ZF* REFRIGERATION SCROLL COMPRESSORS USING R407A, R407F, R448A OR R449A IN LOW TEMPERATURE APPLICATIONS

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1 Date f last update: Oct-16 Ref: C7.19.2/ /E Applicatin Engineering Eurpe ZF* REFRIGERATION SCROLL COMPRESSORS USING R407A, R407F, R448A OR R449A IN LOW TEMPERATURE APPLICATIONS ZF* Refrigeratin Scrll Cmpressrs Using R407A, R407F, R448A r R449A in Lw Temperature Applicatins 1 1 Intrductin Liquid injectin DTC valve cnnectins DTC valve installatin Vapur injectin (EVI = Ecnmized Vapur Injectin) Principle f peratin Subcler selectin and applicatin Liquid receiver Line lengths and insulatin Vapur injectin + liquid injectin (wet vapur injectin) Discharge temperature prtectin Discharge line thermstat specificatins Discharge line thermstat installatin DISCLAIMER C7.19.2/ /E 1/14

2 1 Intrductin The lw temperature applicatin f ZF* Cpeland Scrll cmpressrs with refrigerants R407A, R407F, R448A r R449A requires the use f dedicated injectin technlgies in rder t prvide excellent cmpressr efficiencies and t keep the peratin within safe limits. Depending n the ZF* Cpeland Scrll cmpressr family, the fllwing injectin systems can be used: Cmpressr family ZF06K4E t ZF18K4E Liquid injectin Vapur injectin Vapur + liquid injectin ZF(D)13KVE t ZF(D)25KVE X X Table 1 ZF25K5E t ZF49K5E ZFD41K5E X X X X The ZF*K4E range f cmpressrs wuld need t be equipped with liquid injectin by the usage f a DTC valve. Cmpressr mdels ZF(D)13KVE t ZF(D)25KVE are vapur injectin nly. Liquid injectin alne is nt pssible. Cmpressr mdels ZF25K5E t ZF49K5E and ZFD41K5E are designed and applicable fr bth liquid injectin and vapur injectin (EVI). Fr cmpressr mdels ZF(D)13KVE t ZF(D)25KVE, ZFD41K5E and ZF25K5E t ZF49K5E applied with vapur injectin, the peratin envelpe can be increased by the usage f wet vapur injectin. Wet vapur injectin is a cmbinatin f vapur and liquid injectin at the same time and can be used in rder t perate the scrll cmpressrs in a larger applicatin envelpe. Fr crrespnding peratin envelpes, please refer t the cmpressr technical data, such as Emersn Select Sftware. NOTE: Fr all ZF* cmpressr types in lw temperature applicatins with R407A, R407F, R448A r R449A, the installatin f liquid r vapur injectin is mandatry. All crrespnding perating envelpes are based n the use f liquid r vapur injectin. Special care needs t be taken t ensure that the dedicated discharge temperature thermstats (DLT) installed are fr use with R407A, R407F, R448A r R449A. See dcumented perating envelpes in the cmpressr technical data (Select Sftware). The Select sftware can be dwnladed frm under quick links/prduct selectin sftware/cpeland and Alc selectin sftware/dwnlads. 2 Liquid injectin Liquid injectin fr ZF*K4E and ZF*K5E scrll cmpressrs is mandatry t keep discharge gas temperatures within safe limits. The fllwing ZF* liquid injectin mdels can be used with R407A, R407F, R448A r R449A: ZF06-18K4E-TFD Cmpnents fr liquid injectin: Discharge line thermstat kit 130 C, incl. clip 5/8" Liquid injectin DTC 120 C 11/16" kit including DTC valve, O-ring gasket and prtectin cap Retrfit R404A systems with ZF06-18K4E and R407A, R407F, R448A r R449A: Please install: Liquid injectin DTC kit 120 C 11/16" Discharge line thermstat kit 130 C, incl. clip 5/8" C7.19.2/ /E 2/14

