Method of and system for detecting loss of refrigerant charge

• US 10,352,579 B2
• Filed: 02/03/2016
• Issued: 07/16/2019
• Est. Priority Date: 02/03/2016
• Status: Active Grant

• Current Assignee: Lennox Industries Incorporated (Lennox International Incorporated)
• Original Assignee: Lennox Industries Incorporated (Lennox International Incorporated)
• Inventors: Guo, LiYing, Omlor, David
• Primary Examiner(s): Jules, Frantz F
• Assistant Examiner(s): Tadesse, Martha
• Application Number:
  US15/014,286
• Publication Number:
  US 20170219262A1
• Time in Patent Office: 1,259 Days
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/36 to leakage of heat-exchange fluid
• CPC Class Codes: F24F 11/49 ensuring correct operation, e.g. by trial operation or configuration checks
• CPC Class Codes: F24F 11/523 for displaying temperature data
• CPC Class Codes: F24F 11/62 characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
• CPC Class Codes: F24F 2140/20 Heat-exchange fluid temperature
• CPC Class Codes: F25B 13/00 Compression machines, plants or systems, with reversible cycle defrosting cycles F25B47/02
• CPC Class Codes: F25B 2313/0314 Temperature sensors near the indoor heat exchanger
• CPC Class Codes: F25B 2313/0315 Temperature sensors near the outdoor heat exchanger
• CPC Class Codes: F25B 2500/222 Detecting refrigerant leaks
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 49/005 of safety devices F25B49/02 and F25B49/04 take precedence

Abstract

A method of determining loss of refrigerant charge in a heating, ventilation, and air conditioning (HVAC) system. The method includes receiving, using a controller, a plurality of temperature values from a plurality of temperature sensors placed at multiple locations within the HVAC system and calculating, using the controller using the plurality of temperature values, a plurality of temperature-dependent values. The method further includes determining, using the controller, whether a first temperature-dependent value of the plurality of temperature-dependent values is above a first predetermined temperature value and responsive to a determination that the first temperature-dependent value is above the first predetermined temperature value, transmitting, using the controller to a user interface, a notification indicating that the HVAC system is operating with low refrigerant charge.

Claims

1. A method of determining loss of refrigerant charge in a heating, ventilation, and air conditioning (HVAC) system, the method comprising:

receiving, by a controller operatively coupled to a plurality of temperature sensors, a plurality of temperature values from the plurality of temperature sensors placed at multiple locations within the HVAC system, wherein the plurality of temperature sensors communicate with the controller via at least one of a wired connection and a wireless connection;

calculating, using the controller using the plurality of temperature values, a plurality of temperature-dependent values;

determining, using the controller, whether a first temperature-dependent value of the plurality of temperature-dependent values is above a first predetermined temperature value, wherein the first temperature-dependent value comprises a discharge-superheat temperature of a refrigerant (DSH),

wherein DSH is calculated using the equation listed below;

DSH=(T_disC−

T_mod)*(82/T_od); and

wherein T_disC refers to a compressor-discharge temperature, T_mod refers to an outdoor mid-circuit-condenser temperature, and T_od refers to outdoor ambient temperature; and

responsive to a determination that the first temperature-dependent value is above the first predetermined temperature value, transmitting, using the controller to a user interface, a notification indicating that the HVAC system is operating with low refrigerant charge.

2. The method of claim 1 further comprising:

responsive to a determination that the first temperature-dependent value is below the first predetermined temperature value;

determining, using the controller, whether each of the following three primary conditions is true;

the first temperature-dependent is above a second predetermined temperature value;

a second temperature-dependent value of the plurality of temperature-dependent values is above a third predetermined temperature value; and

a third temperature-dependent value of the plurality of temperature-dependent values is above a fourth temperature-dependent value of the plurality of temperature-dependent values; and

responsive to a determination each of the three primary conditions is true, transmitting, using the controller to the user interface, a notification indicating that the HVAC system is not operating appropriately due to blockage of a component of the HVAC system.

