SYSTEM AND METHOD FOR CALCULATING PARAMETERS FOR A REFRIGERATION SYSTEM WITH A VARIABLE SPEED

COMPRESSOR

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Utility Application No. 12/246,297 filed on October 7, 2008. This application also claims the benefit of U.S. Provisional Application No. 60/978,296, filed on October 8, 2007 and U.S. Provisional Application No. 60/978,258, filed on October 8, 2007. The entire disclosures of each of the above applications are incorporated herein by reference.

FIELD

[0002] The present disclosure relates to compressors and more particularly to a system and method for calculating parameters of a refrigeration system with a variable speed compressor.

BACKGROUND [0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0004] Compressors may be used in a wide variety of industrial and residential applications to circulate refrigerant within a refrigeration, heat pump, HVAC, or chiller system (generically "refrigeration systems") to provide a desired heating or cooling effect. In any of the foregoing applications, the compressor should provide consistent and efficient operation to insure that the particular application (i.e., refrigeration, heat pump, HVAC, or chiller system) functions properly. A variable speed compressor may be used to vary compressor capacity according to refrigeration system load. Operating parameters of the compressor and of the refrigeration system may be used by protection, control, and diagnostic systems to insure optimal operation of the compressor and refrigeration system components. For example, evaporator temperature and/or condenser temperature may be used to diagnose, protect, and control the compressor and other refrigeration system components.

SUMMARY

[0005] A system is provided that may comprise a compressor connected to a condenser and an evaporator, an evaporator sensor that outputs an evaporator signal corresponding to at least one of an evaporator pressure and an evaporator temperature, an inverter drive that modulates electric power delivered to the compressor to modulate a speed of the compressor, and a control module connected to the inverter drive. The control module may receive the evaporator signal, monitor electrical power data and compressor speed data from the inverter drive, and calculate at least one of a condenser temperature and a condenser pressure based on the evaporator signal, the electrical power data, and the compressor speed data.

[0006] In other features, the electrical power data may include compressor current data for the compressor. [0007] In other features, a discharge temperature sensor may output a discharge temperature signal corresponding to a temperature of refrigerant exiting the compressor and the control module may calculate a discharge superheat temperature of the compressor based on the discharge tmeperature signal and at least one of the calculated condenser temperature and the derived condenser pressure.

[0008] In other features, the discharge temperature sensor may comprise a thermocouple located external to the compressor on a discharge tube extending from the compressor.

[0009] In other features, the discharge temperature sensor may comprise a thermistor mounted within the compressor on a non-orbiting scroll of the compressor.

[0010] In other features, the control module may monitor at least one of an overheat condition and a flood back condition of the compressor based on the calculated discharge superheat temperature. [0011] In other features, the control module may calculate at least one of a compressor capacity, a compressor power, an energy efficiency ratio, a compressor load, and a power consumption (Kwh/Day) based on the evaporator

temperature and at least one of the condenser temperature and the condenser pressure.

[0012] In other features, a system is provided comprising a compressor connected to a condenser and an evaporator, a condenser sensor that outputs a condenser signal corresponding to at least one of a condenser pressure and a condenser temperature, a discharge temperature sensor that outputs a discharge temperature signal corresponding to a temperature of refrigerant exiting the compressor, an inverter drive that modulates electric power delivered to the compressor to modulate a speed of the compressor, and a control module connected to the inverter drive. The control module may receive the condenser signal and the discharge temperature signal, monitor electrical power data and compressor speed data from the inverter drive, and calculates at least one of an evaporator temperature and an evaporator pressure based on the condenser signal, the discharge temperature signal, the electrical power data, and the compressor speed data.

[0013] In other features, the discharge temperature sensor may comprise a thermocouple located external to the compressor on a discharge tube extending from the compressor.

[0014] In other features, the discharge temperature sensor may comprise a thermistor mounted within the compressor on a non-orbiting scroll of the compressor.

[0015] In other features, the electrical power data may include compressor current data for the compressor.

[0016] In other features, a suction temperature sensor may output a suction temperature signal corresponding to a temperature of refrigerant entering the compressor and the control module may calculate a suction superheat temperature of the compressor based on a suction temperature signal and at least one of the calculated evaporator temperature and the derived evaporator pressure. [0017] In other features, the control module may monitor at least one of an overheat condition and a flood back condition of the compressor based on the calculated suction superheat temperature.

