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AE4-1327 R2 Revised September, 2006
ECONOMIZED VAPOR INJECTION (EVI)
COMPRESSORS
INDEX 1. Introduction
The Refrigeration Economized Vapor Injection (EVI)
SECTION PAGE Compressor was developed to provide improved
capacity and efficiency. EVI compressor systems
1. Introduction..................................... 1
benefit over standard refrigeration compressor sys-
2. Theory of Operation....................... 1 tems of equivalent horsepower due to the following:
3. Nomenclature.................................. 3
4. ARI Low Temperature Ratings....... 3 • Capacity Improvement - The capacity is improved
5. Approved Refrigerants................... 3 by increasing the h (change in enthalpy) in the
6. Approved Oils................................. 3 system rather than increasing mass flow. This is
accomplished without increasing compressor
7. Power Requirements...................... 3
displacement.
8. Application Envelope..................... 3
• Increased Energy Efficiency Ratio (EER) - The
9. Control Requirements.................... 3 efficiency improves due to the fact that the gain in
10. Discharge Temperature Control.... 3 capacity is greater than the increase in power that
10.1 Thermistor..................................... 3 the compressor consumes.
10.2 Discharge Line Thermostat.......... 4 • Cost and Energy Advantage - Because a smaller
11. TXV and Heat Exchanger............... 4 horsepower compressor can be used to achieve
the same capacity as a larger horsepower
12. System Configuration.................... 4
compressor, there is an inherent cost advantage.
12.1 Downstream Extraction................ 4
12.2 Upstream Extraction..................... 5 2. Theory of Operation
12.3 Heat Exchanger Piping Copeland EVI Scroll compressors are equipped with
Arrangements............................... 5 an injection connection for Economizer Operation.
13. System Design Guidelines............. 5 Economizing is accomplished by utilizing a
13.1 Heat Exchanger Sizing................. 5 subcooling circuit similar to that shown in Figure 1.
13.2 Line Sizing.................................... 6 This mode of operation increases the refrigeration
13.3 Heat Exchanger TXV Sizing......... 6 capacity and in turn the efficiency of the system. The
benefits provided will increase as the compression
13.4 Solenoid Valve.............................. 6
ratio increases, thus, more gains will be made in
13.5 Current Sensing Relay................. 7 summer when increased capacity may actually be
13.6 Multiple Compressor required.
Applications.................................. 7
14. Controlling Liquid Out Temperature 7 The schematic shows a system configuration for the
economizer cycle. A heat exchanger is used to
provide subcooling to the refrigerant before it enters
the evaporator. This subcooling process provides the
increased capacity gain for the system, as described
above. During the subcooling process a small
amount of refrigerant is evaporated and superheated.
This superheated refrigerant is then injected into the
mid compression cycle of the scroll compressor and
compressed to discharge pressure. This injected
vapor also provides cooling at higher compression
ratios, similar to liquid injection of standard ZF Scroll
compressors..
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Figure 1
Circuit Diagram and Cycle for EVI
Definition(s) Description
Tc Condensing temperature
Tli Liquid temperature entering H/X
Tlo Subcooled liquid leaving H/X
Pi Intermediate Pressure
Tsi Saturated temperature at intermediate pressure
Tvo Vapor temperature leaving H/X
Tvi Vapor temperature entering H/X
Tsc Liquid subcooling in H/X
M Evaporator Mass Flow
I Vapor Injection Mass Flow
THX Liquid temp out H/X-Liquid-Saturated temperature at intermediate pressure
TSC Liquid temp in to H/X-subcooled liquid temp out H/X
The P-h diagram shows the theoretical gain in system performance achieved by using the economizer cycle. The
extension outside of the vapor dome is what allows for the extra enthalpy increase in the evaporator, enhancing
system performance. Although power increases due to the vapor injection into the compressor, there is still an effi-
ciency gain given that the capacity gains exceed the power increase.
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3. Nomenclature 7. Power Requirements
The EVI compressor has a model designation as fol- EVI compressors are only available for three phase
lows, with the sixth digit shown as a "V": ZF18KVE-TFD. power.
