Emerson Climate Technologies Gmbh

Emerson Electric Company

Copeland Corporation

Computer Process Controls, Inc.

Nagaraj Jayanth

Hung M Pham

William P Butler

George Ramayya

Troy W Renken

Jean-Luc M Caillat

Kirill M Ignatiev

Masao Akei

Steven L Carey

Dean A Drake

Wayne R Warner

Richard P Vogh, Iii

Antonio Lopez

Carl J Mueller

John Wallace

Hank E Millet

Alan E Mayne

David R Rohn

Richard P Vogh Iii

A diagnostic system for a compressor is provided. The compressor includes a compression mechanism and a motor. The diagnostic system includes processing circuitry and memory and may be operable to differentiate between a low-side fault and a high-side fault by monitoring a rate of current rise drawn by the motor for a first predetermined time period following compressor startup. The diagnostic system may be operable to predict a severity level of a compressor condition based on a fault history stored in the memory.

Diagnostic system

A sensor module for a compressor having an electric motor connected to a power supply is provided. The sensor module includes: a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of the power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of the power supply; and a processor connected to the first and second inputs. The processor monitors the first and second inputs and, based on voltage measurements from the first input and current measurements from the second input, detects at least one of: (i) an unexpected variation of electric power from the power supply; and (ii) a mechanical malfunction. The processor is disposed within an electrical enclosure of the compressor, the electrical enclosure being configured to house electrical terminals for connecting the power supply to the electric motor.

Compressor sensor module

A method for monitoring a compressor includes measuring a power factor of a motor of a compressor. The method includes selectively detecting an occurrence of a fault event of an electrical grid based on the power factor. The method includes, in response to detecting that the fault event has occurred, switching the compressor from a first state to a second state. The compressor consumes less power in the second state than in the first state. The method includes identifying an apparent conclusion of the fault event. The method includes, in response to the apparent conclusion of the fault event, waiting for a first delay period before switching the motor of the compressor back to the first state.

Compressor protection and grid fault detection device

A compressor is provided and may include a shell, a compression mechanism, a motor, and a diagnostic system that determines a system condition. The diagnostic system may include a processor and a memory and may predict a severity level of the system condition based on at least one of a sequence of historical-fault events and a combination of the types of the historical-fault events.

A method of operating a refrigeration system that receives power from an electrical grid includes selectively operating at least one component of the refrigeration system in a first state. The method includes selectively detecting a fault event of the electrical grid in response to a concurrent (i) increase in amount of current drawn by the component and (ii) decrease in voltage of power received by the component. The method includes, in response to detecting the fault event, switching the component from the first state to a second state. The component consumes less power in the second state than in the first state. The method includes determining a first delay period. The method includes identifying a conclusion of the fault event. The method includes, in response to the conclusion of the fault event, waiting for the first delay period before switching the component back to the first state.

A compressor is provided and includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a data module processor and a data module memory. The compressor controller includes a controller processor and a controller memory distinct from the data module processor and the data module memory. The data module receives sensed data, stores the sensed data in the data module memory, determines a first diagnosis of the compressor based on the sensed data, and communicates the sensed data and the first diagnosis to the compressor controller. The compressor controller determines a second diagnosis of the compressor based on the sensed data and verifies the first diagnosis by comparing the first diagnosis to the second diagnosis.

Compressor data module

A method of operating a refrigeration system that receives power from an electrical grid includes operating at least one component of the refrigeration system in a first state. The method includes detecting a fault event of the electrical grid in response to a concurrent increase in amount of current drawn by the component and decrease in voltage of power received by the component. The method includes, in response to detecting the fault event, switching the component from the first state to a second state, wherein the component consumes less power in the second state than in the first state. The method includes determining a first delay period according to a random process. The method includes identifying a conclusion of the fault event. The method includes, in response to the conclusion of the fault event, waiting for the first delay period before switching the component back to the first state.

A sensor module for a compressor having an electric motor connected to a power supply is provided. The sensor module includes an input that receives current measurements generated by a current sensor based on a current of the power supply. The sensor module also includes a processor. The processor is connected to the input, determines a maximum continuous current for the electric motor, and selectively compares the current measurements with a value equal to the maximum continuous current multiplied by a predetermined value. The maximum continuous current is set based on at least one of a type of refrigerant used by the compressor and actual refrigeration system conditions.