3 The use f existing R404A liquid injectin cmpnents is pssible, but nt ptimized fr R407A, R407F, R448A, R449A Liquid injectin DTC kit 90 C Gasket DTC valve 90 C Discharge line thermstat kit 105 C, incl. clip 5/8" ZF25K5E-TFD Cmpnents fr liquid injectin: Discharge line thermstat kit 130 C, incl. clip 5/8" Liquid injectin DTC kit 120 C 1" ZF34-49K5E, ZFD41K5E TFD including DTC valve, Tefln gasket and prtectin cap Cmpnents fr liquid injectin: Discharge line thermstat kit 130 C, incl. clip 7/8" Liquid injectin DTC kit 120 C 1" including DTC valve, Tefln gasket and prtectin cap Liquid injectin is achieved by means f a Discharge Temperature Cntrl (DTC) valve. The DTC valve is equipped with a custm bulb prfile, which must be installed in the tp well f the cmpressr sensing the temperature clsest t the discharge prt. The DTC valve nly allws injectin when cling is needed and in the required amunt. The use f an external discharge thermstat is mandatry fr all cmpressr mdels ZF06K4E t ZF18K4E, ZF25K5E t ZF49K5E and ZF49K5E. Fr all cmpressr mdels ZF*K4E and ZF*K5E, the discharge thermstat is included in the standard delivery f the cmpressr. 2.1 DTC valve cnnectins Figure 1: Liquid injectin with DTC valve C7.19.2/ /E 3/14

T prevent a partial r full blckage at the injectin prt caused by shavings, freign bdies, etc. a filter dryer shuld be installed in the liquid line prir t the DTC valve inlet.

5 mm) braze cnnectin n the liquid inlet f the DTC valve 11/16" 16 UN cnnectin, cmpressr injectin prt Recmmended tightening trque 24-27 Nm Figure 2: Liquid injectin DTC valve 120 C 11/16" 8414390

4 T prevent a partial r full blckage at the injectin prt caused by shavings, freign bdies, etc. a filter dryer shuld be installed in the liquid line prir t the DTC valve inlet Liquid injectin DTC kit 120 C 11/16" 3/8" (9.5 mm) braze cnnectin n the liquid inlet f the DTC valve 11/16" 16 UN cnnectin, cmpressr injectin prt 3/8" (9.5 mm) braze cnnectin n the liquid inlet f the DTC valve 11/16" 16 UN cnnectin, cmpressr injectin prt Recmmended tightening trque Nm Figure 2: Liquid injectin DTC valve 120 C 11/16" Liquid injectin DTC kit 120 C 1" 3/8" (9.5 mm) braze cnnectin n the liquid inlet f the DTC valve 1" 14 UNS cnnectin, cmpressr injectin prt Recmmended tightening trque Nm Figure 3: Liquid injectin DTC valve 120 C 1" C7.19.2/ /E 4/14

5 2.2 DTC valve installatin The valve bulb must be installed in the tp cap t adequately cntrl scrll temperatures. Therefre it has t be checked, that there is the cil spring seated inside the cmpressr. The cil spring is part f the standard delivery f the cmpressr, but culd als be rdered as a spare part. The installatin f the cil spring is required fr a prper installatin. The DTC valve shuld be tightened n the injectin prt n the side f the cmpressr. The recmmended trque is Nm fr the DTC valve 120 C 11/16" and Nm fr the DTC valve 120 C 1". It is recmmended that the valve be lcated perpendicular t the cmpressr rientatin. Hwever it will functin prperly in any rientatin. The capillary tube cnnecting the valve t the bulb shuld be psitined at least 13 mm away frm the side f the scrll t avid cntact during peratin. When cming ut f the therm cap, the capillary tube frm the bulb may als be checked nt t have cntact with the cmpressr tp. The minimum distance fr the insulated capillary tube t the cmpressr tp is 3 mm. The DTC Valves are supplied with a gasket fr the injectin prt cnnectin (O-ring fr the DTC 120 C 11/16 and Tefln gasket fr the DTC 120 C 1") and an insulating cap which is applied t the tp f the cmpressr. Befre starting the cmpressr, ensure that there is liquid refrigerant in frnt f the DTC valve inlet. Otherwise the valve culd be damaged. Figure 4: DTC valve assembly NOTE: When replacing a ZF*K4E r ZF*K5E cmpressr using the DTC valve, it is recmmended t replace bth the cmpressr and the DTC valve at the same time. The filter dryer in the liquid line shuld be replaced as well. 3 Vapur injectin (EVI = Ecnmized Vapur Injectin) Scrll cmpressr mdels ZF(D)13KVE t ZF(D)25KVE, ZFD41K5E and ZF25K5E t ZF49K5E are applied with vapur injectin by implementing an ecnmizer circuit in the system. Ecnmizing is achieved by means f a subcling circuit similar t the ne shwn in Figure 6. The fllwing cmpressr types can be used with R407A, R407F, R448A r R449A and vapur injectin: ZF13KVE t ZF18KVE ZFD13KVE t ZFD25KVE, ZFD41K5E ZF25K5E t ZF49K5E The applicatin envelpes fr the use f R407A, R407F, R448A r R449A with vapur injectin nly have been significantly limited because f pssible high discharge temperatures. Please refer t the envelpe examples in Figure 5. The mtr cling is als affected. Special attentin shuld be paid t the pssible maximum suctin gas temperature / superheat values. A special external discharge temperature prtectin must be used. C7.19.2/ /E 5/14