[0018] In other features, the control module may calculate at least one of a compressor capacity, a compressor power, an energy efficiency ratio, a compressor load, and a power consumption (Kwh/Day) based on the condenser temperature and at least one of the evaporator temperature and the evaporator pressure.

[0019] In other features, a method is provided that includes receiving a condenser signal corresponding to at least one of a condenser pressure and a condenser temperature of a condenser connected to a compressor and an evaporator, modulating a speed of the compressor with an inverter drive configured to modulate electric power delivered to the compressor, receiving electric power data and compressor speed data from the inverter drive, receiving a discharge temperature signal from a discharge temperature sensor, the discharge temperature signal corresponding to a temperature of refrigerant exiting the compressor, and calculating at least one of an evaporator temperature and an evaporator pressure based on the condenser signal, the discharge temperature signal, the electrical power data, and the compressor speed data.

[0020] In other features, the receiving the electric power data may include receiving compressor current data for the compressor. [0021] In other features, the method may include receiving a suction temperature signal from a suction temperature snesor, the suction temperature signal corresponding to a temperature of refrigerant entering the compressor and calculating a suction superheat temperature of the compressor based on the suction temperature signal and at least one of the calculated evaporator temperature and the derived evaporator pressure.

[0022] In other features, the method may include monitoring at least one of an overheat condition and a flood back condition of the compressor based on the calculated suction superheat temperature.

[0023] In other features, the method may include calculating at least one of a compressor capacity, a compressor power, an energy efficiency ratio, a compressor load, and a power consumption (Kwh/Day) based on the condenser

temperature and at least one of the evaporator temperature and the evaporator pressure.

[0024] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0025] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. [0026] Figure 1 is a schematic view of a refrigeration system. [0027] Figure 2 is a schematic view of a refrigeration system. [0028] Figure 3 is a graph of evaporator temperature and condenser temperature. [0029] Figure 4 is a graph of evaporator temperature and condenser temperature.

[0030] Figure 5 is a graph of evaporator temperature and condenser temperature.

[0031] Figure 6 is a graph showing discharge super heat correlated with suction super heat and outdoor temperature.

[0032] Figure 7 is a graph showing condenser temperature correlated with compressor power and compressor speed.

[0033] Figure 8 is a cross-section view of a compressor. [0034] Figure 9 is a flow chart showing derived data for a refrigeration system.

DETAILED DESCRIPTION

[0035] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0036] As used herein, the terms module, control module, and controller refer to one or more of the following: An application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality. As used herein, computer readable medium refers to any medium capable of storing data for a computer. Computer-readable medium includes, but is not limited to, memory, RAM, ROM, PROM, EPROM, EEPROM, flash memory, CD-ROM, floppy disk, magnetic tape, other magnetic medium, optical medium, or any other device or medium capable of storing data for a computer.

[0037] With reference to Figure 1 , an exemplary refrigeration system 5 includes a compressor 10 that compresses refrigerant vapor. While a specific refrigeration system is shown in Figure 1 , the present teachings are applicable to any refrigeration system, including heat pump, HVAC, and chiller systems. Refrigerant vapor from compressor 10 is delivered to a condenser 12 where the refrigerant vapor is liquefied at high pressure, thereby rejecting heat to the outside air. The liquid refrigerant exiting condenser 12 is delivered to an evaporator 16 through an expansion valve 14. Expansion valve 14 may be a mechanical or electronic valve for controlling super heat of the refrigerant. The refrigerant passes through expansion valve 14 where a pressure drop causes the high pressure liquid refrigerant to achieve a lower pressure combination of liquid and vapor. As hot air moves across evaporator 16, the low pressure liquid turns into gas, thereby removing heat from evaporator 16. The low pressure gas is again delivered to compressor 10 where it is compressed to a high pressure gas, and delivered to condenser 12 to start the refrigeration cycle again.

