US 4,628,700 AGrant
Temperature Optimizer Control Apparatus and Method
Issue Date:1986-12-16
•31 Claims
•2 Drawing Sheets
Abstract
Apparatus and method for controlling compressor operation in conjunction with sensing the lowest temperature operating evaporator coil, or area serviced thereby, of a commonly-piped cooling system. A thermoelectric sensor voltage output is compared with a set-point voltage by an integrator, the output of which is applied to control the pressure for the system.
Metadata
Inventor
- Richard H. Alsenz
Application Information
Application Number:US 7064039
Filing Date:1985-02-27
Priority Date:1979-07-31
Art Unit:344
Classifications
IPC:
F25B 100F25D 2106
Field of Search:
21236165229;152;228.3;228.4;228.5;199;200;227;510;226;196.2;176.31 EA26;27
Patent Drawings (2 sheets)
Description
FIELD OF THE INVENTION
This invention relates to increasing the efficiency of cooling or refrigeration systems, especially for those systems employing commonly-piped evaporator coils where at least one set of coils is located for temperature controlling one compartmentalized or non-compartmentalized area and another set of coils is located for temperature controlling another compartmentalized or non-compartmentalized area.
BACKGROUND OF THE INVENTION
Cooling systems generally comprise a condenser coil, a receiving vessel for the condensed liquid from the condenser coil, an expansion valve, an evaporator coil, and a compressor. The compressor is connected to the condensor coil. In addition, such a cooling system includes a defrost mechanism for the evaporator coil since the moisture that tends to accumulate thereon turns to ice during operation and would, in time, build up to a degree that would make the cooling system almost totally inefficient, if not inoperable.
Improvements over the simplest cooling system briefly described above have included using multiple compressors, rather than only one, and alternating their use in accordance with demand so as to use only enough compressor capacity sufficient for the demand and so as to minimize wear on the compressors. Such an energy efficient system is shown and described in co-pending U.S. patent application Ser. No. 257,113, filed Apr. 24, 1981, by the same inventor as the present application. The system of application Ser. No. 257,113 represents a technique for achieving more efficient operation through the use of a single highest fixed "cut in" and a single highest fixed "cut out" operating suction line pressure while insuring adequate temperatures in the refrigerated spaces served by the refrigeration system.
In the past, the cycling of stages of a multiple-stage refrigeration or cooling system has been principally accomplished by setting each stage at a successfully lower "cut in" and "cut out" pressure of the refrigerating fluid flowing in the suction line from the evaporator coil to the compressor(s) or cooling stages. The use of successfully lower "cut in" and "cut out" pressure ranges for each cooling stage results in an average pressure which is lower than the mean pressure of the pressure differential between the "cut in" and "cut out" pressures of the highest stage. Various mechanical and electromechanical systems have been devised to attempt to solve this problem, primarily utilizing the successively lower pressure ranges for each successive cooling stage as described above.
The invention of application Ser. No. 257,113, briefly stated, involves an apparatus and method of controlling the capacity of a multiple compressor refrigeration system. The invention first establishes a selected cooling stage "cut-in" and "cut-out" suction line pressure for the system. Secondly, the system determines when the suction line pressure is equal to either of these pressures, and based on this determination, controls the selection of the appropriate capacity for the system to achieve an average operating suction line pressure between the selected single highest "cut-in" and single highest "cut-out" pressures.
The system described herein is another way or technique for increasing the efficiency of many cooling systems, and may be used independently or with the system described herein and in application Ser. No. 257,113 to achieve a cummulative system efficiency increase.
It is not unusual for the same compressor (or system of compressors) to be commonly piped in a cooling system which employs more than one evaporator coil. The reason for this is that the capacity of the system is sufficiently designed for cooling a given overall area; however, some of this area is compartmentalized separately from the rest of this area. Moreover, it is commonly desirable to reduce the temperature in one area to a lower temperature than is required for another. By example then, if one area is smaller in size than another and both are cooled in the same manner by similar evaporator coils, then the smaller area will be cooled at a lower temperature than the larger of the areas.
Rather than have two completely different systems when there are two or more separate areas to cool, such systems having duplicate compressors, duplicate condensor coils, duplicate condensor fluid vessels, and the like, it is less expensive to have one system with these common components commonly-piped, usually in parallel rather than in-line, with separate evaporator coils only. Although separate coils are commonly employed in respective separate compartments, it is also usual for separate coils to be used for a common large area, where one coil is used, for example, in one room and another coil is used in a second room, one room being kept at a lower temperature than the other.
It is also known that compressors can be operated to raise the pressure in a cooling system to warm the area cooled by an evaporator coil as well as to lower the pressure to cool the area cooled by an evaporator coil. The system to be described hereinafter includes this capability.
Therefore, it is an object of the present invention to provide an improvement for optimizing the pressure control of a cooling system having at least two commonly-piped evaporator coils.
It is another object of the present invention to provide an improvement for providing pressure control to a cooling system wherein the further away from a norm temperature an area may be, e.g. a temperature set point, the more rapid will be the rate of adjustment of pressure.
SUMMARY OF THE INVENTION
The invention herein disclosed is an apparatus and method for controlling compressor operation of a cooling system having a plurality of commonly-piped evaporator coils. One of the coils, or the area cooled by one of the coils, desirably operates at a temperature level lower than the others. A thermoelectric probe senses this temperature and develops a voltage proportional thereto. A voltage reference means is adjustably set to have an output voltage which is equal to the voltage that the thermoelectric probe produces when the monitored coil or area is at the desired temperature.
The voltage outputs of the thermoelectric probe and the reference means are applied as inputs to an integrator, the output of which is connected to a pressure adjustment. When the integrator registers that the detected or sensed temperature is too cold, the setting is raised which raises the pressure in the cooling system and raises the temperature of the coldest area. When the integrator registers that the detected or sensed temperature is too warm, on the other hand, the pressure adjustment is lowered thereby lowering the pressure in the cooling system and, hence, lowering the temperature.
When the coil or compartment being monitored is defrosted, a switch is operated to short the inputs of the integrator and thereby to effectively prevent the output from changing.
Because of the integrator, which is effectively a comparator with an RC time constant, the output therefrom integrates the difference in its inputs. In other words, the output will follow an integration curve and, therefore, accentuate large differences to quickly bring the monitored condition to the desirable temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above-recited features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate only a preferred embodiment of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
In the Drawings
FIG. 1 is a simplified mechanical/electrical block and schematic diagram of a cooling system employing multiple compressors and multiple evaporator coils, all of which are controlled by a controlling apparatus in accordance with the present invention;
FIG. 2 is a block diagram of the electrical portion of the controlling aparatus shown in FIG. 1;
FIG. 3 is a simplified schematic diagram of a portion of the controller apparatus shown in FIG. 1 which generates pressure cut-in and cut-out comparator control signals;
FIG. 4 is a simplified mechanical/electrical block and schematic diagram of a cooling system employing multiple compressors which are controlled by controlling apparatus in accordance with the present invention to control the cooling from a single evaporator coil;
FIG. 5 is a simplified block diagram of one embodiment of a control circuit responsive to the suction line pressure, for controlling the selection of compressors and thereby controlling the suction line pressure, of the cooling system shown in FIG. 4; and
FIG. 6 is a graphical representation of the refrigerating fluid suction line pressure versus time for a multiple-stage refrigeration or cooling system operating within the parameters of the capacity control method and apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 4, the refrigeration system capacity controller circuit 36 is shown disposed in a multiple-stage refrigeration or cooling system 20' consisting of a plurality of parallel staged refrigerant compressors 12', 14', 16', and 18' for discharging compressed pressurized refrigerant vapor through discharge line 22' to a condenser coil 25' where the pressurized refrigerant vapor is condensed to a liquid and then delivered to a receiver vessel 26'. From the receiver 26', the liquid refrigerant flows through line 28' and through an expansion device or valve 30', typically a mechanical expansion valve responding to the temperature in suction line 38 as sensed by temperature sensing device 32. The temperature signal from sensor 32 is applied to valve 30' through conductor 33 to initiate the expansion valve action.