Figure 5: Operating envelpes Vapur injectin nly NOTE: The applicatin envelpes fr R407A, R407F, R448A, R449A can be enlarged with the cmbinatin f vapur injectin and liquid injectin.

6 Figure 5: Operating envelpes Vapur injectin nly NOTE: The applicatin envelpes fr R407A, R407F, R448A, R449A can be enlarged with the cmbinatin f vapur injectin and liquid injectin. See als Chapter 4 "Wet vapur injectin". NOTE: The use f the existing R404A discharge line thermstat is NOT pssible. R407A, R407F, R448A and R449A applicatins require the 130 C discharge gas thermstat. ZF(D)13-18KVE Cmpnents fr vapur injectin: Discharge line thermstat kit 130 C, incl. clamp 5/8" ZF34-49K5E, ZF(D)25K5E, ZFD41K5E Cmpnents fr vapur injectin: Discharge line thermstat kit 130 C, incl. clamp 7/8" 3.1 Principle f peratin Vapur-injected scrll cmpressrs make use f an ecnmizer with the vapur cmpressin cycle. This cycle ffers the advantages f mre cling capacity and a better COP than with a cnventinal cycle. The imprvement f bth the capacity and the COP is prprtinal t the temperature lift and this technlgy ffers best results at lw evaprating temperatures where capacity and efficiency are mst needed. It is usually pssible t specify a smaller displacement cmpressr fr a given cling lad. Figure 6: Circuit diagrams shwing the main circuit, the mass flw rate m, the ecnmizer circuit and the mass flw rate i A prtin f the cndensed liquid i is expanded thrugh an expansin valve int a cunterflw brazed-plate heat exchanger (HX), which acts as a subcler. The superheated vapur is then injected int an intermediate vapur injectin prt in the scrll cmpressr. The additinal subcling increases the evapratr capacity by reducing the C7.19.2/ /E 6/14

temperature f the liquid frm TLI t TLO, thus reducing its enthalpy. The additinal cndenser mass flw i gives a crrespnding increase in the heat rejectin at the cndenser.

pwer. The incremental vapur created in the subcling prcess is cmpressed nly frm the higher interstage pressure rather than frm the lwer suctin pressure.

7 temperature f the liquid frm TLI t TLO, thus reducing its enthalpy. The additinal cndenser mass flw i gives a crrespnding increase in the heat rejectin at the cndenser. The vapur-injected scrll cmpressr cycle efficiency is higher than that with a cnventinal single-stage scrll delivering the same capacity because the added capacity frm subcling is achieved with less pwer. The incremental vapur created in the subcling prcess is cmpressed nly frm the higher interstage pressure rather than frm the lwer suctin pressure. The cling effect is achieved by the additin f vapur t the cmpressin prcess at the intermediate pressure and at temperature TVO which is cntrlled by the HX expansin device. During the subcling prcess a small amunt f refrigerant is evaprated and superheated. This superheated refrigerant is then injected int the mid cmpressin cycle f the scrll cmpressr and cmpressed t discharge pressure. This injected vapur als prvides cling at higher cmpressin ratis, similar t liquid injectin f standard ZF* scrll cmpressrs. The benefits prvided will increase as the cmpressin rati increases, thus, mre gains will be made in summer, when increased capacity may actually be required. Figure 7: Psitin f the injectin prts in the Scrll set and psitin f the internal tubing cnnecting the injectin inlet with the Scrll set The vapur is injected int the scrll set at an intermediate pint in the cmpressin prcess via tw symmetrically psitined prts as shwn n the left in Figure 7. The size and psitin f these prts have been ptimised t ensure maximum COP and capacity benefit at typical perating cnditins. A single inlet cnnectin n the shell cmmunicates with the injectin prts via a flexible tube as shwn n the right, and drillings in the fixed scrll. The flexibility ensures that axial cmpliance is maintained. 3.2 Subcler selectin and applicatin Fr sizing subcler fr different cnditins the first step is t establish the lad. This can be fund using the Select sftware (see belw). The liquid utlet temperature TLO and saturated intermediate temperature TSI can als be fund frm the sftware. The heat balance acrss the HX may then be used t establish the lad. Please refer t Figure 8. Fr ptimum perfrmance it is best t chse 5K heat exchanger ΔT and 5K heat exchanger superheat as shwn. Figure 8: Heat balance methd fr calculating the HX lad and injectin mass flw rate C7.19.2/ /E 7/14

