Climate Control

Non-condensable gasses such as air, hydrogen, nitrogen and hydrocarbons reduce the overall efficiency of refrigeration systems. The effects of non-condensable gasses, in a refrigeration system, increase the system operating pressures. These in turn negatively affect system performance. Increased compressor discharge temperature, higher energy costs, reduced system efficiency, leaks due to higher pressures, and increased wear on mechanical components are all negative consequences of non-condensable gasses in refrigeration systems.

The build-up of non-condensable gasses in the system can be attributed to several factors. These include inadequate system evacuation during service of system equipment, additions of refrigerant, leaks through external seals on equipment as well as refrigerant and oil decomposition.

Common indicators of non-condensable gasses in the system are excessively high condensing pressure or temperature and deviations in the pressure and temperature relationship at saturation conditions. This can be determined by checking the temperature and pressure relationship at a known point in the system where the refrigerant is saturated, such as the condenser drain legs or high pressure receiver, as illustrated in Figure 1. A higher temperature measured at this point, compared to the saturation pressure, indicates the presence of non-condensable gasses in the system.

 

Reduced efficiency

Ammonia refrigeration systems can be robbed of efficiency due to the presences of non-condensables in the system. These gasses lower heat transfer in coils as they take up space that should be occupied by the refrigerant itself. This can result in an overall efficiency reduction. These gasses can also cause compressors to work harder than they should due to increased head pressures in the system. Overall the presence of non-condensables causes your ammonia refrigeration to work harder than it should. 

For example, a 20 psi head pressure increase will result in more than 5% decreased system capacity. 

 

Increased operating costs

The decreased efficiency caused by non-condensables will result in higher power requirements for your system and this additional power comes at a great expense. 

Using the same example, a 20 psi head pressure increase will result in a 10% increase in energy consumption. For every 100 tons of capacity a system operating 6500 hours per year would result in $6300 of additional operating costs. 

 

A safe and effective solution

The V300 Rapid Purger from Parker Sporlan’s Refrigeration Business Unit will safely and effectively remove these non-condensables from your system and restore your system to its peak operational efficiency. The V300 is the 3rd generation of purger technology from Parker and is based on years of experience and testing. The V300 uses both pressure and temperature monitoring combined with a proprietary algorithm to automatically remove the air from the system in a safe and effective manner. If you are working on a system that is showing signs of increased head pressure or decreased operational efficiency the V300 can restore your system to its best.

The V300 Rapid Purger also has the ability to monitor the ammonia loss history. This function calculates the amount of ammonia lost during a standard purge cycle using a proprietary algorithm developed by Parker. Our engineers worked with live ammonia systems, including our own Broadview Ammonia Test Facility, to develop this algorithm based on real world applications and conditions. The result is that the V300 Rapid Purger can now display the amount of ammonia lost as part of its standard history display. The ammonia loss history can be viewed by week, by day, and by point:

Ammonia loss by week

 

Ammonia loss by day

The ammonia loss history will make compliance and reporting even easier when using a Parker Sporlan Rapid Purger. For additional information on the V300 Rapid Purger please click here or call us at 800-506-4261.

 

Download the Parker Sporlan V300 Purger product bulletin here.

 

Article contributed by Drew Stock, business development manager, Sporlan Division of Parker Hannifin.

 

 

 

 

Additional resources for you:

Compressor Overheating is the Number One Refrigeration Problem

Six Reasons Why CDS Conversion Reduces Costs

Using P-T Analysis as a Service Tool for Refrigeration Systems

Contractors provide service to customers with many different system applications in the field with an even wider variety of capacity requirements. Today, the number of refrigerants that a contractor might encounter is simply never ending! While not every system is fitted with a TEV, there are literally thousands of different TEV variations in the market place.

Can you imagine how hard-pressed wholesalers are to stock every version of a valve that might be needed for routine service? This is mind-boggling and needless to say, the contractor is even more unlikely to have the right valve on a service truck for that emergency service or repair job.

 

How does a contractor or wholesaler solve this problem?

