Automatizacion de Refrigeracion

Automatizacin de instalaciones de refrigeracin comerciales
REFRIGERATION AND AIR CONDITIONING

El objeto de este manual consiste en presentar algunos ejemplos de utilizacin de los controles automticos Danfoss para instalaciones de refrigeracin comerciales. Se presenta una instalacin sencilla, con regulacin manual, como punto de partida de una automatizacin efectuada paso a paso y se da al mismo tiempo una breve descripcin del funcionamiento de cada control. Para material de enseanza suplementario, vase:
http://rc.danfoss.com/SW/RC_Training/En/Index.htm
Contenido
Pgina
Instalacin de refrigeracin con regulacin manual..................................................................................................................................................................... 2 Instalacin de refrigeracin con vlvula de expansin termosttica y condensador refrigerado por aire............................................................... 3 Refrigeracin con evaporador provisto de aletas .......................................................................................................................................................................... 4 Vlvula de expansin termosttica .............................................................................................................................................................................................. 5 Vlvula de expansin termosttica con distribuidor ............................................................................................................................................................. 5 Vlvulas de expansin....................................................................................................................................................................................................................... 6 Vlvula de expansin termosttica, mtodo de funcionamiento..................................................................................................................................... 7 Vlvula de expansin termosttica con carga MOP............................................................................................................................................................... 8 Presostato combinado de alta y baja .......................................................................................................................................................................................... 9 Presostato de baja presin y de alta presin............................................................................................................................................................................ 9 Presostato de alta, mtodo de funcionamiento....................................................................................................................................................................10 Termostato ..........................................................................................................................................................................................................................................11 Filtro secador......................................................................................................................................................................................................................................11 Visor .......................................................................................................................................................................................................................................................11 Vlvula de agua automtica..........................................................................................................................................................................................................12 Evaporador provisto de aletas .....................................................................................................................................................................................................13 Instalacin de refrigeracin con separador de aceite e intercambiador de calor ............................................................................................................14 Separador de aceite.........................................................................................................................................................................................................................15 Intercambiador de calor.................................................................................................................................................................................................................15 Instalacin de refrigeracin para cmara fra de gran tamao ...............................................................................................................................................16 Vlvula de solenoide........................................................................................................................................................................................................................17 Vlvula de cierre ................................................................................................................................................................................................................................17 Diagrama clave, corriente de control para instalacin de refrigeracin, figura 20...................................................................................................18 Arrancadores de motor ..................................................................................................................................................................................................................19 Instalacin de refrigeracin centralizada para temperaturas de cmara fra superiores al punto de congelacin .............................................20 Regulador de presin de evaporacin......................................................................................................................................................................................21 Vlvula de retencin ........................................................................................................................................................................................................................21 Diagrama clave, corriente de control para instalacin de refrigeracin de la figura 25 .........................................................................................22 Instalacin de refrigeracin para mostrador de presentacin del tipo de congelador..................................................................................................23 Presostato diferencial......................................................................................................................................................................................................................24 Regulador de presin de aspiracin..........................................................................................................................................................................................25 Regulador de presin de condensacin ..................................................................................................................................................................................25 Vlvula de presin diferencial ......................................................................................................................................................................................................26 Termostato de evaporador............................................................................................................................................................................................................26 Diagrama clave, instalacin de refrigeracin para vitrina de presentacin de productos congelados, figura 29 ........................................27 Diagrama de conexionado principal de los contactores....................................................................................................................................................28 Instalacin de refrigeracin para instalaciones de ventilacin ..............................................................................................................................................29
Danfoss A/S (RC-CMS / MWA), 03 - 2004
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Instalacin de refrigeracin con regulacin manual
Figura 1
Instalacin de refrigeracin con regulacin manual constituida por componentes usuales: Compresor (1) Condensador (2) Evaporador (3) Para mantener la temperatura t, de la cmara fra en el nivel deseado, es necesario equipar la instalacin con vlvulas ajustables (4) y (5) puesto que es preciso tener en cuenta las variaciones de las cargas aplicadas al evaporador y al condensador cuando la demanda de refrigeracin cambia. Por ejemplo, la instalacin no ser capaz de mantener la misma temperatura en verano y en invierno con vlvulas de regulacin ajustadas permanentemente y un compresor en funcionamiento continuo. Esto puede demostrarse fcilmente de manera grfica como se ilustra en la figura 1. Las lneas de trazo continuo representan el funcionamiento de verano y las lneas discontinuas el funcionamiento de invierno (por ejemplo, temperaturas de condensacin en invierno de +25C, y en verano de +35C).
Las curvas C representan la capacidad del compresor que sube cuando la temperatura de evaporacin to aumenta. Las curvas E representan la capacidad del evaporador que sube cuando la diferencial de temperatura tr to entre la temperatura ambiente (tr) y la temperatura de evaporacin (to) aumenta. Cuando la curva C (funcionamiento de invierno) y la curva E (funcionamiento de verano) se cortan, las capacidades del compresor, del condensador y del evaporador estn equilibradas. Como puede verse en la figura 1, la temperatura ambiente disminuir desde tr hasta tr' al bajar la demanda de refrigeracin desde Qo en verano hasta Qo' en invierno. Para satisfacer esta condicin, las capacidades del compresor, del condensador y del evaporador deben ser ajustadas, por ejemplo regulando el funcionamiento del compresor y reduciendo la circulacin del agua que llega al condensador, as como la circulacin del lquido refrigerante que llega al evaporador.
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Instalacin de refrigeracin con vlvula de expansin termosttica y condensador refrigerado por aire
Figura 2
Vlvula de expansin termosttica Vlvula de expansin automtica
En esta instalacin, el condensador refrigerado por agua ha sido sustituido por una unidad refrigerada por aire. Los condensadores refrigerados por aire son normalmente utilizados cuando el agua de enfriamiento no est disponible o donde la utilizacin de agua de enfriamiento est prohibido. Sustituyendo la vlvula manual delante del evaporador por una vlvula de expansin termosttica (1) se garantiza que el evaporador reciba continuamente la cantidad de refrigerante necesaria para mantener un recalentamiento constante en funcin de la carga. Naturalmente, esto presupone que la vlvula de expansin elegida est adaptada al evaporador en cuestin. En este caso, es importante que, en condiciones de carga mxima, la vlvula de expansin suministre exactamente la cantidad de refrigerante que el evaporador es capaz de evaporar. Adems, el reglaje de recalentamiento de la vlvula debe estar adaptado al evaporador. De manera general, se entiende que el recalentamiento es igual en C, a la temperatura del evaporador menos la temperatura de ebullicin del medio a la presin existente y con evaporacin total del lquido.
El recalentamiento que se produce en un evaporador est definido por tI ps = recalentamiento en C, expresin en la cual, tI es la temperatura medida en el punto del evaporador donde est situado el sensor de la vlvula de expansin, y ps es la presin medida en el mismo punto. (La presin en cuestin se transforma en C). Para ms detalles sobre el recalentamiento, vase pgina 7.
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Refrigeracin con evaporador provisto de aletas
Figura 3
El termostato tipo KP 61 (1) conecta y desconecta los ventiladores (2) en funcin de la temperatura ambiente. La vlvula de expansin termosttica tipo TE (3) con igualacin de presin externa regula la inyeccin del lquido en el evaporador, en funcin del recalentamiento, aunque de manera independiente de la prdida de carga a travs del evaporador. El distribuidor de lquido tipo 69G (4) distribuye el refrigerante lquido uniformemente en las secciones individuales del evaporador. El compresor se conecta y se desconecta con el lado de baja presin del presostato de alta y baja tipo KP 15 (5) en funcin de la presin de aspiracin. Adems, el lado de alta presin de este control asegura la proteccin contra una presin de condensacin excesiva desconectando el compresor, si es preciso, (por ejemplo cuando el ventilador es defectuoso o el flujo de aire est bloqueado (suciedad)).
El visor tipo SGN (6) seala cuando existe un contenido de humedad excesivo en el refrigerante y una circulacin insuficiente hacia la vlvula de expansin termosttica. El indicador cambia de color cuando el contenido de humedad es excesivo. La aparicin de burbujas de vapor en el visor puede indicar una carga insuficiente, un subenfriamiento insuficiente o una obturacin parcial del filtro.
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Vlvula de expansin termosttica
Figura 4
T2
La vlvula de expansin termosttica tipo T 2, cuyo bulbo est situado inmediatamente despus del evaporador, se abre cuando el recalentamiento aumenta. La presin aplicada al diafragma (1) aumenta debido al incremento de la temperatura del bulbo y la presin bajo el diafragma aumenta cuando la temperatura de evaporacin aumenta. La diferencial de presin que corresponde al recalentamiento del refrigerante, se manifiesta bajo la forma de una fuerza que intenta abrir la vlvula en contra de la Vlvula de expansin termosttica con distribuidor
fuerza antagnica del muelle (2). Si la diferencial, es decir el recalentamiento, es superior a la fuerza del muelle, la vlvula se abre. Es posible cambiar el conjunto de orificio, con el orificio (3) y el cono (4) de la vlvula. Para satisfacer cualquier exigencia de capacidad hay ocho tamaos distintos a elegir.
Figura 5
TE 5 + 69G
El distribuidor tipo 69G asegura una distribucin uniforme del refrigerante en las secciones paralelas del evaporador. El distribuidor puede instalarse, bien directamente en la vlvula de expansin termosttica como se representa, o bien en la tubera inmediatamente despus de la vlvula. Un distribuidor deber siempre estar montado de modo que la circulacin del lquido a travs de la tobera en los tubos del distribuidor sea vertical. Esto permite obtener que el efecto de la gravedad sobre la distribucin del lquido sea el ms reducido posible. Todos los tubos de distribucin deben tener exactamente la misma longitud.
En el caso de evaporadores con una prdida de carga importante, se utilizarn siempre vlvulas de expansin termosttica con igualacin de presin externa. Los evaporadores con distribuidor de lquido tendrn siempre una importante prdida de carga y, por tanto, estarn siempre dotados de una igualacin de presin externa.
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Vlvulas de expansin
Figura 6
Diagrama superior: Este diagrama representa un evaporador alimentado por una vlvula de expansin termosttica con igualacin depresin interna. El grado de abertura de la vlvula se regula por: La presin pb en el bulbo y en el tubo capilar que acta sobre el lado superior del diafragma y que est determinada por la temperatura del bulbo. La presin po en la conexin de descarga de la vlvula que acta bajo el diafragma est determinada por la temperatura de evaporacin. La presin del muelle (ps) que acta bajo el diafragma y que es ajustable manualmente. En el ejemplo ilustrado, la prdida de carga p en el evaporador, se mide bajo la forma de la presin de refrigerante expresada en C: 15 (20) = 5C. Cuando el muelle de la vlvula ha sido ajustado manualmente a una presin ps que corresponde a 4C, para conseguir el equilibrio entre las fuerzas que actan encima y bajo el diafragma, es preciso que pb = po + ps ~ 15 + 4 = 11C. Esto quiere decir, que el refrigerante ha de ser recalentado en 11 (20) = 9C antes de que la vlvula pueda empezar a abrirse.
Diagrama inferior: Se utiliza el mismo serpentn de evaporador alimentado ahora por una vlvula de expansin termosttica con igualacin de presin externa conectada con la tubera de aspiracin despus del bulbo. El grado de abertura de la vlvula se regula ahora por medio de: La presin pb en el bulbo yen el tubo capilar que acta sobre el lado superior del diafragma y que est determinada por la temperatura del bulbo. La presin po p a la salida del evaporador que acta bajo el diafragma y que est determinada por la temperatura de evaporacin y la prdida de carga en el evaporador. La presin ps del muelle que acta bajo al diafragma y que es ajustable manualmente. A condicin de que, como se ha indicado ms arriba, la prdida de carga p en el evaporador corresponda a 5C y la presin ps del muelle en la vlvula a 4C de presin de refrigeracin, resulta que pb = po p + p s ~ 15 5 + 4 = 16C. Esto quiere decir que el refrigerante ha de ser ahora recalentado en 16 (20) = 4C antes de que la vlvula pueda empezara abrirse. La magnitud de la carga contenida en el evaporador, y por tanto su capacidad, aumenta, puesto que se utiliza una parte ms pequea de la superficie del evaporador para el recalentamiento.
Conclusin: Se utilizarn siempre vlvulas de expansin termosttica con igualacin de presin externa con evaporadores que presentan una importante prdida de carga. Los evaporadores con distribuidor de lquido presentarn siempre una importante prdida de carga y, por tanto, se utilizar siempre en ellos, una igualacin de presin externa.
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Vlvula de expansin termosttica, mtodo de funcionamiento
Figura 7
La vlvula de expansin termosttica se controla por medio de la diferencia entre la temperatura del bulbo tb y la temperatura de evaporacin to. La vlvula se abre cuando la diferencial de temperatura sube, tb to = t, es decir cuando el recalentamiento del refrigerante sube, la vlvula tendr un mayor grado de abertura. Vase figura 6. La curva de trazo continuo po y la curva de trazo discontinuo pb indican la presin de vapor para el refrigerante y la carga respectivamente. La curva de trazo mixto po + ps representa la curva de presin de vapor de refrigerante po decalada paralelamente con una presin de muelle constante ps, que corresponde por ejemplo al reglaje efectuado en fbrica. A una temperatura de evaporacin to dada, una presin po + ps acta bajo el diafragma de la vlvula e intenta cerrar la vlvula. La presin pb acta encima del diafragma e intenta abrir la vlvula. La figura representa el equilibrio entre po + ps a la temperatura de evaporacin to y a la temperatura de bulbo tb respectivamente. En la prctica, el recalentamiento esttico tb to, es el mismo en
la totalidad de la gama de trabajo de la vlvula desde to' hasta to". Esto quiere decir, que cualquiera que sea la temperatura de evaporacin en la gama de trabajo, la vlvula de expansin termosttica regular la inyeccin del lquido para que el recalentamiento del refrigerante despus del evaporador se mantenga en el valor determinado por la presin ps del muelle. Si la diferencial entre la temperatura del bulbo tb y la temperatura de evaporacin to es inferior al recalentamiento esttico t, la vlvula se cierra: (tb to < t; pb < po + ps). Si la diferencial entre la temperatura de bulbo tb y la temperatura de evaporacin to es inferior al recalentamiento esttico t, la vlvula se abre: (tb to > t; pb > po + ps). Si la diferencial entre la temperatura de bulbo tb y la temperatura de evaporacin to es igual al recalentamiento esttico t, la vlvula est justo a punto de abrirse o a punto de cerrarse: (tb to = t; pb = po + ps).
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Vlvula de expansin termosttica con carga MOP
Figura 8
A veces, puede ser conveniente utilizar una vlvula de expansin termosttica en una gama de trabajo limitada, por ejemplo en una instalacin de refrigeracin dotada de un solo evaporador en la cual la refrigeracin a partir de un estado de igualacin completa o parcial de la temperatura ocurre slo excepcionalmente. (Depus de reparacin o de desescarche). En el caso de estas instalaciones, puede ser ms econmico utilizar un motor de compresor de potencia ms reducida, dimensionado de acuerdo con la carga que se le aplica despus de la refrigeracin inicial. Sin embargo, durante la fase de enfriamiento, este tipo de motor ser sobrecargado y se disparar la proteccin contra sobrecarga trmica.
