil cooler
2
Receiver
Expansion valve 1
4
Liquid separator
Refrigerant pump
6
Evaporator
5
How? How?
– Control the compressor capacity according – Pressure: maintain and control the pressure
to the refrigeration load by means of differential across the compressor for oil
bypassing hot gas from the HP side back into circulation, maintain the crankcase pressure
the LP side, compressor ON/OFF step control or (only for piston compressors);
controling the rotating speed of the
– Temperature: bypass some oil around the oil
compressor;
cooler; control the cooling air or water to the
– Install check valve on the discharge line in oil cooler;
order to prevent reverse flow of the refrigerant
– Level: return the oil in ammonia systems and
to the compressor;
low temperature fluorinated systems.
– Keep pressures and temperatures on the inlet
and outlet of the compressor within the
working range.
1. Introduction
(continued) ➂ Condenser Control ➅ Evaporating System Control
Why? Why?
– Maintain the condensing pressure above the – Primary: maintain a constant media
minimum acceptable value in order to temperature;
guarantee sufficient flow through the
– Secondary: optimise operation of the
expansion devices;
evaporators;
– Ensure the right distribution of the refrigerant
– For direct expansion systems: guarantee
in the system.
that no liquid refrigerant from the evaporators
How? enters the suction line of the compressor.
How?
– Design a bypass loop so that the flow can be
maintained above the minimum permissible
flow;
– Shut off the pump if it fails to build up enough
differential pressure.
– Install a pressure regulating valve.
2. Compressor Controls The compressor is the “heart” of the refrigeration If the compressor capacity is bigger than
system. It has two basic functions: the demand, the evaporating pressure and
1. Maintain the pressure in the evaporator so temperature will be lower than that required, and
that the liquid refrigerant can evaporate at the vice versa.
required temperature;
2. Compress the refrigerant so that it can be Additionally, the compressor should not be
condensed at a normal temperature. allowed to operate outside of the acceptable
temperature and pressure range, in order to
The basic function of compressor control, optimise its running conditions.
therefore, is to adjust the capacity of the
compressor to the actual demand of the
refrigeration system so that the required
evaporating temperature can be maintained.
Oil
seperator
� EKC 331
HP vapour refrigerant
LP vapour refrigerant
Oil
M
SVA
Danfoss EVRAT+FA
➀ Step Controller Tapp_0016_02
04-2006 Piston compressor
➁ Pressure Transmitter
Step control solution for compressor capacity can occur as the measure pressure deviates away
be achieved by using a step controller EKC 331 ➀. from the neutral zone settings.
EKC 331 is a four-step controller with up to four
relay outputs. It controls the loading/unloading If control takes place outside the hatched area
of the compressors/pistons or the electric motor (named ++zone and --zone), changes of the cut-
of the compressor according to the suction in capacity will occur somewhat faster than if it
pressure signal from the pressure transmitter AKS were in the hatched area.
33 ➁ or AKS 32R. Based on a neutral zone control,
EKC 331 can control a pack system with up to four For more details, please refer to the manual of
equally sized compressor steps or alternatively EKC 331(T) from Danfoss.
two capacity controlled compressors (each
having one unload valve).
Tapp_0017_02
Compressor capacity control CVC
by hot gas bypass Compressor SCA
Danfoss
09-2007
To
condenser
ICS SVA
Oil
FIA seperator
CVC
SVA EVM
� SVA SVA
EVRAT+FA
� ICS � SVA
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Tapp_0139_02
capacity control
Danfoss
08-2006
M
� AK2
� AKS 33
SVA
From liquid FIA
separator/
evaporator SVA To oil separator
� VLT 5000
PLC/OEM
controller
M
HP vapour refrigerant
LP vapour refrigerant
� AKS 33
SVA
From liquid FIA
separator/
evaporator SVA
➀ Frequency converter To oil separator
➁ Controller
➂ Pressure transducer
Frequency converter control offer the following
advantages:
Energy savings
Improved control and product quality
Noise reduction
Longer lifetime
Simplified installation
Easy to use complete control of the system
2.2 Compressor manufacturers generally There are several ways to reduce the discharge
Discharge Temperature recommend limiting the discharge temperature temperature. One way is to install water cooled
Control with Liquid Injection below a certain value to prevent overheating of heads in reciprocating compressors, another
values, prolonging their life and preventing the method is liquid injection, by which liquid
breakdown of oil at high temperatures. refrigerant from the outlet of the condenser
or receiver is injected into the suction line, the
From the log p-h diagram, it can be seen that the intermediate cooler, or the side port of the screw
discharge temperature may be high when: compressor.
the compressor runs with high pressure
differential.
the compressor receives highly superheated
suction vapour.
the compressor runs with capacity control by
hot gas bypass.
Actuator - ICAD
Material Housing: aluminium
Media temp. range [°F] –22 to 122 (ambient)
Control input signal 0/4-10mA, or 0/2-10
Open-close time 3 to 13 seconds depending on valve size
From oil
cooler ICM ICFE ICFS
Stop valve
Filter
Solenoid valve
Manual opener
Motor valve ICFS ICFF
Stop valve Danfoss
ICFM
➁ Controller Tapp_0020_02
04-2006
� ICF From
receiver
➂ Temperature sensor
For liquid injection, Danfoss can supply a very
compact control solution ICF ➀. Up to six
different modules can be assembled into the
same housing. This solution works in the same
way as example 2.2.2, and is very compact and
easy to install.
2.3 During start-up or after defrost, the suction part of the pistons for multi-piston
Crankcase Pressure Control pressure has to be controled, otherwise it can reciprocating compressors, or bypass some
be too high, and the compressor motor will be suction gas for screw compressors with slide
overloaded. valves, etc.
The electric motor for the compressor may be 2. Control the crankcase pressure for
damaged by this overloading. reciprocating compressors. By installing a
back pressure controlled regulating valve in
There are two ways to overcome this problem: the suction line, which will not open until
1. Start the compressor at part load. The the pressure in the suction line drops below
capacity control methods can be used to the set value, suction pressure can be kept
start compressor at part load, e.g. unload under a certain level.
From Oil
� ICS separator
evaporator � SVA
HP vapour refrigerant
LP vapour refrigerant
Oil
Danfoss
SVA
➀ Crankcase pressure regulator Tapp_0021_02
04-2006 EVRAT+FA
➁ Stop valve
In order to control the crankcase pressure during the downstream suction pressure falls below
start-up, after defrost, or in others cases when the set value of the pilot valve CVC. In this way,
the suction pressure may run too high, the the high pressure vapour in the suction line
pilot-operated servo valve ICS ➀ with the back can be released into the crankcase gradually,
pressure controlled pilot valve CVC is installed which ensures a manageable capacity for the
in the suction line. The ICS will not open until compressor.
HP vapour refrigerant
LP vapour refrigerant
Oil
Oil From separator
evaporator � ICS � SVA
➀ Pilot-operated servo valve
➁ Hand regulating valve
➂ Hand regulating valve
➃ Constant pressure Danfoss
Tapp_0022_02
SVA
pilot valve 04-2006 EVRAT+FA
➄ Stop valve
For refrigeration systems with suction pressures short period of time, the compressor reduces the
above 25 bar (e.g. CO2 systems), the CVC pilot pressure in the suction line below the CVP pilot
valve can not be used. Crankcase pressure control valve set point. When this has happened, the CVP
can be achieved using a CVP constant pressure pilot valve will close, and the main valve ICS will
pilot valve instead. open. During normal operation the ICS valve will
be completely open.
The maximum suction pressure allowed is set
on the CVP pilot valve. When the compressor The manual regulating valves REG ➁ and ➂
starts after an off cycle, the suction pressure will shown are set for an opening which results in
be high. As long as the suction pressure remains a suitable opening and closing time on the ICS
above the set point, the CVP pilot valve will be main valve.
open. The main ICS valve is kept closed, as the
high pressure vapour on the servo piston is Note: The CVH for the pilot CVP should be
released into the suction line of the compressor installed against the main flow direction, as
via the CVP valve. After operating for a very shown in the diagram.
Technical data Constant pressure pilot valve - CVP
Material CVP (LP) Body: steel
Base: steel
CVP (HP) Body: cast iron
Base: stainless steel
CVP (XP) Body: steel
Base: steel
Refrigerants All common refrigerants
Media temp. range [°F] –58 to 248
Max. working pressure [psig] CVP (LP): 247
CVP (HP): 406
CVP (XP): 754
Pressure range CVP (LP): 19.5 in. Hg to 29 psig
CVP (HP): 19.5 in. Hg to 102 psig
CVP (XP): 363 psig to 754 psig
Cv value [US gal/min] CVP (LP): 0.46
CVP (HP): 0.46
CVP (XP): 0.42
2.4 Reverse flow and condensation of refrigerant Furthermore, migration of refrigeration into the
Reverse Flow Control from the condenser to the oil separator and oil separator and further into the compressor at
the compressor should be avoided at all time. standstill should be avoided. To avoid this reverse
For piston compressors, reverse flow can result flow, it is necessary to install a check valve on the
in liquid hammering. For screw compressors, outlet of the oil separator.
reverse flow can cause reversed rotation
and damage to the compressor bearings.
To condenser
Oil
From separator
evaporator SVA
HP vapour refrigerant
LP vapour refrigerant
Oil Danfoss SVA
Tapp_0023_02
04-2006 EVRAT+FA
➀ Stop check valve
The stop check valve SCA ➀ can function as a 2. Consider both the nominal and part load
check valve when the system is running, and working conditions. The velocity in the
can also shut off the discharge line for service nominal condition should be near to the
as a stop valve. This combined stop/check valve recommended value, at the same time
solution is easier to install and has lower flow the velocity in the part load condition should
resistance compared to a normal stop valve plus be higher than the minimum recommended
check valve installation. velocity.
When selecting a stop check valve, it is important For details on how to select valves, please refer to
to note: the product catalogue.
1. Select a valve according to the capacity and
not the pipe size.
2.5
Summary
Compressor capacity control Applicable to compressors Effective to control the Not efficient at part load.
with hot gas bypass using with fixed capacities. capacity continuously Energy consuming.
ICS and CVC PC according to the actual
heat load.The hot gas can
help the oil return from the
evaporator.
Compressor variable speed Applicable to all Low start up current AKD2800 cannot be used
capacity control M compressors with the ability Energy savings for piston compressor
to run at reduced speed. Lower noise applications.
Longer lifetime Compressor must be suited
Simplified installation for reduced speed operation.
Electronic solution for liquid Applicable to systems where Flexible and compact. Not applicable to flammable
injection control with EKC the discharge temperatures Possible to monitor and refrigerants. Injection of
361 and ICM may run too high. control remotely. liquid refrigerant may
Electronic solution for liquid be dangerous to the
injection control with EKC TC compressor. Not as efficient
361 and ICF as intermediate cooler.
M
To download the latest version of the literature please visit the Danfoss internet site
http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning/Products/Documentation.htm
3. Condenser Controls In areas where there are large variations in This condensing capacity control is achieved
ambient air temperatures and/or load conditions, either by regulating the flow of circulating air or
it is necessary to control the condensing water through the condenser, or by reducing the
pressure to avoid it from falling too low. Too effective heat exchange surface area.
low condensing pressures results in there being
insufficient pressure differential across the Different solutions can be designed for different
expansion device and the evaporator is supplied types of condensers:
with insufficient refrigerant. It means that 3.1 Air cooled condensers
condenser capacity control is mainly used in the 3.2 Evaporative condensers
temperate climate zones and to a lesser degree in 3.3 Water cooled condensers
subtropical and tropical zones.
3.1 An air-cooled condenser consists of tubes mounted Air-cooled condensers are used on industrial
Air Cooled Condensers within a fin block. The condenser can be horizontal, refrigeration systems where the relative air humidity
vertical or V-shaped. The ambient air is drawn across is high. Controlling the condensing pressure for air-
the heat exchanger surface with axial or centrifugal cooled condensers can be achieved in the following
fans. ways:
� AKS 33
From
discharge line � SVA Condenser
� SVA � SVA
SFA SFA
SNV
DSV
HP vapour refrigerant
HP liquid refrigerant
Receiver
LLG
➀ Step controller
➁ Pressure transmitter
➂ Stop valve Danfoss
SNV
From � AKS 33
discharge
line SVA
Condenser
SVA
SFV SFV
SVA
DSV
LLG Receiver
HP vapour refrigerant
HP liquid refrigerant
SNV To expansion
Danfoss
➀ Frequency converter Tapp_0141_02 SVA device
08-2006
➁ Pressure transducer
Frequency converter control offer the following
advantages:
Energy savings
Improved control and product quality
Noise reduction
Longer lifetime
Simplified installation
Easy to use complete control of the system
� ICS � SVA
Condenser
Suction � SVA
line
HP vapour refrigerant �
HP liquid refrigerant � SVA � ICS SVA SFA SFA
SNV
DSV
➀ Pressure regulator
➁ Stop valve LLG
Receiver
➂ Check valve
➃ Stop valve
➄ Stop valve SVA SNV
➅ Differential pressure To expansion
regulator Danfoss
Tapp_0148_02 To oil device
➆ Stop valve 09-2007 cooler
This regulating solution maintains the pressure in maintains sufficient pressure in the receiver. This
the receiver at a sufficiently high level during low differential pressure regulator ➅ could also be an
ambient temperatures. overflow valve OFV.
