Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Industrial Refrigeration
Ammonia & CO2 Applications
www.danfoss.com/ir
Application Handbook
Contents Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Compressor Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Discharge Temperature Control with Liquid Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Crankcase Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Reverse Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. Condenser Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Air Cooled Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Evaporative Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Water Cooled Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4. Liquid Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 High Pressure Liquid Level Control System (HP LLRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Low Pressure Liquid Level Control System (LP LLRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5. Evaporator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Direct Expansion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Pumped Liquid Circulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 Hot Gas Defrost for DX Air Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4 Hot Gas Defrost for Pumped Liquid Circulation Air Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Multi Temperature Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.6 Media Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.8 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6. Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 Oil cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2 Oil Differential Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Oil Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.5 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7. Safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.1 Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.2 Pressure and Temperature Limiting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Liquid Level Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.4 Refrigerant detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.6 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8. Refrigerant Pump Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1 Pump Protection with Differential Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.2 Pump Bypass Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3 Pump Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.5 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.1 Filter Driers in Fluorinated Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.2 Water Removal for Ammonia Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.3 Air purging systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.4 Heat Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.5 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10. Using CO2 in refrigeration systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.1 CO2 as a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.2 CO2 as a refrigerant in industrial systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.3 Design pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.5 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.6 Oil in CO2 systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.7 Comparison of component requirements in CO2, ammonia and R134a systems . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.8 Water in CO2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.9 Removing water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.10 How does water enter a CO2 system? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.11 Miscellaneous features to be taken into consideration in CO2 refrigeration systems . . . . . . . . . . . . . . . . . . . . . 112
11. Pumped CO2 in Industrial Refrigeration Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12. Control methods for CO2 systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
13. Design of a CO2 sub-critical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
13.1 Electronic solution for liquid level control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
13.2 Hot Gas Defrost for Pumped Liquid Circulation Air Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
14. Danfoss sub-critical CO2 components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
15. Full range of stainless steel products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
16. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
16.1 Typical Refrigeration Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
17. ON/OFF and modulating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
17.1 ON/OFF control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
17.2 Modulating control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Reference Documents - Alphabetical overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Foreword
DKRCI.PA.000.C6.02 / 520H1623
1. Introduction
Application Handbook
Compressor
Oil
separator
Condenser
Oil cooler
Receiver
Expansion
valve 1
Liquid separator
Refrigerant pump
Evaporator
HP vapour refrigerant
LP vapour refrigerant
HP liquid refrigerant
LP liquid refrigerant
Oil
Compressor Control
Oil control
Why?
Why?
How?
How?
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
1. Introduction
(continued)
Condenser Control
Why?
Why?
Safety Systems
Why?
Why?
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
2. Compressor Controls
2.1
Compressor Capacity Control
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
To
condenser
Oil
separator
HP vapour refrigerant
LP vapour refrigerant
Oil
Step Controller
Pressure Transmitter
Danfoss
Tapp_0016
10-2012
Piston compressor
Pressure transmitter-AKS 33
Refrigerants
1 to 34
1 to 34
40 to 85
4 to 20 mA
10 to 90% of V supply
Refrigerants
0 to 60 (depending on range)
1 to 39 (depending on range)
40 to 80
40 to 85
4 to 20 mA
1 to 5V or 0 to 10V
DKRCI.PA.000.C6.02 / 520H1623
Danfoss
Tapp_0017
10-2012
Application Handbook
Compressor
Oil
separator
To
condenser
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Stop valve
Capacity regulator
Stop valve
From receiver
Evaporator
Refrigerants
Media temp. range [C]
Max. working pressure [bar]
Pressure range [bar]
Kv value [m3/h]
Refrigerants
Media temp. range [C]
Max. working pressure [bar]
Pressure range [bar]
Kv value [m3/h]
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Danfoss
Tapp_0139
10-2012
From liquid
separator
evaporator
To oil separator
HP vapour refrigerant
LP vapour refrigerant
From liquid
separator
evaporator
To oil separator
Frequency converter
Controller
Pressure transducer
PLC/OEM
controller
From liquid
separator
evaporator
To oil separator
Frequency converter
VLT FC 102 / FC 302
1.1 kW to 45 kW
1.1 kW to 250 kW
Up to 1200 kW
Voltage
200-240 V
380-480 V
200-690 V
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
2.2
Discharge Temperature
Control with Liquid Injection
Compressor
From liquid
separator
evaporator
To oil
separator
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Stop valve
Solenoid valve
Thermostatic injection valve
Stop valve
Thermostat
Oil injection
Danfoss
Tapp_0018
10-2012
From
receiver
Thermostat - RT
Refrigerants
Enclosure
IP 66/54
65 to 300
50 to 70
60 to 150
Differential t [C]
1.0 to 25.0
20
3.3 to 274
10
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Compressor
From liquid
separator
evaporator
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Stop valve
Solenoid valve
Motor valve
Stop valve
Controller
Temperature sensor
To oil
separator
Oil injection
Danfoss
Tapp_0019
10-2012
From
receiver
Refrigerants
60 to 120
52 bar
DN [mm]
20 to 80
72 to 22,700
30 to 50 (ambient)
0/4-10mA, or 0/2-10
DKRCI.PA.000.C6.02 / 520H1623
11
Application Handbook
Compressor
To oil
separator
From liquid
separator
evaporator
Oil injection
Stop valve
Filter
Solenoid valve
Manual opener
Motor valve
Stop valve
Controller
Temperature sensor
Danfoss
Tapp_0020
10-2012
From
receiver
Refrigerants
60 to 120
52 bar
DN [mm]
20 to 40
12
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
2.3
Crankcase Pressure Control
Compressor
To condenser
Oil
separator
From
evaporator
HP vapour refrigerant
LP vapour refrigerant
Oil
Danfoss
Tapp_0021
10-2012
Refrigerants
60 to +120
52
DN [mm]
20 to 150
Capacity* [kW]
11 to 2440
50 to 120
0.45 to 7
Kv value [m3/h]
0.2
50 to 120
4-28
Kv value [m3/h]
0.2
DKRCI.PA.000.C6.02 / 520H1623
13
Application Handbook
2.4
Reverse Flow Control
Oil
separator
From
evaporator
HP vapour refrigerant
LP vapour refrigerant
Oil
Danfoss
Tapp_0023_02
10-2012
Technical data
Housing: special cold resistant steel approved for low temperature operation.
Spindle: polished stainless steel
Refrigerants
60 to 150
52
DN [mm]
15 to 125
14
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
2.5
Summary
Solution
Application
Benefits
Limitations
Simple.
Almost as efficient at part
load as at full load.
Applicable to compressors
with fixed capacities.
Applicable to all
compressors with the ability
to run at reduced speed.
Applicable to reciprocating
compressors, normally
used for small and medium
systems.
Applicable to all
refrigeration plants.
Simple.
Easy to install.
Low flow resistance.
DKRCI.PA.000.C6.02 / 520H1623
15
Application Handbook
2.6
Reference Documents
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
AKD 102
PD.R1.B
ICF
PD.FT1.A
AKD 102
MG11L
ICF
PI.FT0.C
AKS 21
RK0YG
ICM
PD.HT0.B
AKS 21
RI14D
ICM 20-65
PI.HT0.A
AKS 33
RD5GH
ICS
PD.HS2.A
AKS 32R
PI.SB0.A
CVC
PD.HN0.A
REG
PD.KM1.A
AKS 33
PI.SB0.A
ICS 25-65
PI.HS0.A
CVP
PD.HN0.A
SCA
PD.FL1.A
CVC-XP
PI.HN0.A
ICS 100-150
PI.HS0.B
EKC 331
RS8AG
SVA
PD.KD1.A
CVC-LP
PI.HN0.M
REG
PI.KM1.A
EKC 361
RS8AE
TEAT
PD.AU0.A
CVP
PI.HN0.C
SCA
PI.FL1.A
EVRA(T)
PD.BM0.B
EKC 331
RI8BE
SVA
PI.KD1.A
EKC 361
RI8BF
TEAT
PI.AU0.A
EVRA(T)
PI.BN0.L
To download the latest version of the literature please visit the Danfoss website.
16
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
3. Condenser Controls
DKRCI.PA.000.C6.02 / 520H1623
17
Application Handbook
From
discharge line
Condenser
HP vapour refrigerant
HP liquid refrigerant
Step controller
Pressure transmitter
Stop valve
Stop valve
Stop valve
Danfoss
Tapp_0031_02
10-2012
To expansion
device
Pressure transmitter-AKS 33
Refrigerants
1 to 34
1 to 34
40 to 85
4 to 20 mA
10 to 90% of V supply
Refrigerants
0 to 60 (depending on range)
1 to 39 (depending on range)
40 to 80
40 to 85
4 to 20 mA
1 to 5V or 0 to 10V
18
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
From
discharge
line
Condenser
Receiver
HP vapour refrigerant
HP liquid refrigerant
Frequency converter
Pressure transducer
To expansion
device
Danfoss
Tapp_0141_02
10-2012
Frequency converter
VLT FC 102 / FC 302
1.1 kW to 45 kW
1.1 kW to 250 kW
Up to 1200 kW
Voltage
200-240 V
380-480 V
200-690 V
DKRCI.PA.000.C6.02 / 520H1623
19
Application Handbook
Condenser
Suction
line
Compressor
HP vapour refrigerant
HP liquid refrigerant
Pressure regulator
Stop valve
Check valve
Stop valve
Stop valve
Differential pressure
regulator
Stop valve
Receiver
Danfoss
Tapp_0148_02
10-2012
To oil
cooler
To expansion
device
Refrigerants
60 to 120
52
DN [mm]
20 to 150
50 to 120
CVPP (LP): 17
CVPP (HP): up to 40
CVPP (LP): 0 to 7
CVPP (HP): 0 to 22
Kv value m3/h
0.4
20
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Technical data
(continued)
50 to 120
CVP (LP): 17
CVP (HP): up to 40
CVP (XP): 52
Kv value m3/h
Material
Body: steel
Refrigerants
50 to 150
40
DN mm
20/25
2 to 8
DKRCI.PA.000.C6.02 / 520H1623
21
Application Handbook
3.2
Evaporative Condensers
22
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Water
pump
Suction
line
Condenser
Compressor
HP vapour refrigerant
HP liquid refrigerant
Water
Pressure controller
Pressure controller
Stop valve
Stop valve
Stop valve
Receiver
Danfoss
Tapp_0033_02
10-2012
To oil
cooler
To expansion
device
Technical data
HP pressure control - RT 5A
Refrigerants
Enclosure
IP 66/54
50 to 70
RT 5A: 4 to 17
22
25
DKRCI.PA.000.C6.02 / 520H1623
23
Application Handbook
Water
pump
Suction
line
Condenser
Compressor
HP vapour refrigerant
HP liquid refrigerant
Water
Step controller
Pressure transmitter
Stop valve
Stop valve
Stop valve
Receiver
Danfoss
Tapp_0034_02
10-2012
To expansion
device
To oil
cooler
24
Pressure transmitter-AKS 33
Refrigerants
1 to 34
1 to 34
40 to 85
4 to 20 mA
10 to 90% of V supply
Refrigerants
0 to 60 (depending on range)
1 to 39 (depending on range)
40 to 80
40 to 85
4 to 20 mA
1 to 5V or 0 to 10V
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
3.3
Water Cooled Condensers
Cooling
water out
Suction
line
Compressor
HP vapour refrigerant
HP liquid refrigerant
Water
Stop valve
Stop valve
Water valve
Condenser
Danfoss
Tapp_0035_02
10-2012
Cooling
water in
To expansion
device
Refrigerants
Media
25 to 90
2.2 to 19
26.4
10
DN [mm]
32 to 100
DKRCI.PA.000.C6.02 / 520H1623
25
Application Handbook
HP vapour refrigerant
HP liquid refrigerant
Water
Pressure transmitter
Controller
Motor-valve
Stop valve
Stop valve
Controller
Cooling
water out
Suction
line
Compressor
Condenser
Danfoss
Tapp_0036_02
10-2012
To expansion
device
Cooling
water in
Motor valve - VM 2
Material
Media
2 to 150
25
DN [mm]
15 to 50
26
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
3.4
Summary
Solution
Application
Benefits
Limitations
Industrial refrigeration
with very large capacity
requirement
Industrial refrigeration
with very large capacity
requirement
Condenser
Receiver
Water
pump
Condenser
Receiver
Cooling
water in
Compressor
Condenser
Cooling
water out
Cooling
water in
Compressor
Condenser
3.5
Reference Documents
For an alphabetical overview of
all reference documents please
go to page 146
Cooling
water out
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
AKD 102
PD.R1.B
ICS
PD.HS2.A
AKD 102
MG11L
ICS 25-65
PI.HS0.A
AKS 21
RK0YG
NRVA
PD.FK0.A
AKS 21
RI14D
ICS 100-150
PI.HS0.B
AKS 33
RD5GH
RT 5A
PD.CB0.A
AKS 32R
PI.SB0.A
NRVA
PI.FK0.A
AMV 20
ED95N
SVA
PD.KD1.A
AKS 33
PI.SB0.A
RT 5A
RI5BC
CVP
PD.HN0.A
VM 2
ED97K
AMV 20
EI96A
SVA
PI.KD1.A
CVPP
PD.HN0.A
WVS
PD.DA0.A
CVP, CVPP
PI.HN0.C
VM 2
VIHBC
CVP-XP
PI.HN0.J
WVS
PI.DA0.A
To download the latest version of the literature please visit the Danfoss website.