Para eliminar este riesgo, es posible utilizar una vlvula de expansin termosttica con MOP (Presin de Funcionamiento Mxima). Esta vlvula de presin limitada empezar a abrirse slo a bajas temperaturas de evaporacin, tMOP puesto que la carga est adaptada para producir un codo en la curva de presin de vapor pb. Esto significa que el recalentamiento esttico t es extremadamente elevado a temperaturas de evaporacin superiores a tMOP, es decir, que en la prctica, la vlvula permanecer cerrada hasta que el compresor haya reducido suficientemente la presin de aspiracin para garantizar que el motor elctrico no ser sobrecargado.
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Presostato combinado de alta y baja
Figura 9
El presostato combinado de alta y baje tipo KP 15 est provisto de un conmutador unipolar (12). KP 15 Lado de baja presin (LP): El conector (10) de LP est conectado con el lado de aspiracin del compresor. Cuando la presin disminuye en el lado de baja presin, el circuito entre los terminales A y C se interrumpe. Haciendo girar el eje (1) de LP en el sentido horario se ajusta la unidad para que produza la desconexin (para abrir el circuito entre los terminales A y C) a una presin ms elevada. Haciendo girar el eje de diferencial (2) en el sentido horario, es posible ajustar la unidad para que restablezca la conexin (para cerrar el circuito entre los terminales A y C) a una diferencial ms pequea. Presin de arranque = presin de parada + diferencial. Seal de baja presin entre los terminales A y B. Lado de alta presin (HP): El conector (20) de HP est conectado con el lado de descarga del compresor. Cuando la presin sube en el lado de alta presin, el circuito se interrumpe entre los terminales A y C. Haciendo girar el eje (5) de HP se ajusta la unidad para que efecte la desconexin (para abrir el circuito entre los terminales A y C) a una presin ms elevada. La diferencial es fija. Presin de parada = presin de arranque + diferencial.
Presostato de baja presin y de alta presin
Figura 10
Presostato de baja tipo KP 1 Este control contiene un conmutador unipolar (SPDT) que interrumpe el circuito entre los terminales 1 y 4 cuando la presin en el elemento de fuelle (9) disminuye (cuando la presin de aspiracin baja), es decir, que el conector (10) debe ser conectado con el lado de aspiracin del compresor. Haceindo girar el eje de gama (1) en el sentido horario, se ajusta la unidad para que efecte la conexin - es decir, para cerrar el circuito entre los terminales 1 y 4 - a una presin ms elevada. Haciendo girar el eje de diferencial (2) en el sentido horario, se ajusta la unidad para que efecte de nuevo la desconexin - es decir, para abrir el circuito entre los terminales 4 y 1, a una diferencial ms pequea. Presin de arranque = presin de parada + diferencial.
Presostado de alta tipo KP 5 Este control est constituido de la misma manera. El fuelle y la escala estn diseados, naturalmente, para una presin de trabajo ms elevada. En este caso, el conmutador abre el circuito entre los terminales 2 y 1 cuando la presion sube en el elemento de fuelle (9), es decir, cuando la presin de condensacin sube (el conector debe ser conectado con el lado de descarga del compresor antes de la vlvula de cierre). Haciendo girar el eje de gama en el sentido horario, se ajusta la unidad para que efecte la desconexin - es decir, para abrir el circuito entre los terminales 2 y 1 a una presin ms elevada. Haciendo girar el eje de diferencial (2) en el sentido horario, se ajusta la unidad para que efecte de nuevo la conecin - es decir, para cerrar el circuito entre los terminales 2 y 1 a una presin ms pequea. Presin de parada = presin de arranque + diferencial.
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Presostato de alta, mtodo de funcionamiento
Figura 11
El presostato de alta tipo KP 5 est conectado con el lado de alta presin de la instalacin de refrigeracin e interrumpe el funcionamiento del compresor cuando la presin de condensacin toma un valor excesivo. El control contiene un conmutador unipolar (SPDT) accionado por la presin, en el cual, la posicin de los contactos depende de la presin que reina en el fuelle (9). Vanse dibujos A y B. Por medio del eje de reglaje (1), el muelle principal (7) puede ser ajustado para ejercer una contrapresin que se opone a la presin del fuelle. La fuerza orientada hacia abajo, que es la resultante de estas dos fuerzas, es transferida por una palanca (21) al brazo principal (3), que presenta una extremidad provista de un conmutador oscilante (16). El conmutador oscilante est mantenido en su posicin en el brazo principal por una fuerza de compresin que puede ser ajustada utilizando el eje (2) para cambiar la fuerza del muelle diferencial (8). Las fuerzas procedentes de la presin del fuelle, del muelle principal y del muelle diferencial son transferidas de esta manera al conmutador oscilante (16) el cual se inclina cuando las fuerzas se desequilibran en razn de los cambios de la presin del fuelle, es decir, de la presin de condensacin. El brazo principal (3) slo puede adoptar dos posiciones. En una posicin, se ejerce una fuerza sobre cada extremidad del brazo y se crean pares opuestos alrededor se su pivote (23). Vase dibujo A. Si la presin disminuye en el fuelle, el muelle principal ejerce una fuerza creciente sobre el brazo principal. Finalmente, cuando ha sido superado el contra-par procedente del muelle diferencial, el brazo principal se inclina y el conmutador oscilante (16) cambia instantneamente de posicin, lo que hace que la fuerza de compresin del muelle diferencial se site en una lnea prxima al punto de pivotamiento (23) del brazo. El contra-par procedente del muelle diferencial toma as un valor casi nulo. Vase figura B. La presin del fuelle debe ahora aumentar para superar la fuerza del muelle principal, porque el 10 RG00A505
par de fuerza del muelle alrededor del punto de pivotamiento (23) debe tambin disminuir hasta un valor nulo antes de que el sistema de accin brusca pueda volver a su posicin inicial. Al disminuir la presin del fuelle (vase figura A), el brazo principal se desplaza instantneamente a la posicin representada en la figura B cuando la presin en el fuelle toma el valor de la presin de parada menos al valor de la presin diferencial ajustada. Inversamente, el brazo principal se desplaza instantneamente desde la posicin de la figura B hasta la posicin de la figura A cuando la presin del fuelle alcanza la presin de parada = presin de arranque + presin diferencial. Vase tambin texto de las figuras 9 y 10 respecto al reglaje del tipo KP. El sistema de contactos diseado especialmente para que el contacto de cierre se desplace a la velocidad inicial de la accin brusca hasta el contacto fijo, mientras que el contacto de abertura se separa del contacto fijo a la velocidad mxima de la accin brusca. El sistema ha podido ser realizado mediante la utilizacin de un pequeo percutor (19) y de muelles de contacto adaptos con precisin. Los contactos (20) se cierran con una fuerza inferior a su fuerza de abertura, lo que significa que se eliminan prcticamente los rebotes durante el cierre de los contactos. La fuerza de mantenimiento de los contactos en la posicin de cierre es excepcionalmente elevada. Al mismo tiempo, el sistema realiza una funcin de abertura instantnea y por consiguiente la fuerza de mantenimiento se mantiene al 100% hasta la abertura. Por estos motivos, el sistema es capaz de funcionar con corrientes intensas y su funcionamiento no est perjudicado por los choques. En comparacin con los diseos tradicionales, el sistema ha dado resultados excepcionalmente favorables.
Manual
Termostato
Figura 12
KP 61
El termostato tipo KP 61 que est provisto de un conmutador unipolar de dos direcciones (12) cierra el circuito entre los terminales 1 y 4 cuando la temperatura del bulbo sube, es decir, cuando la temperatura ambiente sube. Haciendo girar el eje de gama (1) en el sentido horario, se Filtro secador
aumentan las temperaturas de conexin y de desconexin de la unidad. Haciendo girar el eje de diferencial (2) en el sentido horario, se reduce la diferencial entre las temperaturas de conexin y de desconexin.
Figura 13
DML / DCL
El filtro secador tipo DML / DCL tiene una carga sinterizada del tipo llamado de ncleo slido (3). Este ltimo est presionado por el muelle (2) contra la almohadilla de polister (4) y la placa ondulada perforada (5). Visor
La carga, o ncleo del filtro secador, consiste en un material que retiene eficazmente la humedad, los cidos dainos, las partculas extraas, los sedimentos, as como los productos de descomposicin del aceite.
Figura 14
SGI
El visor tipo SGI / SGN tiene un indicador de color (1) que pasa del verde al amarillo cuando el contenido de humedad del refrigerante rebasa el valor crtico. La indicacin de color es reversible, es decir, que el color vuelve del amarillo al
verde cuando la instalacin ha sido secada, por ejemplo, por medio del filtro secador. El visor de tipo SGI es para CFC, el visor de tipo SGN es para HFC y HCFC (R 22).
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Vlvula de agua automtica
Figura 15
WVFX
La vlvula automtica para agua, tipo WVFX se abre cuando la presin sube en el elemento de fuelle (1) es decir, cuando la presin de condensacin aumenta (el conector del crter del fuelle debe ser conectado con el lado de refrigerante del condensador).
Haciendo girar el mando (2) en el sentido antihorario se aprieta el muelle, lo que significa que la vlvula se abrir a una presin de condensacin ms elevada. Si se hace girar el mando en el sentido horario, la vlvula se abrir a una presin de condensacin ms baja.
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Evaporador provisto de aletas
Figura 16
El evaporador provisto de aletas est diseado para la circulacin forzada del aire sobre los serpentines paralelos del evaporador. La circulacin del aire deber efectuarse siempre de acuerdo con el principi de circulacin a contracorriente para que los serpentines del evaporador sean sometidos a una carga uniforme. Por consiguiente, la relacin entre la circulacin de aire y la circulacin de refrigerante deber siempre ser la que se representa en la figura que antecede. De esta manera, se asegura la diferencia de temperatura ms elevada (vase figura derecha) entre la temperatura tI del aire y la temperatura tf de la superficie del evaporador a la salida del refrigerante del evaporador. Es decir que el recalentamiento del refrigerante t ser rpidamente afectado por el cambio de temperatura del aire entrante (la carga) y en consecuencia dar rpidamente una seal a la vlvula de expansin termosttica para cambiar la inyeccin de lquido. Es importante que los serpentines del evaporador estn cargados de manera uniforme. Por ejemplo, con una circulacin de aire vertical orientada hacia abajo a travs del evaporador, el aire entrante aplica a los primeros serpentines del evaporador una carga superior a la que aplica a los siguientes serpentines. Los serpentines posteriores sern los ms cargados y por tanto determinarn en qu grado, la vlvula de expansin termosttica se abrir. Si una pequea cantidad de lquido refrigerante procedente del evaporador pasa por el punto donde est situado el bulbo, la vlvula se cerrar a pesar del hecho de que los primeros serpentines requieren un suministro de refrigerante lquido en razn de una carga ms importante, es decir, una evaporacin ms activa.
El bulbo de la vlvula de expansin termosttica no debe ser sometido a la influencia de efectos parsitos como por ejemplo una circulacin de aire a travs del evaporador y por tanto, el bulbo debe situarse en la tubera de aspiracin fuera de esta circulacin de aire. Si esto no es posible, habr que aislar el bulbo. Se obervar que se utiliza una vlvula de expansin termosttica con igualacin de presin externa.
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Instalacin de refrigeracin con separador de aceite e intercambiador de calor
Figura 17
En principio, en una instalacin de refrigeracin, el aceite debe permanecer en el compresor. Fuera del sistema puede ser ms perjudicial que favorable porque merma la capacidad del evaporador y del condensador. Igualmente, si el nivel del aceite en el crter toma un valor excesivamente bajo, se produce un riesgo de lubricacin insuficiente del compresor. La mejor proteccin contra estos inconvenientes consiste en instalar un separador de aceite eficaz, tipo OUB (1).
Adems, un intercambiador de calor tipo HE (2) presenta las siguientes ventajas: El recalentamiento del gas aspirado proporciona una mayor proteccin contra los golpeteos de lquido en el compresor y contrarresta la formacin de condensado o de escarcha sobre la superficie de las tuberas de aspiracin no aisladas. El subenfriamiento del lquido refrigerante contrarresta la formacin de vapor que reducira la capacidad de la vlvula de expansin termosttica. La economa de funcionamiento se mejorar frecuentemente porque se eliminan completa o parcialmente las fuentes de prdidas tales como las gotas de lquido no evaporado en el gas de succin y un subenfriamiento insuficiente del lquido refrigerante.
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Separador de aceite
Figura 18
OUB
El gas caliente a presin elevada se suministra al separador de aceite tipo OUB a travs del conector (1). A continuacin el gas circula alrededor del depsito de aceite (2) y a travs del filtro (3) donde se separa el aceite. El vapor, que contiene ahora poco aceite, sale del separador de aceite a travs del conector superior (4).
El aceite separado se recoge en la parte inferior del depsito de aceite (2) que est mantenido caliente por el vapor entrante. De esta manera, el aceite separado se almacena en estado caliente, es decir, con el contenido de refrigerante ms pequeo posible. Una vlvula del tipo de flotador (5) regula el retorno de aceite al compresor.
Intercambiador de calor
Figura 19
HE
El intercambiador de calor tipo HE ha sido diseado con el objeto de conseguir la mxima transmisin del calor con una mnima prdida de carga. La cmara externa en forma de espiral (4) lleva el lquido refrigerante caliente a contracorriente respecto a la circulacin del lquido refrigerante fro en la cmara interna (3). En el interior de la cmara interna estn instaladas secciones de aletas decaladas. El intercambiador de calor tipo HE se fabrica con latn y cobre y tiene dimensiones muy pequeas en proporcin a su capacidad de transmisin de calor. La cmara externa en forma de espiral
(4) impulsa el lquido refrigerante caliente sobre la totalidad de la superficie de transmisin de calor e impide la formacin de condensado en la camisa externa. Las secciones de aletas decaladas incorporadas en la cmara interna (3) producen una circulacin turbulenta en el vapor de refrigerante. Por tanto, la transmisin del calor entre lquido y vapor es extremadamente eficaz. Al mismo tiempo, la prdida de carga se mantiene en un nivel razonable.
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Instalacin de refrigeracin para cmara fra de gran tamao
Figura 20
Instalacin de refrigeracin completa para cmara fra de gran capacidad con temperatura superior al punto de congelacin
Para asegurar un cierre eficaz de la tubera de lquido durante los periodos de parada del compresor, ha sido instalada una vlvula de solenoide EVR (1) puesto que puede preverse que la temperatura del bulbo subir ms rpidamente que la temperatura de evaporacin y dar lugar a la abertura de la vlvula de expansin termosttica. La proteccin contra sobrecarga del evaporador durante los periodos de parada del compresor, se obtiene haciendo que la vlvula de solenoide se cierre al mismo tiempo que el compresor se para.
La lnea de lquido est equipada con vlvulas de cierre manual de tipo GBC (2) o BML para facilitar la sustitucin del filtro secador. La presin aplicada a los lados de alta y baja presin del compresor puede ser leda en los manmetros ilustrados. Los manmetros pueden ser desconectados utilizando las vlvulas de tres vas tipo BMT (3).
