Siemens Industry, Inc. MVL661… Series Technical Instructions Document No. 155-400 May 11, 2016 Modulating Refrigerant Valves with Magnetic Actuator Description Control valves with magnetic actuator, for modulating control of refrigerant circuits. Features One valve type for expansion, hot-gas and suction throttle applications. Hermetically sealed towards outside. Selectable control signal interface 0/2...10 Vdc or 0/4...20 mA. High resolution and control accuracy. Precise positioning control and position feedback signal. Short positioning time (less than1 second). Closed when de-energized. Robust and maintenance-free. Five valve sizes with CV (k vs ) values from 0.29 to 13.9 (0.25 to 12). Application The MVL661...Series refrigerant valves are designed for modulating control of refrigerant circuits including chillers and heat pumps. They can be used in expansion, hot-gas and suction throttle applications as well as with all commonly used safety refrigerants (R22, R134a, R227ea, R404A, R407C, R410A, and so on) and R744 (CO 2 ). They are not suitable for flammable refrigerants. Product Numbers See Product Summary. Warning/Caution Notations WARNING: Personal injury or loss of life may occur if you do not follow the procedures as specified. CAUTION: Equipment damage or loss of data may occur if you do not follow the procedures as specified. Technical Instructions MVL661… Modulating Refrigerant Valves Document Number 155-400 Valves with Magnetic Actuator May 11, 2016 Page 2 Product Summary Product Numbers Line Size Inch (mm) C V (k vs ) CV (k vs ) Reduced 1) p max psi (MPa) Q 0 E (kW) Q 0 H (kW) Q 0 D (kW) MVL661.15-0.4 1/2 (15) 0.46 (0.40) 363 (2.5) 47 9.2 1.7 0.29 (0.25) 29 5.7 1.0 MVL661.15-1.0 1/2 (15) 1.2 (1.0) 117 23 4.2 0.73 (0.63) 74 14 2.6 MVL661.20-2.5 3/4 (20) 2.9 (2.5) 293 57 10 1.8 (1.6) 187 37 6.6 MVL661.25-6.3 1 (25) 7.3 (6.3) 737 144 26 4.6 (4) 468 92 17 MVL661.32-12 1-1/4 (32) 13.9 (12) 29 (0.2) 2) 2) 50 9.2 (8) 2) 2) 33 1) 63% of C V (k vs ), see CV (k vs ) Reduction, page 4. 2) MVL661.32-12.0 is only approved for suction throttle applications k vs Nominal flow rate, in m 3 /h, of refrigerant through the fully open valve (H 100 ) at a differential pressure of 100 kPa (1 bar) to VDI 2173 C V Nominal flow rate, in gpm, of refrigerant through the fully open valve (H 100 ) at a differential pressure of 1 psi. Q 0 E Refrigeration capacity in expansion applications Q 0 H Refrigeration capacity in hot-gas bypass applications Q 0 D Refrigeration capacity in suction throttle applications and p = 7 psi (0.5 bar) Q 0 With R407C at t 0 = 32°F (0°C), t c = 104°F (40°C). The pressure drop across the evaporator and condenser is assumed to be 4.35 psi (0.3 bar) each, and 23 psi (1.6 bar) upstream of the evaporator. The capacities specified are based on superheating by 6K and sub-cooling by 2K. The refrigeration capacity for various refrigerants and operating conditions can be calculated for the 3 types of applications using Table 4 through Table 9. For accurate valve sizing, Siemens Industry, Inc. recommends the valve selection program Refrigeration VASP. Ordering Replacement Parts Valve body and magnetic actuator form one integral unit and cannot be separated. Example: Product Number Description Quantity MVL661.15-0.4 Refrigerant valve 1 If the valve’s electronics become faulty, the entire electronics housing must be replaced. Order product number ASR61. MVL661… Modulating Refrigerant Valves Technical Instructions Valves with Magnetic Actuator Document Number 155-400 May 11, 2016 Page 3 Operator controls and indicators in the electronics housing 1 Connection terminals 2 LED for indication of operating state 3 Minimal stroke setting potentiometer Rv 4 Auto-calibration 5 DIP switches for mode control DIP Switch Configurations Table 1. DIP Switch Configurations. Switch Function ON/OFF Description Positioning signal Y ON Current (mA) OFF Voltage (V) 1) Positioning range Y and U ON 2 to 10 Vdc, 4 to 20 mA OFF 0 to 10 Vdc, 0 to 20 mA 1) Position feedback U ON Current (mA) OFF Voltage (V) 1) Nominal flow rate C V (k vs ) ON 63% OFF 100% 1) 1) Factory setting Technical/ Mechanical Design Features and Benefits Four selectable control signals. DIP switch to reduce the C V (k vs ) value to 63% of the nominal value. Potentiometer for adjustment of minimum stroke for suction throttle applications. Automatic stroke calibration. Forced control input for “Valve closed” or “Valve fully open”. LED for indicating the operating state. Control The MVL661… Series valve can be driven by Siemens or third-party controllers that deliver a 0 to 10 Vdc/2 to10 Vdc, 0 to 20 mA/4 to 20 mA control signal. For optimum control performance, Siemens Industry, Inc. recommends a 4-wire connection between controller and valve. The valve stroke is proportional to the control signal. CAUTION: You must use a four-wire connection with Vdc power supply. Spring return action If the positioning signal is interrupted, or in the event of a power failure, the valve’s return spring will automatically close control path A AB. Technical Instructions MVL661… Modulating Refrigerant Valves Document Number 155-400 Valves with Magnetic Actuator May 11, 2016 Page 4 C V (K VS ) reduction For C V (k vs ) reduction (DIP switch 4 in position ON), the stroke is limited to 63% mechanical stroke. 63% of full stroke then corresponds to an input/output signal of 10V. If, in addition, the stroke is limited to 80%, for example, the minimum stroke is 0.63 × 0.8 = 0.50 of full stroke. Minimum stroke setting With a suction throttle valve, it is essential that a minimum stroke limit be maintained to ensure compressor cooling and efficient oil return. This can be achieved with a re-injection valve, a bypass line across the valve, or a guaranteed minimum opening of the valve. The minimum stroke can be defined using the controller and control signal Y, or it can be set directly with potentiometer Rv. The factory setting is zero (mechanical stop in counterclockwise direction, CCW). The minimum stroke can be set by turning the potentiometer clockwise (CW) to a maximum of 80% C V (k vs ). CAUTION: Do not, under any circumstances, use potentiometer Rv to limit the stroke on expansion applications. The valve must be able to fully close. Forced control input ZC MVL661… Modulating Refrigerant Valves Technical Instructions Valves with Magnetic Actuator Document Number 155-400 May 11, 2016 Page 5 Signal priority 1. Forced control signal ZC 2. Signal input Y and/or minimum .stroke setting with potentiometer Rv possible. Calibration The printed circuit board of the MVL661… Series has a slot to facilitate calibration. To calibrate, insert a screwdriver in the slot so that the contacts inside are connected. As a result, the valve will first be fully closed and then fully opened. Calibration matches the electronics to the valve mechanism. During calibration, the green LED flashes for about 10 seconds; see Table 2. Figure 1. Calibration Slot. NOTE: MVL661..-.. Refrigerant Valves are supplied fully calibrated. When is calibration required? Execute a calibration after replacing the electronics, when the red LED is lit or flashing or when the valve is leaking (at seat). Table 2. Indication of Operating State. LED Indication Operating State, Function Remarks, Troubleshooting Green Lit Control mode Automatic operation; everything is OK. Flashing Calibration in progress Wait until calibration is finished (green or red LED will be lit). Red Lit Calibration error Internal error Recalibrate (operate button in opening 1×). Replace electronics module. Flashing Main fault Check electric main network (outside the frequency or voltage range). Both Dark No power supply Electronics faulty Check electric main network, check wiring Replace electronics module. Technical Instructions MVL661… Modulating Refrigerant Valves Document Number 155-400 Valves with Magnetic Actuator May 11, 2016 Page 6 Connection type 4-wire connection 3-wire connection NOTE: Four-wire connections are always preferred. Product Number (VA) (W) (A) Wire Gauge (AWG) 14 12 10 Max. Cable Length Ft (m) MVL661..