The ICS pilot-operated servo valve ➀ opens when The NRVA check valve ➂ ensures increased
the discharge pressure reaches the set pressure condenser pressure by liquid back up within
on the CVP pilot valve. The ICS pilot-operated the condenser. This requires a sufficiently large
servo valve closes when the pressure drops receiver. The NRVA check valve also prevents
below the set pressure of the CVP pilot valve. liquid flow from the receiver back into the
condenser when the latter is colder during
The ICS pilot-operated servo valve ➅ with compressor shut-down periods
the CVPP constant differential pressure pilot
3.2 An evaporative condenser is a condenser cooled air stream. In this way the building up of calcium
Evaporative Condensers by ambient air combined with water sprayed scales on the surface of the main heat exchanger
through orifices and air baffles in counter flow pipes is greatly reduced.
with the air. The water evaporates and the
evaporation effect of the water drops adds much This type reduces the water consumption
to the condenser capacity considerably compared to a normal water cooled
condenser. Capacity control of an evaporative
Today’s evaporative condensers are enclosed in a condenser can be achieved by either two speed
steel or plastic enclosure with axial or centrifugal fan or variable speed control of the fan and
fans at the bottom or at the top of the condenser. at very low ambient temperature conditions
switching off the water circulation pump.
The heat exchanger surface in the wet air stream
consists of steel pipes. The use of evaporative condensers is limited
Above the water spray orifices (in the dry air) it is in areas with high relative humidity. In cold
common to have a de-super heater made of steel surroundings (ambient temperatures < 0°C)
pipes with fins to reduce the hot gas temperature frost damage prevention must be carried out
before it reaches the heat exchanger in the wet by removing the water in the evaporative
condenser.
� SVA
Water
pump
Suction
line Condenser
Compressor
� SVA
� SVA
SFA SFA
SNV DSV
HP vapour refrigerant
HP liquid refrigerant Receiver
Water LLG
➀ Pressure controller
➁ Pressure controller SVA SNV
➂ Stop valve Danfoss
To expansion
To oil device
➃ Stop valve Tapp_0033_02
09-2007 cooler
➄ Stop valve
This solution maintains the condensing In extremely low ambient temperature, when the
pressure, as well as the pressure in the receiver condensing pressure drops below the setting of
at a sufficiently high level in low ambient RT 5A ➀ after all the fans have been switched off,
temperature. RT 5A ➀ will stop the water pump.
When the inlet pressure of the condenser drops When the pump is stopped, the condenser and
below the setting of the pressure controller RT the water pipes should be drained to avoid
5A ➁, the controller will switch off the fan, to scaling and freezing.
decrease the condensing capacity.
SNV
DSV
HP vapour refrigerant
HP liquid refrigerant Receiver
Water LLG
➀ Step controller
➁ Pressure transmitter SVA SNV
➂ Stop valve Danfoss
To expansion
device
➃ Stop valve Tapp_0034_02
09-2007
To oil
cooler
➄ Stop valve
This solution works in the same way as example If control takes place outside the hatched area
3.2.1, but operated via step controller EKC 331 ➀. (named ++zone and --zone), changes of the cut-
For more information on EKC 331, please refer to in capacity will occur somewhat faster than if it
page 7. were in the hatched area.
A capacity regulation solution for evaporative For more details, please refer to the manual of
condensers can be achieved by using an EKC 331 EKC 331(T) from Danfoss.
power regulator and an AKS pressure transmitter.
Sequential control for the water pump must
be selected as the last step. Sequential control
means that the steps will always cut in and out in
the same order.
EKC 331T version can accept a signal from a
PT 1000 temperature sensor, which may be
necessary for secondary systems.
Neutral Zone Control
A neutral zone is set around the reference value,
in which no loading/unloading occurs.
Outside the neutral zone (in the hatched areas
“+zone” and “- zone”) loading/unloading will
occur as the measure pressure deviates away
from the neutral zone settings.
Technical data Pressure transmitter-AKS 33 Pressure transmitter-AKS 32R
Refrigerants All refrigerant including R717
Operating range [psig] 14.5 up to 493 14.5 up to 493
Max. working pressure [psig] Up to 797 >478.6
Operating temp. range [°F] –40 to 185
Compensated temp. range [°F] LP: –22 to +104 / HP: 32 to +176
Rated output signal 4 to 20 mA 10 to 90% of V supply
3.3 The water cooled condenser was originally a shell cooling tower and re-circulated. It can also be
Water Cooled Condensers and tube heat exchanger, but today it is very used as a heat recovery condenser to supply hot
often a plate heat exchanger of modern design. water.
Water cooled condensers are not commonly The control of the condensing pressure can be
used, because in many places it is not allowed achieved by a pressure controlled water valve,
to use the large amount of water these types or a motorised water valve controlled by an
consume (water shortage and/or high prices for electronic controller to control the flow of the
water). cooling water according to the condensing
pressure.
Today water cooled condensers are popular
in chillers, with the cooling water cooled by a
SFA SFA
SNV
Cooling
Suction DSV water out
line
Compressor � WVS
HP vapour refrigerant
HP liquid refrigerant
Condenser Cooling
Water water in
SNV
� SVA
➀ Stop valve Danfoss
➁ Stop valve Tapp_0035_02
09-2007
To expansion
device
➂ Water valve
This solution maintains the condensing pressure
at a constant level. The refrigerant condensing
pressure is directed through a capillary tube to
the top of the water valve WVS ➂, and adjusts the
opening of WVS ➂ accordingly. The water valve
WVS is a P-regulator.
SCA � � SVA
AKS 33
SFA
AMV 20
SFA
SNV
Cooling
Suction DSV water in
HP vapour refrigerant line
HP liquid refrigerant
Water Compressor � VM2
Condenser Cooling
➀ Pressure transmitter water out
➁ Controller SNV
� SVA
➂ Motor-valve Danfoss
➃ Stop valve Tapp_0036_02
09-2007
To expansion
device
➄ Stop valve
The controller ➁ receives the condensing In this solution, PI or PID control can be
pressure signal from the pressure transmitter AKS configured in the controller.
33 ➀, and sends out a corresponding modulating
signal to actuator AMV 20 of the motor valve VM 2 and VFG 2 are motor-valves designed for
VM 2 ➂. In this way, the flow of cooling water is district heating, and can also be used for water
adjusted and the condensing pressure is kept flow control in refrigeration plants.
constant.
3.4
Summary
Fan speed control of air Applicable to all condensers Low start up current Very low ambient
cooled condensers with the ability to run at Energy savings temperatures;
PT reduced speed. Lower noise
Condenser
Longer lifetime
Simplified installation
Receiver
Step control of evaporative Industrial refrigeration Large reduction in water Not applicable in countries
condenser with step with very large capacity consumption compared to with high relative humidity;
controller EKC331 PT requirement water cooled condensers In cold climates special
and relatively easy to precaution has to be taken
From
discharge
line Water
capacity control; Possible so the water pipe is drained
pump
Condenser
to control remotely. Energy for water during water pump
saving. off periods.
Receiver
Liquid flow control with a PC Chillers, heat recovery It is easy to capacity control This type of installation
motor valve PT
Cooling
condensers the condenser and the heat is more expensive than
M water in
recovery; Possible to control a normal set up; Not
Compressor
Condenser Cooling
remotely. applicable when water
water out
availability is a problem.
To download the latest version of the literature please visit the Danfoss internet site
http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning/Products/Documentation.htm
4. Liquid Level Control Liquid level control is an important element in Low pressure systems are typically
the designing of industrial refrigeration systems. characterized by:
It controls the liquid injection to maintain a 1. Focus on the liquid level on the evaporating
constant liquid level. side of the system
2. Receiver is usually big
Two main different principles may be used when 3. Large (enough) charge of refrigerant
designing a liquid level control system: 4. Mainly applied to de-centralized systems
High pressure liquid level control system (HP
LLRS) Both principles can be achieved, using
mechanical and electronic components
Low pressure liquid level control system (LP
LLRS)
4.1 When designing a HP LLRS, the following points hammering). If the system is undercharged the
High Pressure Liquid Level have to be taken into consideration: evaporator will be starved. The size of the low
Control System (HP LLRS) pressure vessel (liquid separator/ shell-tube
As soon as liquid is “formed” in the condenser the evaporator) must be carefully designed so
liquid is fed to the evaporator (low pressure side). that it can accommodate the refrigerant in all
conditions without causing liquid hammering.
The liquid leaving the condenser will have little
or no sub-cooling. This is important to consider Because of the above reasons, HP LLRS are
when the liquid flows to the low pressure side. especially suitable for systems requiring small
If there is pressure loss in the piping or the refrigerant charge, like chiller units, or small
components, flash-gas may occur and cause the freezers. Chiller units usually do not need
flow capacity to be reduced. receivers. As a result of the above, HP LLRS are
especially suitable for systems requiring a small
The refrigerant charge must be precisely refrigerant charge, e.g. liquid chiller units, or
calculated in order to ensure that there small freezers. Liquid chiller units usually do not
is adequate refrigerant in the system. An need receivers, however, if a receiver is necessary
overcharge increases the risk of flooding the in order to install pilots and provide refrigerant
evaporator or the liquid separator causing to an oil cooler, the receiver could be physically
liquid carry over into the compressor (liquid small.
Tapp_0044_02
Mechanical solution for HP
liquid level control
Danfoss
04-2006
From SVA
discharge
line SVA SFA SFA
� SVA
SNV
DSV
HP vapour refrigerant
HP liquid refrigerant
LP liquid refrigerant � SV1
Receiver
LLG
➀ Stop valve
➁ Filter
➂ Servo-operated main valve EVM
SVA
➃ Stop valve SNV � SVA
To seperator
➄ Float valve To oil
cooler
➅ Stop valve � SVA
� FIA � PMFH � SVA
➆ Stop valve
On large HP LLRS the SV1 ➄ or SV3 float valve is
used as a pilot valve for a PMFH ➂ main valve.
As illustrated above, when the liquid level in the
receiver rises above the set level, the SV1 ➄ float
valve provides a signal to the PMFH main valve
to open.
� HFI
Cooling water in
Tapp_0046_02
level control
Danfoss
09-2007
From SVA
discharge � AKS 41
line SFA SFA � SVA
HP vapour refrigerant SVA SNV
HP liquid refrigerant DSV
LP liquid refrigerant
Receiver
➀ Stop valve LLG
➁ Filter � EKC 347
➂ Motor valve
➃ Stop valve ICAD
➄ Controller SVA SNV � SVA
➅ Level transmitter To seperator
To oil
➆ Stop valve cooler � SVA � ICM � SVA
� FIA
➇ Stop valve
When designing an electronic LLRS solution the With a regulating valve REG acting as an
liquid level signal can be given either by an AKS expansion valve and an EVRA solenoid valve
38 which is a level switch (ON/OFF) or an AKS 41 to implement ON/OFF control.
which is a level transmitter (4-20 mA). The system illustrated is an AKS 41 ➅ level
transmitter which sends a level signal to an
The electronic signal is sent to an EKC 347 EKC 347 ➄ liquid level controller. The ICM ➂
electronic controller which controls the injection motor valve acts as an expansion valve.
valve.
4.2 When designing a LP LLRS, the following points As a result of the above, LP LLRS are especially
Low Pressure Liquid have to be taken into consideration: suitable for de-centralised systems in which
Level Control System (LP there are many evaporators, and the refrigerant
LLRS) The liquid level in the low pressure vessel (liquid charge is large, like cold stores. With LP LLRS,
separator/ shell-tube evaporator) is maintained at these systems could run safely even though the
a constant level. This is safe to the system, since refrigerant charge is impossible to be precisely
a too high liquid level in the liquid separator calculated.
may cause liquid hammering to the compressor,
and a too low level may lead to cavitation of the In conclusion, HP LLRS are suitable for compact
refrigerant pumps in a pump circulation system. systems like chillers; the advantage is the reduced
cost (small receiver or no receiver). While LP LLRS
The receiver must be big enough to accumulate are very suitable for de-centralised systems with
the liquid refrigerant coming from the many evaporators and long piping, like a large
evaporators when the content of refrigerant in cold storage; the advantage being the higher
some evaporators vary with the cooling load, safety and reliability.
some evaporators are shut off for service, or part
of the evaporators are drained for defrosting.
If the capacity is large, the float valve SV ➄ is receiver falls below the set level, the float valve
used as a pilot valve for the PMFL main valve. SV ➄ provides a signal to the PMFL value to open.
As illustrated above, when the liquid level in the
Technical data PMFL 80 - 1 to 500
Material Low temp. spherical cast iron
Refrigerants R717, HFC, HCFC and CFC
Media temp. range [°F] –76 to +248
Max. working pressure [psig] 406
Max test pressure [psig] 609
Rated capacity* [HP] 186-18640
➇ Level switch
The level transmitter AKS 41 ➆, monitors the The liquid level controller EKC 347 ➅ also
liquid level in the separator and sends a level provides relay outputs for upper and lower limits
signal to the liquid level controller EKC 347 ➅, and for alarm level. However, it is recommended
which sends a modulating signal to the actuator that a level switch AKS 38 ➇ is fitted as a high
of the motor valve ICM ➃. The ICM motor valve level cut out.
acts as an expansion valve.
