Danfoss Coolselector 2 Compendium
Exercises for Coolselector®2. Training material for use in courses and self-studies for both internal and external use.
Not for use as a design guide. Always remember that selection software is only as good as the person using it.
2018-06-04 | Version 3.0.0
Coolselector®2 Exercises
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Contents
1 Introduction .............................................................................................................................. 1
2 Coolselector®2 - end user license agreement and disclaimer ................................................. 2
1. License .................................................................................................................................. 2
2. Proprietary rights .................................................................................................................. 2
3. Third party components ....................................................................................................... 2
4. Disclaimer of warranty ......................................................................................................... 2
5. Limitation of liability ............................................................................................................. 3
6. Miscellaneous ....................................................................................................................... 3
3 General information and basic selection ................................................................................. 5
Exercise 3.1 Installing and setting up Coolselector®2 .................................................................. 5
Solution 3.1 Installing and setting up Coolselector®2 .................................................................. 6
Exercise 3.2 Starting a new project and basic component selection ......................................... 11
Solution 3.2 Starting a new project and basic component selection ......................................... 12
Exercise 3.3 Selecting components in series .............................................................................. 21
Solution 3.3 Selecting components in series .............................................................................. 22
Exercise 3.4 Understanding superheat and selecting a compressors ........................................ 27
Solution 3.4 Understanding superheat and selecting a compressor ......................................... 28
Exercise 3.5 Selecting electronic controllers .............................................................................. 31
Solution 3.5 Selecting electronic controllers .............................................................................. 32
Exercise 3.6 Creating a report, bill of materials and code numbers .......................................... 33
Solution 3.6 Creating a report, bill of materials and code numbers .......................................... 34
Exercise 3.7 Changing predefined preferences and customizing the interface ......................... 41
Solution 3.7 Changing predefined preferences and customizing the interface ......................... 42
Exercise 3.8 Changing the advanced settings ............................................................................. 47
Solution 3.8 Changing the advanced settings ............................................................................ 48
4 Commercial applications ........................................................................................................ 53
Exercise 4.1 Selecting a thermostatic expansion valve .............................................................. 53
Solution 4.1 Selecting a thermostatic expansion valve .............................................................. 54
Exercise 4.2 Selecting an electronic expansion valve ................................................................. 57
Solution 4.2 Selecting an electronic expansion valve ................................................................ 58
Exercise 4.3 Selecting a solenoid valve ...................................................................................... 63
Solution 4.3 Selecting a solenoid valve ...................................................................................... 64
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Exercise 4.4 Selecting a check valve with reciprocating compressors ....................................... 69
Solution 4.4 Selecting a check valve with reciprocating compressors ...................................... 70
Exercise 4.5 Selecting a check valve with scroll compressors ................................................... 73
Solution 4.5 Selecting a check valve with scroll compressors ................................................... 74
Exercise 4.6 Selecting a check valve for the condenser line ...................................................... 77
Solution 4.6 Selecting a check valve for the condenser line ...................................................... 78
Exercise 4.7 Selecting an evaporation pressure control valve for a one-to-one system ........... 81
Solution 4.7 Selecting an evaporation pressure control valve for a one-to-one system .......... 82
Exercise 4.8 Selecting an evaporation pressure control valve for a power-pack system .......... 85
Solution 4.8 Selecting an evaporation pressure control valve for a power-pack system .......... 86
Exercise 4.9 Calculating heat load and selecting components for a cold room ........................ 89
Solution 4.9 Calculating heat load and selecting components for a cold room ........................ 90
5 Industrial applications .......................................................................................................... 103
Exercise 5.1 Selecting a valve in liquid feed line ...................................................................... 103
Solution 5.1 Selecting a valve in liquid feed line ...................................................................... 104
Exercise 5.2 Selecting an expansion valve ............................................................................... 107
Solution 5.2 Selecting an expansion valve ............................................................................... 108
Exercise 5.3 Selecting an ICF .................................................................................................... 111
Solution 5.3 Selecting an ICF .................................................................................................... 112
Exercise 5.4 Selecting components in series ........................................................................... 113
Solution 5.4 Selecting components in series ........................................................................... 114
Exercise 5.5 Selecting a safety valve ........................................................................................ 117