-.. 22 12 1.6 to 4A 213 (65) 361 (110) 525 (160) MVL661..-.. 22 12 1.6 to 4A 65 (20) 115 (35) 164 (50) S NA = Nominal apparent power for selecting the transformer. P med = Typical power consumption. I F = Required slow fuse. L = Max. cable length; with 4-wire connections, the max. permissible length of the separate 14 AWG (1.5 mm 2 ) copper positioning signal wire is 656 ft (200 m). 1) All information at 24 Vac. 2) With 10 AWG (4 mm 2 ) electrical wiring reduce wiring cross-section for connection inside valve to 12 AWG (2.5 mm 2) . Sizing For straightforward valve sizing, see Application Examples, beginning on page 12 for the relevant application. For accurate valve sizing, Siemens Industry, Inc. recommends using the valve sizing software Refrigeration VASP. NOTE: The refrigeration capacity Q 0 is calculated by multiplying the mass flow by the specific enthalpy differential found in the h, log p-chart for the relevant refrigerant. To help determine the refrigeration capacity more easily, see the selection chart provided for each application. With direct or indirect hot-gas bypass applications, the enthalpy differential of Q c (the condenser capacity) must also be taken into account when calculating the refrigeration capacity. If the evaporating and/or condensing temperatures are between the values shown in the tables, the refrigeration capacity can be determined with reasonable accuracy by linear interpolation. See Application Examples, beginning on page 12. At the operating conditions given in the tables, the permissible differential pressure p max across the valve is not considered. If the evaporating temperature is raised by 1K, the refrigeration capacity increases by about 3%. If, by contrast, sub-cooling is increased by 1K, the refrigeration capacity increases by about 1 to 2% (this applies only to sub-cooling down to approximately 8K). Engineering Notes Depending on the application, additional installation instructions may need to be observed and appropriate safety devices (such as pressostats, full motor protection, and so on) fitted. WARNING: To prevent damage to the seal inside the valve insert, the plant must be vented on the low-pressure side following a pressure test (valve port AB), or the valve must be fully open during the pressure test and during venting (power supply connected and positioning signal at maximum or forced opening by G ZC). MVL661… Modulating Refrigerant Valves Technical Instructions Valves with Magnetic Actuator Document Number 155-400 May 11, 2016 Page 7 Expansion application To prevent formation of flash gas on expansion applications, the velocity of the refrigerant in the fluid pipe may not exceed 3.5 ft/s (1 m/s). To assure this, the diameter of the fluid pipe must be greater than the nominal size of the valve, using reducing pieces for making the connections to the valve. 1 = Evaporator 2 = Compressor 3 = Condenser 4 = Expansion valves a) The differential pressure over reduction must be less than half the differential pressure Δp FL . b) The inlet path between diameter reduction and expansion valve inlet Must straight for at least 2 feet (600 mm) May not contain any valves WARNING: A filter/dryer must be mounted upstream of the expansion valve. The valve is not explosion-proof. It is not approved for use with ammonia (NH3, R717). Installation Notes The valve should be mounted and commissioned by a qualified installer. The same applies to the replacement electronics and the configuration of the controller. The refrigerant valves can be mounted in any orientation above horizontal, but upright mounting is preferable. Arrange the pipework so that the valve is not located at a low point in the plant where oil can collect. The pipes should be fitted so that the alignment does not distort the valve connections. Fix the valve body so that that it cannot vibrate. Vibration can lead to burst connection pipes. Before soldering the pipes, ensure that the direction of flow through the valve is correct. The pipes must be