Turn to Sporlan’s interchangeable cartridge style TEV product line, the type Q and BQ. Simply select the thermostatic element, the body and the right sized cartridge for the application and assemble the parts. They are even available with conventional (Q) and balanced port (BQ) construction. These easy to select and assemble valves mean you’re always carrying the right valve for the job.

Carry the Sporlan Q and BQ valve on your truck and stay on the job…not cruising around looking for parts! You save time and keep customers happy. It is simple. It is easy. It is economical. It just makes sense.

 

What are the advantages of the Q and BQ thermostatic expansion valves?

The mix-and-match components of the Q and BQ product line satisfy thousands of applications. With access to these components, you will be able to assemble valves that are just right for most refrigerated cases, coolers, or freezers and even air conditioning applications.

 

What is involved in the valve assembly?

It is really very easy. Select the correct thermostatic element, the right body assembly and finally pick the cartridge required to handle the system load and thread them all together. Sporlan has easy to follow graphical instructions and literature.

 

 

 

What is so special about the way the cartridge is installed in these valves?

The Q and the BQ valve cartridge is installed through the top of the valve body. This unique design means these valves can use ODF solder or SAE flare fittings. It also means the valve capacity can be changed with a replacement cartridge and the connections can be left undisturbed; simply isolate the valve from system pressure and have at it. No need to remove the Q or BQ valve from the system. 

 

How do I make sure I have the right sized valve?

With 7 different cartridge sizes for the type Q valve and 5 different sized cartridges for the balanced port type BQ, including a bleed port option in 4 of the BQ cartridges, you have many options available to put the right valve together for the job. 

 

What types of refrigerants are compatible with the Q and BQ valves?

The Q and BQ valves are compatible with the new refrigerants on the market, like R-448A and R-449A. They are also compatible with R-22 and the common replacements such as R-422D, R-407A, R-407C and R-407F. And the BQ with its balanced port construction is perfect for high-pressure refrigerants like R-410A. 

The replaceable thermostatic element feature increases the flexibility of the Q and BQ thermostatic expansion valves. This allows the thermostatic elements to be replaced during system conversions to a new refrigerant, or for service, without replacing the valve or removing the valve from the system.

 

Why should I carry a Q and BQ TEV case?

Carrying a stocked Q or BQ TEV case helps prepare contractors and service technicians for most situations - eliminating costly trips back and forth to the wholesaler and special orders. The case can be customized with the components in the greatest demand. With just the components supplied in the Q or BQ case, you can configure valves to satisfy over 100 unique applications.

Learn more about Parker Sporlan Q and BQ thermostatic expansion valves:

Bulletin 10-10 - Sporlan Thermostatic Expansion Valves

Bulletin 210-10-19 - Sporlan BQ Cross Reference

Form 10-165 - Sporlan Type Q and BQ - Interchangable Cartridge TEVs

SD-240 - Parker Sporlan Q and BQ Thermostatic Expansion Valve installation instructions

 

For more information on Parker Sporlan products please visit our website.

 

Article contributed by Jim Jansen, senior application engineer, Sporlan Division of Parker Hannifin

 

 

 

 

 

Additional resources on HVACR Tech Tips:

HVACR Tech Tip: Understanding and Preventing Superheat Hunting in TEVs

HVACR Tech Tip: Using Bi-Directional Solenoid Valves for Heat Pumps

HVACR Tech Tip: Troubleshooting Solenoid Valves in Refrigeration Applications

A refrigerant distributor is a device connected to the outlet of an expansion valve when paired with a multi-circuit evaporator. The outlet of the distributor is machined to accept tubing which connects the distributor to each evaporator coil circuit.

A portion of the liquid refrigerant passing through the expansion valve normally flashes, resulting in two-phase (liquid and vapor) flow at the valve outlet. This mixture is predominately liquid by weight, but the vapor occupies most of the volume. An additional problem arises due to the fact that liquid and vapor move at different velocities. This is sometimes referred to as slip, since gravity has a greater influence on the liquid portion of the flow than the vapor portion.

