SANYO CO2 Technologies

at
Ahlsell Seminar in Norway

SANYO Airconditioners Europe.

Kjell Lundén
Nordic Branch Office

21 April, 2008
 CONTENTS

1. Introduction of CO2 Products

2. Why CO2 as refrigerant for Heat Pump ?

3. Technology of Sanyo CO2 ECO

3-1. Compressor Design
3-2. Introduction of CO2 ECO

4. Summary
 CONTENTS

1. Introduction of CO2 Products

2. Why CO2 as refrigerant for Heat Pump ?

3. Technology of Sanyo CO2 ECO

3-1. Compressor Design
3-2. Introduction of CO2 ECO

4. Summary
Natural Ref. used Products all around the world
Residential Commercial

House-hold Refrig., Ammonia HP chiller

using small amount of HC For A/C
Ammonia （ NH3 ）
HC （ R600a ） ＣＯ２ /Ammonia
Cascade system
High side NH3 and Low side CO2
HEAT PUMP

Heat Pump Water Heater

4.5-6kW

CO2 （ R744 ） Vending Machines

Bottle Coolers
CO2 （ R74
Hydro Space Heater
HEAT PUMP
4 ） Commercial HP
4.5-9kW
Water Heater
CO2 （ R744 ） CO2 （ R74 25-600kW
4）
CO2 (R744) is the promising refrigerant as post HFC.
 It is not the Future Technology at all !
CO2 Heat Pump Water Heater Market in Japan
■the number of units sold in Thousands (Sanyo estimate)
（ Thousands ）
900
460Ｌ以上
460L ~ 800
800
370Ｌ
370L
650
700 300Ｌ以下
~ 300L
Small self
小型機 550 336
600 contained type

500 450 267

220
400 350 169
300 225 123 368
330
200 65 292
130 259
81 28 209
100 148
70 93 8 80
25 39
0
03
03年 04
04年 05
05年 06
06年 07
07年 (08)
08年 (09)
09年 (10)
10年

In Japan, most of HPWH uses CO2 instead of HFC, simply

because CO2 is more suitable than HFC for heating application
.. … WHY ??
 CONTENTS

1. Introduction of CO2 Products

2. Why CO2 as refrigerant for Heat Pump ?

3. Technology of Sanyo CO2 ECO

3-1. Compressor Design
3-2. Introduction of CO2 ECO

4. Summary
Reason #1. CO2 is Natural
Montreal Protocol.
Kyoto Protocol → 　 Natural refrigerant with Energy
savings
■ Characteristics of natural refrigerants
ODP GWP Flammability Toxicity Natural
Substance
Natural CO2 0 1 － － Yes
Refrigerant HC 0 3 ++ － Yes
NH3 0 ≒0 + + Yes
R134a 0 1300 － － No
HFC R410A 0 1900 － － No
R407C 0 1600 － － No
HCFC R22 0.055 1700 － － No

CO2 is Environmentally Friendly: No ODP, negligible GWP

CO2 is Safe: Nonflammable, Nontoxic, no recovery
Reason #2. CO2 is Good for Heat Pump
CO2 (R744) do not condense at high side of Heat Pump cycle because the
Point 1 critical point is lower than working pressure. (Transcritical Cycle)

High Volumetric Capacity, Small Pressure Drop.

Critical Point （ 31℃ ） Temperature

Pressure ［ MPa ］

curve

●
CO2
●
Critical Point
　 R410A 72℃
　 R407C 86℃
　 R134a 101℃
HFCs
R404A 72℃

Enthalpy (kJ/kg)

Point 2 CO2 (R744) has high pressure and high density even at low ambient such
as -20℃.  High Heat Pump Performance even at Nordic Area.
 Reason #2. CO2 is Good for Heat Pump

Point 3 Because it is Transcritical cycle, efficiently heat up the water.

HFC CO2
90℃
Temp Ref. IN Temp Ref. IN
condensation
. . Water OUT
of refrigerant 65℃
The larger the temp.
Water OUT difference, the better
the efficiency.
Ref. OUT Water
Ref. OUT

Water IN
Water Water IN Inlet temp also
affect the system
efficiency a lot.

Point 4
In addition to the non-condensation property,
CO2 has high heat transference ratio.
　　→　 better Heat Pump efficiency, and Hot Water （ 90℃ ） can be obtained. 　
 Summary: Characteristics of CO2 as refrigerant

Advantages: 　
Green
1. Environmentally friendly (ODP=0, GWP=1) Refrigerant
2. Nonflammable, Nontoxic CO2
3. No recovery or recycling required
4. Worldwide availability
5. High volumetric capacity and Heat transfer
6. Heat pump ability at low temperature ambient
Best Refrigerant for Heat Pump!
Especially in the Cold Climate (-20℃)

Challenge: 　
igh pressure （ 12MPa or more ） & Large pressure difference
Advanced technologies were required,
especially for Compressor and Refrigeration system.

