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Alco general presentation

Alco Controls presented an overview of their refrigeration product portfolio and strategy for new refrigerants. They offer a wide range of products including electric control valves, electronic controllers, thermo-expansion valves, solenoid valves, and pressure controls that are qualified for HFO/HFO blends, CO2, A3, and A2L refrigerants. Their goal is to provide customers with solutions to help them transition to new refrigerants that are compliant with F-gas regulations.

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Alco Controls 2020 General Presentation Marcian Muresan
Agenda • Introduction • Alco History & Offices • New refrigerants: • HFO/HFO blends • A3 • CO2 • A2L • Main products overview • Oil management, Liquid level • EXV, Electrical control valves • Electronics • Pressure Switches • Thermo-Expansion Valves • Product guides & Navigator • Summary
Controls Introduction
An extensive Portfolio and Knowhow allows us to become a Solutions Provider and enable Growth for our Customers Refrigeration Cold Rooms Bakery Evaporator Controllers Enterprise Monitoring HVAC Bakery Food Waste Recycling Cargo Monitoring Cold Rooms Supervisory & Building Management Refrigeration Enterprise Monitoring
Alco Controls F-gas Legislation: Affecting all Parties and Businesses in Refrigeration, Heating and A/C Emerson committed to provide solutions and support for most refrigerant • Refrigerant change is a fact • Refrigerant Strategy often by end-user/OEMs • Speed to change also driven by HFC pricing • Many candidates available • CO2 • A2L and A3 (e.g. Propane) • HFO/HFO blends. • Wholesaler/contractor affected: • CO2: high pressure & higher cost installations • A3: Flammable/safety requirements • HFO and HFO blends: many candidates and new candidates still show up as “being best” Ask Emerson!! Refrigerant choices? Components? Technical support?
ALCO History
Controls since 1925: Expertise & Evolution, Key of Success The world’s first automatic expansion valve for use in refrigeration systems in 1925. ‘Automatic Liquid Controls’ = ALCO
Products 1925 → 2020 • ALCO CONTROLS • MECHANICAL CONTROLS • EMERSON • MECHATRONIC CONTROLS • EMERSON • ELECTRONIC CONTROLS • Thermo-Expansion Valves • Solenoid Valves • Pressure Switches • Filter Driers • Ball Valves • Moisture Indicators • Electrical Control Valves • Electronic Oil Level Management Systems • Electronic Liquid Level Monitoring Systems • Superheat Controllers • Compressor Soft Starters • Universal Driver Modules • Display Case and Coldroom Controllers • Refrigeration Unit Controllers High-quality, reliable mechanical controls for refrigeration and comfort applications Precise control of refrigerant flow and superior compressor protection Superior superheat control and monitoring of system behavior through network communication
Controls Manufacturing Locations 1.Filter driers 2.Vessels TXVs/EXVs Pressure switches Sensoric Electronic & Mechatronic Mechanical & Passive Mech. Kolin Czech Republic
Aachen, Germany Headquarters & Electronic Engineering Kolin, Czech Republic Plant & Mechanical Engineering Belluno, Italy Electronic Engineering Cluj-Napoca, Romania Customer Support Oracle Team Controls: Facilities Europe
New refrigerants Emerson Controls Strategy
F-Gas Regulation
F-Gas ALCO Product Strategy A2L/A3 HFO & HFO Blends CO2 HFC in Europe (equivalent of millions of tones CO2)
Refrigerant Selection By Considering Important Facts A1 Safe refrigerants A1 (CO2) High pressure Refrigerant A2L Mildly flammable refrigerants A3 Flammable refrigerants GWP level reduction by upcoming obligations Concerned Concerned Limit for charge amount Concerned Concerned Suitable for Retrofit Yes No No No System design to withstand the pressure Concerned System design to eliminate potential explosion Concerned Concerned Engineering capability / experience to design system Concerned ? Concerned Installation, startup and service Concerned ? Concerned
HFO & HFO Blends Product Offering
HFO and HFO Blends Products Released since 2016, First in the Market to offer a complete SolutionRefrigerants Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • ThermoTM Expansion Valves • Solenoid Valves • Oil Management Components • Pressure Controls • System Protectors and Moisture Indicators • Ball Valves • Suction Accumulators • Mechanical Pressure Regulators Replacement for Safety classification R450A, R513A, R1234ZE R134a A1 R448A, R449A, R452A (2017) R404A A1
A3 (high flammability) Product Offering
A3 (R290/R1270) Product Portfolio Safe and reliable systems Compliance base on: • PED • ATEX • LVD • Components standards Heat Pumps / Self-Contained Display Cabinets / Brine Cooling Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • Thermo-Expansion Valves • Solenoid Valves • Pressure Controls • System Protectors and Moisture Indicators • Ball Valves Product Series Max. capacity or MWP or size Status EXD-SH1 / 2 - Released EXD-HP1 / 2 - Released EC3-P32 / -P33 - Released Compressor Soft Starter CSS-25U/-32U/-32W - Released EX4-7-…FLR 340 kW Released EXM / L 20 kW Released EXR 25 kW Q3 FY20 Oil Management OM3 - Released PT5N-07P-FLR 27 bar Released PT5N-10P-FLR 27 bar Released PT5N-30P-FLR 60 bar Released Electrical plug and cable assembly ECV-05A EXV-M60-FLR PT4-M60-FLR - Released ESC-EX24VAC ATEX - ESC-EX230VAC ATEX - Solenoid Valves 200RB-FLR 30 kW Released TX3-…FLR 22 kW Released TIH-…FLR 30 kW Released TX7-…FLR 160 kW Released Pressure Switch PS4-…ATEX 35 bar Released ADK-…FLR 7/8" BFK-…FLR 1-1/8" Sight glass MIA…-FLR 1-1/8" Released Released Released Solenoid Valve Coil Product Family Mechatronics Mechanical Controls Controllers Filter Driers Electronic Expansion Valves Pressure Transmitter Electronics Passive Mech. Thermo Expansion Valves