Solution 5.5 Selecting a safety valve ........................................................................................ 118
Exercise 5.6 Selecting components in hot gas defrost ............................................................ 121
Solution 5.6 Selecting components in hot gas defrost ............................................................ 122
Exercise 5.7 Selecting components for an industrial evaporator valve station ....................... 123
Solution 5.7 Selecting components for an industrial evaporator valve station ...................... 124
6 CO₂ system calculations ....................................................................................................... 125
Exercise 6.1 Selecting a high-pressure valve ........................................................................... 125
Solution 6.1 Selecting a high-pressure valve ........................................................................... 126
Exercise 6.2 Selecting a gas bypass valve................................................................................. 131
Solution 6.2 Selecting a gas bypass valve ................................................................................ 132
Exercise 6.3 Selecting an expansion valve ............................................................................... 137
Solution 6.3 Selecting an expansion valve ............................................................................... 138
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Exercise 6.4 Selecting a high-pressure ejector ......................................................................... 141
Solution 6.4 Selecting a high-pressure ejector ......................................................................... 142
Exercise 6.5 Selecting a low-pressure ejector .......................................................................... 149
Solution 6.5 Selecting a low-pressure ejector .......................................................................... 150
7 Compressors ......................................................................................................................... 153
Exercise 7.1 Selecting a compressor and finding related technical information ..................... 153
Solution 7.1 Selecting a compressor and find related technical information .......................... 154
Exercise 7.2 Understanding the challenges for compressor selection ..................................... 165
Solution 7.2 Understanding the challenges for compressor selection .................................... 166
Exercise 7.3 Selecting spare parts for compressors and creating a report .............................. 171
Solution 7.3 Selecting spare parts for compressors and creating a report .............................. 172
8 Condensing units .................................................................................................................. 179
Exercise 8.1 Selecting a condensing unit .................................................................................. 179
Solution 8.1 Selecting a condensing unit.................................................................................. 182
Exercise 8.2 Selecting spare parts for a condensing unit ......................................................... 189
Solution 8.2 Selecting spare parts for a condensing unit ......................................................... 190
Exercise 8.3 Selecting a condensing unit in systems with long suction lines ........................... 193
Solution 8.3 Selecting a condensing unit in systems with long suction lines ........................... 194
Exercise 8.4 Selecting an Optyma Plus™ inverter .................................................................... 195
Solution 8.4 Selecting an Optyma™ Plus inverter .................................................................... 196
Exercise 8.5 Finding AWEF values for condensing units in North America .............................. 201
Solution 8.5 Finding AWEF values for condensing units in North America .............................. 202
Exercise 8.6 Evaluating a condensing unit based on the Ecodesign Directive ......................... 207
Solution 8.6 Evaluating a condensing unit based on the Ecodesign Directive ......................... 208
Coolselector®2 Exercises
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Introduction
This document contains a number of exercises designed to introduce you to Coolselector®2 and
take you through the capabilities of the software. In these exercises, we will try to cover both
the general aspects of Coolselector®2 and also some of the more challenging procedures where
you should take extra care when designing your system.
The exercises in this document are not meant as a design guide. The exercises are designed for
the sole purpose of taking you through the features of Coolselector®2. Please also read and
accept the End-user license agreement in the next chapter before continuing with the exercises.
The document is structured so that each exercise is followed by a possible solution.
Coolselector®2 is designed so that it provides an optimized interface based on the application,
user preferences and the type of components you want to calculate/select. Hence, we have tried
to split the exercises into these main Coolselector®2 functionalities and cover the general
aspects in the first chapter.
The exercises are divided into: general information and basic selection, commercial applications,
industrial applications, CO₂ Systems, compressors and, finally, condensing-units; where each
section is designed by an experienced Danfoss expert in the specific functionality. Users coming
from the various application areas would benefit from the exercises in other functionality areas,
despite the differences in the system setups, refrigerants, or other parameters. This is since the
selection methods are similar, and the notes from different experts provide a more
comprehensive understanding and cover more fine tips, all of which can help you to reach the
best results.
All units used in this document are international units. Coolselector®2 supports many different
units and supports switching back and forth between the units in an easy way, so you should be
able to go through the exercises using your preferred units.
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Coolselector®2 - end user license agreement and disclaimer
Please review below terms and conditions and accept them before proceeding with the
exercises.
1. License
This end user license agreement and disclaimer ("Agreement") is entered into between Danfoss
A/S or its Affiliates (each of which is referred to as "Danfoss") and you as an end user ("You" or
"User"). In this Agreement "Affiliate" shall mean an entity directly or indirectly controlled by
Danfoss A/S whether by shares or voting rights.