➆ Level transmitter
This solution is similar to solution 4.2.3. However, The liquid level controller EKC 347 ➅ also
with this example the motor valve ICM is provides relay outputs for upper and lower limits
replaced by a pulse width electronically operated and for alarm level. However, it is recommended
expansion valve AKVA. The servo valve EVRAT ➂ that a level switch AKS 38 is fitted as a high level
is being used as an additional solenoid valve to cut out.
ensure 100% closure during “off” cycles.
Technical data AKVA
Material AKVA 10: stainless steel
AKVA 15: cast iron
AKVA 20: cast iron
Refrigerants R717
Media temp. range [°F] AKVA 10: –58 to +140
AKVA 15/20: –40 to +140
Max. working pressure [psig] 609
DN [in.] 0.39 to 1.96
Nominal capacity* [HP] 5 to 4224
* Conditions: R717, +41/89.6°F, ΔTsub = 8°F
M
� ICF
From evaporator
Stop valve SVA
SNV SVA SVA
Filter
Solenoid valve
Manual opener SVA
Danfoss
Motor valve To evaporator QDV Tapp_0051_02
09-2007
Stop valve
➁ Controller Danfoss can supply a very compact valve This solution works in an identical manner to
➂ Level transmitter solution ICF ➀. Up to six different modules can be
assembled into the same housing, which is easy
example 4.2.3. ICF solution similar to example
4.2.4 is also available. Please refer to ICF literature
to install. The module ICM acts as an expansion for further information.
valve and the module ICFE is a solenoid valve.
➄ Level switch
This solution controls the liquid injection using
on/off control. The level switch AKS 38 ➄, controls
the switching of the solenoid valve EVRA ➁, in
accordance with liquid level in the separator.
The hand regulating valve REG ➂ acts as the
expansion valve.
REG
Material Special cold resistant steel approved for low temperature operation
Refrigerants All common non-flammable refrigerants, including R717.
Media temp. range [°F] –58 to +302
Max. working pressure [psig] 580
Test pressure [psig] Strength test: 1160
Leakage test: 580
Cv value [US gal/min] 0.12 to 57.3 for fully open valves
EVRA
Refrigerants R717, R22, R134a, R404a, R410a, R744, R502
Media temp. range [°F] –40 to +220
Max. working pressure [psig] 609
Rated capacity* [HP] 29 to 3175.5
Cv value [US gal/min] 0.27 to 29.0
4.3
Summary
Solution Application Benefits Limitations
High pressure mechanical Applicable to systems with small Pure mechanical. Unable to control remotely, the
solution: refrigerant charges, like chillers. Wide capacity range. distance between SV and PMFH
Receiver
SV1/3 + PMFH is limited to several meters.
A little bit slow in response.
High pressure mechanical Applicable to systems with small Pure mechanical. Unable to provide
solution: refrigerant charges and with Simple solution. thermosyphon oil cooling.
HFI plate type condensers only. Especially suitable for plate heat
Plate type
condenser
exchanger
High pressure electronic LT Applicable to systems with small Flexible and compact. Not allowed for flammable
solution: refrigerant charges, like chillers. Possible to monitor and control refrigerant.
AKS 41+EKC 347 + ICM LC remotely.
Receiver Covers a wide range of capacity.
M
Low pressure mechanical Applicable to small systems. Pure mechanical. Limited capacity.
solution: Simple, low cost solution.
SV4-6 Liquid separator
Low pressure mechanical Particularly applicable to de- Pure mechanical. Unable to control remotely, the
solution: central systems, like cold stores. Wide capacity range. distance between SV and PMFL
SV 4-6 + PMFL is limited to several meters.
A little bit slow in response.
Liquid separator
Low pressure electronic solution: Particularly applicable to de- Flexible and compact. Not allowed for flammable
AKS 41 + EKC 347 + ICM M LC
central systems, like cold stores. Possible to monitor and control refrigerant.
LT remotely.
Covers a wide range of
capacities.
Liquid separator
Low pressure electronic solution: Particularly applicable to de- Flexible and compact. Not allowed for flammable
AKS 41 + EKC 347 + AKVA AKVA LC
central systems, like cold stores. Possible to monitor and control refrigerant.
LT remotely. The system needs to allow for
Wide capacity range. pulsations.
Faster than motor valve.
Fail safe valve (NC).
Liquid separator
Low pressure electronic solution: Particularly applicable to de- Flexible and compact. Not allowed for flammable
AKS 41 + EKC 347 + ICF M LC
central systems, like cold stores. Possible to monitor and control refrigerant.
LT remotely.
Covers a wide range of
capacities.
Easy to install.
Liquid separator
Low pressure electronic solution: Particularly applicable to de- Simple. Just 40 mm for level adjustment.
AKS 38 + EVRA + REG central systems, like cold stores. In-expensive. Very dependant on the
adjustment of the REG valve.
Not suitable for systems with big
Liquid separator capacity fluctuations.
5. Evaporator Controls The evaporator is the part of the refrigeration Multi-temperature changeover (Section
system where the effective heat is transferred 5.5) for evaporators that need to operate at
from the media you want to cool down (e.g. air, different temperature levels.
brine, or the product directly) to the refrigerant. Media temperature control (Section 5.6)
when the media temperature is required to
Therefore, the primary function of evaporator be maintained at a constant level with high
control system is to achieve the desired media accuracy.
temperature. Furthermore, the control system
should also keep the evaporator in efficient and When introducing media temperature control
trouble-free operation at all times. and defrost, direct expansion (DX) evaporators
and pumped liquid circulation evaporators are
Specifically, the following control methods may discussed separately, because there are some
be necessary for evaporators: differences in the control systems.
Liquid supply control Section 5.1 and 5.2
describes two different types of liquid supply-
direct expansion (DX) and pumped liquid
circulation.
Defrost (Section 5.3 and 5.4), which is
necessary for air coolers operating at
temperatures below 32°F.
5.1 To design liquid supply for direct expansion The liquid injection is controled by a superheat-
Direct Expansion Control evaporators, the following requirements should controlled expansion valve, which maintains the
be satisfied: superheat at the outlet of the evaporator within a
The liquid refrigerant supplied to the desired range. This expansion valve can be either
evaporator is completely evaporated. This is a thermostatic expansion valve, or an electronic
necessary to protect the compressor against expansion valve.
liquid hammer.
The temperature control is normally achieved by
The media “off” temperature from the ON/OFF control, which starts and stops the liquid
evaporator is maintained within the desired supply to the evaporator according to the media
range. temperature.
HP liquid refrigerant
Liquid/vapour mixture
� SVA
� EKC 202
of refrigerant
LP vapour refrigerant
� AKS 21
➀ Stop valve liquid inlet
➁ Filter
➂ Solenoid valve
➃ Thermostatic expansion valve � TEA
From
➄ Stop valve evaporator inlet receiver
➅ Stop valve suction line
� SVA � SVA
➆ Evaporator � FA +
➇ Digital thermostat � EVRA � Evaporator
➈ Temperature sensor
Application example 5.1.1 shows a typical This solution can also be applied to DX
installation for a DX evaporator without hot gas evaporators with natural or electric defrost.
defrosting.
Natural defrost is achieved by stopping the
The liquid injection is controled by the refrigerant flow to the evaporator, and keeping
thermostatic expansion valve TEA ➃, which the fan running. Electric defrost is achieved by
maintains the refrigerant superheat at the stopping the refrigerant flow to the evaporator
outlet of the evaporator at a constant level. TEA and the fan and at the same time switching on an
is designed for ammonia. Danfoss also supply electric heater inside the evaporator fin block.
thermostatic expansion valves for fluorinated
Evaporator Controller EKC 202
refrigerants.
The digital thermostat will control all functions of
The media temperature is controlled by the the evaporator including thermostat, fan, defrost
digital thermostat EKC 202 ➇, which controls the and alarms.
on/off switching of the solenoid valve EVRA ➂
For more details, please refer to the manual of
according to the media temperature signal from
EKC 202 from Danfoss.
the PT 1000 temperature sensor AKS 21 ➈.
Technical data Thermostatic expansion valve - TEA
Refrigerants R717
Evaporating temp. range [°F] –58 to 86
Max. bulb temp. [°F] 212
Max. working pressure [psig] 275.6
Rated Capacity* [HP] 4.7 to 395.6
* Conditions: +5°F/+89.6°F, ΔTsub = 39.2°F
Strainer - FA
Refrigerants Ammonia and fluorinated refrigerants
Media temp. range [°F] –58 to +284
Max. working pressure [psig] 406
DN [in.] 0.59/0.79
Filter insert 150μ stainless steel weave
Cv value [US gal/min] 3.8/8.1
HP liquid refrigerant
Liquid/vapour mixture � SVA
of refrigerant AKS 33
LP vapour refrigerant To suction line � AKS 21
AKS 21
➀ Stop valve liquid inlet
➁ Filter
➂ Solenoid valve
➃ Electronic expansion valve ICAD
➄ Stop valve evaporator inlet
➅ Stop valve suction line From receiver
➆ Evaporator
➇ Controller � SVA � ICM � SVA
➈ Temperature sensor � FA + � Evaporator
� EVRA
Pressure transmitter
Temperature sensor
Application example 5.1.2 shows a typical Compared with the solution 5.1.1, this solution
installation for an electronically controlled DX will operate the evaporator at an optimised
evaporator without hot gas defrost. superheat and constantly adapt the opening
degree of the injection valve to ensure maximum
The liquid injection is controled by the motor- capacity and efficiency. The surface area of the
valve ICM ➃ controlled by the evaporator evaporator will be fully utilised. Furthermore,
controller type EKC 315A ➇. The EKC 315A this solution offers a more accurate media
controller will measure the superheat by means temperature control.
of the pressure transmitter AKS 33 and the
temperature sensor AKS 21 ➈ on the outlet of Evaporator Controller EKC 315A
the evaporator, and controlling the opening of The Digital controller will control all functions of
the ICM in order to maintain the superheat at the the evaporator including thermostat, expansion
optimum level. and alarms.
At the same time, the controller EKC 315A For more details, please refer to the manual of
operates as a digital thermostat, which will EKC 315A from Danfoss.
control the on/off switching of the solenoid valve
EVRA ➂ depending on the media temperature
signal from the temperature sensor AKS 21 .
HP liquid refrigerant
Liquid/vapour mixture � AKS 33
of refrigerant To suction line
LP vapour refrigerant
� AKS 21
� AKS 21
� SVA
➀ ICF control solution with:
M
ICM
Stop valve liquid inlet ICFS
ICFE
Filter
Solenoid valve
Manual opening From receiver � ICF
ICM electronic exp. valve
Stop valve evaporator inlet
➁ Stop valve suction line
➂ Evaporator ICFF ICFM � Evaporator
ICFS
➃ Controller
➄ Temperature sensor
➅ Pressure transmitter Application example 5.1.3 shows the new ICF Similar to the example 5.1.1, this solution
➆ Temperature sensor control solution for an electronically controlled will operate the evaporator at an optimised
DX evaporator without hot has defrost similar to superheat, and constantly adapt the opening
the example 5.1.2. degree of the injection valve to ensure maximum
capacity and efficiency. The surface area of the
The ICF will accommodate up to six different evaporator will be fully utilised. Furthermore,
modules assembled in the same housing offering this solution offers a more accurate media
a compact, easy to install control solution. temperature control.
The liquid injection is controled by the motor- Evaporator Controller EKC 315A
valve ICM which is controlled by the evaporator The Digital controller will control all functions of
controller type EKC 315A ➃. The EKC 315A the evaporator including thermostat, expansion
controller will measure the superheat by means and alarms.
of the pressure transmitter AKS 33 ➅ and the
temperature sensor AKS 21 ➄ on the outlet of the For more details, please refer to the manual of
evaporator, and control the opening of the ICM EKC 315A from Danfoss.
valve in order to maintain the superheat at the
optimum level.
5.2 When compared to ammonia DX systems, The pump separator ensures that only “dry”
Pumped Liquid ammonia pump circulation systems control refrigerant vapour is returned to the compressors.
Circulation Control becomes simpler as a well-dimensioned pump The evaporation control is also simplified as only
separator protects compressors against hydraulic a basic on/off liquid control to the evaporators is
shock. required.
Application example 5.2.1:
Pumped liquid circulation
evaporator, without hot gas
defrost
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
From liquid To liquid
separator separator
➀ Stop valve liquid inlet
➁ Filter � SVA � REG � SVA � SVA
➂ Solenoid valve � FA + � Evaporator
➃ Hand expansion valve � EVRA
➄ Stop valve evaporator inlet
➅ Stop valve suction line
➆ Evaporator
➇ Digital thermostat
➈ Temperature sensor
Application example 5.2.1 shows a typical Too high an opening degree will lead to frequent
installation for a pumped liquid circulation operation of the solenoid valve with resultant
evaporator without hot has defrost, and can wear. Too low an opening degree will starve the
also be applied to pumped liquid circulation evaporator of liquid refrigerant.
evaporators with natural or electric defrost.
