Refrigeration system and method of configuring the same

• US 20040016244A1
• Filed: 06/13/2003
• Published: 01/29/2004
• Est. Priority Date: 03/14/2000
• Status: Active Grant

• Current Assignee: Hussmann Corporation (Panasonic Holdings Corporation)
• Original Assignee: Hussmann Corporation (Panasonic Holdings Corporation)
• Inventors: Street, Norman E., Sunderland, Ted W.
• Granted Patent: US 7,000,422 B2
• Time in Patent Office: Days
• US Class Current: 62/132
• CPC Class Codes: F25B 1/00 Compression machines, plants or systems with non-reversible cycle F25B3/00, F25B5/00, F25B6/00, F25B7/00, F25B9/00 take precedence
• CPC Class Codes: F25B 2400/075 with parallel compressors
• CPC Class Codes: F25B 2400/22 Refrigeration systems for supermarkets
• CPC Class Codes: F25B 25/005 using primary and secondary systems
• CPC Class Codes: F25B 2500/06 Damage
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2600/111 of condenser fans
• CPC Class Codes: F25B 2700/03 Oil level
• CPC Class Codes: F25B 2700/1931 Discharge pressures
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/21151 at the suction side of the compressor
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 2700/21157 at the coil or rotor
• CPC Class Codes: F25B 41/22 between evaporator and compressor
• CPC Class Codes: F25B 49/00 Arrangement or mounting of control or safety devices
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems
• CPC Class Codes: F25B 49/022 Compressor control arrangements
• CPC Class Codes: F25B 5/02 arranged in parallel
• CPC Class Codes: F25B 6/04 arranged in series
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A refrigeration system including a compressor, condenser, valve, and evaporator in fluid communication; a system controller operable to control one or more aspects of the refrigeration system, and a subsystem controller in communication with the system controller. The subsystem controller is operable to control one of the compressor, condenser, valve, and evaporator. A method of operating the refrigeration system includes communicating a code from the subsystem controller to the system controller, obtaining information at the system controller having a relation to the code; and communicating at least a portion of the obtained information from the system controller to the subsystem controller.

Claims

1. A method of configuring a refrigeration system comprising

a compressor, condenser, valve, and evaporator in fluid communication,

a system controller operable to control one or more aspects of the refrigeration system, and

a subsystem controller in communication with the system controller, the subsystem controller operable to control one of the compressor, condenser, valve, and evaporator, the method comprising the acts of:

communicating a code from the subsystem controller to the system controller;

obtaining information at the system controller having a relation to the code; and

communicating at least a portion of the obtained information from the system controller to the subsystem controller.

2. A method as set forth in claim 1 wherein the subsystem controller includes a compressor control module associated with the compressor, wherein the code includes an identification code associated with the compressor, and wherein the communicated information includes an operating parameter for the compressor.

3. A method as set forth in claim 1 wherein the subsystem controller includes a condenser controller associated with the condenser, wherein the code includes an identification code associated with the condenser, and wherein the communicated information includes an operating parameter for the condenser.

4. A method as set forth in claim 1 wherein the condenser includes a fan, wherein the subsystem controller includes a fan control module associated with the fan, wherein the code includes an identification code associated with the fan, and wherein the communicated information includes an operating parameter for the fan.

5. A method as set forth in claim 1 wherein the subsystem controller includes a valve control module associated with the valve, wherein the code includes an identification code associated with the valve, and wherein the communicated information includes an operating parameter for the valve.

6. A method as set forth in claim 1 wherein the refrigeration system further comprises a merchandiser and a case control module, wherein the case control module is in communication with the system controller and is associated with the merchandiser, and wherein the method further comprises the acts of:

communicating a second code from the case control module to the system controller, the second code including an identification code for the merchandiser;

obtaining information at the system controller having a relation to the second code; and

communicating at least a portion of the obtained information from the system controller to the case control module, the information communicated to the case control module includes an operating parameter for the merchandiser.

7. A method as set forth in claim 1 wherein the refrigeration system further comprises a refrigeration branch including the evaporator, and a merchandiser, wherein the subsystem controller includes a branch control module associated with the refrigeration branch, wherein the code includes an identification code associated with the merchandiser, and wherein the communicated information includes an operating parameter for the refrigeration branch.