DKRCI.PA.000.C6.02 / 520H1623
27
Application Handbook
4.1
High Pressure Liquid Level
Control System (HP LLRS)
28
DKRCI.PA.000.C6.02 / 520H1623
From condenser
Danfoss
Tapp_0044_02
10-2012
Application Handbook
From
discharge
line
HP vapour refrigerant
HP liquid refrigerant
LP liquid refrigerant
Receiver
Stop valve
Filter
Servo-operated main valve
Stop valve
Float valve
Stop valve
Stop valve
To separator
To oil
cooler
PMFH 80 - 1 to 500
Material
Refrigerants
60 to + 120
28
42
139-13900
Housing: steel
Cover: low temperature cast iron
Float: stainless steel
Refrigerants
50 to + 65
P-band [mm]
35
28
36
Kv value [m3/h]
0.06 for SV 1
0.14 for SV 3
SV1: 25
SV3: 64
DKRCI.PA.000.C6.02 / 520H1623
29
Application Handbook
HFI
Cooling water in
HP vapour refrigerant
HP liquid refrigerant
LP liquid refrigerant
Water
Danfoss
Tapp_0045_02
10-2012
HP float valve
To liquid
separator
purge pipe
(option 2)
HFI
Material
Refrigerants
R717 and other non-flammable refrigerant. For the refrigerants with density greater than 700kg/m3,
please consult Danfoss.
50 to 80
25 bar
400 to 2400
30
DKRCI.PA.000.C6.02 / 520H1623
From condenser
Danfoss
Tapp_0046_02
10-2012
Application Handbook
From
discharge
line
HP vapour refrigerant
HP liquid refrigerant
LP liquid refrigerant
Receiver
Stop valve
Filter
Motor valve
Stop valve
Controller
Level transmitter
Stop valve
Stop valve
To separator
To oil
cooler
Refrigerants
60 to 120
52
DN [mm]
20 to 80
73 to 22,700
Refrigerants
60 to 100
Process pressure
800 to 8000
DKRCI.PA.000.C6.02 / 520H1623
31
Application Handbook
4.2
Low Pressure Liquid
Level Control System (LP
LLRS)
From evaporator
To
compressor
suction line
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
From
receiver
Liquid
separator
Stop valve
Filter
Solenoid valve
LP float valve
Stop valve
Stop valve
To evaporator
Danfoss
Tapp_0047_02
10-2012
SV 4-6
Material
Housing: steel
Cover: low temperature cast iron(spherical)
Float: stainless steel
Refrigerants
50 to +120
P-band [mm]
35
28
42
Kv value [m3/h]
0.23 for SV 4
0.31 for SV 5
0.43 for SV 6
SV4: 102
SV5: 138
SV6: 186
32
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
From
evaporator
To
compressor
suction line
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
From
receiver
Liquid
separator
Stop valve
Filter
Servo-operated main valve
Stop valve
LP float valve
Stop valve
Stop valve
To evaporator
Danfoss
Tapp_0048_02
10-2012
PMFL 80 - 1 to 500
Material
Refrigerants
60 to +120
28
42
139-13,900
Stop valve
Filter
Solenoid valve
Motor valve
Stop valve
Controller
Level transmitter
Level switch
To
compressor
suction line
From
receiver
Liquid
separator
From evaporator
To evaporator
Danfoss
Tapp_0049_02
10-2012
Application Handbook
To
compressor
suction line
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
From
receiver
Liquid
separator
Stop valve
Filter
Solenoid valve
Electronically operated
From evaporator
expansion valve
Stop valve
Controller
Level transmitter
To evaporator
Refrigerants
Media temp. range [C]
Max. working pressure [bar]
DN [mm]
Nominal capacity* [kW]
Danfoss
Tapp_0050_02
10-2012
AKVA
AKVA 10: stainless steel
AKVA 15: cast iron
AKVA 20: cast iron
R717
AKVA 10: 50 to +60
AKVA 15/20: 40 to +60
42
10 to 50
4 to 3150
To
compressor
suction line
Liquid
separator
From receiver
Stop valve
Filter
Solenoid valve
Manual opener
Motor valve
Stop valve
Controller
Level transmitter
Not all valves are shown.
Not to be used for construction
purposes.
34
From evaporator
To evaporator
DKRCI.PA.000.C6.02 / 520H1623
Danfoss
Tapp_0051_02
10-2012
Application Handbook
To
compressor
suction line
From
receiver
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Liquid
separator
From evaporator
Stop valve
Solenoid valve
Hand regulating valve
Stop valve
Level switch
To evaporator
Danfoss
Tapp_0052_02
10-2012
AKS 38
Material
Refrigerants
50 to +65
28
12.5 to 50
REG
Material
Refrigerants
50 to +150
52
DN [mm]
6 to 65
Kv value [m3/h]
EVRA
Refrigerants
40 to +105
42
21.8 to 2368
Kv value [m3/h]
0.23 to 25.0
DKRCI.PA.000.C6.02 / 520H1623
35
Application Handbook
4.3
Summary
Solution
Application
Benefits
Limitations
Pure mechanical.
Wide capacity range.
Applicable to systems
with small refrigerant
charges and with plate type
condensers only.
Pure mechanical.
Simple solution.
Especially suitable for plate
heat exchanger
Pure mechanical.
Simple, low cost solution.
Limited capacity.
Particularly applicable to
de-central systems, like cold
stores.
Pure mechanical.
Wide capacity range.
Particularly applicable to
de-central systems, like cold
stores.
Particularly applicable to
de-central systems, like cold
stores.
Particularly applicable to
de-central systems, like cold
stores.
Particularly applicable to
de-central systems, like cold
stores.
Simple.
In-expensive.
Receiver
Plate type
condenser
Receiver
Liquid separator
4.4
Reference Documents
For an alphabetical overview of
all reference documents please
go to page 146
Literature no.
PD.GD0.A
PD.SC0.C
PD.VA1.B
PS.G00.A
PD.BM0.B
PD.HT0.B
Product instruction
Type
PMFH/L
ICF
REG
SV 1-3
SV 4-6
Literature no.
PD.GE0.C
PD.FT1.A
PD.KM1.A
PD.GE0.B
PD.GE0.D
Type
AKS 38
AKS 4100/
4100U
AKVA
EKC 347
EVRA(T)
ICM 20-65
Literature no.
PI.GD0.A
PI.SC0.D
PI.SC0.E
PI.VA1.C /
PI.VA1.B
PI.RP0.A
PI.BN0.L
PI.HT0.A
Type
Literature no.
ICM 100-150 PI.HT0.B
PMFH/L
PI.GE0.D /
PI.GE0.A
ICF
PI.FT0.C
REG
PI.KM1.A
SV 1-3
PI.GE0.C
SV 4-6
PI.GE0.B
To download the latest version of the literature please visit the Danfoss website.
36
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
5. Evaporator Controls
5.1
Direct Expansion Control
DKRCI.PA.000.C6.02 / 520H1623
The liquid injection is controled by a superheatcontrolled expansion valve, which maintains the
superheat at the outlet of the evaporator within a
desired range. This expansion valve can be either
a thermostatic expansion valve, or an electronic
expansion valve.
The temperature control is normally achieved by
ON/OFF control, which starts and stops the liquid
supply to the evaporator according to the media
temperature.
37
Application Handbook
Danfoss
Tapp_0062_02
10-2012
To suction line
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
From
receiver
Evaporator
R717
50 to 30
100
19
3.5 to 295
40 to +105
42
21.8 to 2368
Kv value [m3/h]
0.23 to 25.0
38
Refrigerants
50 to +140
28
DN [mm]
15/20
Filter insert
Kv value [m3/h]
3.3/7.0
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Danfoss
Tapp_0063_02
10-2012
To suction line
From receiver
Evaporator
Pressure transmitter
Temperature sensor
Application example 5.1.2 shows a typical
installation for an electronically controlled DX
evaporator without hot gas defrost.
The liquid injection is controled by the motorvalve ICM controlled by the evaporator
controller type EKC 315A . The EKC 315A
controller will measure the superheat by means
of the pressure transmitter AKS and the
temperature sensor AKS 21 on the outlet of
the evaporator, and controlling the opening of
the ICM in order to maintain the superheat at the
optimum level.
At the same time, the controller EKC 315A
operates as a digital thermostat, which will
control the on/off switching of the solenoid valve
EVRA depending on the media temperature
signal from the temperature sensor AKS 21 .
