Application Engineering

B U L L E T I N
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..

© 2006 Copeland Corporation

1 Printed in the USA
 Application Engineering AE4-1327 R2

B U L L E T I N

Figure 1
Circuit Diagram and Cycle for EVI

(Upstream extraction shown here. See section 12 for details.)

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.

© 2006 Copeland Corporation

Printed in the USA 2
 Application
Application Engineering
Engineering AE4-1327 R2

B
B U
U L
L L
L E
E T
T II N
N
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.

The model numbers include the nominal capacity 8. Application Envelope

without the economizer cycle for R-404A refrigerant ZF**KVE Envelope (R-404A/R-507)
at 60 Hz Low Temperature ARI rating conditions.

Model Designation

1 Z = Compressor Family: Z = Scroll

2 F = Low Temperature
3 Nominal Capacity [BTU/h] @ 60 Hz and ARI
low temperature conditions using multipliers
“K” for 1000, without vapor injection
4 Vapor Injection for EVI Operation
5 POE Oil
6 Motor Version
7 Bill of Material Number
Figure 2
The EVI rating curves have been developed to incor-
porate performance improvements while utilizing the 9. Control Requirements
economizer cycle. The capacity displayed is with See Figure 3 for a detailed schematic for this system
maximum possible subcooling at the exit of the sub- (shown for a single compressor application). The fig-
cooling heat exchanger. Compressor performance ure also shows the up-stream extraction method for
information can be obtained by accessing the "Online tapping the liquid for the heat exchanger; see Section
Product Information" (OPI) database via 12 for additional details.
emersonclimatecustomer.com.
10. Discharge Temperature Control
4. ARI Low Temperature Ratings (-25°F/105°F) A discharge temperature control is not required on all
compressors. At this time, liquid injection is not
Model With EVI* Without EVI approved for this application.
ZF13KVE 20100 Btu/hr 13000 Btu/hr
ZF18KVE 29200 Btu/hr 18000 Btu/hr Models ZF24KVE-TW*, ZF33KVE-TW*, ZF40KVE-
ZF24KVE 34200 Btu/hr 24000 Btu/hr TW*, ZF48KVE-TW* have an internal temperature
ZF33KVE 47900 Btu/hr 33000 Btu/hr sensor and no other discharge temperature control is
ZF40KVE 62500 Btu/hr 40000 Btu/hr
required.
ZF48KVE 72000 Btu/hr 48000 Btu/hr
*Maximum possible subcooling.
For models ZF13KVE-TF*, ZF18KVE-TF* use one of
5. Approved Refrigerants the following two methods for discharge temperature
R404A and R507 are approved for use with the Scroll control.
EVI compressors.
10.1 Thermistor
6. Approved Oils A thermistor in the compressor control circuit is used
Polyol Ester (POE) lubricants are the only lubricants to protect against high discharge temperatures and
approved for the EVI compressor. For a complete list must be wired to the rack control systems. The cut
of approved POE lubricants, refer to Form 93-11 out temperature is to be set at 280°F. The tempera-
“Copeland Accepted Refrigerants/Lubricants” via ture resistance values for the sensor can be found in
emersonclimatecustomer.com. Appendix A.