8. A method of configuring a refrigeration system comprising

a compressor, a condenser having a fan, a valve, and a refrigeration branch including an evaporator coil, all of which being in fluid communication,

a merchandiser adapted to be cooled by the evaporator coil,

a system controller operable to control the refrigeration system,

a compressor controller in communication with the system controller, the compressor controller being associated with the compressor and including a first identification code identifying the compressor,

a valve controller in communication with the system controller, the valve controller being associated with the valve and including a second identification code identifying the valve, and

a branch controller in communication with the system controller, the branch controller being associated with the refrigeration branch and including a third identification code identifying the merchandiser, the method comprising the acts of:

communicating the first identification code from the compressor controller to the system controller;

communicating the second identification code from the valve controller to the system controller;

communicating the third identification code from the branch controller to the system controller;

obtaining information at the system controller having a relation to the first code;

obtaining information at the system controller having a relation to the second code;

obtaining information at the system controller having a relation to the third code;

communicating at least a portion of the obtained information having a relation to the first identification code from the system controller to the compressor controller, the communicated information including an operating parameter for the compressor;

communicating at least a portion of the obtained information having a relation to the second identification code from the system controller to the valve controller; and

communicating at least a portion of the obtained information having a relation to the third identification code from the system controller to the branch controller, the information including an operating parameter for the refrigeration branch.

9. A method as set forth in claim 8 wherein the refrigeration system further includes a case controller in communication with the system controller, the case controller being associated with the merchandiser and including a fourth identification code identifying the merchandiser, and wherein the method further comprises the acts of:

communicating the fourth identification code from the case controller to the system controller;

obtaining information at the system controller having a relation to the fourth code, the information including an operating parameter for the merchandiser; and

communicating at least a portion of the obtained information having a relation to the fourth identification code from the system controller to the case controller.

10. A method as set forth in claim 8 wherein the third and fourth codes are the same.

11. A method as set forth in claim 8 wherein the system controller includes a rack PLC.

12. A method as set forth in claim 8 wherein the system controller includes a programmable device.

13. A method of configuring a refrigeration system comprising

a compressor, condenser, valve, and evaporator in fluid communication,

a system controller operable to control one or more aspects of the refrigeration system, and

a compressor control module coupled to the compressor and in communication with the system controller, the compressor control module being operable to control the compressor and including an identification code identifying the compressor, the method comprising the acts of:

communicating the identification code from the compressor control module to the system controller;

obtaining information at the system controller having a relation to the identification code; and

communicating at least a portion of the obtained information from the system controller to the compressor control module, the communicated information including an operating parameter for the compressor.

14. A method as set forth in claim 13 wherein the refrigeration system further comprises

a second compressor in fluid communication with the condenser, expansion valve, and evaporator, and

a second compressor control module coupled to the second compressor and in communication with the system controller, the second compressor control module being operable to control the second compressor and including a second identification code identifying the second compressor, the method comprising the acts of:

communicating the second identification code from the second compressor control module to the system controller;

obtaining information at the system controller having a relation to the second identification code; and

communicating at least a portion of the obtained information having a relation to the second identification code from the system controller to the second compressor control module, the communicated information including an operating parameter for the second compressor.

15. A method as set forth in claim 14 wherein the refrigeration system further comprises a first suction group and a second suction group, and wherein the first suction group includes the first compressor and the second suction group includes the second compressor.

16. A method as set forth in claim 13 wherein the system controller includes a rack controller.

17. A method as set forth in claim 13 wherein the system controller includes an operator station.

18. A method as set forth in claim 13 wherein the refrigeration system is a commercial refrigeration system.

19. A method as set forth in claim 18 wherein the compressor control module includes a processor and memory, and wherein the method further comprises storing the identification code in the memory during the manufacturing of the compressor, and wherein the obtaining and communicating acts occur at the commercial location of the commercial refrigerator system.

20. A method as set forth in claim 13 wherein the communicated operating parameter is selected from the group consisting of a suction pressure cut-in value, suction pressure cut-out value, discharge pressure high limit value, a discharge temperature high limit value, a motor current limit value, a compressor type, an operating voltage parameter, an oil pressure limit value, and a motor temperature limit value.

21. A method as set forth in claim 13 wherein the compressor control module further includes a communication address and wherein the method further comprises the act of, prior to communicating the identification code from the compressor control module to the system controller, communicating the communication address from the compressor control module to the system controller.

22. A method as set forth in claim 13 wherein the method further comprises, prior to communicating the identification code from the compressor control module to the system controller, storing information at the system controller for a plurality of compressor identification codes, the stored information including the information having a relation to the communicated identification code.

