Page 3 - Introduction; this guide should prove to be very helpful.
Introduction This Technical Guide from Emerson Climate Technologies provides a detailed explanation on the operation of common refrigeration system components such as thermal expansion valves, solenoid valves, system protectors, regulators, oil controls and temperature pressure controls. Also includ...
Page 4 - Table of Contents
Table of Contents Thermal Expansion Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Internal Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Factory Setting of TXVs . . . . . . . . . . . . . . . . . . . . . . . ...
Page 6 - Thermal Expansion Valves
2 Thermal Expansion Valves Emerson Climate Technologies P 1 = 45.4 PSIG P 2 = 35 PSIG P 3 = 10.4 PSIG 35 PSIG = 40°F 35 PSIG = 40°F 35 PSIG = 50°F B C TXV with internal equalizer on evaporator with no pressure drop. Fig. 1 A is charged with the same refrigerant as that in the sys - tem. The power as...
Page 7 - Factory Settings of TXVs
3 Thermal Expansion Valves Emerson Climate Technologies Changes in load cause the TXV pin to move: • Increasing the superheat will cause the TXV to open • Decreasing the superheat will cause the TXV to close Factory Settings of TXVs The factory superheat setting of TXVs is made with the TXV pin just...
Page 8 - Location of External Equalizer; Never cap or plug the external equalizer connection
4 Thermal Expansion Valves Emerson Climate Technologies This change from 10°F to 11°F in the operating superheat is caused by the change in the pressure- temperature characteristic of R-134a at the lower suction pressure of 25 psig. Location of External Equalizer The external equalizer line must be ...
Page 9 - Superheat; Neither of these methods will yield an; The only method for checking superheat that will; The amount of superheat depends on how much re-; Superheat Adjustment
5 Thermal Expansion Valves Emerson Climate Technologies P 1 = 45.5 PSIG P 2 = 35 PSIG P 3 = 10.4 PSIG 35 PSIG = 40°F 35 PSIG = 40°F 35 PSIG = 50°F B C TXV with internal equalizer on evaporator with no pressure drop. Fig. 6 A Superheat A vapor is said to be superheated whenever its temperature is hig...
Page 10 - TXV Selection
6 Thermal Expansion Valves Emerson Climate Technologies sible to determine that the cause of the trouble call is because of improper methods of instrumentation rather than any malfunction of the TXV. When troubleshooting in mountain areas (such as Denver, Colorado or Salt Lake City, Utah) use a Pres...
Page 11 - Application Tips
7 Thermal Expansion Valves Emerson Climate Technologies Application Tips For best evaporator performance, the TXV should be installed as close to the evaporator as possible and in an easily-accessible location for adjustment and servic- ing. On pressure drop and centrifugal type distributors, apply ...
Page 12 - Hunting
8 Thermal Expansion Valves Emerson Climate Technologies Large fluctuations in superheat in the suction gas are usually the result of trapped liquid at the remote bulb location. Even on properly designed suction lines, it is sometimes necessary to move the remote bulb a few inches from the original l...
Page 13 - Balanced Port TXV Operation; Double Ported Design; Power Element Charges; same
9 Thermal Expansion Valves Emerson Climate Technologies Balanced Port TXV Operation In conventional TXVs, as the pressure drop across the TXV port changes due to changes in head pressure or suction pressure, the operating superheat of the TXV will vary. Depending on the operating conditions under wh...
Page 14 - REFRIGERANT CODE NAMES; Adsorption Charges; different; Liquid Charge
10 Thermal Expansion Valves Emerson Climate Technologies REFRIGERANT CODE NAMES ARI Standard 750-2007 recommends the following color coding of the TXVs: R-12 White R-22 Light Green R-134a Light Blue R-290 N/A R-404A Orange R-407A Lime Green R-407C Medium Brown (Brown) R-408A Medium Purple R-409A Med...
Page 15 - Other TXV Considerations; Solenoid Liquid Stop Valves; Degrees of SH Per Turn; TXV SUPERHEAT ADJUSTMENT
11 Thermal Expansion Valves Emerson Climate Technologies Other TXV Considerations Solenoid Liquid Stop Valves The TXV is produced as a tight seating device. But if the TXV is exposed to dirt, moisture, corrosion, and erosion the TXV will not be able to positively shut off. If the remote bulb is inst...