Safety Aspects R290/R1270 Products• Device Classification In Scope of ATEX Internal double QC Use only in non-explosive environment Out of scope of ATEX Internal double QC (…-FLR marking) Solenoid valves Electronic Exp. valves Pressure transmitters Pressure switches Thermo Exp. valves Filter driers Sight glasses Helium leak detector
CO2 Product Offering
Refrigeration (Large/Small Scale) CO2 Product Portfolio Everything your Customer needs Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • Solenoid Valves • Oil Management Components • Pressure Controls • System Protectors • Moisture Indicators • Ball Valves Product Series Capacity (kW) PS (bar) Status Universal driver, software update EXD-U02 - - Released EXD-SH1/2 - 130 Released EXD-HP1/2 - 130 Released CV 4-6 150 kW 130 Released CV 7 540 kW 130 tbd CV 1/2/3 30 kW 150 tbd EX4 27 kW 90 Released EX5-7 540 kW 60 Released PWM Expansion valve CX2 28 kW 90 Released OM5 - 130 Released OM4 - 60 Released LW5-H/L - 130 Released LW4-H/L - 60 Released PT5N-150 - 150 Released PT5N-50M - 75 Released Safety pressure switch, fixed CS3 - 140 Released Pressure switch adjustable CS1 - 70 Released 200RH - 60 Released 200RC - 130 Q3 FY20 Ball valve CVE - 60 Released Sight glass CIA - 60 Released Filter drier FDH - 46 Released Electronic Expansion Valves Solenoid valve Mechanical Controls Passive Mech. Product Family ElectronicsMechatronics Pressure transmitters Controller Oil management Liquid level monitoring
A2L (low flammability) Product Offering
Applications: Air conditioning, close Control and heat pump Stage 1: Products released up to 200 kW (DN≤ 28mm) since July 2018 A2L (R32/R452B/R454B) Product Portfolio Leading the Way for A2L Compliance based on: – PED, IEC 60335-2-40 – LVD – Components standards Stage 2: Products release over 200 kW (DN>28mm) Since October 2019 Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • Thermo-Expansion Valves • Solenoid Valves • Pressure Controls • System Protectors and Moisture Indicators • Ball Valves
A2L (R32/R452B/R454B) Product Portfolio Leading the Way for A2L Product Series Max capacity @R32 kW PS (bar) Status EC3-X32/33 - Released EXD-SH1/2 - Released EXD-HP1/2 - Released EXD-U02 - Released EXM/EXL 34 kW 45 Released EXN 62 kW 45 Released EX4 29 kW 90 Released EX5-6 208 kW 60 Released OM3 46 Released OM4 60 Released Pressure Transmitter PT5N-18/30/50 - 18/30/50 Released Solenoid Valves Coils ESC coils ATEX - - Released Solenoid Valves 200RH 50 kW 60 Released TIH 50 kW 46 Q2 FY20 TX7 270 kW 45 Released T-Series (XB1019) 270 kW 45 Released Pressure Switch PS4 - 45/62 Released MIA 45 Released CIA 60 Released BVE / BVS 45 Released CVE / CVS 60 Released ADK 170 kW 45 Released FDB 120 kW 45 Released BFK 73 kW 46 Released FDH 430 kW 46 Released Product Family - Mechatronics Mechanical Controls PassiveMechanical Filder driers Ball valves Sight glass - - Thermo Expansion Valves Electronic Expansion Valves Controllers - Oil Management Electronics R32 / R452B / R454B (R410A successors) Products are qualified for: • R454A • R454C • R1234ze • R1234yf • R447A • R444B • R455A +
• Conditional product offering for refrigeration applications based on: • Outcome of risk assessment by system manufacturers/installers • Requirement to be fulfil in respect to safety aspect for electrical operating devices Other A2L Refrigerants Product Material Compatibility accomplished A2L Refrigerant Pressure/ Characteristic Low GWP (0-150) Medium flammability (A2L) HFO and blends Medium “R-404A like” “R407C like” Low “R-134a like” High “R410A like” R455A R454C R454A R444B R1234yf R1234ze R452B R32 R545B R447A
Many A1 And A2L Refrigerants Are Mixtures Of Several Single Refrigerants
Oil management Product Information
Electronic Oil/ Liquid Management Systems TraxOil OM3/OM4/OM5, OW4/OW5 and LW4/5 • Active Oil level Balancing and Monitoring with integrated solenoid: • OM3: MOP 46 bar • OM4: MOP 60 bar • OM5: MOP: 130 bar CO2 • Oil Level Monitoring: • OW4: MOP 60 bar • OW5: MOP 100 bar • Liquid Watch • LW4-L / -H120: MWP 60 bar for HFCs and CO2 • LW5-L / -H120: MWP 130 bar for CO2 • Alarm und Status indication (all types) • LED’s indication • SPDT Alarm contact Most reliable solution with already 500.000+ pcs installed OM5 OW4 LW5
Electronic Oil Management Systems –TraxOil OM3/OM4/OM5 and OW4/OW5 • Three Zone Level Control by using a floater and precise Hall-Sensor measurement  no errors caused by foaming or light like optical sensors Applications: • Compressors without Oil pump (OW) • Rack systems • High and Low pressure systems • CO2 Subcritical and Transcritical Applications (depending on system architecture) OMgreen zone yellow zone red zone 60% 40% 25% OW4/5: no Injection
The working principle requires the prism surface to be in good condition and clean, and due to the high temperatures and foaming, and oil aging, fouling and scaling on the surface occurs, driving the device to a possible malfunctioning due to false alarms Technologies: Hall vs Optic, proven reliability
ECV/EXV’s Electric control valves
EX6 EX7EX50,4 kW 1000 kWEX4 EX8EXM/L/N(* ) EX2(*) CV6 CV7CV5CV4CX2 5,6 m3/h1,5 kW Common refrigerants & CO2 sub (exc.*) 45 47 90 60 60 6060 90 130 130 130 130 CO2 Trans & sub PS(b) PS(b) STEPPER UNI-POLAR STEPPER BI-POLAR (R410A, +4ºC / +38ºC) ECV, EXV, Drivers: complete line-up *CV4.5 *CV5.5 *CV6.5 *Intermediate sizes on- going MOPD 90 bar