Figure 9: Select Sftware screen shwing HX capacity and system parameters In the Select sftware the value f the liquid temperature TLO is prvided alng with the subcler lad and saturated injectin

8 It shuld be nted that the benefit f natural subcling, ie, cndenser subcling, is limited t a maximum f apprximately 5K. Further natural subcling leads t little additinal reductin in liquid temperature TLO. The subcler perfrmance is based n a temperature difference THX f 5K. Figure 9: Select Sftware screen shwing HX capacity and system parameters In the Select sftware the value f the liquid temperature TLO is prvided alng with the subcler lad and saturated injectin temperature TSI. Additinal system parameters are shwn at the tp right f the screen and these may be input and adjusted by activating the system view buttn. Ensure that when the system view screen appears, the "Shw Vapur Injectin" ptin is activated: Figure 10: Selectin Sftware screen shwing HX capacity and system parameters It is quite ften necessary t make an allwance fr liquid heat gain between the heat exchanger and the expansin valve. If the liquid line is ruted thrugh regins where the surrunding temperature is abve the liquid utlet temperature TLO there will be a rise in temperature with a crrespnding small lss f system capacity. This liquid temperature increase after leaving HX (als called EVI liquid line temperature rise) can be adjusted n this screen. Dwnstream extractin shwn in Figure 11 refers t taking the liquid fr the HX expansin device frm the HX liquid exit as shwn. This methd is smetimes prpsed t ensure gd subcling at the TXV inlet. Whilst there is n verall heat gain r lss cmpared t the usual upstream extractin, it des mean that the injected mass C7.19.2/ /E 8/14

flw i is passing thrugh the HX twice and incurring extra pressure drp n the liquid cling side. This may result in the need fr a larger HX.

Fr these reasns dwnstream extractin is less preferable than upstream shwn in Figure 11.

The expansin valve shuld be cnnected at a distance between 150 mm and 200 mm frm the vapur entry and at a psitin nt lwer than the inlet cnnectin.

9 flw i is passing thrugh the HX twice and incurring extra pressure drp n the liquid cling side. This may result in the need fr a larger HX. Als dwnstream extractin requires mre cnnectins and tubing n the subcled liquid side all f which need t be insulated t ensure minimal heat gain. Fr these reasns dwnstream extractin is less preferable than upstream shwn in Figure 11. Figure 11: Liquid extractin (a) Upstream (recmmended) (b) Dwnstream (nt recmmended) The subcler HX must be installed vertically with the vapur entry at the bttm. The expansin valve shuld be cnnected at a distance between 150 mm and 200 mm frm the vapur entry and at a psitin nt lwer than the inlet cnnectin. Figure 12: Psitin f the expansin valve and bulb when using a plate heat exchanger Where a thermstatic valve is used the bulb f the expansin valve shuld be psitined 400 t 600 mm frm the vapur utlet preferably after a bend and n the inside as shwn n the left in Figure 12. The psitin f the bulb relative t the sectin f the tube is illustrated. It shuld nt be attached underneath the tube. External equalisatin is nt essential. The tubing between the expansin valve and the HX entry may either be straight r include a bend as shwn n the right in Figure 12. Fr multiple cmpressr systems an electrnic expansin valve is recmmended. 3.3 Liquid receiver A liquid receiver may be necessary t accmmdate charge variatins ver the perating cnditin range. It shuld always be fitted in the cndenser utlet liquid line and nt in the heat exchanger utlet liquid line. This is because vapur phase may be present in a receiver and this is nly pssible with saturated liquid. Figure 13: Where NOT t place the liquid receiver C7.19.2/ /E 9/14

