Vapour Compression Refrigeration

PH Diagram

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 Thermal Expansion Valve

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 Thermal Expansion Valve

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 Conventional TXV

The function of the thermostatic expansion valve (TXV or

TEV) is to hold a constant evaporator superheat. When set
and operating properly, the TXV will keep the evaporator
active throughout its entire length. The conventional TXV is
controlled by springs, bellows, and push rods. (See Figure
1.) The spring force is a closing force on the TXV. The
evaporator pressure, which acts under the thermostatic
element's diaphragm, is also a closing force. An opening
force is the remote bulb force, which acts on top of the
thermostatic element's diaphragm.

Figure 1. A conventional
thermostatic expansion valve (TXV
or TEV) is controlled by springs,
bellows, and push rods. (Graphics
courtesy of Sporlan Valve Co.)
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 Thermal Expansion Valve

A thermostatic expansion valve (TXV) is built up around a thermostatic element

separated from the valve body by a diaphragm.
Its purpose is to regulate the rate at which refrigerant flows into the evaporator.

TXVs can contain one of three different types of charge:

universal charge
Maximum operating pressure (MOP) charge.
MOP charge with ballast (standard for Danfoss expansion valves with MOP).

Expansion valves with MOP ballast charges are used mainly in refrigeration
systems with "high dynamic" evaporators, such as in air conditioning systems
and plate heat exchangers with high heat transfer.

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 Thermal Expansion Valve

Remember: the TXV controls only one thing: the rate of flow of liquid
refrigerant into the evaporator.

The TXV is not designed to control air temperature, head pressure, capacity,
suction pressure, or humidity. Attempts to use the TXV to control any of these
system variables will lead to poor system performance and possible compressor
failure.

The TXV responds to the temperature of refrigerant gas as it leaves the

evaporator. This temperature is detected by the sensing bulb, which is located
near the evaporator outlet. The TXV also responds to the refrigerant pressure
within the evaporator, which is transmitted to the TXV by an equalizer line.

By responding to these variables, the TXV maintains a predetermined superheat

within the evaporator.

This is how the TXV keeps the system in balance and operating properly

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 Thermal Expansion Valve

Liquid refrigerant enters the TXV under high pressure. As the flow of liquid
refrigerant is reduced, its pressure drops.
The refrigerant leaving the TXV is now a combination of low-pressure liquid and
vapor.
As the flow is restricted, several things happen:
The pressure on the liquid refrigerant drops;
A small amount of the liquid refrigerant is converted to gas, in response to the
drop in pressure;
This "flash gas" represents a high degree of energy transfer, as the sensible heat
of the refrigerant is converted to latent heat;
The low-pressure liquid and vapor combination moves into the evaporator,
where the rest of the liquid refrigerant "boils off" into its gaseous state as it
absorbs heat from its surroundings.
Changes in gas temperature at the evaporator outlet are detected by the sensing
bulb, which then causes the valve pin to move in or out, regulating the flow of
refrigerant through the TXV.
In this way, the valve allows just enough refrigerant into the evaporator, to
maintain the correct level of superheat in the suction line.
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 Thermal Expansion Valve

Installation Procedures

The expansion valve must be installed in the liquid line, ahead of the evaporator, with bulb
fastened to the suction line as close to the evaporator as possible. If there's external pressure
equalization, the equalizing line must be connected to the suction line immediately after the
bulb. (Figure 1)
The bulb is best mounted on a horizontal suction line tube and in a position corresponding to
between 1 o'clock and 4 o'clock.
The location depends on the outside diameter of the tube. (Figure 2)
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 Thermal Expansion Valve

Note: The bulb must never be located at the bottom of the suction line due to the
possibility of oil laying in the bottom of the pipe causing false signals.
The bulb must be able to sense the temperature of the superheated suction vapour and must
therefore not be located in a position that will expose it to extraneous heat/cold.

