On/Off Control

Lecture
Refrigeration and Air Conditioning Controls
R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 3
Table of contents
Introduction .................................................................................................................................. 4
KP Controls, general .................................................................................................................... 5
Introduction............................................................................................................................. 5
Construction ........................................................................................................................... 5
Design .................................................................................................................................... 5
Function.................................................................................................................................. 6
Cable entry ............................................................................................................................. 7
RT Controls, general .................................................................................................................... 8
Introduction............................................................................................................................. 8
Types of switch....................................................................................................................... 8
Screwed cable entry ............................................................................................................. 11
Thermostats ............................................................................................................................... 12
Example of thermostatic control ........................................................................................... 12
Thermostat design................................................................................................................ 12
Charges ................................................................................................................................ 12
Thermal differential ............................................................................................................... 15
KP thermostats .......................................................................................................................... 16
Setting .................................................................................................................................. 17
KP thermostat program ........................................................................................................ 18
Dual thermostat type KP 98 ................................................................................................. 19
Application examples ........................................................................................................... 20
RT thermostats .......................................................................................................................... 21
Setting, mechanical differential ............................................................................................ 21
Special type RT thermostats ................................................................................................ 22
Differential thermostats .............................................................................................................. 23
Application example ............................................................................................................. 23
Dead zone thermostats .............................................................................................................. 24
Construction ......................................................................................................................... 24
Adjustment ........................................................................................................................... 24
Dead zone ............................................................................................................................ 24
Mechanical differential .......................................................................................................... 24
RT L programme .................................................................................................................. 24
Pressure controls, general ......................................................................................................... 25
KP pressure controls .................................................................................................................. 26
Introduction........................................................................................................................... 26
Fitting.................................................................................................................................... 26
Low pressure controls type KP 1, 2, and 1A ........................................................................ 27
High pressure controls type KP 5 and 5A ............................................................................ 28
Combined high and low pressure control type KP 15 and 15A ............................................ 28
KP pressure controls with LP + HP signal ............................................................................ 30
KP pressure controls with convertible automatic/manual reset ............................................ 30
KP pressure control program ............................................................................................... 31
RT pressure controls .................................................................................................................. 32
Pressure control designs ...................................................................................................... 32
Refrigerants .......................................................................................................................... 33
Safety pressure controls of TV-design .................................................................................... 34
TV-design .......................................................................................................................... 34
Meeting DIN 32733 requirements ........................................................................................ 34
Differential pressure controls ..................................................................................................... 36
Differential control terminology ............................................................................................. 36
MP differential pressure control ............................................................................................ 36
Electrical connections........................................................................................................... 37
Setting .................................................................................................................................. 38
RT differential pressure controls .......................................................................................... 39
Dead zone pressure controls ..................................................................................................... 40
Safety cut-out and liquid level control type RT 280A ................................................................. 41
RT 280A used as safety cut-out ........................................................................................... 41
RT 280A used as liquid level control .................................................................................... 42
Technical data ...................................................................................................................... 42
Examples of application ............................................................................................................. 43
Temperature control of containers ....................................................................................... 43
RT 140L used in ventilation systems.................................................................................... 44
RT 280A and RT 262A as safety equipment in pump recirculatory refrigeration plant ............ 45
4 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Introduction
When a refrigeration system is constantly
loaded, and the load balances the cold output
of the system, adjustment is unnecessary. In
practice, however, there will always be
fluctuating loads on the main components of
the refrigeration plant and the plant capacity
will often be higher than the normal cold
requirement. Therefore, a need for regulation
arises.
Regulation can be carried out manually but
that requires a large personnel and is not
particularly accurate, therefore, automatic
control is used today. To prevent injury to
personnel and damage to refrigeration
equipment, plants must be equipped with
safety controls. Danfoss regulating
equipment covers these requirements. The
following deals with those refrigeration
controls which regulate in accordance with
the on/off principle.
ON/OFF Control,
general
The purpose of on/off control is to keep a
given physical variable, e.g. the ambient
temperature, within certain limits or to change
it according to a predetermined programme.
A control system serves to measure the value
of the controlled variable, compare it with the
desired value, and adjust the control unit, by
which a possible deviation is reduced.
Thermostats and pressure controls for on/off
control are two-position regulators where the
manipulated variable can only lead to two
conditions: cut-in or cut-out.
The temperature sequence for a room
controlled by a thermostat is shown in fig. 1.
The rise in the ambient temperature will not
occur at the same time as the valve opens,
as some time will pass before this happens,
i.e. the dead time T
t
. The dead time is defined
as the time which will pass from when the
valve opens until the bulb begins to register
the temperature increase.
At the measuring point the increase will follow
an exponential function. The tangent to the
starting point of the curve intersects the
tangent to the final value of the curve at
T
t
+ T
s
.
T
s
is denoted the time constant and indicates
the time it takes for the temperature to
increase to 63% of the final value.
In other words, the time constant is an
expression of the rate at which the controlled
variable changes as a result of a sudden
change of the manipulated variable.
Because of the great difference in
temperature the curve of temperature will
increase most rapidly at the beginning, to
fade out gradually and approach the final
value tangentially.
When the temperature has increased to the
point A the thermostat will cut-in and the
cooling begins. However, it takes some time -

1
- before the ambient temperature begins to
fall.
T
1
depends on the following factors among
others:
Bulb position
Air circulation at the bulb
Sizing of the refrigeration plant.
During cooling the temperature drops to the
point B where the thermostats cut out the
refrigeration system. Because of the cold
accumulated there will, however, be a certain
after-cooling -
2
- before the temperature
increases again. The cooling is restarted at
the point A, and a new cycle begins.
t
d
(= the section A to B) denotes the thermal
differential of the thermostat, whereas t
max
indicates the maximum temperature
fluctuations.
C: Temperature
D: Time
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 5
KP Controls, general
Introduction
KP controls are pressure-controlled switches
for on/off control of refrigeration, freezing,
and air-conditioning plant. The KP is based
on entirely new design principles. The
mechanical parts of the control have two
balanced positions only. Therefore, the
contact system operates with well-defined
contact pressure. This means that:
KP has very high contact load both for
inductive and ohmic loads
KP is not sensitive to vibrations and
pulsations
KP has a long mechanical life
KP is free of radio interference, in
accordance with VDE 0875 and CISPR.
Construction The enclosure is a dust-tight mild steel casing
provided with a cover of self-closing ABS-
plastic. The grade of enclosure is IP 44 in
accordance with IEC 144 and DIN 40050.
This grade of enclosure is obtained by
mounting the control onto a plane board or a
bracket. The bracket must be placed on the
control so that all free holes are covered.
Design
Fig. 4. KP-thermostat Fig. 5.
1. Adjustment setting spindle
2. Differential spindle
3. Main arm
18. Locking plate
Fig. 2. KP-thermostat Fig. 3. KP-presssure control
The one function, terminals 1-4, may for
example, cut-in a refrigeration compressor at
increasing pressure/temperature, while the
second function, terminals 1-2, may cut-in a
signal lamp when the refrigeration
compressor has stopped.
KP controls have simple electrical
connections, as both the contact terminals
and the earthing screw are accessible from
the front. See fig. 5. Thus, several KP
controls can be mounted close to each other.
KP has very small overall dimensions
(84 61 45 mm), and is of simple and
robust design.
KP is fitted with an SPDT switch. See fig. 4.
Such a switch has a wide range of
application, among other things because the
make and break functions can be obtained at
increasing as well as decreasing pressure/
temperature. By connecting the three
terminals 1, 2, and 4, two contact functions
are obtained.
6 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
KP Controls, general
Function
The design principle of the KP controls.
The main spring (7) can by means of the
adjustment spindle (1) be adjusted for
balancing the pressure in the bellows.
KP is designed so that the snap action of the
contact system is led to the bellows (9). Thus,
this has two balanced positions only. The
bellows is moved only when the cut-in and
the cut-out value is exceeded.
The knife-edge bearing at the tumbler (16)
exert two forces on it on one side the
pressure of the bellows (9) minus the force of
the main spring (7) on the other side the
pull of the differential spring (8).
From the above description it can be seen
that the KP design distinguishes itself
essentially from the design principles
previously used for mechanical thermostats
and pressure controls.
Contrary to the previous principles, which
were called road proportional or distance
proportional, the power transmission
between the bellows and the contact system
of the KP is based on the power proportional
principle.
The following is a description of how the
principle is put into operation:
Fig. 6 shows a KP control with the contacts 1-
4 open, and 2-1 closed. If the pressure in the
bellows increases, neither contacts will move
until the bellows pressure has reached a
value equal to or higher than that set on the
main spring.