Technical data
Refrigerants
60 to 120
52
DN [mm]
20 to 80
73 to 22700
Refrigerants
0 to 60 (depending on range)
1 to 39 (depending on range)
40 to 80
40 to 85
4 to 20 mA
1 to 5V or 0 to 10V
DKRCI.PA.000.C6.02 / 520H1623
39
Application Handbook
Danfoss
Tapp_0064_02
10-2012
To suction line
From receiver
Evaporator
40
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
Danfoss
Tapp_0160_02
10-2012
To suction line
From receiver
Evaporator
DKRCI.PA.000.C6.02 / 520H1623
41
Application Handbook
5.2
Pumped Liquid
Circulation Control
Danfoss
Tapp_0065_02
10-2012
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
From liquid
separator
To liquid
separator
Evaporator
REG
Material
Refrigerants
50 to +150
52
DN [mm]
6 to 65
Kv value [m3/h]
42
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
To liquid
separator
Evaporator
DKRCI.PA.000.C6.02 / 520H1623
43
Application Handbook
Application 5.2.3
Injecting liquid in an air cooler
in a flooded system
using pulse width modulation
valve AKVA/ICFA, with electrical
or brine defrost
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
Danfoss
Tapp_0155_02
10-2012
From liquid
separator
expansion valve
Evaporator inlet stop valve
Suction line stop valve
Digital thermostat
Temperature sensor
Evaporator
ICF control solution with:
To liquid
separator
Evaporator
Danfoss
Tapp_0156_02
10-2012
From liquid
separator
Stop valve
Filter
Electronic expansion valve
Stop valve
To liquid
separator
Evaporator
44
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
5.3
Hot Gas Defrost
for DX Air Coolers
DKRCI.PA.000.C6.02 / 520H1623
45
Application Handbook
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
To condenser
Compressor
To other
evaporators
Liquid Line
Stop valve liquid inlet
Filter
Solenoid valve
Expansion valve
Stop valve evaporator inlet
Suction Line
Stop valve evaporator inlet
Two step solenoid valve
Stop valve suction line
Hot gas line
Stop valve
Filter
Solenoid valve
Stop valve
Check valve
Discharge line
Stop check valve
on the discharge line
Differential pressure
regulator
Controller
Temperature sensors
Temperature sensors
Temperature sensors
Check valve
From receiver
Evaporator
Danfoss
Tapp_0067_02
10-2012
Defrost Cycle
After initiation of the defrost cycle, the liquid
supply solenoid valve EVRAT is closed. The fan
is kept running for 120 to 600 seconds depending
on the evaporator size in order to pump down
the evaporator of liquid.
The fans are stopped and the GPLX closed. The
GPLX valve is kept in its open position by hot
gas.
The hot gas condenses in the cold valve and
produces liquid on top of the servo piston. When
the pilot valves change position to close the
valve, the pressure on the piston equalises to the
suction pressure.
This equalisation takes time because condensed
liquid is present in the valve.The exact time taken
from when the pilot valves change position to
complete closing of the valve depends on the
temperature, pressure, refrigerant and valve size.
46
From other
evaporators
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Danfoss
Tapp_0157_02
10-2012
From liquid
separator
Evaporator
Pressure regulator
Pressure regulator
Suction line stop valve
Digital thermostat
Temperature sensor
Evaporator
ICF control solution with:
Stop valve
Filter
Electronic expansion valve
Stop valve
To liquid
separator
Hot gas
DKRCI.PA.000.C6.02 / 520H1623
47
Application Handbook
Technical data
Refrigerants
60 to 120
52
DN [mm]
20 to 150
* Conditions: R717, Tliq = 30C, Pdisch. = 12bar, P = 0.2bar, Tdisch. = 80C, Te = 10C, Recirculation Ratio = 4
Gas powered two-step solenoid valve - GPLX
Material
Refrigerants
60 to 150
60 to 120
40
52
DN [mm]
80 to 150
32 to 150
Body: steel
Refrigerants
50 to 140
40
DN [mm]
15 to 65
Filter - FIA
Material
Body: steel
Refrigerants
60 to 150
52
DN [mm]
15 to 200
Filter insert
Refrigerants
60 to 120
52
DN [mm]
20 to 150
* Conditions: R717, Tliq = 30C, Pdisch. = 12bar, P = 0.2bar, Tdisch. = 80C, Te = 10C, Recirculation Ratio = 4
48
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
To condenser
Compressor
Stop Valve
Filter
Solenoid valve
Stop valve
Check valve
Check valve
Stop check valve on the
discharge line
Differential pressure
regulator
Controller
Superheat controller
Temperature sensors
Temperature sensors
Temperature sensors
Temperature sensors
Pressure transmitter
From other
evaporators
To other
evaporators
Evaporator
From receiver
Danfoss
Tapp_0068_02
10-2012
Refrigeration Cycle
The solenoid valve ICFE in the ICF in the liquid
line is kept open. The liquid injection is controled
by the motor-valve ICM in the ICF .
The solenoid valve GPLX on the suction line is
kept open, and the defrosting solenoid valve ICFE
in ICF is kept closed.
The servo valve ICS is kept open by its solenoid
valve pilot EVM.
Defrost Cycle
After initiation of the defrost cycle, the liquid
supply solenoid ICFE in ICF is closed. The fan is
kept running for 120 to 600 seconds depending
on the evaporator size in order to pump down
the evaporator of liquid.
49
Application Handbook
Controller
To receiver
To condenser
Compressor From other
evaporators
Stop Valve
Filter
Solenoid valve
Stop valve
Check valve
Check valve
Stop check valve on the
discharge line
Differential pressure
regulator
Controller
Superheat controller
Temperature sensors
Temperature sensors
Temperature sensors
Temperature sensors
Pressure transmitter
To other
evaporators
Evaporator
From receiver
Danfoss
Tapp_0158_02
10-2012
Refrigeration Cycle
The solenoid valve ICFE in the ICF in the liquid
line is kept open. Liquid injection is controlled by
the motor valve ICM in the ICF .
The motor valve ICM on the suction line is kept
open, and the defrosting solenoid valve ICFE in
ICF is kept closed.
The servo valve ICS is kept open by its solenoid
valve pilot EVM.
Defrost Cycle
After initiation of the defrost cycle, the liquid
supply solenoid ICFE in ICF is closed. The fan is
kept running for 120 to 600 seconds, depending
on the evaporator size, to pump down the liquid
in the evaporator.
The fans are stopped and the motor valve ICM
closed.
A delay of 10 to 20 seconds is required for the
liquid in the evaporator to settle down in the
bottom without vapour bubbles. The solenoid
valve ICFE in ICF is then opened and supplies
hot gas to the evaporator.
50
Application Handbook
5.4
Hot Gas Defrost for Pumped
Liquid Circulation Air
Coolers
Application example 5.4.1:
Pumped liquid circulation
evaporator, with hot gas defrost
system
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
Liquid Line
Stop valve liquid inlet
Filter
Solenoid valve
Check valve
Hand expansion valve
Stop valve evaporator inlet
Suction Line
Stop valve evaporator outlet
Two step solenoid valve
Stop valve suction line
Hot gas line
Stop valve
Filter
Solenoid valve
Stop valve
Check valve
Overflow line
Overflow valve
Controls
Controller
Temperature sensor
Temperature sensor
Temperature sensor
Danfoss
Tapp_0069_02
10-2012
To liquid separator
From liquid
separator
Evaporator
From discharge line
Refrigeration Cycle
The solenoid valve ICS on the liquid line is kept
open. The liquid injection is controled by the
hand regulating valve REG .
Technical data
Body: steel
Refrigerants
50 to 150
40
DN [mm]
20/25
2 to 8
DKRCI.PA.000.C6.02 / 520H1623
51
Application Handbook
Danfoss
Tapp_0070_02
10-2012
To liquid
separator
Stop Valve
Filter
Solenoid valve
Stop valve
Check valve
Float valve
Controller
Temperature sensors
Temperature sensors
Temperature sensors
The fans are stopped and the GPLX closed. The GPLX
valve is kept in its open position by hot gas.
52
Application Handbook
Controller
Danfoss
Tapp_0159_02
10-2012
To liquid
separator
Stop Valve
Filter
Solenoid valve
Stop valve
Check valve
Pressure regulator
Controller
Temperature sensors
Temperature sensors
Temperature sensors
DKRCI.PA.000.C6.02 / 520H1623
53
Application Handbook
5.5
Multi Temperature
Changeover
Danfoss
Tapp_0071_02
10-2012
To liquid separator
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
From liquid
separator
pilot valve
Pressure regulating
pilot valve
Solenoid pilot valve
Evaporator
Example:
I
II
+3C
+8C
Evaporating temperature
2C
+2C
Temperature change
Refrigerant
Evaporating pressure
5K
6K
R 717
R 717
3.0 bar
3.6 bar
54
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
5.6
Media Temperature Control
Danfoss
Tapp_0072_02
09-2013
To liquid separator
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
pilot valve
From liquid
separator
Evaporator
DKRCI.PA.000.C6.02 / 520H1623
55
Application Handbook
Danfoss
Tapp_0073_02
10-2012
To liquid separator
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
From liquid
separator
Pressure regulator
(motor valve)
Controller
Solenoid valve with filter
Evaporator
56
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
5.7
Summary
Solution
Application
Benefits
Limitations
All DX systems
All DX systems
All DX systems
DX evaporator, electronic
expansion control with ICM/
ICF, EVRA and EKC 315A
Evaporator
Evaporator
Multi-temperature Changeover
Multi-temperature control
with ICS and CVP
Evaporator
Evaporator
Evaporator
Option of running at
different temperatures.
DKRCI.PA.000.C6.02 / 520H1623
57
Application Handbook
5.8
Reference Documents
Product instruction
Type
Literature no.
Type
Literature no.
AKS 21
RK0YG
FIA
PD.FN1.A
Type
Literature
no.
Type
Literature
no.
AKS 33
RD5GH
GPLX
AKVA
PD.VA1.B
ICF
PD.BO0.A
AKS 21
RI14D
FIA
PI.FN1.A
PD.FT1.A
AKS 32R
PI.SB0.A
GPLX
PI.BO0.A
PI.SB0.A
ICF
PI.FT0.C
PI.VA1.C /
PI.VA1.B
ICM 20-65
PI.HT0.A
ICM 100-150
PI.HT0.B
ICS 25-65
PI.HS0.A
ICS 100-150
PI.HS0.B
NRVA
PI.FK0.A
OFV
PI.HX0.B
ICLX
PI.HS1.A/B
REG
PI.KM1.A
SV 1-3
PI.GE0.C
SVA
PI.KD1.A
TEA
PI.AJ0.A
CVP
PD.HN0.A
ICM
PD.HT0.B
AKS 33
CVQ
PD.HN0.A
ICS
PD.HS2.A
AKVA
EVM
PD.HN0.A
NRVA
PD.FK0.A
EKC 202
RS8DZ
OFV
PD.HQ0.A
EKC 315A
RS8CS
ICLX
PD.HS1.A
EKC 361
RS8AE
REG
PD.KM1.A
EVRA(T)
PD.BM0.B
SV 1-3
PD.GE0.B
FA
PD.FM0.A
SVA
TEA
PD.KD1.A
PD.AJ0.A
CVP
PI.HN0.C
CVQ
PI.VH1.A
EVM
PI.HN0.N
EKC 202
RI8JV
EKC 361
RI8BF
EVRA(T)
PI.BN0.L
FA
PI.FM0.A
To download the latest version of the literature please visit the Danfoss website.