EX2 / CX2 Series Expansion Valves: longer lifespan • Predominantly for refrigeration applications • EX2 series • MOP 40 bar • MOPD 30 bar • CX2 series applies for CO2 • MOP 90 bar • MOPD 65 bar • PWM operation • >80 MM cycles (15 years) • Leak ratio < 1,3 g/year • Several orifices for capacity match • Integrated strainer • Hermetic design • Positive shut-off • ESC coil: • 24VAC for use with EC2 • 24VAC or 230VAC with third party controllers EX2
EXM / EXL Series Expansion Valves, R290 qualified Unipolar stepper motor driven Electronic Expansion Valves • Hermetic design • Linear modulation, Bi-flow • High MOPD: 40bar in normal flow direction • Removable coils: 12VDC/24VDC • Fine resolution: 500 pulses (half steps) or 250 full steps • Protection class of molded coil is IP65 (acc. EN 60529) excluding the cable end terminals (JST). • Reliability: 225 million pulses at 40 bar differential pressure • EN/IEC 60335-2-40/89 qualification test by VDE approval
Electronic Drivers & Controllers
EXD-U02 driver • NEW Emerson EXD-U02 driver • is the successor of EXD-U01 stepper motor driver, especially designed for the new Emerson CV-valves which uses an analogue input signal to define the valve opening. It enables the operation of CV valves for different type of duties, but also the EX series • Input signal: 4…20mA or 0…10V. • Output: pulses proportional opening/closing • Liquid injection duty • Hot gas bypass • Evaporator pressure regulator • Crankcase pressure regulator • Head pressure regulator • Liquid level control. +
39 Full range of controller for all applications • Controllers for EX valves • Controllers for CV and EX valves EXD-U02 EC3-xxx + ECD-002 EXD-SH1/2 EC2-3xx • Controllers for CX2 and EX valves Superheat controller Superheat controllers and /or temperature control Superheat control by means of a pressure value and one temperature Ec2- 352/372 or by two temperature values EC2- 312/392. Dedicated to the CV and EX series valves for valve actuation function of an analogue input signal Electronic drivers and controllers
Pressure Switches and Thermostats Adjustable / Fixed
Pressure Switches Adjustable Setting Pressure Switch PS4: MOQ 100 pcs CS3: MOQ 60 pcs PS3 CS3PS4CS1PS1 PS2 A2L HFO HFC R290 / R1270 CO2 P P P P P P P P P P P P P P Maximum working pressure (PS) 130 bar62 bar45 bar70 bar31 bar31 bar Protection IP 44 IP 44 IP 33 IP 65 IP 67 IP 65 − − − − − − − − − − − − P Fixed Setting Pressure Switch − − −
CS3 Series Pressure Switch CS3 product series are pressure switches with fixed switch-point settings for R744 applications Features: • Cut-out settings: Range 8/Q: 60-140bar; Range 7/P: 40-70bar • Maximum Working Pressure (PS) 140 bar • Narrow differential (approximately 4-6 bar in micro-switch version) • Contacts are designed as SPDT for control function and alarm/status reporting • Manual reset versions available • TÜV (EN 12263) approved (2 Million Cycles reliability)
Alco Controls Cartridge type Contact: SPST (NC) Contact: SPDT M L1 N P 120 70 100 60 bar 80 110 90 Switch Status Cut-out: 110 ± 10 bar Cut-in: 80 bar ± 20 bar Cut-out: 110 +0 /-6bar Cut-in: 103 +/-3bar Pressure Switch Status Desired cut-out: 110 bar M P Other brands CS3 CS3 Safety Pressure Switch Competitive Advantage: Narrow differential + Better tolerance >> Protects and Reduces idle time of compressor
CS1 The first Adjustable safety pressure controls for CO2 (pressure over 45 bar)CS1 product series are safety pressure controls with adjustable switch-point settings for R744 and R410A applications • Two ranges, 6 and 7 with narrow adjustable differential (4-10 bar) • Maximum Working Pressure (PS) of 70 bar • Contacts are designed as SPDT for control function and alarm/status reporting • 2 million cycles reliability (TÜV EN 12263 approved) CS1-W6A
ThermoTM-Expansion Valves Adjustable / Fixed
Platforms And Style / Applications T-/ZZ-/935-/L-SeriesT Monoblock TX7 Take apart 350 kW**0.5 kW 3,6 - 33,2* 30 - 183* 0,5 - 19,5** 1,9 - 301** TX3 TIH * R410A
Overview Thermo expansion valves Capacity Range R448A (kW) Evaporating Temperature (ᵒC) Main Application Features TI 0,5… 19,4 +20… -45 Refrig./Air Cond. Heat Pumps Exchangeable Orifices T 1,9… 301 +30… -45 Refrig./Air Cond. Heat Pumps Exchangeable Orifices, Power-Assembly and Flange ZZ 1,7… 24,7 -45… -120 Low Temperature Applications Exchangeable Orifices, Power-Assembly and Flange L 1,9… 222 +30… -50 Liquid Injection Superheat Control Exchangeable Orifices, Power-Assembly and Flange 935 5,2… 59,8 +30… -45 Liquid Injection Temperature Control Exchangeable Orifices, Power-Assembly and Flange TIH 0,8… 24,0 +20… -45 Refrig./Air Cond. Heat Pumps Hermetic, Superheat Adjustable, Optional with Check Valve TIH FLR (for R290 / R1270 app.) 3,2… 29,4 (R290) +20… -45 Refrigeration Heat Pumps Hermetic, Superheat Adjustable, Optional with Check Valve TX7 32… 183 (R410A) +20… -45 Air-Cond. Heat Pumps Hermetic, Superheat Adjustable TX7 FLR (for R290 / R1270 app.) 163 (R290) +20… -45 Air-Cond. Heat Pumps Hermetic, Superheat Adjustable Series Selection Criteria
• Monoblock, hermetic valve for: – heat pumps, heating, AC, small chillers, precision cooling and refrigeration • Laser-welded diaphragm with large diameter for high reliability and maximum lifetime • MOP 46 bar, 12 sizes, • Adjustable superheat, Bi-flow application • Refrigerants: R32 / R410A / R452B / R454B / R134a / R513A / R407C / R448A / R449A • Internal strainer • Drop in replacement for TX3 valve – No change in piping and exact fit-function A B Balanced port enables superheat control and prevents shifting of superheat caused by variation of condensing pressure. TIH Thermo-Expansion Valves: Key features