Page 16 - Refrigerant Code Names; THERMOSTATIC CHARGE; REFRIGERANT L
12 Thermal Expansion Valves Emerson Climate Technologies To help you match the correct charge to your specific application, see the TXV Charge Code Selector on the next page. Also provided here are some typical exam- ples of applications by refrigerant charge. Liquid Charge – L Ice makers, pilots, l...
Page 17 - TXV Replacement Charge Symbols Cross Reference; Old Bulb Charges vs. New Replacement Bulb Charge; TXV Charge Code Selector; Applications
13 Thermal Expansion Valves Emerson Climate Technologies HW35 AIR CONDITIONING COMMERCIAL REFRIGERATION LOW TEMPERATURE OLD CHARGE REPLACEMENT OLD CHARGE REPLACEMENT OLD CHARGE REPLACEMENT REFRIGERANT R12/R134 a F OR FL — — FC FC — FW FW FWZ FG55 FC FG35 — — FW55 FW35 FW35 FW15 FQ55 FQ35 FW15 FGA FL...
Page 18 - Electronic Valves
Page 19 - Electronic Valve Applications
Emerson Climate Technologies 15 Electronic Valves & Controls Emerson Climate Technologies Electronic Valve Applications Valves can be used for a variety of applications: • Expansion valves • Capacity control valves – Hot gas bypass – Controlled by temperature or pressure • Evaporator pressure re...
Page 20 - Temperature Sensor ECN-N60
Emerson Climate Technologies 16 Electronic Valves & Controls Emerson Climate Technologies Parts Required for Electronic Valves when used as TXV and Driven by Superheat Description Type PCN Notes Electronic Valves EX4 097719 Select one valve based on capacity requirements of system EX5 097720 EX6...
Page 21 - Pressure Transmitter – PT4; PRESSURE; TXV Controller – EC3-X32
Emerson Climate Technologies 17 Electronic Valves & Controls Emerson Climate Technologies Pressure Transmitter – PT4 The heart of the transmitter is a pressure sensitive piezo resistive cell. This is surrounded by an oil cushion enclosed by a stainless steel diaphragm. The integrated electronic ...
Page 22 - TXV Controller – EC3-X33; XEV22 Superheat Controller
Emerson Climate Technologies 18 Electronic Valves & Controls Emerson Climate Technologies under different operating conditions such as com- pressor start-up, start of further compressor, high head pressure, low head pressure, high load, low load and partial load operation. EC3-X32 is capable for...
Page 23 - Setting; Electrical Control Valve – EX; Function; Time; Third Party Controller
Emerson Climate Technologies 19 Electronic Valves & Controls Emerson Climate Technologies Function Dip Switch Number 1 2 3 4 5 6 7 8 EX4/EX5/EX6 operation 0 1 1 0 1 0 – – EX7 operation 1 0 0 1 0 1 – – EX8 operation 1 1 0 1 1 1 – – 4-20 mA analogue input signal – – – – – – – 0 0-10V analogue inpu...
Page 24 - COMPONENT SELECTION TABLE; Electronic Valves Programming; ) Enter specific data using keypad or laptop com-; ) Driving of stepper motor; There are many different options to drive stepper; ) Follow manufacturers additional instructions.
Emerson Climate Technologies 20 Electronic Valves & Controls Emerson Climate Technologies COMPONENT APPLICATION TXV LIQUID INJECTION HOT GAS HEAD PRESSURE EPR CPR KEYPAD (ECD-002) YES NO NO NO NO NO LAPTOP * NO NO NO NO NO TEMP SENSOR (ECN-N60) YES NO NO NO NO NO PRESSURE TRANSDUCER (PT4) YES NO...
Page 25 - Solenoid Valves
Page 26 - Direct Acting Solenoid Anatomy; What Are Solenoid Valves?
22 Solenoid Valves Emerson Climate Technologies Direct Acting Solenoid Anatomy What Are Solenoid Valves? A solenoid valve consists of two distinct but integral acting parts, a coil and a valve. See drawing below for complete valve anatomy. Solenoid Valves In most refrigeration applications, it is ne...