58
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
6. Oil Systems
6.1
Oil cooling
DKRCI.PA.000.C6.02 / 520H1623
59
Application Handbook
Oil cooler
Cooling water in
Water
Oil
Water valve
Stop valve
Stop valve
Media
10
Bulb: 0 to 90
Liquid: 25 to 90
DN [mm]
32 to 100
12.5 to 125
Water valve - AVTA
Media
16
Bulb: 0 to 90
Liquid: 25 to 130
DN [mm]
10 to 25
1.4 to 5.5
60
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Compressor
From liquid
separator/
evaporator
Condenser
Oil separator
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
Oil
Receiver
Oil cooler
To liquid
separator
Danfoss
Tapp_0084_02
10-2012
Media
40
Continuous operation: 10 to 85
Short operation: 10 to 120
DN [mm]
25 to 80
DKRCI.PA.000.C6.02 / 520H1623
61
Application Handbook
From
separator/
evaporator
Oil separator
Oil cooler
HP vapour refrigerant
LP vapour refrigerant
Oil
Danfoss
Tapp_0085_02
10-2012
62
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
6.2
Oil Differential
Pressure Control
To
condenser
Compressor
From liquid
separator/
evaporator
Oil separator
HP vapour refrigerant
LP vapour refrigerant
Oil
Differential pressure
regulator
To oil cooler
Oil cooler
Refrigerants
60 to 120
52
DN [mm]
20 to 150
20 to 4000
* Conditions: R717, hot gas line, Tliq = 30C, Pdisch. = 12bar, P = 0.2bar, Tdisch. = 80C, Te = 10C
Differential pressure pilot valve-CVPP
Material
Refrigerants
50 to 120
CVPP (LP): 17
CVPP (HP): up to 40
CVPP (LP): 0 to 7
CVPP (HP): 0 to 22
Kv value m3/h
0.4
DKRCI.PA.000.C6.02 / 520H1623
63
Application Handbook
Compressor
From liquid
separator/
evaporator
Oil separator
Check valve
HP vapour refrigerant
LP vapour refrigerant
Oil
Differential pressure
regulator
Check valve
(normally built into the
compressor)
To oil cooler
Technical data
Refrigerants
50 to 150
40
DN [mm]
65 to 200
435 to 4207
64
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
To condenser
Compressor
From liquid
separator/
evaporator
Oil separator
HP vapour refrigerant
LP vapour refrigerant
Oil
Multifunctional
compressor valve
Solenoid pilot
(normally close)
Solenoid pilot
(normally open)
To oil cooler
DKRCI.PA.000.C6.02 / 520H1623
65
Application Handbook
6.3
Oil Recovery System
From
evaporator
From
receiver
Liquid separator
HP vapour refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Stop valve
Stop valve
Stop valve
Quick closing oil drain valve
Regulating valve
Safety relief valve
To refrigerant pump
Oil receiver
Danfoss
Tapp_0089_02
10-2012
Hot gas in
66
Housing: steel
Refrigerants
50 to 150
25
DN [mm]
15
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
From
receiver
Liquid separator
Stop valve
Solenoid valve
Regulating valve
Heat exchanger
Sight glass
Stop valve
Stop valve
Solenoid valve
Regulating valve
To refrigerant
pump
Stop valve
In fluorinated systems miscible oil is
predominantly used. In systems using good
piping practice (slopes, oil loops etc.), it is not
necessary to recover oil, as it returns with the
refrigerant vapour.
However in low temperature plants oil may stay
in the low pressure vessels. Oil is lighter than
commonly used Fluorinated refrigerants, so
its impossible to drain it in a simple way as in
ammonia systems.
Oil stays on top of the refrigerant, and the level
fluctuates together with refrigerant level.
In this system the refrigerant moves from the
liquid separator into the heat exchanger due
to gravity.
Technical data
Danfoss
Tapp_0090_02
10-2012
Heat exchanger - HE
Refrigerants
60 to 120
DN [mm]
Liquid line: 6 to 16
Suction line: 12 to 42
DKRCI.PA.000.C6.02 / 520H1623
67
Application Handbook
6.4
Summary
Solution
Application
Benefits
Limitations
Heavy commercial
refrigeration systems with
power packs.
Hot oil in
Oil cooler
Compressor
Oil separator
Condenser
Receiver
Oil cooler
Compressor
Oil separator
Oil cooler
Compressor
Oil separator
KDC
Compressor
Oil separator
KDC+EVM
Compressor
Oil separator
To LP vessels
Low temperature
Fluorinated systems
Adjusting could be
complicated
Liquid separator
Oil receiver
Compressor
Liquid separator
68
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
6.5
Reference Documents
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
BSV
PD.IC0.A
MLI
PD.GH0.A
BSV
PI.IC0.A
MLI
PI.GH0.A
CVPP
PD.HN0.A
ORV
PD.HP0.B
CVPP
PI.HN0.C
ORV
PI.HP0.A
EVM
PD.HN0.A
QDV
PD.KL0.A
EVM
PI.HN0.N
QDV
PI.KL0.A
FIA
PD.FN0.A
REG
PD.KM1.A
FIA
PI.FN0.A
REG
PI.KM1.A
HE
PD.FD0.A
SVA
PD.KD1.A
HE
PI.FD0.A
SVA
PI.KD1.A
ICS
PD.HS2.A
ICS 25-65
PI.HS0.A
KDC
PD.FQ0.A
ICS 100-150
PI.HS0.B
KDC
PI.FQ0.A
To download the latest version of the literature please visit the Danfoss website.
DKRCI.PA.000.C6.02 / 520H1623
69
Application Handbook
7. Safety systems
7.1
Pressure Relief Devices
70
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
NO PERSONNEL
SHOULD WORK
IN THE OUTLET
AREA OF THE
RELIEF PIPE
From
condenser
Oil level
From
discharge
line
Receiver
HP vapour refrigerant
HP liquid refrigerant
Danfoss
Tapp_0099_02
10-2012
To oil cooler
To liquid separator
DKRCI.PA.000.C6.02 / 520H1623
71
Application Handbook
Technical data
Refrigerants
R717, R744 ,HFC, HCFC, other refrigerants (depending on the sealing material compatibility)
30 to 100
133
10 to 40
Safety relief valve - SFV 20-25 (Back pressure dependent)
Material
Refrigerants
R717, R744 ,HFC, HCFC, other refrigerants (depending on compatibility with gasket material)
30 to 100
10 to 25
72
Material
Refrigerants
50 to 100
40
Kv value [m3/h]
DSV1: 17.5
DSV2: 30
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Compressor
Oil separator
HP vapour refrigerant
LP vapour refrigerant
Oil
To condenser
From
Evaporator
Pilot-operated internal
safety valve
Danfoss
Tapp_0100_02
10-2012
Refrigerants
R717, R744, HFC, HCFC and other refrigerants (depending on the sealing material compatibility)
10 to 25
50
Pilot-operated internal safety valve - POV
Material
Housing: steel
Refrigerants
R717, HFC, HCFC and other refrigerants (depending on the sealing material compatibility)
15 to 25
DN [mm]
40/50/80
DKRCI.PA.000.C6.02 / 520H1623
73
Application Handbook
7.2
Pressure and Temperature
Limiting Devices
Application example 7.2.1:
Pressure /temperature cut-out
for compressors
HP vapour refrigerant
LP vapour refrigerant
Oil
From liquid
separator/
evaporator
To oil separator
Compressor
cut-out
High temperature cut-out
High pressure cut-out
Danfoss
Tapp_0101_02
10-2012
Thermostat - RT
Refrigerants
Enclosure
IP 66/54
65 to 300
50 to 70
60 to 150
Differential t [C]
1.0 to 25.0
Enclosure
IP 20
MP 54: 0.65/0.9
MP 55/55A: 0.3 to 4.5
17
22
Operation range
on LP side [bar]
1 to 12
74
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
7.3
Liquid Level Devices
Application example 7.3.1:
Low / high level controls for
liquid separator
To compressor
suction line
Liquid separator
From receiver
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
From
evaporator
To evaporator
Danfoss
Tapp_0102_02
10-2012
Refrigerants
50 to +65
28
12.5 to 50
Sight glass - LLG
Refrigerants
10 to 100 or 50 to 30
25
Length [mm]
185 to 1550
DKRCI.PA.000.C6.02 / 520H1623
75
Application Handbook
7.4
Refrigerant detector
Catalytic
Infrared
(4)
(4)
(4)
(4)
(4)
(4)
(4)
Not suitable
76
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
7.4.2
The need for gas detection
DKRCI.PA.000.C6.02 / 520H1623
77
Application Handbook
7.5
Summary
Solution
Application
Safety Valves
Safety valves SFA + change over valve DSV
Receiver
Thermostat RT
Refrigerant detection
Gas detection sensors, GD
7.6
Reference Documents
For an alphabetical overview of
all reference documents please
go to page 146
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
AKS 38
PD.GD0.A
POV
PD.ID0.A
AKS 38
PI.GD0.A
POV
PI.ID0.A
BSV
PD.IC0.A
RT 1A
PD.CB0.A
BSV
PI.IC0.A
RT 1A
RI5BC
DSV
PD.IE0.A
RT 107
PD.CB0.A
DSV
PI.IE0.A / PI.IE0.B1
RT 5A
RI5BC
LLG
PD.GG0.A
RT 5A
PD.CB0.A
LLG
PI.GG0.A
SFA
PI.IB0.A
MLI
PD.GH0.A
SFA
PD.IF0.A
MLI
PI.GH0.A
GD
PI.S00.A
MP 55 A
PD.CG0.B
GD
PD.S00.A
MP 55 A
PI.CG0.E
To download the latest version of the literature please visit the Danfoss website.
78
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
8.
Refrigerant Pump
Controls
Fig. 8.1
Placing of the pump
Liquid separator
In order to keep the refrigerant pump in troublefree operation, the flow through the pump
should be maintained within the permissible
operating range, fig. 8.2.
Refrigerant
pump
Danfoss
Tapp_0107_02
10-2012
LP liquid refrigerant
Fig. 8.2
A typical Q-H curve for pumps
Danfoss
Tapp_0108_02
10-2012
8.1
Pump Protection with
Differential Pressure Control
DKRCI.PA.000.C6.02 / 520H1623
79
Application Handbook
Danfoss
Tapp_0109_02
10-2012
To
compressor
suction line
From
evaporator
From receiver
Liquid separator
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Stop valve
Filter
Differential pressure switch
Check valve
Stop valve
Stop valve
Filter
Differential pressure switch
Check valve
Refrigerant
pump
To evaporator
Stop valve
Differential pressure controls are used for
protection against too low pressure difference.