Model Designation
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The thermistor must conform to the curve character- Conduit Alarm
istics outlined in Appendix A. The table expresses Kit Number
Connector Contact Lead
the ratio of the resistance at the indicated tempera- 998-7022-02 Yes No
ture and the resistance at 77°F (25°C). The resist-
ance at 77°F (25°C) is 86Kohms nominal. The curve 998-0540-00 No No
fit is Ratio = 0.8685e-0.257x, where x = resistance at 998-0541-00 No Yes
the indicated temperature.
Table 1
NOTE: The system controller must open the Discharge Line Thermostat Kit Numbers
contactor when the discharge line temperature
exceeds 280°F 11. Thermostatic Expansion Valve (TXV) & Heat
Exchanger
In order to properly use an Enhanced Vapor Injection
compressor a thermostatic expansion valve (TXV)
and heat exchanger are needed in the system.
Copeland provides a kit that has these components
properly sized for the ZF13 and ZF18 single com-
pressor applications, see Table 2. For multiple com-
pressor applications, the subcooling components
may be designed using the subcooling load and pres-
sure and temperature data provided by the EVI cal-
culator program.
Model 24V 120V 240V Kits Include:
985- 985- 985-
ZF13
1500-00 1500-01 1500-02
985- 985- 985-
Figure 3 ZF18
1500-00 1500-01 1500-02 TXV,
ZF24 N/A N/A N/A Solenoid Valve,
10.2 Discharge Line Thermostat
Current
Another method of discharge temperature control is ZF33 N/A N/A N/A Sensing Relay,
the use of a discharge line thermostat. It is required Heat Exchanger
in the compressor control circuit. The thermostats ZF40 N/A N/A N/A
have a cut out setting that will insure discharge line
temperatures below the 260°F (127°C) maximum ZF48 N/A N/A N/A
limit. (This value differs from the cut out value set on
the thermistor because the temperature is measured Table 2
closer to the discharge gas from the scroll when
using the thermistor.) The discharge line thermostat
should be installed approximately 7 (178mm) inches 12. System Configuration
from the discharge tube outlet. If a service valve is There are two methods of controlling refrigerant flow
installed at the discharge tube outlet, the thermostat at the heat exchanger - downstream and upstream
should be located 5 (127mm) inches from the valve extraction.
braze. For proper functioning, it is recommended the
thermostat should be insulated to protect it from a 12.1 Downstream Extraction
direct air stream. Kits have been set up to include the The downstream extraction is the preferred method
TOD thermostat, retainer, and installation instruc- employed in the United States. In downstream
tions. These thermostats must be used with ½" O.D. extraction the TXV is placed between the liquid outlet
discharge lines to ensure proper thermal transfer and and vapor inlet of the heat exchanger. The advantage
temperature control. They work with either 120 or 240 of downstream extraction is that subcooling is
volt circuits, and are available with or without an ensured because the liquid is further subcooled as it
alarm circuit capability. See Table 1 for a list of dis- flows through the heat exchanger. Therefore, more
charge line thermostat kit numbers. subcooled liquid enters the TXV which increases the
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probability that the valve will not hunt. The disadvan-
tage with this method is that it is not as efficient as the VO = Vapor temperature leaving H/X
upstream method; however, the difference is too VI = Vapor temperature entering H/X
