SYSTEM AND METHOD FOR CALIBRATING 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.

12/470,001 , filed on October 7, 2008 and U.S. Provisional Application No. 60/978,292, filed on October 8, 2007. The application also claims the benefit of 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 calibrating 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 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 sensed condenser pressure and a sensed condenser temperature, an inverter drive that modulates a frequency of 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 that determines a measured condenser temperature based on the condenser signal, monitors electric power data and compressor speed data from the inverter drive, calculates a derived condenser temperature based on the electric power data, the compressor speed data, and compressor map data for the compressor, compares the measured condenser temperature with the derived condenser temperature, and selectively updates the compressor map data based on the comparison. [0006] In other features, the control module may calculate a difference between the derived condenser temperature and the calculated condenser temperature, compare the difference with a predetermined threshold, and select one of the derived condenser temperature and the calculated condenser temperature as being more accurate when the difference is greater than the predetermined threshold.

[0007] In other features, the control module may generate an alarm when the difference is greater than the predetermined threshold.

[0008] A method is provided and 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 a frequency of electric power delivered to the compressor, receiving electric power data and compressor speed data from the inverter drive, calculating a derived condenser temperature based on the electric power data, the compressor speed data, and compressor map data associated with the compressor, determining a measured condenser temperature based on the condenser signal, comparing the derived condenser temperature with the

measured condenser temperature, and selectively updating the compressor map data based on the comparing.

[0009] In other features, the method may include calculating a difference between the derived condenser temperature and the calculated condenser temperature, comparing the difference with a predetermined threshold, and selecting one of the derived condenser temperature and the calculated condenser temperature as being more accurate when the difference is greater than the predetermined threshold.

[0010] In other features, the method may include generating an alarm when the difference is greater than the predetermined threshold.

[0011] Another system is provided and comprises a compressor connected to a condenser and an evaporator, an evaporator sensor that outputs an evaporator signal corresponding to at least one of a sensed evaporator pressure and a sensed evaporator 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 a frequency of 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 determine a measured evaporator temperature based on the evaporator signal, monitor electric power data and compressor speed data from the inverter drive, calculate a derived evaporator temperature based on the electric power data, the compressor speed data, the discharge temperature signal, and compressor map data for the compressor, compare the measured condenser temperature with the derived condenser temperature, and selectively update said compressor map data based on the comparison.

[0012] In other features, the control module may calculate a difference between the derived evaporator temperature and the calculated evaporator temperature, compare the difference with a predetermined threshold, and select one of the derived evaporator temperature and the calculated evaporator temperature as being more accurate when the difference is greater than the predetermined threshold.

[0013] In other features, the control module may generate an alarm when the difference is greater than the predetermined threshold.

[0014] 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

[0015] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. [0016] Figure 1 is a schematic view of a refrigeration system. [0017] Figure 2 is a flow chart illustrating an algorithm to calibrate condenser temperature.

[0018] Figure 3 is a schematic view of a refrigeration system. [0019] Figure 4 is a flow chart illustrating an algorithm to calibrate evaporator temperature.

[0020] Figure 5 is a graph showing discharge super heat correlated with suction super heat and outdoor temperature.

[0021] Figure 6 is a graph showing condenser temperature correlated with compressor power and compressor speed.

[0022] Figure 7 is a flow chart showing derived data for a refrigeration system.

[0023] Figure 8 is a cross-section view of a compressor.

DETAILED DESCRIPTION

[0024] 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. [0025] 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.

[0026] 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.

[0027] 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.

[0028] 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. [0029] 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. [0030] 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.

[0031] As described 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. As described therein, condenser temperature (Tcond) may be used to derive DSH. Likewise, evaporator temperature (Tevap) may be used to derive SSH.

[0032] A compressor floodback or overheat condition is undesirable and may cause damage to compressor 10 or other refrigeration system components. Suction super heat (SSH) and/or discharge super heat (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). Suction super heat (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).

[0033] SSH and DSH may be correlated as shown in Figure 5. 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 5, 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 5 is an example only and specific correlations for specific compressors may vary by compressor type, model, capacity, etc.

[0034] 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.

[0035] 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. [0036] In Figure 5, 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.

[0037] As further described 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. As further described in the disclosure, control module 25 may use Tcond to derive other parameters including compressor capacity, power, energy efficiency ratio, load, Kwh/Day, etc.

[0038] 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.

[0039] In the case of a variable speed compressor, Tcond may also be a function of compressor speed, in addition to compressor power.

[0040] A graphical correlation between compressor power in watts and compressor speed is shown in Figure 6. 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. [0041] 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.

[0042] After measuring or calculating Tcond, control module 25 may calculate DSH as the difference between Tcond and DLT, with DLT data being receiving from external DLT sensor 28 or internal DLT sensor 30 (as shown in Figure 8). [0043] As further described 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, Tevap may be a function of compressor power, compressor speed, and DLT. Control module 25 may derive Tevap based on compressor power or current, compressor speed, and DLT. Control module 25 may use Tevap to derive other parameters including compressor capacity, power, energy efficiency ratio, load, Kwh/Day, etc.

[0044] Tevap and Tcond may be determined by using compressor map data, for different speeds, based on DLT and compressor power, based on the following equations:

Equation 1 : Tevap = f(compressor power, compressor speed, DLT)

Equation 2: Tcond = f(compressor power, compressor speed, DLT)

[0045] 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 3: delta T = Ts - Ti [0046] 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 7, mass flow may be derived based on lost heat of inverter drive 22 and delta T.

[0047] With reference to Figure 7, 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. [0048] 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 7 may alternatively be sensed or measured directly. In such the remaining variable may be calculated or derived based on the sensed or measured data.

