MAKING MODERN LIVING POSSIBLE

Vlvulas de Expansin Electrnicas

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Danfoss Refrigeration

OPCIONES DE AHORRO DE ENERGIA EN APLICASIONES DE REFRIGERACIN

1. 2. 3. 4. 5. 6. 7. 8. 9. Seleccin adecuado de Intercambiadores de calor. Vlvulas de expansin electrnicas. Dimensionamiento de tuberas. Eleccin adecuada del refrigerante. Opciones de compresores de alta eficiencia. Compresin en paralelo. Sistema de control. Variador de frecuencia en compresores y condensadores. Sistemas en paralelo con variador de frecuencia.

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CONSUMO TIPICO DE ENERGIA EN UN SUPERMERCADO

AIRE CONDICIONADO OTROS

SALAS DE PREPAROS 8% EXTERNA 4% COMPRESSORES 30% VENTILADORES 4% DIVERSOS 6% AR CONDICIONADO 7%

ILUMINACION
INTERNA 21%

REFRIGERACION

BALCES FRIGORCOS 16%

VENTILADORES DOS CONDENSADORES 4%

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CONSUMO TIPICO DE ENERGIA EN UN CUARTO FRIO

SH afectan el COP del compresor

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PRESION DE EVAPORACION Y CONDENSACION

Pressure

Condensing temperature
A E D

Dtcond.

Out temperature

Room temperature

Dtevap.

Evaporating temperature
Heat Enthalpy

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UNIDADES CONDENSADORAS ENFRIADAS POR AIRE

Tcond. = Tamb. + 15C

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CUANTO PAGAMOS POR UN CONDENSADOR PEQUEO?

T cond = 45C Tevap= - 5C

COP1 = 2,39

T amb = 25C T cuarto = 2C MT 100 (9 HP) R22

T cond = 40C Tevap= - 5C

SC=4, SH=5/8

COP2 = 2,73

Q comp. = 7,2 KW Tcond = 40C, T evap = - 5C

Costo $ /mes = 7,2 KW x 18 horas x 30 das/mes x 400 $/KWH = 1.550.000 $ /mes COP1/COP2 = 12,5%, = $ 190.000 / mes! $ 2.300.000 al ao
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EVAPORADORES ALETADOS

Tevap. = Tcuarto 6 10 C

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CUANTO PAGAMOS POR UN EVAPORADOR PEQUEO?

T cond = 40C Tevap= - 10C

COP1 = 2,29

T amb = 25C MT 100 (9 HP) R22 T cuarto = 2C

T cond = 40C Tevap= - 5C COP2 = 2,73

Q comp. = 7,2 KW Tcond = 40C, T evap = - 5C

COP1/COP2 = 16% = $ 248.000 / mes! $ 3.000.000 /ao
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CONTROL SOBRECALENTAMIENTO SH

Super Heat: Diferencia entre la temperatura de succin y la temperatura de evaporacin o saturacin. SH

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SOBRECALENTAMIENTO TOTAL

SH 2

SH 1

SH 1 = 5C, vlvula de Expansin SH2 Aislamiento.

SH 1 + SH 2

20C
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Function of TXV-TE SH control

Pcharge x Adiaphragm = (Pevaporator x Adiaphragm) + Fspring

Tcharge -> Pcharge

Charges:

Universal
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MOP (ballast)

Adsorption
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RELATIVE COP
INDEX COP vs SH

100 98 96 94 92 90 88 86 5
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10

12

16

SUPERHEAT ( S2-S1)
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Injection Control Superheat

Large superheat => Low evaporation Temperature => High energy consumption

S4

Temperature

S2 S5 S3 Po

S3

S1

Air te

mp e

ratur e

S4 S2

Po Po Po

No superheat Small superheat Large superheat

Inlet Position

Refrigerant temperature
Outlet
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Por cada 1C que vare el SH, la temperatura de succin varia 1C.

SH 2 = 3C SH 1 = 5C

TEMP. Cuarto Frio = + 2C

COP1 = 2,73 (ptimo), 7,2 Kw.

7,2Kw x 400 $/Kw x 18 h/da x 30 das/mes = $ 1.550.000 / mes

T evap. = - 5C

TEMP. Cuarto Frio = + 2C COP2 = 2,28 (evap. sin llenar)

SH 2 = 3C

SH 1 = 10C

COP2/COP1 = 17% ms de consumo de energa. 17% = $ 264.000 / mes. $ 3.150.000 / ao

T evap. = - 10C
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CUANTO PAGAMOS POR ALTOS SH?

