TEST REPORT #34. Compressor Calorimeter Test of Refrigerant DR-7 in a R-404A Scroll Compressor

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Julianna Harmon
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Rajendran Autumn Nicholson Emerson Climate Technologies, Inc. 1675 West Campbell Rd.

1 Air-Conditioning, Heating, and Refrigeration Institute (AHRI) Low-GWP Alternative Refrigerants Evaluation Program (Low-GWP AREP) TEST REPORT #34 Compressor Calorimeter Test of Refrigerant DR-7 in a R-404A Scroll Compressor Rajan Rajendran Autumn Nicholson Emerson Climate Technologies, Inc West Campbell Rd. Sidney, OH April 14, 2014 This report has been made available to the public as part of the author company s participation in the AHRI s Low-GWP AREP.

2 List of Tested Refrigerants Compositions (Mass%) DR-7 R-32/R-1234yf (36/64)

3 Contents Introduction... 3 Details of Test Setup... 4 Description of Test Refrigerant-Lubricant and Charge... 4 Description of Compressor... 4 Table 1. Compressor Calorimeter Test Points... 4 Description and Size of Test Loop... 5 Figure 1. Simplified System Diagram of Test Setup... 5 Table 2. Test Loop Component Accuracy... 6 Results... 7 Table 3. DuPont DR-7 Test Results (20F Superheat)- Dew Point... 8 Performance Curves and Coefficients... 9 Figure 2. DR-7 10-Coefficient Polynomial Equations for Cooling Capacity and Power (20F Superheat, 0F Subcool)... 9 Figure 3a and 3b. ZF18K4E-TFD R-404A Low Temperature and Medium Temperature Operating Map-With Liquid Injection (65 F Return Gas, 0F Subcool)... 9 Figure 4. R-404A Cooling Capacity vs. Evaporating Temperature (Dew Point)...10 Figure 5. DR-7 Cooling Capacity vs. Evaporating Temperature (Dew Point)...11 Figure 6. R-404A Input Power vs. Evaporating Temperature (Dew Point)...12 Figure 7. DR-7 Input Power vs. Evaporating Temperature (Dew Point)...13 Figure 8. R-404A Cooling COP vs. Evaporating Temperature (Dew Point)...14 Figure 9. DR-7 Cooling COP vs. Evaporating Temperature (Dew Point)...15 Comparative Analysis...16 Figure 10. DR-7/R-404A Cooling COP vs. Evaporating Temperature (Dew Point)...17 Figure 11. DR-7/R-404A Cooling Capacity vs. Evaporating Temperature (Dew Point)...18 Summary

4 Introduction This Report covers the calorimeter testing results of DuPont DR-7 performed by Emerson Climate Technologies, Inc. (Emerson) for the AHRI Low-GWP AREP study. The testing was done in Emerson s A2L Research calorimeter lab test facility located in Sidney, Ohio. The refrigerant was tested with a R-404A Copeland Scroll compressor ZF18K4E-TFD for refrigeration applications. This report is based on a drop-in test. No optimization, oil or hardware changes were made to account for the alternative refrigerant. All compressor tests are performed at a refrigerant s dew point temperature for suction and discharge pressure conditions, per AHRI Standard 540 requirements. This does not have an impact on comparing compressor performance between two or more refrigerants that do not exhibit temperature glide. However, when refrigerants exhibit temperature glide, it is important to note that actual systems operate closer to the mid-point condition. When comparing compressor performance of one refrigerant with glide to another refrigerant without glide, or comparing two refrigerants with significantly different glides, comparison at pressures corresponding to the mid-point of the temperature glide rather than the dew point will yield results that are more representative of actual operation in a system. 3

5 Details of Test Setup Description of Test Refrigerant-Lubricant and Charge Refrigerant/Refrigerant Blend tested: DuPont DR-7 o Initial Refrigerant Charge: 3.3 lbs (1.5 kg) Lubricant: o 32-3MAF POE Oil o Viscosity grade: 32 cst o Any modifications to base lubricant? No Description of Compressor Copeland R-404A Scroll No compressor modifications Emerson Climate Technologies, Inc. Copeland Brand Model No. ZF18K4E-TFD, Serial No. 12A5735AD Motor Nameplate Rating: 460V-3Ø-60Hz, 2 hp, 8.9A RLA (MCC/1.4), 3500 RPM (nominal) Displacement: in 3 /rev Air Flow Required (Y/N?): Yes Quantity: 1,360 ft 3 /min (38.5 m 3 /min) Velocity and Temperature of Air: 95 F Ambient Orientation of Air Flow In Relation to the compressor: Perpendicular to the vertical axis of the compressor Compressor Test Points (see Test Points in Table 1) Table 1. Compressor Calorimeter Test Points Refrigerant Vapor Saturated Saturated Suction Ambient Air Suction Temperature Discharge Discharge Discharge Volts-Phase- Temperature Temperature Pressure Entering Pressure Temperature Temperature 1 Frequency (Dew Point) Compressor (Dew Point) Speed F C psia Bar F C F C psia Bar F C F C V-Ø-Hz RPM , , , , , , , , , , , , , , , , Measured on Discharge Line 6" from Compressor Discharge Port. 4