10 3.4 Line lengths and insulatin The liquid line frm the HX t the expansin valve(s) needs t be well insulated. Vapur lines between bth expansin devices and the heat exchangers (evapratr and subcler) need t be kept as shrt as practical and well insulated. The subcler HX shuld als be insulated. All lines shwn in blue clur in the circuit diagrams require insulatin. Liquid line temperature rise: In many installatins where the cmpressr(s) is (are) situated away frm the evapratr(s) the liquid temperature will increase during its travel frm the HX t the evapratr. Even with insulated lines this temperature rise can result in a small lss f capacity. The heat gain may be estimated by calculatin methds and a typical value fr liquid temperature rise is apprximately. 0.7K ver 10 meters when passing thrugh areas at 20 C air temperature. T adjust capacity fr this effect in the Select sftware g t "System View => Shw Vapur Injectin" and enter a value fr liquid temperature rise. 4 Vapur injectin + liquid injectin (wet vapur injectin) When using scrlls in lw temperature applicatins with R407A, R407F, R448A r R449A and extended envelpe (see Figure 14), additinal liquid injectin with a DTC valve is required in cnjunctin with the vapur injectin t prtect the scrll frm higher discharge temperatures. The fllwing cmpressr types can be used with R407A, R407F, R448A, R449A and wet injectin: ZF13KVE-TFD and ZF18KVE-TFD ZFD13KVE-TFD, ZFD18KVE-TFD, ZFD25KVE-TFD, ZFD41K5E-TFD ZF25K5E-TFD t ZF49K5E-TFD Figure 14: R407A, R407F, R448A and R449A perating envelpes fr wet injectin ZF(D)13-18KVE Cmpnents fr wet vapur injectin (vapur + liquid injectin): Discharge line thermstat kit 130 C, incl. clamp 5/8" Wet injectin DTC Quest kit The kit includes: Liquid injectin DTC kit 120 C 11/16" Adapter 11/16" t ½" brazing, DTC valve t ½ brazing EVI line NOTE: Fr the installatin f wet vapur injectin n existing digital cmpressrs ZFD13KVE t ZFD25KVE, the DTC valve bulb must replace the existing NTC sensr at the side f the cmpressr tp cap. The previus NTC sensr has t be remved and the cntrller, eg, ALCO EC3-D*, has t be mdified (disable discharge sensr input). A new thermstat must be installed n the discharge line. DO NOT use the previus slutin NTC sensr + cntrller as a discharge temperature prtectin, as its rating is nt suitable fr R407A, R407F, R448A r R449A. C7.19.2/ /E 10/14

11 ZF25K5E, ZFD25KVE Cmpnents fr wet vapur injectin (vapur + liquid injectin): Discharge line thermstat kit 130 C, incl. clamp 5/8" Wet vapur injectin DTC Summit + Stretch Quest kit The kit includes: Liquid injectin DTC kit 1", incl. gasket Adapter DTC valve t ½" line, 1" 14UN Rtalck t ½" inner diameter brazing Adapter kit incl. gasket, injectin prt 1" UNS 14 t ½" brazing ZF34-49K5E-TFD, ZFD41K5E Cmpnents fr wet vapur injectin (vapur + liquid injectin): Discharge line thermstat kit 130 C, incl. clamp 7/8" Wet vapur injectin DTC Summit + Stretch Quest kit The kit includes: Liquid injectin DTC kit 1", incl. gasket Adapter DTC valve t ½" line, 1" 14UNS rtalck t ½" inner diameter brazing Adapter kit incl. gasket, injectin prt 1" UNS 14 t ½" brazing Figure 15: Wet vapur injectin fr R407A, R407F, R448A r R449A lw temp applicatins C7.19.2/ /E 11/14