When this pressure has been reached the
movable parts of the control move
momentary, so that the contact system
changes to the opposite contact position,
where contacts 1-4 are closed, and contacts
2-1 are open.
See fig. 7.
Generally, on contact systems, when the
movable contact hits the fixed one at high
speed, the movable contact will jump back a
couple of times. Each time the contacts jump
apart arcing occurs. Consequently the
contact surfaces wiIl melt, and can weld
together when meeting again.
These very small welds, which occur during
cut-in, are the most frequent cause of failure
in a contact system.
The time from the moment when the movable
contact hits the fixed one for the first time,
until the cut-in function is established is called
bounce time. The bounce time for the KP
contact system is less than 100
microseconds = 1/10 000 second, which is
exceptional. It is 10-50 times less than for
common contact systems and permits high
contact load combined with long electrical
and mechanical life.
The electrical data for the constant system
are:
Alternating current
16 (16) A 400 V a.c.
Locked rotor 112 A
i.e.:
- 16: maximum ohmic load in amp.
- (16): maximum full load current at
inductive load
- 400 V: maximum permitted voltage
- Locked rotor 112 A: maximum permitted
starting current.
In practice the high contact load means that
single phase alternating current motors of
up to 2 hp can be direct started.
Direct current
12 W 220 V d.c. pilot current
Fig. 6 Fig. 7
1. Adjustment setting spindle
2. Differential spindle
3. Main arm
7. Main spring
8. Differential spring
9. Bellows
16. Tumbler
18. Locking plate
20. Contact system
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 7
KP Controls, general
Cable entry
KP controls have a soft rubber entry as
standard. See fig. 9. The entry will take
cables from 6 to 14 mm diameter.
As accessories Pg 13,5 and Pg 16 cable
entries are available, fig. 8.
Fig. 8 Fig. 9
8 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
RT Controls, general
Introduction
Types of switch
Fig. 12
Discription
Type of switch normally used for RT. Terminals 1-4 make on increases.
Terminals 1-2 make on decreases.
Terminal 1 is common.
Single-pole change-over switch with neutral centre position.
Terminals 1-4: Make the circuit when the temperature/pressure increases.
Terminals 1-2: Make the circuit when the temperature/pressure decreases.
The neutral setpoint will be dealt with in the section of dead zone
thermostats, page 22.
Single-pole switch breaking two circuits at the same time when the pressure/
temperature increases. Momentary contact change-over. Terminals 1-4 and
1-2 are cut-out when the pressure/temperature increases.
Single-pole switch making two circuits at the same time when the pressure/
temperature increases. Momentary contact change-over. Terminals 1-4 and
1-2 are cut-in when the pressure/temperature increases.
Single-pole change-over switch with non-snap action. It gives less
mechanical differential than 17-4030, but the rated capacity is, therefore,
lower and the switch must not be used where vibration occurs.
Single-pole switch with the same functions as described for switch
No. 17-4030.
The switch is equipped with silver contacts coated with gold.
Therefore, it can be used with advantage for small electrical loads as well as
in plants where the demand is for exeptional make reability, even after long
periods of intermittent contact load.
Code Nos Fig.
17-4030 13-14
17-4032 15
17-4036 16
17-4034 17
17-0181 18
17-4240 19
Fig 13
Fig 15
Fig 17
Fig 19
Fig 14
Fig 16
Fig 18
Designs and materials
Most RT controls are equipped with switch
17-4030 which is an SPDT system (Single
Pole Double Throw system). Switch 17-4030
can be replaced, without adjusting the
controller. The switch has a transparent
protective cover over the moving parts.
Replacement systems are also equipped with
a protective cover over the contact arm. This
system is also available with manual reset on
actuation for rising or falling pressure/
temperature (max. reset and min. reset
respectively).
Danfoss RT controls are characterized by a
hoseproof bakelite housing which is equipped
with a steel cover, robust construction, and
small differentials. Therefore, the control are
suitable for industrial systems.
The RT-control is a pressure or temperature-
controlled electric switch which makes or
breaks an electric circuit depending on
pressure or temperature variations at the
bulb.
Fig. 10. RT thermostat Fig. 11. RT pressure control
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 9
RT Controls, general
Type of switch a.c. d.c.
Non-inductive Inductive rating
Full-load Locked
Code No. current rotor
17-4030
10 A 400 V 4 A 400 V 24 A 400 V 12 W 220 V
17-4032
17-4036
10 A 400 V 3 A 400 V 18 A 400 V 12 W 220 V
17-4034
17-0181 25 VA 24 V 25 VA 24 V
17-4240 10 A 400 V 2 A 400 V 12 A 400 V 12 W 220 V
Rating
Marking
The covers of switches 17-4030 and 17-4032
are marked:
10 (4) 400 V a.c.
12W 220 V d.c.
The marking complies with the demands of
VDE 0671 test class II which prescribes the
above rating in relation to a minimum of
100,000 operations.
Fig. 20
Alternating current (a.c.)
It should be remembered that the two main
demands are 10 A non-inductive rating and
30 A locked rotor. The 4 A inductive rating
(or, more correctly, motor rating) is derived
from 30 A locked rotor, since the maximum
ratio between locked rotor/operating current
for single-phase motors is approx. 7.5
30
= 4 A
7.5
This means that normally motors with an
operating current of 4 A can be connected. It
is permissible to connect motors with a higher
operating current than 4 A, provided that
locked rotor does not exceed 30 A.
10 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
RT Controls, general
Application of two-circuit switches
An RT control with a switch 17-4034 or
17-4036 can, for example, be used in pilot
circuits with several RT controllers. When the
above types of switch are used, auxiliary
relays can be omitted.
The two examples, fig. 21 and fig. 22, show
the wiring diagrams for thermostatic control of
two deep-freeze stores and one refrigerated
store, where the three evaporators are
connected to a centrally located compressor.
The thermostats control the opening and
closing of the solenoid valves in the liquid
lines, depending on the ambient temperature.
Fig. 21 shows the wiring diagram for RT
thermostats with a standard switch 17-4030
and auxiliary contacts. Fig. 22 shows the
same system, but in this case the switches
have been replaced by the two-circuit
switches 17-4034, and the auxiliary contacts
can thus be omitted.
Fig. 22
Fig. 21
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 11
RT Controls, general
Screwed cable entry All RT controls are equipped with a Pg 13.5
nylon cable entry.
The rubber ring of the cable entry consists of
concentric rings which can be taken out to
accommodate cable diameters of from 6 to
14 mm.
The rubber rings are made of Nitril rubber.
This gives a good seal, and it can be used
with plastic cables.
Fig. 23
12 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Thermostats
Example of thermostatic
control
In the refrigeration system, fig. 24, a room
thermostat is used to control the temperature
in the refrigerated space. When the
temperature of the refrigerated store room
exceeds the value required, the thermostat
makes the circuit to the compressor motor,
and the refrigeration system starts. When the
temperature required is reached, the
thermostat breaks the circuit to the
compressor motor, and the refrigeration
system stops.
Thermostat design Thermostats are temperature-controlled
electrical switches which can break or make
an electrical circuit, depending on
temperature variations at the bulb.
A thermostat, fig. 25, consists of the following
main elements:
The power element which consists of the bulb
(29), the capillary tube (28), and the bellows
element (23). The most important parts of the
mechanical section are the spindle (15), the
range spring (12), the knob (5) for adjusting
the spring pressure, and the differential
adjusting nut for adjusting the mechanical
differential. The switch (16) is a single-pole
change-over switch with momentary contact
change-over.
The power element contains a charge, the
pressure of which changes with the
temperature at the bulb. A fixed pressure
corresponds to a given bulb temperature. If
the bulb temperature increases, the pressure
in the power element increases. Hence the
spindle is moved until the pressure on the
lower side of the bellows balances the
counter-pressure of the main spring.
Fig. 24
Fig. 25
Charges Depending on the field of application, the
charge of a thermostat can be:
I : Vapour fade-out charge
II : Adsorption charge
III: Partial charge
Vapour fade-out and adsorption charges will
be described overleaf since these charges
are used in our thermostats for refrigeration
purposes.
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 13
Vapour fade-out charge
Saturated vapour +
some liquid
Vapour pressure curve
Room thermostats
Evaporator thermostats
Thermostats for low temperatures
Thermostats
I. Vapour fade-out charge
A vapour fade-out charge consists of a very
small amount of liquid and the saturated
vapours of that liquid. This type of charge
utilizes the interdependence between the
temperature and pressure of saturated
vapour.
The pressure of the charge depends on the
temperature at the free liquid surface. As long
as liquid remains, a pressure increase
caused by ingress of heat into the liquid will
progress according to the vapour pressure
curve for the saturated vapour of the liquid.