Comparison TIH Versus TX3Features TX3 TIH Benefits/Advantages Capacity R410A (kW) 2.8 -> 28.8 3.6 -> 33.2 TIH is available in 12 sizes up to 33,2 kW (R410A) Models / Sizes 12 (fixed orifice) 12 (fixed orifice) Refrigerants R410A, R134a, R407C, R404A, R507, R290 R32, R410A, R452B, R454B, R134a, R513A, R407C, R448A, R449A, R290 TIH Available for A2L refrigerants Capillary tube length (m) 1.5 1.5 TIH’s standard capillarity tube has 1.5 meters in length. Bi-flow capability O P HP, single valves instead of two vaves. Balanced port in normal flow O P Eliminates disturbance of inlet pressure during cooling operation i.e stable superheat PS (MWP) (bar) 45 46 46 bar meets R410A/R32 system requirement Factory pressure test (bar) 1.1 x PS (49.5 bar) 1.1 x PS (50.6 bar) System manufacturers can apply 10% higher pressure to deliver system according EN378 Diaphragm diameter (mm) 44.5 45 Largest diaphragm enables smooth and stable superheat during varying operating conditions Multipack (pieces) 24 20 Singlepack O P For service and sampling purposes
TIH Versus TX3 Dimensions (mm): Note: other dimensions are almost identical ± 0.5mm Capillary tube length 1.5mTX3: Black numbers TIH: Red numbers
TI-Series Comparison: Superheat Competitor Superheat Performance Display case Factory setting -1/2 turn Factory setting -1 turn Factory setting -1/2 turn Factory setting -1/4 turn Factory setting -1/4 turn Alco TISE-SW Superheat performance Display case Alco TI-Series Competitor PS: 45 bar PS: 34 bar PT: 49.5 bar PT: 38 bar Diaphragm: 45 mm diameter Diaphragm: 38 mm diameter Nominal static superheat: 4K Nominal static superheat: 5K Nominal opening superheat: 3K Nominal opening superheat: 6K Nominal operating superheat: 7K Nominal operating superheat: 11K Adjusting stem: total number of turs: 11 Adjusting stem: total number of turns: 6-1/4 Superheat change per turn ≈ 1.5K Superheat change per turn ≈ 4K
General catalogue Product guide Product guide Product guide Product guide Product guide HFC (A1) R290/1270 (A3) HFO-blends (A1) CO2 (A1) R32/R52B/R454B (A2L) Other A2L (Revision is pending) (Revision is pending) (2019) 2019 Chillventa2018 Products Guides for all refrigerant groups 52 Non-Electrical operated devices: Pressure & external leakage aspects Standard products Standard QC Standard/modified products Internal double QC Standard/modified products Standard QC High pressure side: 60-90-130 bar Standard/modified products 45 bar / 50 bar / 53 bar ? Standard/modified products 45 bar / 50 bar / 53 bar ? Electrical operated devices: Potential ignition aspect - ATEX compliance products - - Fulfill IEC60335-2-40 Fulfill IEC60335-2-89
• Published quarterly with a different releavant topic • In 10 languages • Each customer will have it’s own Logo on his flyer to send out to his customers Alco Tech Sheets / “Did you know?” 88 Customer logo
Navigator & Retrofit Selection tool Retrofit example
Navigator: Selection tool• Selection of products for HFC & HFO/HFO blends • Selection of over 95% of Alco product • Offering simultaneously part code number of selected product for ordering • Multiple refrigerants including HFO • Multiple languages • 12 languages • Access link to all technical documentation on Web by one Click • System diagrams for each application 55
Navigator: TXV Selection Features• Offering simultaneously part code number of selected product for ordering • Offering match product • Indicating percentage of usage
Capacity Comparison: HFO/HFO-Blends Versus HFCs Know the Facts!
Consideration For Retrofit: HFC to HFO-Blend (A1) Capacity: TXVs orifice selection • Example: R404A to R448A/R449A • Installed system: R404A, Q= 10 kW, Tc=+50°C, Te=-10°C Orifice 4 Ratio= 10/11.5= 87% • Retrofit to R448A: Orifice 4: Q= 17.6 Ratio:10/17.6= 56% Orifice 3.5 Ratio=10/12.1= 83% • Retrofit to R449A: Orifice 4: Q= 17.1 Ratio:10/17.1= 58% Orifice 3.5 Ratio=10/11.7= 85% R404A @ +50/-10°C R448A @ +50/-10°C R449A @ +50/-10°C
Alco Controls • Example: • Installed 3 system with R404A and plan to retrofit from R404A to R448A/R449A • Installed Thermo Expansion valve in each system: TI-SW (R404A) and operating superheat of 6K Consideration For Retrofit: HFCs To HFO Blends (A1) Charge of TXV Navigator offers solution
Guidance For Retrofit: HFC To HFO-Blend (A1) Solution 1: TXV Valves With Replaceable/Exchangeable Orifices • Readjusting by considering operating evaporator temperature • Available information: Operating instruction, Navigator tool R452AR452A Dedicated charges (BW) available for R448A/R449A
Guidance For Retrofit: HFC To HFO-Blend (A1) Solution 2: Replacing TXV Valve With Optimized Charge For Dedicated New Refrigerant • Solution 2 • Eliminates the readjusting • It is ideal for non-replaceable/exchangeable TXVs • Available charge for R448A/R449A: • TI valve • BW: Liquid charge • BW30: MOP charge (-18°C) • T-series valves (XB1019 / XC726) • BW: Liquid charge • BW30: MOP charge (-18°C) • BW100: MOP charge (+12°C) (Substitution for MOP +7°C for R404A) • TXV charges for R513A • CW Charges: Pending • R450A • No demand/Not planned TI-BW charge for R448A/R449A
Emerson Can Help to Grow your ALCO Business • Committed to provide products for most new alternative refrigerants • Broad product portfolio, supporting today’s needs of contractors • Providing technical support: • Selection Navigator software package • New product selections & retrofitting • Selection guidelines for each new refrigerant group (leaflets) • Direct technical support by phone • Committed to release new products for viable new refrigerants as they appear

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Alco general presentation

  • 1.