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Vlvula de solenoide
Figura 21
EVR
La vlvula de solenoide tipo EVR es una vlvula de cierre electromagntica servo-controlada. A travs de los orificios de igualacin (2) se iguala la presin aplicada al lado superior del diafragma (1) con la presin de entrada de la vlvula aplicada al lado inferior. Cuando la corriente energiza la bobina (3) el orificio piloto (4) se abre. Este orificio tiene una superficie de circulacin superior a la superficie total de los orificios de igualacin. La presin encima del diafragma es Vlvula de cierre
reducida por la circulacin a travs del orificio piloto hacia el lado de salida de la vlvula y el diafragma sube bajo el efecto la presin de entrada ms importante que se aplica a su lado inferior. Cuando s des energiza la bobina, el orificio piloto se cierra y el diafragma se desplaza hasta el asiento de vlvula al aumentar la presin que se le aplica a travs de los orificios de igualacin.
Figura 22
BM
Las vlvulas de cierre BM tienen una triple junta de diafragma (1) hecha de acero inoxidable. Una zapata de empuje (2) impide el contacto directo con el eje (3). El muelle (4), conjuntamente con el diafragma pretensazo, k es capaz de mantener la vlvula abierta a presiones de funcionamiento que pueden no ser superiores a pe = 1 bar.
El contraasiento de la cubierta (5) impide la penetracin de humedad. Las vlvulas estn disponibles en versiones de paso recto, y de tres vas de 1/4 pulg. Se puede obstruir la circulacin a travs del puerto lateral de la versin de tres vas dejando los otros puertos permanentemente abiertos.
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Diagrama clave, corriente de control para instalacin de refrigeracin, figura 20
Figura 23
El diagrama debe ser ledo de la parte superior a la parte inferior y de la izquierda a la derecha. Los circuitos individuales estn dibujados de tal manera que no existan cruces entre conductores. Los componentes que consumen energa se ilustran en la parte inferior del diagrama. Estos incluyen las bobinas de rel de los arrancadores del motor, las bobinas de solenoide, los motores de regulacin, etc. Los rels trmicos F del arrancador de motor estn representados en una posicin adyacente a los contactos entre los terminales 95 y 96. Se representa igualmente el rearme manual S. Los contactos K de rel auxiliar entre los terminales 13 y 14 se representan en la parte superior del diagrama. Las designaciones 13, 14, 95, 96 etc., corresponden a las que estn contenidas en la informacin Danfoss sobre contactores y arrancadores de motor. Las bobinas de rel K1 accionan los contactos auxiliares entre los terminales 13 y 14. Los contactos auxiliares estn dibujados en la posicin que tienen cuando la bobina est desenergizada Bajo el hilo neutro y bajo cada bobina de rel se indica en qu circuito los contactos auxiliares asociados pueden encontrarse. La designacin de terminal 13-14 es, por definicin, siempre la de un contacto de cierre (NO) mientras que la designacin de terminal 11-12 es siempre la de un contacto de abertura (NC).
El diagrama clave ha de ser ledo como sigue: Cuando se produce una elevacin de la temperatura en la cmara fra, estando cerrados los interruptores S1 y S2, el termostato tipo KP 61 establece el contacto entre los terminales 2 y 3, los rels K1 y K2 de los arrancadores de motor tipo CIT se energizan y arrancan los ventiladores del evaporador. Al mismo tiempo, los contactos auxiliares asociados con los circuitos 3 y 4 se cierran. El rel K3 del arrancador de motor del compresor tipo CIT se energiza si el presostato combinado de alta y baja tipo KP 15 establece el contacto entre los terminales 2 y 3, y si el interruptor S3 est cerrado. El compresor arranca y al mismo tiempo el contacto auxiliar del circuito 5 conecta la corriente con la bobina E de la vlvula de solenoide EVR situada en la tubera de lquido. La vlvula de solenoide se abre y el lquido refrigerante se inyecta en el evaporador, efectundose la regulacin por medio de la vlvula de expansin termosttica tipo TE.
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Arrancadores de motor
Figura 24
La gama de arrancadores de motor Danfoss de hasta 420 A est constituida por mdulos. Consiste en un mdulo bsico (contactor tipo CI) en el cual pueden adaptarse cuatro bloques de contactos auxiliares (tipo CB) segn las necesidades. Existe tambin una gama de rels trmicos (tipo TI). El diagrama de la izquierda representa un arrancador de motor con funcin de arranque-parada/ rearme. El contacto de arranque (tipo CB-S) lleva la designacin de terminales 13-14. El diagrama de la derecha representa un arrancador de motor con funcin de parada / rearme, controlado por un termostato, un presostato, o un aparato similar. Los arrancadores de motor estn equipados de un ret trmico que tiene tres bimetales calentados indirectamente. Gracias a un mecanismo de desconexin, los bimetales abren el interruptor desprovisto de rebote entre los terminales 95 y 96 en el caso de sobrecarga. Una importante asimetra de la intensidad de la corriente entre las tres fases del motor, activa un dispositivo de desconexin diferencial incorporado que asegura una abertura acelerada distinta de la que se produce en condiciones de
sobrecarga simtrica normal. La desconexin est parcialmente compensada en temperatura; hasta una temperatura de 35C se produce una compensacin de cualquier elevacin de la temperatura ambiente no producida por sobrecarga. Los arrancadores de motor estn disponibles en diversas versiones. Los ejemplos ilustrados estn provistos de un dispositivo de parada y rearme del ret trmico bloqueable manualmente, es decir, que los arrancadores deben ser rearmados manualmente despus de una desconexin trmica. Los materiales de las cajas son de resina termoplstica (CI) y baquelita/resina termoplstica (TI), y todos los contactos principales y auxiliares estn ejecutados en una aleacin de plata especial. Adems, todas las partes de hierro estn protegidas eficientemente contra la oxidacin. Danfoss tambin puede suministrar arrancadores suaves de tipo MCII e interruptores automticos de tipo CTI.
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Instalacin de refrigeracin centralizada para temperaturas de cmara fra superiores al punto de congelacin
Figura 25
La temperatura y la humedad relativa juegan un papel importante en la conservacin de productos alimenticios y los diversos artculos han de ser almacenados en las condiciones ms favorables. Por tanto, se utilizan cmaras fras que tienen temperaturas y humedades diferentes. Es preciso controlar, no solamente la temperatura ambiente, sino tambin la temperatura de evaporacin. En el ejemplo ilustrado, deben tenerse en cuenta las siguientes temperaturas:
Temp. ambiente Cmara para productos vegetales Cmara para carne troceada y ensaladas Cmara para carne +8C Temp. de Evaporacin +3C
aspiracin despus del evaporador en las cmaras fras de +8C y +5C de modo que las temperaturas de evaporacin se mantengan en +3C y 5C, respectivamente. El presostato de alta y baja tipo KP 15 (2) energiza y desenergiza el compresor a una presin de aspiracin convenientemente baja para mantener en 10C la temperatura de evaporacin en la cmara a 0C. Durante la parada del compresor, la vlvula de retencin, tipo NRV (3) impide que el refrigerante procedente de los evaporadores de las cmaras fras a +8C y +5C se condense en el evapordor ms fro, es decir en el condensador de la cmara a 0C. La vlvula de retencin tipo NRV (4) asegura la proteccin contra la condensacin del refrigerante en el separador de aceite y en la tapa superior del compresor, si estos componentes llegan a ser ms fros que el evaporador durante los periodos de parada de la instalacin.
+5C
5C
0C
10C
La temperatura ambiente en las tres cmaras fras es controlada por termostatos de tipo KP-62 que cierran y abren las vlvulas de solenoide EVR. Dos reguladores de temperatura de evaporacin, tipo KVP (1) regulan la circulacin en la tubera de
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Regulador de presin de evaporacin
Figura 26
KVP
El regulador de presin de evaporacin tipo KVP se abre cuando la temperatura sube por su lado de entrada, es decir, cuando la presin del evaporador sube (aumento de carga). Haciendo girar el tornillo de regulacin (1) en el sentido horario, se comprime el muelle (5) y la presin de abertura aumenta, es decir, que la temperatura de evaporacin sube. El regulador tiene un fuelle (10) del mismo dimetro que la placa de vlvula (2) .Esto significa que las variaciones depresin en el lado de salida del regulador no tienen ningn efecto sobre la regulacin automtica del grado de abertura, puesto que la presin aplicada a la parte superior de la placa de vlvula Vlvula de retencin
Figura 27
est equilibrada por la presin aplicada al fuelle. El regulador incluye tambin un dispositivo de amortiguacin (11) que hace que las pulsaciones de presin en la instalacin no tengan ningn efecto sobre el funcionamiento del regulador. Para facilitar el reglaje de la vlvula, esta ltima est provista de una conexin especial (9) para manmetro, que permite conectar o desconectar un manmetro sin tener que vaciar previamente la tubera de aspiracin y el evaporados.
NRV
La vlvula de retencin tipo NRV puede obtenerse en versin recta o angular, con conexiones abocardadas o para soldar cobre. El funcionamiento de la vlvula se controla slo por medio de la prdida de carga a travs de ella. NRV, versin de paso recto: La placa de vlvula est montada en un pistn de freno (1) que est mantenido contra el asiento de la vlvula por un muelle de fuerza reducida (2). Cuando la vlvula se abre, el volumen detrs del pistn de freno disminuye. Un agujero de
igualacin (ranura) permite que el refrigerante se escape lentamente hacia el lado de salida de la vlvula. De esta manera, el movimiento del pistn est frenado; este dispositivo hace que la vlvula sea perfectamente apropiada para ser utilizada en tuberas en las cuales pueden producirse pulsaciones de presin.
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Diagrama clave, corriente de control para instalacin de refrigeracin de la figura 25
Figura 28
El termostato tipo KP 62 situado en la cmara a +8C controla la vlvula de solenoide E1, tipo EVR, situada en la tubera de lquido, mientras que los otros dos termostatos tipo KP 62 situados en las cmaras a +5C y 0C, respectivamente, controlan los arrancadores de motor K1 y K3, tipo CIT, de los ventiladores de evaporados, y las vlvulas de solenoide K2 y K3, tipo EVR, de las tuberas de lquido. El presostato combinado de alta y baja KP 15 controla el arrancador de motor K4, tipo CIT, del motor del compresor. Para obtener este funcionamiento, es preciso que los interruptores manuales S1, S2 y S3 estn cerrados. Por tanto, el motor del compresor est controlado slo indirectamente por los termostatos de cmara, y es capaz, por ejemplo, de funcionar durante algn tiempo despus de que todos los termostatos han abierto sus contactos.
Sin embargo, puesto que es improbable que todos los termostatos de cmara abran sus contactos al mismo tiempo, esta forma de control dar lugar a un cierto grado de post-evaporacin que puede ser ventajoso respecto a los efectos del golpe de lquido en el compresor, aunque perjudicial respecto al final del perodo de refrigeracin. Cuando un termostato de cmara abre sus contactos, sigue producindose todava una ligera evaporacin y la carga del evaporados en cuestin va disminuyendo. Cuando el termostato de la cmara cierra de nuevo sus contactos, el efecto de la reduccin de la carga dificulta la penetracin del refrigerante no evaporado en la tubera de aspiracin durante el brusco cebado que se produce en el comienzo del perodo de funcionamiento del evaporados.
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Instalacin de refrigeracin para mostrador de presentacin del tipo de congelador
Figura 29
Puesto que esta instalacin funciona la mayor parte del tiempo a bajas temperaturas de evaporacin y puesto que su funcionamiento se interrumpe por medio del desescarche automtico, slo una o dos veces cada 24 horas, es ventajoso utilizar un motor elctrico de compresor que tiene una potencia que corresponde a las condiciones de funcionamiento normales, es decir, una carga relativamente pequea a bajas presiones de aspiracin. Sin embargo, despus del desescarche, este pequeo motor podra ser sobrecargado y podra quemarse. Como proteccin contra este riesgo, se ha previsto un regulador de presin de crter tipo KVL (1) que se abre en cuanto la presin de aspiracin antes del compresor ha disminuido suficientemente para evitar la sobrecarga del motor. Se utiliza el sistema de regulacin KVR (2) + NRD (3) para mantener una presin de condensacin constante y suficientemente elevada en el condensador refrigerado por aire a bajas temperaturas ambientes. Durante el funcionamiento de invierno, la temperatura ambiente disminuye y con ella, la presin de condensacin del condensador refrigerado por aire. El KVR efecta la regulacin en funcin de la presin de entrada y empieza a reducir la circulacin cuando la presin baja a un valor inferior al valor ajustado. Por consiguiente, el condensador se carga parcialmente con lquido y su superficie eficaz disminuye. De esta manera, se restablece la presin de condensacin requerida. Puesto que atarea real de la regulacin durante el funcionamiento de invierno consiste en mantener la presin del recipiente a un nivel apropiadamente elevado, el KVR se combina con una vlvula de presin diferencial tipo NRD instalada en la tubera de derivacin que se ilustra. La NRD empieza a abrirse a una presin diferencial de 1,4 bar. Cuando
la presin de condensacin disminuye, el KVR empieza a reducir la circulacin. Esto aumenta la prdida de carga total a travs del condensador + KVR. Cuando esta prdida de carga alcanza 1,4 bar el NRD empieza a abrirse y por tanto, garantiza el mantenimiento de la presin en el recipiente. Como regla experimental, puede considerarse que la presin en el recipiente es igual a la presin ajustada en el KVR, menos 1 bar.
Durante el funcionamiento de verano, cuando el KVR est totalmente abierto, la prdida de carga total a travs del condensador y del KVR es inferior a 1,4 bar. Por tanto, la NRD permanece cerrada. La carga puede acumularse en el recipiente durante el funcionamiento de verano. Por consiguiente, la instalacin debe estar equipada de un recipiente suficientemente amplio. El KVR puede utilizarse tambin como vlvula de alivio entre el lado de alta presin y el lado de baja presin para proteger el lado de alta presin contra una presin excesiva (funcin de seguridad). El compresor lubricado a presin con bomba de aceite est protegido contra fallo de aceite mediante un presostato diferencial de tipo MP 55 (4). El presostato para el compresor si la diferencial entre la presin de aceite y la presin de aspiracin en el crter toma un valor demasiado bajo.
Un termostato 077B est instalado en la vitrina de presentacin, con su sensor situado en la cmara fra. Si la temperatura toma un valor superior al valor ajustado, una lmpara de sealizacin se ilumina.
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Presostato diferencial
Figura 30
MP 55
El presostato diferencial tipo MP 55 se utiliza como control de presin de seguridad en compresores de refrigeracin lubricados bajo presin. Despus de un tiempo de retardo fijo, el control interrumpe el funcionamiento del compresor en caso de, fallo de aceite. El elemento de presin de aceite OIL (1) est conectado con la salida de la bomba de aceite y el elemento de baja presin LP (2) est conectado con el crter del compresor. Si la diferencial entre la presin de aceite y la presin en el crter toma un valor inferior al valor ajustado en el control, el ret de tiempo se energiza (los contactos T1 - T2 se cierran, vase diagrama de conexionado). Si los contactos T1 - T2 permanecen cerrados durante un largo perodo de tiempo en razn de una disminucin de la presin respecto a la presin en el crter (presin de aspiracin), el ret de tiempo desconecta la corriente del control aplicada al arrancador del motor del compresor (el contacto del ret de tiempo pasa de A a B, es decir que la corriente de control se interrumpe entre L y M).