Evaporator Controller EKC 202
The media temperature is maintained at the The Digital thermostat will control all functions of
desired level by the digital thermostat EKC 202 the evaporator including thermostat, fan, defrost
➇, which controls the on/off switching of the and alarms.
solenoid valve EVRA ➂ according to the media
temperature signal from the PT 1000 temperature For more details, please refer to the manual of
sensor AKS 21 ➈. EKC 202 from Danfoss.
5.3 In applications where the air cooler operates Electric defrost is achieved by stopping the fan
Hot Gas Defrost at evaporating temperatures below 32°F, frost and the refrigerant flow to the evaporator and
for DX Air Coolers will form on the heat exchange surface, with its at the same time switching on an electric heater
thickness increasing with time. The frost build up inside the evaporator fin block. With a timer
leads to a drop in performance of the evaporator function and/or a defrost termination thermostat,
by reducing the heat transfer coefficient and the defrosting can be terminated when the heat
blocking the air circulation at the same time. exchange surface is completely free of ice. Whilst
Therefore, these air coolers should be defrosted this solution is easy to install and low in initial
periodically to keep their performance at a investment, the operating costs (electricity) are
desired level. considerably higher than for other solutions.
Different types of defrost commonly used in For hot gas defrost systems, hot gas will be
industrial refrigeration are: injected into the evaporator to defrost the
Natural defrost surface. This solution requires more automatic
controls than other systems, but has the lowest
Electric defrost operating cost over time. A positive effect of
Hot gas defrost hot gas injection into the evaporator is the
removal and return of oil. To ensure enough hot
Natural defrost is achieved by stopping the gas capacity, this solution must only be used
refrigerant flow to the evaporator and keeping in refrigeration systems with three or more
the fan running. This can only be used for room evaporators. Only a third of the total evaporator
temperatures above 32°F. The resulting defrosting capacity can be under defrost at a given time.
time is long.
➂ Solenoid valve
➃ Expansion valve � SVA � SVA
� FIA 18 AKS 21
➄ Stop valve evaporator inlet
13 NRVA Evaporator
Suction Line From receiver
EVM
➅ Stop valve evaporator inlet
➆ Two step solenoid valve Danfoss
➇ Stop valve suction line Tapp_0067_02
09-2007
� SVA FIA
ICS 12 SVA
The fans are stopped and the GPLX closed. It After the GPLX fully opens, ICS ➂ is opened to
takes 45 to 700 seconds to close the gas powered restart the refrigeration cycle. The fan is started
solenoid valve GPLX ➆ depending on the valve after a delay in order to freeze remaining liquid
size, refrigerant and evaporating temperature. A droplets on the surface of the evaporator.
further delay of 10 to 20 seconds is required for
the liquid in the evaporator to settle down in the
bottom without vapour bubbles. The solenoid
valve ICS is then opened by its solenoid valve
pilot EVM and supplies hot gas to the evaporator.
Gas powered two-step solenoid valve - GPLX Gas powered two-step solenoid valve - PMLX
Material Body: low temp. steel Body: low temp. cast iron
Refrigerants All common non-flammable refrigerants, incl. All common non-flammable refrigerants, incl.
R717. R717.
Media temp. range [°F] –76 to 302 –76 to 248
Max. working pressure [psig] 580 406
Size [in.] 3 to 6 11/4 to 6
Nominal capacity* [HP] On dry suction line: 493 to 2561 On dry suction line: 102 to 1742
On wet suction line: 374 to 1616 On wet suction line: 64 to 1100
* Conditions R717, ΔP = 0.73 psi, Te = 14°F, Tliq = 86°F, Recirculation Ratio = 4
Filter - FIA
Material Body: steel
Refrigerants All common refrigerants, incl. R717
Media temp. range [°F] –76 to 302
Max. working pressure [psig] 580
Size [in.] ½ to 8
Filter insert 100/150/250/500μ stainless steel weave
ICFS ICFE
�
M
To other NRVA
15 AKS 21
evaporators
Stop valve liquid inlet � ICF
Filter ICFF ICFM ICFS 14 AKS 21
Solenoid valve
Manual opening � NRVA Evaporator
ICM expansion valve From receiver ICFS ICFE
Stop valve evaporator inlet
➁ Stop valve evaporator outlet Danfoss � ICF
➂ Two step solenoid valve Tapp_0068_02
04-2006
ICFF ICFS
5.4 Danfoss
Hot Gas Defrost for Pumped 16 Controller Tapp_0069_02
04-2006
Liquid Circulation Air
Coolers
of refrigerant NRVA
EVM
LP liquid refrigerant
From liquid AKS 21
separator � NRVA 19
Liquid Line
➀ Stop valve liquid inlet � SVA � ICS � REG � SVA
➁ Filter � FIA 18 AKS 21
➂ Solenoid valve EVM Evaporator
➃ Check valve From discharge line
➄ Hand expansion valve ICS 13 SVA
SVA 12
➅ Stop valve evaporator inlet FIA
Suction Line Application example 5.4.1 shows a typical During the defrost cycle, the overflow valve
➆ Stop valve evaporator outlet installation for a pumped liquid circulation OFV opens automatically subject to the
➇ Two step solenoid valve evaporator with hot gas defrost. differential pressure. The overflow valve allows
the condensed hot gas from the evaporator to
➈ Stop valve suction line Refrigeration Cycle be released into the wet suction line. The OFV
The solenoid valve ICS ➂ on the liquid line is kept could also be replaced with a pressure regulator
Hot gas line
open. The liquid injection is controled by the ICS+CVP depending on the capacity, or a high
Stop valve hand regulating valve REG ➄. pressure float valve SV1/3 which only drains
Filter liquid to the low pressure side.
The solenoid valve GPLX ➇ in the suction line is
Solenoid valve
kept open, and the defrosting solenoid valve When the temperature in the evaporator
Stop valve ICS is kept closed. (measured by AKS 21 ) reaches the set value,
Check valve defrost is terminated, the solenoid valve ICS is
Defrost Cycle closed, and the two-step solenoid valve GPLX ➇
Overflow line After initiation of the defrost cycle, the liquid is opened.
Overflow valve supply solenoid ICS ➂ is closed. The fan is kept
running for 120 to 600 seconds depending on After the GPLX fully opens, the liquid supply
Controls the evaporator size in order to pump down the solenoid valve ICS ➂ is opened to start the
evaporator of liquid. refrigeration cycle. The fan is started after a delay
Controller in order to freeze remaining liquid droplets on
Controller The fans are stopped and the GPLX closed. It the surface of the evaporator.
Controller takes 45 to 700 seconds to close the gas powered
solenoid valve GPLX ➇ depending on the valve
Controller
size, refrigerant and evaporating temperature. A
further delay of 10 to 20 seconds is required for
the liquid in the evaporator to settle down in the
bottom without vapour bubbles. The solenoid
valve ICS is then opened and supplies hot gas
to the evaporator.
Technical data Overflow valve - OFV
Material Body: steel
Refrigerants All common refrigerants, incl. R717
Media temp. range [°F] –58 to 302
Max. working pressure [psig] 580
Size [in.] /4 or 1
3
ICFS
Stop Valve
Filter Application example 5.4.2 shows an installation without vapour bubbles. The solenoid valve ICFE
Solenoid valve for pumped liquid circulation evaporators in ICF ➄ is then opened and supplies hot gas to
Stop valve with hot gas defrost using the new ICF control the evaporator.
solution and SV 1/3 float valve.
➅ Check valve During the defrost cycle, the condensed hot
➆ Float valve The ICF will accommodate up to six different gas from the evaporator is injected into the
➇ Controller modules assembled in the same housing offering low pressure side. The injection is controlled
a compact, easy to install control solution. by the high pressure float valve SV 1 or 3 ➆
➈ Temperature sensors complete with special internal kit. Compared to
Temperature sensors Refrigeration Cycle the overflow valve OFV in the solution 5.4.1, this
Temperature sensors The solenoid valve ICFE in ICF ➀ in the liquid line float valve controls the overflow according to the
is kept open. The liquid injection is controled by liquid level in the float chamber.
the hand regulating valve ICFR in ICF ➀.
The use of a float valve ensures that the hot
The solenoid valve GPLX ➂ in the suction line is gas does not leave the evaporator until it is
kept open, and the defrosting solenoid valve ICFE condensed into liquid, resulting in an increase
in ICF ➄ is kept closed. in overall efficiency. Furthermore, the float valve
is specifically designed for modulating control
Defrost Cycle providing a very stable control solution.
After initiation of the defrost cycle, the liquid
supply solenoid module ICFE of the ICF ➀ is When the temperature in the evaporator
closed. The fan is kept running for 120 to 600 (measured by AKS 21 ) reaches the set value,
seconds depending on the evaporator size in defrost is terminated, the solenoid valve ICFE
order to pump down the evaporator of liquid. in ICF ➄ is closed, and after a small delay the
solenoid valve GPLX ➂ is opened.
The fans are stopped and the GPLX closed. It
takes 45 to 700 seconds to close the gas powered After the GPLX fully opens, the liquid supply
solenoid valve GPLX ➂ depending on the valve solenoid valve ICFE in ICF ➀ is opened to start the
size, refrigerant and evaporating temperature. A refrigeration cycle. The fan is started after a delay
further delay of 10 to 20 seconds for the liquid in order to freeze remaining liquid droplets on
in the evaporator to settle down in the bottom the surface of the evaporator.
SVA �
ICS
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
From liquid
➀ Pressure regulating valve separator
➁ Pressure regulating
pilot valve SVA REG SVA
➂ Pressure regulating FA+EVRA
pilot valve Evaporator
➃ Solenoid pilot valve
Application example 5.5.1 shows a solution Example:
for controlling two evaporating pressures in I II
evaporators. This solution can be used for DX or Outlet air temperature 37.4°F 46.4°F
pumped liquid circulation evaporators with any Evaporating temperature 28.4°F 35.6°F
type of defrost system.
Temperature change 5K 6K
Refrigerant R22 R22
The servo valve ICS is equipped with one EVM
(NC) solenoid valve pilot in the S1 port and two Evaporating pressure 52 psi 64 psi
CVP constant pressure pilots in the ports S2 and P
respectively. S2: CVP is preset to 52 psi, and
P: CVP is preset to 64 psi.
The CVP I the S2 port is adjusted to the lower
operating pressure and the CVP in the P port is I: EVM pilot opens.
adjusted to the higher operating pressure. Hence the evaporating pressure is controlled
by S2: CVP.
When the solenoid in S1 port is energised, the II: EVM pilot closes.
evaporator pressure will follow the setting of the Hence the evaporating pressure is controlled
CVP pilot in S1 port. When the solenoid is de- by P: CVP.
energised, the evaporator pressure will follow the
setting of the CVP pilot in the P port.
�
To liquid S2:CVP
�
separator P:A+B
SVA �
ICS
� AKS 21
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
To liquid separator
SVA �
ICM
AKS 21
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant From liquid
separator
5.7
Summary
Solution Application Benefits Limitations
DX evaporator, electronic All DX systems Optimised superheat; Quick Not suitable for flammable
expansion control with ICM/ response; Possible to control refrigerant.
ICF, EVRA and EKC 315A remotely; Wide capacity
M
range.
Evaporator
EVM
EVM All DX systems Quick defrost; The hot gas Not capable for systems with
defrost GPLX
can bring out the oil left less than 3 evaporators.
ICS
in the low temperature
TC
evaporator.
Evaporator
Multi-temperature Changeover
Multi-temperature control PC CVP Evaporators that need The evaporator can change Pressure drop in suction line.
with ICS and CVP EVM CVP
PC to work at different over between 2 different
temperature levels temperature levels.
ICS
Evaporator
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http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning/Products/Documentation.htm
6. Oil Systems Generally, industrial refrigeration compressors side, equalization of oil level in systems with
are lubricated with oil, which is forced by the oil several piston compressors and oil drain off
pump or due to pressure difference between the points. Most of these are supplied by compressor
high and the low pressure sides to the moving manufacturer.
parts of the compressors (bearings, rotors,
cylinder walls etc.). In order to guarantee reliable The oil system design of an industrial
and efficient operation of the compressor the refrigeration plant depends on the type of
following oil parameters should be controlled: the compressor (screw or piston) and on the
Oil temperature. This should be kept within refrigerant (ammonia, HFC/HCFC or CO2).
the limits specified by manufacturer. The Normally immiscible oil type is used for ammonia
oil should have the correct viscosity and and miscible for Fluorinated refrigerants.
the temperature should be kept below the As oil systems are very compressor related,
ignition point. some of the above mentioned points have been
described in compressor controls (section 2) and
Oil pressure. Oil pressure difference should be safety systems (section 7).
kept above the minimum acceptable level.
6.1 Refrigeration compressors (including all screw Oil can also be cooled by means of injection
Oil cooling compressors and some piston compressors) of the liquid refrigerant directly into the
generally require oil cooling. Too high discharge intermediate compressor port. For piston
temperatures can destroy oil, which leads to the compressors, it is quite common not to have any
damage of the compressor. It is also important special oil cooling systems at all, as temperature
for the oil to have the right viscosity, which is less critical than for screw compressors, with
largely depends on the temperature level. It is the oil being cooled in the crankcase.
not enough just to keep the temperature below
critical limit, it is also necessary to control it.