    Alco Controls 2020 GeneralPresentation Marcian Muresan
  • 2.
    Agenda • Introduction • AlcoHistory & Offices • New refrigerants: • HFO/HFO blends • A3 • CO2 • A2L • Main products overview • Oil management, Liquid level • EXV, Electrical control valves • Electronics • Pressure Switches • Thermo-Expansion Valves • Product guides & Navigator • Summary
  • 3.
  • 4.
    An extensive Portfolioand Knowhow allows us to become a Solutions Provider and enable Growth for our Customers Refrigeration Cold Rooms Bakery Evaporator Controllers Enterprise Monitoring HVAC Bakery Food Waste Recycling Cargo Monitoring Cold Rooms Supervisory & Building Management Refrigeration Enterprise Monitoring
  • 5.
    Alco Controls F-gas Legislation: Affectingall Parties and Businesses in Refrigeration, Heating and A/C Emerson committed to provide solutions and support for most refrigerant • Refrigerant change is a fact • Refrigerant Strategy often by end-user/OEMs • Speed to change also driven by HFC pricing • Many candidates available • CO2 • A2L and A3 (e.g. Propane) • HFO/HFO blends. • Wholesaler/contractor affected: • CO2: high pressure & higher cost installations • A3: Flammable/safety requirements • HFO and HFO blends: many candidates and new candidates still show up as “being best” Ask Emerson!! Refrigerant choices? Components? Technical support?
  • 6.
  • 7.
    Controls since 1925:Expertise & Evolution, Key of Success The world’s first automatic expansion valve for use in refrigeration systems in 1925. ‘Automatic Liquid Controls’ = ALCO
  • 8.
    Products 1925 → 2020 •ALCO CONTROLS • MECHANICAL CONTROLS • EMERSON • MECHATRONIC CONTROLS • EMERSON • ELECTRONIC CONTROLS • Thermo-Expansion Valves • Solenoid Valves • Pressure Switches • Filter Driers • Ball Valves • Moisture Indicators • Electrical Control Valves • Electronic Oil Level Management Systems • Electronic Liquid Level Monitoring Systems • Superheat Controllers • Compressor Soft Starters • Universal Driver Modules • Display Case and Coldroom Controllers • Refrigeration Unit Controllers High-quality, reliable mechanical controls for refrigeration and comfort applications Precise control of refrigerant flow and superior compressor protection Superior superheat control and monitoring of system behavior through network communication
  • 9.
  • 10.
    Aachen, Germany Headquarters & ElectronicEngineering Kolin, Czech Republic Plant & Mechanical Engineering Belluno, Italy Electronic Engineering Cluj-Napoca, Romania Customer Support Oracle Team Controls: Facilities Europe
  • 11.
  • 12.
  • 13.
    F-Gas ALCO Product Strategy A2L/A3 HFO& HFO Blends CO2 HFC in Europe (equivalent of millions of tones CO2)
  • 14.
    Refrigerant Selection ByConsidering Important Facts A1 Safe refrigerants A1 (CO2) High pressure Refrigerant A2L Mildly flammable refrigerants A3 Flammable refrigerants GWP level reduction by upcoming obligations Concerned Concerned Limit for charge amount Concerned Concerned Suitable for Retrofit Yes No No No System design to withstand the pressure Concerned System design to eliminate potential explosion Concerned Concerned Engineering capability / experience to design system Concerned ? Concerned Installation, startup and service Concerned ? Concerned
  • 15.
    HFO & HFOBlends Product Offering
  • 16.
    HFO and HFOBlends Products Released since 2016, First in the Market to offer a complete SolutionRefrigerants Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • ThermoTM Expansion Valves • Solenoid Valves • Oil Management Components • Pressure Controls • System Protectors and Moisture Indicators • Ball Valves • Suction Accumulators • Mechanical Pressure Regulators Replacement for Safety classification R450A, R513A, R1234ZE R134a A1 R448A, R449A, R452A (2017) R404A A1
  • 17.
  • 18.
    A3 (R290/R1270) ProductPortfolio Safe and reliable systems Compliance base on: • PED • ATEX • LVD • Components standards Heat Pumps / Self-Contained Display Cabinets / Brine Cooling Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • Thermo-Expansion Valves • Solenoid Valves • Pressure Controls • System Protectors and Moisture Indicators • Ball Valves Product Series Max. capacity or MWP or size Status EXD-SH1 / 2 - Released EXD-HP1 / 2 - Released EC3-P32 / -P33 - Released Compressor Soft Starter CSS-25U/-32U/-32W - Released EX4-7-…FLR 340 kW Released EXM / L 20 kW Released EXR 25 kW Q3 FY20 Oil Management OM3 - Released PT5N-07P-FLR 27 bar Released PT5N-10P-FLR 27 bar Released PT5N-30P-FLR 60 bar Released Electrical plug and cable assembly ECV-05A EXV-M60-FLR PT4-M60-FLR - Released ESC-EX24VAC ATEX - ESC-EX230VAC ATEX - Solenoid Valves 200RB-FLR 30 kW Released TX3-…FLR 22 kW Released TIH-…FLR 30 kW Released TX7-…FLR 160 kW Released Pressure Switch PS4-…ATEX 35 bar Released ADK-…FLR 7/8" BFK-…FLR 1-1/8" Sight glass MIA…-FLR 1-1/8" Released Released Released Solenoid Valve Coil Product Family Mechatronics Mechanical Controls Controllers Filter Driers Electronic Expansion Valves Pressure Transmitter Electronics Passive Mech. Thermo Expansion Valves
  • 19.
    Safety Aspects R290/R1270 Products•Device Classification In Scope of ATEX Internal double QC Use only in non-explosive environment Out of scope of ATEX Internal double QC (…-FLR marking) Solenoid valves Electronic Exp. valves Pressure transmitters Pressure switches Thermo Exp. valves Filter driers Sight glasses Helium leak detector
  • 20.
  • 21.