La presin diferencial mnima admisible, es decir la presin de aceite mnima a la cual, en caso de funcionamiento normal, el presostato diferencial mantiene desconectada la corriente del ret de tiempo (contacto T1 - T2 abierto), puede ser ajustada en el disco de ajuste de presin (3). La rotacin en el sentido horario aumenta la diferencial, es decir, que aumenta la presin de aceite mnima a la cual el compresor puede seguir funcionando. La diferencial de contacto est fijada en 0,2 bar. Por consiguiente, se desconectar en primer lugar la corriente aplicada al rel de tiempo durante el arranque al tomar la presin del aceite un valor superior en 0,2 bar respecto a la presin diferencial mnima admisible. Esto significa que, en el momento del arranque del compresor, la bomba de aceite debe ser capaz de aumentar la presin de aceite hasta un valor superior en 0,2 bar respecto a la presin de aceite mnima admisible antes de que termine el tiempo de retardo. El contacto T1 - T2 debe abrirse, despus del arranque, con una rapidez suficiente para que el ret de tiempo no llegue nunca a su punto de cambio de A a P (interrupcin entre L y M). Vase tambin diagrama clave, figura 35.
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Regulador de presin de aspiracin
Figura 31
KVL
El regulador de presin de aspiracin tipo KVL se abre cuando la presin disminuye en el lado de salida, es decir, cuando la presin disminuye antes del compresor. Haciendo girar el eje (1) Regulador de presin de condensacin
en el sentido horario, se comprime el muelle (5) y por tanto el regulador empieza a efectuar la regulacin a una presin ms elevada en el lado de salida.
Figura 32
KVR
El regulador de presin de condensacin tipo KVR se abre cuando la presin sube en el lado de entrada, es decir, cuando la presin de condensacin sube. La rotacin del eje (1) en el Como el regulador de presin de evaporacin mencionado ms arriba tipo KVP, todos los reguladores estn provistos de un fuelle de igualacin de presin (10) para eliminar las variaciones de presin en el lado de entrada del tipo KVL y en el lado de salida del tipo KVR. Todos
sentido horario aprieta el muelle (5) y aumenta la presin de abertura, lo que hace que la presin de condensacin suba.
los reguladores estn provistos igualmente de un dispositivo de amortiguacin (11) para que las pulsaciones de presin en la instalacin no afecten el funcionamiento del regulador.
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Vlvula de presin diferencial
Figura 33
NRD
La vlvula de presin diferencial tipo NRD empieza a abrirse con una prdida de carga de 1,4 bar y est totalmente abierta a 3 bar. Cuando la vlvula se utiliza como dispositivo de derivacin asegura el mantenimiento de la presin en el recipiente.
Termostato de evaporador
Figura 34
077B
El sistema de contactos del termostato de evaporador tipo 077B se cierra cuando la temperatura aumenta. Haciendo girar el eje de gama en el sentido horario se obtiene un incremonto de la temperatura de conexin del termostato, es decir, de la temperatura a la cual la lmpara de sealizacin se ilumina.
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Diagrama clave, instalacin de refrigeracin para vitrina de presentacin de productos congelados, figura 29
Figura 35
El interruptor de tiempo P controla el contacto inversor t, circuito 2, que establece o interrumpe la circulacin de la corriente de control en los contactores K1 y K2, tipo CI, de los respectivos elementos de calentamiento situados bajo los evaporadores, y los ventiladores del evaporador. Cuando K2 est energizado, K1 est desenergizado, es decir, que los ventiladores del evaporador estn parados durante el desescarche. Al mismo tiempo, el arrancador de motor K3, tipo CIT, del ventilador del condensador se desenergiza por medio del contacto auxiliar (contacto de abertura entre 21 y 22) situado en el circuito 4. Una lmpara de sealizacin Hl se ilumina por medio del contacto auxiliar (contacto de cierre entre 13 y 14) situado en el circuito 6. Cuando el arrancador del motor K3 se abre, el contacto auxiliar (contacto de cierre entre 13 y 14) del circuito 5 se abre y el arrancador de motor K4, tipo CIT, del compresor se desenergiza. Por tanto, el compresor permanece tambin parado. El presostato tipo KP (1) est conectado de manera que abra sus contactos cuando la presin sube. Esto interrumpe el desescarche cuando la presin de aspiracin ha aumentado en un grado tal que ya no queda escarcha en el evaporador Cuando el contactor K2 est desenergizado, el arrancador de motor K3 y al mismo tiempo el arrancador de motor K4 se energizan por medio de los contactos auxiliares (contacto de cierre entre 21 y 22) del circuito 4 y del circuito 5 (contacto de cierre entre 13 y 14), suponiendo que los interruptores S1 y S2 estn cerrados. Esto pone en funcionamiento el ventilador del condensador y el compresor. Al mismo tiempo, la lmpara de sealizacin H1 es desconectada
por el contacto de cierre entre 13 y 14 en el circuito 6 y la lmpara de sealizacin H2 se ilumina por medio del contacto auxiliar (contacto de cierre entre 13 y 14) en el circuito 7. Los ventiladores de evaporador se ponen en funcionamiento despus de un cierto periodo de tiempo, por medio del interruptor de tiempo P que energiza el contactor K1. Durante este retardo, el compresor es capaz de disipar el calor acumulado en los evaporadores mientras se estaba efectuando el desescarche, antes de que los ventiladores de evaporador arranquen. El presostato de baja tipo KP 1 (11) est conectado para controlar la instalacin de refrigeracin durante el funcionamiento normal. El presostato de alta tipo KP 5 interrumpe el funcionamiento del ventilador del condensador cuando la presin de condensacin toma un valor excesivo. Un termostato tipo 077B energiza la lmpara de sealizacin H3 cuando la temperatura en la vitrina de presentacin rebasa el valor de 18C. Las lmparas de sealizacin estn conectadas con un sistema de batera de 12 voltios, de tal manera que la lmpara H3 sea capaz de funcionar incluso en caso de fallo de la red de suministro de electricidad.
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Diagrama de conexionado principal de los contactores
Figura 36
Diagrama de conexionado de los contactores K1 y K2, tipo CI, para la instalacin de refrigeracin de una vitrina de presentacin, figura 29. Para diagrama clave, vase figura 35. Los contactores estn controlados por el conmutador inversor del interruptor de tiempo P de tal manera que uno est energizado mientras
el otro est desenergizado. Los contactos principales 1-2 y 3-4 del contactor K2 estn conectados cada uno con un elemento de calefaccin elctrica. El contactor K1 tiene cuatro contactos principales, cada uno de los cuales est conectado con un ventilador monofsico (1-2, 3-4, 5-6, 13-14).
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Instalacin de refrigeracin para instalaciones de aire de ventilacin
Figura 37
En la lnea de aspiracin hay montado un regulador de presin de aspiracin electrnico tipo KVS (1). El regulador electrnico recibe la seal de mando de un sistema de control centralizado, como por ejemplo un PLC, que a su vez tiene su sensor situado en el aire de retorno del local cuyo aire de ventilacin debe ser refrigerado. La vlvula KVS se abre cuando la temperatura del aire de retorno aumenta. Si la temperatura del sensor sube, la vlvula se abre un poco ms y la aspiracin del evaporador aumenta. Al mismo tiempo disminuye la prdida de carga a travs de la vlvula, ya que la temperatura de evaporacin baja y la presin de aspiracin sube. As se aumenta la capacidad del evaporador y del compresor. Si la temperatura del sensor baja, la vlvula se cierra un poco ms y la aspiracin del evaporador disminuye. Al mismo tiempo aumenta la prdida de carga a travs de la vlvula, ya que la temperatura de evaporacin sube y la presin de aspiracin baja. As se reduce la capacidad del evaporador y del compresor. Puesto que una instalacin de estas caractersticas tiene que poder funcionar independientemente de las condiciones de carga, ser necesario realizar una regulacin de capacidad del compresor. Se puede utilizar el regulador de capacidad tipo KVC (2), este regulador puede impedir que la presin de aspiracin caiga tanto que el
presostato de baja presin dispare el compresor o que el compresor tome un valor de presin de aspiracin mnima permisible. Esto se puede evitar ajustando el regulador KVC para que empiece a abrir de manera que no se sobrepasen las citadas limitaciones. Con esta derivacin de gas caliente se traslada una cantidad del gas de descarga del lado de descarga de la instalacin al lado de aspiracin, con lo cual se reduce la capacidad frigorfica. Esta forma de regulacin de capacidad hace que el gas de aspiracin se recaliente bastante. Y como en consecuencia la temperatura del gas de descarga sube, aumenta el riesgo de carbonizacin del aceite en las vlvulas de compresin del compresor. Para compensar esto se ha montado una vlvula de expansin termosttica de tipo T (3) en derivacin desde la lnea de lquido a la lnea de aspiracin. El bulbo de esta vlvula est situado en la lnea de aspiracin inmediatamente antes del compresor. Si el recalentamiento de este lugar toma un valor demasiado grande, se abre la vlvula y se inyecta un poco de lquido en la lnea de aspiracin. Con la evaporacin de este lquido se reduce el recalentamiento y en consecuencia la temperatura del gas de descarga. La vlvula de solenoide tipo EVR (4) est montada inmediatamente antes de la vlvula de expansin termosttica (3) para impedir que entre lquido refrigerante en la lnea de aspiracin cuando la instalacin de refrigeracin est parada. Sigue... 29
RG00A505
Manual
Figura 38
Figura 39
KVS
KVC
Regulador de presin de evaporacin electrnico El KVS (1) es un regulador de presin de evaporacin accionado por un motor paso a paso, que modifica el grado de abertura en funcin de las seales del regulador EKC 368 que emite impulsos de manera que el motor de la vlvula gire en una u otra direccin, segn la necesidad de abrir o cerrar ms.
Regulador de capacidad El regulador de capacidad tipo KVC se abre cuando la presin disminuye en el lado de descarga, es decir, con presin de aspiracin descendente antes del compresor.
30
RG00A505
La gama de productos Danfoss para la industria de la refrigeracin y del aire acondicionado

Compresores para refrigeracin comercial y aire acondicionado Estos productos incluyen compresores hermticos de pistones, compresores Scroll y unidades condensadoras enfriadas por ventilador. Las aplicaciones tpicas son unidades de aire acondicionado, enfriadoras de agua y sistemas de refrigeracin comercial. Compresores y unidades condensadoras Esta parte de la gama incluye compresores hermticos y unidades condensadoras enfriadas por ventilador para frigorficos y congeladores de uso domstico, y para aplicaciones comerciales tales como enfriadores de botellas y dispensadores de bebidas. Tambin ofrecemos compresores para bombas de calor y compresores de 12 y 24 V para pequeos aparatos frigorficos y congeladores en vehculos comerciales y embarcaciones. Controles para muebles y vitrinas de refrigeracin y congelacin Danfoss ofrece una amplia gama de termostatos electromecnicos adaptados a las necesiadades del cliente para refrigeradores y congeladores, controles electrnicos de temperatura con o sin display, y termostatos de serivicio para el mantenimiento de muebles frigorficos y congeladores. Controles de refrigeracin y de aire acondicionado Nuestra completa gama de productos cubre todas las exigencias de control, seguridad, proteccin y monitorizacin de instalaciones de refrigeracin y sistemas de aire acondicionado, mecnicos y electrnicos. Estos productos se utilizan en innumerables aplicaciones dentro de los sectores de la refrigeracin comercial e industrial y del aire acondicionado.
RG00A505
Produced by Danfoss RC-CMS. 03.2004.MWA
Refrigeration and Air Conditioning Controls
Lecture
On/Off Control
R E F R I G E R AT I O N A N D A I R C O N D I T I O N I N G
Table of contents
Introduction .................................................................................................................................. 4 KP Controls, general .................................................................................................................... 5 Introduction ............................................................................................................................. 5 Construction ........................................................................................................................... 5 Design .................................................................................................................................... 5 Function .................................................................................................................................. 6 Cable entry ............................................................................................................................. 7 RT Controls, general .................................................................................................................... 8 Introduction ............................................................................................................................. 8 Types of switch ....................................................................................................................... 8 Screwed cable entry ............................................................................................................. 11 Thermostats ............................................................................................................................... 12 Example of thermostatic control ........................................................................................... 12 Thermostat design ................................................................................................................ 12 Charges ................................................................................................................................ 12 Thermal differential ............................................................................................................... 15 KP thermostats .......................................................................................................................... 16 Setting .................................................................................................................................. 17 KP thermostat program ........................................................................................................ 18 Dual thermostat type KP 98 ................................................................................................. 19 Application examples ........................................................................................................... 20 RT thermostats .......................................................................................................................... 21 Setting, mechanical differential ............................................................................................ 21 Special type RT thermostats ................................................................................................ 22 Differential thermostats .............................................................................................................. 23 Application example ............................................................................................................. 23 Dead zone thermostats .............................................................................................................. 24 Construction ......................................................................................................................... 24 Adjustment ........................................................................................................................... 24 Dead zone ............................................................................................................................ 24 Mechanical differential .......................................................................................................... 24 RT L programme .................................................................................................................. 24 Pressure controls, general ......................................................................................................... 25 KP pressure controls .................................................................................................................. 26 Introduction ........................................................................................................................... 26 Fitting .................................................................................................................................... 26 Low pressure controls type KP 1, 2, and 1A ........................................................................ 27 High pressure controls type KP 5 and 5A ............................................................................ 28 Combined high and low pressure control type KP 15 and 15A ............................................ 28 KP pressure controls with LP + HP signal ............................................................................ 30 KP pressure controls with convertible automatic/manual reset ............................................ 30 KP pressure control program ............................................................................................... 31 RT pressure controls .................................................................................................................. 32 Pressure control designs ...................................................................................................... 32 Refrigerants .......................................................................................................................... 33 Safety pressure controls of TV-design .................................................................................... 34 TV-design .......................................................................................................................... 34 Meeting DIN 32733 requirements ........................................................................................ 34 Differential pressure controls ..................................................................................................... 36 Differential control terminology ............................................................................................. 36 MP differential pressure control ............................................................................................ 36 Electrical connections ........................................................................................................... 37 Setting .................................................................................................................................. 38 RT differential pressure controls .......................................................................................... 39 Dead zone pressure controls ..................................................................................................... 40 Safety cut-out and liquid level control type RT 280A ................................................................. 41 RT 280A used as safety cut-out ........................................................................................... 41 RT 280A used as liquid level control .................................................................................... 42 Technical data ...................................................................................................................... 42 Examples of application ............................................................................................................. 43 Temperature control of containers ....................................................................................... 43 RT 140L used in ventilation systems .................................................................................... 44 RT 280A and RT 262A as safety equipment in pump recirculatory refrigeration plant ............ 45
Danfoss A/S (RC-CM/sw), 02 - 2002
RF.5X.A1.02
Introduction
When a refrigeration system is constantly loaded, and the load balances the cold output of the system, adjustment is unnecessary. In practice, however, there will always be fluctuating loads on the main components of the refrigeration plant and the plant capacity will often be higher than the normal cold requirement. Therefore, a need for regulation arises.
Regulation can be carried out manually but that requires a large personnel and is not particularly accurate, therefore, automatic control is used today. To prevent injury to personnel and damage to refrigeration equipment, plants must be equipped with safety controls. Danfoss regulating equipment covers these requirements. The following deals with those refrigeration controls which regulate in accordance with the on/off principle.