From the moment the last drop has
evaporated, the pressure increase will, on the
other hand, follow the curve for superheated
vapour. At this point the pressure increase is
considerably slower since it is now only the
thermal expansion of the vapour which
causes the pressure to increase.
The temperature at which the vapour passes
from saturated vapour to superheated vapour
is called the pressure limiting temperature,
denoted t
3
in fig. 26.
The advantages of a vapour fade-out charge
are e.g.
1. A very short reaction time (a short time
constant). Heat has only to be supplied or
given off for the respective evaporation
and condensation of a very small quantity
of liquid.
2. The charge is pressure-limited, i.e. the
element is designed to resist temperatures
higher than the maximum temperature
setting.
Fig. 26
Small reaction time
Pressure limited
No capsule sensivity
Capillary sensor
The coldest part of the thermostatic
element controls the function
Pressure-temperature curve: Non-linear
It can be seen from the inclination of the
vapour pressure curve (fig. 28) that the
differentials at the lower and upper parts of
the curve are different when a given pressure
variation p is kept constant. A thermostat
with a vapour fade-out charge has, therefore,
smaller mechanical differentials at the upper
end of its temperature range than at the lower
end.
Vapour fade-out charges are preferable for
thermostats which are to work at low
temperatures.
In a vapour-filled thermostat the charge will
condense at the coldest point of the power
element, and the thermostat will regulate the
temperature accordingly. Therefore, to obtain
the regulation required it is a condition that
the bulb must always be placed colder than
the rest of the power element.
Fig. 28
+
Fig 27.
14 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Thermostats
II. Adsorption charge Adsorption charge is no doubt the most
interesting one and the charge which is most
universally applicable. By using the same two
substances, e.g. active carbon as adsorbent
and CO
2
as adsorbate, it is possible to
produce many different pressure-temperature
curves by varying the ratio between the
quantities of the substances.
Some porous substances, adsorbents, have
the capacity of being able to bind molecules
from another substance, the adsorbate, in
their microscopic pores. Because of the
porosity of the adsorbent, it has a surface
area of several hundred m
2
per gram.
If, in this way, CO
2
molecules are bound to
active carbon in a closed container, the
pressure is reduced. In the gaseous phase,
CO
2
is known to participate in the pressure
formation by means of its partial pressure.
The capacity of an adsorbent to bind an
adsorbate depends on temperature. When
binding occurs in a closed system, it also
depends on the counter-pressure which is set
up.
If the adsorbent is heated, it can no longer
retain all the gas molecules previously
retained by it. Some of them will be released,
and, together with the other gas molecules
which were already free, they will increase
the concentration of gas molecules. The
pressure in the element then increases.
Fig. 31
Fig. 29
Fig. 29 shows a pressure-temperature curve
for an adsorption charge. The S-shape is
typical for these curves. When carbon
charges are used in power elements, the
temperature range is mostly placed
symmetrically about the turning point t
v
.
Hence, a maximum pressure increase is
obtained by means of a
minimum quantity of carbon, and hence the
smallest size of bulb. A great advantage of
the adsorption charge is that a thermostat
with this charge is CROSS AMBIENT, i.e. the
bulb can be placed warmer or colder than the
thermostat housing.
This is possible because the carbon is always
placed in the bulb. Therefore, the bulb always
controls the thermostatic regulation.
Adsorption charge
Granulated material +
superheated gas
Physical mass attraction
Room thermostats
Thermostats for high temperatures
Cross ambient
Small bulb
Pressure-temperature curve: Linear
A disadvantage of an adsorption charge is
the capsule sensitivity. This means that
greater temperature fluctuations at the
capsule may influence the control accuracy.
Capsule sensitive
Moderate reaction time
+
Fig. 30
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 15
Thermostats
Thermal differential The thermal differential is the differential at
which the system operates. It is always
higher than the mechanical differential. The
thermal differential depends on several
factors:
1. Velocity of medium.
The higher the velocity at which the air or
liquid pass the sensor, the smaller the
thermal differential. Therefore, the sensor
should always be located at a point with
good circulation of the air and the liquid
respectively.
2. Temperature variation rate of medium
(temperature variation per time unit).
The thermal differential increases with the
temperature variation rate.
If the temperature is to be controlled in the
range from 5C to +30C, to ensure that
the thermal differential will not be
increased because of too high a
temperature variation rate, an RT 4
thermostat with an electric heater in the
bellows element can be used.
3. Heat transmission to the sensor.
The sensor should have optimum contact
with the medium to be temperature-
controlled. Difficulties occur especially if
the sensor is inserted in a pocket, where
the thermal conduction between sensor
and pocket is poor. The application of a
heat-conductive compound between
sensor and pocket will, normally, result in
satisfactory heat transmission.
Measuring the time constant
To get an idea of what the time constant can
be, measuring has been done on an RT 14
with an adsorption charge. The measuring
was done under the following conditions:
The sensor at 10C was placed in an air
current of 20C. The contact change-over at
increasing temperature was set at 16.3C.
The time constant indicates the time interval
from the moment the bulb was placed in the
air duct, and until contact change-over took
place.
Fig. 32
Measuring results
Type RT 14
Air velocity m/s 0.1 0.5 1 1.5
sec. 205 147 99 73
16 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
KP thermostats
KP thermostats are single-pole double-throw
(SPDT) temperature-controlled electrical
switches for on/off control. Typical fields of
application for KP thermostats are:
- large refrigerated cabinets and display
counters
- freezing cabinets and display counters
- commercial freezing plant
- commercial refrigeration plant
- air-conditioning plant
KP thermostats The total temperature range is from -50C to
+180C with independent temperature and
differential settings. The thermostats can be
obtained with vapour fade-out or adsorption
charge and with the following sensor, see
fig. 33.
As standard range setting KP thermostats are
provided with a knob for range setting.
Fig. 33
1a. Vapour charge
1b. Adsorption charge
2 Capillary tube sensor
3. Capillary tube with a coiled
capillary tube sensor
4. 3/8 in. cylindrical or double
contact sensor
5. 1/4 in. cylindrical sensor
6. 25 mm duct sensor.
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 17
Setting
The setting can be seen in fig. 34. Illustrated
here, the range setting is the maximum
actuating value, and the differential is to be
deducted from this setting to obtain the
minimum actuating value. In addition the cut-
in and cut-out functions of the thermostat, is
depending on the terminal connection
applied. If the thermostat is to start and stop
a refrigeration compressor (terminals 1-4) the
cut-out temperature is equal to the cut-in
temperature minus the differential.
All KP thermostats with vapour fade-out
charge are provided with a setting diagram as
shown in fig. 35, to be used for the exact
setting of the thermostat.
Example of setting
For temperature control in a deep-freeze box,
the KP 61 thermostat should be set so that
when temperature increases, the electric
circuit is made at 17C (starting
temperature), assuming a requirement for a
cut-out temperature (stopping temperature) of
-24C. The differential (the value to be set on
the differential scale) must be determined. In
the diagram for KP 61, fig. 35, the cut-in
temperature -17C is read on the range scale
(contact change-over when temperature
increases). On the horizontal scale (contact
change-over on decreases in temperature)
the temperature -24C is read. The solid lines
differential curve are followed from the
intersection point between the lines from -
17C and -24C. The differential wanted = 6
K can be read from the differential scale.
Consequently, the thermostat should be set
as follows:
Range scale: 17C
Differential scale: 6 K.
Locking the setting
The range setting spindle (1) or the
differential setting spindle (2) can be locked
by the locking plate (18). See fig. 36.
KP thermostats
Fig. 35 Fig. 36
Fig. 34
18 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
KP thermostat program KP thermostats can be divided into three
main groups:
1) KP 61-69, which all - with the exception of
KP 62 - are vapour fade-out charged.
(KP 62, is available with adsorption charge
and vapour fade-out charge (room
thermostat)).
2) KP 71-77, which all have an adsorption
charge (cross ambient)
3) KP 98, which is a dual thermostat.
The table in fig. 37 shows the regulating
ranges for group one and two. The type
designation and the code No. are stamped on
the underside of the control, while the
approval, electrical data, and place of origin
are printed on the scale plate.
KP thermostats
Fig. 37
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 19
KP thermostats
Dual thermostat
type KP 98
The thermostat has two separate functions:
1. As a protection against too high a
discharge gas temperature. After cut-out
the control must be reset manually (max.
reset). This function applies to KP 98,
code No. 60L1131 and 60L1132.
2a. As a protection against too high an oil
temperature in the compressor
crankcase. After cut-out the control must
be reset manually (max. reset). This
function applies to KP 98, code No.
60L1131.