    Refrigeration (Large/Small Scale) CO2Product Portfolio Everything your Customer needs Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • Solenoid Valves • Oil Management Components • Pressure Controls • System Protectors • Moisture Indicators • Ball Valves Product Series Capacity (kW) PS (bar) Status Universal driver, software update EXD-U02 - - Released EXD-SH1/2 - 130 Released EXD-HP1/2 - 130 Released CV 4-6 150 kW 130 Released CV 7 540 kW 130 tbd CV 1/2/3 30 kW 150 tbd EX4 27 kW 90 Released EX5-7 540 kW 60 Released PWM Expansion valve CX2 28 kW 90 Released OM5 - 130 Released OM4 - 60 Released LW5-H/L - 130 Released LW4-H/L - 60 Released PT5N-150 - 150 Released PT5N-50M - 75 Released Safety pressure switch, fixed CS3 - 140 Released Pressure switch adjustable CS1 - 70 Released 200RH - 60 Released 200RC - 130 Q3 FY20 Ball valve CVE - 60 Released Sight glass CIA - 60 Released Filter drier FDH - 46 Released Electronic Expansion Valves Solenoid valve Mechanical Controls Passive Mech. Product Family ElectronicsMechatronics Pressure transmitters Controller Oil management Liquid level monitoring
  • 22.
  • 23.
    Applications: Air conditioning,close Control and heat pump Stage 1: Products released up to 200 kW (DN≤ 28mm) since July 2018 A2L (R32/R452B/R454B) Product Portfolio Leading the Way for A2L Compliance based on: – PED, IEC 60335-2-40 – LVD – Components standards Stage 2: Products release over 200 kW (DN>28mm) Since October 2019 Products Qualified and Released • Electrical Control Valves • Electronic Controllers and Sensors • Thermo-Expansion Valves • Solenoid Valves • Pressure Controls • System Protectors and Moisture Indicators • Ball Valves
  • 24.
    A2L (R32/R452B/R454B) ProductPortfolio Leading the Way for A2L Product Series Max capacity @R32 kW PS (bar) Status EC3-X32/33 - Released EXD-SH1/2 - Released EXD-HP1/2 - Released EXD-U02 - Released EXM/EXL 34 kW 45 Released EXN 62 kW 45 Released EX4 29 kW 90 Released EX5-6 208 kW 60 Released OM3 46 Released OM4 60 Released Pressure Transmitter PT5N-18/30/50 - 18/30/50 Released Solenoid Valves Coils ESC coils ATEX - - Released Solenoid Valves 200RH 50 kW 60 Released TIH 50 kW 46 Q2 FY20 TX7 270 kW 45 Released T-Series (XB1019) 270 kW 45 Released Pressure Switch PS4 - 45/62 Released MIA 45 Released CIA 60 Released BVE / BVS 45 Released CVE / CVS 60 Released ADK 170 kW 45 Released FDB 120 kW 45 Released BFK 73 kW 46 Released FDH 430 kW 46 Released Product Family - Mechatronics Mechanical Controls PassiveMechanical Filder driers Ball valves Sight glass - - Thermo Expansion Valves Electronic Expansion Valves Controllers - Oil Management Electronics R32 / R452B / R454B (R410A successors) Products are qualified for: • R454A • R454C • R1234ze • R1234yf • R447A • R444B • R455A +
  • 25.
    • Conditional productoffering for refrigeration applications based on: • Outcome of risk assessment by system manufacturers/installers • Requirement to be fulfil in respect to safety aspect for electrical operating devices Other A2L Refrigerants Product Material Compatibility accomplished A2L Refrigerant Pressure/ Characteristic Low GWP (0-150) Medium flammability (A2L) HFO and blends Medium “R-404A like” “R407C like” Low “R-134a like” High “R410A like” R455A R454C R454A R444B R1234yf R1234ze R452B R32 R545B R447A
  • 26.
    Many A1 AndA2L Refrigerants Are Mixtures Of Several Single Refrigerants
  • 27.
  • 28.
    Electronic Oil/ LiquidManagement Systems TraxOil OM3/OM4/OM5, OW4/OW5 and LW4/5 • Active Oil level Balancing and Monitoring with integrated solenoid: • OM3: MOP 46 bar • OM4: MOP 60 bar • OM5: MOP: 130 bar CO2 • Oil Level Monitoring: • OW4: MOP 60 bar • OW5: MOP 100 bar • Liquid Watch • LW4-L / -H120: MWP 60 bar for HFCs and CO2 • LW5-L / -H120: MWP 130 bar for CO2 • Alarm und Status indication (all types) • LED’s indication • SPDT Alarm contact Most reliable solution with already 500.000+ pcs installed OM5 OW4 LW5
  • 29.
    Electronic Oil ManagementSystems –TraxOil OM3/OM4/OM5 and OW4/OW5 • Three Zone Level Control by using a floater and precise Hall-Sensor measurement  no errors caused by foaming or light like optical sensors Applications: • Compressors without Oil pump (OW) • Rack systems • High and Low pressure systems • CO2 Subcritical and Transcritical Applications (depending on system architecture) OMgreen zone yellow zone red zone 60% 40% 25% OW4/5: no Injection
  • 30.
    The working principle requiresthe prism surface to be in good condition and clean, and due to the high temperatures and foaming, and oil aging, fouling and scaling on the surface occurs, driving the device to a possible malfunctioning due to false alarms Technologies: Hall vs Optic, proven reliability
  • 31.
  • 32.
    EX6 EX7EX50,4 kW1000 kWEX4 EX8EXM/L/N(* ) EX2(*) CV6 CV7CV5CV4CX2 5,6 m3/h1,5 kW Common refrigerants & CO2 sub (exc.*) 45 47 90 60 60 6060 90 130 130 130 130 CO2 Trans & sub PS(b) PS(b) STEPPER UNI-POLAR STEPPER BI-POLAR (R410A, +4ºC / +38ºC) ECV, EXV, Drivers: complete line-up *CV4.5 *CV5.5 *CV6.5 *Intermediate sizes on- going MOPD 90 bar
  • 33.
    EX2 / CX2Series Expansion Valves: longer lifespan • Predominantly for refrigeration applications • EX2 series • MOP 40 bar • MOPD 30 bar • CX2 series applies for CO2 • MOP 90 bar • MOPD 65 bar • PWM operation • >80 MM cycles (15 years) • Leak ratio < 1,3 g/year • Several orifices for capacity match • Integrated strainer • Hermetic design • Positive shut-off • ESC coil: • 24VAC for use with EC2 • 24VAC or 230VAC with third party controllers EX2
  • 34.