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 Thermal Expansion Valve

The bulb must not be installed after a heat exchanger. In this position it will give false
signals to the expansion valve (Figure 4). Additionally, the bulb must not be installed close
to components of large mass, as this also will give rise to false signals to the expansion
valve.
As previously mentioned, the bulb must be installed to the horizontal part of the suction line
immediately after the evaporator. It must not be installed to a collection tube or a riser after
an oil pocket. The expansion valve bulb must always be installed ahead of any liquid lock.
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 Thermal Expansion Valve - Alco

Operating Principles

Alco thermo expansion valves control the superheat of refrigerant vapour at the outlet of the
evaporator.

They act as a throttle device between the high pressure & the low pressure sides of the
system & ensure that the rate of refrigerant flow into the evaporator exactly matches the rate
of evaporation of the liquid refrigerant in the evaporator.

Thus the evaporator is fully utilised & no liquid refrigerant may reach the compressor.

MOP (Maximum Operating Pressure)

MOP functionality is somewhat similar to the application of a crankcase pressure regulator.

Evaporator pressures are limited to a maximum value to protect the compressor from
overload conditions.

MOP selection should be within the maximum allowed evaporating temperature of the
compressor.
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 Thermal Expansion Valve

Dimensioning

To correctly size a thermo expansion valve on a system, the following design conditions
must be available.

- Cooling capacity Qo
- Nett pressure differential across the TEV Dp
- Evaporating temperature/pressure
- Lowest possible condensing temperature/pressure
- Liquid temperature
- Refrigerant
- Vertical liquid line lift from the receiver to the TEV (see below)

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 Thermal Expansion Valve

As opposed to refrigerants where phase change takes place at a constant

temperature/pressure, the evaporation & condensation of zeotropic blend R407C is in a
gliding form (e.g. at a constant pressure the temperature varies within a certain range)
through the evaporator & condenser.
Therefore the evaporating/condensing pressure must be determined at saturation
temperatures bubble/dew for the dimensioning of the valve.

Selection Example - 1

System cooling capacity = 18kW

Condensing temperature (saturated liquid) = 35°C
Condensing pressure = 15.5bar
Evaporating temperature (saturated vapour) = 0°C
Evaporating pressure = 4.61bar
Subcooling = 1K
Pressure drop through the liquid line = 0.2bar
Hydrostatic head due to liquid lift to TEV = 0.7bar
Pressure drop type liquid distributor = 2bar
Refrigerant = R407C

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 Thermal Expansion Valve

To select a valve, the system cooling capacity has to be corrected to establish

a nominal valve capacity, which can then be used to select a valve from the
list of nominal duties.

1. Establish Kt factor.
Referring to the following Correction Tables, a Kt factor is established from
the R407C chart of 0.98 for this example.
2. Establish nett pressure differential.
Determine the pressure differential across the valve using the data previously
shown.
Dp = 15.5 - (4.61 + 0.2 + 0.7 + 2) = 7.99 = ~ 8 bar
The next stage is to select the KDp factor, again from the following Correction
Tables for R407C. For this particular example the factor of 1.18 will need to
be applied.
3. Calculate Qn the nominal valve capacity.
Qn = 18 x 0.98 x 1.18 = 20.82kW
Looking at the TI(E) Series nominal duties, it can be seen that this family is
not large enough. Therefore referring to T Series we can establish that valve
TCLE 550 @ 24kW nominal should be selected.
Optimised % = (20.82/24) x 100 = 86.7% loaded @ design conditions.

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 Thermal Expansion Valve

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 Thermal Expansion Valve

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 Thermal Expansion Valve

Selection Example - 2

System cooling capacity = 9kW

Condensing temperature (saturated liquid) = 36°C
Condensing pressure = 13.9bar
Evaporating temperature (saturated vapour) = -10°C
Evaporating pressure = 3.6bar
Pressure drop through the liquid line = 0.3bar
Hydrostatic head due to liquid lift to TEV = 0.7bar
Pressure drop type liquid distributor = 1bar
Refrigerant = R22

To select a valve, the valve nett pressure drop has to be calculated, from this
it’s a simple matter of referring to the valve capacity charts to find the
appropriate valve.