2b. As a protection against too low an oil
temperature. At too low an oil
temperature a heating element in the
crankcase is cut-in. When the required oil
temperature has been attained, the
heating element is cut-out and the
compressor is ready for start. This
function applies to KP 98, code No.
60L1132.
The regulating ranges for the control are
given in the diagram below:
Type Range [C] Differential [K] Charge Reset Code No.
Oil: +60 to +120 Oil: fixed 14 max.
60L1131
HT: +100 to +180 HT: fixed 25 max.
KP 98 Adsorption
OIL: 0 to +30 Oil: fixed 12 aut.
60L1132
HT: +100 to +180 HT: fixed 25 max.
Fig. 39
Fig. 38
KP 98 is used partly to safeguard against too
high a discharge gas temperature on
refrigerant compressors, partly to ensure
regulation of the oil temperature in the
compressor crankcase.
20 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Application examples In the following a few examples of
applications for KP thermostats are given. In
an air-conditioning system, fig. 40, it is
desired to protect the pre-heating coil against
bursting due to frost (low outdoor
temperature). For this purpose the frost-
protection thermostat KP 61 is used. This
vapour fade-out charged thermostat
distinguishes itself by the fact that the entire
capillary tube is used as a sensor. The
capillary tube should be formed over the
whole cross section of the duct. If the
injection air is too cold, KP 61 gives a signal
to the actuating motor, which closes the
damper, so that only return air is used.
Temperature control of refrigerated display
counters etc.
In many commercial freezing and refrigerated
counters there is a need for an attractively
designed thermostat with a fixed differential
for temperature control. Often the control
must be mounted visibly as an integrated part
of the counter without spoiling the total
impression. See fig. 41.
Danfoss thermostat programme includes a
KP 61 with a top plate, fig. 42, specially
designed for surface mounting.
The advantages with this thermostat are:
- it can be operated from one side
- hand switch STOP/AUTO
- simple surface mounting.
Fig. 42
KP thermostats
Fig. 40
Fig. 41
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 21
RT thermostats
An RT thermostat is a temperature-controlled
electric switch which makes or breaks an
electrical circuit depending on temperature
variations at the bulb.
Our RT thermostats are characterized by a
hoseproof bakelite housing which is equipped
with a steel cover, robust construction, and
small differentials. Therefore, the controls are
suitable for industrial systems.
Fig. 43 shows the design of an RT
thermostat. As mentioned above, the power
element contains a charge, the pressure of
which varies with the temperature at the bulb.
The main spring can be set for different
pressures within the setting range. The
pressure in the bellows element counteracts
this pressure. A pressure change in the
bellows moves the main spindle until balance
is re-established between the forces. The
movement of the main spindle is transferred
to the contact arm of the switch by a guiding
knob and a differential adjusting nut so that a
break or make function can be obtained.
Setting,
mechanical differential
Fig. 43
By turning the knob, the lowest temperature
at which the switch is to operate is set on the
range scale (break or make the circuit).
The mechanical differential is then set by
turning the differential adjusting nut.
Maximum actuating temperature at the bulb is
equal to the actuating temperature + preset
mechanical differential. The mechanical
differential is set by turning the differential
adjusting nut according to the nomogram fig.
45.
Example: Setting of RT 3
Range setting = 5C
Differential required = 2 K
On the nomogram, a setting of the differential
adjusting nut at 4 can be read. Resulting in:
- Minimum actuating temperature = 5C
- Maximum actuating temperature
= 5 + 2 = 7C
Fig. 44
Fig. 45
5. Knob
9. Scale
19. Differential adjusting nut
25. Mounting hole
26. Bulb holder
30. Bulb pocket
31. Capillary tube gland
38. Earth terminal
A: Range setting
B: Obtained differential
C: Differential setting
22 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
RT thermostats
Special type
RT thermostats
Besides covering a large temperature range,
there are some types of RT thermostats
which are suitable for conditions where
special demands are made. Of these
thermostats the below types can be
mentioned:
RT 4 with an electric heater in the bellows
element
As mentioned on page 13 an increased rate
of temperature change will increase the
thermal differential. To control the ambient
temperature, a small thermal differential is,
however, often necessary even if the rate of
air temperature change is high. The
application of RT 4 with an electric heater in
the bellows element is recommended for this
kind of system.
The electric heater is heating when the
refrigeration compressor is not operating,
with the effect that the bellows and the
bellows housing are always a little warmer
than the phial.
Without this arrangement, the bellows and
the bellows housing would become the
coldest parts of the power element at rapidly
increasing temperatures, since the mass of
the bellows housing is larger than that of the
phial, and the charge vapours would
condense in the bellows and thus not create
the requisite pressure for changing over the
switch.
RT thermostats with small differentials
Danfoss has developed thermostats with
small differentials. These types are: RT 21,
23 and 24 as well as RT 17 and 103. The
technical data can be seen in the below table.
The thermostats cover a range from 50C to
+45C.
Nature of controls Type Charge Range [C] Mechanical differential [K]
5 to 18
RT 2 25 to 15
6 to 20
Brine, surface or 1 to 3
RT 23 Adsorption 5 to 22
room thermostat 1 to 3
1.4 to 4
RT 24 15 to 34
1.4 to 3.5
2.2 to 7
RT 17 50 to 15
1.5 to 5
Vapour
Room thermostat
fade-out
10 to 45 1.3 to 7
RT 103
1 to 5
Fig. 46
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 23
Differential thermostats
An RT differential thermostat is a single-pole
electric change-over switch, the contact
position of which is controlled by the
temperature difference between the two
bulbs of the thermostat.
RT 270 is designed for use in processing
plants, ventilation plants, refrigeration and
heating plants where it is desired to maintain
a fixed temperature difference of from 0C to
15C between two media.
One sensor temperature is used as a
reference and the other as an indirectly
controlled variable. (The directly controlled
variable is the temperature differential).
Fig. 47 shows a cross section of an RT 270.
The differential thermostat is equipped with
two bellows elements: the LT element, the
sensor (1) of which is to be placed in the
medium with the lowest temperature, and the
HT element, the sensor (2) of which is to be
placed in the medium with the highest
temperature.
The range spring (3) has a rectilinear
characteristic. Within the differential range it
can be set for different temperature
differentials by rotating the setting disc (4).
The setting indicates the scale value at which
contact change-over occurs when the spindle
moves downwards. (Contacts 2-1 make the
circuit).
When the differential between the LT and HT
bulb temperatures is reduced, the spindle (5)
moves downwards and thus actuates the
contact arm (7) of the switch via the upper
guiding knob (6).
When the temperature differential between
HT and LT increases, the switch changes
over when the temperature differential has
increased to the setting plus the fixed contact
differential of approx. 2 K.
Application example It is desired to maintain a temperature at 5C
above another temperature which is assumed
to be constant at 12C. The LT sensor is
placed in the medium with the lowest
temperature (reference temperature) and the
HT sensor in the medium with the highest
temperature (controlled temperature). The
thermostat is set for a temperature differential
of 5 K.
It is assumed that at first the controlled
temperature is 14C. The main spindle then
moves downwards and closes the contacts
1-2 because the actual differential of
14 - 2 = 2 K is smaller than the desired
differential of 5 K.
When the contacts 1-2 are closed, a heating
system is cut-in so that the controlled
temperature increases, and the main spindle
moves upwards until the differential between
the sensor temperatures is 7 K = setting
differential plus contact differential.
Afterwards the controlled temperature will
then fluctuate between 19C and 17C.
If the reference temperature (LT temperature)
falls or in creases, the HT temperature falls
and increases proportionately. The
differential will continue to fluctuate between
7 K and 5 K.
Fig. 48
Fig. 47
24 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Nature of controls Type Charge Range [C] at low temp. C at low temp. C
RT 8L 20 to +12 1.5-4.4 1.5-4.9
Brine surface or
room thermostat
RT 14L Adsorption 5 to + 30 1.5-5 1.5-5
Air duct thermostat RT 140L + 15 to +45 3-4.5 2-5
Vapour
Room thermostat RT 16L 0 to +38 1.5-5 0.7-1.9
fade-out
Dead zone thermostats
The RT L thermostats have an adjustable
dead zone since they are fitted with a three
position contact system, code No. 17-4032.
Construction Fundamentally the RT L thermostats are
constructed as the other RT controls but to
satisfy the dead zone function the contact
system has two contact levers which mesh
with two guide rollers, see fig. 49.
Adjustment,
fig. 41 and 50 The adjusted scale value corresponds to the
break value of contact 2-3. The required dead
zone is found in the diagram for the particular
control.
On the lower scale of the diagram the
position in which the setting knob should be
set, is read off.
Dead zone The interval of the controlled variable during
which the control device is at rest is called
the dead zone. Looking at fig. 50 the dead
zone is the interval where no make function is
obtained.