12 Figure 16: Installatin f wet vapur injectin fr R407A, R407F, R448A r R449A lw temp applicatins, example with ½" EVI vapur injectin line 5 Discharge temperature prtectin When using R407A, R407F, R448A r R449A in lw temperature applicatins, the discharge temperature must be bserved. Special care shuld be taken fr the usage f R407A, R407F, R448A and R449A dedicated discharge line thermstats. Excessive discharge gas temperatures can lead t premature cmpressr failure. The discharge line thermstat is required in the cmpressr cntrl circuit. The recmmended thermstats have a cut-ut setting that will ensure a discharge line temperature belw the maximum allwed limit. The discharge line thermstat shuld be installed apprximately 120 mm frm the discharge tube utlet. Fr crrect functin, it is recmmended that the thermstat shuld be insulated t prtect it frm a direct air stream. Kits have been set up t include the thermstat, a clamp and installatin instructins. Thermstats fr cmpressr mdels ZF06K4E t ZR18K4E, ZF25K5E, ZF13KVE, ZF18KVE and ZFD13KVE t ZFD25KVE must be used with 5/8" (15.8 mm) utside diameter discharge lines t ensure prper thermal transfer and temperature cntrl. Cmpressr mdels ZF34K5E t ZF49K5E require a discharge line thermstat with 7/8" (22.2 mm) utside diameter. The discharge line thermstat will wrk with either 120 r 240 vlt supply. High discharge temperature prtectin shuld always be fitted t each cmpressr. This ensures that the cmpressr cannt verheat in the event f lss f liquid r vapur injectin cling. 5.1 Discharge line thermstat specificatins ZF06-18K4E, ZF(D)13-18KVE (R404A, R407A, R407F, R448A, R449A) Discharge line thermstat kit 130 C, incl. clamp 5/8" (15.8 mm) clamp diameter Open 129 C ± 4K C7.19.2/ /E 12/14

ZF25K5E, ZFD25KVE (R404A, R407A, R407F, R448A, R449A) 8409496 Discharge line thermstat kit 130 C, incl. clamp 5/8" (15.

clamp 7/8" (22.2 mm) clamp diameter Open 129 C ± 4K 5.

Snap the retainer clip ver the tube and nt the thermstat.

Ensure that the thermstat is nt tilted. The wire must nt be in cntact with the tp cap f the cmpressr r the discharge tube.

13 ZF25K5E, ZFD25KVE (R404A, R407A, R407F, R448A, R449A) Discharge line thermstat kit 130 C, incl. clamp 5/8" (15.8 mm) clamp diameter Open 129 C ± 4K ZF34-49K5E, ZFD41K5E (R404A, R407A, R407F, R448A, R449A) discharge line thermstat kit 130 C, incl. clamp 7/8" (22.2 mm) clamp diameter Open 129 C ± 4K 5.2 Discharge line thermstat installatin Install the discharge line thermstat n the discharge tube 120 mm frm tp cap. Snap the retainer clip ver the tube and nt the thermstat. The thermstat shuld be placed n the discharge tube s that its bdy is in upward psitin n a hrizntal tube installatin. Ensure that the thermstat is nt tilted. The wire must nt be in cntact with the tp cap f the cmpressr r the discharge tube. Care shuld be taken t rute wires s that they d nt cme int cntact with sharp bjects. T avid any impact n tripping temperature by the ambient, the discharge line thermstat must be insulated. Wrap thermal insulatin arund the pipe left and right f the thermstat and secure it with plastic straps. Wrap a secnd layer f insulatin arund the first ne and arund the thermstat, and secure it with plastic straps. Figure 17: Installatin recmmendatins fr the discharge temperature prtectin C7.19.2/ /E 13/14

14 DISCLAIMER 1. The cntents f this publicatin are presented fr infrmatinal purpses nly and are nt t be cnstrued as warranties r guarantees, express r implied, regarding the prducts r services described herein r their use r applicability. 2. Emersn Climate Technlgies GmbH and/r its affiliates (cllectively "Emersn"), as applicable, reserve the right t mdify the design r specificatins f such prducts at any time withut ntice. 3. Emersn des nt assume respnsibility fr the selectin, use r maintenance f any prduct. Respnsibility fr prper selectin, use and maintenance f any Emersn prduct remains slely with the purchaser r end user. 4. Emersn des nt assume respnsibility fr pssible typgraphic errrs cntained in this publicatin. C7.19.2/ /E 14/14

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