If a simple header is used instead of a refrigerant distributor, circuits will not receive equal amounts of refrigerant. This is because there is a natural tendency for the liquid and vapor to separate, resulting in unequal amounts of liquid being fed to the various circuits. Gravity will pull the liquid to the lower circuits, and vapor will go to the upper circuits. This will lead to hunting from the expansion valve and possibly cause flood-back issues.

To achieve proper distribution, the liquid portion of the two-phase flow must be divided equally to each evaporator coil circuit. Two-phase refrigerant flow leaving the expansion valve enters the distributor nozzle. The nozzle increases the velocity of the two-phase flow, mixing its liquid and vapor components. Furthermore, the nozzle is positioned such that flow is focused onto the dispersion cone, equally dividing the mixture into passageways spaced evenly around the cone. The refrigerant is then transferred to each evaporator circuit through the distributor tubes.

To ensure equal refrigerant flow, it is important to size the distributor nozzle and tubes to match the system capacity as closely as possible. By doing this, the proper pressure drops and velocities are created to completely mix the liquid and vapor.

In addition to feeding equal amounts of liquid and vapor into each circuit to utilize the full capacity of the evaporator, each circuit must be equally loaded. Figure A is a schematic illustration of typical temperature conditions in the evaporator when both equal distribution and equal loading occur.

Figure B illustrates the same evaporator but with the air flow (and thus the load) less over circuit #3. The load imbalance will be indicated by low superheat at the outlet of circuit #3, and high super-heat at the outlet of circuits #1 and #2. Other symptoms are lower than normal suction pressure, reduced evaporator capacity and expansion valve hunting with possible flood-back.

Optimum distributor performance is obtained when the distributor is mounted directly to the expansion valve outlet. If the distributor cannot be mounted directly to the valve outlet, it can be connected by a piece of straight tubing. The tubing should not exceed two feet, and it should be sized to maintain high refrigerant velocities. Elbows located between the expansion valve and distributor hinder proper distribution, and are not recommended. The expansion valve should be tied to a single distributor. Multiple distributors on a single expansion valve results in poor refrigerant distribution in the evaporator coil.

A distributor can be mounted in any position. If the system operates over widely varying conditions, best performance is usually obtained when the distributor feeds vertically upward or downward, see Figure C. For applications where the distributor is not mounted directly to the expansion valve, the vertical feed arrangement is recommended.

When planning a system refrigerant conversion, it is critical to consider nozzle and tube sizing due to differing net refrigerating effects of refrigerants. For complete sizing and application information refer to Parker Sporlan Bulletin 20-10.

A product selection program is available at www.Parker.com/Sporlan. View Parker Sporlan Refrigerant Distributors here.

 

HVACR Tech Tip Article contributed by Jason Forshee, application engineer,  Sporlan Division of Parker Hannifin

 

 

 

 

 

Additional resources for you:

HVACR Tech Tip: What You Need to Know About Flooded Head Pressure Control

HVACR Tech Tip: Guidelines for How to Size Solenoid Valves for Split Condensers

HVACR Tech Tip: Guide to Servicing Blended Refrigerants

HVACR Tech Tip: 12 Solutions for Fixing Common TEV Problems

 

To obtain long term system life, it is important to keep contaminants to a minimum. This is particularly true of a heavy duty application such as a heat pump. Therefore, all heat pumps should have at least one filter-drier. Two standard driers are preferred, but where this creates a piping problem, then a single reversing filter-drier provides adequate protection. In this blog we cover the benefits of applying filter-driers on heat pump systems and tips for any problems that may occur. 

  Using two standard driers

OEMs may prefer using two standard driers rather than a single reversible drier. This has several advantages – more desiccant in the system, less complicated drier parts, and lower cost. Field service people should follow the recommendations of the OEM. The use of two standard driers gives protection equal to, or greater than, the use of a single reversible filter-drier, see Figure 1.

Standard driers are often installed directly ahead of the expansion device – one in the outdoor section and one in the indoor section. Another common design is to locate both driers in the outdoor section, where they are easier to service. In this design one drier is ahead of the expansion device, and the other drier is ahead of the check valve. When installed in these locations, the flow through each drier is always in the same direction, see Figure 2. Standard filter-driers will not tolerate flow in the reverse direction. Reverse flow washes out the dirt previously collected, and also tends to result in high pressure drop.

