Heat pumps use less energy to warm a car's interior than a resistive heater, so are becoming popular on various makes and models of electric vehicle.
Whilst a heat pump has several components, we can share some of these with the car's existing air conditioning components, just adding a few pieces to vastly improve heating efficiency.
As is the case with many EV technologies (such as batteries, battery cooling, brakes and other systems), each manufacturer does things slightly differently.
The system used by Nissan, and in a modified form by Renault (to allow for battery cooling), adds just a few components to the standard air conditioning system. Kia and Hyundai's heat pump is a little more complex, but allows waste heat to be taken from motor, charger and inverter cooling thanks to a heat exchanger. It also allows the heat pump to cool and heat the interior at the same time, useful for demisting.
The system on the BMW i3 (an optional extra on models without the Range Extender) is different again, as the heat pump circuit is relatively simple, although the heat generated is used to heat liquid, which then flows through a traditional heater matrix to warm the interior.
The system we are looking at in this article is one fitted to one of the UK's less popular models- the Volkswagen e-Golf, which is one of the most interesting (and complex!) arrangements.
But first we will discuss how a heat pump works.
As you may know, increasing the pressure of a gas increases its temperature. Reducing the pressure will reduce the temperature. If we squash something (and therefore warm it up), then allow it to cool, and then allow it to expand again, we can end up with something colder than we started with- like the cold air out of a tyre when someone has blocked a charging point (JOKE- we do not condone things like this!).
The gas used (generally HFC134a or HFO1234yf) is chosen because it has a suitable boiling point that means we can actually cool it down enough for it to become a liquid, and then turn back into a gas on expansion, meaning it can absorb significantly more heat than just compressing and expanding a gas.
An electric compressor is used both for increasing the pressure and for pumping the refrigerant around the circuit. The electric compressor runs on the high-voltage system, and it is important to use the correct oil when servicing the system as normal air conditioning oil conducts electricity!
The e-Golf's refrigerant circuit is shown below (the green coloured section on the left hand side is the coolant circuit and is not relevant to this article).
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When the system is in cooling mode, the compressor pumps the refrigerant through the interior condenser and it goes on to the condenser on the front of the car. Here, the air coming through the front of the car (assisted by an electric fan if necessary) cools the refrigerant. We then push the refrigerant through an expansion valve, where it then expands again, and the reduced pressure causes a reduced temperature. The ice-cold refrigerant can now collect heat from the evaporator (located inside the car), which cools the car down. The flaps in the car's heater box (not shown) direct air through the cold evaporator but not through the (warm) interior condenser.
The refrigerant then returns to the compressor to start the cycle again.
So what about heating?
The same circuit is shown again below, but instead in heating mode. You will notice some of the valves have changed.
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The compressor (which always spins in the same direction) is still pushing refrigerant into the interior condenser, but now it is going through the evaporator and going into the condenser in the opposite direction. As it travels through the expansion valve, it cools, now allowing the refrigerant to collect heat from outside the car. The flow then returns to the compressor. The hot refrigerant is further heated by the compressor and the heat is "dropped" inside the car via the interior condenser.
Other cars with heat pumps also use a resistive heating element (known as a PTC heater*) as the heat pump only operates effectively within certain temperature limits, and the PTC heater can reduce warmup time. The e-Golf's PTC heater is part of the coolant circuit, and it has no heater matrix.
Below is the now familiar system layout with a few changes- the refrigerant follows largely the same path as before, but is now collecting heat from the coolant circuit via a heat exchanger.
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Even in this mode, there are different methods of operation. On a cold morning, the PTC heater warms the coolant, and the heat pump refrigerates it again and "moves" the heat into the car. However, if the car has been driving for some time, we can use waste heat from the cooling system. The radiator bypass valve is opened, so instead of heat being removed by the radiator, the valve labelled N632 allows warm coolant to circulate from the high voltage cooling circuit into the heater circuit, where it is then cooled by the heat pump, the waste heat becoming useful heat for the interior.
The system is also able to operate in combined mode, collecting heat from outside air and the coolant circuit simultaneously (see below).
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The diagrams shown are the same diagrams that we make available to HEVRA member garages to aid fault diagnosis. Fault diagnosis is generally done via diagnostic equipment (there are an array of temperature sensors, each shown as a G-number) and pressure gauges (to measure the difference in refrigerant pressure). The operation of the various valves is generally checked with an oscilloscope in conjunction with a thermal imager- the oscilloscope can check the valve is receiving the correct signal, and the thermal imager confirm whether the valve is in the required position.
*PTC stands for positive temperature coefficient, meaning that as the temperature of the heating element rises, its electrical resistance also rises. This reduces the current flow, making it to a certain extent self-regulating. The heating element can also be switched on and off as required to control temperature. PTC heaters are generally fed with high voltage and operate via a Local Interconnection Network (LIN)- a type of network used in vehicles to reduce the need to run separate wires to each component.