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• Extensive experiments for R454C through an EEV were carried out and studied. • Two semi-empirical correlations were developed for mass flow rate prediction. • The proposed correlations can predict 95% of the experimental results within 10%. • A potential relation between molar mass and mass flow coefficient was observed. The use of electronic expansion valves (EEVs) in heat pump systems has seen a rapid increase in recent years due to their advantages such as fast response, accurate control, and ability to improve seasonal performance. Modeling of the refrigerant flow characteristics through EEVs is needed during design for optimizing system performance and operation. Previous studies have not led to any generalized correlations for EEVs that accurately predict performance for different refrigerants. When working with a new refrigerant and/or EEV, it is necessary to perform mass flow measurements for the EEV over a wide range of operating conditions that are then used to develop and validate a refrigerant and EEV specific correlation. R454C, a low-GWP refrigerant mixture, is gaining attention as a potential replacement for R404A and R410A systems. However, there is currently no available EEV experimental data or correlation specifically for R454C in the literature. The objective of this paper is to present experimental results and characterization of R454C flowing through an EEV in a heat pump split system across a wide range of operational conditions. The impacts of valve opening, subcooling degree and inlet pressure on mass flow rate though the EEV were investigated. Two semi-empirical correlations were developed that map the experimental data based on the Buckingham π theorem and a polynomial function. Both mapping methods predicted mass flow rate for test data within 10%. The Buckingham π correlation was slightly more accurate. Both correlations were developed to enable mass flow rate predictions for R454C passing through EEVs with different valve sizes. Finally, a relationship between refrigerant molar mass and mass flow coefficient was observed that could be useful in developing a general EEV correlation that can be applied for different refrigerants. However, further investigation is needed to validate this relationship. [ABSTRACT FROM AUTHOR]

Refrigerant mass flow rate is an important measurement for monitoring equipment performance and enabling fault detection and diagnostics. This paper presents and evaluates three different virtual refrigerant mass flow (VRMF) sensors that use mathematical models to estimate flow rate using low cost measurements. The first model uses a compressor map that relates refrigerant flow rate to measurements of condensing and evaporating saturation temperature, and to compressor inlet temperature measurements. The second model uses an energy-balance method on the compressor that uses the compressor power consumption. The third model is developed using an empirical correlation for an electronic expansion valve (EEV) based on an orifice equation. The three VRMFs are shown to work well in estimating refrigerant mass flow rate for various systems under fault-free conditions with less than 5% RMS error. The combination of the three VRMFs can be utilized to detect and diagnose when the compressor and/or expansion device is not providing the expected flow. [ABSTRACT FROM AUTHOR]

The primary goal of the work described in this paper was to evaluate and extend a virtual refrigerant charge sensor (VRC) for determining refrigerant charge for equipment having variable-speed compressors and fans. Based on the evaluations, the original VRC sensor (termed model I) was found to work well in estimating the refrigerant charge level for systems with a variable-speed compressor. However, for extreme test conditions such as low compressor speed, the model I needed to be improved. To overcome the limitations, the model was modified to include a term involving the inlet quality to the evaporator (termed model II). The model II gave better performance for systems with a variable-speed compressor. When the superheat of the compressor was zero, neither model II could accurately predict charge level. Therefore, a third approach (Model III) was developed that includes the discharge superheat of the compressor. [ABSTRACT FROM AUTHOR]

Modifications such as economization aim to improve the efficiency of vapor compression equipment by cooling the refrigerant during the compression process. A previous study ( Mathison et al., 2010 ) explored the theoretical limit to cycle performance with economizing, which was defined as the performance when a saturated vapor state was maintained in the compressor by continuously injecting a two-phase mixture. However, achieving continuous injection and controlling the quality of the injected refrigerant poses a substantial challenge. Therefore, the current paper investigates the ability of an economized cycle with saturated vapor injection through a finite number of ports to approach the limiting cycle performance. For an air-conditioner using R-410A with an evaporation temperature of 5 °C and a condensing temperature of 40 °C, the model predicts that injecting saturated vapor through three ports will improve the COP by 12%, which is approximately 67% of the maximum benefit provided by economizing in the limiting case. [ABSTRACT FROM AUTHOR]