soldered with care. To avoid dirt and the formation of scale (oxide), inert gas is recommended for soldering. Technical Instructions MVL661… Modulating Refrigerant Valves Document Number 155-400 Valves with Magnetic Actuator May 11, 2016 Page 8 The flame should be large enough to ensure that the junction heats up quickly and the valve does not get too hot. The flame should be directed away from the valve. During soldering, cool the valve with a wet cloth, for example, to ensure that it does not become too hot. Port B must be sealed off when a 2-port valve (AB A) is used. The valve is supplied complete with mounting instructions 74 319 0232 0. Maintenance The refrigerant valve is maintenance-free. Repair The valve cannot be repaired. Only the electronics (ASR61) can be replaced. If the valve is damaged or not functioning properly after changing the electronics, replace the entire unit. Disposal Do not dispose of the actuator or its electrical and electronic components with domestic waste. The law may require special handling of certain components, or it may make sense from an ecological point of view. NOTE: Observe all applicable local laws. Warranty Observe all application-specific technical data. If you ignore specified limits, Siemens Industry, Inc./CPS Products will not assume any responsibility. Specifications Electrical Power supply (extra low-voltage use only) (SELV, PELV) 24 Vac Operating voltage 24 Vac ± 20% Frequency 45 to 65 Hz Typical power consumption P med 12W Standby <1 W (valve fully closed) Apparent power, S NA 22 VA (for selecting the transformer) Required fuse Slow, 1.6 to 4A 24 Vdc Operating voltage 20 to 30 Vdc Current draw 0.5A/2A (maximum) Signal inputs Control signal Y 0/2 to 10 Vdc, 0/4 to 20 mA, Impedance 0/2 to 10 Vdc 100K ohm/5nF 0/4 to 20 mA 240 ohm/5nF Forced control ZC Input impedance 22K ohm Closing the valve (ZC connected to G0) <1 Vac; <0.8 Vdc Opening the valve (ZC connected to G) >6 Vac; >5 Vdc No function (ZC not wired) Positioning signal Y active Signal outputs Position feedback signal U Voltage 0/2 to 10 Vdc; load resistance > 500 Ω Current 0/4 to 20 mA; load resistance < 500 Ω Stroke measurement Inductive Nonlinearity Accuracy +3% full scale Positioning time Less than 1 second MVL661… Modulating Refrigerant Valves Technical Instructions Valves with Magnetic Actuator Document Number 155-400 May 11, 2016 Page 9 Electrical connections Cable entry glands 3 × ø × 17 mm (for M16) Min. wire size 20 AWG (0.75 mm 2) Max. cable length See Connection Type Functional data of valve Nominal pressure 232 psi (PN 16) Permissible Operating pressure 1) max. 652 psi (45 bar) Max. differential pressure p max 363 psi (25 bar) 1-1/4-inch (DN32): 29 psi (2 bar) Valve characteristic (stroke vs. C V or k V ) Linear (to VDI/VDE2173) Leakage rate (internally across seat) Max. 0.002% C V (K V ) or Max. 1 NI/h gas at p = 58 psi (4 bar) Shut/off function, like solenoid normally closed (NC) function External seal Hermetically sealed (fully welded, no static or dynamic seals) Permissible media Commonly used safety refrigerants (R22, R134a, R227ea, R404A, R407C, R410A, R422D, and so on) and R744 (CO 2 ) Not suitable for flammable refrigerants 2 Not suitable for ammonia (R717). For refrigerants belonging to Fluid group 1, please contact your local Siemens representative. Media temperature -40°F to 248°F (-40°C to 120°C), Max. 284°F (140°C) for 10 min. Stroke resolution H/H 100 1:1000 (H = Stroke) Hysteresis Typically 3% Mode of operation Modulating Position when de-energized Control path A → AB closed Orientation: Upright to horizontal Materials Valve body and parts Steel/CrNi steel Seat/piston CrNi steel/brass Sealing disk PTFE Pipe connections Sleeves Internally soldered, CrNi steel Ambient conditions Temperature Operation -13°F to 131°F (-25°C to 55°C) Transport -13°F to 158°F (-25°C to 70°C) Storage 23°F to 113°F (-5°C to 45°C) Humidity Operation 10 to 100% rh Transport < 95% rh Storage 5 to 95% Miscellaneous Weight See Figure 13. Dimensions See Figure 13. Next >