Normally, oil temperature is specified by the
compressor manufacturer.
� SVA
Oil cooler
Cooling water out
Cooling water in
SNV � WVTS
Water
Oil
Cold oil out
➀ Water valve Danfoss
➁ Stop valve � SVA
Tapp_0083_02
09-2007
➂ Stop valve
These types of systems are normally used in Please contact your local Danfoss sales company
plants where it is possible to get cheap water to check suitability of components to be used
source. Otherwise, it is necessary to install a with sea water as the cooling medium.
cooling tower to cool down the water. Water
cooled oil coolers are quite common for marine
refrigeration plants.
Oil separator
HP vapour refrigerant SVA SFA SFA
SVA
HP liquid refrigerant SVA
LP vapour refrigerant DSV
Oil SNV
Receiver
� FIA LLG
➀ Oil regulating valve
� ORV
➁ Filter � MLI
➂ Sight glass Oil cooler � MLI � SVA SNV
To liquid
➃ Stop valve � REG*
separator
➄ Hand regulating valve Danfoss
➅ Sight glass Tapp_0084_02
04-2006 SNV
➆ Stop valve
These types of systems are very convenient, as oil Otherwise the refrigerant will not return from
gets cooled inside the system. It is only necessary the oil cooler and the system will not function.
to oversize the condenser for the amount of Only minimal number of SVA stop valves should
heat taken from the oil cooler. Conversely, be installed. No pressure dependent solenoid
thermosyphon oil cooling requires additional valves are allowed. On the return pipe it is
piping on site and sometimes it is also necessary recommended to install a MLI ➅ sight glass.
to install an additional priority vessel (in cases
when the HP liquid receiver is placed too low or Oil temperature is maintained at the correct level
not installed). by the ORV ➀ three-way valve. The ORV keeps
the oil temperature within the limits defined by
High pressure liquid refrigerant flows from the its thermostatic element. If the oil temperature
receiver due to gravity force into the oil cooler rises too high then all the oil returns back to the
where it evaporates and cools the oil. Refrigerant oil cooler. If it is too low, then all the oil flow is
vapour rises back to the receiver or, in certain bypassed around the oil cooler.
cases, to the condenser inlet. It is critical that the
pressure drop in the feed and the return pipes is * REG regulating valve may be usefull in case of
minimal. largely oversized oil cooler.
Compressor
From
seperator/
evaporator
Oil seperator
SVA
� FIA
� MLI
� ORV
Oil cooler
HP vapour refrigerant
LP vapour refrigerant
Oil
6.2 During normal running of the refrigeration For the latter method it is necessary to check
Oil Differential compressor, oil is circulated by the oil pump and/ if the compressor manufacturer allows a few
Pressure Control or pressure difference between the HP and LP seconds of dry operation. Normally, this is
sides. The most critical phase is during start-up. possible for screw compressors with ball bearings
but not possible for those with slide bearings
It is vital to have a quick build up of oil pressure
otherwise the compressor may be damaged.
Compressor � ICS
From liquid
separator/
evaporator
Oil separator
SVA
HP vapour refrigerant
LP vapour refrigerant
Oil From oil cooler
Danfoss
Compressor To
condenser
From liquid
separator/
evaporator
Oil separator
�
SVA Check valve
HP vapour refrigerant
LP vapour refrigerant
Oil From oil cooler
RT 1A RT 5A
� KDC
Compressor To condenser
From liquid
separator/
evaporator
Oil separator
HP vapour refrigerant SVA
LP vapour refrigerant
Oil
➀ Multifunctional
compressor valve
From oil cooler
➁ Solenoid pilot
(normally close) Danfoss
Tapp_0088_02
➂ Solenoid pilot 04-2006 To oil cooler
(normally open)
When there is no possibility to install a check When the compressor stops, EVM NC ➁ should
valve in the suction line or there is a check valve be closed and EVM NO ➂ opens. That equalizes
between the compressor and the oil separator, it the pressure over the KDC spring and it closes.
is possible to use KDC ➀ equipped with EVM pilot
valves. Please note the installation direction of the CVH
and EVM pilot valves.
These EVM pilots are installed in external lines
using CVH bodies, as illustrated. During start up
of the compressor the system works as in the
previous example (6.2.2).
6.3 The compressors within industrial refrigeration level falling below the minimum limit set by the
Oil Recovery System ammonia systems are generally the only compressor manufacturer. Oil return systems are
components that which require oil lubrication. primarily used together with refrigerants that
Therefore the function of the compressor oil can be mixed with the oil e.g. HFC/HCFC systems.
separator is to prevent any of the lubricating oil The oil return system can therefore have two
passing into the refrigeration system. functions:
However, oil can carry over through the oil To remove oil from the low pressure side
separator into the refrigeration system and To feed the oil back to the compressor.
often collects in the low pressure side in liquid It is however extremely important to be aware
separators and evaporators, decreasing their that any oil removed from the low pressure side
efficiency. of the ammonia cooling system is unsuitable for
If too much oil carries over from the compressor further use with the compressor and it should
into the system, the oil in the compressor will be removed from the refrigeration system and
be reduced and there is then a risk of the oil discarded.
Application example 6.3.1:
Oil drain from ammonia
systems
AKS 41
To compressor From
SVA evaporator
suction line SFA SFA
SNV SVA
From receiver
SVA SVA
DSV
AKS 38
AKS 38
HP vapour refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant � SVA
SNV SVA SVA
Oil
� SVA � BSV
➀ Stop valve
➁ Stop valve � SVA � QDV
SVA
To refrigerant pump
➂ Stop valve
➃ Quick closing oil drain valve Danfoss
Oil receiver
Hot gas in
➄ Regulating valve Tapp_0089_02
08-2006 � REG
➅ Safety relief valve
In ammonia systems immiscible oil is used. As the Then drain the oil using the quick closing oil
oil is heavier than liquid ammonia, it stays in the drain valve QDV ➃, which can be closed quickly
bottom of the liquid separator and is unable to after oil evacuation and when ammonia starts to
return to the compressor via the suction line. come out.
Therefore, oil in ammonia systems is normally Stop valve SVA ➂ between QDV and the receiver
drained from the liquid separator into the oil must be installed. This valve is opened before
receiver. It makes separation of oil from ammonia evacuation of oil and closed afterwards.
easier. Necessary precautions during drain of oil from
When draining the oil, close the stop valve ➀ and ammonia should be taken.
➁, and open the hot gas line, allowing the hot gas
to increase the pressure and heat up the cold oil.
Technical data Quick closing drain valve - QDV
Material Housing: steel
Refrigerants Commonly used with R717; applicable to all common non-flammable refrigerants.
Media temp. range [°F] –58 to 302
Max. working pressure [psig] 580
Size [in.] ½
EVM
SVA AKS 41
HP vapour refrigerant
SFA SFA SVA
HP liquid refrigerant SNV
� MLI SVA ICM ICS SVA From
Liquid/vapour mixture FIA receiver
of refrigerant DSV
LP vapour refrigerant
LP liquid refrigerant
� HE AKS 38
Liquid separator
LLG
➀ Stop valve
AKS 38
➁ Solenoid valve
➂ Regulating valve
➃ Heat exchanger
➄ Sight glass � REG SVA SVA SNV
Oil stays on top of the refrigerant, and the level Refrigerant could also be taken from pump
fluctuates together with refrigerant level. discharge lines. In this case it doesn’t really
matter if the refrigerant is taken from the working
In this system the refrigerant moves from the level or not.
liquid separator into the heat exchanger ➃ due
to gravity.
6.4
Summary
Thermosyphon cooling, ORV Compressor All types of refrigeration Oil is cooled by refrigerant Require extra piping and HP
plants without loss of installation liquid receiver installed on
Oil seperator
Oil cooler
Oil cooler
To oil cooler
KDC PDC
Requires no discharge check It is necessary to install
Compressor
valve, pressure drop lower check valve in the suction
Screw compressors (should than ICS solution. line, no change of setting
Oil seperator
To oil cooler
KDC+EVM NC NO
As previous, but installation Requires external piping, no
Compressor
PDC
of the check valve in the change of setting possible
suction line is not necessary.
Oil seperator
From oil
cooler
To oil cooler
QDV
Oil receiver
Liquid separator
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7. Safety systems All industrial refrigeration systems are designed Pressure limiter is a device that protects against
with different safety systems to protect them high or low pressure with automatic resetting.
against unsafe conditions, like excessive pressure.
Any foreseeable excessive internal pressure Safety pressure cut out
should be prevented or relieved with minimum Safety switches are designed for limiting the
risk for people, property and the environment. pressure with manual resetting.
Requirements on the safety systems are heavily Liquid level cut out is a liquid level actuated
controled by authorities, and it is therefore device designed to prevent against unsafe liquid
always necessary to verify the requirements in levels.
the local legislation in various countries.
Refrigerant detector is a sensing device which
Pressure relief device e.g. pressure relief valves responds to a pre-set concentration of refrigerant
are designed to relieve excessive pressure gas in the environment. Danfoss produces
automatically at a pressure not exceeding the refrigerant detectors type GD, please see specific
allowable limit and reseat after the pressure has application guide for more information.
fallen below the allowable limit.
7.1 Safety valves are installed in order to prevent Main parameters for safety valves are the relief
Pressure Relief Devices the pressure in the system from rising above the pressure and reseating pressure. Normally the
maximum allowable pressure of any component relief pressure should not exceed more than 10%
and the system as a whole. In case of excessive of the set pressures. Furthermore, if the valve
pressure, safety valves relieve refrigerant from the does not reseat or reseats at too low a pressure,
refrigeration system. there can be significant loss of system refrigerant.
From
condenser
� MLI
OIL LEVEL
SVA
From
discharge
line � SFA � SFA
SVA
SVA SNV
� DSV
Receiver
LLG
AKS 38
HP vapour refrigerant
HP liquid refrigerant
SNV
➀ Double stop valve
➁ Safety relief valve SVA SVA
Pressure relief devices should be installed on all Please note: Some countries do not allow
vessels in the systems, as well as on compressors. installation of u-trap.
Generally, back pressure dependent safety relief Outlet pipe from the safety valve should be
valves (SFA) are normally used. Safety valves designed in such a way that people are not
should be installed with a changeover valve endangered in the event that refrigerant is
DSV ➀, to enable the servicing of one valve whilst relieved.
the other is still in operation.
Pressure drop in the outlet pipe to the safety
Pressure relief devices should be mounted close valves is important for the function of the
to the part of the system they are protecting. In valves. It is recommended to check the relative
order to check if the relief valve has discharged to standards for recommendations on how to size
the atmosphere a u-trap filled with oil and with a these pipes.
sight glass MLI ➃ mounted can be installed after
the valve.
Technical data Safety relief valve - SFA
Material Housing: special steel approved for low temperature operation
Refrigerants R717, HFC, HCFC, other refrigerants (depending on the sealing material compatibility)
Media temp. range [°F] –22 to 212
Test pressure [psig] Strength test: 624
Leakage test: 363
Set pressure [psig] 145 to 580
� BSV
� POV
� MLI
� �
SFA SFA
SCA
Compressor
� DSV To condenser
Oil separator
HP vapour refrigerant From
evaporator SVA
LP vapour refrigerant
Oil
➀ Pilot-operated internal
safety valve
➁ Internal safety valve
➂ Double stop valve
SVA
➃ Sight glass Danfoss
Tapp_0100_02
04-2006 EVRAT+FA
➄ Safety relief valve
To relieve refrigerant from high pressure If a stop valve is mounted in the discharge line
side to low pressure side only back pressure from the oil separator, it is necessary to protect
independent relief valves should be used (BSV/ the oil separator and the compressor against
POV). excessive pressure caused by external heat or
compression heat.
BSV ➁ can act either as a direct relief valve with
low capacity or as a pilot valve for POV ➀ main This protection can be achieved with standard
valve. When the discharge pressure exceeds the safety relief valves SFA ➄ combined with a
set pressure, BSV will open the POV to relieve change over valve DSV ➂.
high pressure vapour into the low pressure side.
The back pressure independent relief valves are
installed without change over valve. In case it is
necessary to replace or readjust the valves, the
compressor has to be stopped.
Technical data Safety relief valve - BSV
Material Housing: special steel approved for low temperature operation
Refrigerants R717, HFC, HCFC and other refrigerants (depending on the sealing material compatibility)
Media temp. range [°F] –22 to 212 as an external safety relief valve
–58 to 212 as a pilot valve for POV
Set pressure [psig] 145 to 363
Test pressure [psig] Strength test: 624
Leakage test: 363
7.2
Pressure and Temperature
Limiting Devices
�
RT 107 �
HP vapour refrigerant
From liquid RT 5A
LP vapour refrigerant separator/ SVA
Oil evaporator
To oil separator
FIA
➀ Low pressure cut-out
➁ Low differential pressure Compressor
Danfoss
cut-out Tapp_0101_02
7.3
Liquid Level Devices
� AKS 38
Liquid/vapour mixture
of refrigerant SNV
LP vapour refrigerant SVA From
LP liquid refrigerant SVA evaporator
SVA
SVA
➀ High level switch To evaporator Danfoss
➁ Low level switch QDV Tapp_0102_02
09-2007
Vessels on the high pressure side and low A high level switch is installed to protect
pressure side have different liquid level switches. compressors against liquid hammering.