    EXM / EXLSeries Expansion Valves, R290 qualified Unipolar stepper motor driven Electronic Expansion Valves • Hermetic design • Linear modulation, Bi-flow • High MOPD: 40bar in normal flow direction • Removable coils: 12VDC/24VDC • Fine resolution: 500 pulses (half steps) or 250 full steps • Protection class of molded coil is IP65 (acc. EN 60529) excluding the cable end terminals (JST). • Reliability: 225 million pulses at 40 bar differential pressure • EN/IEC 60335-2-40/89 qualification test by VDE approval
  • 37.
  • 38.
    EXD-U02 driver • NEWEmerson EXD-U02 driver • is the successor of EXD-U01 stepper motor driver, especially designed for the new Emerson CV-valves which uses an analogue input signal to define the valve opening. It enables the operation of CV valves for different type of duties, but also the EX series • Input signal: 4…20mA or 0…10V. • Output: pulses proportional opening/closing • Liquid injection duty • Hot gas bypass • Evaporator pressure regulator • Crankcase pressure regulator • Head pressure regulator • Liquid level control. +
  • 39.
    39 Full range ofcontroller for all applications • Controllers for EX valves • Controllers for CV and EX valves EXD-U02 EC3-xxx + ECD-002 EXD-SH1/2 EC2-3xx • Controllers for CX2 and EX valves Superheat controller Superheat controllers and /or temperature control Superheat control by means of a pressure value and one temperature Ec2- 352/372 or by two temperature values EC2- 312/392. Dedicated to the CV and EX series valves for valve actuation function of an analogue input signal Electronic drivers and controllers
  • 40.
  • 41.
    Pressure Switches Adjustable Setting PressureSwitch PS4: MOQ 100 pcs CS3: MOQ 60 pcs PS3 CS3PS4CS1PS1 PS2 A2L HFO HFC R290 / R1270 CO2 P P P P P P P P P P P P P P Maximum working pressure (PS) 130 bar62 bar45 bar70 bar31 bar31 bar Protection IP 44 IP 44 IP 33 IP 65 IP 67 IP 65 − − − − − − − − − − − − P Fixed Setting Pressure Switch − − −
  • 42.
    CS3 Series PressureSwitch CS3 product series are pressure switches with fixed switch-point settings for R744 applications Features: • Cut-out settings: Range 8/Q: 60-140bar; Range 7/P: 40-70bar • Maximum Working Pressure (PS) 140 bar • Narrow differential (approximately 4-6 bar in micro-switch version) • Contacts are designed as SPDT for control function and alarm/status reporting • Manual reset versions available • TÜV (EN 12263) approved (2 Million Cycles reliability)
  • 43.
    Alco Controls Cartridge type Contact:SPST (NC) Contact: SPDT M L1 N P 120 70 100 60 bar 80 110 90 Switch Status Cut-out: 110 ± 10 bar Cut-in: 80 bar ± 20 bar Cut-out: 110 +0 /-6bar Cut-in: 103 +/-3bar Pressure Switch Status Desired cut-out: 110 bar M P Other brands CS3 CS3 Safety Pressure Switch Competitive Advantage: Narrow differential + Better tolerance >> Protects and Reduces idle time of compressor
  • 44.
    CS1 The first Adjustablesafety pressure controls for CO2 (pressure over 45 bar)CS1 product series are safety pressure controls with adjustable switch-point settings for R744 and R410A applications • Two ranges, 6 and 7 with narrow adjustable differential (4-10 bar) • Maximum Working Pressure (PS) of 70 bar • Contacts are designed as SPDT for control function and alarm/status reporting • 2 million cycles reliability (TÜV EN 12263 approved) CS1-W6A
  • 45.
  • 46.
    Platforms And Style/ Applications T-/ZZ-/935-/L-SeriesT Monoblock TX7 Take apart 350 kW**0.5 kW 3,6 - 33,2* 30 - 183* 0,5 - 19,5** 1,9 - 301** TX3 TIH * R410A
  • 47.
    Overview Thermo expansionvalves Capacity Range R448A (kW) Evaporating Temperature (ᵒC) Main Application Features TI 0,5… 19,4 +20… -45 Refrig./Air Cond. Heat Pumps Exchangeable Orifices T 1,9… 301 +30… -45 Refrig./Air Cond. Heat Pumps Exchangeable Orifices, Power-Assembly and Flange ZZ 1,7… 24,7 -45… -120 Low Temperature Applications Exchangeable Orifices, Power-Assembly and Flange L 1,9… 222 +30… -50 Liquid Injection Superheat Control Exchangeable Orifices, Power-Assembly and Flange 935 5,2… 59,8 +30… -45 Liquid Injection Temperature Control Exchangeable Orifices, Power-Assembly and Flange TIH 0,8… 24,0 +20… -45 Refrig./Air Cond. Heat Pumps Hermetic, Superheat Adjustable, Optional with Check Valve TIH FLR (for R290 / R1270 app.) 3,2… 29,4 (R290) +20… -45 Refrigeration Heat Pumps Hermetic, Superheat Adjustable, Optional with Check Valve TX7 32… 183 (R410A) +20… -45 Air-Cond. Heat Pumps Hermetic, Superheat Adjustable TX7 FLR (for R290 / R1270 app.) 163 (R290) +20… -45 Air-Cond. Heat Pumps Hermetic, Superheat Adjustable Series Selection Criteria
  • 48.
    • Monoblock, hermeticvalve for: – heat pumps, heating, AC, small chillers, precision cooling and refrigeration • Laser-welded diaphragm with large diameter for high reliability and maximum lifetime • MOP 46 bar, 12 sizes, • Adjustable superheat, Bi-flow application • Refrigerants: R32 / R410A / R452B / R454B / R134a / R513A / R407C / R448A / R449A • Internal strainer • Drop in replacement for TX3 valve – No change in piping and exact fit-function A B Balanced port enables superheat control and prevents shifting of superheat caused by variation of condensing pressure. TIH Thermo-Expansion Valves: Key features
  • 49.