ON/OFF Control, general
C: Temperature D: Time
The purpose of on/off control is to keep a given physical variable, e.g. the ambient temperature, within certain limits or to change it according to a predetermined programme. A control system serves to measure the value of the controlled variable, compare it with the desired value, and adjust the control unit, by which a possible deviation is reduced. Thermostats and pressure controls for on/off control are two-position regulators where the manipulated variable can only lead to two conditions: cut-in or cut-out. The temperature sequence for a room controlled by a thermostat is shown in fig. 1. The rise in the ambient temperature will not occur at the same time as the valve opens, as some time will pass before this happens, i.e. the dead time Tt. The dead time is defined as the time which will pass from when the valve opens until the bulb begins to register the temperature increase. At the measuring point the increase will follow an exponential function. The tangent to the starting point of the curve intersects the tangent to the final value of the curve at Tt + T s . Ts is denoted the time constant and indicates the time it takes for the temperature to increase to 63% of the final value.
In other words, the time constant is an expression of the rate at which the controlled variable changes as a result of a sudden change of the manipulated variable. Because of the great difference in temperature the curve of temperature will increase most rapidly at the beginning, to fade out gradually and approach the final value tangentially. When the temperature has increased to the point A the thermostat will cut-in and the cooling begins. However, it takes some time 1 - before the ambient temperature begins to fall. T1 depends on the following factors among others: Bulb position Air circulation at the bulb Sizing of the refrigeration plant. During cooling the temperature drops to the point B where the thermostats cut out the refrigeration system. Because of the cold accumulated there will, however, be a certain after-cooling - 2 - before the temperature increases again. The cooling is restarted at the point A, and a new cycle begins. td (= the section A to B) denotes the thermal differential of the thermostat, whereas tmax indicates the maximum temperature fluctuations.
RF.5X.A1.02
KP Controls, general
Introduction
Fig. 2. KP-thermostat
Fig. 3. KP-presssure control
KP controls are pressure-controlled switches for on/off control of refrigeration, freezing, and air-conditioning plant. The KP is based on entirely new design principles. The mechanical parts of the control have two balanced positions only. Therefore, the contact system operates with well-defined contact pressure. This means that: Construction The enclosure is a dust-tight mild steel casing provided with a cover of self-closing ABSplastic. The grade of enclosure is IP 44 in accordance with IEC 144 and DIN 40050.
KP has very high contact load both for inductive and ohmic loads KP is not sensitive to vibrations and pulsations KP has a long mechanical life KP is free of radio interference, in accordance with VDE 0875 and CISPR.
This grade of enclosure is obtained by mounting the control onto a plane board or a bracket. The bracket must be placed on the control so that all free holes are covered.
Design
1. Adjustment setting spindle 2. Differential spindle 3. Main arm 18. Locking plate
Fig. 4. KP-thermostat
Fig. 5.
KP has very small overall dimensions (84 61 45 mm), and is of simple and robust design. KP is fitted with an SPDT switch. See fig. 4. Such a switch has a wide range of application, among other things because the make and break functions can be obtained at increasing as well as decreasing pressure/ temperature. By connecting the three terminals 1, 2, and 4, two contact functions are obtained.
The one function, terminals 1-4, may for example, cut-in a refrigeration compressor at increasing pressure/temperature, while the second function, terminals 1-2, may cut-in a signal lamp when the refrigeration compressor has stopped. KP controls have simple electrical connections, as both the contact terminals and the earthing screw are accessible from the front. See fig. 5. Thus, several KP controls can be mounted close to each other.
RF.5X.A1.02
Function
The design principle of the KP controls.
1. Adjustment setting spindle 2. Differential spindle 3. Main arm 7. Main spring 8. Differential spring 9. Bellows 16. Tumbler 18. Locking plate 20. Contact system
Fig. 6
Fig. 7
The main spring (7) can by means of the adjustment spindle (1) be adjusted for balancing the pressure in the bellows. KP is designed so that the snap action of the contact system is led to the bellows (9). Thus, this has two balanced positions only. The bellows is moved only when the cut-in and the cut-out value is exceeded. The knife-edge bearing at the tumbler (16) exert two forces on it on one side the pressure of the bellows (9) minus the force of the main spring (7) on the other side the pull of the differential spring (8). From the above description it can be seen that the KP design distinguishes itself essentially from the design principles previously used for mechanical thermostats and pressure controls. Contrary to the previous principles, which were called road proportional or distance proportional, the power transmission between the bellows and the contact system of the KP is based on the power proportional principle. The following is a description of how the principle is put into operation: Fig. 6 shows a KP control with the contacts 14 open, and 2-1 closed. If the pressure in the bellows increases, neither contacts will move until the bellows pressure has reached a value equal to or higher than that set on the main spring. When this pressure has been reached the movable parts of the control move momentary, so that the contact system changes to the opposite contact position, where contacts 1-4 are closed, and contacts 2-1 are open. See fig. 7.
Generally, on contact systems, when the movable contact hits the fixed one at high speed, the movable contact will jump back a couple of times. Each time the contacts jump apart arcing occurs. Consequently the contact surfaces wiIl melt, and can weld together when meeting again. These very small welds, which occur during cut-in, are the most frequent cause of failure in a contact system. The time from the moment when the movable contact hits the fixed one for the first time, until the cut-in function is established is called bounce time. The bounce time for the KP contact system is less than 100 microseconds = 1/10 000 second, which is exceptional. It is 10-50 times less than for common contact systems and permits high contact load combined with long electrical and mechanical life. The electrical data for the constant system are: Alternating current 16 (16) A 400 V a.c. Locked rotor 112 A i.e.: - 16: maximum ohmic load in amp. - (16): maximum full load current at inductive load - 400 V: maximum permitted voltage - Locked rotor 112 A: maximum permitted starting current. In practice the high contact load means that single phase alternating current motors of up to 2 hp can be direct started. Direct current 12 W 220 V d.c. pilot current
RF.5X.A1.02
Cable entry
Fig. 8
Fig. 9
KP controls have a soft rubber entry as standard. See fig. 9. The entry will take cables from 6 to 14 mm diameter.
As accessories Pg 13,5 and Pg 16 cable entries are available, fig. 8.
RF.5X.A1.02
RT Controls, general
Introduction
Fig. 10. RT thermostat
Fig. 11. RT pressure control
The RT-control is a pressure or temperaturecontrolled electric switch which makes or breaks an electric circuit depending on pressure or temperature variations at the bulb. Types of switch Designs and materials Most RT controls are equipped with switch 17-4030 which is an SPDT system (Single Pole Double Throw system). Switch 17-4030 can be replaced, without adjusting the controller. The switch has a transparent protective cover over the moving parts. Replacement systems are also equipped with a protective cover over the contact arm. This system is also available with manual reset on actuation for rising or falling pressure/ temperature (max. reset and min. reset respectively).
Code Nos 17-4030 Fig 13 Fig 14 17-4032 15 Fig. 13-14
Danfoss RT controls are characterized by a hoseproof bakelite housing which is equipped with a steel cover, robust construction, and small differentials. Therefore, the control are suitable for industrial systems.
Fig. 12
Discription Type of switch normally used for RT. Terminals 1-4 make on increases. Terminals 1-2 make on decreases. Terminal 1 is common. Single-pole change-over switch with neutral centre position. Terminals 1-4: Make the circuit when the temperature/pressure increases. Terminals 1-2: Make the circuit when the temperature/pressure decreases. The neutral setpoint will be dealt with in the section of dead zone thermostats, page 22. Single-pole switch breaking two circuits at the same time when the pressure/ temperature increases. Momentary contact change-over. Terminals 1-4 and 1-2 are cut-out when the pressure/temperature increases. Single-pole switch making two circuits at the same time when the pressure/ temperature increases. Momentary contact change-over. Terminals 1-4 and 1-2 are cut-in when the pressure/temperature increases. Single-pole change-over switch with non-snap action. It gives less mechanical differential than 17-4030, but the rated capacity is, therefore, lower and the switch must not be used where vibration occurs. Single-pole switch with the same functions as described for switch No. 17-4030. The switch is equipped with silver contacts coated with gold. Therefore, it can be used with advantage for small electrical loads as well as in plants where the demand is for exeptional make reability, even after long periods of intermittent contact load.
Fig 15
Fig 16
17-4036
16
17-4034
17
Fig 17
Fig 18
17-0181
18
17-4240 Fig 19
19
RF.5X.A1.02
Rating
Type of switch Non-inductive Code No. 17-4030 17-4032 17-4036 17-4034 17-0181 17-4240 10 A 10 A 25 VA 10 A 400 V 400 V 24 V 400 V 2A 400 V 12 A 400 V a.c. Inductive rating Full-load current 4A 3A 400 V 400 V Locked rotor 24 A 400 V 18 A 400 V 12 W 220 V 12 W 220 V 25 VA 24 V 12 W 220 V d.c.
Marking The covers of switches 17-4030 and 17-4032 are marked: 10 (4) 400 V a.c. 12W 220 V d.c. The marking complies with the demands of VDE 0671 test class II which prescribes the above rating in relation to a minimum of 100,000 operations.
Fig. 20
Alternating current (a.c.) It should be remembered that the two main demands are 10 A non-inductive rating and 30 A locked rotor. The 4 A inductive rating (or, more correctly, motor rating) is derived from 30 A locked rotor, since the maximum ratio between locked rotor/operating current for single-phase motors is approx. 7.5 30 = 4A 7.5 This means that normally motors with an operating current of 4 A can be connected. It is permissible to connect motors with a higher operating current than 4 A, provided that locked rotor does not exceed 30 A.
RF.5X.A1.02
Application of two-circuit switches
Fig. 21
Fig. 22
An RT control with a switch 17-4034 or 17-4036 can, for example, be used in pilot circuits with several RT controllers. When the above types of switch are used, auxiliary relays can be omitted. The two examples, fig. 21 and fig. 22, show the wiring diagrams for thermostatic control of two deep-freeze stores and one refrigerated store, where the three evaporators are connected to a centrally located compressor.
The thermostats control the opening and closing of the solenoid valves in the liquid lines, depending on the ambient temperature. Fig. 21 shows the wiring diagram for RT thermostats with a standard switch 17-4030 and auxiliary contacts. Fig. 22 shows the same system, but in this case the switches have been replaced by the two-circuit switches 17-4034, and the auxiliary contacts can thus be omitted.
10
RF.5X.A1.02
Screwed cable entry
All RT controls are equipped with a Pg 13.5 nylon cable entry. The rubber ring of the cable entry consists of concentric rings which can be taken out to accommodate cable diameters of from 6 to 14 mm.
The rubber rings are made of Nitril rubber. This gives a good seal, and it can be used with plastic cables.
Fig. 23
RF.5X.A1.02
11
Thermostats
Example of thermostatic control
Fig. 24
In the refrigeration system, fig. 24, a room thermostat is used to control the temperature in the refrigerated space. When the temperature of the refrigerated store room exceeds the value required, the thermostat makes the circuit to the compressor motor, and the refrigeration system starts. When the temperature required is reached, the thermostat breaks the circuit to the compressor motor, and the refrigeration system stops.
Thermostat design
Thermostats are temperature-controlled electrical switches which can break or make an electrical circuit, depending on temperature variations at the bulb. A thermostat, fig. 25, consists of the following main elements: The power element which consists of the bulb (29), the capillary tube (28), and the bellows element (23). The most important parts of the mechanical section are the spindle (15), the range spring (12), the knob (5) for adjusting the spring pressure, and the differential adjusting nut for adjusting the mechanical differential. The switch (16) is a single-pole change-over switch with momentary contact change-over. The power element contains a charge, the pressure of which changes with the temperature at the bulb. A fixed pressure corresponds to a given bulb temperature. If the bulb temperature increases, the pressure in the power element increases. Hence the spindle is moved until the pressure on the lower side of the bellows balances the counter-pressure of the main spring.
Fig. 25
Charges
Depending on the field of application, the charge of a thermostat can be: I : Vapour fade-out charge II : Adsorption charge III: Partial charge Vapour fade-out and adsorption charges will be described overleaf since these charges are used in our thermostats for refrigeration purposes.
12
RF.5X.A1.02
Thermostats
I. Vapour fade-out charge
The pressure of the charge depends on the temperature at the free liquid surface. As long as liquid remains, a pressure increase caused by ingress of heat into the liquid will progress according to the vapour pressure curve for the saturated vapour of the liquid. From the moment the last drop has evaporated, the pressure increase will, on the other hand, follow the curve for superheated vapour. At this point the pressure increase is considerably slower since it is now only the thermal expansion of the vapour which causes the pressure to increase. The temperature at which the vapour passes from saturated vapour to superheated vapour is called the pressure limiting temperature, denoted t3 in fig. 26.
Fig. 26
A vapour fade-out charge consists of a very small amount of liquid and the saturated vapours of that liquid. This type of charge utilizes the interdependence between the temperature and pressure of saturated vapour.
The advantages of a vapour fade-out charge are e.g. 1. A very short reaction time (a short time constant). Heat has only to be supplied or given off for the respective evaporation and condensation of a very small quantity of liquid. 2. The charge is pressure-limited, i.e. the element is designed to resist temperatures higher than the maximum temperature setting.
Vapour fade-out charge Saturated vapour + some liquid Vapour pressure curve
+ Small reaction time Pressure limited No capsule sensivity Capillary sensor
The coldest part of the thermostatic element controls the function Pressure-temperature curve: Non-linear Room thermostats Evaporator thermostats Thermostats for low temperatures
It can be seen from the inclination of the vapour pressure curve (fig. 28) that the differentials at the lower and upper parts of the curve are different when a given pressure variation p is kept constant. A thermostat with a vapour fade-out charge has, therefore, smaller mechanical differentials at the upper end of its temperature range than at the lower end. Vapour fade-out charges are preferable for thermostats which are to work at low temperatures. In a vapour-filled thermostat the charge will condense at the coldest point of the power element, and the thermostat will regulate the temperature accordingly. Therefore, to obtain the regulation required it is a condition that the bulb must always be placed colder than the rest of the power element. RF.5X.A1.02
Fig. 28
Fig 27.
13
Thermostats
II. Adsorption charge
Adsorption charge is no doubt the most interesting one and the charge which is most universally applicable. By using the same two substances, e.g. active carbon as adsorbent and CO2 as adsorbate, it is possible to produce many different pressure-temperature curves by varying the ratio between the quantities of the substances. Some porous substances, adsorbents, have the capacity of being able to bind molecules from another substance, the adsorbate, in their microscopic pores. Because of the porosity of the adsorbent, it has a surface area of several hundred m2 per gram. If, in this way, CO2 molecules are bound to active carbon in a closed container, the pressure is reduced. In the gaseous phase, CO2 is known to participate in the pressure formation by means of its partial pressure. The capacity of an adsorbent to bind an adsorbate depends on temperature. When binding occurs in a closed system, it also depends on the counter-pressure which is set up. If the adsorbent is heated, it can no longer retain all the gas molecules previously retained by it. Some of them will be released, and, together with the other gas molecules which were already free, they will increase the concentration of gas molecules. The pressure in the element then increases.