High pressure receivers only need to have low Liquid level sight glass LLG for visual level
level switch (AKS 38) in order to guarantee indication should also be installed.
minimum refrigerant level to feed expansion
devices. LLG liquid level indicators for low pressure vessels
may require that a sight adapter is mounted
Sight glass LLG for visual monitoring of the liquid which makes it possible to observe the level,
level can also be installed. even though there may be a certain amount of
frost on the liquid level indicator.
Low pressure vessels normally have both low
and high level switches. The low level switch is
installed to make sure that there is sufficient head
of refrigerant to avoid cavitation of pumps.
7.4
Summary
Solution Application
Safety Valves
Safety valves SFA + change over valve DSV Protection of vessels, compressors, and heat
exchangers against excessive pressure
Receiver
Overflow valve BSV + pilot operated overflow Protection of compressors and pumps against
valve POV excessive pressure
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http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning/Products/Documentation.htm
Tapp_0108_02
operating range, fig. 8.2.
H H1
Danfoss
09-2007
If the flow is too low, the motor heat may Q -H
evaporate some of the refrigerant and result in
dry running or cavitation of the pump. H2
8.1 Pumps are easily damaged by cavitation. To avoid For example, incorrect operations on the
Pump Protection with cavitation, it is important to maintain sufficient evaporators may cause increased flow through
Differential Pressure Control positive suction head for the pump. To achieve the pump, the low level switch may fail, and the
enough suction head, low level switch AKS 38 is filter before the pump may be blocked, etc.
installed on the liquid separator.
All these may lead to cavitation. Therefore, it is
However, even if the low level switch is installed necessary to shut down the pump for protection
on the liquid separator is kept above the when the differential pressure drops below H2 in
minimum acceptable level, cavitation can still fig. 8.2 (equivalent to Qmax).
occur.
AKS 38
AKS 38
SNV SVA
Liquid/vapour mixture
of refrigerant � SVA
REG
LP vapour refrigerant REG
LP liquid refrigerant
� SVA SVA
SVA
➀ Stop valve � FIA � FIA
SVA
➁ Filter
➂ Differential pressure switch �
�
➃ Check valve RT 260A QDV RT 260A
➄ Stop valve Refrigerant
pump BSV
➅ Stop valve � NRVA
➆ Filter
➇ Differential pressure switch BSV SVA
� NRVA
➈ Check valve � SVA To evaporator
Stop valve
Differential pressure controls are used for Since pressure drop can lead to cavitation, it
protection against too low pressure difference. is recommended to install a 500µ mesh. Finer
RT 260A ➂ and ➇ are supplied without a timing meshes could be used during the cleaning up,
relay and cause a momentary cut-out when the but be sure to take into account the pressure
differential pressure drops below the pressure drop when designing the piping. Additionally, it
controls setting. is necessary to replace the mesh after a period of
time.
The filters FIA ➁ and ➆ are installed on the pump
line to remove particles and protect automatic If a filter is installed in the discharge line, pressure
control valves and pumps from damage, drop is not as crucial and a 150-200µ filter can
blockage, and general wear and tear. The filter be used. It is important to note that in this
can be installed in either suction line or discharge installation, particles can still enter the pump
line of the pump. before being removed from the system.
If the filter is installed in the suction line before The check valves NRVA ➃ and ➈ are installed on
the pump, it will primarily protect the pump the discharge lines of the pumps to protect the
against particles. This is particularly important pumps against reverse flow (pressure) during
during initial clean-up during commissioning. standstill.
Technical data Differential pressure control - RT 260A/252A/265A/260AL
Refrigerants R717 and fluorinated refrigerants
Enclosure IP 66/54
Ambient temperature [°F] –58 to 158
Regulating range [psig] 1.4 to 159.5
Max. working pressure [psig] 319/609
8.2 The most common way to keep the flow through Even if the liquid supply to all evaporators in the
Pump Bypass Flow Control the pump above the minimum permissible value system is stopped, the bypass line can still keep a
(Qmin in fig. 8.2) is to design a bypass flow for the minimum flow through the pump.
pump.
The bypass line can be designed with regulating
valve REG, differential pressure overflow valve
OFV, or even just an orifice.
Application example 8.2.1: Danfoss
Pump bypass flow control with Tapp_0110_02
09-2007
REG
To AKS 41
compressor SVA From
suction line SFA SFA SVA evaporator
SNV
AKS 38
AKS 38
SNV SVA
8.3 It is of great importance to some types of By using pilot controlled servo valve ICS and pilot
Pump Pressure Control pump circulation systems that a constant valve CVPP, it is possible to maintain a constant
differential pressure can be maintained across differential pressure across the pump, and
the permanently set throttle valve before the therefore a constant differential pressure across
evaporator. the throttle valve.
Application example 8.3.1:
Danfoss
Pump differential pressure Tapp_0111_02
control with ICS and CVPP 09-2007
To AKS 41
compressor SVA From evaporator
suction line SVA
SFA SFA
SNV SVA From receiver
SVA
DSV
AKS 38
LLG Liquid separator
AKS 38
CVPP
SNV SVA � SVA
SVA SVA � ICS � SVA
SVA
FIA FIA
Liquid/vapour mixture
RT 260A RT 260A
of refrigerant
LP vapour refrigerant QDV BSV
LP liquid refrigerant Refrigerant
pump
NRVA NRVA
➀ Stop valve
➁ Differential pressure BSV
SVA
SVA
To evaporator
regulator
➂ Stop valve
8.4
Summary
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http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning/Products/Documentation.htm
9. Others Water, acids and particles appear naturally in Cooling of the bearings is reduced due to less oil
fluorinated refrigeration systems. Water may circulating through the bearing gap. This causes
9.1 enter the system as a result of installation, these components to get hotter and hotter. Valve
Filter Driers in service, leakage, etc.. plates start to leak by causing higher discharge
Fluorinated Systems superheating effect. As the problems escalate the
Acid is formed as a result of the breakdown of the compressor failure is imminent.
refrigerant and oil.
Filter driers are designed to prevent all the above
Particles usually result from soldering and circumstances. Filter driers serve two functions:
welding residue, the reaction between refrigerant drying function and filtering function.
and oil, etc.
The drying function constitutes the chemical
Failure to keep the contents of acids, water and protection and includes the adsorption of water
particles within acceptable limits will significantly and acids. The purpose is to prevent corrosion of
shorten the lifetime of the refrigeration system the metal surface, decomposition of the oil and
and even burn out the compressor. refrigerant and avoid burn-out of motors.
Too much moisture in systems with evaporating The filter function constitutes the physical
temperatures below 0°C could form ice which protection and includes retention of particles and
may block control valves, solenoid valves, filters, impurities of any kind. This minimizes the wear
and so on. Particles increase the wear-and-tear and tear of the compressor, protects it against
of the compressor and valves, as well as the damage and significantly prolongs its life.
possibility of creating a blockage. Acids are
not corrosive if there is no water. But in water
solution, acids can corrode the pipe work and
plate the hot bearing surfaces in the compressor.
Oil separator
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant Receiver
Oil
➀ Filter drier
➁ Filter drier � SVA
SNV
➂ Filter drier � DCR
➃ Stop valve SVA
�
SGRI
➄ Stop valve � SVA
➅ Stop valve SNV
➆ Sight glass � DCR
TE �
➇ Sight glass Evaporator SVA SGRI
➈ Sight glass � SVA
Stop valve Danfoss
SNV
Stop valve Tapp_0116_02 � DCR
12
04-2006
�
Stop valve SVA SGRI
For fluorinated systems, filter driers are normally DA - 30% molecular sieve and 70% activated
installed in the liquid line before the expansion alumina solid core suitable for clean up after
valve. In this line, there is only pure liquid flow compressor burn-out and compatible with
through the filter drier (unlike the two-phase flow CFC / HCFC / HFC refrigerants.
after the expansion valve). In addition to the above normal solid cores,
Danfoss also provide other customer-tailored
The pressure drop across the filter drier is small,
solid cores. And Danfoss also provide filter driers
and the pressure drop in this line has little
with fixed solid cores. For more information,
influence on the performance of the system. The
please refer to the product catalogue or contact
installation of filter drier could also prevent ice
your local sales companies.
formation in the expansion valve.
In industrial installations the capacity of one filter The sight glass with indicator for HCFC/CFC, type
drier is not normally sufficient to dry the whole SGRI, is installed after the filter drier to indicate
system, therefore several filter driers could be the water content after drying. Sight glasses with
installed in parallel. indicator for other types of refrigerants can also
be provided. For more information, please refer
DCR is a filter drier with interchangeable solid
to Danfoss product catalogue.
cores. There are three types of solid cores: DM, DC
and DA.
DM - 100% molecular sieve solid core suitable
for HFC refrigerants and CO2;
DC - 80% molecular sieve and 20% activated
alumina solid core suitable for CFC & HCFC
refrigerants and compatible with HFC
refrigerants;
Technical data Filter drier - DCR
Refrigerants CFC/HFC/HCFC/R744
Material Housing: steel
Max. working pressure [psig] HP: 667
Operating temp. range [°F] –40 to 160
Solid cores DM/DC/DA
9.2 In many respects CO2 is a far less complicated In the evaporator, when the liquid CO2 vaporizes,
Filter Driers in CO2 Systems refrigerant, but it does have some unique the water solubility in the refrigerant decreases
features compared with other common significantly especially when the circulation ratio
refrigerants. One such feature is the water is near to one. This brings a risk of creating free
solubility in CO2. As shown in the figure below, water. If this happens and the temperature is
there is little difference between the solubility below 32°F, the free water will freeze, and the ice
in both the liquid and vapour phases of R134a. crystals may block control valves, solenoid valves,
However, with CO2 this difference is quite filters and other equipment.
significant.
Installing filter driers is still the most efficient
What happens in fluorinated system will also method to avoid the above mentioned freezing,
happen in CO2 systems when water, acids and blockages and chemical reactions. And the
particles are present in the system, e.g. blockage zeolite type filter drier commonly used in
by particles and corrosion by acids. fluorinated systems has proven to be effective for
CO2 systems. To install filter driers in a CO2 system,
Furthermore the unique water solubility of CO2 the unique water solubility should also be taken
will increase the risk of freezing in CO2 systems. into consideration.
Water solubility in CO 2
1000 Liquid
Maximum solubility [ppm}
100 Vapour
R134a
(mg/kg)
10
Danfoss
Tapp_0117_02
1
04-2006 -50 -30 -10 10 [°C]
Oil separator
NH3 in
Condenser
Receiver
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture Liquid Separator
of refrigerant Expansion
LP vapour refrigerant valve 1
LP liquid refrigerant
Oil
� SVA
� SVA
➀ Stop valve SNV
➁ Filter drier � DCR
Danfoss
➂ Sight glass Evaporator
� Tapp_0118_02
SGRN 04-2006
➃ Stop valve
To install a filter drier in a CO2 system, the In a CO2 pumped liquid circulation systems, filter
following criteria should be considered: driers are recommended to be installed on the
Relative Humidity liquid lines before evaporators. On these lines,
As shown in the figure below, when the RH RH is high, there is no two phase flow, and it’s not
is too low, the capacity of the filter drier sensitive to pressure drop.
decreases quickly.
Installation in other positions is not
Pressure Drop recommended for the following reasons:
The pressure drop across the filter drier should 1. In the compressor-condenser-expansion valve
be small. And the system performance should loop the RH is low. In the liquid separator,
not be sensitive to this pressure drop. more than 90% water exists in the liquid phase
Two Phase Flow because of the much lower solubility of
Two phase flow through the filter drier should vapour CO2 compared with liquid. Therefore,
be avoided, which brings risk of freezing little water is brought into the compressor
and blocking because of the unique water loop by the suction vapour. If filter driers are
solubility characteristics. installed in this loop, the drier will have too
little capacity.
Relative drier capacity 2. In the wet suction line there is a risk of
Molecular Sieves “freezing” because of the two phase flow as
100 mentioned.
3. In the liquid line before the refrigerant pumps,
80 pressure drop increases the risk of cavitation
Relative capacity [%]
to the pumps.
60
If the capacity of one filter drier is not enough,
40 several filters driers in parallel could be
considered.
20
0
Danfoss 0 20 40 60 80 100
Tapp_0119_02
04-2006 Relative humidity - RH [%]
Compressor
Oil separator
NH3 in
➀ Filter drier
➁ Filter drier � SVA
➂ Filter drier � DCR SNV
➃ Stop valve �
SVA SGRI
➄ Stop valve � SVA
➅ Stop valve
SNV
➆ Sight glass � DCR
➇ Sight glass TE �
Evaporator SVA SGRI
➈ Sight glass � SVA
Stop valve
� DCR SNV
Stop valve Danfoss
Tapp_0120_02 12 �
Stop valve 04-2006 SVA SGRI
In a CO2 DX system, the water concentration is 1. In the suction line and discharge line, it is
the same throughout the system, so the RH is sensitive to the pressure drop, as well as the
only up to the water solubility of the refrigerant. high risk of freezing in the suction line. Filter
driers are not recommended to be installed
Although the RH in the liquid line before the here although the RHs are high.
expansion valve is relatively small because of the 2. In the liquid line after the expansion valve,
high water solubility of the high temperature installation of filter drier should also be
liquid CO2, it’s still recommended that filter driers avoided because of the two phase flow.
be installed on this line (same position as in
fluorinated system) for the following reasons:
9.3 The issue of water in ammonia systems is unique Basically, there are three ways to deal with water
Water Removal compared with fluorinated systems and CO2 contamination:
for Ammonia Systems systems: Change the charge
The molecular structure of ammonia and water This is suitable for systems with small charges
are similar, both small and polar and as a result (e.g. chillers with plate type evaporators), and
both ammonia and water are completely soluble. it should comply with local legislation.