The liquid refrigerant is injected through expansion device 30' into the evaporator coil 35 where the liquid refrigerant, encountering the low pressure of the evaporator coil, boils and evaporates thus absorbing heat from the evaporator coil. The hot vaporized refrigerant from the evaporator coil is drawn through suction line 38 to the inlet ports of the multiple compressors 12'-18'. The number of parallel compressors to be staged in the system varies according to the refrigerating or cooling system load. In FIG. 4, three compressors are shown as 12', 14' and 16', and an "Nth" compressor represented in dotted lines by compressor 18'.
A pressure transducer 40' is attached to the suction line 38 and determines the refrigerant vapor pressure within suction line 38 and generates an electrical signal representative of the measured suction line pressure. The signal is applied through conductor 42' as an input to the capacity controller circuit 10', which will be hereinafter described in greater detail. The output of the controller circuit 36 is a plurality of outputs corresponding to the number of the plurality of cooling stages or parallel compressors staged in the system. Accordingly, there are a corresponding "N" number of outputs from the capacity controller circuit 36 labelled 1, 2, 3 and N.
The controller circuit output 1 is applied through conductor 56 to the coil of a relay 44' which controls relay switch contacts 45 for applying AC power via conductors 52 and 54 to the first compressor 12' for energizing the compressor when it is desired to cut the compressor into the system. Similarly, the 2, 3 and N outputs of the capacity controller circuit are applied through conductors 58, 60 and 62, respectively, to the coils of relays 46', 48' and 50', respectively, for successively closing switches 47', 49 and 51, respectively, for successively applying AC electrical power to the 2, 3 and N compressors, respectively, for either turning on or turning off the compressors in a staged sequence.
Referring now to FIGS. 4, 5 and 6, the operation of the capacity controller circuit 36 will be described in greater detail. The pressure detecting means or transducer 40' is shown sealingly inserted into the refrigerant vapor flow 65 in suction line tubing 38. Pressure transducer 40' may be any conventional pressure detecting means for generating an electrical signal representative of the pressure within line 38. The pressure signal from transducer 40' is applied through conductors 42' and 70 to the positive input of a comparator circuit 74, and through conductors 42' and 72 to the negative input of a second comparator circuit 76. To set a predetermined "cut-in" pressure for the system, a voltage potential is applied through a voltage varying means, such as a potentiometer 75, to the negative input of the comparator circuit 74. Similarly, a voltage is applied through a voltage varying means, such as a potentiometer 77, to the positive input of the comparator circuit 76 to set a predetermined "cut-out" pressure for the system. As will be pointed out below with respect to the cut-in and cut-out comparator control voltages generated in accordance with the present invention (See FIG. 3), the "cut-in" control voltage for the negative input of comparator 74 and the "cut-out" control voltage for the positive input of comparator 76 to control a multiple compressor, multiple evaporator coil cooling system could be generated in response to the temperature of the coldest compartment to be cooled thereby to dynamically achieve the highest suction line pressure operating condition while meeting the cooling requirements of the coldest compartment.
Comparator circuit 74 compares the predetermined cooling system "cut-in" pressure (set by potentiometer 75) against the suction line pressure continuously detected by pressure transducer 40' and produces a "cut-in" electrical signal when the measured pressure exceeds the predetermined "cut-in" pressure. Comparator circuit 76 compares the predetermined cooling system "cut-in" pressure (set by potentiometer 77) against the pressure continuously detected by the pressure transducer 40' and produces a "cut-out" electrical signal when the detected system pressure exceeds the predetermined "cut-out" pressure. The combination of transducer 40', potentiometers 75 and 77 for establishing system pressure "cut-in" or "cut-out" pressure levels and the comparators 74 and 76 also comprise detection means 64 for establishing a selected cooling stage "cut-in" or "cut-out" pressure and determining when those established pressures have been reached and providing an output signal in response thereto, i.e., output of comparators 74 or 76.
The "cut-in" signal of comparator 74 is applied through conductor 78 to a timer circuit 82' which generates an output electrical control signal after a first predetermined minimum time delay. The delayed time output control signal is applied through conductor 86' as an input to a counter 90. Counter 90 is a conventional counter circuit that generates a successive plurality of outputs 1 to N corresponding to the number of staged parallel compressors in the system. Each delayed control signal received from timer 82' by counter 90 will cause a counter output signal to appear at one of the series of successive counter outputs 1, 2, 3 or N in repetitive succession, and are applied via a conductor 95 as a "set" input to a latch circuit 94.
The latch circuit 94 is of conventional solid-state design and generates a series of repeatable successive "cut-in" electrical control signals at outputs 1, 2, 3 and N, to be applied through conductors 56, 58, 60 and 62, respectively, to a series of repeatable successive compressor control relays 44', 46', 48' and 50', respectively, in response to successive "set" input signals received via conductors 95 from the 1, 2, 3 or N outputs of counter 90. For example, if the counter 90 has an output signal at output 1 applied through a conductor 95 as a "set" input to latch circuit 94, latch circuit 94 will generate a control signal output voltage at its 1 output (conductor 56). Similarly, output signals from counter 90 appearing in a series successively at 2, 3 and N are applied through conductors 95 as repeatably successive "set" inputs to latch circuit 94, thereby generating "cut-in" or turn on control signals appearing at outputs 2, 3 and N (conductors 58, 60, and 62, respectively). The electrical control signals are voltages applied through conductors 56, 58, 60 and 62, respectively to relays 44', 46', 48' and 50', respectively, as hereinabove described for successively energizing the relays 44', 46', 48' and 50', respectively, and successively energizing or turning on one of the multiple compressors 12', 14', 16' and 18', respectively.
Similarly, the "cut-out" output signal of comparator 76 is applied through conductor 80' to a timer 84'. Timer circuit 84' generates a delayed "cut-out" electrical control signal after a predetermined time delay. The control signal is applied through conductor 88 as an input to another counter circuit 92. Counter 92 may be identical to the counter 90 hereinabove described. Each successive delayed "cut-out" control signal received from timer circuit 84' generates one of a series of repeatable successive electrical signals at counter 92 outputs 1, 2, 3 and N, which are applied thorugh conductors 93 as "reset" inputs to latch circuit 94. Receipt of the successive series of delayed "cut-out" control signals from counter 92 causes the latch circuit 94 to be reset in the succession in which the counter signals are received.