Fig. 29
Fig. 29 shows a pressure-temperature curve for an adsorption charge. The S-shape is typical for these curves. When carbon charges are used in power elements, the temperature range is mostly placed symmetrically about the turning point tv. Hence, a maximum pressure increase is obtained by means of a minimum quantity of carbon, and hence the smallest size of bulb. A great advantage of the adsorption charge is that a thermostat with this charge is CROSS AMBIENT, i.e. the bulb can be placed warmer or colder than the thermostat housing. This is possible because the carbon is always placed in the bulb. Therefore, the bulb always controls the thermostatic regulation.
Adsorption charge Granulated material + superheated gas Physical mass attraction + Cross ambient Small bulb Pressure-temperature curve: Linear Capsule sensitive Moderate reaction time
Room thermostats Thermostats for high temperatures
A disadvantage of an adsorption charge is the capsule sensitivity. This means that greater temperature fluctuations at the capsule may influence the control accuracy.
Fig. 30
Fig. 31
14
RF.5X.A1.02
Thermostats
Thermal differential
The thermal differential is the differential at which the system operates. It is always higher than the mechanical differential. The thermal differential depends on several factors: 1. Velocity of medium. The higher the velocity at which the air or liquid pass the sensor, the smaller the thermal differential. Therefore, the sensor should always be located at a point with good circulation of the air and the liquid respectively. 2. Temperature variation rate of medium (temperature variation per time unit). The thermal differential increases with the temperature variation rate. If the temperature is to be controlled in the range from 5C to +30C, to ensure that the thermal differential will not be increased because of too high a temperature variation rate, an RT 4 thermostat with an electric heater in the bellows element can be used. Measuring the time constant
3. Heat transmission to the sensor. The sensor should have optimum contact with the medium to be temperaturecontrolled. Difficulties occur especially if the sensor is inserted in a pocket, where the thermal conduction between sensor and pocket is poor. The application of a heat-conductive compound between sensor and pocket will, normally, result in satisfactory heat transmission.
To get an idea of what the time constant can be, measuring has been done on an RT 14 with an adsorption charge. The measuring was done under the following conditions: The sensor at 10C was placed in an air current of 20C. The contact change-over at increasing temperature was set at 16.3C. The time constant indicates the time interval from the moment the bulb was placed in the air duct, and until contact change-over took place.
Fig. 32
Measuring results
Type Air velocity m/s sec. 0.1 205 0.5 147 RT 14 1 99 1.5 73
RF.5X.A1.02
15
KP thermostats
KP thermostats
KP thermostats are single-pole double-throw (SPDT) temperature-controlled electrical switches for on/off control. Typical fields of application for KP thermostats are: - large refrigerated cabinets and display counters - freezing cabinets and display counters - commercial freezing plant - commercial refrigeration plant - air-conditioning plant
The total temperature range is from -50C to +180C with independent temperature and differential settings. The thermostats can be obtained with vapour fade-out or adsorption charge and with the following sensor, see fig. 33. As standard range setting KP thermostats are provided with a knob for range setting.
1a. Vapour charge 1b. Adsorption charge 2 Capillary tube sensor 3. Capillary tube with a coiled capillary tube sensor 4. 3/8 in. cylindrical or double contact sensor 5. 1/4 in. cylindrical sensor 6. 25 mm duct sensor.
Fig. 33
16
RF.5X.A1.02
KP thermostats
Setting
Fig. 34
Fig. 35
Fig. 36
The setting can be seen in fig. 34. Illustrated here, the range setting is the maximum actuating value, and the differential is to be deducted from this setting to obtain the minimum actuating value. In addition the cutin and cut-out functions of the thermostat, is depending on the terminal connection applied. If the thermostat is to start and stop a refrigeration compressor (terminals 1-4) the cut-out temperature is equal to the cut-in temperature minus the differential. All KP thermostats with vapour fade-out charge are provided with a setting diagram as shown in fig. 35, to be used for the exact setting of the thermostat.
Example of setting For temperature control in a deep-freeze box, the KP 61 thermostat should be set so that when temperature increases, the electric circuit is made at 17C (starting temperature), assuming a requirement for a cut-out temperature (stopping temperature) of -24C. The differential (the value to be set on the differential scale) must be determined. In the diagram for KP 61, fig. 35, the cut-in temperature -17C is read on the range scale (contact change-over when temperature increases). On the horizontal scale (contact change-over on decreases in temperature) the temperature -24C is read. The solid lines differential curve are followed from the intersection point between the lines from 17C and -24C. The differential wanted = 6 K can be read from the differential scale. Consequently, the thermostat should be set as follows: Range scale: 17C Differential scale: 6 K. Locking the setting The range setting spindle (1) or the differential setting spindle (2) can be locked by the locking plate (18). See fig. 36.
RF.5X.A1.02
17
KP thermostats
KP thermostat program
KP thermostats can be divided into three main groups: 1) KP 61-69, which all - with the exception of KP 62 - are vapour fade-out charged. (KP 62, is available with adsorption charge and vapour fade-out charge (room thermostat)). 2) KP 71-77, which all have an adsorption charge (cross ambient) 3) KP 98, which is a dual thermostat.
The table in fig. 37 shows the regulating ranges for group one and two. The type designation and the code No. are stamped on the underside of the control, while the approval, electrical data, and place of origin are printed on the scale plate.
Fig. 37
18
RF.5X.A1.02
KP thermostats
Dual thermostat type KP 98
Fig. 38
KP 98 is used partly to safeguard against too high a discharge gas temperature on refrigerant compressors, partly to ensure regulation of the oil temperature in the compressor crankcase. The regulating ranges for the control are given in the diagram below:
Type Range [C] Oil: +60 to +120 HT: +100 to +180 OIL: 0 to +30 HT: +100 to +180
The thermostat has two separate functions: 1. As a protection against too high a discharge gas temperature. After cut-out the control must be reset manually (max. reset). This function applies to KP 98, code No. 60L1131 and 60L1132. 2a. As a protection against too high an oil temperature in the compressor crankcase. After cut-out the control must be reset manually (max. reset). This function applies to KP 98, code No. 60L1131. 2b. As a protection against too low an oil temperature. At too low an oil temperature a heating element in the crankcase is cut-in. When the required oil temperature has been attained, the heating element is cut-out and the compressor is ready for start. This function applies to KP 98, code No. 60L1132.
Differential [K] Oil: fixed 14 HT: fixed 25 Oil: fixed 12 HT: fixed 25
Charge
Reset max. max. aut. max.
Code No. 60L1131 60L1132
KP 98
Adsorption
Fig. 39
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19
KP thermostats
Application examples
Fig. 40
In the following a few examples of applications for KP thermostats are given. In an air-conditioning system, fig. 40, it is desired to protect the pre-heating coil against bursting due to frost (low outdoor temperature). For this purpose the frostprotection thermostat KP 61 is used. This vapour fade-out charged thermostat distinguishes itself by the fact that the entire capillary tube is used as a sensor. The capillary tube should be formed over the whole cross section of the duct. If the injection air is too cold, KP 61 gives a signal to the actuating motor, which closes the damper, so that only return air is used. Temperature control of refrigerated display counters etc. In many commercial freezing and refrigerated counters there is a need for an attractively designed thermostat with a fixed differential for temperature control. Often the control must be mounted visibly as an integrated part of the counter without spoiling the total impression. See fig. 41. Danfoss thermostat programme includes a KP 61 with a top plate, fig. 42, specially designed for surface mounting. The advantages with this thermostat are: - it can be operated from one side - hand switch STOP/AUTO - simple surface mounting.
Fig. 41
Fig. 42
20
RF.5X.A1.02
RT thermostats
An RT thermostat is a temperature-controlled electric switch which makes or breaks an electrical circuit depending on temperature variations at the bulb. Our RT thermostats are characterized by a hoseproof bakelite housing which is equipped with a steel cover, robust construction, and small differentials. Therefore, the controls are suitable for industrial systems. Fig. 43 shows the design of an RT thermostat. As mentioned above, the power element contains a charge, the pressure of which varies with the temperature at the bulb. The main spring can be set for different pressures within the setting range. The pressure in the bellows element counteracts this pressure. A pressure change in the bellows moves the main spindle until balance is re-established between the forces. The movement of the main spindle is transferred to the contact arm of the switch by a guiding knob and a differential adjusting nut so that a break or make function can be obtained.
5. Knob 9. Scale 19. Differential adjusting nut 25. Mounting hole 26. Bulb holder 30. Bulb pocket 31. Capillary tube gland 38. Earth terminal
Fig. 43
Setting, mechanical differential
Fig. 44
By turning the knob, the lowest temperature at which the switch is to operate is set on the range scale (break or make the circuit). The mechanical differential is then set by turning the differential adjusting nut. Maximum actuating temperature at the bulb is equal to the actuating temperature + preset mechanical differential. The mechanical differential is set by turning the differential adjusting nut according to the nomogram fig. 45. Example: Setting of RT 3 Range setting = 5C Differential required = 2 K On the nomogram, a setting of the differential adjusting nut at 4 can be read. Resulting in: - Minimum actuating temperature = 5C - Maximum actuating temperature = 5 + 2 = 7C 21
A: Range setting B: Obtained differential C: Differential setting

Fig. 45
RF.5X.A1.02
RT thermostats
Special type RT thermostats
Besides covering a large temperature range, there are some types of RT thermostats which are suitable for conditions where special demands are made. Of these thermostats the below types can be mentioned: RT 4 with an electric heater in the bellows element As mentioned on page 13 an increased rate of temperature change will increase the thermal differential. To control the ambient temperature, a small thermal differential is, however, often necessary even if the rate of air temperature change is high. The application of RT 4 with an electric heater in the bellows element is recommended for this kind of system. The electric heater is heating when the refrigeration compressor is not operating, with the effect that the bellows and the bellows housing are always a little warmer than the phial. Without this arrangement, the bellows and the bellows housing would become the coldest parts of the power element at rapidly increasing temperatures, since the mass of the bellows housing is larger than that of the phial, and the charge vapours would condense in the bellows and thus not create the requisite pressure for changing over the switch. RT thermostats with small differentials Danfoss has developed thermostats with small differentials. These types are: RT 21, 23 and 24 as well as RT 17 and 103. The technical data can be seen in the below table. The thermostats cover a range from 50C to +45C.
Nature of controls Type RT 2 Brine, surface or room thermostat RT 23 RT 24 RT 17 Room thermostat RT 103 Vapour fade-out Adsorption Charge Range [C] Mechanical differential [K]
Fig. 46
25 to 15 5 to 22 15 to 34 50 to 15 10 to 45
5 to 18 6 to 20 1 to 3 1 to 3 1.4 to 4 1.4 to 3.5 2.2 to 7 1.5 to 5 1.3 to 7 1 to 5
22
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Differential thermostats
An RT differential thermostat is a single-pole electric change-over switch, the contact position of which is controlled by the temperature difference between the two bulbs of the thermostat. RT 270 is designed for use in processing plants, ventilation plants, refrigeration and heating plants where it is desired to maintain a fixed temperature difference of from 0C to 15C between two media. One sensor temperature is used as a reference and the other as an indirectly controlled variable. (The directly controlled variable is the temperature differential). Fig. 47 shows a cross section of an RT 270. The differential thermostat is equipped with two bellows elements: the LT element, the sensor (1) of which is to be placed in the medium with the lowest temperature, and the HT element, the sensor (2) of which is to be placed in the medium with the highest temperature. The range spring (3) has a rectilinear characteristic. Within the differential range it can be set for different temperature differentials by rotating the setting disc (4). The setting indicates the scale value at which contact change-over occurs when the spindle moves downwards. (Contacts 2-1 make the circuit). When the differential between the LT and HT bulb temperatures is reduced, the spindle (5) moves downwards and thus actuates the contact arm (7) of the switch via the upper guiding knob (6). When the temperature differential between HT and LT increases, the switch changes over when the temperature differential has increased to the setting plus the fixed contact differential of approx. 2 K.
Fig. 47
Application example
It is desired to maintain a temperature at 5C above another temperature which is assumed to be constant at 12C. The LT sensor is placed in the medium with the lowest temperature (reference temperature) and the HT sensor in the medium with the highest temperature (controlled temperature). The thermostat is set for a temperature differential of 5 K. It is assumed that at first the controlled temperature is 14C. The main spindle then moves downwards and closes the contacts 1-2 because the actual differential of 14 - 2 = 2 K is smaller than the desired differential of 5 K.
When the contacts 1-2 are closed, a heating system is cut-in so that the controlled temperature increases, and the main spindle moves upwards until the differential between the sensor temperatures is 7 K = setting differential plus contact differential. Afterwards the controlled temperature will then fluctuate between 19C and 17C. If the reference temperature (LT temperature) falls or in creases, the HT temperature falls and increases proportionately. The differential will continue to fluctuate between 7 K and 5 K.
Fig. 48
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23
Dead zone thermostats
The RT L thermostats have an adjustable dead zone since they are fitted with a three position contact system, code No. 17-4032. Construction Fundamentally the RT L thermostats are constructed as the other RT controls but to satisfy the dead zone function the contact system has two contact levers which mesh with two guide rollers, see fig. 49.
Fig. 49
Adjustment, fig. 41 and 50
The adjusted scale value corresponds to the break value of contact 2-3. The required dead zone is found in the diagram for the particular control.
On the lower scale of the diagram the position in which the setting knob should be set, is read off.
Dead zone
The interval of the controlled variable during which the control device is at rest is called the dead zone. Looking at fig. 50 the dead zone is the interval where no make function is obtained.
Fig. 50
Mechanical differential
The interval between the values of the controlled variable making the control device move is called mechanical differential. RT L controls are available in various designs as shown in the table.
Nature of controls Brine surface or room thermostat Air duct thermostat Room thermostat Type RT 8L RT 14L RT 140L RT 16L Vapour fade-out Adsorption Charge Range [C] at low temp. C at low temp. C 1.5-4.4 1.5-5 3-4.5 1.5-5 1.5-4.9 1.5-5 2-5 0.7-1.9 20 to +12 5 to + 30 + 15 to +45 0 to +38
RT L programme
24
RF.5X.A1.02
Pressure controls, general
A pressure control contains a pressure operated change-over switch the contact position of which depends on the pressure in the bellows. Via the pipe connector the bellows is connected to the pressure in the plant. The fundamental layout is shown in fig. 51. The main spring (12) can be set for different pressures to balance the pressure on the bellows. On a rise in pressure the bellows is affected so that the main spindle (15) moves upwards until the spring and bellows pressures are in equilibrium. The movements on the main spindle are then transferred to the electric contact system.
12. Main spring 15. Main spindle 16. Contact system (RT) 23. Bellows element 27. Pipe connector 44. Range spindle
Fig. 51
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25
KP pressure controls
Introduction
Like the KP thermostats the KP pressure controls are single pole electrical switches. As standard, pressure controls for freon are supplied with 1/4 in flare, 6mm or 1/4 in solder connection, or with 1 m fixed capillary tube with 1/4 in flare connection. Depending on the type, the connection must be made on the suction and/or pressure side of the refrigeration plant.
The controls for ammonia are provided with a 1 m loose capillary tube of steel. Generally, KP pressure controls can be used for all fluorinated refrigerants, but those for ammonia are made from materials which will tolerate this refrigerant. KP pressure controls are made in the following basic types: - low pressure controls - high pressure controls - combined high and low pressure controls The pressure control can be fitted using one of the two types of brackets shown in fig. 53. These may be ordered separately. When wall mounting, the plain holes in the back of the control are to be used.
