CAPACITY REGULATORS = HOT GAS BY-PASS VALVES

APPLICATIONS
The capacity regulators series 3310, shown in this chapter, are classified “Pressure accessories” in the
sense of the Pressure Equipment Directive 94/23/EC, Article 1, Section 2.1.4 and are subject of Article
3, Section 1.3 of the same Directive.
They are designed to operate on refrigerating systems, which use the following refrigerant fluids: R22,
R134a, R404A , R407C, R507 proper to the Group II (as defined in Article 9, Section 2.2 of Directive
97/23/EC and referred to in Directive 67/548/EEC).
Capacity regulator is specifically designed so that it can operate on refrigerating system which use
R22, R134a, R404A , R407C, R507 as its refrigerant fluids.
On air conditioning systems it is desirable to limit the minimum evaporating pressure during periods of
low load to prevent coil icing. On refrigerating systems it is desirable to limit the minimum evaporating
pressure during periods of low load to avoid operating the compressor at a lower suction pressure than
it was designed to operate. Capacity regulators series 3310 are a practical and economical solution to
these problems while they permit to bypass a portion of the hot discharge gas directly to the low side
maintaining a desired minimum evaporating pressure regardless of the decrease in evaporator load.
To avoid coil icing on an air conditioning system it is necessary to restrict the minimum evaporating
pressure during periods of low load. It is also very important to restrict the minimum evaporation
pressure during periods of low load to prevent operating the compressor at lower suction pressures than
it was designed to operate on a refrigerating systems. Capacity regulator can be used to overcome those
problems because it may permit to bypass an amount of hot discharge gas directly to the low side to
hold a desired minimum evaporating pressure.
OPERATION
Capacity regulators series 3310 adjust the flow of hot gas according to changes of suction pressure,
downstream the regulator. When the evaporating pressure is above the valve setting, the shutter remain
closed. As the suction pressure drops below the valve setting, the shutter begins to open and the amount
of its opening is proportional to the change of suction pressure. As the suction pressure continues to
drop, the shutter continues to open farther until the limit of the stoke is reached and the valve is
completely open. On normal applications there is not sufficient pressure change available to open these
valves to the limit of their stroke; so the shutter works inside its stroke. Regulators series 3310 regulate
only in dependence on the outlet pressure change, pressure change on the inlet side do not affect the
degree of opening since the valve is equipped with an equalization bellow with an effective area equal
to valve seat. The factory pressure setting of these valves is 2 bar, this means that until the suction
pressure is above the 2 bar the valve remains closed, when the suction pressure drops below the 2 bar
the valve begin to open. According to the characteristics of the refrigerating system it can be necessary
to change the valve setting adjusting the setting screw on the top of the body; the pressure setting range
is from 0,2 bar up to 6 bar.
The flow of gaseous refrigerant can be adjusted by capacity regulator according to the changes of
suction pressure, downstream the regulator.
This is how it works:
In a system, if evaporating pressure is higher than the valve setting, the shutter will be closed. As long
as the suction pressure is lower than the valve setting, the shutter will begin to open. The amount of
shutter's opening is proportional to the change of suction pressure. If suction pressure continues to
drop, the shutter continues to open farther until it has reached the limit of the stoke and the valve is
completely open. On normal applications there is not sufficient pressure change available to open these
valves to the limit of their stroke; so the shutter works inside its stroke. Regulators series 3310 regulate
only in dependence on the outlet pressure change, pressure change on the inlet side do not affect the
degree of opening since the valve is equipped with an equalization bellow with an effective area equal
to valve seat. The factory pressure setting of these valves is 2 bar, this means that until the suction
pressure is above the 2 bar the valve remains closed, when the suction pressure drops below the 2 bar
the valve begin to open. Valve setting can be modified by adjusting the setting screw on the top of the
body. Pressure setting is available in the range of 0,2 to 6 bar.

CONSTRUCTION
The main parts of capacity regulators series 3310 are made with the following materials:
• Hot forged brass EN 12420 – CW 617N for body
• Copper tube EN 12735-1 – Cu-DHP for solder connections
• Austenitic stainless steel AISI 321 for bellow
• Brass bar EN 12164 – CW 614N for shutter
• Brass bar EN 12164 – CW 614N for setting screw
• Spring steel DIN 17223/84 Class C/D for setting spring
• Chloroprene rubber (CR) for outlet seal gaskets

Capacity regulator has several main parts which are made with particular materials as follows:
• Capacity regulator's body is made of hot forged brass
• Solder connections are made of copper tube
• Bellow is made of austenitic stainless steel
• Shutter is made of brass bar
• Setting screw is made of brass bar
• Setting spring is made of spring steel
• Outlet seal gaskets are made of chloroprene rubber (CR)

INSTALLATION
Capacity regulators series 3310 are applied in a branch line off the discharge line. The bypassed vapor
can enter in the low side at one of the following locations:
• to evaporator inlet (with or without distributor)
• to suction line
On this second application to avoid the danger of overheating the compressor it is required to install a
liquid injection valve (desuperheating TEV) that supplies enough liquid refrigerant in the suction line,
to cool the bypassed hot gas.

The location of capacity regulator installation is in a branch line off the discharge line. There are two
locations where the bypassed vapor can enter in the low side :
• to evaporator inlet (with or without distributor)
• to suction line
In the suction line, to prevent the effect of overheating on the compressor, a liquid injection valve
(desuperheating TEV) should be installed. This valve supplies enough liquid refrigerant in the suction
line, to cool the bypassed hot gas.