Page 27 - . Pilot Operated Valve
23 Solenoid Valves Emerson Climate Technologies Figures 1A and 1B show a simple schematic of a Direct Acting Solenoid Valve in operation. 2 . Pilot Operated Valve The pilot operated solenoid valve uses a combination of the solenoid coil and the line pressure to operate. In this type valve the plunge...
Page 28 - Solenoid Valve Selection
24 Solenoid Valves Emerson Climate Technologies Solenoid Valve Selection The selection of a Solenoid Valve for a control ap- plication requires the following information: 1. Fluid to be controlled 2. Capacity required 3. Maximum operating pressure differential (MOPD) 4. Electrical characteristics 5....
Page 29 - Application Overview
25 Solenoid Valves Emerson Climate Technologies Installation Solenoid Valves having a spring loaded piston or dia- phragm may be installed and operated in any position, but installing more than 90° from vertical is not recom - mended since dirt or debris may collect in the solenoid area and prevent ...
Page 30 - System Protectors
Page 31 - Acid Pick-Up Capability
27 System Protectors Emerson Climate Technologies Acid Pick-Up Capability Various organic acids result during the decomposition of the refrigerant and oil in a system. This decomposition can be the result of moisture in the system, excessive temperatures, air, or exposure to foreign substances in th...
Page 32 - Absorption vs . Adsorption; Molded core
28 System Protectors Emerson Climate Technologies Compacted bead style filter drier, Emerson’s EK-Plus Absorption vs . Adsorption One factor to consider in selection is ab- vs. ad- sorption. Absorption means a material’s ability to take another substance into its inner molecular structure. An adsorb...
Page 33 - HFC Refrigerants and POE Lubricants
29 System Protectors Emerson Climate Technologies Refrigerant Water Concentration (ppm) 0 0.05 0.1 0.15 0.2 0 100 200 300 400 500 600 700 Total Acid Number HFC Refrigerants and POE Lubricants The use of HFC refrigerants and Polyolester (POE) lubricants for air-conditioning and refrigeration has gene...
Page 34 - Suction Filter Driers; liquid
30 System Protectors Emerson Climate Technologies EK Typical drier Solid Contamination Captured Flow Restrictio n The filter driers for use in HFC and POE oil systems must keep the system dry and free of any acids gener- ated. However, since water capacity is of primary im - portance the filter drie...
Page 35 - Internal Design; a rigid, cylindrical, porous core that may perform; drier should provide for greater capacity than a
31 System Protectors Emerson Climate Technologies Cross-section shows desiccant beads surrounding accordion-type filter element Typical system arrangements show suction line filter drier installed ahead of the compressor. Internal Design Internally, suction line filter driers employ the same types o...
Page 36 - Clean-Up Procedure for Compressor Motor Burnout; contact with the contaminated liquid.; Compressor Burnout; A compressor burnout can be expected to release a
32 System Protectors Emerson Climate Technologies Clean-Up Procedure for Compressor Motor Burnout 1. Determine the extent of the burnout. For mild burnouts where contamination has not spread thru the system it may be economical to save the refrigerant charge, if the system has service valves on the ...
Page 37 - Filter Driers for Heat Pumps
33 System Protectors Emerson Climate Technologies Schematic of a basic heat pump system. Filter Driers for Heat Pumps A heat pump is essentially a refrigeration sys- tem that can flow in either direction. The key to its operation is a four-way reversing valve that routes the discharge gas from the c...
Page 38 - Simplifying While Servicing; Emerson System Protectors
34 System Protectors Emerson Climate Technologies Bi-directional components allow simplification of system Cross section showing BFK internal components Simplifying While Servicing When servicing or repairing heat pump systems, especially older units, it’s a good idea to simplify them by replacing u...
Page 39 - Regulators
Page 40 - Suction Line Regulators; EPR Installation
36 Regulators Emerson Climate Technologies EVAPORATOR PRESSURE REGULATOR EVAPORATOR PRESSURE REGULATOR EXTERNAL STRAINER RECOMMENDED NOTE: HIGH SIDE PILOT PRESSURE REQUIRED FOR EPRBS NOTE: HIGH SIDE PILOT PRESSURE REQUIRED FOR EPRBS EXTERNAL STRAINER RECOMMENDED 60 PSIG HIGH EVAPORATOR PRESSURE 50 P...