For example, upon receipt of a counter 92 output 1 signal applied through conductor 93 as a "reset" input to latch circuit 94, the latch 94 output at 1 will be reset and no voltage will appear on conductor 56 thus de-energizing relay 44', opening relay switch contacts 45 and "cutting-out" the first compressor 12', which has run the longest. Accordingly, successive counter 92 signals received from outputs 2, 3 and N as "reset" inputs to latch circuit 94 will successively reset the latch circuit and remove the latch circuit voltage outputs appearing at lines 2, 3 and N (conductors 58, 60 and 62, respectively), for "cutting-out" compressors 14', 16' and 18' in succession.
In addition, the latch circuit outputs 1, 2, 3 and N (conductors 56, 58, 60 and 62, respectively) are also connected by conductors 99 as inputs to a conventional AND gate 96. When all of the latch circuit outputs 1, 2, 3 and N have positive output voltages appearing thereon, the AND gate 96 generates an output signal applied through conductor 97 to counter 90 to disable counter 90 at its last count and prevent further delayed "cut-in" electrical signals received from timer 82' from generating further counter 90 output electrical signals for application to the latch circuit 94. Similarly, the latch circuit outputs 1, 2, 3, and N are also connected by means of conductors 101 as inputs to a conventional NOR gate 98. NOR gate 98 will generate an electrical output signal to be applied through conductor 103 to disable counter 92 when all of the latch circuit outputs 1, 2, 3 and N have been reset and there are no output voltage signals present thereon. The electrical signal received from NOR gate 98 disables counter 92 and prevents any further "cut-out" delayed signals received from timer 84' from triggering any further counter 92 output signals to be applied as reset inputs to latch circuit 94.
The operation of the capacity controlling circuit 10' can now further be described with reference to FIGS. 4, 5 and 6. The graph of FIG. 6 depicts the system suction line refrigeration fluid pressure vs. time and is represented by pressure trace 121. The selected suction line "cut-in" pressure represented by line 120 is set for the system by potentiometer 75 (or possibly the "cut-in" comparator voltage from FIG. 3) as one input to the comparator 74, as hereinabove described. The selected "cut-out" pressure represented by line 130 is set by potentiometer 77 (or possibly the "cut-out" comparator voltage from FIG. 3) as one input to comparator 76, as hereinabove described. The desired system suction line pressure range .DELTA.P has been selected for optimum efficiency of the system. The timer 82', as hereinabove described, establishes a predetermined delay time which is represented by the time interval .DELTA.T, and the delay time established by timer circuit 84' is represented by the shorter time interval .DELTA.t. Assuming that compressors 1 and 2 are operating in the system within the .DELTA.P established by "cut-in" pressure (120) and the "cut-out" pressure (130), if the refrigerator load increases, then the suction line pressure will rise. If the load is heavy enough, the pressure (121) will rise until it exceeds the predetermined value established by potentiometer 75 (line 120) at point 122 and comparator 74 will generate an electrical "cut-in" signal to be applied to the timer 82.
The comparator signal output occurs at point 122 which is the point at which the suction line pressure 121 rises above or exceeds the predetermined cut-in system pressure and establishes the beginning of the delay time .DELTA.T or timer 82'. The suction pressure may continue to rise as shown in FIG. 4 until timer 82' generates its delayed "cut-in" electrical control signal which is applied to counter 90, and since compressors 1 and 2 are already operating, counter 90 will generate an output signal at output 3 which is then applied through a conductor 95 as a "set" input to latch circuit 94. Receipt of the delayed "cut-in" signal from output 3 of timer 82' by the latch circuit 94 causes a positive voltage to appear at latch output 3 (conductor 60) which is applied to relay 48' for energizing the relay, closing relay switch 49 and "cutting-in" the third compressor 16', which has been "turned off" the longest time period. The end of the predetermined time delay, .DELTA.T, established by timer 82', occurs at point 124, and the third compressor or cooling stage now in the system adds cooling capacity and returns the pressure to the operating pressure differential .DELTA.P range established by pressures 120 and 130. In the event that the combined operating capacity of compressors 12', 14' and 16' is still insufficient for the load, the suction pressure will not drop below the cut-in pressure (120) and cut-in timer 82' will generate another delayed "cut-in" signal to cut-in another compressor stage, up to the Nth stage to match the load demand.
In the event the suction pressure (121) declines because of over-capacity in the system, and falls below the predetermined "cut-out" pressure represented by line 130, then comparator 76 will generate a "cut-out" signal applied to the timer 84' occurring at point 126, which begins the established time delay .DELTA.t. When the predetermined time delay .DELTA.t has elapsed, timer 84' generates a "cut-out" electrical control signal applied through conductor 88 as an input to the counter 92. The counter 92, in response to the received signal, will generate an output signal on line 1 applied through a conductor 93 to latch circuit 94 as a "reset" input. The counter reset signal applied to latch circuit 94 will "reset" output line 1 of the latch circuit, thereby removing the positive voltage output at conductor 56 and de-energizing relay 44', opening switch contacts 45 and "cutting-out" compressor 12' (which has been operating the longest time period) from the system, as reflected in FIG. 6 at 128, the end of the delay .DELTA.t and the point where the suction pressure again begins to increase. When compressor 12' is "cut-out" of the system, the suction line pressure begins to increase until it returns to the desired operating range between the pressure differentials 120 and 130. Similarly, in the event that the combined operating capacity of the compressors or cooling stages still exceeds the load, another "cut-out" signal will be generated by timer 84' to "cut-out" another compressor stage until the operating stage capacity matches the system load.
In this way the multiple staged compressors can be "cut-in" or "cut-out" of the system to increase or decrease refrigeration capacity depending on the system refrigeration load by a discrete combination of compressor stages, thus matching as closely as possible the available compressor stage capacity with the system load. The compressor that has operated the longest will always be the first to be "cut-out" when the system capacity needs to be diminished, and the compressor that has not operated the longest will be the next to be "cut-in" when the system capacity needs to be increased.
The timers 82' and 84' and counters 90 and 92 "remember" the length of their respective time delays, .DELTA.T and .DELTA.t. For example, referring to FIGS. 4, 5, and 6, if .DELTA.T is five (5) minutes, and .DELTA.t is five (5) seconds, if suction pressure 121 rises above the "cut-in" pressure (120) at point 122, the five (5) minute .DELTA.T period begins. However, if suction pressure trace 121 had dropped back below "cut-in" pressure 120 after only two (2) minutes had elapsed (or before reaching poing 124), the "cut-in" signal from comparator 74 will cease, disabling timer 82'. Similarly, if suction pressure trace 121 falls below the "cut-out" pressure 130 as at point 126, the five (5) second .DELTA.t period begins. However, if the suction pressure (121) increases and rises above "cut-out" pressure (130) after only three (3) seconds, the "cut-out" signal from comparator 76 will cease and disable timer 84', and no delayed "cut-out" signal will be sent to counter 92. Accordingly, no delayed "cut-in" signal will be addressed to counter 90. Therefore, no additional compressor or cooling stage will be "cut-in", but the next time the suction pressure 121 exceeds the "cut-in" pressure, timer 82' will again be energized and will produce a delayed "cut-in" signal after only three (3) minutes (the balance of .DELTA.T left over from the last .DELTA.T period) and "cut-in" or turn on the next compressor or cooling stage of the system. Similarly, the next time the pressure trace 121 decreases to fall below the "cut-out" pressure, timer 84' will again be enabled and will produce a delayed "cut-out" signal after only two (2) seconds (the balance of .DELTA.t left over from the last .DELTA.t period) and "cut-out" or turn off the compressor which has run the longest.