Mechanical differential The interval between the values of the
controlled variable making the control device
move is called mechanical differential.
RT L programme RT L controls are available in various designs
as shown in the table.
Fig. 49
Fig. 50
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 25
Pressure controls, general
A pressure control contains a pressure
operated change-over switch the contact
position of which depends on the pressure in
the bellows. Via the pipe connector the
bellows is connected to the pressure in the
plant. The fundamental layout is shown in fig.
51.
The main spring (12) can be set for different
pressures to balance the pressure on the
bellows. On a rise in pressure the bellows is
affected so that the main spindle (15) moves
upwards until the spring and bellows
pressures are in equilibrium. The movements
on the main spindle are then transferred to
the electric contact system.
12. Main spring
15. Main spindle
16. Contact system (RT)
23. Bellows element
27. Pipe connector
44. Range spindle
Fig. 51
26 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
KP pressure controls
Like the KP thermostats the KP pressure
controls are single pole electrical switches.
As standard, pressure controls for freon are
supplied with 1/4 in flare, 6mm or 1/4 in
solder connection, or with 1 m fixed capillary
tube with 1/4 in flare connection. Depending
on the type, the connection must be made on
the suction and/or pressure side of the
refrigeration plant.
The controls for ammonia are provided with a
1 m loose capillary tube of steel. Generally,
KP pressure controls can be used for all
fluorinated refrigerants, but those for
ammonia are made from materials which will
tolerate this refrigerant.
KP pressure controls are made in the
following basic types:
- low pressure controls
- high pressure controls
- combined high and low pressure controls
Fitting The pressure control can be fitted using one
of the two types of brackets shown in fig. 53.
These may be ordered separately. When wall
mounting, the plain holes in the back of the
control are to be used.
The KP pressure controls can be fitted in any
position. However, as shown in fig. 52, the
capillary tube is fitted in a way preventing
direct downpiping of oil and refrigerant. In this
way the risk of blocking the bellows is
eliminated, and at the same time a correct
pressure control is ensured.
Fig. 52
Fig. 53
Introduction
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 27
KP pressure controls
Low pressure controls
type KP 1, 2, and 1A
As previously mentioned the KP 1 and 2 are
provided with 1/4 in flare connection, fig. 54,
or with 1 m fixed capillary tube, fig. 55.
KP 1A is provided with a 1 m loose capillary
tube of steel, fig. 56. The low pressure controls
must be connected to the suction side.
The function of the control may be, for
example:
1) Used to start and stop the compressor,
depending of the pressure in the suction
line. At too low a pressure the compressor
is cut-out. When the pressure has
increased by a value corresponding to the
differential, the circuit to the compressor
motor is made again.
2) Used as a low pressure safety switch. The
pressure control will cut-out the
compressor at too low a suction pressure.
The compressor can then for example be
controlled by a room thermostat.
Fig. 54
The range spindle (1), and the differential
setting spindle (2) can be locked by the
locking plate (18), fig. 57.
The normal function of the low pressure
control - cutting out the compressor at
decreasing suction pressures - is shown in
fig. 58. The electric connection to the
terminals of the contact system are also
shown as well. The cut-in value (terminals 1-
4) required is set on the range scale (START)
of the control. See fig. 59. The differential
required is set on the differential scale,
(DIFF). The cut-out value (STOP) (terminals
1-2) is then derived from the expression:
STOP = START minus DIFF
KP 1 and 1A are also available in a design
with minimum reset. See fig. 60. A manual
reset can be carried out only when the
pressure has increased by a value higher
than or equal to the fixed differential. The
scales on KP 1 and 1A reset controls are
calibrated differently from the remaining KP
low pressure controls.
On these reset controls the scale value
corresponding to the required cut-out value
(STOP), while the scale value for the
remaining KP low pressure controls
corresponds to the cut-in value (START). KP
low pressure controls with minimum reset
have a locking plate on the range spindle, so
that both the cut-in and the cut-out values of
the control are fixed.
Fig. 55 Fig. 56
Fig. 57
Fig. 58
Fig. 59
Fig. 60
28 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
KP pressure controls
High pressure controls
type KP 5 and 5A
KP 5 and 5A are usually connected to the
high pressure side of the refrigeration
compressor. The usual function of the high
pressure control is to cut the current supply to
the compressor motor or relay, when the
pressure exceeds that set on the range scale.
KP 5 and 5A can be obtained in two designs:
1) With adjustable differential, fig. 61.
In this design the compressor is
automatically cut-in again, when the
pressure has fallen by a value equal to or
higher than the differential setting. The
electric connection of the high pressure
control can be seen in fig. 62, and also
how it is set. The cut-out value (terminals
1-4) required is set on the range scale
(STOP) of the control. See fig. 63. The
differential required is set on the
differential scale (DIFF), fig. 61. The cut-in
value (START, terminals 1-2) is then
derived from the expression
START = STOP minus DIFF
The locking plate can lock both spindles.
Fig. 62
Fig. 61
2) With maximum reset-function and fixed
differential setting (4 bar), fig. 63.
This type of pressure control is used as a
safety switch and can be manually reset
only when the pressure has fallen by a
value equal to or higher than the fixed
differential of 4 bar. The pressure control is
provided with a locking plate, which
ensures that the range setting is locked.
For safety reasons it is often desirable to
seal reset controls. This can be done by
using a DIN-standardized sealing screw,
see fig. 64. The sealing screw must be
ordered separately.
Fig. 64
Combined high and low
pressure control type KP
15 and 15A
Fig. 63
Fig. 65
1. low pressure setting spindle, LP
2. differential setting spindle, LP
3. main arm
5. high pressure setting spindle, HP
18. locking plate
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 29
With maximum reset
It has been possible to work out, practically,
the reset function for all KP controls with
reset, so that a control will start operating
together with the change-over. The setting of
KP 15 and 15A with maximum reset follows
the same procedure as described in the
section concerning controls without reset.
When the compressor is cut-out because of
too high a condensing pressure, the resetting
of controls with maximum reset cannot take
place until the pressure has fallen to approx.
4 bar below the cut-out pressure setting on
the high pressure scale. Reset can be
performed only by actuating the maximum
reset knob manually. See fig. 67.
KP pressure controls
KP 15 and 15A are combined low and high
pressure controls having setting facilities both
on low and high pressure sides. As shown in
fig. 65, the functions of the low pressure side
and the high pressure side are mechanically
separated. This means that both the low
pressure side and the high pressure side are
able to cut-in and cut-out the compressor,
independently.
For safety reasons, the high pressure side is
provided with an internal scale, while the low
pressure side is provided with an external
scale. KP 15 and 15A exist in the following
designs:
1) without reset, fig. 66
2) with maximum reset, fig. 67
3) with minimum/maximum reset, fig. 68
Fig. 68
High pressure setting
The condensing pressure (~ STOP pressure)
is determined according to the required
working conditioning of the plant. This
pressure is set by means of the high pressure
spindle on the internal HP scale of the control.
The cut-in value (START pressure) is then
derived from the expression:
START = STOP minus DIFF
where DIFF is the fixed differential of approx.
4 bar.
Low pressure setting
Pressure controls with automatic reset LP:
Set the LP start pressure on the CUT-IN
scale (range scale).
One rotation of the low pressure spindle
0.7 bar.
Set the LP differential so the DIFF scale.
One rotation of the differential spindle
0.15 bar.
The LP stop pressure is the LP start pressure
minus the differential.
Note! The LP stop pressure must lie above
absolute vacuum (p = 1 bar)!
If with low stop pressure the refrigeration
compressor will not stop, check to ensure that
the differential value has not been set too
high!
Pressure controls with automatic reset HP:
Set the HP pressure on the CUT-OUT scale.
One rotation of the HP spindle 2.3 bar.
Set the HP differential on the DIFF scale.
One rotation of the differential spindle
0.28 bar. The HP start pressure is the HP
stop pressure minus the differential.
Pressure controls with manual reset
Set the stop pressure on CUT-OUT scale
(range scale).
Low pressure controls can be manually reset
when the pressure is equal to the stop
pressure plus the differential.
High pressure controls can be manually reset
when the pressure is equal to the stop
pressure plus the differential.
Start and stop pressures for both the LP and
HP sides of the system should always be
checked with an accurate pressure gauge.
Combined high and low
pressure control type KP
15 and 15A
(cont.)