When servicing units in the field, it is advisable to replace the original filter-drier with the next larger size, or the size recommended by the unit manufacturer. Where other information is lacking, the Parker Sporlan C-080 Series Catch-Alls are recommended for use on heat pumps up through 2 tons R-410A; the C-160 Series Catch-Alls are recommended for 2 through 5 tons R-410A; and the C-300 Series Catch-Alls are recommended for systems of 5 to 10 tons R-410A. When replacing the original driers on a unit, standard filter-driers are preferred. If the original unit does not have a drier, a reversible HPC-160-HH style drier is recommended.

 

  Using HPC reversible filter-driers

The simplest way to install a drier on a heat pump system is to use a Parker Sporlan Reversible Filter-Drier. For most A/C systems select an HPC-160-HH Series Catch-All with the appropriate fitting size. This reversible filter-drier series is suitable for heat pump systems up through 5 tons R-410A capacity. These driers are installed in the reversing liquid line that runs between the indoor and outdoor section. Reversible driers should never be installed in the reversing gas line that runs between the indoor coil and the 4-Way valve, or the reversing gas line that runs between the outdoor coil and the 4-Way valve. Installation in this location will not give protection to the close tolerance parts of the system, and may result in excessive pressure drop. If the reversible drier is used on a highly contaminated system, such as after a hermetic motor burnout, it is essential that the old filter-driers be removed, see Figures 3 and 4.

In the past, Parker Sporlan offered several other types of reversible driers. These included the HCG-030 Series, HPCG-030 Series, and the HPC-080 Series. The HPC-160-HH Series are the proper replacements for any of these obsolete types.

Some heat pumps have only one expansion device – a bi-directional thermostatic expansion valve, or special short-tube flow restrictor. These systems are properly protected using a reversible filter-drier in the line between the expansion device and the outdoor coil. In this location the drier receives solid liquid on the cooling cycle, and a mixture of liquid and vapor on the heating cycle. Under these conditions, the Parker Sporlan HPC-160-HH Series Catch-Alls are suitable for use up through 5 tons capacity.

  Clean-up after burnout

Typical recommendations for clean-up after a hermetic motor burnout are as follows:

1. Install the same size drier (or an oversized drier) in the liquid line ahead of each expansion device, and a drier in the common suction line. In units with two liquid line driers, both should be changed.
2. Install an oversized drier in the common liquid line and, if possible, a drier in the common suction line. Run the unit in one mode of operation for a day. Then replace the liquid line drier with a reversible filter-drier.
3. Install a reversible filter-drier in the common liquid line. If possible, install a drier in the common suction line.

  The suction line drier location

A filter-drier should be installed in the suction line to clean up a heat pump after severe hermetic motor burnout. First, make sure the burnout is “severe” by testing the acidity of the oil from the burned out compressor using the Parker Sporlan TA-1 Acid Test Kit. If the burnout is severe, install a standard “HH” Catch-All in the common suction line. This drier can be installed either before or after the accumulator, but always between the 4-Way valve and the compressor. If some contaminants have remained in the accumulator, then the preferred location is between the accumulator and the compressor. This is usually a crowded location on the unit, and installing the drier may be difficult. In some cases, it may be necessary to re-pipe the suction line so the drier is located outside the cabinet.

Follow the unit manufacturer’s size recommendations if possible. Where this information is not available, use C-140-S-TT-HH Series Catch-Alls in systems up to 5 tons. Select a C-4300-S-T-HH Series Catch-All for units in the range of 5 to 10 tons. The exact model should be selected according to capacities and line size, consult Parker Sporlan Bulletin 40-10.

  If the filter-drier doesn't fit

Most heat pumps are compact, unitary systems, with cramped piping, making it difficult to replace or install filter-driers. Here are some suggestions to solve these practical problems.