As above described, it will be evident that controller circuit 10' will "cut-in" or "cut-out" the next compressor or compressor stage as above described until the combination of stages has an operating capacity closest to matching the system load, i.e., causing the system suction pressure to return to the previously established .DELTA.P range as hereinabove described and shown in FIG. 6. For example, if the compressors 12', 14' and 16' are the only compressors in the system, then the capacity controller 10' will select and provide increased or decreased compressor capacity in combinations to most closely match the load demand. The various combinations of compressors 12', 14' and 16' will be 12' alone, 12'-14', 12'-14'-16', 12'-16', 14'-16', 14' alone or 16' alone.
Similarly, if the compressors 12', 14' and 16' are unequal in capacity, and rated at 1, 2 and 4 horsepower (HP), respectively, then it has been found that the capacity controller 36 will select and provide increased or decreased compressor horsepower capacity in discrete increments or combinations to match the load demand. Assuming the above described ratings of 1, 2 and 4 HP for compressors 12', 14' and 16', then the various possible combinations of those compressors will provide capacities of 1, 2, 3, 4, 5, 6, and 7 HP in response to changing load demand. The number of combinations for multiple compressors whether of equal or unequal capacity will always be larger than the number of compressors or compressor stages in the system. It will be further evident from the above described operation and drawings showing multiple compressors 12', 14', 16', and 18' (1, 2, 3 to N number of compressors) that any number of parallel compressors can be controlled, such as a system of two (compressors 12' and 14'), a system of three (compressors 12', 14' and 16') or a system of N number (compressors 12', 14', 16'-N).
The refrigeration capacity control invention herein disclosed may also be utilized in controlling multiple stage refrigeration of cooling systems having multicylinder compressors that are staged by controlling the compression of a plurality of compressor cylinders using conventional control valves by having controller 36 outputs control the utilization of the cooling stages by controlling the cylinders used by the compressors in the system. In addition, it is important to understand that while the system above described in FIGS. 4, 5, and 6 uses a separate time delay after determination of the reaching of the established "cut-in" or "cut-out" pressures, only a single time delay is necessary to enable selection of successive cooling stages utilizing a single selected "cut-in" system pressure and a single selected "cut-out" system pressure. For instance, in FIG. 5, the output of "cut-out" comparator 76 could be applied to timer 82' and utilize a single delay time for both "cut-in" and "cut-out" determinations. Further, the .DELTA.P differential between "cut-in" pressure 120 (FIG. 6) and "cut-out" pressure 130 may be large or small, depending on the system design and the best system operating pressure. In certain systems, the .DELTA.P could be set at zero, with the "cut-in" and "cut-out" pressures being established at the same value.
Turning now to FIG. 1, a multiple compressor, multiple evaporator coil cooling or refrigeration system suitable for operation in conjunction with the present invention is illustrated. The multiple compressor system of FIG. 1 can also be operated in accordance with the above described principles of system compressor pressure control.
As shown in FIG. 1, a plurality of parallelstaged refrigerant compressors 10, 12 and 14 are each separately connected for discharging compressed pressurized refrigerant vapor through common discharge line 16 to a condenser coil 18. The pressurized refrigerant vapor is condensed to a liquid in condenser coil 18 and delivered to a receiving vessel 20. From this receiving vessel 20, the liquid refrigerant flows through a common line 22 and then through line 24 to an expansion device or valve 26 for operation in conjunction with a first evaporator coil 27. The liquid refrigerant also flows from common line 22 through line 23 to an expansion device or valve 25 for operation in conjunction with a second evaporator coil 29.
The liquid refrigerant is injected through the respective expansion valves 26 and 25 into their respective evaporator coils 27 and 29, where the liquid refrigerant, encountering the low pressure of the evaporator coils, boils and evaporates, thus absorbing heat from the coils and cooling the surrounding respective areas 30 and 32.
The outputs of evaporator coils 27 and 29 are connected together and to common suction line 34. The vaporized refrigerant from the evaporator coils is drawn through suction line 34 where it is then delivered to the respective inlet ports of multiple compressors 10, 12 and 14. The pressure transducer 40' described with respect to the multiple compressor, single evaporator coil system shown in FIG. 4, is shown in FIG. 1 coupled to suction line 34 for measuring the suction line pressure, i.e., the compressor pressure operation.
Although it is beneficial to use the inventive optimizing temperature control apparatus hereinafter described more in detail with a simplified system using only a single compressor, it is desirably used in conjunction with the illustrated multiple compressor system for cumulative results therewith. That is, the substantial advantages of the multiple compressor system operated in accordance with the above described compressor pressure control operation are further enhanced by optimizing in a refrigeration system having multiple evaporator coils the compressor pressure control range to achieve the minimum system compressor capacity required to maintain the highest suction line pressure thereby to maintain the desired temperature of the coldest compartment to be cooled.
The compressors shown in FIG. 1 may be cycled using suitable cut-in and cut-out suction line pressure control signals developed by potentiometer 75 and 77, respectively, in the manner above described. That is, the desired cut-in pressure is set by potentiometer 75 and compared in comparator 74 to the actual measured suction line pressure from pressure transducer 40'. If the measured pressure exceeds the setting, a cut-in signal is generated to timer 82'. Similarly, potentiometer 77 sets the cut-out pressure, and when the measured pressure is less than the cut-out pressure, a cut-out signal is generated to timer 84'.
In accordance with the present invention, a circuit is disclosed for optimizing the compressor pressure operation in a cooling system having multiple compressor and multiple evaporator coils to obtain the highest possible suction line pressure, i.e., the lowest compressor capacity, that will satisfy the lowest desired temperature required by any of the evaporator coils. A thermoelectric probe or sensing device 44 is positioned with respect to the evaporator coil or the area served by the evaporator coil that operated at the lowest temperature to generate an output voltage representative of the temperature in such compartment. In FIG. 1, it is assumed that coil 27, or area 30, is operated at a temperature lower than coil 29, or area 32. Devices known as thermocouples are well known examples of suitable thermoelectric probes.
For simplicity, area 32 is assumed to be warmer than area 30 even though substantially identical coils 27 and 29 are shown in FIG. 1. In an actual system, the maintaining of coil 29 warmer with respect to coil 27 is usually accomplished by the presence of an evaporator pressure regulator valve 31 in the warmer of the two coils. Such a valve 31 effectively restricts the line opening and raises the pressure, and hence the temperature, in coil 29 vis-a-vis the temperature of coil 27. A suitable thermocouple is used as the temperature sensing element 44 for sensing the temperature of the coldest area to be maintained.
In addition to whatever other initiating signals are produced by compressor controlled circuit 36, the signal produced by temperature sensor 44 is also used as an additional control signal, which can be better understood by reference to FIG. 2. Referring to FIG. 2, a voltage set point device 46 establishes a reference voltage output which is equal in value to the output from temperature sensor 44 when the monitored coil or area is at the desired norm temperature. The outputs from temperature sensor 44 and from voltage set points 46 and then connected as the respective inputs to an integrator 48.
