System And Method For Monitoring Compressor Floodback

[0001] This application is a continuation of U.S. patent application Ser. No. 12/247,033 filed on Oct. 7, 2008. This application claims the benefit of U.S. Provisional Application No. 60/978,258, filed on Oct. 8, 2007 and of U.S. Provisional Application No. 60/978,312, filed Oct. 8, 2007. The entire disclosures of each of the above applications are incorporated herein by reference.

[0002] The present disclosure relates to compressors and more particularly to a system and method for monitoring a floodback condition of a compressor.

[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.

[0005] A system is provided comprising a compressor connected to an evaporator, a suction sensor that outputs a suction temperature signal corresponding to a suction temperature of refrigerant entering the compressor, and a control module connected to the suction sensor. The control module determines a saturated evaporator temperature, calculates a suction superheat temperature based on the saturated evaporator temperature and the suction temperature, and monitors a floodback condition of the compressor by comparing the suction superheat temperature with a predetermined threshold. When the suction superheat temperature is less than or equal to the predetermined threshold, the control module increases a speed of the compressor or decreases an opening of an expansion valve associated with the compressor.

[0006] A method is provided comprising determining, with a control module, a saturated evaporator temperature of an evaporator connected to a compressor and receiving, with the control module, a suction temperature signal that corresponds to a suction temperature of refrigerant entering the compressor. The method further comprises calculating, with the control module, a suction superheat temperature based on the saturated evaporator temperature and the suction temperature. The method further comprises monitoring, with the control module, a floodback condition of the compressor by comparing the suction superheat with a predetermined threshold. The method further comprises increasing a speed of the compressor or decreasing an opening of an expansion valve, with the control module, when the suction superheat temperature is less than or equal to the predetermined threshold.

[0007] 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.

[0017] 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.

[0018] 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.

[0019] With reference to FIG. 1, an exemplary refrigeration system 5 includes a compressor 10 that compresses refrigerant vapor. While a specific refrigeration system is shown in FIG. 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.

[0020] Compressor 10 may be monitored and controlled by a control module 25. Control module 25 includes a computer readable medium for storing data including the software executed by a processor to monitor and control compressor 10 and to perform the algorithms of the present teachings.

[0021] As described in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference, suction superheat (SSH) may be used to monitor or predict an overheat condition of compressor 10. As described therein, an overheat condition is undesirable and may result in damage to compressor 10, a compressor component, or a refrigeration system component.

[0022] 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 floodback or overheating condition of compressor 10 and may be monitored to detect and/or predict a floodback 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).

[0023] SSH and DSH may be correlated as shown in FIG. 4. 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 FIG. 4, 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 FIG. 4 is an example only and specific correlations for specific compressors may vary by compressor type, model, capacity, etc.

[0024] A floodback 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 floodback condition and its severity. When SSH is at zero degrees, SSH may not indicate the severity of the floodback 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 floodback 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 floodback condition may be occur. When DSH is below ten degrees Fahrenheit, a severe floodback condition may occur.

[0025] With respect to overheating, when SSH is between thirty degrees Fahrenheit and fifty degrees Fahrenheit, the onset of an overheating condition may occur. When SSH is greater than fifty degrees Fahrenheit or when DSH is greater than one-hundred degrees Fahrenheit, a severe overheating condition may be present.

[0026] In FIG. 4, 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.

[0027] With reference to FIG. 1, evaporator 16 may include an evaporator temperature sensor 40 that may sense an evaporator temperature. Alternatively, an evaporator pressure sensor may be used. Control module 25 receives evaporating temperature (Tevap) from evaporator temperature sensor 40.

[0028] A suction sensor 34 monitors a temperature of refrigerant entering compressor 10 (i.e., SLT). Alternatively, a combination suction temperature/pressure sensor may be used. In such case, control module 25 may receive SLT from the temperature portion of the sensor and Tevap from the pressure portion of the sensor, as Tevap may be derived or measured based on suction pressure. Further, Tevap may be derived from other system parameters, as disclosed in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference.

[0029] For example, Tevap may be derived as a function of Tcond and DLT, as described in commonly assigned U.S. application Ser. No. 11/059,646, U.S. Publication No. 2005/0235660. For variable speed compressors, the correlation may also reflect compressor speed. In this way, Tevap may be derived as a function of Tcond, DLT and compressor speed.