A model of a novel rotary spool compressor has been developed to explore the effect of multiple injection ports on compressor and cycle performance. The thermodynamic model includes the effects of heat transfer and leakage and is numerically solved to predict the compressor power consumption and mass flow rate. Saturated vapor injection is modeled assuming that the injection pressures and the timing of the injection process can be controlled. The model predicts that adding a single injection port will provide a 12% increase in the cycle coefficient of performance (COP) when the compressor runs at 1907 rpm with R-22 evaporating at −7 °C, condensing at 49 °C, and 15 °C of superheat. Adding a second, non-optimized injection port increases the COP by 16% compared to the cycle without injection. The model is used to investigate the effect of injection pressure, port location, and port diameter on cycle performance. [ABSTRACT FROM AUTHOR]

Abstract: The primary goal was to evaluate and enhance a virtual refrigerant charge (VRC) sensor developed by Li and Braun (2006, 2009). Based on the evaluation, the VRC sensor was found to work well in estimating refrigerant charge for systems that do not utilize accumulators when using the default parameters. For systems with accumulators, however, the parameters needed to be improved for better accuracy. To overcome those limitations, a simulation method for estimating parameters was developed that depends on test data at rated conditions and system information. The simulation parameters decreased the errors between the actual and predicted charge. Even better performance was achieved for the VRC sensor when the parameters were tuned by minimizing charge prediction errors using test data and linear regression. The overall RMS error for the VRC sensors using tuned parameters was 3.8% over a wide range of operating conditions for different types of systems. [Copyright &y& Elsevier]

Abstract: The paper provides results that show the impact of charge level on capacity and efficiency for several units tested in the laboratory. To evaluate the performance, capacity ratio and COP ratio were determined from measurements at various refrigerant charge levels and operating conditions. For all systems considered in this study, a refrigerant charge reduction of 25% led to an average energy efficiency reduction of about 15% and capacity degradation of about 20%. To evaluate the economic value of charge detection and correction, Seasonal Energy Efficiency Ratio (SEER) and annual cost of electricity were determined for some case studies based on the tested units. The results imply that charging inaccuracies could cause significant decreases in SEER, leading to increases in the operating costs. When the refrigerant was charged to 75% of design, the SEER value decreased by 16% and annual operating cost was increased by US$ 100 per ton of capacity. [Copyright &y& Elsevier]

Abstract: While economizing can improve the performance of vapor compression cycles, the cost of multi-stage compressors has limited its implementation to large-scale applications. However, the development of compressors with injection ports presents new opportunities for economizing in smaller-scale applications. In addition to eliminating the need for a costly multi-stage compressor, multiple injection ports can be added at relatively low cost to further improve cycle performance. In the current study, a model was developed to study the effect of the number of injection ports on performance and determine the limit to performance with injection. The model predicts that continuous injection, in which economized refrigerant is injected at an infinite number of ports to maintain saturated vapor in the compressor, provides very significant performance improvements for air-conditioning and refrigeration applications. At standard operating conditions, the COP increases between 18% and 51% depending on the application, with higher temperature lift cycles benefiting most significantly. [ABSTRACT FROM AUTHOR]

Abstract: Models for unitary air conditioners and heat pumps typically have difficulties in providing accurate predictions for the following situations: 1) charge modeling over a large range of charge levels, 2) two-phase refrigerant entering fixed-orifice expansion devices, 3) two-phase refrigerant entering compressors, and 4) non-uniform refrigerant mass flow allocation among evaporator circuits at low indoor air flow rates. This paper gives descriptions and assessments of improved modeling methodologies for all four issues. The study utilizes data obtained from extensive testing at a wide range of operating conditions for two R-410A units and one R-407C unit. [Copyright &y& Elsevier]

Abstract: A companion paper [Kim, J.-H., Braun, J.E., Groll, E.A., 2009. A hybrid method for refrigerant flow balancing in multi-circuit evaporators: upstream versus downstream control. International Journal of Refrigeration doi:10.1016/j.ijrefrig.2009.01.013 presented a hybrid approach for providing control of refrigerant flow distribution in evaporators that involves the use of small balancing valves in each circuit along with a primary expansion device to control the overall superheat from the evaporator. Furthermore, the companion paper demonstrated that the flow balancing valves should be located upstream rather than downstream of the evaporator in order to realize significant benefits. The current paper utilizes the model presented in the companion paper to more fully evaluate the effects of uneven air and refrigerant flow distributions and the benefits of upstream hybrid control in response to these effects. [Copyright &y& Elsevier]