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 Thermal Expansion Valve

Selection Example - 2

1. Estimate liquid line pressure drop (Dp1).

Include frictional losses as well as line components such as solenoid valve,
drier & sight glass.

2. Establish static pressure drop due to vertical lift (Dp2).

Refer to the chart, interpolate where necessary to establish the value.

3.Estimate distributor/evaporator pressure drop (Dp3).

Dp = (pc - pe) - (Dp1 + Dp2 + Dp3)
Dp = (13.9 - 3.6) - (0.3 + 0.7 + 1) = 8.3bar
5. Determination of capacity.
Referring to the TX2/TEX2 table we need to interpolate the data for
te = -10°C & Dp = 8.3bar. Nearest selection is an orifice 04:
Qe = 9.5 + [(8.3 - 8)/(10.1 - 8)] = 9.65kW

Optimised % = (9/9.65) x 100 = 93.2% loaded @ design conditions

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 Thermal Expansion Valve

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 Thermal Expansion Valve

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 Thermal Expansion Valve

Guidelines

1. When choosing the condensing temperature/pressure on systems with out

any head pressure control, always estimate a lowest value, (i.e. winter
operation) rather than the pressure at design summer ambient. Because the
valve capacity is proportional to the nett Dp, should the valve be dimensioned
at design condensing temperature/pressure, it may be undersized during
cooler times of the year. For systems employing head pressure control, use
design condensing temperature/pressure.

2. Even without a subcooling circuit or suction/liquid line heat exchanger,

there will usually be some amount of subcooling, obtained through heat lost
through convection from the liquid refrigerant to the ambient air surrounding
the tube, especially systems employing head pressure control.

3. We have produced a table to give an indication of pressure loss due to the

liquid refrigerant working against gravity. Please note for effective operation of
the valve the refrigerant entering should be 100% liquid, therefore systems
with vertical lifts will require additional subcooling.

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 Thermal Expansion Valve

Guidelines

4. The pressure drop through the distributor/evaporator is a function of

refrigerant type, mass flow & distributor type.

Obviously small single circuit coils will have little pressure drop, followed by venturi
distributors then the pressure drop type (versions fitted with an orifice). This is an
estimation & will vary with each application.

5. When selecting a valve it should be noted that generally the maximum capacity
of the valve is usually 20% above nominal.

Because over-sizing the valve can lead to hunting (especially on systems

employing capacity control) try to size the valve as fully optimised as possible.

Sometimes this may mean sizing the valve marginally above 100% rather than
having a valve in the system operating at a value far below its rated capacity.

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 Electronics TXV

electronic expansion valve (EEV) operates with a much

more sophisticated design. EEVs control the flow of
refrigerant entering a direct expansion evaporator. They do
this in response to signals sent to them by an electronic
controller. A small motor is used to open and close the valve
port. The motor is called a step or stepper motor. Step
motors do not rotate continuously. They are controlled by an
electronic controller and rotate a fraction of a revolution for
each signal sent to them by the electronic controller. The step
motor is driven by a gear train, which positions a pin in a
port in which refrigerant flows. A cutaway of an EEV with
step motor and drive assembly is shown in Figure 2

Figure 2. A cutaway of an
electronic expansion valve (EEV)
with step motor and drive assembly
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 Expansion Valve Sizing for Wind tunnel cascade System

1) Minimum and Maximum Cooling Capacity of the system

2) Pressure drop for all components in the circuit
3) Compressor Flow rate
4) refrigerant type : R23 / R404A
5) Selection of conventional type (TXV or TEV)
6) Selection of Electronics type TXV (EEV)

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 Danfoss expansion valves

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 Types of expansion valves

• Thermostatic expansion valves (TEV or TXV)