Upon acceptance of this Agreement Danfoss grants You a limited, non-exclusive, nontransferable, royalty-free, worldwide license ("License") to install and use the Coolselector®2
("Application"), for User's use on any device that User owns or controls. The License is granted
subject to User's compliance with the following:
a) The terms of this Agreement
b) Danfoss Terms of Use (available at www.Danfoss.com)
c) Danfoss Privacy Policy (available at www.Danfoss.com)
2. Proprietary rights
This License and the Application contains proprietary information which is owned by Danfoss
and protected by applicable intellectual property rights. Except as expressly permitted herein,
such Danfoss information herein may not
i. be used for any purpose except in compliance with this Agreement,
ii. be copied or reproduced in any form, or
iii. be modified, rented, leased, sold, distributed or exploited commercially.
Danfoss reserves the right to change, suspend, remove or disable User's access at any time
without notice. The Danfoss name, Danfoss logo and other Danfoss trademarks, graphics and
logos are trademarks or registered trademarks of Danfoss or its affiliated companies. User is
granted no right or license with respect to such trademarks.
3. Third party components
The Application may include certain third party software components ("Third Party
Components") including open source and free software components, each of which has its own
copyright and its own license conditions ("Third Party License"). A list of included Software
Components and their respective licenses can be found in the third_party_licenses.txt file.
To the extent any Third Party License grants the User rights to use, copy or modify the Open
Source Component that are broader or narrower than the rights granted in this Agreement, then
such rights shall take precedence over the rights and restrictions granted in this Agreement
solely for such Third Party Components.
4. Disclaimer of warranty
This License is provided on an "as is" and "as available" basis for the intended purposes as
determined by Danfoss only and any use hereof is at User's sole risk. The Application and results
and information generated thereby cannot substitute technical advice but must be verified by
the User, they are not promises and should not be relied on as accurate data or analyses.
Coolselector®2 Exercises
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Danfoss disclaims all warranties and conditions regarding the Application, whether express,
implied, or statutory, including, but not limited to, conditions of merchantability, satisfactory
quality, fitness for a particular purpose, accuracy and non-infringement of third parties' rights.
Danfoss does not warrant that the Application will meet your requirements or that the
operation hereof will be uninterrupted or error-free.
5. Limitation of liability
To the extent not prohibited by law, in no event shall Danfoss be liable for any direct, special,
indirect or consequential damages, whatsoever, including, without limitation, damage to
property, damages for loss of savings or profits, or loss of data arising out of any use of the
Application.
6. Miscellaneous
The License shall automatically terminate upon User's breach of any of the terms of this
Agreement. Danfoss may terminate the License at its sole discretion without prior notice.
This Agreement and the License is subject to the substantive law of Denmark. Any dispute
arising out of or in connection with this Agreement shall be submitted to the exclusive
jurisdiction of the courts in Denmark.
App License Terms, 2014-08
Coolselector®2 Exercises
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General information and basic selection
Installing and setting up Coolselector®2
We need to get Coolselector®2 up and running if you have not done so already. You can
download and install Coolselector®2 from http://coolselector.danfoss.com.
Check if there are any updates available for Coolselector®2?
Change the country and language based on your preferences:
1. Note, the type of components you can select on the “Valves and Line Components”
page. Then, change the Country to USA (if your country is USA, change it to, for
example, Denmark)
2. Have the available components in “Valves and Line Components” changed?
3. Change your Country back (or select to show all products)
What was the last change in this release of Coolselector®2?
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Installing and setting up Coolselector®2
You can download and install Coolselector®2 from http://coolselector.danfoss.com.
Go to the “About | Updates” menu:
Once you see the ‘Updates screen’, click on the “Check for new version” button:
Note that, if you cannot update automatically (i.e. due to your company policies), it is
possible to subscribe to an email service, which will notify you whenever a new version is
released.
Once you have clicked the button, Coolselector®2 will notify you if there is a newer
version available. If that is the case, you can install the new version directly from the
prompt.
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You can set the preferences for the country and
language in “Options | User, Language, Country”
menu. As an example, for this exercise, you can
change your country to ‘USA’:
From the drop down, set your country to ‘United States’ and click OK:
When you change your country to USA, you will see that the available components in
“Valves and Line Components” have changed. You will no longer be able to select “Safety
relief valves” – the reason being that Danfoss does not sell safety valves for the US market
(this might change in the future).
The important thing to note here is that Coolselector®2 will use your country to display as
relevant as possible information to you (this is even more pronounced for condensing
units, where each unit has a specific sales region).
Coolselector®2 Exercises
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Country = Denmark (or any other EU country as an example):
Country = United States:
Do not forget to revert back to your preferred settings.