6 Description and Size of Test Loop Test Loop Components: See Figure 1. Instrumentation/Accuracy: See Table 2. Figure 1. Simplified System Diagram of Test Setup 5

7 Table 2. Test Loop Component Accuracy Device Instrumentation Accuracy Full Scale/Span 3051S1TA3A2E11A2AT1 Suction Pressure Transducer +/ % span 300 psia Discharge Pressure Transducer +/ % span 800 psia EVI Pressure Transducer +/ % span 400 psia G4AD3 Suction Pressure Signal Conditioning Module +/_ 0.08% full scale 300 psia Discharge Pressure Signal Conditioning Module +/_ 0.08% full scale 800 psia EVI Pressure Signal Conditioning Module +/_ 0.08% full scale 400 psia 3144PD1A1NA Suction Temperature Transducer ± 0.45⁰F ±0.02% of span 200 ᴼF Discharge Temperature Transducer ± 0.45⁰F ±0.02% of span 400 ᴼF Compressor Ambient Temperature Transducer ± 0.45⁰F ±0.02% of span 200 ᴼF G4AD3 Suction Temperature Signal Conditioning Module +/_ 0.08% full scale 200 ᴼF Discharge Temperature Signal Conditioning Module +/_ 0.08% full scale 400 ᴼF Compressor Ambient Temperature Signal Conditioning Module +/_ 0.08% full scale 200 ᴼF G4AD18 EVI Temperature Signal Conditioning Module ± 1.62 F 435 ᴼF DSP-1Y25A125 Watts +/- 0.1% reading +/- 0.01% full scale kW Volts +/- 0.1% full scale 720 V Amps +/- 0.1% full scale 125 A CMF025 W/MVD Transmitter Compressor Mass Flow ±0.35% of rate CMF010 W/MVD Transmitter Oil Circulation Mass Flow ±0.1% of rate 6

8 Results Table 3 shows the test results from drop-in compressor testing with DR-7. The R-404A baseline data is from published nominal rating data (capacity and EER within ±5% of test data). Capacity calculations for DR-7 are done via measured mass flow multiplied by enthalpy change using the refrigerant properties supplied by the chemical manufacturer. All compressor performance is based on dew temperature/pressure and was tested per AHRI Standard The comparison is only provided for 20F compressor superheat, as running at higher superheat / return gas conditions resulted in discharge line temperatures greater than Copeland application guidelines permit without additional discharge temperature protection (i.e. liquid injection). 7