[0030] As shown in FIG. 5, Tevap is shown correlated with DLT, for various Tcond levels. For this reason, compressor map data for different speeds may be used.

[0031] Tcond and Tevap may be calculated based on a single derivation.

[0032] In addition, iterative calculations may be made based on the following equations:

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

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

[0033] Multiple iterations of these equations may be performed to achieve convergence. For example, three iterations may provide optimal convergence. As discussed above, more or less iteration, or no iterations, may be used.

[0034] Tevap and Tcond may also be determined by using compressor map data, for different speeds, based on DLT and compressor power, based on the following equations:

Tevap=f(compressor power,compressor speed,DLT)  Equation 3:

Tcond=f(compressor power,compressor speed,DLT)  Equation 4:

[0035] Once Tevap and Tcond are known, additional compressor performance parameters may be derived. For example, compressor capacity and compressor efficiency may be derived based on additional compressor performance map data for a specific compressor model and capacity. Such additional compressor map data may be derived from test data. For example, compressor mass flow or capacity, may be derived according to the following equation:

Tevap=f(compressor speed,Tcond,mass flow)  Equation 5:

[0036] Control module 25 may calculate Tevap or receive Tevap data from the pressure portion of sensor 34. Control module 25 may then calculate SSH as a difference between SLT and Tevap.

[0037] As shown in FIG. 1, suction sensor 34 is external to compressor 10 and monitors a temperature of refrigerant as it is entering the suction inlet of compressor 10. Alternatively, a suction sensor internal to the compressor may be used. As shown in FIG. 2, a suction sensor 32 may be disposed within a shell of compressor 10. In such case, SLT may be communicated to control module 25 through an electrical connection via terminal box 24.

[0038] Control module 25 may monitor an overheat condition of compressor 10 by comparing SSH with a predetermined overheat threshold. As shown in FIG. 3, control module 25 receives SLT data in step 302. In step 304, control module 25 receives Tevap from evaporator temperature sensor 40. In step 306, control module 25 calculates SSH based on SLT and Tevap. Alternatively, Tevap may be estimated or derived based on other sensed parameters, as described above and in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference.

[0039] In step 308, control module compares SSH with a predetermined threshold to determine whether an overheat condition exists.

[0040] Control module 25 may determine that compressor 10 is operating within a normal temperature range when SSH is between zero and thirty degrees Fahrenheit. When SSH is between thirty degrees Fahrenheit and fifty degrees Fahrenheit, control module 25 may detect an overheat condition and take responsive measures. A SSH temperature above fifty degrees Fahrenheit may indicate that components of the compressor, including the compressor scrolls, bearings, etc., are at risk of being damaged.

[0041] Control module 25 may also determine whether SSH is greater than a predetermined threshold for a predetermined period of time. For example, control module 25 may determine when SSH is between thirty degrees and fifty degrees Fahrenheit, or greater than fifty degrees Fahrenheit, for a predetermined period. For example, the predetermined period may be a number of minutes (e.g., one minute, two minutes, five minutes, etc.). A first predetermined period (e.g., five minutes) may be used for monitoring when SSH is between thirty degrees and fifty degrees Fahrenheit. A second predetermined period, shorter than the first predetermined period, (e.g., one minute or two minutes) may be used for monitoring when SSH is greater than fifty degrees Fahrenheit. It is understood that any time period may be used as appropriate.

[0042] As described in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference, in response to an overheat condition, control module 25 may adjust compressor operation and/or adjust expansion valve 14. In a severe overheat condition, control module 25 may stop operation of compressor 10. Control module 25 may also generate an alarm or notification that an overheat condition exists.

[0043] As shown in FIG. 6, a compressor operating envelope may provide maximum floodback and maximum SSH limits. In addition, a maximum scroll temperature limit (Tscroll) may be provided, in the case of a scroll compressor. In addition, a maximum motor temperature (Tmotor) may be provided. As shown in FIG. 6, compressor speed and expansion valve 14 may be adjusted based on SSH to insure compressor operation within the compressor operating envelope. In this way, SSH may be maintained within an acceptable range as indicated by FIG. 6. Compressor speed adjustment may take priority over expansion valve adjustment. In some cases, such as a defrost state, it may be difficult for expansion valve 14 to respond quickly and compressor speed adjustment may be more appropriate.