Fitting
The KP pressure controls can be fitted in any position. However, as shown in fig. 52, the capillary tube is fitted in a way preventing direct downpiping of oil and refrigerant. In this way the risk of blocking the bellows is eliminated, and at the same time a correct pressure control is ensured.
Fig. 52
Fig. 53
26
RF.5X.A1.02
Low pressure controls type KP 1, 2, and 1A
Fig. 54
Fig. 55
Fig. 56
As previously mentioned the KP 1 and 2 are provided with 1/4 in flare connection, fig. 54, or with 1 m fixed capillary tube, fig. 55.
Fig. 57
KP 1A is provided with a 1 m loose capillary tube of steel, fig. 56. The low pressure controls must be connected to the suction side. The range spindle (1), and the differential setting spindle (2) can be locked by the locking plate (18), fig. 57. The normal function of the low pressure control - cutting out the compressor at decreasing suction pressures - is shown in fig. 58. The electric connection to the terminals of the contact system are also shown as well. The cut-in value (terminals 14) required is set on the range scale (START) of the control. See fig. 59. The differential required is set on the differential scale, (DIFF). The cut-out value (STOP) (terminals 1-2) is then derived from the expression: STOP = START minus DIFF
Fig. 58
The function of the control may be, for example: 1) Used to start and stop the compressor, depending of the pressure in the suction line. At too low a pressure the compressor is cut-out. When the pressure has increased by a value corresponding to the differential, the circuit to the compressor motor is made again. 2) Used as a low pressure safety switch. The pressure control will cut-out the compressor at too low a suction pressure. The compressor can then for example be controlled by a room thermostat.
Fig. 59
Fig. 60
KP 1 and 1A are also available in a design with minimum reset. See fig. 60. A manual reset can be carried out only when the pressure has increased by a value higher than or equal to the fixed differential. The scales on KP 1 and 1A reset controls are calibrated differently from the remaining KP low pressure controls.
On these reset controls the scale value corresponding to the required cut-out value (STOP), while the scale value for the remaining KP low pressure controls corresponds to the cut-in value (START). KP low pressure controls with minimum reset have a locking plate on the range spindle, so that both the cut-in and the cut-out values of the control are fixed.
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27
High pressure controls type KP 5 and 5A
KP 5 and 5A are usually connected to the high pressure side of the refrigeration compressor. The usual function of the high pressure control is to cut the current supply to the compressor motor or relay, when the pressure exceeds that set on the range scale.
KP 5 and 5A can be obtained in two designs: 1) With adjustable differential, fig. 61. In this design the compressor is automatically cut-in again, when the pressure has fallen by a value equal to or higher than the differential setting. The electric connection of the high pressure control can be seen in fig. 62, and also how it is set. The cut-out value (terminals 1-4) required is set on the range scale (STOP) of the control. See fig. 63. The differential required is set on the differential scale (DIFF), fig. 61. The cut-in value (START, terminals 1-2) is then derived from the expression START = STOP minus DIFF
Fig. 61
The locking plate can lock both spindles.
Fig. 62
Fig. 63
2) With maximum reset-function and fixed differential setting (4 bar), fig. 63. This type of pressure control is used as a safety switch and can be manually reset only when the pressure has fallen by a value equal to or higher than the fixed differential of 4 bar. The pressure control is provided with a locking plate, which ensures that the range setting is locked. For safety reasons it is often desirable to seal reset controls. This can be done by using a DIN-standardized sealing screw, see fig. 64. The sealing screw must be ordered separately.
Fig. 64
Combined high and low pressure control type KP 15 and 15A
Fig. 65
1. 2. 3. 5. 18.
low pressure setting spindle, LP differential setting spindle, LP main arm high pressure setting spindle, HP locking plate
28
RF.5X.A1.02
Combined high and low pressure control type KP 15 and 15A (cont.)
KP 15 and 15A are combined low and high pressure controls having setting facilities both on low and high pressure sides. As shown in fig. 65, the functions of the low pressure side and the high pressure side are mechanically separated. This means that both the low pressure side and the high pressure side are able to cut-in and cut-out the compressor, independently. For safety reasons, the high pressure side is provided with an internal scale, while the low pressure side is provided with an external scale. KP 15 and 15A exist in the following designs: 1) without reset, fig. 66 2) with maximum reset, fig. 67 3) with minimum/maximum reset, fig. 68
High pressure setting The condensing pressure (~ STOP pressure) is determined according to the required working conditioning of the plant. This pressure is set by means of the high pressure spindle on the internal HP scale of the control. The cut-in value (START pressure) is then derived from the expression: START = STOP minus DIFF where DIFF is the fixed differential of approx. 4 bar. Low pressure setting Pressure controls with automatic reset LP: Set the LP start pressure on the CUT-IN scale (range scale). One rotation of the low pressure spindle 0.7 bar. Set the LP differential so the DIFF scale. One rotation of the differential spindle 0.15 bar. The LP stop pressure is the LP start pressure minus the differential. Note! The LP stop pressure must lie above absolute vacuum (p = 1 bar)! If with low stop pressure the refrigeration compressor will not stop, check to ensure that the differential value has not been set too high! Pressure controls with automatic reset HP: Set the HP pressure on the CUT-OUT scale. One rotation of the HP spindle 2.3 bar. Set the HP differential on the DIFF scale. One rotation of the differential spindle 0.28 bar. The HP start pressure is the HP stop pressure minus the differential. Pressure controls with manual reset Set the stop pressure on CUT-OUT scale (range scale). Low pressure controls can be manually reset when the pressure is equal to the stop pressure plus the differential. High pressure controls can be manually reset when the pressure is equal to the stop pressure plus the differential. Start and stop pressures for both the LP and HP sides of the system should always be checked with an accurate pressure gauge. With maximum reset It has been possible to work out, practically, the reset function for all KP controls with reset, so that a control will start operating together with the change-over. The setting of KP 15 and 15A with maximum reset follows the same procedure as described in the section concerning controls without reset. When the compressor is cut-out because of too high a condensing pressure, the resetting of controls with maximum reset cannot take place until the pressure has fallen to approx. 4 bar below the cut-out pressure setting on the high pressure scale. Reset can be performed only by actuating the maximum reset knob manually. See fig. 67. 29
Fig. 66
Fig. 67
Fig. 68
Without reset When the compressor is running, terminals AC are connected. See fig. 65. If the pressure on the HP side exceeds the cut out pressure on the high pressure spindle, or if the suction pressure on the LP side falls below the cutout pressure setting, in contact change-over occurs, so cutting the current to the compressor motor is cut-out. The compressor motor will restart when the conditions have returned to normal, i.e: 1) either when the suction pressure has increased by a value equal to or higher than the differential setting 2) or when the pressure on the condenser side has fallen by a value equal to or higher than the fixed differential of the control, approx. 4 bar. As mentioned previously on combined high and low pressure controls the two pressure ranges are set separately.
RF.5X.A1.02
With minimum/maximum reset On KP 15 and 15A with minimum reset the low pressure scale is calibrated in a way corresponding to KP 1 and 1A with minimum reset. The STOP value set on the low pressure scale corresponds to change-over at falling pressures. The cut-out value required on the low pressure side should be set by means of the low pressure spindle.
Cutting-in the compressor motor, which has been stopped because of too low a suction pressure, cannot take place until the minimum reset knob is actuated, see fig. 68, and not until the pressure has increased by a value corresponding to the fixed differential of 0.7 bar. Setting and restarting after stop on the high pressure side are described in the section concerning KP 15 and 15A with maximum reset. On HP signal contact mk. D the current marking is 50 VA 380 V a.c. / 12 W 220 V d.c. ON LP signal contact mk. B the current marking is 16 A 380 V a.c. / 12 W 220 V d.c. (see fig. 71).
KP pressure controls with LP + HP signal
On variants of KP 15, KP 15A and 17W with both LP and HP signal contacts it is possible to take out two separate signals. The signal taken will depend on whether the pressure control is to cut out the compressor because of too low a suction pressure or too high a discharge pressure.
et. al. Fig. 70 Fig. 71
KP pressure controls with convertible automatic/ manual reset
KP 15 pressure controls with manual reset are available with convertible automatic/ manual reset. Convertible automatic/manual reset means that when the unit is installed it is possible to choose between manual reset mode or automatic reset mode on both high pressure and low pressure sides. This facility is also advantageous when servicing: the installer can allow the pressure control to operate with automatic reset while servicing the system. Changeover from one reset function to the other can be performed by turning the eccentric (A) with a screwdriver in the slot provided (fig. 72).
Fig. 72
This function increases flexibility in both stocking and application, in that the pressure control can be set for four different reset functions and thus four different types of application, see table below.
Low Pressure High Pressure
Manual reset Manual reset
Automatic reset Manual reset
Automatic reset Automatic reset
Manual reset Automatic reset
30
RF.5X.A1.02
KP pressure control program
In fig. 73 is a table of the KP control programme with technical data.
Fig. 73
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31
RT pressure controls
Pressure control designs
The pressure controls are available in three designs: 1. Low pressure controls which makes the circuit when the pressure on the suction side of the system exceeds a preset value, and breaks it when the pressure falls to a value below the differential setting. The following types are low-pressure controls: RT 1, 1A, 110, 112, 113, 116, 121 and 200. 2. High pressure controls which breaks the circuit when the pressure on the highpressure side of the system exceeds a preset value, and makes the circuit when the pressure falls to a value below the differential setting. The following types are high-pressure controls: RT 5, 5A, 6W, 6B, 6S, 6AW, 6AB, 6AS, 117 and 118. The high pressure controls are, normally, supplied without a knob. Instead the main spindle is covered by a protective cap. Setting is only possible when the protective cap has been removed. Setting By turning the knob, the minimum pressure at which the switch is to operate (break or make the circuit) is set. This value can be read on the main scale of the control. Next, the differential is set by rotating the differential adjusting nut. Maximum actuating pressure = minimum actuating pressure + differential setting. The diagram, fig. 74, shows the number on the differential scale which corresponds to the differential required. The diagram applies to switch 17-4030.
Fig. 74
Example: Setting type RT 1 at 7 will result in a differential of approx. 1.2 bar, while the same setting on type RT 5A will result in a differential of approx. 3.0 bar.
Fig. 75
Fig. 76
32
RF.5X.A1.02
RT pressure controls
3. Pressure controls with reset In those cases where the pressure control is used as a safety cut-out, reset must not be automatic. Therefore, RT 1 and 1A as well as RT 5 and 5A are available with a reset but so that reset can only be effected manually after the pressure has become normal. The low pressure controls RT 1 and 1A are available in designs with minimum reset (fig. 77) which cut-out when the pressure has fallen to a preset value. Manual reset (41) cannot take place until the pressure in the bellows system has increased to a value corresponding to the setting + differential. The factory locked differential adjusting nut (19) has been shortened at the top so that it cannot actuate the arm of the switch when the pressure increases. When the pressure falls, the guiding knob (17) actuates the arm of the switch in the usual way, and causes a contact change-over from 1-4 to 1-2.
The scale is calibrated in such a way that the value set on the scale corresponds to contact change-over on decreases in the pressure.
Fig. 77
The high pressure controls RT 5 and 5A are available in designs with maximum reset (fig. 78) which cut-out when the pressure has increased to a value corresponding to the pressure setting. Manual reset (41) cannot be effected until the pressure has fallen to a value which corresponds to the pressure setting minus the differential. The factory locked differential adjusting nut (19) is in this case used as a guiding knob. When the pressure increases, the differential adjusting nut (19) actuates the arm.of the switch and causes a contact change-over from 1-2 to 1-4. The scale is calibrated in such a way that the value set on the scale corresponds to contact change-over on increases in the pressure, which is quite the opposite of the usual RT controls.
Fig. 78
Refrigerants
All the pressure controls can be used for all fluorinated refrigerants. The RT 1A and 5A designs can also be used for ammonia (NH3).
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33
Safety pressure controls of TV-design
TV-design
Today, in West Germany, the TV (Technische berwachungs Verein) exercises authority over refrigeration plants. The TV deals especially with safety and, therefore, lays down the following regulations (which came into force 1st December 1974).
Refrigeration plant in operation in Germany affected by TVs regulations must be converted and equipped with safety controls complying with DIN 32733 requirements. This means that manufacturers exporting to Germany will have to supply refrigeration plants able to obtain TV approval.
A. Accident prevention measures on Of special interest to Danfoss are TV refrigeration plants (VBG 20). requirements on high pressure controls with B. Instructions and procedures for accident prevention on refrigeration plants (VBG 20). fail-safe bellows elements. Meeting DIN 32733 requirements TV safety pressure controls with fail-safe functions are covered by three types of control. - DWK - Druckwchter (pressure control) - DBK - Druckbegrenzer (pressure limiter) - SDBK - Sicherheitsdruckbegrenzer (safety pressure limiter) These pressure controls must be able to cutout the refrigeration compressor, when the cut-out pressure is exceeded. A parallel requirement is, that the pressure control must cut-out the refrigeration compressor if the bellows ruptures. A practical solution of this problem has been found by providing the pressure controls with a bellows element consisting of an external and an internal bellows. The space between the bellows is evacuated, so that the pressure control will cut-out the compressor, if one of the bellows ruptures. The cross-sectional drawings show some TV approved controls. Please, note the bellows elements with the two bellows.
Fig. 79
Fig. 81
Fig. 80
Fig. 82
34
RF.5X.A1.02
Safety pressure controls of TV-design
The three designs covering DIN 32733 requirement are as follows: DWK - pressure control This type of pressure control is used for regulation. The pressure control resets itself, after having cut-out when the pressure has fallen by a value equal to the differential. DBK - pressure limiter The pressure limiter is for use as a safety switch. It operates if the pressure increases to a value higher than the normal working pressure. TV approved pressure controls Danfoss market the program of pressure controls shown in the table. All the controls are TV approved.
DBK pressure controls are provided with external reset and, therefore, they can be reset only when the pressure has fallen by a value equal to the fixed differential. SDB - safety pressure limiter The safety pressure limiter is also for use as a safety switch, just like the DBK types. The SDBK pressure limiters have internal reset, meaning that the control cannot be reset until the cover has been removed.
The controls are suitable for the following categories of refrigeration plants: - Refrigeration plants with fluorinated refrigerants - Refrigeration plants with ammonia - Refrigeration plants with turbo refrigeration compressors.