RT 260A and are supplied without a timing
relay and cause a momentary cut-out when the
differential pressure drops below the pressure
controls setting.
The filters FIA and are installed on the pump
line to remove particles and protect automatic
control valves and pumps from damage,
blockage, and general wear and tear. The filter
can be installed in either suction line or discharge
line of the pump.
If the filter is installed in the suction line before
the pump, it will primarily protect the pump
against particles. This is particularly important
during initial clean-up during commissioning.
80
Enclosure
IP 66/54
50 to 70
0.1 to 11
22/42
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
8.2
Pump Bypass Flow Control
Danfoss
Tapp_0110_02
10-2012
To
compressor
suction line
From
evaporator
From receiver
Liquid separator
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Refrigerant
pump
Overflow valve
Stop valve
Overflow valve
Stop valve
Internal safety relief valve
Internal safety relief valve
To evaporator
Body: steel
Refrigerants
50 to 150
40
DN [mm]
20/25
2 to 8
Material
Refrigerants
R717, R744, HFC, HCFC and other refrigerants (depending on the sealing material compatibility)
10 to 25
50
DKRCI.PA.000.C6.02 / 520H1623
81
Application Handbook
8.3
Pump Pressure Control
Danfoss
Tapp_0111_02
10-2012
To
compressor
suction line
From evaporator
From receiver
Liquid separator
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Refrigerant
pump
Stop valve
Differential pressure
To evaporator
regulator
Stop valve
Technical data
Refrigerants
60 to 120
52
DN [mm]
20 to 150
Differential pressure pilot valve-CVPP
Refrigerants
50 to 120
CVPP (LP): 17
CVPP (HP): up to 40
CVPP (LP): 0 to 7
CVPP (HP): 0 to 22
Kv value m3/h
0.4
82
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
8.4
Summary
Solution
Application
Benefits
Limitations
Liquid separator
Simple.
Effective in protecting
the pump against low
differential pressure
(corresponding to high
flow).
Liquid separator
Simple.
Effective in protecting the
pump against back flow and
particles.
Simple.
Effective and reliable in
keeping the minimum flow
for the pump.
Safety valve can effectively
prevent excessive pressure.
Applicable to pump
circulation systems that
require constant differential
pressure across the
regulating valves before
evaporators.
Provides a constant
differential pressure and
circulation ratio for the
evaporators.
Liquid separator
8.5
Reference Documents
For an alphabetical overview of
all reference documents please
go to page 146
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
BSV
PD.IC0.A
NRVA
PD.FK0.A
BSV
PI.IC0.A
NRVA
PI.FK0.A
CVPP
PD.HN0.A
REG
PD.KM1.A
CVPP
PI.HN0.C
REG
PI.KM1.A
FIA
PD.FM1.A
RT 260A
PD.CB0.A
FIA
PI.FN1.A
RT 260A
RI5BB
ICS
PD.HS2.A
SVA
PD.KD1.A
ICS 25-65
PI.HS0.A
SVA
PI.KD1.A
DKRCI.PA.000.C6.02 / 520H1623
83
Application Handbook
9. Others
9.1
Filter Driers in
Fluorinated Systems
84
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Compressor
Oil separator
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
Oil
Filter drier
Filter drier
Filter drier
Stop valve
Stop valve
Stop valve
Sight glass
Sight glass
Sight glass
Stop valve
Stop valve
Stop valve
Condenser
Receiver
Evaporator
Danfoss
Tapp_0116_02
10-2012
CFC/HFC/HCFC/R744
Material
Housing: steel
HP: 46
40 to 70
Solid cores
DM/DC/DA
DKRCI.PA.000.C6.02 / 520H1623
85
Application Handbook
9.2
Water Removal
for Ammonia Systems
86
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
To suction line
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Solenoid valve
Float valve
Hand regulating valve
Pressure regulating valve
Solenoid valve
Hand regulating valve
Internal safety valve
Quick drain valve
Stop valve
Sight
glass
Sight
glass
HP condensed
liquid in
HP condensed
liquid out (to
pump separator)
Contaminated
ammonia in
DKRCI.PA.000.C6.02 / 520H1623
Danfoss
Tapp_0121_02
09-2014
87
Application Handbook
9.3
Air purging systems
Evaporative condenser
Receiver
Danfoss
Tapp_0124_02
10-2012
88
DKRCI.PA.000.C6.02 / 520H1623
Vertical
shell-tube
condenser
Application Handbook
To liquid separator
Water tank
From
discharge
line
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
Air
From
refrigerant
pump
Solenoid valve
Solenoid valve
Solenoid valve
Float valve
Pressure switch
Solenoid valve
Hand regulating valve
Hand regulating valve
Danfoss
Tapp_0125_02
09-2014
Condenser
Receiver
DKRCI.PA.000.C6.02 / 520H1623
89
Application Handbook
9.4
Heat Recovery System
To
suction
line
Danfoss
Tapp_0126_02
10-2012
Heat recovery
condenser
Water in
Water out
HP vapour refrigerant
HP liquid refrigerant
LP vapour refrigerant
Water
Pressure regulator
Solenoid valve
Check valve
Solenoid valve
Hand regulating valve
From
discharge
line
Condenser
To receiver
90
DKRCI.PA.000.C6.02 / 520H1623
Heat recovery
condenser
Danfoss
Tapp_0127_02
10-2012
Application Handbook
Water in
Water out
HP vapour refrigerant
HP liquid refrigerant
Water
From
discharge
line
Differential pressure
regulator
Thermostat
Check valve
Condenser
To receiver
Danfoss
Tapp_0128_02
10-2012
Heat recovery
condenser
Water in
Water out
To receiver
HP vapour refrigerant
HP liquid refrigerant
Water
From
discharge
line
solenoid valve
Thermostat
Check valve
Condenser
DKRCI.PA.000.C6.02 / 520H1623
To receiver
91
Application Handbook
9.5
Reference Documents
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
BSV
PD.IC0.A
REG
PD.KM1.A
BSV
PI.IC0.A
REG
PI.KM1.A
CVP
PD.HN0.A
RT 107
PD.CB0.A
CVP
PI.HN0.C
SGR
PI.EK0.A
DCR
PD.EJ0.A
SGR
PD.EK0.A
DCR
PI.EJ0.B
SNV
PI.KB0.A
EVM
PD.HN0.A
SNV
PD.KB0.A
EVM
PI.HN0.N
SVA
PI.KD1.A
EVRA(T)
PD.BM0.B
SVA
PD.KD1.A
EVRA(T)
PI.BN0.L
SV 1-3
PI.GE0.C
ICS
PD.HS2.A
SV 1-3
PD.GE0.B
ICS 25-65
PI.HS0.A
SV 4-6
PI.GE0.B
NRVA
PD.FK0.A
SV 4-6
PD.GE0.D
PI.FK0.A
To download the latest version of the literature please visit the Danfoss website.
92
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
10.
Using CO2 in refrigeration
systems
Pressure - Temperature
Pressure
Triple point
Critical point
Figure 10.1
Refrigerant
Natural substance
Ozone Depletion Potential (ODP)*
Global Warming Potential (GWP)*
Critical point
bar
C
Triple point
bar
C
Flammable or explosive
Toxic
DKRCI.PA.000.C6.02 / 520H1623
Temperature
[psi]
[F]
[psi]
[F]
R 134a
NO
0
1300
40.7 [590]
101.2
[214]
0.004
[0.06]
103 [153]
NO
NO
NH3
YES
0
113 [1640]
132.4
[270]
0.06 [0.87]
77.7 [108]
(YES)
YES
CO2
YES
0
1
73.6
31.1
5.18
56.6
NO
NO
[1067]
[87.9]
[75.1]
[69.9]
93
Application Handbook
10.1
CO2 as a refrigerant
Pressure
Supercritical
Liquid
Critical point:
Solid - Liquid
Solid
Liquid - Vapour
Solid - Vapour
Enthalpy
Figure 10.1.1
Pressure
Vapour
Subcritical
Figure 10.1.2
94
DKRCI.PA.000.C6.02 / 520H1623
Enthalpy
Application Handbook
10.1
CO2 as a refrigerant
(Continued)
Pressure
Gas cooling
Enthalpy
Figure 10.1.3
CO2 is most commonly used in cascade or
hybrid system designs in industrial refrigeration,
because its pressure can be limited to such
extent that commercially available components
like compressors, controls and valves can be
used.
10.2
CO2 as a refrigerant in
industrial systems
Pressure
Principal diagram
R717 - CO2 cascade system
Heat exchanger
CO2 compressor
CO2 receiver
Pressure
Enthalpy
Enthalpy
CO2 evaporator
Figure 10.2.1
DKRCI.PA.000.C6.02 / 520H1623
95
Application Handbook
10.2
CO2 as a refrigerant in
industrial systems
(Continued)
Pressure
Principal diagram
R717 - CO2 cascade system with CO2 hot gas defrosting
Heat exchanger
CO2 compressor
CO2 receiver
CO2 defrost
compressor
Pressure
Enthalpy
Enthalpy
CO2 evaporator
Figure 10.2.2
The CO2 system is a pump circulating system
where the liquid CO2 is pumped from the receiver
to the evaporator, where it is partly evaporated,
before it returns to the receiver. The evaporated
CO2 is then compressed in a CO2 compressor,
and condensed in the CO2-NH3 heat exchanger.
The heat exchanger acts as an evaporator in the
Pressure
Principal diagram
R717 - CO2 brine system
Heat exchanger
CO2 receiver
Pressure
Enthalpy
Enthalpy
CO2 evaporator
Figure 10.2.3
96
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
10.2
CO2 as a refrigerant in
industrial systems
(Continued)
Principal diagram
CO2 cascade system with 2 temperature levels
(e.g. supermarket refrigeration)
Figure 10.2.4
10.3
Design pressure
DX system
DKRCI.PA.000.C6.02 / 520H1623
97
Application Handbook
10.3
Design pressure
(Continued)
Danfoss
Tapp_0161
10-2012
Cascade
Cooler
CO2 receiver
Low stage
Evaporator
24 / 40 bar
(350 / 580 psi)
40 bar
(580 psi)
24 bar
(350 psi)
Design pressure
"p" + 10%
(barg/psig)
"Saturated"
pressure "p"
(bara/psig)
Design temperature
Figure 10.3.2
Saturated pressure
Figure 10.3.3
98
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
10.4
Safety
DKRCI.PA.000.C6.02 / 520H1623
99
Application Handbook
10.5
Efficiency
Ammonia
single stage
Ammonia
two stage
R22 single
stage
R22 two
stage
Ammonia/CO2
cascade
system
Source: IIAR Albuquerque, New Mexico 2003, P.S Nielsen & T.Lund
Introducing a New Ammonia/CO2 Cascade Concept for Large Fishing Vessels
Figure 10.5.1
10.6
Oil in CO2 systems
PAO
Poly-alpha-olefin oil
(synthetic oil)
Solubility
Low (immiscible)
Hydrolysis
Low
Oil separation system Special requirements:
High filtration performance
Challenge
100
POE
Special requirement:
Oil drain from low temperature
receiver (oil density lower than
CO2 - opposite of NH3)
Oil separation and return system
Long term oil accumulation in
e.g. evaporators
DKRCI.PA.000.C6.02 / 520H1623
Simple
Application Handbook
10.6
Oil in CO2 systems
(Continued)
Oil recovery system connected to the stand pipe of the CO2 separator
Danfoss
Tapp_0162
10-2012
T
Cascade
Cooler
CO2 receiver
EVRST
REG
Oil rectifier
Example 10.6.2
Oil management system
for systems with soluble
(miscible) oils
Cascade
Cooler
CO2 receiver
EVRST
REG
Oil rectifier
DKRCI.PA.000.C6.02 / 520H1623
101
Application Handbook
10.7
Comparison of component
requirements in CO2,
ammonia and R134a systems
Compared to ammonia and
R134a, CO2 differs in many
respects. The following
comparison illustrates this fact;
to allow an true comparison,
operating conditions such
as evaporating temperature,
condensing temperature, are
kept constant.