Fig. 66
Fig. 67
Without reset
When the compressor is running, terminals A-
C are connected. See fig. 65. If the pressure
on the HP side exceeds the cut out pressure
on the high pressure spindle, or if the suction
pressure on the LP side falls below the cut-
out pressure setting, in contact change-over
occurs, so cutting the current to the
compressor motor is cut-out. The compressor
motor will restart when the conditions have
returned to normal, i.e:
1) either when the suction pressure has
increased by a value equal to or higher
than the differential setting
2) or when the pressure on the condenser
side has fallen by a value equal to or
higher than the fixed differential of the
control, approx. 4 bar.
As mentioned previously on combined high
and low pressure controls the two pressure
ranges are set separately.
30 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
KP pressure controls
With minimum/maximum reset
On KP 15 and 15A with minimum reset the
low pressure scale is calibrated in a way
corresponding to KP 1 and 1A with minimum
reset. The STOP value set on the low
pressure scale corresponds to change-over
at falling pressures. The cut-out value
required on the low pressure side should be
set by means of the low pressure spindle.
Cutting-in the compressor motor, which has
been stopped because of too low a suction
pressure, cannot take place until the
minimum reset knob is actuated, see fig. 68,
and not until the pressure has increased by a
value corresponding to the fixed differential of
0.7 bar. Setting and restarting after stop on
the high pressure side are described in the
section concerning KP 15 and 15A with
maximum reset.
KP pressure controls with
LP + HP signal
On variants of KP 15, KP 15A and 17W with
both LP and HP signal contacts it is possible
to take out two separate signals. The signal
taken will depend on whether the pressure
control is to cut out the compressor because
of too low a suction pressure or too high a
discharge pressure.
On HP signal contact mk. D the current
marking is 50 VA 380 V a.c. / 12 W 220 V d.c.
ON LP signal contact mk. B the current
marking is 16 A 380 V a.c. / 12 W 220 V d.c.
(see fig. 71).
Fig. 70 Fig. 71
KP pressure controls with
convertible automatic/
manual reset
KP 15 pressure controls with manual reset
are available with convertible automatic/
manual reset. Convertible automatic/manual
reset means that when the unit is installed it
is possible to choose between manual reset
mode or automatic reset mode on both high
pressure and low pressure sides. This facility
is also advantageous when servicing: the
installer can allow the pressure control to
operate with automatic reset while servicing
the system.
Changeover from one reset function to the
other can be performed by turning the
eccentric (A) with a screwdriver in the slot
provided (fig. 72).
This function increases flexibility in both
stocking and application, in that the pressure
control can be set for four different reset
functions and thus four different types of
application, see table below.
Fig. 72
Low
Manual reset Automatic reset Automatic reset Manual reset
Pressure
High
Manual reset Manual reset Automatic reset Automatic reset
Pressure
et. al.
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 31
In fig. 73 is a table of the KP control
programme with technical data.
KP pressure controls
KP pressure control
program
Fig. 73
32 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
RT pressure controls
Pressure control designs The pressure controls are available in three
designs:
1. Low pressure controls which makes the
circuit when the pressure on the suction
side of the system exceeds a preset value,
and breaks it when the pressure falls to a
value below the differential setting.
The following types are low-pressure
controls: RT 1, 1A, 110, 112, 113, 116,
121 and 200.
2. High pressure controls which breaks the
circuit when the pressure on the high-
pressure side of the system exceeds a
preset value, and makes the circuit when
the pressure falls to a value below the
differential setting.
The following types are high-pressure
controls: RT 5, 5A, 6W, 6B, 6S, 6AW,
6AB, 6AS, 117 and 118.
The high pressure controls are, normally,
supplied without a knob. Instead the main
spindle is covered by a protective cap.
Setting is only possible when the
protective cap has been removed.
Setting
By turning the knob, the minimum pressure at
which the switch is to operate (break or make
the circuit) is set. This value can be read on
the main scale of the control.
Next, the differential is set by rotating the
differential adjusting nut. Maximum actuating
pressure = minimum actuating pressure +
differential setting.
The diagram, fig. 74, shows the number on
the differential scale which corresponds to
the differential required. The diagram applies
to switch 17-4030.
Fig. 74
Fig. 75 Fig. 76
Example:
Setting type RT 1 at 7 will result in a
differential of approx. 1.2 bar, while the same
setting on type RT 5A will result in a
differential of approx. 3.0 bar.
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 33
RT pressure controls
3. Pressure controls with reset
In those cases where the pressure control is
used as a safety cut-out, reset must not be
automatic. Therefore, RT 1 and 1A as well as
RT 5 and 5A are available with a reset but so
that reset can only be effected manually after
the pressure has become normal.
The low pressure controls RT 1 and 1A are
available in designs with minimum reset (fig.
77) which cut-out when the pressure has
fallen to a preset value. Manual reset (41)
cannot take place until the pressure in the
bellows system has increased to a value
corresponding to the setting + differential.
The factory locked differential adjusting nut
(19) has been shortened at the top so that it
cannot actuate the arm of the switch when
the pressure increases. When the pressure
falls, the guiding knob (17) actuates the arm
of the switch in the usual way, and causes a
contact change-over from 1-4 to 1-2.
The scale is calibrated in such a way that the
value set on the scale corresponds to contact
change-over on decreases in the pressure.
Fig. 77
Fig. 78
The high pressure controls RT 5 and 5A are
available in designs with maximum reset (fig.
78) which cut-out when the pressure has
increased to a value corresponding to the
pressure setting. Manual reset (41) cannot be
effected until the pressure has fallen to a
value which corresponds to the pressure
setting minus the differential. The factory
locked differential adjusting nut (19) is in this
case used as a guiding knob.
When the pressure increases, the differential
adjusting nut (19) actuates the arm.of the
switch and causes a contact change-over
from 1-2 to 1-4.
The scale is calibrated in such a way that the
value set on the scale corresponds to contact
change-over on increases in the pressure,
which is quite the opposite of the usual RT
controls.
Refrigerants All the pressure controls can be used for all
fluorinated refrigerants. The RT 1A and 5A
designs can also be used for ammonia (NH
3
).
34 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Safety pressure controls of TV-design
Today, in West Germany, the TV
(Technische berwachungs Verein) exercises
authority over refrigeration plants. The TV
deals especially with safety and, therefore,
lays down the following regulations (which
came into force 1st December 1974).
A. Accident prevention measures on
refrigeration plants (VBG 20).
B. Instructions and procedures for accident
prevention on refrigeration plants (VBG 20).
TV-design Refrigeration plant in operation in Germany
affected by TVs regulations must be
converted and equipped with safety controls
complying with DIN 32733 requirements. This
means that manufacturers exporting to
Germany will have to supply refrigeration
plants able to obtain TV approval.
Of special interest to Danfoss are TV
requirements on high pressure controls with
fail-safe bellows elements.
Meeting DIN 32733
requirements
TV safety pressure controls with fail-safe
functions are covered by three types of
control.
- DWK - Druckwchter (pressure control)
- DBK - Druckbegrenzer (pressure limiter)
- SDBK - Sicherheitsdruckbegrenzer (safety
pressure limiter)
These pressure controls must be able to cut-
out the refrigeration compressor, when the
cut-out pressure is exceeded.
A parallel requirement is, that the pressure
control must cut-out the refrigeration
compressor if the bellows ruptures.
A practical solution of this problem has been
found by providing the pressure controls with
a bellows element consisting of an external
and an internal bellows. The space between
the bellows is evacuated, so that the
pressure control will cut-out the compressor,
if one of the bellows ruptures.
The cross-sectional drawings show some
TV approved controls.
Please, note the bellows elements with the
two bellows.
Fig. 79 Fig. 81
Fig. 80 Fig. 82
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 35
Regulation Mechanical
range differential
Pressure DIN
Type
2
) Reset
Connection approvals
P
bar
RT 36 B
0 2.5 fixed 0.2 1/4 in. / 6 mm flare manual DBK 4B04091
RT 36S
RT 30AW fixed 0.7 automatic DWK 4B03991
RT 30AB 110 1/2 BSP ext.
fixed 0.5 manual DWK 4B03891
RT 30 AS
RT 6W 525 fixed 3 automatic DWK 4B03791
RT 6B 1/4 in. / 6 mm flare
1028 fixed 1.5 manual DBK 4B03691
RT 6S
RT 6AW 525 fixed 3 automatic DWK 4B03791
RT 6AB
1028 fixed 1.5 manual DBK 4B03691
RT 6AS
1
) Meets the requirements in VBG 20 dealing with safety equipment and excess pressures.
2
) W = Wchter (pressure control, B= Begrenzer (pressure control with ext. reset), S = Sicherheitsdruckbegrenzer (pressure control with int. reset):
A bellows rupture will cause the refrigeration plant compressor to stop.