Technology Break-through by Sanyo

 CONTENTS

1. Introduction of CO2 Products

2. Why CO2 as refrigerant for Heat Pump ?

3. Technology of Sanyo CO2 ECO

3-1. Compressor Design
3-2. Introduction of CO2 ECO

4. Summary
Feature of Sanyo CO2 Compressor
Since Y2001, The World’s First Rotary 2-Stage CO2 Compressor

・2-Stage Compression Mechanism in One Compressor

　 against large pressure difference

・Internal Intermediate Pressure Structure

　 　　　 against high working
pressure
・Very efficient DC Brushless Inverter Motor
　 　　　 comply with varied Heating Load

・SANYO’s Unique Technologies 　

Excellent Processing & Assembly Technology
Optimized Pump Dimension
System Advantages
belong to only 2-Stage Compressor
Low-Vibration
High Performance 　 Compact
High Reliability Low-Noise
Design
Feature of Sanyo CO2 Compressor
Working for Heating Applications.

High Low
Pressure Motor Shell Pressure

2nd Stage

Internal
Intermediate
Pressure

1st Stage
Feature of Sanyo CO2 Compressor
Working for Heating Applications.
Heat the Water
過熱能力高い
High Low
without condensation
高温出湯可能
Pressure圧力Motor
Pressure
圧力 （ ＭＰ(MPa)
ａ） Shell Pressure
40 50 60 70℃
14

12

10

8 2-stage
２ 段圧縮： Compression
低温時の過熱能力高い
realizes the high
6
（ 高圧縮比運転可能
isentropic ）
efficiency
4
and high reliability
2

Internal 0
100 200 300 400 500 600
Intermediate Enthalpy
ｴ ﾝﾀﾙ(kJ/kg)
ﾋﾟｰ
Pressure
 CONTENTS

1. Introduction of CO2 Products

2. Why CO2 as refrigerant for Heat Pump ?

3. Technology of Sanyo CO2 ECO

3-1. Compressor Design
3-2. Introduction of CO2 ECO

4. Summary
CO2 ECO System Features

Heater (radiator)

For
Shower Mixing
Valve

Hot Water Cold Water

W-W
Gas Cooler Expansion Device(No.1) (Main)
HX Heater
9kW
Inter . Heat
Excha ng er
Second St.

Heater
First St. 6kW
Expansion Device(No.2)

(Bypass )
Water
Ｐ
Compressor Evaporator Pump
Accumlator
For HP
 Sanyo Original CO2 Technology

Only Available for Sanyo Original 2-stage CO2 Cycle !

This Technology was applied to new 9kW CO2 ECO!
Hot Water Cold Water
Gas Cooler Expansion Device(No.1) (Main)

Inter . Heat
Excha ng er
Second St.

First St.
Expansion Device(No.2)
(Bypass )

Evaporator
Compressor
Accumulator

State of the Art Technology !

 New Refrigerant Circuit “Split Cycle”
Tank
Only Available for Sanyo Original 2-stage CO2 Cycle ! Pum
CO2 Compressor

H ot Wa t er Cold Wa t er
Ga s Cooler E xpa n sion Device(No.1)(Ma in )

In t er. H ea t
porator E xch a n ger
Secon d St .

F ir st St .
E xpa n sion Device(No.2)
Gas (Bypa ss )
cooler
Com pr essor E va por a t or
Accu m la t or

Expansion Valve Pump

(Data) New Refrigerant Circuit “Split Cycle”
Conventional Cycle （OutdoorTemp. －20℃、3.0kW、40→55℃） Main Cir.
H ot Wa t er Cold Wa t er 14
12

Pressure (Mpa)
Ga s Cooler E xpa n sion Device(No.1)(Ma in ) 10
8
6
4

In t er. H ea t 2
0
400 500 600 700 800 900
E xch a n ger Enthalpy(kJ/kg)

Secon d St .
Addition of split cycle

F ir st St . Split Cycle （Outdoor Temp.－20℃、3.0kW、40→55℃） Main Cir.

E xpa n sion Device(No.2) Bypass Cir.
14
12
(Bypa ss )

Pressure (Mpa)
10
8
6
4

Com pr essor E va por a t or 2

Accu m la t or 0
400 500 600 700 800 900
Enthalpy(kJ/kg)

Adjustment of COMP Hz
- Heat Pump Unit COP is increased
by 17% at -20℃, by 16% at 　 -10℃. 　　 　　 Split Cycle （Outdoor Temp.－20℃、4.0kW、40→55℃） Main Cir.

　　　　　　　 14
12
Bypass Cir.