3. The method of claim 2 further comprising:

responsive to a determination that at least one of the three primary conditions is not true, determining, using the controller, whether each of the following three secondary conditions is true;

the first temperature-dependent is above the second predetermined temperature value;

the second temperature-dependent value of the plurality of temperature-dependent values is below the third predetermined temperature value; and

the third temperature-dependent value of the plurality of temperature-dependent values is above the fourth temperature-dependent value of the plurality of temperature-dependent values; and

responsive to a determination that each of the three secondary conditions is true, transmitting, using the controller to the user interface, the notification indicating that the HVAC system is operating with low refrigerant charge.

4. The method of claim 3 further comprising:

responsive to a determination that at least one of the three secondary conditions is not true, determining, using the controller, whether each of the following three tertiary conditions is true;

the first temperature-dependent is below the second predetermined temperature value;

the second temperature-dependent value of the plurality of temperature-dependent values is below the third predetermined temperature value; and

the third temperature-dependent value of the plurality of temperature-dependent values is above the fourth temperature-dependent value of the plurality of temperature-dependent values; and

responsive to a determination that each of the three tertiary conditions is true, transmitting, using the controller to the user interface, the notification indicating that the HVAC system is operating with low refrigerant charge.

5. The method of claim 4 further comprising:

responsive to a determination that at least one of the three tertiary conditions is not true, determining, using the controller, whether each of the following three quaternary conditions is true;

the first temperature-dependent is below the second predetermined temperature value;

the second temperature-dependent value of the plurality of temperature-dependent values is above the third predetermined temperature value; and

the third temperature-dependent value of the plurality of temperature-dependent values is above the fourth temperature-dependent value of the plurality of temperature-dependent values; and

responsive to a determination that each of the three quaternary conditions is true, transmitting, using the controller to the user interface, a notification indicating that the HVAC system is not operating appropriately due to blockage of a component of the HVAC system.

6. The method of claim 5 further comprising:

responsive to a determination that at least one of the three quaternary conditions is not true, determining, using the controller, whether each of the following three quinary conditions is true;

the first temperature-dependent is above the second predetermined temperature value;

the second temperature-dependent value of the plurality of temperature-dependent values is below the third predetermined temperature value; and

the third temperature-dependent value of the plurality of temperature-dependent values is below the fourth temperature-dependent value of the plurality of temperature-dependent values; and

responsive to a determination that each of the three quinary conditions is true, transmitting, using the controller to the user interface, a notification indicating a calibration error.

7. The method of claim 6, wherein the second temperature-dependent value comprises a temperature difference between an outdoor mid-circuit-condenser temperature (T_mod) and an outdoor ambient temperature (T_od).

8. The method of claim 6, wherein the third temperature-dependent value comprises an actual temperature difference between a lower section of a refrigerant evaporator coil (T_evapL) and an upper section of the refrigerant evaporator coil (T_evapH).

9. The method of claim 6, wherein the fourth temperature-dependent value comprises two times a normal temperature difference between a lower section of a refrigerant evaporator coil (nT_evapL) and an upper section of the refrigerant evaporator coil (nT_evapH).

10. The method of claim 6, wherein the first predetermined temperature value is approximately 100°

F.

11. The method of claim 6, wherein the second predetermined temperature value is approximately 50°

F.

12. The method of claim 6, wherein the third predetermined temperature value is approximately 20°

F.

13. The method of claim 1, wherein:

a first temperature sensor of the plurality of temperature sensors is thermally exposed at at least an upper section of a refrigerant evaporator coil and is configured to measure temperature around the upper section of the refrigerant evaporator coil;

a second temperature sensor of the plurality of temperature sensors is thermally exposed at at least a lower section of the refrigerant evaporator coil and is configured to measure temperature around the lower section of the refrigerant evaporator coil;

a third temperature sensor of the plurality of temperature sensors is thermally exposed at a compressor discharge line and is configured to measure compressor-discharge temperature;

a fourth temperature sensor of the plurality of temperature sensors is thermally exposed at at least a central section of a condenser coil and is configured to measure outdoor mid-circuit-condenser temperature; and

a fifth temperature sensor of the plurality of temperature sensors is configured to measure outdoor ambient temperature.

14. The method of claim 1, wherein the plurality of temperature sensors comprise thermistors.