1. The reversible filter-drier is usually the simplest to install because it can be installed anywhere in the reversing liquid line leading from the outdoor section to the indoor section. Even when using the reversible filter-drier, it is important to remove any old filter-driers installed on the unit, since they may be plugged if the unit is severely contaminated. If it is not possible to replace the previous filter-driers directly, the best alternative is to remove them. Reattach the line at the drier location, and use a reversible filter-drier to protect the system in the future. The old driers must be removed; they may be severely plugged.
2. The HPC-160-HH Series Catch-Alls are recommended for most field applications requiring a reversible filter-drier. The smaller HPC-100 Series is used by OEMs and can be used on new field built systems. The HPC-100 Series is 1.0” shorter than the HPC-160-HH Series. This difference may make the HPC-100 Series more desirable on systems with cramped piping.
3. The installation of two standard driers is usually easier if both are installed in the outdoor section. One drier is installed directly ahead of the expansion valve in the out-door coil, and the other drier is installed directly ahead of the check valve that leads to the expansion valve on the indoor coil. Each of these locations has refrigerant flow in only one direction at all times. If there is not sufficient space for two standard driers on a particular unit, perhaps satisfactory contaminant protection can be obtained by using only one drier. When there is no room inside the cabinet to install or replace the drier, the serviceman has no choice but to mount the drier outside the cabinet, and do the necessary re-piping.
4. The suction line connection on the 4-Way valve is usually the middle connection, of the three connections on one side. The single connection on the opposite side of the valve is the discharge line connection.
5. Whenever a drier is added to the liquid line of a system that did not originally have a drier, additional refrigerant charge should be added to the unit to fill the interior space of the drier. No additional charge is necessary for a drier installed in the suction line.

  Protect your system

Reversible Heat Pump Catch-Alls are designed for installation in the reversing liquid line. The smaller HPC-100 Series, using the standard Catch-All core, is designed specifically for new installations and for use on OEM equipment. The HPC-160-HH Series uses a larger core which includes activated charcoal for maximum performance in removing all types of contaminants generated from a hermetic motor burnout. Both filter-driers consist of one core in a shell with a check valve at either end. The check valves control the flow so the filtration occurs on the outside of the core, regardless of the flow direction.

The reliability of the check valves used in these filter-driers have passed the most rigid OEM testing – no synthetic materials are used. The check valves have been thoroughly proven in actual field performance over a period of many years. They function well, even in the presence of solid contaminants.

For more information on sizing filter-driers in heat pump systems please see Parker Sporlan Bulletin 40-10. For various HVAC and Refrigeration product information visit www.Parker.com/Sporlan. 

 

Article contributed by Glen Steinkoenig, product manager, Contaminant Controls, Sporlan Division of Parker Hannifin.

 

 

 

 

Additional resources for you:

HVACR Tech Tip: Understanding Heat Pump Systems and Thermostatic Expansion Valves

HVACR Tech Tip: When Should a Catch-All Filter-Drier be Changed?

Use of Suction Line Filter-Driers for HVAC Clean-up After Burnout

HVACR Tech Tip: What You Need to Know About Flooded Head Pressure Control

 

Manufacturers have been successfully applying Parker Sporlan Thermostatic Expansion Valves on Heat Pump Applications for many years. Parker Sporlan's large diaphragm and durable welded element result in unmatched thermostatic expansion valve quality and life. In this blog we discuss using thermostatic expansion valves on different types of heat pump systems.

 

Conventional thermostatic expansion valve on heat pumps

Many variations and matches of expansion devices have been used to regulate flow to the evaporator coils of a heat pump system. Optimum control is achieved by employing two thermostatic expansion valves, one to feed each coil as shown in Figure 1. Each valve can be tuned to control desired super­heat for uniquely different coils and operating conditions.