[0038] Compressor 10 may be driven by an inverter drive 22, also referred to as a variable frequency drive (VFD), housed in an enclosure 20. Enclosure 20 may be near compressor 10. Inverter drive 22 receives electrical power from a power supply 18 and delivers electrical power to compressor 10. Inverter drive 22 includes a control module 25 with a processor and software operable to modulate and control the frequency of electrical power delivered to

an electric motor of compressor 10. Control module 25 includes a computer readable medium for storing data including the software executed by the processor to modulate and control the frequency of electrical power delivered to the electric motor of compressor and the software necessary for control module 25 to execute and perform the protection and control algorithms of the present teachings. By modulating the frequency of electrical power delivered to the electric motor of compressor 10, control module 25 may thereby modulate and control the speed, and consequently the capacity, of compressor 10.

[0039] Inverter drive 22 includes solid state electronics to modulate the frequency of electrical power. Generally, inverter drive 22 converts the inputted electrical power from AC to DC, and then converts the electrical power from DC back to AC at a desired frequency. For example, inverter drive 22 may directly rectify electrical power with a full-wave rectifier bridge. Inverter driver 22 may then chop the electrical power using insulated gate bipolar transistors (IGBT's) or thyristors to achieve the desired frequency. Other suitable electronic components may be used to modulate the frequency of electrical power from power supply 18.

[0040] Electric motor speed of compressor 10 is controlled by the frequency of electrical power received from inverter driver 22. For example, when compressor 10 is driven at sixty hertz electric power, compressor 10 may operate at full capacity operation. When compressor 10 is driven at thirty hertz electric power, compressor 10 may operate at half capacity operation.

[0041] Control module 25 may generate data corresponding to compressor current and/or compressor power during the routines executed to modulate the electric power delivered to the electric motor of compressor 10. Control module 25 may utilize data corresponding to compressor current and/or compressor power to calculate and derive other compressor and refrigeration system parameters.

[0042] As described below and in the disclosure titled "VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD", U.S. Application Serial No. 60/978,258, which is incorporated herein by reference, suction super heat (SSH) and discharge super heat (DSH) may be used to

monitor or predict a flood back condition or overheat condition of compressor 10. Further, Tcond may be used to derive DSH. Likewise, Tevap may be used to derive SSH.

[0043] A compressor floodback or overheat condition is undesirable and may cause damage to compressor 10 or other refrigeration system components. SSH and/or DSH may be correlated to a flood back or overheating condition of compressor 10 and may be monitored to detect and/or predict a flood back or overheating condition of compressor 10. DSH is the difference between the temperature of refrigerant vapor leaving the compressor, referred to as discharge line temperature (DLT) and the saturated condenser temperature (Tcond). SSH is the difference between the temperature of refrigerant vapor entering the compressor, referred to as suction line temperature (SLT) and saturated evaporator temperature (Tevap).

[0044] SSH and DSH may be correlated as shown in Figure 6. The correlation between DSH and SSH may be particularly accurate for scroll type compressors, with outside ambient temperature being only a secondary effect. As shown in Figure 6, correlations between DSH and SSH are shown for outdoor temperatures (ODT) of one-hundred fifteen degrees Fahrenheit, ninety-five degrees Fahrenheit, seventy-five degrees Fahrenheit, and fifty-five degrees Fahrenheit. The correlation shown in Figure 6 is an example only and specific correlations for specific compressors may vary by compressor type, model, capacity, etc.

[0045] A flood back condition may occur when SSH is approaching zero degrees or when DSH is approaching twenty to forty degrees Fahrenheit. For this reason, DSH may be used to detect the onset of a flood back condition and its severity. When SSH is at zero degrees, SSH may not indicate the severity of the flood back condition. As the floodback condition becomes more severe, SSH remains at around zero degrees. When SSH is at zero degrees, however, DSH may be between twenty and forty degrees Fahrenheit and may more accurately indicate the severity of a flood back condition. When DSH is in the range of thirty degrees Fahrenheit to eighty degrees Fahrenheit, compressor 10 may operate within a normal range. When DSH is below thirty degrees

Fahrenheit, the onset of a flood back condition may be occur. When DSH is below ten degrees Fahrenheit, a severe flood back condition may occur.

[0046] With respect to overheating, when DSH is greater than eighty degrees Fahrenheit, the onset of an overheating condition may occur. When DSH is greater than one-hundred degrees Fahrenheit, a severe overheating condition may be present.