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To see the latest changes in Coolselector®2, go to the “About | About Coolselector2”
menu and click on the <Changelog> button:
Also, check out the “About | News” menu item for new product releases.
Coolselector®2 Exercises
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In the following part of this section, we will go through creating a project in which we try
selection and calculation for a few components in a very simplified refrigeration cycle as it can
be seen in the following graph and properties snippet. Following this, we will discuss how to
customize the project with your own name, how to get bill of materials and how to generate a
report for this project. Make sure your preferences choice is set to all applications in “Options |
Preferences | All applications” before you start the exercises.
System Properties 1
TC
DCR-DA
Speed 12±3 m/s
Refrigerant R404A
Copper DIN-EN 10 m
Speed 0,9±0,2 m/s
Copper DIN-EN 1 m
Speed 15±3 m/s
AKV
Load 80%
Condenser
Evaporator
Cycle Diagram 1
Starting a new project and basic component selection
Using information in System Properties 1 and Cycle Diagram 1:
Start Coolselector®2 and then in the option for “Valves and Line Components” start
selecting a DCA-DA burnout filter for the suction line in a dry system with the default
operating conditions. What is the Coolselector®2 suggestion?
Now, first change the refrigerant to R404A. Then, in three steps, change the capacity,
evaporator dew-point temperature and condenser dew point temperature to those
shown in the above snippet. Explain the effect of each step on the suggestion.
Can you explain the usage of the different segments of the screen?
How can you check the calculations done for the cycle and see calculation details for the
selected component?
Save your project.
Now continue the selection for the components in the liquid line by creating new tabs and
using the option for “Valves and Line Components” selection. What does Coolselector®2
suggest for each of the components?
Check for possible warnings and the calculated inlet and outlet results for these
components. Is there any problem in the selection results? Is this as it was expected for
the cycle diagram?
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Starting a new project and basic component selection
Open Coolselector®2; you will find that the program starts on the tab for ‘Valves and Line
Components’. From this screen, among the different component functionalities choose
“Burnout filters”.
Coolselector®2 creates a dry system by default, select the suction line and then click on
the DCR-DA in the product families. You will see the list of valid products and the best one
matching the selection criteria:
Here you can also see the other parameters for the filter in the table, such as the acid
capacity, as well as the pressure-drop as a function of changing the cooling capacity and
keeping the other parameters constant.
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When you change the refrigerant, Coolselector®2 asks for a confirmation, as this would
mean creating a new selection procedure:
By clicking “Yes”, a new selection will be made. Note that, the ‘evaporation temperature’
and ‘condenser temperature’ are now changed to ‘dew point temperature’. This is since
R404A is a glide-refrigerant and hence it is required to have a reference for the evaporator
and condenser temperatures.
The current suggestion is “DCR 0967-DA”, which is different from the suggestion made by
the exact same properties in the system running with R134a; this is of course due to the
different properties of the two refrigerants.
Now you can proceed to changing the system properties. If you change them in the order
mentioned in the exercise, the suggestion will consequently be “DCR 01447-DA”, “DCR
0969-DA” and “DCR 0489-DA”.
Increasing the capacity would increase the mass flow in line and hence the speed in the
component, which results in a larger component. Decreasing the evaporation
temperature increases the mass flow-rate as the cycle COP would be lower. Decreasing
the condensation temperature has the opposite effect, which is the cause of the changes
in the suggestion.
As you noticed, the Coolselector®2 suggestion can change and can very easily be affected
by the system properties.
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Once in the calculation and selection interface, you will find that the screen is separated in
different segments:
Segment “1” is dedicated to the application criteria for your selection. These criteria
include, but are not exclusive to, system type, line, refrigerant, connection type, and
product family.
Segment “2” is where you insert your system operating conditions, such as cooling
capacity, evaporation and condensation temperature, and useful superheat. These
operating conditions have significant impact on the calculations and a lack of due
care when filling them in might lead to inapplicable results. Whereas great care has
been taken to set meaningful default conditions, there is no guarantee that these
will mirror the operating conditions for your system design.
Segment “3” is dedicated to the product selection criteria for the suggestion to be
made in the next segment based on your inputs in functionality criteria and
operating conditions segments.
In segment “4” you will find the selection table. In this area you will see the options
matching the functionality criteria and operating conditions that you specified in
the selected family. For each calculation, Coolselector®2 has a ‘suggestion’ which
remains highlighted in green based on your input in the product selection criteria
input. The selection table also includes some of the most relevant information for
the product.
In segment “5”, you will find the performance details and information about the
chosen product from the previous segment. This information updates as you choose
other products from the list. The next part of this exercise gives some more
information about this segment.
