Beruflich Dokumente
Kultur Dokumente
1 Introduction ............................................................................................................................................... 2
2 Principle of operation ................................................................................................................................. 2
3 Capacity effect .......................................................................................................................................... 3
4 Operating envelope with vapour Injection for models ZH09-48KVE ............................................................ 4
5 Multiple compressors configuration ............................................................................................................ 4
6 Economizer selection and application ........................................................................................................ 5
7 Liquid receiver ........................................................................................................................................... 8
8 Expansion valve and solenoid valve selection for injection line................................................................... 8
9 Injection expansion valve setting ............................................................................................................... 9
10 Injection line diameter................................................................................................................................ 9
11 Expansion valve selection for main evaporator .......................................................................................... 9
12 Main liquid line components ...................................................................................................................... 9
13 Line lengths and insulation ...................................................................................................................... 10
14 Additional application points .................................................................................................................... 10
14.1 Operation without vapour injection ................................................................................................... 10
14.2 Discharge temperature protection .................................................................................................... 10
14.3 Current sensing relay ...................................................................................................................... 10
15 Reference List of Copeland Related Technical Information ...................................................................... 10
1/10
Technical Information C7.4.3/1107-0512/E
1 Introduction
This Technical Information describes the principle of operation and the system design of the Enhanced Vapour
Injection for ZH*KVE Heat Pump optimized Copeland Scroll compressors, whatever they are used in single or
tandem configuration.
The vapour injection scroll compressor is for use with an economized vapour compression cycle heat pump. This
cycle offers the advantages of more heat delivered and a better COP than with a conventional cycle. Both the
heating capacity and the COP improvement are proportional to the temperature lift and this technology offers best
results at high condensing operation where capacity and efficiency are most needed. Due to this increase in
capacity, it is possible to specify a smaller displacement compressor for a given heating load. Additionally the
cooling provided by injection inter-stage allows the operation of the compressor over a larger envelope compared
to a conventional single stage model, providing higher heat delivery temperatures at low evaporating temperatures.
2 Principle of operation
As shown in Figure 1, a portion of the condensed liquid, i, is expanded through an expansion valve into a counter
flow plate heat exchanger, HX, which acts as a sub-cooler. Superheated vapour is then injected into the
intermediate vapour injection port in the scroll compressor. The additional subcooling increases the evaporator
capacity by reducing the temperature of the liquid from TLI to TLO, thus reducing its enthalpy. The additional
condenser mass flow, i, increases the heating capacity by the same amount.
Figure 1: Circuit diagrams showing the main circuit, mass flow rate m, and the economizer circuit, mass flow rate i
Efficiency with vapour injection scroll compressor cycle is higher than that of a conventional single-stage scroll
delivering the same capacity because the added capacity is achieved with less power. The incremental vapour
created in the subcooling process is compressed only from the higher inter-stage pressure rather than from the
lower suction pressure.
The cooling effect is achieved by the addition of vapour to the compression process at the intermediate pressure
and at temperature TVO, controlled by the HX expansion valve.
Superheated vapour is injected into the scroll set at the intermediate point of the compression process, via two
symmetrically positioned ports as shown on the left in Figure 2. The size and position of these ports have been
optimized to ensure maximum COP and capacity benefit at typical operating conditions. The superheated vapour
enters the compressor via an additional inlet connection on the compressor shell and flows to the injection ports of
the fixed scroll via a tube as shown on the right. The tubing characteristics flexibility ensures that axial compliance
is maintained.
2/10
Technical Information C7.4.3/1107-0512/E
Figure 2: Position of the injection ports in the scroll set and the internal tubing connecting the injection inlet with the
scroll set
3 Capacity effect
The vapour injection (VI) scroll is particularly suited to Air Source Heat Pumps (ASHP).
3/10
Technical Information C7.4.3/1107-0512/E
Figure 4: Operating envelope for vapour injection and standard Scroll compressors (considering condenser
subcooling and temperature approach at the economizer of 5 K)
Figure 4 shows the comparison of the compressor operating envelope for the standard and the VI scrolls,
illustrating clearly the additional high temperature capability at evaporating temperatures below 5C.
For air-to-water heat pump application, an envelope extension may be required for high temperature water
production by low outdoor temperature. This can be carried out by the use of wet vapour injection. For further
information about wet injection, contact the Application Engineering department of Emerson Climate Technologies.
5 Multiple compressors configuration
Multiple Vapour Injection compressors can share one economizer (HX) and one expansion valve (Figure 5). Due to
the larger range of capacity brought by such configuration, an electronic expansion valve is recommended.
Solenoid valves must be fitted to the individual vapour injection lines to close when the compressor is switched off,
in order to avoid excessive quantities of liquid entering the compressor during standstill.
Figure 5: Multiple compressors configuration when one injection expansion valve is sufficient.
For further information about multiple ZH compressors possibilities, refer to the technical information C071703
Paralleling of ZH Copeland scroll compressors for heat pump applications.
4/10
Technical Information C7.4.3/1107-0512/E
Natural
subcooling
Additional
information
on vapour
injection
5/10
Technical Information C7.4.3/1107-0512/E
Figure 8: Position of the expansion valve and bulb when using a plate heat exchanger
The bulb of the expansion valve should be located 400 600 mm from the vapour outlet, preferably after a bend
and on the inside as shown on the left in Figure 8. The position of the bulb relative to the section of the tube is
illustrated. It should not be attached underneath the tube. External equalisation is not essential. The tubing
between the expansion valve and the economizer entry may either be straight or include a bend as shown on the
right in Figure 8. It is most important that the connection diameter at the entry to the economizer is small enough to
induce the turbulence required for uniform distribution and evaporation.
6/10
Technical Information C7.4.3/1107-0512/E
The following table gives the recommended economizer size and inner diameter at the economizer ports.
Table 3: Alfa Laval heat exchanger recommendation for single compressor configuration
The recommendations above give the best economizer performance with the lowest number of economizer
models. If the diameter of the pipe work is not fitting to the economizer ports, use reducers into the economizer at
the inlet and outlet. Use Emerson Climate Technologies recommended pipe work sizes (see below).
If heat exchangers with recommended port sizes are not available, order the same economizer with larger ports
and use reducers to fit required port diameters.
7/10
Technical Information C7.4.3/1107-0512/E
7 Liquid receiver
A liquid receiver may be necessary to accommodate charge variations over the operating condition range and limit
the condenser subcooling. It should always be fitted in the condenser outlet liquid line and not in the heat
exchanger outlet liquid line (Figure 9). This is because vapour phase may be present in a receiver, and this is only
possible with saturated liquid.
Table 4: Electronic (EXV), thermostatic expansion valve (TXV) and liquid solenoid valve recommendations for the
injection (single configuration only)
If an electronic expansion valve is used, it should be a variable orifice type. Pulse modulating types are unsuitable
because the internal volume of the economizer is low, and they will give rise to unstable operating conditions which
may result in an unacceptable quantity of liquid overfeed.
8/10
Technical Information C7.4.3/1107-0512/E
Table 6: Electronic and thermostatic expansion valve recommendations for main evaporator (single application only)
9/10
Technical Information C7.4.3/1107-0512/E
Figure 10: Approximate % heating capacity reduction obtained if changing to operation without VI
10/10