Abstract: A hybrid method for optimizing refrigerant distribution in evaporators is presented that involves the use of small balancing valves in each circuit along with a primary expansion device to control the overall superheat from the evaporator. The flow balancing valves could be located upstream or downstream of the evaporator. This paper presents the results of a study to investigate the benefits of this hybrid scheme for both upstream and downstream flow balancing for the case of air flow mal-distribution. In order to perform this investigation, a simulation model was developed to consider evaporator flow mal-distributions for a 10.55kW residential R410A heat pump and then validated through comparisons of predicted results with measurements. Simulation results show that there are significant benefits in controlling the superheat of each circuit of evaporators through the hybrid–individual superheat control method. Furthermore, the upstream refrigerant flow control consistently outperforms the downstream refrigerant flow control, and recovers most of the loss in cooling capacity and COP due to non-uniform air flow distribution. [Copyright &y& Elsevier]

Refrigerant pressures are critical measurements for monitoring, control, diagnostics, and optimization of vapor compression cycle equipment. Direct refrigerant pressure measuring practices are expensive and more than often problematic. This paper describes a method, termed virtual pressure sensing, wherein refrigerant pressure values are indirectly derived from low-cost temperature sensors that can be surface-mounted. In this manner, physical pressure sensors are eliminated and pressure sensing can be achieved at a much lower cost and in a non-invasive way. Five virtual pressure sensors are developed to obtain the five most important pressures in vapor compression cycle equipment: compressor discharge line pressure, condensing pressure, liquid line pressure, evaporating pressure, and suction line pressure. The performance of the proposed virtual pressure sensors, in terms of accuracy in estimating pressures and inferring liquid line subcooling, suction superheat, compressor power consumption, and refrigerant flow rate, is evaluated extensively using laboratory data collected from four systems. These systems include air conditioners and heat pumps, split and packaged systems, refrigerants R-22 and R-410α, fixed-orifices and thermal expansion valves, and reciprocating compressors and scroll compressors. Ultimately, the virtual sensors are used as a part of a decoupling-based fault detection and diagnosis (FDD) technique to diagnose multiple simultaneous faults. The impact of the virtual pressure sensors on the FDD performance is evaluated extensively using the laboratory data collected from the four various systems. [ABSTRACT FROM AUTHOR]

This paper presents the development and validation of a computer model for hermetic two-stage rotary compressors that can be used for design optimization. The model considers the effects of refrigerant leakage between the compressor chambers, heat transfer between the cylinder wall and the refrigerant gas, and heat loss by natural convection to the surroundings. The model numerically solves mass and energy balances for each of the compressor's chambers to predict the pressure and temperature variations over a crankshaft revolution. The compressor power input and refrigerant mass flow rate are calculated and used to determine the isentropic and volumetric efficiencies. The model can operate both with and without intercooling between the stages to allow for study of the effects of intercooling on compressor performance. The model results are compared to the results of external performance tests that were conducted using a prototype compressor. The intermediate temperature and pressure, discharge temperature, power consumption, and mass flow rate were recorded for 17 different operating conditions. The model predicts the compressor power consumption and mass flow rate within ±5% of the experimental results. [ABSTRACT FROM AUTHOR]

A detailed model for hermetic scroll compressors was presented in a companion paper. The current paper presents validation results for this model based upon detailed experimental measurements and application of the model to study the impact of design changes. The experimental study included a range of operating conditions that were controlled using a hot gas bypass compressor load stand. The model was validated in terms of overall performance predictions (refrigerant mass flow rate, discharge temperature, and compressor power consumption) and predictions of internal measurements (refrigerant pressures within the scrolls as a function of orbiting angle, temperatures along the scroll wraps, and temperatures at various points within the shell). The model performed very well in terms of predicting overall performance and was adequate in predicting the internal measurements. The parametric modeling study identifies some areas for potential improvement. Most significantly, a relative improvement of about 5% in overall compressor efficiency can be achieved through small changes in the scroll geometry. [ABSTRACT FROM AUTHOR]