As a result of the similarity of ammonia and water Purging from some evaporators
molecular, there has been no efficient filter drier This is suitable for some gravity driven systems
for ammonia. Furthermore, because of the high without hot gas defrost. In these systems,
solubility of water in ammonia, free water is water remains in the liquid when ammonia
difficult to extract from the solution. vaporizes, and accumulates in the evaporators.
Water rectifier
Water and ammonia will co-exist and act as a Part of contaminated ammonia is drained
kind of zeotropic refrigerant, whose saturated P-T into the rectifier, where it is heated, with the
relationship is no longer the same as anhydrous ammonia vaporising and the water drained.
ammonia. This is the only way of removing water for
pumped liquid circulation systems.
These are factors as to why ammonia systems
are seldom designed as DX systems: on one For more information on water contamination
hand, the liquid ammonia is hard to completely and water removal in ammonia refrigeration
vaporize when water is present, which will lead systems, please refer to IIAR bulletin 108.
to liquid hammer; on the other hand, how can a
thermostatic expansion valve function correctly It is necessary to mention that there is a down
when the saturated P-T relationship changes? side to too low water content - the possibility of
a special kind of steel corrosion. However it is not
Pumped liquid circulation systems could well likely in a real plant.
avoid the potential damages of water to the
compressors. With only vapour entering in the
suction line, liquid hammer is avoided; and so
long as there is not too much water in the liquid,
the vapour will contain nearly no water
(< the recommended max. of 0.3%), which could
effectively avoid the oil pollution by water.
LP vapour refrigerant
LP liquid refrigerant
Oil
Water
Sight
glass SVA
� NRVA
➀ Ball valve Sight
➁ Check valve Hot water in glass � REG � Contaminated
➂ Hand regulating valve Ball valve ammonia in
➃ Solenoid valve SVA
�
� REG
➄ Hand regulating valve EVRA+FA
➅ Pressure regulating valve
➆ Solenoid valve SVA
➇ Hand regulating valve
➈ Internal safety relief valve Danfoss
Hot water out QDV
Quick drain valve Tapp_0123_02
SVA 09-2007
Stop valve
9.4 Presence of Non Condensable Gases The capacity reduced in the condenser is a
Air purging systems Non-condensable gases are present in fact but is very hard to determine. Air purger
refrigeration systems at the outset of the manufacturers have provided some data, which
installation process, with pipes and fittings being indicates a 9-10 % capacity reduction for every
full of air. Therefore, if a good vacuum process is psi of increased condensing pressure. If a more
not undertaken air can remain within the system. accurate calculation is required, ASHRAE gives
some guidelines on how to estimate it
Additionally, air can enter the system as a result as well as some examples of research undertaken
of the system leaking, when the system is open with the results achieved. (HVAC Systems &
for maintenance, penetration through the system Equipment Manual, Non-Condensable Gases).
components, leaking at welded connections
where the pressure of the ammonia is lower than Other manufacturers estimate the risks and the
atmospheric pressure (below –29.2°F evaporating associated costs rising from the compressor
temperature), when adding oil, etc. side. As the condensing pressure and discharge
temperature increase, there will be higher risks
Moreover, impurities in the refrigerant and to the bearings due to oil problems, as well as an
/ or decomposition of the refrigerant or increase in the running cost of a compressor. The
the lubricating oil due to high discharge cost estimation is related to the compressor type
temperatures may generate non-condensable and size in the plant.
gases (e.g. Ammonia decomposes into nitrogen
and hydrogen). All in all the presence of non-condensable gases
is as undesirable as unavoidable and air purging
Location & Detection equipment is often used.
Non-condensable gases are contained within the
high pressure side of the refrigeration system, Air purging systems
mainly in the coldest and less agitated points in The air or non-condensable gases can be purged
the condenser. out of the system manually. This is performed
by maintenance personnel and may lead to
A simple way to check for the presence of non- excessive refrigerant losses.
condensable gases in the system, is to compare
the pressure difference between the actual Another way of purging is called refrigerated
condensing pressure, read at the pressure purging: gases coming from the sampling
gauge of the receiver and the saturated pressure points are cooled down inside a chamber with a
corresponding to the temperature measured at cooling coil in order to condense the refrigerant
the condenser outlet. and return it back to the system. The gases
then left in the chamber should be purged out
For example if 86°F is measured at the outlet to the atmosphere. The idea of cooling down
of the condenser in an ammonia system, the and condensation is to reduce the amount of
related saturated temperature is 155 psig and refrigerant released.
if the pressure gauge reading is 169.7 psig then
there is 14.5 psi difference and this is due to the The refrigerant used for the cooling coil could be
presence of non-condensable gases. the same as the refrigeration plant; it can also be
another different refrigerant.
Problems generated
The air tends to form a film over the condenser Location for purge connection is quite difficult
pipes isolating the heat transfer surface from and depends on the system and condenser type.
the refrigerant in the condenser. The result is a Below are some examples of purge points. In the
reduction of the condenser capacity and thus an picture, the arrows in the condenser coils and the
increase in the condensing pressure. The energy vessels represent the flow velocities. The length
efficiency will then decline and depending on the of arrow decreases as the velocity decreases.
condensing pressure, the potential for oil related
problems would increase. The air accumulation is shown by the black dots.
These places with high content of air are where
samples for purging should be taken.
� Evaporative condenser
�
� Receiver Verticle
shell-tube
Danfoss condenser
Tapp_0124_02
04-2006
From
discharge
line
� SV1 � RT 280A
SVA SVA
HP vapour refrigerant SVA
REG
HP liquid refrigerant REG �
Liquid/vapour mixture � FA+EVRA
EVRAT+
of refrigerant From SVA FA
refrigerant
LP liquid refrigerant pump � FA+EVRAT
Air Condenser
SVA
SVA
➀ Solenoid valve
➁ Solenoid valve
➂ Solenoid valve
➃ Float valve Danfoss
➄ Pressure switch Tapp_0125_02
09-2007 Receiver
➅ Solenoid valve
Steps for air purging:
1. Energise the solenoid valve EVRA ➀, so that 3. With the air that accumulates in the top of
low pressure liquid refrigerant enters the coil the vessel, the total pressure inside the vessel
and cools down the refrigerant contained in compared with the saturated pressure of the
the vessel. liquid refrigerant increases. When this pressure
reaches the setting on the pressure switch RT
2. Energise the solenoid valve EVRAT ➁ or ➂. 280A ➄ opens the solenoid valve EVRA ➅
Gas refrigerant with accumulated air is drawn and purges some air from the vessel.
into the vessel, inside which refrigerant vapour
condenses and air rises to the top of the
vessel. The float valve SV1 ➃ drains the
condensed liquid refrigerant automatically.
9.5 The free heat from de-superheating and/or The purpose of control is to coordinate heat
Heat Recovery System condensing in the condenser can be reclaimed recovery and refrigeration:
if there are requirements for heating in the 1. The basic function of refrigeration should be
plant. These include heating of air in offices or ensured whether the heat recovery is running
shops, heating water for washing or processing, or not. The condensing pressure should not be
preheating boiler feed water, etc. too high when heat recovery stops.
Furthermore for DX systems, the condensing
To make heat recovery an economic solution, pressure should not be too low either (See
it is important to ensure that the free heat and section 3).
the heating requirements match in terms of 2. The requirements for heat recovery, e.g.
timing, temperature level and heat flow. For the temperature and the heat flow, should be
example, for production of hot water, i.e. when fulfilled.
heat at high temperature level is required, the 3. Trouble free on/off control of the heat
de-superheating heat could be recovered; whilst recovery loop according to the demand.
for office heating, usually the recovery of all the
condenser heat could be considered. Heat recovery control needs very sophisticated
design, which may vary from plant to plant. The
A well designed control system is crucial following are some examples:
for trouble free and efficient operation of
refrigeration systems with heat recovery.
Tapp_0126_02
suction
of recovery heat exchanger and line
Danfoss
09-2007
condenser SVA
� REG
� EVRAT+FA
EVM Heat recovery
SVA condenser
Water in
� ICS
Water out
� NRVA SVA
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant CVP
Water
Tapp_0127_02
Control for series arrangement SVA condenser
of recovery heat exchanger and
Danfoss
09-2007
condenser
Water in
� RT 107
➀ Differential pressure
regulator
➁ Thermostat Condenser To receiver
➂ Check valve
This heat recovery system is applicable to central When this pressure drop exceeds the setting of
refrigeration plant with several compressors. differential pressure pilot CVPP(HP) on the servo
valve ICS ➀ partially opens and excess pressure
Provided only a small proportion of compressor gas is led direct into the main condenser.
capacity is used, all the discharge gas will pass
through the recovery condenser and then to the When the desired water or air temperature has
main condenser. been achieved by means of the heat recovery
condenser, the thermostat RT 107 ➁ activates the
The greater the amount of compressor capacity on/off pilot EVM, and the servo valve ICS ➀ will
used, the higher becomes the pressure drop in open fully.
the recovery condenser.
Application example 9.5.3:
Heat recovery
Tapp_0128_02
Control for parallel arrangement SVA condenser
of recovery heat exchanger and
Danfoss
09-2007
condenser
Water in
� RT 107
Water out SVA
� NRVA
To receiver
To download the latest version of the literature please visit the Danfoss internet site
http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning/Products/Documentation.htm
10. Appendix
10.1 Refrigeration systems are basically characterized By the way of supplying refrigerant to
Typical Refrigeration by the refrigeration cycle and the way of evaporators, the systems could be categorized
Systems supplying refrigerant to the evaporator. By into two basic types:
the refrigeration cycle, industrial refrigeration
systems are categorized into three types: Direct expansion system
The liquid/vapour mixture of refrigerant after
Single-stage system expansion is directly fed into evaporators.
This is the most basic cycle: compression-
condensation-expansion-evaporation. Circulated system
The liquid and vapour of refrigerant after
Two-stage system expansion are separated in a liquid separator and
In this kind of system, compression is undertaken only the liquid is fed into evaporators. The liquid
in two stages, typically by two compressors. circulation could be either gravity circulation or
Intermediate cooling is often used for optimizing pump circulation.
the performance of the system.
These types of refrigeration systems will be
illustrated by some examples:
Cascade system
This system is actually two basic cycles in
cascade. The evaporator in the high temperature
cycle acts also as the condenser of the low
temperature cycle.
Oil separator
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture Condenser
of refrigerant
LP vapour refrigerant
Oil
Receiver
Tapp_0129_02
➁ Oil control zone Thermostatic
➂ Condenser control zone
Danfoss
04-2006
Evaporator expansion
4
➃ Evaporator control zone valve
Single-stage refrigeration system with direct Please notice that thermostatic expansion
expansion is the most basic refrigeration valve can only keep a constant superheat,
system, which is very popular in air conditioning instead of a constant evaporating temperature.
and small refrigeration systems, fig.10.1. The Specifically, if no other controls happen, the
refrigeration cycle is: low pressure vapour evaporating temperature will rise with a load
refrigerant is compressed by the compressor increase and drop with a load decrease. Since
into the condenser, where the high-pressure a constant evaporating temperature is the
vapour condensates into high pressure liquid. aim of refrigeration, some other controls are
The high-pressure liquid then expands through also necessary, e.g. compressor control and
the thermal expansion valve into the evaporator, evaporator control. The compressor control
where the low pressure liquid evaporates into could adjust the refrigeration capacity of the
low-pressure vapour, and will be drawn into the system, and the evaporator control could secure
compressor again. a right flow of refrigerant to the evaporator.
Details of these two kinds of controls can be seen
The oil separator and the receiver have nothing in Section 2 and Section 5, respectively.
to do with the refrigeration cycle, but they are
important to the control: Theoretically, the lower the condensing
The oil separator separates and collects the oil temperature, the higher the refrigeration
from the refrigerant, then sends the oil back efficiency is. But in a direct expansion system,
to the compressor. This oil loop is important if the pressure in the receiver is too low, the
to secure safe and efficient running of the pressure difference across the expansion
compressor, e.g. good lubrication. And oil valve will be too low to provide enough flow
control (Section 6) is essential for keeping the oil of refrigerant. Therefore, controls should be
temperature and pressure at an acceptable level. designed to prevent a too low condensing
pressure, if the condensing capacity of a direct
The receiver could absorb/release refrigerant expansion system is possible to vary too much.
when the refrigerant contents in different This is discussed in Condenser Controls (Section
components vary with the load, or some 3).
components shut off for service. The receiver
could also maintain a supply of liquid refrigerant The main drawback of direct expansion is the low
at constant pressure to the expansion valve. efficiency. Since a certain superheat has to be
maintained:
The thermostatic expansion valve is controlled Part of the heat transfer area in the evaporator
by the superheat. This is of great importance for is occupied by vapour, and the heat transfer
the functions of both the evaporator and the efficiency is lower.
compressor:
The compressor consumes more power to
By keeping a constant superheat at the compress the superheated vapour than the
outlet of the evaporator, the thermostatic saturated vapour.
expansion valve supplies the right flow of
liquid refrigerant to the evaporator according This drawback becomes especially terrible in a
to the load. low-temperature refrigeration plant or a large
A certain superheat could ensure that only refrigeration plant. In these refrigeration systems,
vapour enters the compressor suction. circulated system with pump circulation or
Liquid droplet in the suction will cause liquid natural circulation is designed in order to save
hammering, which is equivalent to knocking energy.
in a motor.