small for practical purposes. See Figure 4. LI = Liquid temperature entering H/X
LO = Subcooled liquid leaving H/X
Figure 6
H/X Piping Arrangement
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Table 4
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Appendix A
Temp Ratio Temp Ratio Temp Ratio Temp Ratio Temp Ratio
-40°C 33.60000 7°C 2.30130 8°C 2.19180 99°C 0.07000 145°C 0.02090
-39°C 31.44900 8°C 2.19180 9°C 2.08830 100°C 0.06800 146°C 0.02039
-38°C 29.45200 9°C 2.08830 10°C 1.99030 101°C 0.06612 147°C 0.01990
-37°C 27.59700 10°C 1.99030 11°C 1.89720 102°C 0.06430 148°C 0.01942
-36°C 25.87300 11°C 1.89720 12°C 1.80900 103°C 0.06255 149°C 0.01895
-35°C 24.27000 12°C 1.80900 13°C 1.72550 104°C 0.06085 150°C 0.01850
-34°C 22.76100 13°C 1.72550 14°C 1.64640 105°C 0.05920 151°C 0.01801
-33°C 21.35700 14°C 1.64640 15°C 1.57140 106°C 0.05760 152°C 0.01754
-32°C 20.05100 15°C 1.57140 16°C 1.50000 107°C 0.05605 153°C 0.01708
-31°C 18.83400 16°C 1.50000 17°C 1.43230 108°C 0.05456 154°C 0.01663
-30°C 17.70000 17°C 1.43230 18°C 1.36810 109°C 0.05310 155°C 0.01620
-29°C 16.63420 18°C 1.36810 19°C 1.30710 110°C 0.05170 156°C 0.01584
-28°C 15.64040 19°C 1.30710 20°C 1.24930 111°C 0.05027 157°C 0.01549
-27°C 14.71340 20°C 1.24930 21°C 1.19420 112°C 0.04889 158°C 0.01515
-26°C 13.84820 21°C 1.19420 22°C 1.14180 113°C O.04755 159°C 0.01482
-25°C 13.04020 22°C 1.14180 23°C 1.09210 114°C 0.04625 160°C 0.01450
-24°C 12.28070 23°C 1.09210 24°C 1.04490 115°C O.04500 161°C 0.01418
-23°C 11.57100 24°C 1.04490 25°C 1.00000 116°C 0.04372 162°C 0.01388
-22°C 10.90750 25°C 1.00000 26°C 0.95710 117°C 0.04248 163°C 0.01358
-21°C 10.28680 26°C 0.95710 27°C 0.91640 118°C 0.04128 164°C 0.01328
-20°C 9.70600 27°C 0.91640 28°C 0.87760 119°C 0.04012 165°C 0.01300
-19°C 9.15880 28°C 0.87760 29°C 0.84070 120°C O.03900 166°C 0.01275
-18°C 8.64630 29°C 0.84070 30°C 0.80560 121°C O.03793 167°C 0.01250
-17°C 8.16620 30°C 0.80560 31°C 0.77200 122°C 0.03690 168°C 0.01226
-16°C 7.71620 31°C 0.77200 32°C 0.74010 123°C 0.03590 169°C 0.01203
-15°C 8.29400 32°C 0.74010 33°C 0.70960 124°C 0.03494 170°C 0.01180
-14°C 6.89570 33°C 0.70960 34°C 0.68060 125°C 0.03400 171°C 0.01157
-13°C 6.52190 34°C 0.68060 35°C 0.65300 126°C 0.03315 172°C 0.01134
-12°C 6.17110 35°C 0.65300 36°C 0.62660 127°C 0.03233 173°C 0.01112
-11°C 5.84150 36°C 0.62660 37°C 0.60140 128°C 0.03153 174°C 0.01091
-10°C 5.53190 37°C 0.60140 38°C 0.57740 129°C 0.03075 175°C 0.01700
-9°C 5.23920 38°C 0.57740 39°C 0.55460 130°C 0.03000 176°C 0.01049
-8°C 4.96400 39°C 0.55460 40°C 0.53270 131°C 0.02926 177°C 0.01029
-7°C 4.70520 40°C 0.53270 41°C 0.51170 132°C 0.02854 178°C 0.10090
-6°C 4.46170 41°C 0.51170 42°C 0.49180 133°C 0.02784 179°C 0.00989
-5°C 4.23240 42°C 0.49180 43°C 0.47270 134°C 0.02716 180°C 0.00970
-4°C 4.01530 43°C 0.47270 44°C 0.45440 135°C 0.02650 181°C 0.00949
-3°C 3.81090 44°C 0.45440 45°C 0.43700 136°C 0.02586 182°C 0.00928
-2°C 3.61820 45°C 0.43700 46°C 0.42030 137°C 0.02525 183°C 0.00908
-1°C 3.43670 46°C 0.42030 47°C 0.40420 138°C 0.02465 184°C 0.00889
0°C 3.26540 47°C 0.40420 48°C 0.38890 139°C 0.02407 185°C 0.00870
1°C 3.10300 48°C 0.38890 49°C 0.37430 140°C 0.02350 186°C 0.00853
2°C 2.94980 49°C 0.37430 95°C 0.07870 141°C 0.02295 187°C 0.00837
3°C 2.80520 5°C 2.53960 96°C 0.07641 142°C 0.02242 188°C 0.00821
4°C 2.66860 6°C 2.41710 97°C 0.07420 143°C 0.02190 189°C 0.00805
5°C 2.53960 7°C 2.30130 98°C 0.07206 144°C 0.02139 190°C 0.00790
6°C 2.41710