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You can click on the performance details and check the system diagram calculations,
system details and the performance of the selected product from the list in the
corresponding tabs.
System diagram and different points calculations:
System calculation details:
Coolselector®2 Exercises
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Product performance details:
Notice, that the performance details are presented for any selected product and are not
limited to the suggested product. You can click on any of the products in the list and see
the calculations for the selected product.
To save the project, open File | Save Project… or click “Ctrl+S” on the keyboard. You will
then be asked for the name and the location of the file:
You can also use the “Save Project As…” option to save it with a different name or “Save
and Send…” option to save and send it to a customer or a colleague.
Coolselector®2 Exercises
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You can add a new tab for your new selection by clicking the “+ New” tab at the top
beside the tab for “Burnout filter 1”. The components, we need for the liquid line, are two
pipes and an expansion valve from the AKV family, which is an electronic expansion valve.
The suggested results would be:
Pipe before the expansion valve:
Note, that Coolselector®2 keeps your operating conditions for the system based on your
previous selection.
Coolselector®2 Exercises
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Electronic expansion valve:
Pipe after expansion valve:
Coolselector®2 Exercises
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As can be seen, the selected pipe to be placed after the expansion valve has a warning
“Flashing in liquid line”, which is due to flashing before the expansion valve.
Coolselector®2 always calculates the outlet conditions based on the inlet conditions.
Hence, by selecting a single component, which is going to be placed after other products,
in a line, the effect of the previous components in the line would be neglected. This effect
exists in every line; however, it is much more tangible in the liquid line since there is a
phase change after the expansion valve.
Comparing the product calculation results with the results from the system diagram
calculations, you can see that the inlet condition for all products is the condenser outlet
and the fact that the pipes cannot meet the outlet conditions required by the evaporator.
To overcome this, the inlet of each component should be the outlet of the previous
component. This is possible by using the components in series functionality, which we will
discuss in the next exercise.
Notice that the subcooling reference is the bubble-point temperature.
Coolselector®2 Exercises
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Selecting components in series
Using information in System Properties 1 and Cycle Diagram 1:
Load the project you saved before selection of components in the liquid line in the
previous exercise. (If you saved it after that, simply close the tabs for the liquid line
components)
Create a new tab and repeat the selection process for all the components in the liquid
line, using the option “Components in Series”.
What is the difference between the two selection methods? Does the inlet and outlet
calculation results for each component match what was expected for the cycle diagram?
Can you change the selected component to improve the design? What is the share of each
component in the pressure drop of the line? What is the minimum and maximum capacity
which can be gained in this system using the selected expansion valve?
Save your project for the next exercises.
Coolselector®2 Exercises
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Selecting components in series
You can load the previously saved project from the menu File | Open Project… or by
clicking “Ctrl+O” on the keyboard.
Create a new tab and select the option “Components in Series” and then the liquid line in
a dry system:
Now, you need to add the components to the line. To do so, first, you need to select the
functionality you would like to add to the line, and then double click on the family or drag
the family and drop it in the location that you need it.
Coolselector®2 Exercises
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Add a copper pipe with DIN-EN connection to the line and set its length to one meter:
Now you need the AKV electronic expansion valve:
Notice that Coolselector®2 automatically added a “Copper expander DIN-EN 15 × 18”
between the two components. The software recognizes the material of the piping as well
as the connection sizes and standard between two components. When two connections
do not match, it adds the required expander/reducer between the two componets for
common cases, or informs you in the row shown by the blue triangle and you can fix the
connection problem manually by adding an expander/reducer from the proper family in
the piping function.
Coolselector®2 Exercises
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Now add the pipe after the expansion valve:
As can be seen, there are no warnings in the selected pipe anymore, since the expansion is
now happening in the expansion valve. It is also interesting to notice, that the load for the
AKV valve is increased. This is due to the fact that the added pipes after the valve increase
the pressure drop and hence the opening load of the valve will also increase. Additionally,
as can be seen, the target criteria for the pipe suggestion after the expansion valve are
clearly different to the one before the expansion valve.
Proper selection of AKV valves requires extra care, which we will discuss later in detail in
Error! Reference source not found.. Please be sure to check that before selecting an AKV v
alve.
Here Coolselector®2 calculates components one after another. Furthermore, you can see
the collective effect on the performance curve for the components in the liquid line and
the need for an expander/reducer if you want to select the suggested components. The
detailed calculation of each component with the right inlet condition as shown by
numbers 1-5 on the snippet can also be extracted.
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