Approaching quasi-isothermal compression is possible by flooding the refrigerant vapor stream with a liquid that has high specific heat to absorb some heat of compression. To evaluate the benefits of liquid flooded compression, an R410A scroll compressor was tested over a wide range of operating conditions while flooding POE oil into the compression chamber using a hot-gas bypass test stand. The experimental results indicate that oil flooded compression leads to an increase in refrigerant mass flow rate and a decrease in compressor discharge temperature. Also, every operating condition has a maximum limit of possible oil injection, which depends on the system pressure ratio and the dimensions of the injection and discharge ports. By fitting the experimental data, a performance map for the compressor with oil flooding is developed using a semi-empirical model. This map can be used to assess the benefits of the oil flooding technology for various conditions employed in other applications. [ABSTRACT FROM AUTHOR]

In conventional vapor compression systems, electronic expansion valves (EXVs) are used for refrigerant flow control. In addition, the EXV control signal can be used along with a model and measurements of boundary conditions to provide a virtual sensor for refrigerant mass flow rate as outlined by Kim and Braun (2012). For typical single-phase inlet conditions, models for characterizing the relationship between the inlet and outlet conditions, the opening, and the mass flow rate have been extensively studied, e.g. by Park et al. (2007), and semi-empirical as well as empirical correlations have been developed. However, two-phase inlet conditions can exist at low refrigerant charge, or for certain applications such as when balancing valves are used in a hybrid control scheme as proposed by Kim et al. (2008). This paper presents a continuous correlation that can be used for both two-phase and subcooled valve inlet conditions. [ABSTRACT FROM AUTHOR]

Abstract: Vapor compression refrigeration technology has seen great improvement over the last several decades in terms of cycle efficiency through a concerted effort of manufacturers, regulators, and research engineers. As the standard vapor compression systems approach practical limits, cycle modifications should be investigated to increase system efficiency and capacity. One possible means of increasing cycle efficiency is to flood the compressor with a large quantity of oil to achieve a quasi-isothermal compression process, in addition to using a regenerator to increase refrigerant subcooling. In theory, compressor flooding and regeneration can provide a significant increase in system efficiency over the standard vapor compression system. The effectiveness of compressor flooding and regeneration increases as the temperature lift of the system increases. Therefore, this technology is particularly well suited towards lower evaporating temperatures and high ambient temperatures as seen in supermarket refrigeration applications. While predicted increases in cycle efficiency are over 40% for supermarket refrigeration applications, this technology is still very beneficial for typical air-conditioning applications, for which improvements in cycle efficiency greater than 5% are predicted. It has to be noted though that the beneficial effects of compressor flooding can only be realized if a regenerator is used to exchange heat between the refrigerant vapor exiting the evaporator and the liquid exiting the condenser. [ABSTRACT FROM AUTHOR]

Abstract: The objective of this study was to measure the effects of improper airflow and refrigerant charge on the seasonal performance of a typical 10.6kW, R-410A residential heat pump with a thermostatic expansion valve. Heating and cooling tests were performed in combinations of three refrigerant charges of 75%, 100%, and 125% of nominal value and two airflows of 75% and 100% of rated airflow. In addition, cyclic tests were performed to estimate the heating and cooling seasonal coefficient of performance (COP) at six climate zones specified by Air-Conditioning, Heating, and Refrigeration Institute (AHRI) Standard 210/240-2008. Results showed that, in each climate zone, increases in refrigerant charge at the rated airflow could improve the unit''s heating seasonal COP by as much as 5%. However, combined decreases in airflow and refrigerant charge could penalize the unit''s heating seasonal COP by as much as 10%. [Copyright &y& Elsevier]

This paper presents a detailed model for the compression process of a scroll compressor, which is used for investigating a compressor''s performance under different operating conditions and subject to design changes. Upon defining the compressor chambers as suction chambers, compression chambers and discharge chambers, a geometry study was conducted and the governing mass and energy conservation equations were developed for each chamber. Models for the refrigerant flow in the suction and discharge processes, radial and flank leakage, and heat transfer between the gas and scroll wraps were combined with the conservation equations. The state of the refrigerant changes with a period of angle 2π, and thousands of step are used to solve the governing differential equations during each period. It is assumed that in each step the compressor is in steady state. Since the differential equations for the different chambers are coupled, all these equations are solved simultaneously using a nonlinear equation solver. A description of the corresponding computer code and some results are included in this paper. Verification of the compression process model can be referred to that of the overall model, which is described in Chen et al. [Chen Y, Halm N, Braun J, Groll E. Mathematical modeling of scroll compressors—part II: overall scroll compressor modeling. International Journal of Refrigeration 2002;25(6):751–764.]. [Copyright &y& Elsevier]