[0049] DLT data may be received by an external DLT sensor 28. DLT sensor 28 may be a thermocouple located on the discharge tube extending from compressor 10. DLT data from DLT sensor 28 may correspond to a compressor discharge gas temperature. Alternatively, an internal DLT sensor 30 (as shown in Figure 8), embedded within compressor 10, may be used. In other words, DLT sensor 30 may be incorporated inside compressor 10. In the case of a scroll compressor, DLT sensor 30 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.

[0050] In addition to deriving Tcond or Tevap from compressor power and compressor speed, Tcond or Tevap may be measured directly with a sensor. The derived Tcond or Tevap may be compared with the measured Tcond or Tevap. Based on the comparison, control module 25 may calibrate the derived parameter against the measured parameter to more accurately determine actual Tcond or Tevap.

[0051] With reference to Figure 1 , condenser 12 includes a condenser temperature sensor 42 that generates a signal corresponding to Tcond. Condenser sensor temperature 42 is connected to control module 25. In this way, control module 25 receives the Tcond measurement from condenser temperature sensor 42. Alternatively, a condenser pressure sensor may be used instead of condenser temperature sensor 42. [0052] As shown in Figure 2, an algorithm for calibrating Tcond begins in step 300. In step 302, condenser temperature sensor 42 may measure Tcond and communicate Tcond to control module 25. In step 304, control module 25 may calculate Tcond from compressor power and compressor speed data from inverter drive 22, 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.

[0053] In step 306, control module 25 may compare the sensed Tcond with the calculated Tcond. In step 308, control module 25 may determine a difference between the sensed Tcond and the calculated Tcond. When the difference is less than a predetermined threshold in step 308, control module 25 may proceed to step 310. In step 310, control module 25 may calibrate the calculated Tcond with the measured Tcond.

[0054] Calibration may include updating compressor map data to more accurately reflect the measured Tcond. In this way, over time control module 25 may "learn" more accurate compressor map data for the compressor and may consequently be able to more accurately derive Tcond. Compressor map data may be stored in a computer readable medium accessible to control module 25. In addition, calibration may include determining an error parameter for condenser temperature sensor 42.

[0055] Thus, by measuring Tcond, calculating Tcond, and checking the measurement against the calculation, control module 25 may determine actual Tcond with high accuracy. The algorithm may end in step 312.

[0056] In step 308, when the difference is greater than the predetermined threshold, control module 25 may proceed to step 314 and determine whether the measured Tcond or the calculated Tcond is more accurate for use. Control module 25 may compare each of the measurement and the calculation to historical data for Tcond to determine which is closer to the historical Tcond. In this way, control module 25 may determine if the measurement or the calculation is correct for subsequent use.

[0057] In step 316, control module may then use the Tcond that is more accurate for subsequent calculations. In other words, control module 25 may proceed based on the Tcond (either sensed or derived) that is more accurate. In addition, control module 25 may generate an alarm to indicate a problem. For example, if control module 25 determines that the calculation is more accurate, condenser temperature sensor 42 may have malfunctioned. Control module 25 may generate an alarm to indicate that there has been a malfunction related to temperature condenser sensor 42. In addition, if control module 25 determines that the Tcond measurement is more accurate, control

module 25 may generate an alarm to indicate a problem with the Tcond calculation. For example, an inaccurate calculation may be an indication of a malfunction of inverter drive 22 or that inverter drive 22 is not accurately reporting compressor speed or compressor power data. [0058] As shown in Figure 3, refrigeration system 5 may include evaporator 16 with an evaporator temperature sensor 40. An evaporator pressure sensor may alternatively be used. Evaporator temperature sensor 40 generates a signal corresponding to evaporator temperature and communicates Tevap to control module 25. Refrigeration system 5 may also include DLT sensor 28 for generating a DLT signal corresonding to DLT.

[0059] As shown in Figure 4, an algorithm to calibrate Tevap starts in step 400. In step 402, evaporator temperature sensor 40 measures Tevap and reports Tevap to control module 25. In step 404, control module 25 calculates Tevap from compressor power, compressor speed data from inverter drive 22, and DLT.

[0060] In step 406, control module 25 compares the sensed or measured Tevap with the calculated Tevap. In step 408, control module 25 calculates a difference between the sensed Tevap and the calculated Tevap. When the difference is less than a predetermined threshold, control module 25 may proceed to step 410 and calibrate derived Tevap with measured Tevap. As with Tcond described above, control module 25 may update compressor map data if necessary to more accurately reflect measured Tevap. In this way, control module 25 may over time "learn" more accurate compressor map data. In addition, control module 25 may calculate an error parameter for evaporator temperature sensor 40. After step 410, the algorithm may end in step 412.

[0061] In step 408 when the difference is greater than the predetermined threshold, control module 25 may proceed to step 414 and determine whether the sensed or derived Tevap is more accurate for subsequent use. As with Tcond described above, control module 25 may compare both the sensed and calculated Tevap with historical data of Tevap to determine which is more accurate. When control module 25 has determined which Tevap is more accurate, control module 25 may proceed to step 416 and use the more accurate

Tevap for subsequent calculations. In addition, control module 25 may generate an alarm indicating a problem with the Tevap measurement or calculation. For example, if the calculated Tevap is more accurate, control module 25 may generate an alarm indicating a malfunction associated with evaporator temperature sensor 40. If control module 25 determines that the measured Tevap is more accurate, control module 25 may generate an alarm indicating a malfunction associated with inverter drive 22. For example, inverter drive 22 may have malfunctioned with respect to calculating or reporting compressor speed, compressor power data, or DLT. [0062] In this way, control module 25 may generate accurate Tevap and Tcond data for subsequent use in additional diagnostic, control and protection algorithms 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.