KP pressure controls with DIN 32733 approval 1)

Low pressure (LP) Regulating range Differential High pressure (HP) Regulating range bar 8 28 8 28 8 28 8 28 8 28 0.2 7.5 0.2 7.5 0.2 7.5 0.7 4 0.7 4 0.7 4 8 28 8 28 8 28 Differential Reset High press. Contact system DIN approvals
Pressure
Type 2)
bar High High High KP7W KP7B KP7S KP7BS KP7ABS 3) Dual KP17W KP17W KP17B
1
p bar
p bar 4 10 fixed 4 fixed 4 fixed 4 fixed 4 fixed 4 fixed 4 fixed 4
HP aut. man. man. man. man. SPDT + aut. aut. man. SPDT SPDT SPDT SPST SPST HP and HD signal SPDT SPDT DWK 4B00194 DBK 4B00394 DBK 4B00394 DBK/DBK 4B00294 DBK/DBK 4B00294 DWK 4B00594 DWK 4B00594 DBK 4B00494
) Meets the requirements in VBG 20 dealing with safety equipment and excess pressures. 2) W = Wchter (pressure control, B= Begrenzer (pressure control with ext. reset), S = Sicherheitsdruckbegrenzer (pressure control with int. reset): A bellows rupture will cause the refrigeration plant compressor to stop. A rupture of the outer bellows wiill cause the stop pressure to fall approx. 3 bar under the set value. 3) KP 7 ABS can also be used for R 717 (NH ). 3
RT pressure controls with DIN 32733 approval 1)

Regulation range Type 2) P bar RT 36 B RT 36S RT 30AW RT 30AB RT 30 AS RT 6W RT 6B RT 6S RT 6AW RT 6AB RT 6AS
1 2
Mechanical differential
Pressure Connection
Reset
DIN approvals
0 2.5
fixed 0.2 fixed 0.7
1/4 in. / 6 mm flare
manual automatic
DBK 4B04091 DWK 4B03991 DWK 4B03891 DWK 4B03791 DBK 4B03691 DWK 4B03791 DBK 4B03691
1 10 5 25 10 28 5 25 10 28
1/2 BSP ext. fixed 0.5 fixed 3 1/4 in. / 6 mm flare fixed 1.5 fixed 3 fixed 1.5 manual automatic manual manual automatic
3/8 BSP ext. + 6.5 / 10 mm weld nipple
) Meets the requirements in VBG 20 dealing with safety equipment and excess pressures. ) W = Wchter (pressure control, B= Begrenzer (pressure control with ext. reset), S = Sicherheitsdruckbegrenzer (pressure control with int. reset): A bellows rupture will cause the refrigeration plant compressor to stop.
RF.5X.A1.02
35
Differential pressure controls
A differential pressure control is a pressure controlled electrical switch which makes and breaks the circuit depending on the difference between the pressures in the two opposite acting bellows elements. Within the operating range, the functioning of the pressure control only depends on the said pressure difference, where as it is independent of the absolute pressures which act on the bellows. The differential pressure control is used for protecting refrigeration compressors with forced lubrication, where under any operating conditions the oil pressure has to be kept higher than the suction pressure or the crankcase pressure. Furthermore, the differential pressure control can be used for the protection of filters, pumps, etc. Contact differential The pressure rise in excess of the set pressure differential which is necessary to make the contact system change from cut in to cut out. See the example in the section Setting on page 36. Release time The time the differential pressure control allows the compressor to run with too low an oil pressure. See the example in the section Setting on page 36.
3. LP connection 4. LP bellows element 5. Setting disc 12. Main spring 15. Main spindle 17. Upper guiding Knob 18. Contact system 20. Lower guiding Knob 24. HP bellows element 34. HP connection
Fig. 83
Differential control terminology
Differential range The difference in pressure between the OIL and the LP connections within which the differential pressure control can be set to operate. Scale reading The difference that exists between the OIL and LP pressures at the moment the contact system changes over when the main spindle travels down. The downward travel corresponds to falling differential pressure. Function range The pressure range on the LP connection within which the differential pressure control is able to operate.
MP differential pressure control
Types MP 54, 55 and 55A are for use as safety controls on pressure-lubricated refrigeration compressors. The units will stop a compressor after a certain time in the event of an oil pressure failure. The MP 54 and 55 are for refrigeration plants with fluorinated refrigerants like R 12, R 22, R 500 and R 502. The MP 55A is for refrigeration plants with R 717(NH3) and can also be used with fluorinated refrigerants. Types MP 54, 55 and 55A have built-in thermal time relay with a fixed release time.
Fig. 84
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RF.5X.A1.02
Fitting The differential pressure control can be installed in any position. It can be mounted direct on a wall or on the compressor installation panel by using the fitting holes in the back of the unit. The unit can also be installed on a bracket. See Accessories. Bellows element OIL is connected to the lubrication system at the point where the required minimum oil pressure must be maintained during operation. This will normally be at the outlet side of the pump or at the discharge from the crankshaft lubrication system. Bellows element LP is connected to the compressor crankcase. Connection must not be made to the suction manifold or a similar position where the pressure can vary from the pressure in the crankcase because of flow resistance. The connection must be made in such a way that the line to the pressure control cannot be shut off. On R 717(NH3) refrigeration installations and out of consideration for the oil-ammonia mixture viscosity at ambient temperatures lower than approx. +15C the inside diameter of the connection tube must be at least 4 mm. The weld connection on the MP 55A is designed for 04/06 mm steel tube. Electrical connections The wiring diagram printed in the cover of the unit shows how the electrical connections are to be made. See fig. 86. Connection terminal S need not necessarily be connected to obtain correct function. Terminal S is for the connection of a signal lamp which will light up when the time relay cuts out the compressor because of an oil pressure failure. If indication of normal compressor operation is required, a signal lamp can be connected in parallel with the motor relay.
Fig. 85
If there is a requirement for a heating element in the crank case oil sump to be cut in during compressor standstill periods, an auxiliary contact in the motor relay or a KP 98 may be used. As can be seen in fig. 87, the unit contains two separate electrical circuits. One of the advantages of this is that the differential pressure control does not need to be the last link in the electrical circuit of the plant. The control unit (pressure control, thermostat) can be anywhere in the control circuit, before or after the differential pressure control.
Fig. 86
Fig. 87
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Setting
MP 54 has a fixed setting of 0.7 bar differential pressure and cannot be re-adjusted. MP 55 and 55A By inserting a pressure gauge, as shown in fig. 88, the lubricating oil pressure (p1) and the pressure in the crankcase (p2) can be read off. The difference between these pressures is the oil pressure available for the lubrication system. The least allowable oil pressure is set by using the setting disc (3). Turning it upwards decreases pressure and vice versa. NB.: On starting, the oil pressure must rise at least 0.2 bar over the set value. Example Types MP 55 and 55A are set at 3 bar = set value + fixed contact differential. If the oil pressure does not reach 3.2 bar within the release time, current to the coil of the motor starter is cut off and the compressor stops.
Fig. 88
Function If during start the oil fails to reach the set value, or if during operation it falls below the set value, the compressor will stop after the release time has expired. The reset button (4) can be used to cut in the compressor again. Restarting is possible about 2 minutes after cut out but should not be attempted before the reason for the oil pressure failure has been found and the fault corrected. After restarting the compressor a check should be made to see that the differential pressure control is operating according to requirements. This check can be carried out by pressing the test device (5). When the device is pressed upwards and held in that position the compressor must stop after the expiration of the release time given on the time relay. The compressor can then be started as described above.
Fig. 89
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RF.5X.A1.02
RT differential pressure controls
RT differential pressure controls can be delivered in two different designs: RT 260A and RT 262A. Fig. 90 shows the principle of a RT differential pressure control. The bellows (1) and (2) are connected to the LP connection, which is connected to the lower pressure (suction pressure), and the HP connection, which is connected to the higher pressure (oil pressure), respectively. The range spring (3) can be set for different differential pressures, by rotating the setting disc (4). If the pressure differential between the higher and the lower pressures is reduced, the spindle (5) moves downwards and thus actuates the contact arm of the switch through the upper guiding knob. On increase in the pressure differential between the HP and LP bellows, the switch is actuated to change over when the pressure differential has increased to the setting plus the fixed contact differential setting.
1. LP bellow element 2. HP bellow element 3. Main spring 4. Setting disc 5. Main spindle 6. Upper guiding knob 7. Contact arm
Fig. 90
Setting The setting disc (4) can be turned with a screwdriver so that the differential pressure control can be set to make the switch change-over (break or make) at different required differential pressures. The setting can be read on the main scale. Contact position. Terminals 1-4 If the differential pressure falls below the setting, the switch breaks the circuit. The switch makes the circuit again when the differential pressure has increased to the setting + the fixed contact differential.
Example Differential pressure setting = 2 bar (RT 260A). When the pressure falls below the setting, the switch breaks the circuit. Differential pressure setting + contact differential = 2 + 0.3 = 2.3 bar. At this value the switch makes the circuit again. Contact position. Terminals 1-2 If the differential pressure falls below the setting, the switch makes the circuit. The switch breaks the circuit again when the differential pressure has increased to the setting + the fixed contact differential. Example Differential pressure setting = 2 bar (RT 260A). When the pressure falls below the setting, the switch makes the circuit. Differential pressure setting + contact differential = 2 + 0.3 = 2.3 bar. At this value the switch breaks the circuit.
Fig. 91
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Dead zone pressure controls
The pressure controls type RT L are controls with an adjust able dead zone, because they are equipped with a change-over switch, code No. 17-4032. Design In principle, the RT L pressure controls are built up like the other RT controls, but in order to comply with the dead zone function, the switch has two contact arms which engage two guiding knobs, see fig. 92. Setting, fig. 92 and table below. The set scale value corresponds to the break value of contacts 1-4. The dead zone required is found in the diagram for the control in question. On the lower scale of the diagram it is then possible to read the position to which the knob is to be turned.
Fig. 92 Max. neutral zone 0.2 0.9 bar 0.25 0.7 bar 0.35 1.4 bar 1.5 3.5 bar
Nature of controls Low pressure controls High pressure control
Type RT 1 AL RT 200 L RT 5 AL RT 117 L
Range 0.8 +5 bar 0.2 6 bar 4 17 bar 10 30 bar
Differential fixed 0.2 bar fixed 0.25 bar fixed 0.35 bar fixed 1.0 bar
Dead zone The interval of the controlled variable where the control unit is idle is called the dead zone. From the table it can be seen that the dead zone is the interval without a make function. Mechanical differential The interval between the values of the controlled variable which makes the control unit move is called the mechanical differential.
RT L pressure control range RT L controls can be obtained in different thermostat and pressure control designs as shown in the above table. They are also available with gold plated contacts.
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Safety cut-out and liquid level control type RT 280A
RT 280A used as safety cut-out
RT 280A is the designation of a safety cut-out which has been designed primarily for use as a protection against too high a liquid level e.g. in separators or pump receivers in refrigeration plants with pump circulation. The regulation principle is anon/off control based on the thermal conduction difference between the liquid and vapour phases of a refrigerant. In principle, the RT 280A is-built like a differential pressure control, but the lower bellows system is here in the form of a thermal element with the sensor surrounded by an electric heater.
When RT 280A is used as a safety cut-out, the thermal bulb is mounted in the tank side at the desired maximum level, fig. 95. The upper bellows system, which is a pressure element, is connected in such a way that the reference pressure corresponds to the pressure in the tank. The control switch is connected to the compressor motor starter so that the compressor will be cut-out as soon as the sensor is surrounded by the liquid in the tank, which is at maximum level. When the level drops again, more heat is transferred from the electric heater to the sensor, and the compressor is cut in again.
Fig. 94
Fig. 95
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Safety cut-out and liquid level control type RT 280A
RT 280A/RT 281A used as liquid level control
RT 280A and RT 281A can also be used as a liquid level control in cases where a level differential of 40 mm can be permitted, fig. 96. Among other factors, the liquid level differential depends on the design of the system and the refrigerant rate of level variation. The differential will, normally, be considerably smaller.
When RT 280A or RT 281A is used as a liquid level control, the switch has to send its impulses to a solenoid valve in the liquid inlet which then opens and closes to the liquid supply accordingly.
Fig. 96
Technical data
RT 280A has the following technical data: Refrigerants R 12, R 22, R 502 and R 717(NH3) Temperature range RT 280A RT 281A R 12: 50C to 10C R 22 and R 717(NH3):50C to 0C 30/20 R 502: 65C to 5C 30/20 Power element Adsorption charge 2 m capillary tube Maximum permissible bulb temperature +60C
Thermal bulb Electric heater for 24 V d.c. and a.c. (10 W). The electric heater must be constantly cut-in when the system is operating. The bulb is equipped with a 1.5 m cable. Type of switch A single-pole change-over switch (SPDT) 17-4030.
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Examples of application
Examples of the application of RT thermostats and pressure controls. Temperature control of containers
Fig. 97
In the temperature control of containers for refrigeration and freezing purposes, RT thermostats are often used for regulation and alarm. 1. Freezing
Fig. 99
Fig. 98
When a container is used for freezing, the freezing compartment temperature is controlled by RT 7 (25C to +15C) e.g. 20C to 17C. Another RT 7 thermostat is used for actuating the alarm at too high a temperature e.g. 14C. The alarm may be by signal lamp. (Connection of thermostats is shown in fig. 98).
2. Refrigeration For refrigeration for example at +2 C to +5C, an RT 14L thermostat with a dead zone is used for temperature control (see fig. 99). At too high a temperature the compressor (terminals 1-4 closed) is cut-in. If the ambient temperature is lower than the temperature required in the container, it may be necessary to cut-in the electric heaters (terminals 1-2 closed) to maintain the temperature required for the refrigerated compartment. Another RT 14L is used as a safety thermostat, giving a signal if the temperature is higher or lower than the interval required. The compressor is protected on the high pressure side by an RT 5 pressure control which cuts out the compressor at excessive pressure. An RT 1 pressure control is used on the suction side, this control breaking the circuit to the compressor motor at too low a suction pressure.
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RT 140L used in ventilation systems
Fig. 100 shows a ventilation system in which RT 140L is used as control unit for two solenoid valves for the heating and cooling surfaces in the ventilation duct.
Fig. 100
Operating principle (fig. 101) The regulating thermostat type RT 140L (3) makes the circuit at too high a temperature by closing contacts 1-4 so that the solenoid valve (4) to the cooling surface (water) opens. For a suitable temperature interval (max. 5.5C) the thermostat switch remains in the neutral position, and none of the solenoid valves are actuated. At too low a temperature the contacts 1-2 are closed so that the solenoid valve (5) to the heating surface (water) is actuated.
The safety thermostat type RT 140 (2), normally, remains with the contacts 1-4 closed. In this position, the motor starter (1) is cut-in, with the actuator motor (6) turned to one extreme position, resulting in the damper being open. If the temperature falls below the thermostat setting, contacts 2-1 are closed, and the motor starter is cut-out. At the same time, the actuator motor turns to the opposite extreme position and the air damper is closed.
Fig. 101
NOTE: Fig. 101 does not show how the motor starter is cut out.
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RT 280A and RT 262A used as safety equipment in a pump recirculatory refrigeration plant
In large cold stores, a refrigeration plant with a separator is often used. The normal liquid level in the separator is controlled by the electronic liquid level control type 38E. RT 280A is used as a protection against too high a liquid level. RT 280A breaks the circuit to the compressor when the sensor is surrounded by liquid. It is necessary to maintain a fixed minimum liquid level in the separator to protect the circulation pump against cavitation. If cavitation occurs, the circulation pump should be stopped as soon as possible. Fig. 102 shows a section of a piping layout diagram for a pump system with two pumps, one of which is used as a spare.
The differential pressure control RT 262A is, in this case, installed for use as a safety cutout for the circulation pump and is connected to its suction and high pressure sides. RT 262A is very suitable for this application because of the small differential of the control, 0.1 bar. RT 262A may be combined with a timing relay with manual reset. When the pump is started, a sufficiently high pressure must be built-up on the high pressure side in a suitable time. Failing this, the pump motor is stopped by the timing relay breaking the circuit.
Fig. 102
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RF.5X.A1.02

Automatizacion de Refrigeracion

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