Integrator 48 is a comparison type of adjustment means that produces an integrated output voltage dependent on the difference in the applied inputs. Whenever the output from temperature sensor 44 indicates that the monitored conditions in the area 30 are warmer than the reference setting, then an adjustment output voltage is produced on the output of integrator 48 for reducing the suction line pressure and hence the temperature being monitored. On the other hand, whenever the output from temperature sensor 44 indicates that the monitored conditions are colder than the reference, then an adjustment output voltage is produced for increasing the suction line pressure and raising the temperature being monitored. The output of integrator 48 is an integrated voltage, either positive or negative depending on which of the two input voltages is positive with respect to the other.
In accordance with operation well-known in the art, defrosters 28 and 40, respectively, are operated in suitable fashion for defrosting, respectively, coils 27 and 29. A defrost control 42, which may include a timer or frost sensor or similar device, activates and deactivates the respective defrosters. When defroster 28 is operated by defrost control 42, a signal is also produced for operating switch 47 to short together the inputs to integrator 48. This asures that there is no further change in the output from integrator 48 during this time. When the defrost cycle is over and defroster 28 is deactivated, then switch 47 is allowed to open to place the circuit in operation to continue as before.
It is well known by those skilled in the art that an integrator is an analog memory device, it remembers what has happened in the past. If the input voltage to be integrated is zero volts, there will be no change in the integrator output voltage. That is, whatever voltage is on the output of the integrator, that voltage will remain unchanged as long as there is no further voltage to be integrated. Further, the rate at which an integrator changes its output voltage is dependent upon the magnitude of the voltage to be integrated. Thus, when the defrost lockout switch 47 is closed, there will be no further change in the signal, TEMP. INT. INPUT, at the output of the integrator 48. Similarly, when defrost lockout switch 47 is open, the magnitude of the difference between the voltage generated by the temperature probe 44 and the voltage set point 46, i.e., the norm temperature desired for area 30, will determine the rate at which TEMP. INT. INPUT changes and by how much.
In accordance with the present invention, this integrated comparison between the measured temperature of area 30 and the desired norm temperature for that area is used to dynamically control the compressor pressure operation to optimize the operating suction line pressure at the highest pressure that will maintain the cooling in the coldest compartment, i.e., compartment 30. As described above with respect to the multiple compressor refrigeration system shown in FIGS. 4 and 5, the compressor control circuit 10' (See FIG. 5) (compressor control circuit 36 of the system of FIG. 1) produces a fixed "cut-in" and fixed "cut-out" suction line operating pressure (see, for example, FIG. 6). The pressure of the suction line is monitored and compared to these two reference pressure settings by comparators 74 and 76, respectively, to produce control signals to adjust the compressor capacity to effect control of the suction line pressure to an average value between the cut-in and cut-out pressure settings.
Now turning to FIG. 3, there is shown a circuit responsive to the temperature in the coldest compartment to be maintained, for generating cut-in and cut-out voltages for use in conjunction with the comparators 74 and 76 shown and described with respect to FIG. 5. In other words, the circuit of FIG. 3 produces a cut-in and a cut-out voltage as a function of the difference between the actual and the desired temperature in area 30 to respectively replace the voltage generated by potentiometers 75 and 77 in the control circuit shown in FIG. 5. In this manner, the two fixed voltages, the cut-in and cut-out pressures, normally generated by potentiometers 75 and 77, are now adjustable in reponse to the integrated difference between the desired and the actual temperature in the coldest compartment to be cooled.
As previously described, the integrator 48 acts as a memory device, it remembers what has happened in the past. If the compartment 30 temperature is below the desired norm, the integrator 48 will increase its output voltage at a rate controlled by the temperature difference, i.e., the voltage difference. A greater difference produces a faster change. This increased voltage increases both the cut-in and cut-out voltages to the comparators 74 and 76. These increased pressure limits result in an increase in the average controlled suction line pressure.
The rate at which this suction line pressure seeks out the new higher pressure is controlled in part by the difference between the desired and the actual temperatures in the coldest compartment. An increased suction line pressure results in less cooling from coil 27 and a warming of area 30. When the temperature in area 30 reaches the desired setting, there will no longer be any voltage into integrator 48, and the signal, TEMP. INT. INPUT will stabilize at a higher than previous value. This integrator process eventually results in an optimum suction line pressure operating condition, i,e., the highest suction line operating pressure possible to satisfy the cooling demands of the coldest compartment. A higher suction line pressure equates directly to a lower compressor capacity requirement which, in turn, produces a reduction in power consumption to run the refrigeration system.
Referring now to the circuit shown in FIG. 3, the signal TEMP. INT. INPUT is shown coupled through a forward conducting diode 87 into a voltage setting network of resistors 86 and 89 operating in combination with a pair of Zener diodes 82 and 84 connected in series arrangement. The Zener diode arrangement of diodes 82 and 84 is connected across the potentiometer 86 thereby to set a constant voltage drop thereacross. The voltage from the high side of the potentiometer 86 is the pressure control voltage for the CUT-IN COMPARATOR while the wiper voltage of potentiometer 86 is the pressure control voltage for the CUT-OUT COMPARATOR. The low side of the potentiometer is connected to circuit ground through an appropriate resistor 89. Because of the voltage divider effect of the variable potentiometer 86 and the constant voltage drop of Zener diodes 82 and 84 thereacross, the voltage of the CUT-OUT COMPARATOR signal will always differ by a constant value from the voltage of the CUT-IN COMPARATOR signal.
The voltage CUT-IN COMPARATOR will be controlled by the summation of the voltage from potentiometer 80 and the output of integrator 48, TEMP. INT. INPUT, applied to the summing junction through diode 87. Thus, as the output of integrator 48 increases, the suction line cut-in and cut-out pressure control voltages will likewise increase indicating that the normal operating suction line pressure will have to increase in order to bring the temperature of the coldest compartment back to the norm setting. Eventually, the control circuit 36 selects the appropriate compressor capacity to achieve an average desired suction line operating pressure which will satisfy the cooling requirement of the coldest compartment. Because of the pressure regulator valves included in the evaporator coils of the other evaporator coils in the multiple evaporator coil system plus the fact that each of the other areas or compartments to be cooled by the other evaporator coils are at a warmer temperature, the resulting average suction line pressure will be adequate to achieve the desired cooling of those compartmentalized areas.
It has been discovered that operation of the current apparatus achieves approximately a 20 percent reduction in energy consumption over the best known prior art system.
While a particular embodiment of the present invention has been shown and described, it will be understood that the invention is not limited thereto, since many modifications may be made and will become apparent to those skilled in the art. For example, the above system has described temperature operation in conjunction with one coil or area which is desirably operated colder than another coil or area. If desired, it is possible to utilize a thermoelectric sensing means in conjunction with both coils or areas in a two-coil or two-area system. An average output or other suitable combined output can then be employed as the variable or operating output to integrator 48.