Wet return
Liquid
Refrigerant
Wet return line
Liquid line
R 134a
[TR]
250
T
p
Velocity
K
bar
m/s
[F]
[psi]
[ft/s]
Diameter
Wet return area
mm [inch]
mm2 [inch2]
215
36385
[8.5] 133
[56.40] 13894
[5.2] 69
[21.54] 3774
[2.7]
[5.85]
Velocity
m/s
0.8
[2.6]
0.8
[2.6]
0.8
[2.6]
61
2968
39353
[2.4]
[4.6]
[61.0]
36
998
14892
[1.4] 58
[1.55] 2609
[23.08] 6382
[2.3]
[4.04]
[9.89]
Diameter
Liquid area
Total pipe cross
"Wet return" +
section area
"liquid" area
Liquid cross section area
mm [inch]
mm2 [inch2]
mm2 [inch2]
250
CO2
kW
[ft/s]
[71]
R 717
Capacity
[71]
250
[71]
41
Leqv = 50 [m] / 194 [ft] - Pump circ.: ncirc = 3 - Evaporating temp.: TE = 40[C] / 40[F]
Table 1
Comparison of pipe cross section area
Dry suction / Liquid lines
Dry suction
Liquid
Refrigerant
Dry suction line
Liquid line
R 134a
[71]
R 717
250
[71]
CO2
Capacity
kW
[TR]
250
250
T
p
Velocity
K
bar
m/s
[F]
[psi]
[ft/s]
[71]
Diameter
mm [inch]
Dry suction area mm2 [inch2]
168
22134
[6.6] 102
[34.31] 8097
[4.0] 53
[12.55] 2242
[2.1]
[3.48]
Velocity
0.8
[2.6]
[2.6]
0.8
[2.6]
37
1089
23223
[1.5] 21
[1.69] 353
[36.00] 8450
[0.8] 35
[0.55] 975
[13.10] 3217
[1.4]
[1.51]
[4.99]
Diameter
Liquid area
Total pipe cross
Dry suction +
section area
liquid area
Liquid cross section area
m/s
[ft/s]
mm [inch]
mm2 [inch2]
mm2 [inch2]
%
0.8
30
Leqv = 50 [m] / 194 [ft] - Evaporating temp.: TE = 40[C] / 40[F] - Condensing temp.: TE = 15[C] / 5[F]
Table 2
102
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
10.7
Comparison of component
requirements in CO2,
ammonia and R134a systems
(Continued)
Refrigerant
Capacity
R 134a
kW
[TR]
mm2 [inch2]
mm2 [inch2]
mm2 [inch2]
R 717
[71]
[3.48]
[1.51]
[4.99]
7.2
5
95
%
%
CO2
2.6
4
96
1.0
30
70
Liquid
Suction
Leqv = 50 [m] / 194 [ft] - Evaporating temp.: TE = 40[C] / 40[F] - Condensing temp.: TE = 15[C] / 5[F]
Table 3
Comparison of compressor displacement
Compressor
Refrigerant
Refrigerant capacity
kW
[TR]
R 134a
R 717
250 [71]
250 [71]
250
CO2
[71]
1628 [57489]
13.1
1092 [38578]
8.8
124
[4387]
1.0
Table 4
Comparison of pressure / subcooling
produced in liquid risers
Refrigerant
Hight of liquid riser H
R 134a
m
R 717
CO2
[ft]
3 [9.8] 3 [9.8] 3
[9.8]
[psi]
[F]
[4.77]
[1.6]
CO2 receiver
Table 5
Danfoss A/S (RC-MDP/MWA), 2014-09
DKRCI.PA.000.C6.02 / 520H1623
103
Application Handbook
Liquid lines:
10.8
Water in CO2 Systems
Figure 10.8.1
104
DKRCI.PA.000.C6.02 / 520H1623
Liquid CO2
Vapour CO2
Temperature
Danfoss A/S (RC-MDP/MWA), 2014-09
Application Handbook
10.8
Water in CO2 Systems
(Continued)
Temperature
Figure 10.8.2
Liquid
Vapour
Temperature
Figure 10.8.3
Maximum solubility
Liquid
Maximum solubility
Vapour
Figure 10.8.4
DKRCI.PA.000.C6.02 / 520H1623
105
10.8
Water in CO2 Systems
(Continued)
Application Handbook
CO2 +
WATER
CO2 + ICE
Figure 10.8.5
Chemical reactions
CO2 + H2O
vapour phase
Temperature
PAO lubricant
106
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
10.9
Removing water
Water
R134a
CO2
Figure 10.9.1
NH3
1 * 10-6 mm [39 * 10-9 in.]
Example:
-40/-10C - CO2
pump circulating system
with 20 [ppm] water
CO2
Compressor
NH3
Compressor
CO2 receiver
Figure 10.9.2
DKRCI.PA.000.C6.02 / 520H1623
107
Application Handbook
10.9
Removing water
(Continued)
Example:
-40/-10C - CO2
DX system
with 20 [ppm] water
NH3
Compressor
Compressor
Dry suction
Heat exchanger
(condenser)
Evaporator
Liquid
Figure 10.9.3
Principle diagram: CO2 - NH3 cascade system
Dry suction
Filter drier
CO2
Compressor
CO2 receiver
CO2
Evaporator
Moisture
indicator
Liquid
Filter driers installed in:
- bypass lines or
- main liquid line
Filter drier
Moisture indicator
CO2
Heat exchanger
Liquid
Figure 10.9.4
CO2 is a non-polar molecule, so the removal
process is different. Like water molecules, CO2
molecules are small enough to pass through the
molecular sieve. However, the water molecules
adsorbed on the molecular sieve tend to displace
the CO2 molecules, due to the difference in
polarity. Zeolite filter driers cannot be used in
ammonia systems, because both water and
ammonia are very polar. Even though the driers
function differently in this respect in CO2 systems,
the efficiency is fairly good. The water retention
capacity is approximately the same as in R134a
systems.
The most effective location to detect and remove
water is where the concentration is high. The
solubility of water in CO2 is much lower in the
vapor phase than in the liquid phase, so more
water can be transported in liquid lines.
108
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
NH3 out
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
NH3 in
Condenser
Receiver
Stop valve
Filter drier
Sight glass
Stop valve
Liquid separator
Expansion
valve 1
Evaporator
Filters in by-pass
NH3 out
Compressor
Oil separator
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Stop valve
Filter drier
Sight glass
Stop valve
NH3 in
Condenser
Receiver
Liquid separator
Expansion
valve 1
Evaporator
109
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
NH3 out
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
Oil
Filter drier
Filter drier
Filter drier
Stop valve
Stop valve
Stop valve
Sight glass
Sight glass
Sight glass
Stop valve
Stop valve
Stop valve
Oil separator
Compressor
NH3 in
Condenser
Receiver
Evaporator
Danfoss
Tapp_0120_02
10-2012
DKRCI.PA.000.C6.02 / 520H1623
110
Application Handbook
10.10
How does water enter a CO2
system?
DKRCI.PA.000.C6.02 / 520H1623
111
Application Handbook
10.11
Miscellaneous features to be
taken into consideration in
CO2 refrigeration systems
Safety valve
CO2s particularly high triple point can cause solid
CO2 to form under certain conditions. Figure
10.11.1 shows the expansion processes occurring
in pressure relief valves starting at three different
conditions. If the set pressure of a pressure relief
Pressure
Supercritical
Vapour
50 bar [725 psi]
Liquid
Vapour
35 bar [507 psi]
Liquid
20 bar [290 psi]
Solid - Liquid
Solid
Liquid - vapour
Solid - Vapour
Figure 10.11.1
If the set pressure of a safety valve in the vapor
phase is 50 bar [725 psi], e.g., the middle line,
the relief line pressure will pass the triple point
and 3% of the CO2 will change into solid during
relief. In a worst-case scenario (e.g., a long relief
line with many bends), solid CO2 may block this
line. The most effective solution to this problem
would be to mount the safety valve without an
outlet line, and relieve the system directly to the
atmosphere. The phase change of the CO2 does
not take place in the valve, but just after the
valve, in this case, in the atmosphere.
112
0% solid CO2 at
the triple point
DKRCI.PA.000.C6.02 / 520H1623
3% solid CO2 at
the triple point
Vapour
Enthatpy (J)
Application Handbook
Charging CO2
Filter cleaning
Trapped liquid
Figure 10.11.2
Leaks in CO2- NH3
cascade systems
Temperature
DKRCI.PA.000.C6.02 / 520H1623
113
Application Handbook
Material compatibility
References
[1]
Bondinus, William S
[6] IoR. Safety Code for Refrigeration Systems Utilizing Carbon Dioxide
The Institute of Refrigeration. 2003.
[7]
114
Vestergaard N.P.
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
11.
Pumped CO2 in Industrial
Refrigeration Systems
Cascade heat
exchanger
NH3/CO2
5
4
CO2 receiver
1
2
General description
of the systems
Differences to traditional
NH3/brine systems
System performance:
NH3/CO2 fluid systems have significantly lower
energy consumption compared to traditional
systems with NH3 and water based brines. COP of
the system is higher due to the following:
Evaporation temperature and PHE efficiency
Typically the high side NH3 system
evaporation temperature is a few degrees
higher. The reason for this is the better CO2
heat transfer coefficient in the air coolers and
the PHE, resulting in a lower temperature
difference in the heat exchangers. This directly
reduces the energy consumption of the NH3
compressors. Some figures indicate that the
COP of NH3/CO2 systems is close to that of
pure NH3 systems.
Line and component sizes in a flooded system:
Due to the high specific heat content of CO2 and
its lower density, smaller components and line
sizes can be used compared to a traditional brine
system, for both the outward and the return lines.
The smaller volume of circulating CO2 to circulate
means that smaller pumps can be used which
yields lower energy consumption for the
circulated cooling capacity.
Pump energy
The pump energy needed to circulate the
CO2 through the air coolers is significantly
lower, due to the fact that less CO2 needs to
circulate, but also thanks to the lower density
of CO2. The pump recirculation rate for CO2 is
relatively low as well (typically between 1.1
and 2), and this also makes it possible to use a
smaller pump.