Pressure (Mpa)
- Heating Capacity is increased by 50% at -20℃.
10
8
6
4

（ Return Temp. ;40℃ ,Output Temp. ； 55℃ ） 2

0
400 500 600 700 800 900
Enthalpy(kJ/kg)

- Heating System Ave. COP is increased by 8%. ※Data source:

Sanyo test data
Strength of CO2 ECO for Northern Europe

Outlet Water Inlet Water Sanyo Original Freeze

Tank Unit Prevention Coil
Expansion
Valve
Air – Gas Air Flow
Heat Exchanger
Heat Pump Unit
Gas – Water Heat 　 Exchanger Air Low Pressure
Gas

Compressor Air

Accumulator High Pressure

Hot Gas

*Cross-section Diagram
at the bottom of the Evaporator
Actual Effect
of Evaporator

Special Refrigerant flow was adopted to prevent heat exchanger coil from
freezing without stopping the operation. (No Heater, No reverse cycle required)
 Strength of CO2 ECO for Northern Europe
Heat
ﾍ ﾞﾝ Pump Capacity Comparison
11
ﾁ ﾏ ｰ ｸ _欧州ﾒｰ ｶ 製HPの加熱能力の比較
Actual Test Results by Sanyo Labo.
10 Sanyo SANYO
三洋9kW
　 [ ｋW] (kW)

9 Model Co. A Co. B Co. C SHP-

8
A C90GDN
Capacity

Co.
NIBE
7
6
加熱能力

5 C
Co.KCC
Co. CTC Outlook
Heat Pump

B
4
3 Co. A
NIBE_Fighter 2020
2 Co. B
CTC_EcoAir
Co. C
KCC_Arctec 10
1 H1045 H1040 H 952 H1230
SANYO
三洋 _SHP-9kW
C9 0 GDN
0 Dimension W1200 W1280 W1086 W 930
- 30 - 20 - 10 0 10 D 500 D 407 D 600 D 340
Ambient Temp (℃)
Weight 132kg 135kg 150kg 105kg
4
COP Comparison
R404A R407C R407C CO2
Refrigerant
2.0kg 2.2kg 2.6kg 1.6kg

Heating
STOP at STOP at
3 Amb. Capacity[ 5.0 8.0
-20℃ -11℃
(W/W)

Temp. kW]
[-]

-20 ℃
COP　
COP

COP ― ― 1.6 1.8

2
Co. A
NIBE_Fighter 2 0 20 Heating
Co. B
CTC_EcoAir Amb. Capacity 10.4 9.0 9.0 9.0
Co. C
KCC_Arctec 10 Temp.
三洋SANYO
_SHP-9kW
C90 GDN
[kW]
1 7℃
- 30 - 20 - 10 0 10 COP 3.2 3.2 3.0 3.2
外気温度
Ambient Temp 　 [ ℃]
(℃)
Correlations between
Outdoor Temp. and HP Performance

Demanded Heat Level for a house

H FC
.0kW
al 9
NEW 1phase-230V 9kW io n
10kW v e nt
NEW 3phase-400V 9kW Con

kW HFC
al 6 . 0
en t i on
Conv

5kW
4.5kW CO2

-25℃ -20℃ -10℃ 0℃ 10℃ 10℃

 SUMMARY

1. CO2 HP is widely used in Japan and best matches

the use in cold climate. (works even at -25℃)
 Big Energy Saving compared to HFCs.

2. Easy Installation. (No Drilling, No connection kit)

3. Sanyo 2-stage compression enabled the very

reliable CO2 cycle and cutting edge technology,
“Split Cycle”.

4. CO2 ECO is the best and only product for Nordic!

How CO2 can be applied to Cooling ?
Feature of Sanyo CO2 Compressor

Internal Intermediate Pressure Structure

High Pressure Structure High Pressure Intermediate Pressure
Structure Structure
Pressure in Chamber [MPa]

ON OFF ON

△F h

△F i

Intermediate Pressure Structure

The fluctuation of Inner Pressure is below 25% 100% 65%

compared with high Pressure Structure.
Thickness 　　　　　　 ： 65%
Weight of the vessel ： 50%

Internal intermediate pressure structure

gives high reliability and light weight design.
Feature of Sanyo CO2 Compressor

Lower Vibration & Noise

Comparison of compression torque fluctuation

Torque Fluctuation

100 2-Stage Compression

25
0
-25
1-Stage Compression
-100
0 90 180 270 360
Crankshaft Angle [deg]

2-Stage Compression Mechanism by 2-Rolling Pistons

can achieve high discharge pressure while suppressing
both vibration and noise.
Feature of Sanyo CO2 Compressor
Working for Cooling
Applications.
High Low
Pressure Motor Shell Pressure

Intermediate
Pressure 2nd Stage

Inter Cooler
1st Stage
 Feature of Sanyo CO2 Compressor

　　 Only belongs to Sanyo’s 2 stage compressor! 　　 Animation

AT ： 32℃
RH ： 65 ％
Feature of Sanyo CO2 Compressor

CO2 Compressor Conventional Rotary Compressor for AC

Motor

Cylinder

Oil

Parts and materials used for CO2 compressor are almost same as those for
conventional HFC or HCFC rotary compressor for AC.
If the production quantity of CO2 compressors is closer to that of the
conventional rotary compressors for AC, the incremental cost of CO2
compressor will ultimately become the difference of material usage.
Feature of Sanyo CO2 Compressor

Comparison of various CO2 Compressors for 4.5kW ～ 6.0kW

Same Heating Capacity, Half size.

▲146mm

Smallest and
Lightest
Co. A Co. B Co. C
Swing-Rotary Scroll Scroll Sanyo
20kg 18kg 15kg 2-stage Rotary
9kg
Let’s go with the natural choice!
 32

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