Page 41 - Upstream Regulators; Valve; Adjustable Range Table; Voltage; Standard Voltage & Frequencies Table
37 Regulators Emerson Climate Technologies Upstream Regulators The sole function of the Evaporator Pressure Regu - lator is to prevent the evaporator pressure from falling below a predetermined pressure setting. This enables the system to meet certain load requirements over a wide range of condition...
Page 42 - Crankcase Regulators
38 Regulators Emerson Climate Technologies Fig 4. Cutaway of crankcase pressure regulator (Emerson OPR) Fig 5. Cutaway of evaporator pressure regulator (Emerson EPRB). Crankcase Regulators Normally open, the CPR (Fig. 4) closes when com - pressor pressure rises above the pre-set maximum, forcing the...
Page 43 - HeadMaster Head Pressure Controls
39 Regulators Emerson Climate Technologies HeadMaster Head Pressure Controls The application of air-cooled condensers for year- round operation, or during periods of low ambient temperature, requires some means of control to main - tain adequate condensing pressures that ensure proper system perform...
Page 44 - Installation of HP HeadMaster Series; Pressure Drop – PSI
40 Regulators Emerson Climate Technologies NOTE : Should the outdoor temperature fall below de - sign conditions, more refrigerant will be required. The total above is the total charge needed for satis- factory system performance during the lowest expected ambient air temperature conditions. During ...
Page 46 - Applications: Hot Gas Bypass to
42 Regulators Emerson Climate Technologies Figure 7: Direct acting hot gas regulator admitting flow between TEV and venturi distributor. Applications: Hot Gas Bypass to Compressor Suction Line Figure 6 shows the most common hot gas bypass system. In this system, the bypass line is taken directly fro...
Page 47 - Thermal Valves for Liquid Injection
43 Regulators Emerson Climate Technologies Thermal Valves for Liquid Injection When hot gas is bypassed directly into the suction line, it is necessary to make some provision for desuper- heating the gas returning to the compressor. Without a small Thermal valve to lower suction gas temperature to t...
Page 49 - Oil Controls
Page 50 - OMB; Emerson Oil Controls
Emerson Climate Technologies 46 Oil Controls Emerson Climate Technologies OMB Common Suction To Condenser Filter-Drier Compressor Discharge OMB OMB OMB Oil Separator Reservoir Oil Controls Any time that compressors are operated in a paral- lel operation (Suction and Discharge lines manifolded togeth...
Page 52 - Temperature Pressure Controls; TS1 Top Operated; Temperature Sensing
Emerson Climate Technologies Emerson Climate Technologies Temperature-Pressure Controls 48 Emerson Climate Technologies Temperature Pressure Controls Temperature pressure controls serve a number of purposes in refrigeration systems, including the control of compressor cycling, pump-down, defrost con...
Page 53 - Setpoints; Automatic reset contact function
Emerson Climate Technologies Emerson Climate Technologies 49 Temperature-Pressure Controls Emerson Climate Technologies + - 2 4 1 + - 2 4 1 Adsorption Charge – Sensor Type F Adsorption charged sensor types operate on a tem- perature dependent adsorption material, which is inside the bulb only. These...
Page 54 - Bellows heater; Pressure Sensing; Single Pressostat PS1; Pressure Connectors
Emerson Climate Technologies Emerson Climate Technologies Temperature-Pressure Controls 50 Emerson Climate Technologies For operational safety, all TS1 with manual reset are designed as trip-free controls, i.e. pressing the manual reset button while the temperature has not reached its reset threshol...
Page 55 - lower setpoint = upper setpoint – differential; Contact Function; Automatic Reset; Manual Reset Low Pressure; Manual reset low pressure contact function; Manual Reset High Pressure; Manual reset high pressure contact function
Emerson Climate Technologies Emerson Climate Technologies 51 Temperature-Pressure Controls Emerson Climate Technologies Setpoints PS1/PS2 are adjustable controls with external ad - justment spindles for range and differential. Note that manual reset controls have a fixed differential and no differen...
Page 56 - PSC Pressure Switch; Features; PSC Introduction; PSC
Emerson Climate Technologies Emerson Climate Technologies Temperature-Pressure Controls 52 Emerson Climate Technologies PSC Pressure Switch The Emerson PSC is a Pressure Switch with fixed switch-point settings. Features • Maximum Operating Pressure up to 623 psig Test Pressure up to 696 psig • Stand...