[0044] For example, at a SSH between thirty degrees Fahrenheit and fifty degrees Fahrenheit, control module 25 may reduce compressor speed or cause expansion valve 14 to open. At a SSH greater than fifty degrees Fahrenheit, control module 25 may stop operation of compressor 25.

[0045] With reference to FIG. 7, another exemplary refrigeration system 5a includes a compressor 10 that compresses refrigerant vapor. While a specific refrigeration system is shown in FIG. 7, 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.

[0046] With reference to FIG. 7, 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.

[0047] 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.

[0048] 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.

[0049] Piping from evaporator 16 to compressor 10 may be routed through enclosure 20 to cool the electronic components of inverter drive 22 within enclosure 20. Enclosure 20 may include a cold plate 15. Suction gas refrigerant may cool the cold plate prior to entering compressor 10 and thereby cool the electrical components of inverter drive 22. In this way, cold plate 15 may function as a heat exchanger between suction gas and inverter drive 22 such that heat from inverter drive 22 is transferred to suction gas prior to the suction gas entering compressor 10.

[0050] To determine DSH, DLT may be subtracted from Tcond. DLT may be sensed by a DLT sensor 28 that senses a temperature of refrigerant exiting compressor 10. As shown in FIG. 7, DLT sensor 28 may be external to compressor 10 and may be mounted proximate a discharge outlet of compressor 10. Alternatively, an internal DLT sensor may be used. The internal DLT sensor may be embedded in an upper fixed scroll of a scroll compressor and may sense a temperature of discharge refrigerant exiting the intermeshing scrolls.

[0051] In the alternative, a combination temperature/pressure sensor may be used. In such case, Tcond may be measured based on the pressure of refrigerant exiting compressor 10 as measured by the combination sensor. Moreover, in such case, DSH may be calculated based on DLT, as measured by the temperature portion of the sensor, and on Tcond, as measured by the pressure portion of the combination sensor.

[0052] 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 Ser. 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.

[0053] In the case of a variable speed compressor, Tcond may also be a function of compressor speed, in addition to compressor power.

[0054] A graphical correlation between compressor power in watts and compressor speed is shown in FIG. 8. 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.

[0055] 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.

[0056] After measuring or calculating Tcond, control module 25 may calculate DSH as the difference between Tcond and DLT, with DLT data being received from external DLT sensor 28 or an internal DLT sensor.

[0057] Control module 25 may monitor DSH to detect a floodback or overheat condition, based on the correlation between DSH and floodback and overheat conditions described above. Upon detection of a floodback or overheat condition, control module 25 may adjust compressor speed or adjust expansion valve 14 accordingly. Control module 25 may communicate with or control expansion valve 14. Alternatively, control module 25 may communicate with a system controller for refrigeration system 5 and may notify system controller of the floodback or overheat condition. System controller may then adjust expansion valve or compressor speed accordingly.

[0058] DSH may be monitored to detect or predict a sudden floodback or overheat condition. A sudden reduction in DLT or DSH without significant accompanying change in Tcond may be indicative of a sudden floodback or overheat condition. For example, if DLT or DSH decreases by fifty degrees Fahrenheit in fifty seconds, a sudden floodback condition may exist. Such a condition may be caused by expansion valve 14 being stuck open. Likewise, a sudden increase in DLT or DSH with similar magnitude and without significant accompanying change in Tcond may be indicative of a sudden overheat condition due to expansion valve 14 being stuck closed.

[0059] In the event of a floodback condition, control module 25 may limit a compressor speed range. For example, when DSH is below thirty degrees Fahrenheit, compressor operation may be limited to the compressor's cooling capacity rating speed. For example, the cooling capacity rating speed may be 4500 RPM. When DSH is between thirty degrees Fahrenheit and sixty degrees Fahrenheit, compressor operating speed range may be expanded linearly to the full operating speed range. For example, compressor operating speed range may be between 1800 and 7000 RPM.