    Comparison TIH Versus TX3FeaturesTX3 TIH Benefits/Advantages Capacity R410A (kW) 2.8 -> 28.8 3.6 -> 33.2 TIH is available in 12 sizes up to 33,2 kW (R410A) Models / Sizes 12 (fixed orifice) 12 (fixed orifice) Refrigerants R410A, R134a, R407C, R404A, R507, R290 R32, R410A, R452B, R454B, R134a, R513A, R407C, R448A, R449A, R290 TIH Available for A2L refrigerants Capillary tube length (m) 1.5 1.5 TIH’s standard capillarity tube has 1.5 meters in length. Bi-flow capability O P HP, single valves instead of two vaves. Balanced port in normal flow O P Eliminates disturbance of inlet pressure during cooling operation i.e stable superheat PS (MWP) (bar) 45 46 46 bar meets R410A/R32 system requirement Factory pressure test (bar) 1.1 x PS (49.5 bar) 1.1 x PS (50.6 bar) System manufacturers can apply 10% higher pressure to deliver system according EN378 Diaphragm diameter (mm) 44.5 45 Largest diaphragm enables smooth and stable superheat during varying operating conditions Multipack (pieces) 24 20 Singlepack O P For service and sampling purposes
  • 50.
    TIH Versus TX3Dimensions (mm): Note: other dimensions are almost identical ± 0.5mm Capillary tube length 1.5mTX3: Black numbers TIH: Red numbers
  • 51.
    TI-Series Comparison: Superheat Competitor Superheat Performance Displaycase Factory setting -1/2 turn Factory setting -1 turn Factory setting -1/2 turn Factory setting -1/4 turn Factory setting -1/4 turn Alco TISE-SW Superheat performance Display case Alco TI-Series Competitor PS: 45 bar PS: 34 bar PT: 49.5 bar PT: 38 bar Diaphragm: 45 mm diameter Diaphragm: 38 mm diameter Nominal static superheat: 4K Nominal static superheat: 5K Nominal opening superheat: 3K Nominal opening superheat: 6K Nominal operating superheat: 7K Nominal operating superheat: 11K Adjusting stem: total number of turs: 11 Adjusting stem: total number of turns: 6-1/4 Superheat change per turn ≈ 1.5K Superheat change per turn ≈ 4K
  • 52.
    General catalogue Productguide Product guide Product guide Product guide Product guide HFC (A1) R290/1270 (A3) HFO-blends (A1) CO2 (A1) R32/R52B/R454B (A2L) Other A2L (Revision is pending) (Revision is pending) (2019) 2019 Chillventa2018 Products Guides for all refrigerant groups 52 Non-Electrical operated devices: Pressure & external leakage aspects Standard products Standard QC Standard/modified products Internal double QC Standard/modified products Standard QC High pressure side: 60-90-130 bar Standard/modified products 45 bar / 50 bar / 53 bar ? Standard/modified products 45 bar / 50 bar / 53 bar ? Electrical operated devices: Potential ignition aspect - ATEX compliance products - - Fulfill IEC60335-2-40 Fulfill IEC60335-2-89
  • 53.
    • Published quarterlywith a different releavant topic • In 10 languages • Each customer will have it’s own Logo on his flyer to send out to his customers Alco Tech Sheets / “Did you know?” 88 Customer logo
  • 54.
    Navigator & Retrofit Selectiontool Retrofit example
  • 55.
    Navigator: Selection tool•Selection of products for HFC & HFO/HFO blends • Selection of over 95% of Alco product • Offering simultaneously part code number of selected product for ordering • Multiple refrigerants including HFO • Multiple languages • 12 languages • Access link to all technical documentation on Web by one Click • System diagrams for each application 55
  • 56.
    Navigator: TXV Selection Features•Offering simultaneously part code number of selected product for ordering • Offering match product • Indicating percentage of usage
  • 57.
    Capacity Comparison: HFO/HFO-BlendsVersus HFCs Know the Facts!
  • 58.
    Consideration For Retrofit:HFC to HFO-Blend (A1) Capacity: TXVs orifice selection • Example: R404A to R448A/R449A • Installed system: R404A, Q= 10 kW, Tc=+50°C, Te=-10°C Orifice 4 Ratio= 10/11.5= 87% • Retrofit to R448A: Orifice 4: Q= 17.6 Ratio:10/17.6= 56% Orifice 3.5 Ratio=10/12.1= 83% • Retrofit to R449A: Orifice 4: Q= 17.1 Ratio:10/17.1= 58% Orifice 3.5 Ratio=10/11.7= 85% R404A @ +50/-10°C R448A @ +50/-10°C R449A @ +50/-10°C
  • 59.
    Alco Controls • Example: •Installed 3 system with R404A and plan to retrofit from R404A to R448A/R449A • Installed Thermo Expansion valve in each system: TI-SW (R404A) and operating superheat of 6K Consideration For Retrofit: HFCs To HFO Blends (A1) Charge of TXV Navigator offers solution
  • 60.
    Guidance For Retrofit:HFC To HFO-Blend (A1) Solution 1: TXV Valves With Replaceable/Exchangeable Orifices • Readjusting by considering operating evaporator temperature • Available information: Operating instruction, Navigator tool R452AR452A Dedicated charges (BW) available for R448A/R449A
  • 61.
    Guidance For Retrofit:HFC To HFO-Blend (A1) Solution 2: Replacing TXV Valve With Optimized Charge For Dedicated New Refrigerant • Solution 2 • Eliminates the readjusting • It is ideal for non-replaceable/exchangeable TXVs • Available charge for R448A/R449A: • TI valve • BW: Liquid charge • BW30: MOP charge (-18°C) • T-series valves (XB1019 / XC726) • BW: Liquid charge • BW30: MOP charge (-18°C) • BW100: MOP charge (+12°C) (Substitution for MOP +7°C for R404A) • TXV charges for R513A • CW Charges: Pending • R450A • No demand/Not planned TI-BW charge for R448A/R449A
  • 62.
    Emerson Can Helpto Grow your ALCO Business • Committed to provide products for most new alternative refrigerants • Broad product portfolio, supporting today’s needs of contractors • Providing technical support: • Selection Navigator software package • New product selections & retrofitting • Selection guidelines for each new refrigerant group (leaflets) • Direct technical support by phone • Committed to release new products for viable new refrigerants as they appear