Claims
What is claimed is:
1. A compressor controller circuit for use in a multiple compressor cooling system, said controller circuit having a control means responsive to the operating suction line pressure for cycling said compressors on and off in a sequence to select a combination of said compressors to provide the minimum compressor capacity sufficient to obtain an average operating suction line pressure in the range defined from an upper to a lower pressure limit, said control means including a comparator means for generating increase and decrease capacity signals when the suction pressure is, respectively, above said upper pressure limit and below said lower pressure limit, said control means selectively energizing and deenergizing said compressors by applying said increase and decrease capacity signals to said compressors in a sequence where the first energized of the energized compressors is the next to be deenergized and the first deenergized of the deenergized compressors is the next to be energized, said controller further including a means responsive to the temperature of an area cooled by a system evaporator coil for dynamically adjusting said upper and lower pressure limits, said means for adjusting said upper and lower pressure limits including an integrator means responsive to a desired operating set point area temperature and the area temperature for integrating the difference therebetween, the integrated difference adjusting said pressure limits thereby to obtain a combination of said compressors having the minimum system compressor capacity required to obtained the highest average suction line pressure which will maintain said area temperature at a desired level.
2. The controller circuit of claim 1 wherein said means for adjusting said upper and lower pressure limits further includes: (a) a temperature sensor for measuring the temperature of said area; (b) a means for generating a signal representative of a desired operating temperature for the area; and (c) a reference voltage circuit responsive to the integrated difference signal from said integrator means for generating first and second reference voltages respectively representative of said upper and lower pressure limits, said second reference voltage differing from said first reference voltage by a fixed amount, said control means including means responsive to said suction line pressure and said first and second reference voltage to increase and decrease said compressor capacity when said suction line pressure is, respectively, greater than said upper pressure limit and said suction line pressure is less than said lower pressure limit, said integrator and said reference voltage circuit cooperating together to raise and lower said pressure range thereby to obtain the minimum compressor capacity required to operate with the highest average suction line pressure in said range of pressures which will maintain the desired area temperature.
3. The controller circuit of claim 2 wherein said comparator means includes: (a) a pressure sensor for measuring the suction line operating pressure; (b) a first comparator responsive to said upper pressure limit voltage and to the output from said pressure sensor for generating an increase capacity signal when the measured pressure is greater than said upper limit; and (c) a second comparator responsive to said lower pressure limit voltage and to the output from said pressure sensor for generating a decrease capacity signal when the measured pressure is less than said lower limit.
4. The controler circuit of claim 1, 2 or 3 wherein said upper and lower pressure limits are the same pressure.
5. A compressor controller circuit for controlling the compressor capacity in a multiple compressor cooling system, said cooling system including an evaporator coil for cooling an area to be cooled, said controller circuit comprising: (a) a pressure selecting means for establishing an operating suction line pressure range having an upper limit and a lower limit; (b) a detection means for sensing the suction line pressure and cooperating with said pressure selecting means for determining when said suction pressure exceeds said upper limit and providing an increase capacity signal in response thereto, and when said suction pressure is below said lower limit and providing a decreased capacity signal in response thereto; (c) a sequencing means connected to said detection means for establishing a first-off first-on sequence for energizing the compressors in response to increase capacity signals and for establishing a first-on first-off sequence for deenergizing the compressors in response to decrease capacity signals; (d) a control circuit means responsive to said sequencing means for energizing said compressors in a first-off first-on sequence, and for deenergizing said compressors in a first-on first-off sequence to select a combination of said compressors to provide the compressor capacity sufficient to obtain an average operating suction line pressure in said suction line pressure range defined from said upper to said lower suction pressure limits; and (e) a presure range control means responsive to the temperature of an area cooled by a system evaporator coil for dynamically adjusting said upper and lower suction pressure limits to obtain a combination of energized said compressors having the minimum system compressor capacity required to obtain the highest average suction line pressure which will maintain said area temperature at a desired level.
6. The controller circuit of claim 5 wherein said pressure range control means for adjusting said upper and lower pressure limits includes: (a) a temperature sensor for measuring the temperature of said area; (b) a means for generating a signal representative of a desired operating temperature for the area; and (c) an integrator responsive to said measured area temperature and said desired operating temperature signal for integrating the difference therebetween.
7. The controller circuit of claim 6 wherein said pressure selecting means comprises: (a) a reference voltage circuit for generating first and second reference voltages respectively representative of said upper and lower pressure limits; and (b) a comparator means responsive to said suction line pressure and said first and second reference voltages to generate said increase and decrease capacity signals when said suction line pressure is, respectively, greater than said upper pressure limit and said suction line pressure is less than said lower pressure limit, said pressure range control means and said pressure selecting means cooperating together to raise and lower said pressure range limits thereby to obtain the minimum compressor capacity required to operate with the highest average suction line pressure in said range of pressures which will maintain the desired area temperature.
8. The controller circuit of claim 7 wherein said comparator means includes: (a) a first comparator responsive to said upper pressure limit voltage and to the output from said detection means for generating said increase capacity signal when the measured pressure is greater than said upper limit; and (b) a second comparator responsive to said lower pressure limit voltage and to the output from said detection means for generating said decrease capacity signal when the measured pressure is less than said lower limit, said control circuit means selectively energizing and deenergizing said compressors by applying said increase and decrease capacity signals to said compressors in a sequence where the first energized of the enerzied compressors is the next to be deenergized and the first deenergized of the deenergized compressors in the next to be the energized.
9. Apparatus for controlling the capacity of a preselected number of commonly piped compressors in a refrigeration system to obtain a minimum average system compressor capacity sufficient to obtain an average operating suction line pressure, comprising: (a) a pressure selecting means for establishing an operating suction pressure range having an upper limit and a lower limit; (b) a detection means for sensing the suction pressure in the system and cooperating with said pressure selecting means for determining when said pressure exceeds said upper limit and providing an increase capacity signal in response thereto, and when said pressure is below said lower limit and providing a decrease capacity signal in response thereto; (c) a selection means for receiving said increase capacity signals and said decrease capacity signals and in respective response thereto, selectively energizing and deenergizing said compressors to provide combinations of energized compressors that exceed in total possible numbers of combinations the number of compressors in the system so that the average compressor capacity of the system produces an average suction line pressure in said operating suction pressure range; and (d) a suction pressure range control means responsive to the temperature of an area cooled by a system evaporator coil for dynamically adjusting said upper and said lower pressure limits to obtain the minimum average system compressor capacity required to obtain the highest average suction line pressure which will maintain said area temperature at a desired level.
10. The apparatus of claim 9 wherein said suction pressure range control means for adjusting said upper and lower pressure limits includes: (a) a temperature sensor for measuring the temperature of said area; (b) a means for generating a signal representative of a desired operating temperature for the area; and (c) an integrator responsive to said measured area temperature and said desired operating temperature signal for integrating the difference therebetween.
11. The apparatus of claim 10 wherein said pressure selecting means comprises: (a) a reference voltage circuit for generating first and second reference voltages respectively representative of said variable upper and lower pressure limits, said second reference voltage differing from said first reference voltage by a fixed amount; and (b) a comparator means responsive of said suction line pressure and said first and second reference voltages to increase and decrease said compressor capacity when said suction line pressure is, respectively, greater than said upper pressure limit and said suction line pressure is less than said lower pressure limit, said pressure range control means and said pressure selecting means cooperating together to raise and lower said pressure range thereby to obtain the minimum average compressor capacity required to operate with the highest average suction line pressure which will maintain the desired area temperature.