3/8 BSP ext. +
6.5 / 10 mm
weld nipple
Safety pressure controls of TV-design
KP pressure controls with DIN 32733 approval
1
)
Low pressure (LP) High pressure (HP) Reset
Regulating Differential Regula- Differential High
range ting press. Contact DIN
Pressure Type
2
)
system approvals
range
p p
bar bar bar bar HP
High KP7W 828 410 aut. SPDT DWK 4B00194
High KP7B 828 fixed 4 man. SPDT DBK 4B00394
High KP7S 828 fixed 4 man. SPDT DBK 4B00394
KP7BS 828 fixed 4 man. SPST DBK/DBK 4B00294
KP7ABS
3
) 828 fixed 4 man. SPST DBK/DBK 4B00294
SPDT +
Dual KP17W 0.27.5 0.74 828 fixed 4 aut. HP and HD DWK 4B00594
signal
KP17W 0.27.5 0.74 828 fixed 4 aut. SPDT DWK 4B00594
KP17B 0.27.5 0.74 828 fixed 4 man. SPDT DBK 4B00494
1
) Meets the requirements in VBG 20 dealing with safety equipment and excess pressures.
2
) W = Wchter (pressure control, B= Begrenzer (pressure control with ext. reset), S = Sicherheitsdruckbegrenzer (pressure control with int. reset):
A bellows rupture will cause the refrigeration plant compressor to stop. A rupture of the outer bellows wiill cause the stop pressure to fall approx. 3 bar under the set value.
3
) KP 7 ABS can also be used for R 717 (NH3).
RT pressure controls with DIN 32733 approval
1
)
The three designs covering DIN 32733
requirement are as follows:
DWK - pressure control
This type of pressure control is used for
regulation. The pressure control resets itself,
after having cut-out when the pressure has
fallen by a value equal to the differential.
DBK - pressure limiter
The pressure limiter is for use as a safety
switch. It operates if the pressure increases
to a value higher than the normal working
pressure.
DBK pressure controls are provided with
external reset and, therefore, they can be
reset only when the pressure has fallen by a
value equal to the fixed differential.
SDB - safety pressure limiter
The safety pressure limiter is also for use as
a safety switch, just like the DBK types.
The SDBK pressure limiters have internal
reset, meaning that the control cannot be
reset until the cover has been removed.
TV approved pressure controls
Danfoss market the program of pressure
controls shown in the table. All the controls
are TV approved.
The controls are suitable for the following
categories of refrigeration plants:
- Refrigeration plants with fluorinated
refrigerants
- Refrigeration plants with ammonia
- Refrigeration plants with turbo refrigeration
compressors.
36 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Differential pressure controls
A differential pressure control is a pressure
controlled electrical switch which makes and
breaks the circuit depending on the difference
between the pressures in the two opposite
acting bellows elements.
Within the operating range, the functioning of
the pressure control only depends on the said
pressure difference, where as it is independent
of the absolute pressures which act on the
bellows. The differential pressure control is
used for protecting refrigeration compressors
with forced lubrication, where under any
operating conditions the oil pressure has to be
kept higher than the suction pressure or the
crankcase pressure. Furthermore, the
differential pressure control can be used for the
protection of filters, pumps, etc.
Fig. 83
Differential control
terminology
Differential range
The difference in pressure between the OIL
and the LP connections within which the
differential pressure control can be set to
operate.
Scale reading
The difference that exists between the OIL
and LP pressures at the moment the
contact system changes over when the main
spindle travels down. The downward travel
corresponds to falling differential pressure.
Function range
The pressure range on the LP connection
within which the differential pressure control
is able to operate.
3. LP connection
4. LP bellows element
5. Setting disc
12. Main spring
15. Main spindle
17. Upper guiding Knob
18. Contact system
20. Lower guiding Knob
24. HP bellows element
34. HP connection
Contact differential
The pressure rise in excess of the set
pressure differential which is necessary to
make the contact system change from cut in
to cut out. See the example in the section
Setting on page 36.
Release time
The time the differential pressure control
allows the compressor to run with too low an
oil pressure. See the example in the section
Setting on page 36.
MP differential pressure
control
Types MP 54, 55 and 55A are for use as
safety controls on pressure-lubricated
refrigeration compressors. The units will stop
a compressor after a certain time in the event
of an oil pressure failure. The MP 54 and 55
are for refrigeration plants with fluorinated
refrigerants like R 12, R 22, R 500 and R
502. The MP 55A is for refrigeration plants
with
R 717(NH
3
) and can also be used with
fluorinated refrigerants. Types MP 54, 55 and
55A have built-in thermal time relay with a
fixed release time.
Fig. 84
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 37
Differential pressure controls
Fitting
The differential pressure control can be
installed in any position. It can be mounted
direct on a wall or on the compressor
installation panel by using the fitting holes in
the back of the unit. The unit can also be
installed on a bracket. See Accessories.
Bellows element OIL is connected to the
lubrication system at the point where the
required minimum oil pressure must be
maintained during operation. This will
normally be at the outlet side of the pump or
at the discharge from the crankshaft
lubrication system.
Bellows element LP is connected to the
compressor crankcase. Connection must not
be made to the suction manifold or a similar
position where the pressure can vary from
the pressure in the crankcase because of
flow resistance.
The connection must be made in such a way
that the line to the pressure control cannot be
shut off.
On R 717(NH
3
) refrigeration installations and
out of consideration for the oil-ammonia
mixture viscosity at ambient temperatures
lower than approx. +15C the inside diameter
of the connection tube must be at least 4 mm.
The weld connection on the MP 55A is
designed for 04/06 mm steel tube.
Fig. 85
The wiring diagram printed in the cover of the
unit shows how the electrical connections are
to be made. See fig. 86. Connection terminal
S need not necessarily be connected to
obtain correct function. Terminal S is for the
connection of a signal lamp which will light up
when the time relay cuts out the compressor
because of an oil pressure failure. If
indication of normal compressor operation is
required, a signal lamp can be connected in
parallel with the motor relay.
Electrical connections If there is a requirement for a heating element
in the crank case oil sump to be cut in during
compressor standstill periods, an auxiliary
contact in the motor relay or a KP 98 may be
used.
As can be seen in fig. 87, the unit contains
two separate electrical circuits. One of the
advantages of this is that the differential
pressure control does not need to be the last
link in the electrical circuit of the plant. The
control unit (pressure control, thermostat) can
be anywhere in the control circuit, before or
after the differential pressure control.
Fig. 86 Fig. 87
38 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Differential pressure controls
Setting MP 54 has a fixed setting of 0.7 bar differential
pressure and cannot be re-adjusted.
MP 55 and 55A
By inserting a pressure gauge, as shown in
fig. 88, the lubricating oil pressure (p
1
) and the
pressure in the crankcase (p
2
) can be read off.
The difference between these pressures is the
oil pressure available for the lubrication
system.
The least allowable oil pressure is set by
using the setting disc (3). Turning it upwards
decreases pressure and vice versa.
NB.: On starting, the oil pressure must rise at
least 0.2 bar over the set value.
Example
Types MP 55 and 55A are set at 3 bar = set
value + fixed contact differential.
If the oil pressure does not reach 3.2 bar
within the release time, current to the coil of
the motor starter is cut off and the
compressor stops.
Fig. 88
Function
If during start the oil fails to reach the set
value, or if during operation it falls below the
set value, the compressor will stop after the
release time has expired. The reset button (4)
can be used to cut in the compressor again.
Restarting is possible about 2 minutes after
cut out but should not be attempted before
the reason for the oil pressure failure has
been found and the fault corrected.
After restarting the compressor a check
should be made to see that the differential
pressure control is operating according to
requirements.
This check can be carried out by pressing the
test device (5).
When the device is pressed upwards and
held in that position the compressor must
stop after the expiration of the release time
given on the time relay.
The compressor can then be started as
described above.
Fig. 89
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 39
Differential pressure controls
RT differential pressure
controls
RT differential pressure controls can be
delivered in two different designs: RT 260A
and RT 262A.
Fig. 90 shows the principle of a RT
differential pressure control. The bellows (1)
and (2) are connected to the LP connection,
which is connected to the lower pressure
(suction pressure), and the HP connection,
which is connected to the higher pressure (oil
pressure), respectively. The range spring (3)
can be set for different differential pressures,
by rotating the setting disc (4).
If the pressure differential between the higher
and the lower pressures is reduced, the
spindle (5) moves downwards and thus
actuates the contact arm of the switch
through the upper guiding knob.
On increase in the pressure differential
between the HP and LP bellows, the switch is
actuated to change over when the pressure
differential has increased to the setting plus
the fixed contact differential setting.
Setting
The setting disc (4) can be turned with a
screwdriver so that the differential pressure
control can be set to make the switch
change-over (break or make) at different
required differential pressures. The setting
can be read on the main scale.