SELECTION
A correct selection of capacity regulators series 3310 is possible if complete system information are
available. The selection involves these basic items:
1. Refrigerant
2. Minimum allowable evaporating temperature at reduced load condition.
This data depends on the system, for air conditioning system this value must be set to prevent coil
icing, in refrigerating system this value must be set to avoid suction temperature lower than minimum
values recommended by compressors manufacturers.
3. Minimum required evaporating temperature. The temperature when the valve begins to open.
4. Compressor capacity at minimum allowable evaporating temperature. Consult compressor
manufacturer for this value.
5. Minimum evaporator load at which the system is to be operated. It depends on the type of
system; it can be a percentage of maximum load ( 15-25%) or near to zero.
6. Liquid temperature when minimum load exist.

The following requirements have to be considered for selecting the correct capacity regulators:
1. Refrigerant
2. Minimum allowable evaporating temperature at reduced load condition
This data depends on the system, for air conditioning system this value must be set to prevent coil
icing, in refrigerating system this value must be set to avoid suction temperature lower than minimum
values recommended by compressors manufacturers.
3. Minimum required evaporating temperature.
The temperature when the valve begins to open.
4. Compressor capacity at minimum allowable evaporating temperature.
5. Minimum evaporator load at which the system is to be operated.
It depends on the type of system; it can be a percentage of maximum load ( 15-25%) or near to zero.
6. Liquid temperature when minimum load exist.

HOT GAS BYPASS CAPACITY REGULATOR Danfoss

KVC capacity regulators are used to adapt compressor capacity to actual evaporator load by supplying
a replacement capacity in form of hot/cool gas. It is installed in a bypass line between the high and low
pressure sides of the refrigeration system and is designed for direct gas injection into the suction line
Hot gas bypass capacity regulator is located in a bypass line between the high and low pressure sides of
the refrigeration system.
Its functions are :
• To adapt compressor capacity to actual evaporator load by supplying a replacement capacity in
form of hot/cool gas.
• To direct gas injection into the suction line

Sizing
For optimum performance, it is important to select a KVC valve according to system conditions and
application. The following data must be used when sizing a KVC valve:
• Refrigerant: HCFC, HFC and HC
• Suction temperature at maximum compressor/evaporator load ts in [°F]/[psig]
• Minimum suction temperature ts in [°F]/[psig]
 • Compressor capacity in [TR]
• Evaporating load in [TR]
• Condensing temperature tl in [°F]
• Connection type: flare or solder
• Connection size [in.]
Selecting a correct hot gas bypass capacity regulator based on the system conditions and application is
necessary to ensure system best performance.
There are several factors that must be considered to determine the proper size of hot gas bypass
capacity regulator:
• Refrigerant
• Suction temperature at maximum compressor/evaporator load ts in [°F]/[psig]
• Minimum suction temperature ts in [°F]/[psig]
• Compressor capacity in [TR]
• Evaporating load in [TR]
• Condensing temperature tl in [°F]
• Connection type: flare or solder
• Connection size [in.]

Design / Function
Capacity regulator type KVC opens on a fall in pressure on the outlet side, i.e. when the pressure in the
evaporator reaches the set value. Type KVC regulates on outlet pressure (suction pressure) only.
Pressure variations on the inlet side of the regulator do not affect the degree of opening as the valve is
equipped with equalization bellows (6). The bellows has an effective area corresponding to that of the
valve seat neutralizing any affect to the setting. The regulator is also equipped with a damping device
(9) providing protection against pulsations which can normally arise in a refrigeration system. The
damping device helps to ensure long life for the regulator without impairing regulation accuracy.
Capacity regulator will open if the pressure on the outlet side decreases, which may happen when
evaporator pressure has reached the set value. This regulator only regulates the outlet pressure. Because
the valve is equipped with equalization bellows, pressure variations on the inlet side of the regulator do
not have significant effect to the degree of opening. There are an effective area on the bellows
corresponding to that of the valve seat neutralizing any affect to the setting. The regulator also comes
complete with a damping device to provide protection against pulsations which can normally occur in a
refrigeration system. The damping device helps to ensure long life for the regulator without impairing
regulation accuracy.

Refrigeration and Air Conditioning. G.F. Hundy, A.R. Trott, T.C.Welch

HOT GAS BY-PASS VALVES
Where a compressor does not have any capacity reduction device and on–off switching will not give
the degree of control required by the process, the cooling capacity can be regulated by injecting
discharge gas back into the suction (see Figure 9.2). It has the effect of keeping the evaporator pressure
constant, regardless of the load, and can have a wide range of capacity reduction, down to 10% of full
load. It is a constant pressure valve, balancing the suction pressure against a pre-set spring. They may
be either direct or pilot operated. They are often equipped with an external equalizer which works just
like an externally equalized expansion valve. Injecting the hot gas upstream of the evaporator enables
the expansion valve to open and admit more cool refrigerant which maintains gas velocity in the
evaporator and aids oil return. Note the solenoid valve in Figure 9.2. If the system is set up with a
pump down, then this solenoid must be wired in parallel with the pump down solenoid in order to
achieve pump down. This control method is wasteful of energy.

Injecting discharge gas back into the suction can regulate the cooling capacity. Such condition occurs
when a compressor does not have any capacity reduction device and on–off switching will not give the
degree of control required by the process. It has the effect of keeping the evaporator pressure constant,
regardless of the load, and can have a wide range of capacity reduction, down to 10% of full load. It is
a constant pressure valve, balancing the suction pressure against a pre-set spring. They may be either
direct or pilot operated and equipped with an external equalizer which works just like an externally
equalized expansion valve. Injecting the hot gas upstream of the evaporator enables the expansion
valve to open and admit more cool refrigerant which maintains gas velocity in the evaporator and aids
oil return. If the system is set up with a pump down, then this solenoid must be wired in parallel with
the pump down solenoid in order to achieve pump down. This control method is wasteful of energy.