12. The apparatus of claim 10 wherein said comparator means includes: (a) a first comparator responsive to said variable upper pressure limit voltage and to the output from said detection means for generating an increase capacity signal when the measured pressure is greater than said upper limit; and (b) a second comparator responsive to said variable lower pressure limit voltage and to the output from said detection means for generating a decrease capacity signal when the measured pressure is less than said lower limit.
13. The apparatus of claim 12 wherein each said compressor has a maximum cycle repetition rate, said system further including a time delay means responsive to said first and second comparators for delaying said compressor turn on and turn off operations in response to receipt of increase and decrease capacity signals, respectively.
14. The apparatus of claim 9, wherein said selection means comprises: (a) a sequencing means for establishing a first-off first-on sequence for energizing the compressors and a first-on first-off sequence for deenergizing the compressors and receiving said increase and decrease capacity signals for generating a compressor turn-on signal in response to receiving said increase capacity signal and a compressor turn-off signal in response to receiving said decrease capacity signal; and (b) a control circuit means for applying said turn-on signal to the deenergized compressor stage that was the first to be deenergized and applying said turn-off signal to the energized compressor stage that was the first to be energized.
15. The system as described in claim 14, wherein said sequencing means comprises a counting means receiving said increase or decrease capacity signals from said detection means and generating in response to each of said received signals a cut-in or cut-out control signal to respectively turn on or turn off a compressor stage, said cut-in control signals occurring in a first-off first-on sequence and said cut-out control signals occurring in a first-on first-off sequence.
16. A method of optimizing the system compressor capacity in a multiple compressor cooling system to obtain the highest average operating suction line pressure which results in an evaporator coil maintaining the temperature of an area cooled by said coil to a desired temperature, comprising the steps of: (a) establishing an operation suction pressure range having an upper limit and a lower limit; (b) detecting the suction pressure in the system for determining when said suction pressure exceeds said upper limit and when said suction pressure is below said lower limit; (c) generating an increase capacity signal when said operating suction pressure exceeds said upper limit and a decrease capacity signal when said operation suction pressure is below said lower limit; (d) applying said increase capacity signal and said decrease capacity signal to respectively energize and deenergize the preselected number of compressors in a sequence where the first deenergized compressor is the next to be energized and the first energized compressor is the next to be deenergized; (e) sensing the temperature of said area; (f) integrating the difference between the sensed area temperature and a desired temperature; and (g) adjusting said suction pressure limits as a function of the integrated difference obtained in step (f) to obtain the minimum compressor capacity which will produce the highest average operating suction line pressure to maintain the area temperature at the desired temperature.
17. Apparatus for controlling the system compressor capacity for a cooling system having a plurality of commonlypiped compressors coupled to a plurality of evaporator coils and operated in accordance with control suction line pressure limits, comprising: (a) a temperature sensor for measuring the temperature of the evaporator coil to be operated at the coldest temperature; (b) a setpoint means for setting a desired operating temperature for the evaporator coil to be operated at the coldest temperature; (c) a pressure level setting means responsive to said measured evaporator temperature and said desired operating temperature for dynamically adjusting an upper and a lower suction line pressure limit as a function of the difference between the desired temperature and the measured temperature, said pressure level setting means including, (i) an integrator responsive to said measured evaporator temperature and said desired operating temperature for integrating the difference therebetween, and (ii) a comparator reference voltage generator circuit responsive to the output voltage from said integrator for generating first and second reference voltages respectively representative of said upper and lower suction line pressure limits, said second reference voltage differing from said first reference voltage by a fixed amount, said integrator and said reference voltage generator circuit cooperating together to increase said upper and lower pressure limits when said measured temperature is less than said desired temperature, and to decrease said upper and lower pressure limits when said measured temperature is greater than said desired temperature; and (d) a compressor controller circuit responsive to said variable upper and lower suction line pressure limits for cycling said compressors on and off in a sequence to select a combination of said compressors which produces the minimum system compressor capacity required to obtain the highest average operating suction line pressure between said variable upper and lower pressure limits which maintains the measured evaporator temperature at the desired operating temperature, said evaporator coil to be maintained at the coldest temperature including a defrost means having a lock-out switch coupled to said integrator for disabling said integrator when said lowest temperature evaporator coil switches to defrost operation.
18. Apparatus for controlling the system compressor capacity for a cooling system having a plurality of commonlypiped compressors coupled to a plurality of evaporator coils, said apparatus controlling the compressor capacity in accordance with control suction line pressure limits, comprising: (a) a temperature sensor for measuring the temperature of the evaporator coil to be operated at the coldest temperature; (b) a setpoint means for setting a desired operating temperature for the evaporator coil to be operated at the coldest temperature; (c) a pressure level setting means responsive to said measured evaporator temperature and said desired operating temperature for dynamically adjusting an upper and a lower suction line pressure limit as a function of the difference between the desired temperature and the measured temperature, said pressure level setting means including, (i) an integrator responsive to said measured evaporator temperature and said desired operating temperature for integrating the difference therebetween, and (ii) a comparator reference voltage generator circuit responsive to the output voltage from said integrator for generating first and second reference voltages respectively representative of said upper and lower suction line pressure limits, said second reference voltage differing from said first reference voltage by a fixed amount, said integrator and said reference voltage generator circuit cooperating together to increase said upper and lower pressure limits when said measured temperature is less than said desired temperature, and to decrease said upper and lower pressure limits when said measured temperature is greater than said desired temperature; and (d) a compressor controller circuit responsive to said variable upper and lower suction line pressure limits for cycling said compressors on and off in a sequence to select a combination of said compressors which produces the minimum system compressor capacity required to obtain the highest average operating suction line pressure between said variable upper and lower pressure limits which maintains the measured evaporator temperature at the desired operating temperature, said compressor controller circuit including, (i) a pressure sensor for measuring the suction line operating pressure, (ii) a first comparator responsive to said upper pressure limit voltage and to the output from said pressure sensor for generating an increase capacity signal when the measured pressure is greater than said upper limit, and (iii) a second comparator responsive to said lower pressure limit voltage and to the output from said pressure sensor for generating a decrease capacity signal when the measured pressure is less than said lower limit, said control means selectively energizing and deenergizing said compressors by applying said increase and decrease capacity signals to said compressors in a sequence where the first energized of the energized compressors is the next to be deenergized and the first deenergized of the deenergized compressors is the next to be the energized.