– Mechanical valve (”self regulating”)
– Uses bulb (thermal element) to sense temperature of
superheated gas in evaporator outlet
• Electronic expansion valves (EEV or EXV)
– Electrically controlled valve actuator
– Electronic controller uses temperature and pressure
sensors to ”measure” superheat

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 Thermostatic expansion valve

Expansion valve Capillary tube

Pressure
equalization
(optional)

Evaporator Suction line

(to compressor)

Liquid line Bulb

(from condenser) (thermal element)
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 Available pressure drop across valve

Dp = (pC - pE) - DpL

DpL
pC Evaporating
Estimated pressure pressure
Condensing drop in evaporator
pressure (and distributor)
pE

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 Available pressure drop across valve
(example)

Dp = (14.5 - 4) bar – 0.5 bar

Dp = 10 bar

0.5 bar
14.5 bar Evaporating
pressure
Estimated pressure
Condensing drop in evaporator
pressure (and distributor) 4 bar

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 Selection from capacity table

 
 R22

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 Selection from capacity table

R22

Refrigerant R22
Q0,REQ = 5.0 kW
pC = 14.2 bar
pE = 5.8 bar  TE = +10 °C pE = 5.8 bar
DpL = 0.4 bar
Dp = ?
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 A note on subcooling

• All Danfoss capacity tables for TEV’s are based on

test conditions with subcooling (Dtsub) equal to 4 K
• If subcooling in real system is different from 4 K the
required capacity (Q0,REQ) must be converted to test
conditions (Q0,CONV)

Q0,REQ
Q0,CONV 
Correction factor
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 Features
• Changeable orifice
– Can change the maximum capacity of the valve
• Internal or external pressure equalization
– If the pressure drop in evaporator is significant or if liquid distributor is
used
• Maximum operating pressure (MOP)
– To protect the compressor by limiting the evaporating pressure
• Change of superheat setting
– To adapt valve to different evaporator types

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 Feature: Internal or external
equalization

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 Electrically Operated Expansion Valves

The AKV's are electrically operated expansion valves designed for refrigeration
plants. They are suitable for HCFC and HFC refrigerants.

The AKV-10 valves range from 1kW to 16kW (R22).

The AKV-15 valves range from 25kW to 100kW (R22).

On plants using AKV 15 a filter must be mounted in front of the valve.

AKV 10 has built-in filter, so external filter is not required.

Danfoss AKV 15-4

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 Electrically Operated Expansion Valves

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 Electrically Operated Expansion Valves

Characteristic Value Max. Working Pressure [bar] 28,0 bar

Type AKV 15-4 Max. OPD, 10 W a.c. [bar] 22 bar
Weight 1.38 Kg Medium temperature range [°C] -50 - 60 °C
Actuator system [mm] 13,5 mm Min. ODP [bar] 0,000 bar
Ambient temperature [°C] -40 - 50 °C MOPD [bar/psi] 22 bar
Cv value [gal/min] 1,156 gpm US Orifice size [mm] 5,60 mm
Direction Straightway Outlet connection type SOLDER, ODF
EAN number 5702422187202 Outlet size [in] 1 1/8 in
Function NC Pack format Single pack
Inlet connection type SOLDER, ODF Quantity per pack format 1 PC
Inlet size [in] 1 1/8 in Rated capacity R22 [kW] 100,00 kW
Kv value [m³/h] 1,000 m3/h
Refrigerant(s) R134a, R22/R407C, R23,
Manual Operation No
R404A/R507, R407A, R410A, R744

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 Electrically Operated Expansion Valves

Electronic Expansion Valves Vs. Thermal Expansion Valves by

By Renato Lazzarin, Daniele Nardotto, and Marco Noro, Ph.D.

The following article was published in ASHRAE Journal, February 2009. ©Copyright 2009
American Society of Heating, Refrigerating and Air- Conditioning Engineers, Inc. It is presented for
educational purposes only. This article may not be copied and/or distributed electronically or in
paper form without permission of ASHRAE.

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 Line Sizing

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 Line Sizing

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 Line Sizing

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 Line Sizing

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