The durable construction of the standard Parker Sporlan valve is ideal for heat pump applications. It is recommended that the external equalizer be connect­ed to the common suction line, as shown in Figure 1. The underside of the diaphragm will be exposed to high side pressures if the equalizer is connected to the suction line ahead of the reversing valve. Parker Sporlan diaphragms can withstand these pressures but discharge pulsations are a possible source of problems. Discharge pulses can be dampened but the OEM tests should be performed to prove reliability. When using a thermostatic expansion valve to con­trol flow in one direction only, as shown in Figure 1, there are two options available:

1. Employ a standard Parker Sporlan valve and install a bypass check valve for reverse flow.
2. Install a Parker Sporlan valve which incorporates an internal check valve that minimizes reverse flow pressure drop. There are two Parker Sporlan valves which incorporate this check valve feature. The RC valve and the CBBI valve. The CBBI valve is only available to OEM customers whereas the RC valve is also available to wholesalers. These valves are available for capacities through a nominal 6 tons, R-410A. 

 

Bi-Directional thermostatic expansion valves on heat pumps

The "Bi-Directional" Thermostatic Expansion Valve has successfully been used to replace two expansion devices as shown in Figure 2. It controls refrigerant flow to either coil when the coil is serv­ing as the system evaporator. The Bi-Directional valve is generally applied on packaged units with close coupled components. The bulb and external equalizer are mounted to the common suction line. The suggested flow direction for the Bi-Directional valve is with the valve flowing in its normal direc­tion when the system is in the heating mode. This flow direction will normally result in a lower superheat in the heating mode. The preferred flow direction for each application should be verified by test­ing. There are two valves which have been designed for Bi-Directional applications. The ER valve which is available to wholesale customers and the BBI valve which is only available to OEM customers. These valves are available in capacities through a nominal 15 tons, R-410A.

 

For more information on Parker Sporlan Thermostatic Expansion valves please see Bulletin 10-10. For selecting your appropriate valve configuration, visit our webpage.

 

For more information on applying filter-driers in the same heat pump system please see Bulletin 240-10-2.

 

HVACR Tech Tip Article contributed by Jason Forshee, application engineer,  Sporlan Division of Parker Hannifin

 

 

 

 

 

Additional resources for you:

HVACR Tech Tip: What You Need to Know About Flooded Head Pressure Control

HVACR Tech Tip: Guidelines for How to Size Solenoid Valves for Split Condensers

HVACR Tech Tip: Guide to Servicing Blended Refrigerants

 

Working in the HVAC and Refrigeration industry there are many times when you are going to have applied torque when working on a particular job. In this blog, we help you understand the basics of torque and a method of applying torque. A bolt that has been over tightened can be just as disastrous as one that hasn't been tightened enough. A bolt that has been tightened beyond recommended torque specs can easily break in service.

 

Torque Specifications

Torque is measured as a unit of force acting on a rotating lever of some set length. North American made hex head cap screws have radial lines on their heads that indicate their tensile strength. When replacing a fastener, use a quality at least equal to or greater than the original fastener used on the machine. The more marks on the head, the higher the quality. Thus, bolts of the same diameter vary in strength and require a correspondingly different tightening torque or preload. Remembering that torque is the turning effort or force applied to the fastener to preload it, or place it in tension, and is normally expressed in inch-pounds (in.lb) or foot-pounds (ft.lb). A one pound weight or force applied to a lever arm one foot long exerts one foot-pound or twelve inch-pounds of torque. Note: Where possible always use OEM torque values which may differ from the table below.

 

SAE Bolt head markings

              Maximum torque table

All torque values are expressed in ft.lb.

 

Method of applying torque

Always run fasteners up snug (do not over tighten) with a regular wrench and then observe the following four steps unless OEM instructions are available.

1. Run each fastener in the proper sequence up to 1/3 of their recommended torque setting.
2. Repeat the process running up to 2/3 of the required torque setting.
3. Repeat the process again, running every fastener up to full torque.
4. Repeat step #3 to be positive you have not missed a fastener.

For various HVAC and Refrigeration product information visit www.Parker.com/Sporlan. 

 

Article contributed by Glen Steinkoenig, product manager, Contaminant Controls, Sporlan Division of Parker Hannifin.

 

 

 

 

Related, helpful climate control content for you:

HVACR Tech Tip: What You Need to Know About Flooded Head Pressure Control

Six Reasons Why CDS Conversion Reduces Costs

HVACR Tech Tip: 12 Solutions for Fixing Common TEV Problems