19. A refrigeration system having in a closed loop connection a plurality of commonly piped compressors, each having an inlet and an outlet end and where the pressure at the inlet ends of said commonly piped compressors is the suction line pressure for the system, a condenser connected to the outlet end of said compressor and responsive to a high pressure gaseous phase recirculating refrigerant for condensing the refrigerant from its gaseous to its liquid phase, at least one evaporator coil having an inlet and an outlet end and connected to said condenser and to said compressors, an expansion valve associated with each said evaporator coil and having an inlet and an outlet end connected between the outlet end of said condenser and the inlet end of said associated evaporator coil, said condenser delivering high pressure liquid refrigerant to the inlet end of said expansion valve, said refrigerant expanding as it flows through said expansion valve, one said evaporator coil associated with an area to be cooled, and a compressor controller circuit for controlling the compressor capacity, said controller circuit comprising: (a) a pressure selecting means for establishing an operating suction line pressure range having an upper limit and a lower limit; (b) a detection means for sensing the suction line pressure and cooperating with said pressure selecting means for determining when said suction pressure exceeds said upper limit and providing an increase capacity signal in response thereto, and when said suction pressure is below said lower limit and providing a decrease capacity signal in response thereto; (c) a sequencing means connected to said detection means for establishing a first-off first-on sequence for energizing the compressors in response to increase capacity signals and for establishing a first-on first-off sequence for deenergizing the compressors in response to decrease capacity signals; (d) a control circuit means responsive to said sequencing means for energizing said compressors in a first-off first-on sequence, and for deenergizing said compressors in a first-on first-off sequence to select a combination of said compressors to provide the compressor capacity sufficient to obtain an average operating suction line pressure in said suction line pressure range defined from said upper to said lower suction pressure limits; and (e) a pressure range control means responsive to the temperature of an area cooled by a system evaporator coil for dynamically adjusting said upper and lower suction pressure limits to obtain a combination of energized said compressors having the minimum system compressor capacity required to obtain the highest average suction line pressure which will maintain said area temperature at a desired level.
20. The refrigeration system of claim 19 wherein said pressure range control means for adjusting said upper and lower pressure limits includes: (a) a temperature sensor for measuring the temperature of said area; (b) a means for generating a signal representative of a desired operating temperature for the area; and (c) an integrator responsive to said measured area temperature and said desired operating temperature signal for integrating the difference therebetween.
21. The controller circuit of claim 19 wherein said pressure selecting means comprises: (a) a reference voltage circuit for generating first and second reference voltages respectively representative of said upper and lower pressure limits; and (b) a comparator means responsive to said suction line pressure and said first and second reference voltages to generate said increase and decrease capacity signals when said suction line pressure is, respectively, greater than said upper pressure limit and said suction line pressure is less than said lower pressure limit, said pressure range control means and said pressure selecting means cooperating together to raise and lower said pressure range limits thereby to obtain the minimum compressor capacity required to operate with the highest average suction line pressure in said range of pressures which will maintain the desired area temperature.
22. The refrigeration system of claim 21 wherein said comparator means includes: (a) a first comparator responsive to said upper pressure limit voltage and to the output from said detection means for generating said increase capacity signal when the measured pressure is greater than said upper limit; and (b) a second comparator responsive to said lower pressure limit voltage and to the output from said detection means for generating said decrease capacity signal when the measured pressure is less than said lower limit, said control means selectively energizing and deenergizing said compressors by applying said increase and decrease capacity signals to said compressors in a sequence where the first energized of the energized compressors is the next to be deenergized and the first deenergized of the deenergized compressors is the next to be the energized.
23. A refrigeration system having in a closed loop connection a plurality of commonly piped compressors, each having an inlet and an outlet end and where the pressure at the inlet ends of said commonly piped compressors is the suction line pressure for the system, a condenser connected to the outlet end of said compressor and responsive to a high pressure gaseous phase recirculating refrigerant for condensing the refrigerant from its gaseous to its liquid phase, at least one evaporator coil having an inlet and an outlet end and connected to said condenser and to said compressors, an expansion valve associated with each said evaporator coil and having an inlet and an outlet end connected between the outlet end of said condenser and the inlet end of said associated evaporator coil, said condenser delivering high pressure liquid refrigerant to the inlet end of said expansion valve, said refrigerant expanding as it flows through said expansion valve, one said evaporator coil associated with an area to be cooled, and a compressor controller circuit for controlling the capacity of said commonly piped compressors to obtain a minimum average system compressor capacity sufficient to obtain an average operating suction line pressure, comprising: (a) a pressure selecting means for establishing an operating suction line pressure range having an upper limit and a lower limit; (b) a detection means for sensing the suction pressure in the system and cooperating with said pressure selecting means for determining when said pressure exceeds said upper limit and providing an increase capacity signal in response thereto, and when said pressure is below said lower limit and providing a decreased capacity signal in response thereto; (c) a selection means for receiving said increase capacity signals and said decrease capacity signals and in respective response thereto, selectively energizing and deenergizing said compressors to provide combinations of energized compressors that exceed in total possible numbers of combinations the number of compressors in the system so that the average compressor capacity of the system produces an average suction line pressue in said operating suction pressure range; and (d) a suction pressure range control means responsive to the temperature of an area cooled by a system evaporator coil for dynamically adjusting said upper and said lower pressure limits to obtain the minimum average system compressor capacity required to obtain the highest average suction line pressure which will maintain said area temperature at a desired level.
24. The refrigeration system of claim 23 wherein said suction pressure range control means for adjusting said upper and lower pressure limits includes: (a) a temperature sensor for measuring the temperature of said area; (b) a means for generating a signal representative of a desired operating temperature for the area; and (c) an integrator responsive to said measured area temperature and said desired operating temperature signal for integrating the difference therebetween.
25. The refrigeration system of claim 23 wherein said pressure selecting means comprises: a reference voltage circuit for generating first and second reference voltages respectively representative of said variable upper and lower pressure limits, said second reference voltage differing from said first reference voltage by a fixed amount; and (b) a comparator means responsive to said suction line pressure and said first and second reference voltages to increase and decrease said compressor capacity when said suction line pressure is, respectively, greater than said upper pressure limit and said suction line pressure is less than said lower pressure limit, said pressure range control means and said pressure selecting means cooperating together to raise and lower said pressure range thereby to obtain the minimum average compressor capacity required to operate with the highest average suction line pressure which will maintain the desired area temperature.
26. The refrigeration system of claim 25 wherein said means includes: (a) a first comparator responsive to said variable upper pressure limit voltage and to the output from said detection means for generating an increase capacity signal when the measured pressure is greater than said upper limit; and (b) a second comparator responsive to said variable lower pressure limit voltage and to the output from said detection means for generating a decrease capacity signal when the measured pressure is less than said lower limit.
27. The refrigeration system of claim 26 wherein each said compressor has a maximum cycle repetition rate, said system further including a time delay means responsive to said first and second comparators for delaying said compressor turn on and turn off operations in response to receipt of increase and decrease capacity signals, respectively.
28. The refrigeration system of claim 23, wherein said selection means comprises: (a) a sequencing means for establishing a first-off first-on sequence for energizing the compressors and a first-on first-off sequence for deenergizing the compressors and receiving said increase and decrease capacity signals for generating a compressor turn-on signal in response to receiving said increase capacity signal and a compressor turn-off signal in response to receiving said decrease capacity signal; and (b) a control circuit means for applying said turn-on signal to the deenergized compressor stage that was the first to be deenergized and applying said turn-off signal to the energized compressor stage that was the first to be energized.
29. The apparatus of claim 17 wherein said upper and lower suction line pressure limits comprise a single suction line control pressure setpoint.
30. The apparatus of claim 18 wherein said control suction line pressure limits comprises a single suction line control pressure for both said upper and lower pressure limits.
31. The refrigeration system of claim 19 or 23 wherein said operating suction line pressure range comprises a single suction line control pressure for both said upper and lower pressure limits.