Tcond = 40C, T cuarto frio = + 2C, mismo evaporador, MT 100.
SH 2 = 3C SH 1 = 5C

COP1 = 2,73 (ptimo)

Q comp = 7,2 Kw

T evap. = - 5C

SH 2 = 15C

SH 1 = 5C

COP3 = 2,58 (succin mal aislada)

COP3/COP1 = 6% 7,2Kw x 400 $/Kw x 18 h/dia x 30 dias/mes = $ 1.550.000 / mes 6% = $ 93.000 / mes. $ 1.000.000 / ao
T evap. = - 5C

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EXPANSION TERMOSTATICA vs ELECTRONICA

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EXPANSION TERMOSTATICA vs ELECTRONICA

Bajo costo inicial Fcil seleccin y manejo tcnico Posibilidad de intercambio de orificios Instalacin sencilla Maneja variaciones de cargas mx. 20%

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+ Rpida + Segura, retornos de lquido Maneja variaciones de carga altas 90% Maneja SH estables Ahorro de energa Posibilidad de intercambiar orificios Misma vlvula para todos los refrigerantes Un controlador puede manejar varias vlvulas Precisin en la lectura de los sensores Menos problema con ubicacin de sensores No ajustes manuales No hay problemas con variaciones de Pcond. Opera como solenoide. 17/06/2011 / 18

1.

VALVULAS ELECTRONICAS MODULANTES

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2.

DX ELECTRONICA PULSANTE

AKV Valve
PWM Principle (Pulse Width Modulating)

Periode time (PT) = 6 seconds OD % =

AKV OD %

OT x 100 PT

OT = Opening Time.

Time AKV Open

AKV closed

12 seconds

Homework Intro Temp. control Injection AKV valve Defrost Ctrl. types Next session
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AKV electronic expansion valves

AKV 10

AKV 20

AKV 15

Pulse width modulated Integrated solenoid function Exchangeable orifices Wide capacity range All refrigerants Hydraulic damping system Coil program

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AKV electronic expansion valves

7 CAPACITY STEP FLARE/SOLDER VERSION PARTSPROGRAMME

Coil: 2.5 - 5 and 8 meter cable

SEMIHERMETIC DESIGN WIDE TEMP. RANGE 230 - 24 V AC AND DC 18F COIL PRINCIPPLE ALL REFRIGERANTS AMMONIA VERSION
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AKV 15

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AKV capacity range

AKV 10
16

AKV 15
100

AKV 20
800

R22 Capacity in kW

2 0 1 5 1 0 5
1 6,3 1,6 2,5 4 10

10 0

630

7 5 5 0
2 5

63 40 25

600 400 200

100

400 250

160

1 2 3 4 5 6 7

1 2 3 4 Orifice no.

1 2 3 4 5

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CONTROLADORES DX ELECTRONICA

EKC 315A

AKC 24P / P2

AKV/A PARA TODOS LOS REFRIGERANTES

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AKV/A

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CONTROLADORES DX ELECTRONICA

AKV/A PARA TODOS LOS REFRIGERANTES

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AKV/A

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AHORRO DE ENERGIA CON DX ELECTRONICA

7,2Kw x 400 $/Kw x 18 h/da x 30 das/mes = $ 1.550.000 / mes 23,2% = $ 360.000 / mes
15% = 230.000 / mes $ 2.760.000 //ao 17/06/2011 27

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How do measure superheat?

Air of temperature S4 Refrigerant temperature S2 Refrigerant temperature S1

Evaporator
Surface temperature: S5

Pressure Po

Air on temperature S3

One measurement to much on refrigerant side...

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How do measure superheat?