A sensor module for a compressor having an electric motor connected to a power supply and a processor disposed within an electrical enclosure of the compressor is provided, with the electrical enclosure being configured to house electrical terminals for connecting the power supply to the electric motor. The sensor module includes a first input connected to a voltage sensor that generates a voltage signal corresponding to a voltage of the power supply and a second input connected to a current sensor that generates a current signal corresponding to a current of the power supply. The processor is connected to the first and second inputs. The processor may calculate a power factor of the compressor, detect an unexpected variation in the power supply, and/or detect a mechanical malfunction of the compressor based on the voltage measurements and the current measurements.

A system includes a control module and a monitor module. The control module selectively operates a component of the system in an ON state. The system receives power from an electrical grid. The monitor module selectively detects a fault event of the electrical grid in response to (i) an amount of current drawn by the component or (ii) a voltage of power received by the component. In response to detecting the fault event, the control module switches the component from the ON state to a second state, determines a first delay period according to a random process, identifies an apparent conclusion of the fault event, and in response to the apparent conclusion of the fault, waits for the first delay period before switching the component back to the ON state. The component consumes less power in the second state than in the ON state.

A compressor monitoring system includes current and voltage monitors, current and voltage averaging modules, a control module, and a switch. The current monitor measures a current drawn by a motor of a compressor. The current averaging module generates first and second average current values based on the current measured by the current monitor. The voltage monitor measures a utility power voltage. The voltage averaging module generates first and second average voltage values based on the voltage measured by the voltage monitor. The control module selectively generates a fault signal when a first ratio is greater than a first predetermined threshold and a second ratio is less than a second predetermined threshold. The first ratio is based on the first and second average current values. The second ratio is based on the first and second average voltage values. The switch deactivates the motor when the fault signal is generated.

A three-phase electric motor of a compressor receives first, second, and third phases from a three-phase power supply. A method for protecting the motor includes, using a line break protector, disconnecting the motor from only the first phase in response to a temperature being greater than a predetermined temperature threshold. The method also includes measuring a first current flowing through the line break protector, and determining a current value based on the first current independent of current in the second and third phases. The method further includes disconnecting the motor from the first, second, and third phases in response to the current value being less than or equal to a predetermined threshold.

Systems and methods for protecting three-phase motors

A compressor includes at least one current sensor and processing circuitry in communication with the at least one current sensor. The processing circuitry declares a locked rotor condition when current drawn by the compressor is at least forty percent of peak locked rotor current.

Compressor protection and diagnostic system

An interactive system for controlling the operation of an HVAC system is provided that comprises a thermostat for initiating the operation of the HVAC system in either a full capacity mode of operation or at least one reduced capacity mode of operation, and a controller for an outside condenser unit having a condenser fan motor and a compressor motor, the controller being capable of operating the compressor in a full capacity mode and at least one reduced capacity mode. The system also comprises a controller for an indoor blower unit having a blower fan motor, the controller being capable of operating the blower fan motor in a full capacity mode and at least one reduced capacity mode. The system further includes a communication means for transmitting information between the outside condenser unit controller and at least the indoor blower controller, where the information relates to the operation of the indoor blower and the outdoor condenser unit. The indoor blower controller responsively controls the operation of the blower fan motor in a full capacity mode or a reduced capacity mode based on the information received from the outdoor unit controller, and the outdoor unit controller responsively controls the operation of the compressor in a full capacity mode or a reduced capacity mode based on the information received from the indoor blower controller.

Interactive control system for an HVAC system

A system for protecting a three-phase electric motor of a compressor, the motor receiving first, second, and third phases from a three-phase power supply, the system including a single-phase line break protector, a first current sensor, and a control module. The single-phase line break protector disconnects the motor from the first phase in response to a temperature being greater than a predetermined temperature threshold. The first current sensor measures a current through the single-phase line break protector. The control module determines a current value based on the measured current, and disconnects the motor from the second and third phases in response to the current value being less than or equal to a predetermined threshold.

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Sidney, OH, United States of America

Nagaraj Jayanth