[0047] In Figure 6, typical SSH temperatures for exemplar refrigerant charge levels are shown. For example, as the percentage of refrigerant charge in refrigeration system 5 decreases, SSH typically increases. [0048] As described below and in the disclosure titled "VARIABLE

SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD", U.S. Application Serial No. 60/978,258, which is incorporated herein by reference, Tcond may be a function of compressor power and compressor speed. Control module 25 may derive Tcond based on compressor power or current and compressor speed.

[0049] Tcond may be derived from other system parameters. Specifically, Tcond may be derived from compressor current and voltage (i.e., compressor power), compressor speed, and compressor map data associated with compressor 10. A method for deriving Tcond based on current, voltage and compressor map data for a fixed speed compressor is described in the commonly assigned application for Compressor Diagnostic and Protection System, U.S. Application No. 11/059,646, Publication No. U.S. 2005/0235660. Compressor map data for a fixed speed compressor correlating compressor current and voltage to Tcond may be compressor specific and based on test data for a specific compressor type, model and capacity.

[0050] In the case of a variable speed compressor, Tcond may also be a function of compressor speed, in addition to compressor power.

[0051] A graphical correlation between compressor power in watts and compressor speed is shown in Figure 7. As shown, Tcond is a function of compressor power and compressor speed. In this way, a three-dimensional compressor map with data correlating compressor power, compressor speed, and Tcond may be derived for a specific compressor based on test data.

Compressor current may be used instead of compressor power. Compressor power, however, may be preferred over compressor current to reduce the impact of any line voltage variation. The compressor map may be stored in a computer readable medium accessible to control module 25. [0052] In this way, control module 25 may calculate Tcond based on compressor power data and compressor speed data. Control module 25 may calculate, monitor, or detect compressor power data during the calculations performed to convert electrical power from power supply 18 to electrical power at a desired frequency. In this way, compressor power and current data may be readily available to control module 25. In addition, control module 25 may calculate, monitor, or detect compressor speed based on the frequency of electrical power delivered to the electric motor of compressor 10. In this way, compressor speed data may also be readily available to control module 25. Based on compressor power and compressor speed, control module 25 may derive Tcond.

[0053] After measuring or calculating Tcond, control module 25 may calculate DSH as the difference between Tcond and DLT. DLT data may be received by an external DLT sensor 41. Alternatively, an internal DLT sensor 30, embedded within compressor 10, may be used. [0054] Control module 25 may use Tcond to derive other parameters including compressor capacity, power, energy efficiency ratio, load, Kwh/Day, etc.

[0055] Tcond or Tevap may be derived from other measured refrigeration system parameters. Specifically, Tcond may be derived from Tevap, compressor current, and compressor speed. Likewise, Tevap may be derived from Tcond, DLT, compressor current, and compressor speed.

[0056] As shown in Figure 1 , evaporator 16 includes an evaporator temperature sensor 40 which measures Tevap and communicates Tevap to control module 25. Alternatively, an evaporator pressure sensor may be used. As discussed below with reference to Figure 2, a condenser temperature or pressure sensor may also be used.

[0057] Control module 25 may receive Tevap and, as described above, may receive compressor speed and compressor current data as a result of operating inverter drive 22 and modulating the frequency of power delivered to compressor 10. [0058] Control module 25 may calculate Tcond from Tevap, compressor speed, and compressor current based on compressor map data derived from field tests for a particular compressor type, model, and capacity. The compressor map data may correlate Tcond with Tevap, compressor current, and compressor speed. [0059] As shown in Figures 3, 4 and 5, Tcond is graphically correlated with Tevap and compressor current for various compressor speeds. Specifically, Figure 3 shows Tcond related to Tevap and compressor current for compressor speed of 3600 RPM. Figure 4 shows Tcond related to Tevap and compressor current for compressor speed of 4500 RPM. Figure 5 shows Tcond related to Tevap and compressor current for compressor speed of 6000 RPM. Figures 3, 4 and 5 are exemplary. Additional compressor map data, spanning a range of compressor speeds and compressor currents may be used by control module 25 and stored in a computer readable medium accessible to control module 25.