Contact position. Terminals 1-4
If the differential pressure falls below the
setting, the switch breaks the circuit. The
switch makes the circuit again when the
differential pressure has increased to the
setting + the fixed contact differential.
Example
Differential pressure setting = 2 bar (RT
260A). When the pressure falls below the
setting, the switch breaks the circuit.
Differential pressure setting + contact
differential = 2 + 0.3 = 2.3 bar.
At this value the switch makes the circuit
again.
Contact position. Terminals 1-2
If the differential pressure falls below the
setting, the switch makes the circuit. The
switch breaks the circuit again when the
differential pressure has increased to the
setting + the fixed contact differential.
Example
Differential pressure setting = 2 bar
(RT 260A). When the pressure falls below the
setting, the switch makes the circuit.
Differential pressure setting + contact
differential = 2 + 0.3 = 2.3 bar.
At this value the switch breaks the circuit.
Fig. 90
1. LP bellow element
2. HP bellow element
3. Main spring
4. Setting disc
5. Main spindle
6. Upper guiding knob
7. Contact arm
Fig. 91
40 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Dead zone pressure controls
The pressure controls type RT L are controls
with an adjust able dead zone, because they
are equipped with a change-over switch,
code No. 17-4032.
Design
In principle, the RT L pressure controls are
built up like the other RT controls, but in order
to comply with the dead zone function, the
switch has two contact arms which engage
two guiding knobs, see fig. 92.
Setting, fig. 92 and table below.
The set scale value corresponds to the break
value of contacts 1-4. The dead zone
required is found in the diagram for the
control in question. On the lower scale of the
diagram it is then possible to read the
position to which the knob is to be turned.
Max. neutral
Nature of controls Type Range Differential
zone
RT 1 AL 0.8 +5 bar fixed 0.2 bar 0.2 0.9 bar
Low pressure controls
RT 200 L 0.2 6 bar fixed 0.25 bar 0.25 0.7 bar
RT 5 AL 4 17 bar fixed 0.35 bar 0.35 1.4 bar
High pressure control
RT 117 L 10 30 bar fixed 1.0 bar 1.5 3.5 bar
Fig. 92
RT L pressure control range
RT L controls can be obtained in different
thermostat and pressure control designs as
shown in the above table. They are also
available with gold plated contacts.
Dead zone
The interval of the controlled variable where
the control unit is idle is called the dead zone.
From the table it can be seen that the dead
zone is the interval without a make function.
Mechanical differential
The interval between the values of the
controlled variable which makes the control
unit move is called the mechanical
differential.
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 41
Safety cut-out and liquid level control type RT 280A
RT 280A used as safety
cut-out
RT 280A is the designation of a safety cut-out
which has been designed primarily for use as
a protection against too high a liquid level
e.g. in separators or pump receivers in
refrigeration plants with pump circulation.
The regulation principle is anon/off control
based on the thermal conduction difference
between the liquid and vapour phases of a
refrigerant.
In principle, the RT 280A is-built like a
differential pressure control, but the lower
bellows system is here in the form of a
thermal element with the sensor surrounded
by an electric heater.
When RT 280A is used as a safety cut-out,
the thermal bulb is mounted in the tank side
at the desired maximum level, fig. 95.
The upper bellows system, which is a
pressure element, is connected in such a way
that the reference pressure corresponds to
the pressure in the tank. The control switch is
connected to the compressor motor starter so
that the compressor will be cut-out as soon
as the sensor is surrounded by the liquid in
the tank, which is at maximum level.
When the level drops again, more heat is
transferred from the electric heater to the
sensor, and the compressor is cut in again.
Fig. 95
Fig. 94
42 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Safety cut-out and liquid level control type RT 280A
RT 280A/RT 281A used as
liquid level control
When RT 280A or RT 281A is used as a
liquid level control, the switch has to send its
impulses to a solenoid valve in the liquid inlet
which then opens and closes to the liquid
supply accordingly.
RT 280A and RT 281A can also be used as a
liquid level control in cases where a level
differential of 40 mm can be permitted, fig.
96.
Among other factors, the liquid level
differential depends on the design of the
system and the refrigerant rate of level
variation. The differential will, normally, be
considerably smaller.
Technical data RT 280A has the following technical data:
Refrigerants
R 12, R 22, R 502 and R 717(NH
3
)
Temperature range RT 280A RT 281A
R 12: 50C to 10C
R 22 and R 717(NH3):50C to 0C 30/20
R 502: 65C to 5C 30/20
Power element
Adsorption charge
2 m capillary tube
Maximum permissible bulb temperature
+60C
Thermal bulb
Electric heater for 24 V d.c. and a.c. (10 W).
The electric heater must be constantly cut-in
when the system is operating. The bulb is
equipped with a 1.5 m cable.
Type of switch
A single-pole change-over switch (SPDT)
17-4030.
Fig. 96
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 43
Examples of application
Examples of the application of RT
thermostats and pressure controls.
Temperature control of
containers
Fig. 97
In the temperature control of containers for
refrigeration and freezing purposes, RT
thermostats are often used for regulation and
alarm.
1. Freezing
When a container is used for freezing, the
freezing compartment temperature is
controlled by RT 7 (25C to +15C) e.g.
20C to 17C. Another RT 7 thermostat is
used for actuating the alarm at too high a
temperature e.g. 14C. The alarm may be
by signal lamp. (Connection of thermostats is
shown in fig. 98).
2. Refrigeration
For refrigeration for example at +2 C to +5C,
an RT 14L thermostat with a dead zone is
used for temperature control (see fig. 99). At
too high a temperature the compressor
(terminals 1-4 closed) is cut-in. If the ambient
temperature is lower than the temperature
required in the container, it may be necessary
to cut-in the electric heaters (terminals 1-2
closed) to maintain the temperature required
for the refrigerated compartment.
Another RT 14L is used as a safety
thermostat, giving a signal if the temperature
is higher or lower than the interval required.
The compressor is protected on the high
pressure side by an RT 5 pressure control
which cuts out the compressor at excessive
pressure. An RT 1 pressure control is used
on the suction side, this control breaking the
circuit to the compressor motor at too low a
suction pressure.
Fig. 98
Fig. 99
44 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
RT 140L used in
ventilation systems
Fig. 100 shows a ventilation system in which
RT 140L is used as control unit for two
solenoid valves for the heating and cooling
surfaces in the ventilation duct.
Operating principle (fig. 101)
The regulating thermostat type RT 140L (3)
makes the circuit at too high a temperature
by closing contacts 1-4 so that the solenoid
valve (4) to the cooling surface (water)
opens. For a suitable temperature interval
(max. 5.5C) the thermostat switch remains in
the neutral position, and none of the solenoid
valves are actuated. At too low a temperature
the contacts 1-2 are closed so that the
solenoid valve (5) to the heating surface
(water) is actuated.
The safety thermostat type RT 140 (2),
normally, remains with the contacts 1-4
closed. In this position, the motor starter (1) is
cut-in, with the actuator motor (6) turned to
one extreme position, resulting in the damper
being open. If the temperature falls below the
thermostat setting, contacts 2-1 are closed,
and the motor starter is cut-out. At the same
time, the actuator motor turns to the opposite
extreme position and the air damper is
closed.
Examples of application
Fig. 100
Fig. 101
NOTE: Fig. 101 does not show how the motor
starter is cut out.
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 45
Examples of application
RT 280A and RT 262A
used as safety equipment
in a pump recirculatory re-
frigeration plant
In large cold stores, a refrigeration plant with
a separator is often used. The normal liquid
level in the separator is controlled by the
electronic liquid level control type 38E. RT
280A is used as a protection against too high
a liquid level. RT 280A breaks the circuit to
the compressor when the sensor is
surrounded by liquid.
It is necessary to maintain a fixed minimum
liquid level in the separator to protect the
circulation pump against cavitation. If
cavitation occurs, the circulation pump should
be stopped as soon as possible.
Fig. 102 shows a section of a piping layout
diagram for a pump system with two pumps,
one of which is used as a spare.
The differential pressure control RT 262A is,
in this case, installed for use as a safety cut-
out for the circulation pump and is connected
to its suction and high pressure sides. RT
262A is very suitable for this application
because of the small differential of the
control, 0.1 bar.
RT 262A may be combined with a timing
relay with manual reset. When the pump is
started, a sufficiently high pressure must be
built-up on the high pressure side in a
suitable time. Failing this, the pump motor is
stopped by the timing relay breaking the
circuit.
Fig. 102
46 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002
Danfoss A/S (RC-CM/sw), 02 - 2002 RF.5X.A1.02 47
48 RF.5X.A1.02 Danfoss A/S (RC-CM/sw), 02 - 2002