Page 57 - FSX Introduction; Figure 1 – FSX Output Voltage Versus Input Pressure; Description of control behavior
Emerson Climate Technologies Emerson Climate Technologies 53 Temperature-Pressure Controls Emerson Climate Technologies FSX Introduction FSX electronic speed controllers are designed to control the speed of fan motors in commercial refrigera- tion system depending on condensing pressure chang- es. I...
Page 59 - DOs; them against accurately calibrated instruments .; Good diagnoses can’t be made with faulty inputs.; make adjustments or repairs .; is cheap insurance for a compressor.; moisture contamination .; adjusted to the equipment manufacturer’s specifications.; Basic Rules of Good Practice; application second nature.
55 Basic Rules of Good Practice Emerson Climate Technologies DOs DO maintain test instruments in good working order and periodically check them against accurately calibrated instruments . Good diagnoses can’t be made with faulty inputs. DO familiarize yourself with the operation of a control before ...
Page 60 - DON’Ts; think of a TXV as a temperature or pressure control .; check with the manufacturer.; energize a solenoid coil while it is removed from the valve .
56 Basic Rules of Good Practice Emerson Climate Technologies DON’Ts DON’T be a “parts-changer .” Analyze problems based on the symptoms, and determine the specific cause be - fore making any changes or repairs. Emerson’s Troubleshooting Guide describes a wide variety of problems that may be encounte...
Page 62 - SYSTEM TROUBLESHOOTING GUIDE
58 System Problem Discharge Pressure Suction Pressure Superheat Subcooling Amps Overcharge Undercharge Liquid Restriction (Drier) Low Evaporator Airflow Dirty Condenser Low Outside Ambient Temperature Inefficient Compressor TXV Bulb Loose Mounted TXV Bulb Lost Charge Poorly Insulated Bulb SYSTEM TRO...
Page 63 - Troubleshooting Expansion Valves
59 Superheat Is Too Low -- TXV Feeds Too Much Problem Symptoms Causes Corrective Action Valve Feeds Too Much 1) Liquid Slugging 2) Low Superheat 3) Suction Pressure Normal or High Oversized Valve Replace with correct size valve Incorrect Superheat Setting Adjust the superheat to correct setting Mois...
Page 64 - Superheat Appears Normal -- System Performs Poorly; Troubleshooting Electronic Valves & Controls
60 Symptom Possible Cause Action Remark Valve is not moving Digital input has priority to analogue signal input Digital input must be activated and deactivated along with compressor start and stop Wrong setting of dipswitches Adjust the dip switches cor - rectly. The power supply must be off during ...
Page 67 - Troubleshooting Solenoid Valves
63 Troubleshooting Solenoid Valves Problem Causes Corrective Action Normally Closed Valve Will Not Open -or- Normally Open Valve Will Not Close Movement of plunger or diaphragm restricted a) Corroded parts b) Foreign material lodged in valve c) Dented or bent enclosing tube d) Warped or distorted bo...
Page 68 - Troubleshooting Ball Valves; Troubleshooting Storage Devices; Troubleshooting System Protectors
64 Symptoms Causes Corrective Action Doesn't Flow Valve Isn't Open Turn Stem Leak at Access Schrader Valve Schrader Valve Isn't Tight Tighten Schrader Valve Leak at Stem Valve Stem is Leaking Replace Valve Excessive Pressure Drop Valve Isn't Fully Open Turn Stem to Open Valve Troubleshooting Ball Va...
Page 70 - Troubleshooting Head Pressure Controls
66 Problem Causes Corrective Action Compressor tripping on Internal Thermal Protector - Fails to Start-Up and Run Long Enough to Pull Down Temperature CPR setting too high Re-adjust the CPR to a lower setting - see adjustment procedure Valve Fails to Open CPR setting is too lowValve defective - bell...
Page 72 - Wholesaler/Contractor Support
EmersonClimate.com/flowcontrols Wholesaler/Contractor Support Customer Service: 1-866-298-2482Technical Support: 1-866-625-8416 2004FC-141 R10 (6/14) Emerson is a trademark of Emerson Electric Co. ©2014 Emerson Electric Co. All rights reserved.