9 1 Measured on Discharge Line 6" from Compressor Discharge Port. COP Base 2 Evaporating Temperature, F ( C) Dew Point Evaporator Glide, F (C) Condensing Temperature, F ( C) Dew Point Table 3. DuPont DR-7 Test Results (20F Superheat)- Dew Point Condenser Glide, F (C) Discharge Temperature 1 F ( C) Applicable Superheating, F (C) Applicable Subcooling, F (C) Cooling Compressor Capacity, Btu/hr (W) Refrigerant Mass Flow Rate, lbm/hr (kg/hr) Amperes, A (A) Input Power, W Cooling EER, Btu/W-hr Cooling COP, W/W -40 (-40) 10.8 (6) 70 (21.1) 10.7 (5.9) 202 (94.4) 20 (11) 0 (0) (3812) 177 (80) 5.1 2, (-40) 10.8 (6) 90 (32.2) 10.3 (5.7) 235 (112.8) 20 (11) 0 (0) (3331) 173 (79) 5.4 2, (-40) 10.8 (6) 108 (42.2) 9.7 (5.4) 274 (134.4) 20 (11) 0 (0) 9813 (2876) 168 (76) 5.9 3, (-32) 10.8 (6) 105 (40.6) 9.8 (5.5) 232 (111.1) 20 (11) 0 (0) (4666) 257 (117) 6.3 3, (-29) 10.9 (6) 70 (21.1) 10.7 (5.9) 171 (77.2) 20 (11) 0 (0) (6657) 297 (135) 5.5 2, (-29) 10.9 (6) 90 (32.2) 10.3 (5.7) 197 (91.7) 20 (11) 0 (0) (6005) 298 (135) 6.0 3, (-29) 10.9 (6) 128 (53.3) 8.8 (4.9) 276 (135.6) 20 (11) 0 (0) (4203) 274 (124) 7.5 4, (-18) 11 (6.1) 80 (26.7) 10.5 (5.8) 161 (71.7) 20 (11) 0 (0) (10366) 468 (213) 6.3 3, (-18) 11 (6.1) 100 (37.8) 10 (5.5) 188 (86.7) 20 (11) 0 (0) (9156) 462 (210) 7.0 4, (-18) 11 (6.1) 120 (48.9) 9.2 (5.1) 221 (105) 20 (11) 0 (0) (7832) 453 (206) 7.9 5, (-18) 11 (6.1) 135 (57.2) 8.3 (4.6) 254 (123.3) 20 (11) 0 (0) (6565) 431 (196) 8.8 5, (-7) 11 (6.1) 80 (26.7) 10.5 (5.8) 146 (63.3) 20 (11) 0 (0) (16574) 722 (328) 6.9 4, (-7) 11 (6.1) 100 (37.8) 10 (5.5) 169 (76.1) 20 (11) 0 (0) (14560) 706 (321) 7.6 4, (-7) 11 (6.1) 120 (48.9) 9.2 (5.1) 196 (91.1) 20 (11) 0 (0) (12866) 711 (323) 8.8 5, (-7) 11 (6.1) 120 (48.9) 9.2 (5.1) 193 (89.4) 20 (11) 0 (0) (13143) 726 (330) 8.7 5, (-7) 11 (6.1) 140 (60) 7.9 (4.4) 231 (110.6) 20 (11) 0 (0) (10272) 672 (305) , (7) 10.9 (6.1) 100 (37.8) 10 (5.5) 159 (70.6) 20 (11) 0 (0) (24716) 1146 (521) 8.9 6, (7) 10.9 (6.1) 120 (48.9) 9.2 (5.1) 180 (82.2) 20 (11) 0 (0) (21451) 1127 (512) 9.9 6, (7) 10.9 (6.1) 140 (60) 7.9 (4.4) 207 (97.2) 20 (11) 0 (0) (17959) 1107 (503) , Base Refrigerant is R-404A Cooling COP alt / 8

10 Performance Curves and Coefficients The following plots show baseline R-404A and LGWP alternative DR-7 capacity, input power and COP using the 10-Coefficient polynomial equation for each refrigerant (see Figure 2 for DR- 7 Coefficients). These coefficients should only be applied within the acceptable compressor operating envelope to avoid excessive extrapolation error in the results. Testing was only run between -25 F and 30 F evaporating temperatures in order to maintain acceptable discharge temperatures without requiring liquid injection. The R-404A operating envelope(s) for the test compressor is shown in Figure 3. The x and y axes show dew point temperatures. COOLING CAPACITY (Btu/hr): C0 C1 C2 C3 C4 C5 C6 C7 C8 C POWER (W): P0 P1 P2 P3 P4 P5 P6 P7 P8 P Figure 2. DR-7 10-Coefficient Polynomial Equations for Cooling Capacity and Power (20F Superheat, 0F Subcool) a. Low Temperature Liquid Injected Map b. Medium Temperature Liquid Injected Map Figure 3a and 3b. ZF18K4E-TFD R-404A Low Temperature and Medium Temperature Operating Map-With Liquid Injection (65 F Return Gas, 0F Subcool) 9

11 Figure 4. R-404A Cooling Capacity vs. Evaporating Temperature (Dew Point) 10

12 Figure 5. DR-7 Cooling Capacity vs. Evaporating Temperature (Dew Point) 11

13 Figure 6. R-404A Input Power vs. Evaporating Temperature (Dew Point) 12

14 Figure 7. DR-7 Input Power vs. Evaporating Temperature (Dew Point) 13

15 Figure 8. R-404A Cooling COP vs. Evaporating Temperature (Dew Point) 14

16 Figure 9. DR-7 Cooling COP vs. Evaporating Temperature (Dew Point) 15

17 Comparative Analysis Figures 10 through 11 show the ratio of DR-7 to R-404A cooling COP and cooling capacity, respectively, versus evaporating temperature. At extreme operating conditions, testing uncertainties could lead to higher than normal variability in reported results. 16

18 Figure 10. DR-7/R-404A Cooling COP vs. Evaporating Temperature (Dew Point) 17

19 Figure 11. DR-7/R-404A Cooling Capacity vs. Evaporating Temperature (Dew Point) 18

20 Summary The compressor calorimeter testing of DuPont DR-7 was carried out at dew point conditions and compared to R-404A. DR-7 has moderate refrigerant glide of about 11F (6C). The compressor capacity versus R-404A is within 90 to 110% of rated performance across the operating map of the tested compressor (refer back to Figures 3a and 3b). The capacity was less than R-404A capacity at condensing temperatures less than 110 F (43.3 C). The compressor COP of DR-7 is between about 100 and 115% of R-404A across the reduced compressor operating envelope (less liquid injection). 19

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