Return/Supply MT:
DN 65
DN 125
Return/Supply LT:
DN 150
CO2 pipes,
copper or steel
Brine pipes,
steel or plastic
DKRCI.PA.000.C6.02 / 520H1623
115
Application Handbook
Differences to traditional
NH3/brine systems.
(Continued)
Plant controller
From
cold rooms
Pump
Danfoss
Tapp_0169_02
10-2012
To cold rooms
116
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Frequency control
of the CO2 pumps
From
evaporators
To
compressor
suction line
From
receiver
Liquid separator
Refrigerant
pumps
Danfoss
Tapp_0170_02
10-2012
To
evaporators
Figure 11.4 - CO2 pump stations with AKD and the necessary valves and controls
DKRCI.PA.000.C6.02 / 520H1623
117
Application Handbook
Defrosting pumped
CO2 systems
Controller
To liquid
separator
For this application
only ICS 25-5,
ICS 25-10 and
ICS 25-15 are
recommended
From liquid
separator
From defrost
compressor
Evaporator
Danfoss
Tapp_0171_02
10-2012
118
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Controller
To liquid
separator
From liquid
separator
Danfoss
Tapp_0172_02
10-2012
Evaporator control in
pumped CO2 systems
Circulation rate
n
DKRCI.PA.000.C6.02 / 520H1623
119
Application Handbook
Evaporator control in
pumped CO2 systems
(continued)
Danfoss
Tapp_0173_02
10-2012
Option 1
From liquid
separator
To liquid
separator
Option 2
Evaporator
Figure 11.7
Refrigerant side:
Q cooler = mass flow h (1)
Mass flow [kg/s evaporated liquid]
h [kJ/K]
Refrigerant/Air side:
Q cooler = k A T (2)
K [W/(m2.K] : the total heat transfer coefficient,
(depending on the heat transfer coefficient of
the air and refrigerant, which depend on air/
refrigerant flow) and the heat conductivity of the
materials used in the coolers.
A [m2]: cooler surface
T [K]: the difference between the evaporation
and air temperatures.
cut in
cut out
120
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
cut in
MTR ref
DKRCI.PA.000.C6.02 / 520H1623
121
Application Handbook
122
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Danfoss
Tapp_0174_02
09-2013
Pumped
liquid
To liquid
separator
Evaporator
Hot gas
Figure 11.8 - CO2 hot gas defrosting with ICF, ICM and ICS+CVP
DKRCI.PA.000.C6.02 / 520H1623
123
Application Handbook
Product instruction
Type
Literature no.
Type
Literature no.
Type
Literature no.
Type
Literature no.
AK-CC 450
RS8EU
EKC 347
PS.G00.A
AKD 102
MG11L
EVRA / T
PI.BN0.L
AKD 102
PD.R1.B
EVM
PD.HN0.A
AKS 21
RI14D
FIA
PI.FN1.A
AK-PC 730
RS8EG
EVRA / T
PD.BM0.B
AKS 32R
PI.SB0.A
ICF
PI.FT0.C
AKS 21
RK0YG
FIA
PD.FN1.A
AKS 33
PI.SB0.A
ICM / ICAD
AKS 33
RD5GH
ICF
PD.FT1.A
PD.SC0.C
ICM / ICAD
PD.HT0.B
PI.SC0.D /
PI.SC0.E
PI.HT0.A (ICM)
PI.HT0.B (ICAD)
AKS
4100/
4100U
ICS
PD.HS2.A
AKS
4100/
4100U
ICS
PD.FE0.A
PI.VA1.B
PI.VA1.C
PI.HS0.A /
PI.HS0.B
NRV
AKVA
NRV
PI.FE0.A
AKVA
PD.VA1.B
OFV
PD.HQ0.A
CVC-XP
PI.HN0.A
OFV
PI.HX0.B
CVC-XP
PD.HN0.A
REG
PD.KM1.A
CVC-LP
PI.HN0.M
REG
PI.KM1.A
CVC-LP
PD.HN0.A
RT 260A
PD.CB0.A
CVP
PI.HN0.C
RT 260A
RI5BB
CVP
PD.HN0.A
SCA
PD.FL1.A
CVPP
PI.HN0.C
SCA
PI.FL1.A
CVPP
PD.HN0.A
SGR
PD.EK0.A
DCR
PI.EJ0.B
SGR
PI.EK0.A
DCR
PD.EJ0.A
SNV
PD.KB0.A
EKC 347
PI.RP0.A
SNV
PI.KB0.A
EKC 315A
RS8CS
SVA-S/L
PD.KD1.A
EVM
PI.HN0.N
SVA-S/L
PI.KD1.A
To download the latest version of the literature please visit the Danfoss website.
124
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
12.
Control methods for
CO2 systems
Controller
Danfoss
Tapp_0164
09-2014
2 Auxillary refrigeration
system / stand still unit
(cooling)
3 Solenoid valve
4 Safety valve
5 Bypass valve
Low stage
evaporator
Cascade
Cooler
CO2
separator
Controller
Figure 12.1
Compressor control
There is no difference in the way the compressors
can be controlled in CO2 systems compared to
a normal industrial refrigeration installation,
but as they are cascade systems, it must be
ensured that the NH3 compressor is started /
ready to start before the start signal is given to
the CO2 compressor (see the section regarding
compressor control).
Liquid level control
There is no difference in the way the liquid level
can be controlled in CO2 systems compared to a
normal industrial refrigeration installation (see
the section regarding liquid level control).
Possible control devices in case of high
pressure in the CO2 separator
If the pressure in the CO2 separator rises above
the normal range, the following steps can be
taken in order to minimize the escape of CO2:
1. The CO2 compressor can be forced to start
and the CO2 liquid pump forced to stop to
prevent relatively warm liquid returning to the
CO2 separator.
2. If there is a fault preventing the CO2
compressor from starting, the pressure will
continue to increase. This will force the standstill unit to start.
3. If the pressure continues to rise, a solenoid
valve can be forced open to provide a controlled
release of the CO2 pressure down to a defined
pressure.
4. The last device is the safety valve, which
operates at its set pressure.
Controller
DKRCI.PA.000.C6.02 / 520H1623
125
Application Handbook
13.
Design of a CO2
sub-critical installation
13.1
Electronic solution for
liquid level control
Application example 13.1.1:
Electronic solution for LP liquid
level control
To
compressor
suction line
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
From
receiver
Liquid separator
Stop valve
Filter
Solenoid valve
Motor valve
Stop valve
Controller
Level transmitter
From evaporator
To evaporator
Danfoss
Tapp_0165_02
10-2012
To
compressor
suction line
Liquid separator
From
receiver
Stop valve
Filter
Solenoid valve
Manual opener
Motor valve
Stop valve
Controller
Level transmitter
Not all valves are shown.
Not to be used for construction
purposes.
126
From
evaporator
To evaporator
DKRCI.PA.000.C6.02 / 520H1623
Danfoss
Tapp_0166_02
10-2012
Application Handbook
13.2
Hot Gas Defrost for Pumped
Liquid Circulation Air
Coolers
Application example 13.2.1:
Pumped liquid circulation
evaporator, with hot gas defrost
system
Danfoss
Tapp_0168_02
09-2013
Controller
To liquid separator
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
Liquid Line
Liquid inlet stop valve
Filter
Solenoid valve
Check valve
Manual expansion valve
Evaporator inlet stop valve
Suction Line
Evaporator outlet stop valve
Motor valve
Suction line stop valve
Hot gas line
Stop valve
Filter
Motor valve
Stop valve
Check valve
Overflow line
Overflow valve
Controls
Controller
Controller
Controller
Controller
From liquid
separator
Evaporator
From discharge line
127
Application Handbook
13.2
Hot Gas Defrost for
Pumped Liquid Circulation
Air Coolers
Application example 13.2.2:
Pump circulated evaporator,
with hot gas defrost system,
fully welded, using ICF Valve
station for evaporator with hot
gas defrost
Controller
Danfoss
Tapp_0167_02
10-2012
To liquid
separator
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP liquid refrigerant
From liquid
separator
Stop valve
Filter
Solenoid valve
From discharge line
Check valve
Manual expansion valve
Evaporator inlet stop valve
Evaporator outlet stop valve
Pressure regulator
(motor valve)
Suction line stop valve
Application example 13.2.2 shows an installation
for pumped liquid circulation evaporators
Hot gas line ICF with:
with hot gas defrost using the new ICF control
solution.
Stop Valve
Filter
Solenoid valve
Stop valve
Check valve
Pressure regulator
Controller
Temperature sensors
Temperature sensors
Temperature sensors
Evaporator
128
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
14.
Danfoss sub-critical CO2
components
Stop Valves
Regulating Valves
Stop Check Valves
Filters
Check Valves
Solenoid Valves
Electrically operated expansion valve
Filter drier
Liquid level transmitter
Gas detectors
DN
ICS 1 ICS 3
ICF
CVP-XP
CVP-XP
CVC-XP
CVP-HP
CVPP-HP
EVM (NC)
EVM (NO)
SVA-S
SVA-L
REG-SA/SB
SCA-X
FIA
CHV-X
EVRS/EVRST
ICS + EVM
AKVA
ICM
ICMTS
CCMT
CCM
SFA
DSV
POV
DCRH
all
all
all
all
all
all
all
all
all
all
all
all
all
15
1, 2
40, 50, 80
High pressure version
AKS 4100/4100U GD
DKRCI.PA.000.C6.02 / 520H1623
all
all
PS
40bar
[580 psi]
PS
52 bar
[754 psi]
20-150
20-40
65 bar
6-200
15-40
15 - 65
15-125
15-200
15- 125
3-20
20-150
10-20
20-65
25
15
15-25
20-32
40-80
140 bar
140 bar
90 bar
46 bar
-
129
Application Handbook
14.
Danfoss sub-critical CO2
components
(Continued)
PS
42bar
[609 psi]
PS
46 bar
[667 psi]
PS
52 bar
[754 psi]
PS
90 bar
[1305 psi]
PS
140 bar
[2031 psi]
EVR 2 - EVR 15
EVUL
EVUB
Check Valves
AKVH 10
AKV 15
ETS 12.5 -100
CCM10 - 40
CCMT2 - 8
ICMTS
ICV
MBR
Filter Driers
DCR
DML
DMT
Moisture Indicator
SG (Inline)
SG (Socket)
Case controllers:
AK-CC 550A, AK-CC 750
Evaporator controllers: EKC 315A, AKC 316, EKD 316, EKC 312
Pack controllers:
EKC 331T, AK-PC 530, AK-PC 420, AK-PC 781, AK-PC 840
Chiller controls:
AK-CH 650, AK-CH 650A
Cascade controller:
EKC 313
Pressure controller:
EKC 326A
130
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
15.