Po [C] is equal to S1
S4 S1 S5 S3 S2 Po

Po S1 S2

Po [C] is not equal to S1, superheat = S2-Po[C]

S1

Po S2

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Injection Control Superheat

Comparison of two ways of measuring the superheat signal: SH = S2 - S1 or SH = S2 Te (true value) (Te must be calculated from a Pe measurement)

Temp. C

S2

5K

AKS32R (Te)

AKS32R

S1

S2

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Injection Control Superheat

Comparison of two ways of measuring the superheat signal: SH = S2 - S1 (bad measure) SH = S2 Te (true value) (Te must be calculated from a Pe measurement)

Temp. C

S2

5K 7K

AKS32R (Te)

AKS32R

S1

S2

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Pressure Transmitter advantage

Po is a better measurement than S1 and is used/required in newest controller versions
S4 S1 S5 S3 S2 Po

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Porque DX electrnica ahorra energa? Adaptive superheat control

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Injection function
To S2

S2-To

Stable

Unstable

Stable

Length MSS start

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Minimum stable superheat - Theory

1 When an evaporator is under filled with refrigerant, the superheat signal is high and very stable at the outlet of the evaporator. Only a small area of the evaporator is utilised => degraded performance. 2 When the evaporator is almost full, liquid drops of refrigerant will be present at the outlet of the evaporator and this will result in an unstable superheat signal. This will result in control hunting problems => degraded performance.
3 If the evaporator is over filled with refrigerant, liquid will flow back into the suction line => Degraded system performance + risk of damaging the compressor. The superheat signal will be very stable at 0K.

Minimum stable superheat => Best evaporator performance

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Minimum stable superheat - Theory

MSS curve
100 98 96 94 92 90 88 86 5 6 8 10 12 16

Relative COP

The superheat is reduced until the signal becomes unstable. Then superheat is increased a bit until stability is found followed by a new reduction and so on! It happen in all conditions.

Superheat
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Injection Control Electronic valve

MSS = f (Q0,T0 etc.)

Q0
Load range for the evaporator

Adaptive valve

Unstable zone

Stable zone

Homework Intro Temp. control Injection AKV valve Defrost Ctrl. types Next session
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Superheat

Adaptive vs. Fixed superheat control

Other suppliers are often using a fixed set point for the control of the evaporator superheat.
In theory this means that the evaporator can be fully utilised in one operation point, but this would require a very time consuming manual adjustment of the set point which is never carried out in praxis. A fixed superheat control algorithm will not detect when liquid is present at the evaporator outlet. Hence the superheat set point must be set in a safe distance from the The adaptive superheat for the Danfoss minimum stable superheat in order to ensure that liquid will not flow back into controller enables extra savings compared to other suppliers. the suction line.
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Other suppliers

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Adaptive vs. Fixed superheat control

The measuring accuracy of the evaporating pressure and the gas outlet temp. must be very accurate in order to control superheat at low values. Competitors often use low cost and thereby low precision pressure transmitters. The result is that the superheat set point has to be set a quite high value in order to eliminate the risk of having liquid flow back to the suction line due to lousy measuring accuracy.

The result is of course even higher savings with the Danfoss adaptive control of superheat.

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Adaptive vs. Fixed superheat control

The adaptive superheat control will typically obtain a 2-3 K lower superheat reference than with a competitor fixed superheat reference. By lowering the superheat, the suction pressure can be increased by approx. the same amount. The energy savings by increasing suction pressure by 1K is typically 3 %. So the energy savings by using Danfoss adaptive superheat control will typically be 6-9 % compared to a fixed superheat control.
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Saving example:

MT100 (9 HP hermetic):
7,2Kw x 400 $/Kw x 18 h/dia x 30 dias/mes = $ 1.550.000 / mes

9% = $ 140.000 / mes. $ 1.680.000 / ao Medium sized supermarket with 3 compressor MT100: Save energy: $ 420.000 / mes 17/06/2011 Total $ 5.040.000 / year

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Aplicaciones:
Instalaciones con variaciones de cargas trmicas Instalaciones con variacin de presin de condensacin Tneles de congelacin Intercambiadores de placas Intercambiadores con variacin de carga (caudal, diferencial temp.) Equipos que requieran proteccin y precisin

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How to select the right size AKV

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How to select the right size AKV

1. 2. 3. Find evaporator capacity Calculate pressure drop across AKV Correct for sub-cooling

4.
5. 6.

Correct capacity to pull-down capability

Select correct AKV size Determine correct liquid line dimension

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How to select the right size AKV

1.

Find evaporator capacity

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How to select the right size AKV

2. Calculate pressure drop across AKV

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How to select the right size AKV

3. Correct for sub-cooling

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How to select the right size AKV

4. Correct capacity to pull-down capability

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How to select the right size AKV

5. Select correct AKV size

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How to select the right size AKV

6. Determine correct liquid line dimension

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Questions

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