dkemper
05-04-2007, 03:24 PM
All,
I’ve a Carlyle 5H80 compressor using R404a on a brine chiller and I cannot get temperatures, and pressures right. Being quite new to refrigeration (6 months), I’m running out of ideas.
A bit of history, the brine chiller is an Italian design, originally running a Frascold TSL1-70-2404 screw compressor. My company has seen a limited life of only about 2 years continuous use on the compressors and made the decision to replace the compressor with a less expensive, easier to source and repair (here in the US) reciprocating compressor.
A Carlyle 5H80 was chosen as the replacement, driven by a 50 HP (37Kw), 1770 RPM motor.
Expansion valve is an ALCO TER using an X9117-B8B cage assembly. Power head assembly is correct for R404a/low temp.
Load on the system is from 32 oz (900g) of sugar water at 30F (-1c) dropping into forms 22 times a minute and being drawn down to -15F (-26c) in 3 minutes in the brine bath.
The initial install was very poorly done. My predecessor had Carlyle engineer the solution, then attempted to build and commission himself.
To date, I’ve added head pressure controls on the condenser to get head pressures up, built and installed a bypass for the unloader system on the 5H80 to keep capacity up on the compressor and corrected a major flaw/shortcoming in the oil separator/return system.
I’ve made huge progress. Initially, temps were 10F/18c warmer than they are now head pressure 60% of current and suction about double, brine was barely at -15F(-26c)
But I’ve still got a ways to go. My target is to maintain -30F (-35c) brine with an increase on load of about 10% (25 drops per minute)
At this point:
Compressor discharge is 225 psi (15.5bar) / 117F (47c)
Condenser discharge is at 86.5F (30c)
Precooler discharge is at 64F (18c) – Total of about 30F subcooling.
Evaporator discharge is at 10 psi (.7 bar) / -11F (-24c) Makes it about 19F of superheat!
Only frost back on the compressor is at the service valve so I don't think I'm flooding the evaporator.
Clearly, superheat on the system is WAY off. But, before I jump in and make further alterations, am looking for advice. Am I down to the expansion valve, or are there pieces I’ve missed elsewhere?
Many thanks in advance!
Win
I’ve a Carlyle 5H80 compressor using R404a on a brine chiller and I cannot get temperatures, and pressures right. Being quite new to refrigeration (6 months), I’m running out of ideas.
A bit of history, the brine chiller is an Italian design, originally running a Frascold TSL1-70-2404 screw compressor. My company has seen a limited life of only about 2 years continuous use on the compressors and made the decision to replace the compressor with a less expensive, easier to source and repair (here in the US) reciprocating compressor.
A Carlyle 5H80 was chosen as the replacement, driven by a 50 HP (37Kw), 1770 RPM motor.
Expansion valve is an ALCO TER using an X9117-B8B cage assembly. Power head assembly is correct for R404a/low temp.
Load on the system is from 32 oz (900g) of sugar water at 30F (-1c) dropping into forms 22 times a minute and being drawn down to -15F (-26c) in 3 minutes in the brine bath.
The initial install was very poorly done. My predecessor had Carlyle engineer the solution, then attempted to build and commission himself.
To date, I’ve added head pressure controls on the condenser to get head pressures up, built and installed a bypass for the unloader system on the 5H80 to keep capacity up on the compressor and corrected a major flaw/shortcoming in the oil separator/return system.
I’ve made huge progress. Initially, temps were 10F/18c warmer than they are now head pressure 60% of current and suction about double, brine was barely at -15F(-26c)
But I’ve still got a ways to go. My target is to maintain -30F (-35c) brine with an increase on load of about 10% (25 drops per minute)
At this point:
Compressor discharge is 225 psi (15.5bar) / 117F (47c)
Condenser discharge is at 86.5F (30c)
Precooler discharge is at 64F (18c) – Total of about 30F subcooling.
Evaporator discharge is at 10 psi (.7 bar) / -11F (-24c) Makes it about 19F of superheat!
Only frost back on the compressor is at the service valve so I don't think I'm flooding the evaporator.
Clearly, superheat on the system is WAY off. But, before I jump in and make further alterations, am looking for advice. Am I down to the expansion valve, or are there pieces I’ve missed elsewhere?
Many thanks in advance!
Win