[0060] Figures 3, 4 and 5 graphically relate Tcond, Tevap and various compressor currents for a particular compressor speed. For example in Figure 4, compressor currents are shown for various amperage levels between 4.5 and 30. Corresponding Tcond vs. Tevap curves are shown for each compressor current at the compressor speed of 4500 RPM.

[0061] In this way, control module may derive Tcond from Tevap, as measured by evaporator temperature sensor 40, and compressor speed and compressor current data from operating inverter drive 22.

[0062] As shown in Figure 2, condenser 12 may include a condenser temperature sensor 42, which may sense Tcond and communicate Tcond to control module 25. Alternatively, a condenser pressure sensor may be used. Based on Tcond as measured by condenser temperature sensor 42, control module 25 may calculate Tevap from Tcond, DLT, compressor current, and

compressor speed according to compressor map data as shown in Figures 3, 4 and 5, and as described above.

[0063] In this way, control module 25 may derive Tevap from Tcond, as measured by condenser temperature sensor 42, DLT as measured by DLT sensor 41 , and compressor current and compressor speed data from operating inverter drive 22. Likewise, control module 25 may derive Tcond from Tevap, as measured by evaporator temperature sensor 40, and compressor current and compressor speed data from operating inverter drive 22.

[0064] DLT data may be received by an external DLT sensor 41. DLT sensor 41 may be a thermocouple located on the discharge tube extending from compressor 10. DLT data from DLT sensor 41 may correspond to a compressor discharge gas temperature. Alternatively, an internal DLT sensor 41 , embedded within compressor 10, may be used. In other words, DLT sensor 41 may be incorporated inside compressor 10. In the case of a scroll compressor, DLT sensor 41 may be a thermistor exposed to the gas discharging from the compression mechanism and mounted on the non-orbiting scroll. The thermistor may be a positive temperature coefficient (PTC) or a negative temperature coefficient (NTC) thermistor. An internal DLT sensor, labeled as element 30, is shown in Figure 8, mounted on the non-orbiting scroll of compressor 10. [0065] As described above and in the disclosure titled "VARIABLE

SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD", U.S. Application Serial No. 60/978,258, which is incorporated herein by reference, various refrigeration system performance characteristics and data may be derived from Tcond and Tevap. Specifically, discharge super heat, suction super heat, capacity, power, energy efficiency ratio, load, and Kwh/Day may be derived from Tcond and Tevap.

[0066] Because Tevap may be calculated from mass flow, Tcond, and compressor speed, control module 25 may derive mass flow from a difference in temperature between suction gas entering cold plate 15 (Ts) and a temperature of a heat sink (Ti) located on or near inverter drive 22. Control module 25 may calculate delta T according to the following equation: Equation 1 : delta T = Ts - Ti

[0067] Control module 25 may determine mass flow based on delta T and by determining the applied heat of inverter drive 22. As shown in Figure 9, mass flow may be derived based on lost heat of inverter drive 22 and delta T.

[0068] With reference to Figure 9, inputs include compressor speed (RPM) 120, compressor current 122, compressor voltage 124, compressor power factor 126, Ti 128 and Ts 130. From compressor current 122, compressor voltage 124, and power factor 126, compressor power 132 is derived. From temperatures Ti 128 and Ts 130, delta T 134 is derived. From RPM 120 and power, Tcond 136 is derived. Also from RPM 120 and power 132, inverter heat loss 138 is derived. From inverter heat loss, and delta T 134, mass flow 140 is derived. From RPM 120, Tcond 136, and mass flow 140, Tevap 142 is derived. From Tevap 142 and Ts 130, SSH 144 is derived. From SSH 144 and ambient temperature as sensed by ambient temperature sensor 29, DSH 146 is derived. Once DSH 146 is derived, all of the benefits of the algorithms described above may be gained, including protection of compressor 10 from flood back and overheat conditions.

[0069] As shown by dotted line 141 , Tcond and Tevap may be iteratively calculated to more accurately derive Tcond and Tevap. For example, optimal convergence may be achieved with three iterations. More or less iterations may also be used. Further, any of the calculated or derived variables described in Figure 9 may alternatively be sensed or measured directly. In such the remaining variable may be calculated or derived based on the sensed or measured data.