© 2006 Copeland Corporation

3 Printed in the USA
 Application Engineering AE4-1327 R2

B U L L E T I N
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

© 2006 Copeland Corporation

Printed in the USA 4
 Application
Application Engineering
Engineering
B
B U
U L
L L
L E
probability that the valve will not hunt. The disadvan-
tage with this method is that it is not as efficient as the
upstream method; however, the difference is too
small for practical purposes. See Figure 4.
Figure 4
Downstream Extraction
12.2 Upstream Extraction
In upstream extraction the TXV is placed between the
condenser and the heat exchanger. The TXV regu-
lates the flow of subcooled refrigerant out of the con-
denser and into the heat exchanger. With this type of
configuration there is a potential for flash gas which
would cause the valve to hunt. See Figure 5.
Figure 5
Upstream Extraction
12.3 Heat Exchanger Piping Arrangements
Best subcooling effect is assured if counter flow of
gas and liquid is provided as shown (see Figure 6).
In order to guarantee optimum heat transfer, the plate
heat exchanger should be mounted vertically and
vapor should exit it at the top.
5 Printed in the USA
AE4-1327 R2
E T
T II N
N
VO = Vapor temperature leaving H/X
VI = Vapor temperature entering H/X
LI = Liquid temperature entering H/X
LO = Subcooled liquid leaving H/X
Figure 6
H/X Piping Arrangement
13. System Design Guidelines:
NOTE: The following sections discuss system design
guide lines for the EVI product. Please refer to the
compressor Performance Calculator which can be
found in the Online Product Information (OPI) data-
base located in emersonclimatecustomer.com for fur-
ther information needed to accommodate your sizing
needs.
13.1 Heat Exchanger Sizing
Heat exchangers should be sized so that they have
adequate design margin for the entire range of sys-
tem operation, but they should be optimized for nor-
mal operating conditions. The parameters used to
determine the proper heat exchanger size are
described below:
• SIT = Heat Exchanger saturated evaporating
temperature at its outlet pressure.
• LIT = Liquid in Temp ~ Condensing Outlet
• LOT = Liquid Out Temp = SIT + TD
• VIT = Vapor In Temp ~ SIT + Loss
• VOT = Vapor Out Temp = SIT + Superheat
• H = Enthalpy
• Subcooling = LIT - LOT
• Superheat = VOT - SIT
• TD = LOT - SIT
The key parameter in determining the proper heat
exchanger is the Saturated Injection Temperature
(SIT). It is imperative the following procedure be fol-
lowed for optimized performance. The SIT has been
derived experimentally and can be approximated by
using Figure 7. After determining the SIT, a 10°F
Condenser Subcooling, TD, and Superheat are tar-
geted. This is done in order to optimize system per-
formance while at the same time maintaining system
reliability and functionality. Once these parameters
have been established, the heat exchanger Btu/Hr
capacity can be established, which gives the required
heat exchanger size.
© 2006 Copeland Corporation
 Application Engineering AE4-1327 R2

B U L L E T I N

13.2 Line Sizing

In single compressor applications, the vapor injection
line from the heat exchanger to the compressor
should be 3/8" - 1/2" and kept as short as possible in
order to minimize pressure drop loss. The liquid line
from the heat exchanger to the evaporator should be
insulated and kept as short as possible in order to
maximize the subcooling at the evaporator. If a vapor
injection header is used, the header diameter should
be such that the cross-sectional area is equal to the
sum of the cross-sectional areas of the individual
cross-sectional lines to the compressor.

For example, for four compressors, each with a 3/8"

vapor injection line, the header tube diameter should
Figure 7 be a 7/8" tube. In addition, the individual injection
lines to the compressors should tap into the header
Example of Heat Exchanger Sizing Optimized either on top or on the sides of the header tube; a
ZF18KVE 404A bottom tap will increase the risk of returning liquid
Step 1 into the compressor through the vapor injection line.
• Know Conditions -25/105/0/65°
Te / Tc / Cond SC / Suct RG 13.3 Heat Exchanger TXV Sizing
Step 2 TXV's should be sized so that they have adequate
• Determine Flow Me 355 lb/hr design margin for the entire range of system opera-
From Product Data tion, but they should be optimized for normal operat-
ing conditions. Select a TXV that is able to handle the
Step 3 Btu/hr capacity of the heat exchanger determined in
• Estimate SIT From Guideline 12°
the section above.
Step 4
• Use the 10° Guidelines To Derive 13.4 Solenoid Valve & Ball Valve
• LIT = T° - 10° 95° A solenoid valve is required to stop the flow of vapor
• LOT = SIT + 10° 22° from the system to the compressor when the com-
• HX SC =LIT - LOT 73° pressor is in the off cycle. This must be a vapor sole-
=(T - SIT-20°) noid sized equivalent to or larger than the vapor
• HX Btu/hr =M°° x (Hft - Hlot) 9550
=355 x (47.0 - 20.1) injection tube size. For minimum orifice sizes see
Table 3. For service purposes, a mechanical ball
Example of Heat Exchanger Sizing – valve (not provided by Copeland) is also recommend-
Fixed Liquid Temperature ed in the vapor injection line.
ZF18KVE 404A
Step 1 Minimum Flow Control
• Know Conditions -25/105/0/65° Model
Orifice Size Valve Series
Te / Tc / Cond SC / Suct RG
ZF13 3/16" 200RB 3
Step 2
• Determine Flow M° 355 lb/hr ZF18 3/16" 200RB 3
From Product Data
ZF24 1/4" 200RB 4
Step 3
• Use the 10° Guideline ZF33 1/4" 200RB 4
• LIT = T - 10° 95° ZF40 5/16" 200RB 5
• LOT user° defined 50°
• HX SC =LIT - LOT 45° ZF48 5/16" 200RB 5
• HX [Btu/hr] =M° x (Hft - Hlot) 6140
=355 x (47.0 - 29.7) Table 3
For multiple compressor applications the same
process can be used to determine the heat exchang-
er size needed by adding together the individual heat
exchanger capacities for each compressor.
© 2006 Copeland Corporation
Printed in the USA 6
 Application Engineering AE4-1327 R2