Single-stage system Fig.10.2 Single-stage Refrigeration System with Pump Circulation and Hot Gas Defrost
with pump circulation of 2 3
1
refrigerant
Compressor
Oil separator
HP vapour refrigerant
HP liquid refrigerant Oil cooler Condenser
Liquid/vapour mixture
of refrigerant
Receiver
LP vapour refrigerant
LP liquid refrigerant Expansion
Oil valve 1
valve 2
Expansion
Liquid separator
➀ Compressor control zone
➁ Oil control zone Refrigerant
pump
Evaporator
➂ Condenser control zone 5 4
➃ Liquid level control zone Danfoss
Tapp_0130_02
➄ Evaporator control zone 04-2006
The circuit for a single-stage refrigeration system In circulation systems there is no superheating
as shown in figure 10.2 has many similarities to which can be used as a control variable for a
the DX system shown in figure 10.1. The main thermostatically controlled expansion valve
difference is that in this system the refrigerant operation.
vapour entering the compressor suction is
Expansion Valve 1 is usually controlled by the
saturated vapour instead of superheated vapour.
level in the liquid separator or sometimes by the
This is caused by the installation of a liquid level in the receiver/condenser. This is also called
separator between the evaporator and the liquid level control, which is discussed in Section 4.
compressor. In the liquid separator the liquid
If the evaporators are of a fin and tube design
from the liquid/vapour mix comes partly from
and used with air and if the evaporation
the evaporator and partly from expansion
temperature is below 0°C, a layer of frost/ice
valve 1. Only saturated vapour will pass to the
builds up on the evaporator surface which
compressor suction whilst only liquid is fed by
originates from the water/moisture present in
the refrigerant pumps to the evaporator.
the air. This layer must be removed regularly as
As the suction vapour is not superheated, the otherwise it will restrict the evaporator airflow
evaporation temperature will be lower than and reduce the evaporator capacity.
in a DX system. Due to the lower evaporation
Possible defrosting methods are hot gas,
temperature the compressor will work more
electrical heat, air and water. In figure 10.2 hot
efficiently. The evaporator will provide more
gas is used for defrosting. Part of the hot gas
capacity as its surface area is used totally for
from the compressor is led to the evaporator for
cooling and not partially to superheat the
defrosting.
refrigerant. Therefore a circulation system is more
efficient than a corresponding DX system. The hot gas warms up the evaporator and
melts the ice layer on the evaporator and
The line between the condenser inlet and the
simultaneously the hot gas condenses and
receiver is intended for pressure equalisation
becomes high-pressure liquid. Using an overflow
to ensure that the condensing liquid from the
valve, this high-pressure liquid can be returned to
condenser can run to the receiver without
the liquid separator in the suction pipe.
problems.
Hot gas defrosting can only be used in systems
In pump circulation systems it is important to keep
that contain at least three parallel evaporators.
the pump running, i.e. that the pump operation is
not unintentionally interrupted. Therefore pump During defrosting, at least two of the evaporators
control is important to ensure that the pump has (by capacity) must be cooling and a maximum of
the correct pressure difference, that a constant one evaporator should be defrosting – otherwise
supply of liquid is ensured and that the condition there is insufficient hot-gas available for the
of the pump is not compromised. This subject is defrosting process.
discussed in Section 7.
The method for switching between refrigeration
and defrosting cycles is discussed in the section
on evaporator control (Section 5).
Two-stage system A typical two-stage system is shown in fig 10.3. Compared with pump circulation, gravity
Part of the liquid refrigerant from the receiver circulation is driven by the thermosyphon effect
first expands into the intermediate pressure, in the evaporator, instead of the pump. Natural
and evaporates to cool the other part of liquid circulation is simpler and more reliable (on pump
refrigerant in the intermediate cooler. failure), but the heat transfer is generally not as
good as the pump circulation.
The intermediate-pressure vapour is then
directed into the discharge line of the low-stage Two-stage system could be theoretically
pressure, cools the low-stage discharge vapour, effective. However, it difficult to find a kind
and enters the high-stage compressor. of refrigerant that is suited for both the high
temperature and the low temperature in low-
The power used to compress this part of vapour temperature refrigeration systems.
from the suction pressure into the intermediate
pressure is saved and the discharge temperature At high temperatures, the refrigerant pressure
of the high-stage compressor is lower. will be very high, posing high requirement on the
compressor. At low temperatures, the refrigerant
So the two-stage system is especially suitable pressure may be vacuum, which leads to more
for low-temperature refrigeration system, for the leakage of air into the system (the air in the
high efficiency and low discharge temperature. system will reduce heat transfer of the condenser,
see Section 9.4). Therefore, cascade system may
The intermediate cooler could also supply be a better choice for low refrigeration system.
refrigerant to intermediate-temperature
evaporators. In fig. 10.3, the intermediate supply
refrigerant to the plate type evaporator by gravity
circulation.
Booster/low-stage
compressor
High-stage
Oil separator
compressor
Oil separator
Condenser
Oil cooler
Receiver
Inter-
HP vapour refrigerant mediate
cooler
HP liquid refrigerant Expansion
Liquid/vapour mixture Expansion valve
of refrigerant valve
LP vapour refrigerant
LP liquid refrigerant Evaporator
Intermediate pressure Liquid separator
liquid refrigerant
Intermediate pressure Refrigerant Evaporator
pump
vapour refrigerant
Other media Danfoss
Tapp_0131_02
(oil, water, etc.) 09-2007
Cascade system A cascade system consists of two separate example, the refrigerant could be NH3 for the
refrigeration circuits, as shown in fig. 10.4. A high temperature circuit and CO2 for the low
cascade condenser interconnected the two temperature circuit.
circuits by acting as both the condenser of the
high temperature circuit and the evaporator of This CO2/NH3 system needs less charge of
the low temperature circuit. ammonia and proves to be more efficient in low
temperature refrigeration than a similar two-
The refrigerant for the two circuits could be stage ammonia system.
different, and optimized for each circuit. For
Oil separator
Oil separator
Condenser
Oil cooler
Receiver
Receiver
Expansion
valve
Expansion
HP vapour refrigerant valve
HP liquid refrigerant Liquid separator
Liquid/vapour mixture Evaporator
Cascade
of refrigerant Liquid separator
condenser
LP vapour refrigerant
LP liquid refrigerant Refrigerant
Refrigerant pump
Other media pump
(oil, water, etc.)
10.2 Detailed below is the basic theory for ON/OFF and the technical terms used. Furthermore some
ON/OFF and and modulating control. The intension is to practical advice will also be given.
modulating controls provide a basci understanding of control theory
10.2.1 In some cases a control application in practice Normally ON/OFF is used because:
ON/OFF control can be achived with ON/OFF control. This means Low price, less complicated system, no
that the regulating device (valve, thermostat) feedback loop.
only has two positions:,contacts closed or open
This control principle is called ON/OFF control. It can be accepted that PV varies a little from
Historically ON/OFF was iimployed widely SP, along with that the ON/OFF device is
within refrigeration, particularly in refrigerators operating.
equipped with thermostats. The process has so big capacity that the ON/
OFF operation does not have any influence
However ON/OFF principles can also be used on PV
in advanced systems where PID principles are In systems with dead time, ON/OFF control
used. E.g. is an ON/OFF valve (i.e. Danfoss type can be advantageous
AKV/A) used to control superheat with PID
available parameters on the dedicated electronic In ON/OFF systems you will have a feed back,
controller. (Danfoss type EKC 315A) as for modulating systems, but, characteristic of
ON/OFF systems is that PV varies and the system
An ON/OFF controller will only react within some is not able to eliminate any offset.
given limit values, like e.g. Max and Min. Outside
these limit values an ON/OFF controller can not
carry out any action.
From
receiver
AKS 38
EVRA+FA
Liquid separator
10.2.2 The main difference between modulating like P, I and D. This gives a high degree of
Modulating control controls and ON/OFF systems is that modulating flexibility which again is very useful because the
systems will constantly react when there is a controller can then be adjusted to suit different
change of PV. applications.
From
ICM receiver
PV Liquid separator
measured
Danfoss
HP liquid refrigerant Tapp_0134_02
04-2006
LP liquid refrigerant
P-controller
In every controller a P component exists. In a P-
controller there is a linear relation between input Controller
and output.
50%
SP + x KP + y%
Controller
%
Tapp_0136_02
- + Danfoss
04-2006
SP + x y
PV %
Tapp_0135_02
- Y = Kp (PV – SP)+50%
Danfoss
04-2006
PV
Some controllers do not use PB, but Kp.
X = SP – PV → Y = Kp (PV-SP) The relation between PB and Kp is:
PB[%] = 100/Kp
Practical P-controllers are designed so when
SP=PV the controller must give an output that Please observe that PB can be bigger than 100%,
corresponds to the normal load of the system. corresponding to that Kp is less than 1.
Tapp_0137_02
between PV and SP of 6%. As Kp is assumed to
proportional band PB be 3.33, a deviation of 6% means that output
Danfoss
04-2006
increases by 6% x 3.33 = 20%, i.e. if PV rises to
y, % 46%, the output increases to 50% + 20% = 70%.
100
80 The deviation of the 6% is a deviation that a
P regulator cannot overcome. The resulting
60 (40, 50) deviation stems from the basic function of a P
40 regulator.
20
SP PV, % In order to achieve a minimum deviation it is
0 25 55 important that the regulation device (the valve) is
0 50 100 shaped so that the output (y) from the regulator
can control the process so that it is equal to the
SP = 40%, PB = 30% (Kp = 3.33)
standard average load. Then the deviation will
When PV = SP = 40% the regulator gives an always be as small as possible and will in time
output (y) of 50%. (This means that the valve has approach zero.
an opening degree of 50%).
10.2.2 I-controller
Modulating control The most important characteristic for an I- Basically the tendency to fluctuations is worse for
(continued) controller is that it eliminates offset, and that is an I-controller than a P-controller.
why it is used. I-controller continues to change
its output as long as offset exists. However the The ability to counteract on load changes is
ability to fully remove offset is linked to that it in slower for an I-controller than a P-controller.
practice, is proportioned correctly.
PI controller
The combination of advantages and When Ti has to be entered, it has to be
disadvantages for both P and I makes it compromise between stability and elimination
advantageous to combine P and I into a PI- of offset.
controller.
Decreased Ti (bigger integration influence) means
In a PI controller it would be possible to adjust: faster elimination of offset, but also increased
PB and Ti. Ti is normally entered in seconds or tendency to fluctuations.
minutes.
D-controller
The most important characteristic for a D- In controllers with D influence the Td can be
controller (derivative) is that it can react on adjusted. Td is normally entered in seconds or
changes. This also means that if a constant offset minutes.
is present, a D-controller will not be able to do
any action to remove the offset. D-component It has to be observed not to make Td too big, as
makes the system fast respond on load changes. then the influence, when e.g. changing SP, will be
too dramatic. During start-up of plants it may be
D effect improves stability and makes the system advantageous simply to remove the D influence.
faster. It does not have any significance for offset, (Td=0)
but it works to make tendency to fluctuations
smaller. D reacts on changes in the error and The above means that a D-controller will never
the loop reacts faster against load changes than be used alone. Its typical use is in combination as
without D. The fast reaction on changes means a PD or PID with its ability to damp fluctuations.
damping of all fluctuations.
PID-controller
The combination of all three components into a I component increases the tendency to
PID controller has become of general use. fluctuations.
D component damps the tendency to
The general guidelines / properties for a PID fluctuations and makes the control faster.
controller are: Bigger D (bigger Td) the stronger influence
Decreased PB improves offset (less offset), but on above, however until a specific limit. A
the stability is worse; too big Td will mean that it reacts too strong
I component eliminates offset. Bigger I (less Ti) on sudden changes, and the control loop
makes faster elimination of offset. becomes unstable.
Above shows variation of PB for PID control when becomes more unstable (oscillatory). When PB is
is influenced by SP is changed by +1 unit. From too big it becomes too slow.
above it is clear when PB is too small the systems
Above shows variation of Ti for PID control when becomes more unstable (oscillatory). When Ti is
is influenced by SP is changed by +1 unit. From too big it takes a very long time to eliminate the
above it is clear when Ti is too small the systems last offset.
Above shows variation of Td for PID control when big compared to the optimal (Td=12) the systems
is influenced by SP is changed by +1 unit. From become more unstable (oscillatory).
above it is clear when Td is either too small or too
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