Full range of
stainless steel products
Vented cap
X
X
X
Handwheel
X
DKRCI.PA.000.C6.02 / 520H1623
131
Application Handbook
Features
Stainless steel valve body and connections
Max. working pressure 50 barg
Used for ammonia and all fluorinated refrigerants
MOPD up to 38 bar with 20 watt a.c. coil
Wide choice of a.c. and d.c. coils
Designed for temperatures of media up to 105C
Manual stem on EVRS and EVRST 10, EVRST 15
and EVRST 20
132
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
16. Appendix
16.1
Typical Refrigeration
Systems
DKRCI.PA.000.C6.02 / 520H1623
133
Application Handbook
Single-stage system
with direct expansion (DX)
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
Oil
Receiver
Evaporator
Thermostatic
expansion
valve
134
DKRCI.PA.000.C6.02 / 520H1623
Danfoss
Tapp_0129_02
10-2012
Condenser
Application Handbook
Single-stage system
with pump circulation of
refrigerant
Fig.16.1.2 Single-stage Refrigeration System with Pump Circulation and Hot Gas Defrost
Compressor
Oil separator
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Oil
Condenser
Receiver
Expansion
valve 2
Oil cooler
Evaporator
Expansion
valve 1
Liquid separator
Refrigerant
pump
Danfoss
Tapp_0130_02
10-2012
DKRCI.PA.000.C6.02 / 520H1623
135
Application Handbook
Two-stage system
Oil separator
Oil separator
High-stage
compressor
Condenser
Oil cooler
Receiver
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Intermediate pressure
liquid refrigerant
Intermediate pressure
vapour refrigerant
Other media
(oil, water, etc.)
Intermediate
cooler
Expansion
valve
Expansion
valve
Evaporator
Liquid separator
Refrigerant
pump
Evaporator
Danfoss
Tapp_0131_02
10-2012
136
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
Cascade system
Compressor
Compressor
Oil separator
Oil separator
Oil cooler
Condenser
Receiver
Receiver
Expansion
valve
HP vapour refrigerant
HP liquid refrigerant
Liquid/vapour mixture
of refrigerant
LP vapour refrigerant
LP liquid refrigerant
Other media
(oil, water, etc.)
Expansion
valve
Liquid separator
Evaporator
Cascade
condenser
Liquid separator
Refrigerant
pump
Refrigerant
pump
DKRCI.PA.000.C6.02 / 520H1623
137
Application Handbook
17.
ON/OFF and
modulating controls
P Proportional
I Integration
D Derivative
PB
Proportional Band [%] in a P, PI or PID controller. Number in percent, that Process variable
(PV),has to change, in order for the controller to change the output (y) from 0 to 100 %
Kp
Amplification factor in a P, PI or PID controller
Ti
Integration time [s] in a PI or PID controller
Td
Differential time [s] in a PID controller
PID
A typical controller that includes both P, I and D functions
SP
Set point
PV
Process Variable (the controlled parameter: temperature, pressure, liquid level, etc)
offset (x) Difference between Set point (SP) and Process Variable (PV)
y
Calculated output of a controller.
dead time If Process Variable (PV) measurement is physically mounted thus the signal is always has
a time delay , compared to if Process Variable (PV) measurement was installed locally
without time delay.
References
[1]
138
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
17.1
ON/OFF control
From
receiver
Liquid separator
HP liquid refrigerant
LP vapour refrigerant
LP liquid refrigerant
Danfoss
Tapp_0133_02
10-2012
DKRCI.PA.000.C6.02 / 520H1623
139
Application Handbook
17.2
Modulating control
Controller with
parameters to
be entered:
SP
P
I
D
PV
measured
From
receiver
Liquid separator
Danfoss
Tapp_0134_02
10-2012
HP liquid refrigerant
LP liquid refrigerant
Basic P, I and D principles
Generally, in most common controllers there is
the facility to adjust parameters for P, PI, or PID
settings
In a P controller it is possible to adjust: PB or
Kp;
In a PI controller it is possible to adjust: PB or
Kp and Ti;
In a PID controller it is possible to adjust: PB or
Kp and Ti and Td.
P-controller
In every controller a P component exists. In a Pcontroller there is a linear relation between input
and output.
Controller
X = SP PV Y = Kp (PV-SP)
Danfoss
Tapp_0136_02
10-2012
Danfoss
Tapp_0135_02
10-2012
Controller
Y = Kp (PV SP)+50%
140
DKRCI.PA.000.C6.02 / 520H1623
17.2
Modulating control
(continued)
P-controller (continued)
Amplification factor Kp and
proportional band PB
Danfoss
Tapp_0137_02
10-2012
Application Handbook
DKRCI.PA.000.C6.02 / 520H1623
141
Application Handbook
17.2
Modulating control
(continued)
I-controller
The most important characteristic for an Icontroller is that it eliminates offset, and that is
why it is used. I-controller continues to change
its output as long as offset exists. However the
ability to fully remove offset is linked to that it in
practice, is proportioned correctly.
PI controller
The combination of advantages and
disadvantages for both P and I makes it
advantageous to combine P and I into a PIcontroller.
In a PI controller it would be possible to adjust:
PB and Ti. Ti is normally entered in seconds or
minutes.
D-controller
The most important characteristic for a Dcontroller (derivative) is that it can react on
changes. This also means that if a constant offset
is present, a D-controller will not be able to do
any action to remove the offset. D-component
makes the system fast respond on load changes.
D effect improves stability and makes the system
faster. It does not have any significance for offset,
but it works to make tendency to fluctuations
smaller. D reacts on changes in the error and
the loop reacts faster against load changes than
without D. The fast reaction on changes means a
damping of all fluctuations.
PID-controller
The combination of all three components into a
PID controller has become of general use.
The general guidelines / properties for a PID
controller are:
Decreased PB improves offset (less offset), but
the stability is worse;
I component eliminates offset. Bigger I (less Ti)
makes faster elimination of offset.
142
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
17.2
Modulating control
(continued)
Ti
Td
66.7 %
PI
100 %
60 s
PID
41.7 %
40 s
12 s
No controller
DKRCI.PA.000.C6.02 / 520H1623
143
Application Handbook
17.2
Modulating control
(continued)
Ti
Td
PID-a
25.0 %
40 s
12 s
PID-b
41.7 %
40 s
12 s
PID-c
83.3 %
40 s
12 s
Ti
Td
PID-a
41.7 %
20 s
12 s
PID-b
41.7 %
40 s
12 s
PID-c
41.7 %
120 s
12 s
DKRCI.PA.000.C6.02 / 520H1623
Application Handbook
17.2
Modulating control
(continued)
Ti
Td
PID-a
41.7 %
40 s
24 s
PID-b
41.7 %
40 s
12 s
PID-c
41.7 %
40 s
6s
DKRCI.PA.000.C6.02 / 520H1623
145
Application Handbook
Type
Title
Technical leaflet /
Manual
Product
instruction
AKD 102
AKS 21
AKS 32R
AKS 33
AKS 38
AKS 4100/4100U
AKVA
AMV 20
BSV
PD.R1.B
MG11L
RK0YG
RI14D
CVC-XP
CVC-LP
CVP
CVPP
CVQ
DCR
DSV
EKC 202
EKC 315A
EKC 331
EKC 347
EKC 361
EVM
EVRA / EVRAT
FA
FIA
GD
GPLX
HE
ICF
ICM / ICAD
ICS
KDC
LLG
MLI
MP 55 A
NRVA
OFV
ORV
PMFL / PMFH
ICLX
POV
QDV
REG-SA/SB
RT 107
RT 1A
RT 260A
RT 5A
SCA-X
SFA
SGR
SNV
SV 1-3
SV 4-6
SVA-S/L
TEA
TEAT
VM 2
WVS
PI.SB0.A
RD5GH
PI.SB0.A
PD.GD0.A
PI.GD0.A
PD.SC0.C
PI.SC0.D
PI.SC0.E
PD.VA1.B
PI.VA1.C
PI.VA1.B
ED95N
EI96A
PD.IC0.A
PI.IC0.A
PD.HN0.A
PI.HN0.A
PD.HN0.A
PI.HN0.M
PD.HN0.A
PI.HN0.C
PD.HN0.A
PI.HN0.C
PD.HN0.A
PI.VH1.A
PD.EJ0.A
PI.EJ0.B
PD.IE0.A
PI.IE0.A
RS8DZ
RI8JV
RI.7D.A
RS8CS
RS8AG
RI8BE
PS.G00.A
PI.RP0.A
RS8AE
RI8BF
PD.HN0.A
PI.HN0.N
PD.BM0.B
PI.BN0.L
PD.FM0.A
PI.FM0.A
PD.FN1.A
PI.FN1.A
PD.S00.A
PI.S00.A
PD.BO0.A
PI.BO0.A
PD.FD0.A
PI.FD0.A
PD.FT1.A
PI.FT0.C
PD.HT0.B
PI.HT0.A
PI.HT0.B
PD.HS2.A
PI.HS0.A
PI.HS0.B
PD.FQ0.A
PI.FQ0.A
PD.GG0.A
PI.GG0.A
PD.GH0.A
PI.GH0.A
PD.CG0.B
PI.CG0.E
PD.FK0.A
PI.FK0.A
PD.HQ0.A
PI.HX0.B
PD.HP0.B
PI.HP0.A
PD.GE0.C
PI.GE0.D
PD.HS1.A
PI.HS1.A/B
PD.ID0.A
PI.ID0.A
PD.KL0.A
PI.KL0.A
PD.KM1.A
PI.KM1.A
PI.GE0.A
PD.CB0.A
PD.CB0.A
RI5BC
PD.CB0.A
RI5BB
PD.CB0.A
RI5BC
PD.FL1.A
PI.FL1.A
PD.IF0.A
PI.IB0.A
PD.EK0.A
PI.EK0.A
PD.KB0.A
PI.KB0.A
PD.GE0.B
PI.GE0.C
PD.GE0.D
PI.GE0.B
PD.KD1.A
PI.KD1.A
PD.AJ0.A
PI.AJ0.A
PD.AU0.A
PI.AU0.A
ED97K
VIHBC
PD.DA0.A
PI.DA0.A
To download the latest version of the literature please visit the Danfoss website.
146
DKRCI.PA.000.C6.02 / 520H1623
Notes
DKRCI.PA.000.C6.02 / 520H1623
147
Notes
148
DKRCI.PA.000.C6.02 / 520H1623
Danfoss FlexlineTM
Simple. Efficient. Flexible.
Designed to offer clever simplicity, timesaving efficiency and advanced flexibility the FlexlineTM series includes three popular
product categories:
ICV Flexline
Control valves and solenoid valves
ICF Flexline
Valve stations
SVL Flexline
Line components
All products are based on a modular design with no functionality in the house. This set-up reduces complexity right from the
design phase to the installation, commissioning and service. All key to lower total life cycle costs and major savings.
Go to www.danfoss.com/flexline for more information on the FlexlineTM platform.
Global knowhow
Local support
Backed by more than 60 years of experience producing valves and controllers for industrial refrigeration applications Danfoss is
a solid partner to turn to when you are looking for quality components.
Our global knowhow combined with local support offers you the best possible products and service.
DKRCI.PA.000.C6.02