B U L L E T I N

13.5 Current Sensing Relay

To prevent the solenoid from remaining open during
a "motor protector trip" a current sensing relay must
be provided that senses whenever the compressor is
"off" and closes the solenoid to stop injection. See
Table 2 for a kit with the correct current sensing relay.

13.6 Multiple Compressor Applications

EVI can also be used in multiple compressor applica-
tions. Unlike a standard compressor system, the EVI
compressor system changes its delivered capacity by
changing the amount of sub-cooling provided at the
sub-cooling heat exchanger. The result is that in high Figure 8
ambient temperature conditions (summer operation) EVI Paralleling with HX Thermostatic valves of
and in low ambient temperature conditions (winter different capacity
operation), the same number of compressors tend to
run. It is important to note this since most personnel
are used to seeing fewer compressors in operation in
the cooler winter months compared to the hotter summer
months; with EVI, almost the same number of com-
pressors will be running in the summer and winter.

Multiple EVI compressors can be used with either a

single heat exchanger for each compressor or a com-
mon heat exchanger for all compressors. In case of
a common heat exchanger, a solenoid valve should
be installed on each individual vapor injection line.

Special care has to be given to the design of the heat Figure 9

exchanger and of the thermostatic expansion valve EVI Paralleling with HX Electronic Expansion valve (EXV)
(TXV) to allow for part load operation. Good refriger-
ant distribution is required in the common heat
exchanger as well as sufficient velocities for oil 14. Controlling Liquid Out Temperature (LOT)
return, even at part load. The LOT will typically be determined by the operating
condition of the compressor. If the LOT needs to be
In the case of a large range of capacity modulation fixed at any specific value (for example, 50°F) for pur-
(more than 2 compressors in parallel), the use of an poses of good system control, an Evaporator
Electronic Expansion Valve (EXV) or of two different Pressure Regulator (EPR) valve may be introduced
TXV(s) controlled by individual solenoid valves, may at the vapor outlet of the subcooling heat exchanger.
improve performance. For example, one at 100% full Table 4 shows approximate EPR settings for different
load and the second solenoid valve for 30% of full liquid temperature.
load. (See Figure 8 and Figure 9). It is necessary to
ensure that the solenoid valves, vapor injection lines
and header(s) are adequately sized in order to keep R404A
pressure drop to a minimum. At the same time, the Subcooler Liquid Out Approximate EPR
layout should be such that excessive amounts of oil Temperature, F Setting, psig (psia)
do not accumulate in the header.
60 124.4 (139.0)
50 103.8 (118.4)
40 85.6 (100.2)

Table 4

© 2006 Copeland Corporation

7 Printed in the USA
 Application Engineering AE4-1327 R2

B U L L E T I N

The performance calculator program can be used to determine

the effect of fixing LOT on the capacity and efficiency of the
compressor. See Figures 10 & 11 below.

Figure 10. Screen shot of the Calculator program, showing the

maximum sub-cooling obtained when the default "Auto" is select-
ed for Economizer sub-cool.

Figure 11. Screen shot of the Calculator program, showing the

constant liquid temperature at outlet of the subcooling heat
exchanger.
© 2006 Copeland Corporation
Printed in the USA 8
 Application Engineering AE4-1327 R2

B U L L E T I N

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

© 2006 Copeland Corporation

Printed in the USA