23. A method as set forth in claim 13 wherein the system controller includes a rack PLC, wherein the refrigeration system further includes an operator station, and wherein the method further comprises, prior to communicating the identification code from the compressor control module to the system controller, storing information at the operator station for a plurality of compressor identification codes, the stored information including the portion of the information having a relation to the communicated identification code, and wherein obtaining information at the system controller includes acquiring the information having a relation to the communicated identification code from the operator station.

24. A method of configuring a refrigeration system comprising

a compressor, condenser, and refrigeration branch in fluid communication,

a system controller operable to control one or more aspects of the refrigeration system, and

a branch control module coupled to the refrigeration branch and in communication with the system controller, the branch control module being operable to control the refrigeration branch and including a code, the method comprising the acts of:

communicating the code from the branch control module to the system controller;

obtaining information at the system controller having a relation to the code; and

communicating at least a portion of the obtained information from the system controller to the branch control module, the communicated information including an operating parameter for the refrigeration branch.

25. A method as set forth in claim 24 wherein the refrigeration system further comprises

a second refrigeration branch, and

a second branch control module coupled to the second refrigeration branch and in communication with the system controller, the second branch control module being operable to control the second refrigeration branch and including a second code, the method comprising the acts of:

communicating the second code from the second branch control module to the system controller;

obtaining information at the system controller having a relation to the second code; and

communicating at least a portion of the obtained information having a relation to the second code from the system controller to the second branch control module, the communicated information including an operating parameter for the second refrigeration branch.

26. A method as set forth in claim 24 wherein the system controller includes a rack controller.

27. A method as set forth in claim 24 wherein the system controller includes an operator station.

28. A method as set forth in claim 24 wherein the refrigeration system is a commercial refrigeration system.

29. A method as set forth in claim 24 wherein the communicated operating parameter is selected from the group consisting of a defrost schedule, a discharge air temperature set point value, defrost type, a number of defrosts per day, a discharge air temperature limit value, a defrost termination temperature value, a time, and a date.

30. A method as set forth in claim 24 wherein the branch control module further includes a communication address and wherein the method further comprises the act of, prior to communicating the code from the branch control module to the system controller, communicating the communication address from the branch control module to the system controller.

31. A method as set forth in claim 24 wherein the code is an identification code identifying a merchandiser connected to the refrigeration branch.

32. A method as set forth in claim 31 wherein the method further comprises, prior to communicating the identification code from the branch control module to the system controller, storing information at the system controller for a plurality of merchandiser identification codes, the stored information including the information having a relation to the communicated identification code.

33. A method as set forth in claim 31 wherein the system controller includes a rack PLC, wherein the refrigeration system further includes an operator station, and wherein the method further comprises, prior to communicating the identification code from the branch control module to the system controller, storing information at the operator station for a plurality of merchandiser identification codes, the stored information including the portion of the information having a relation to the communicated identification code, and wherein obtaining information at the system controller includes acquiring the information having a relation to the communicated identification code from the operator station.

34. A method of configuring a refrigeration system comprising

a compressor, condenser, and evaporator in fluid communication,

a merchandiser adapted to be cooled by the evaporator,

a system controller operable to control one or more aspects of the refrigeration system, and

a case control module coupled to the merchandiser and in communication with the system controller, the case control module being operable to control the merchandiser and including an identification code identifying the merchandiser, the method comprising the acts of:

communicating the identification code from the case control module to the system controller;

obtaining information at the system controller having a relation to the identification code; and

communicating at least a portion of the obtained information from the system controller to the case control module, the communicated information including an operating parameter for the merchandiser.

35. A method as set forth in claim 34 wherein the refrigeration system further comprises

a second evaporator in fluid communication with the compressor and condenser,

a second merchandiser adapted to be cooled by the second evaporator, and

a second case control module coupled to the second merchandiser and in communication with the system controller, the second case control module being operable to control the second merchandiser and including a second identification code identifying the second merchandiser, the method comprising the acts of:

communicating the second identification code from the second case control module to the system controller;

obtaining information at the system controller having a relation to the second identification code; and

communicating at least a portion of the obtained information having a relation to the second identification code from the system controller to the second case control module, the communicated information including an operating parameter for the second merchandiser.

36. A method as set forth in claim 34 wherein the system controller includes a rack controller.

37. A method as set forth in claim 34 wherein the system controller includes an operator station.

38. A method as set forth in claim 34 wherein the refrigeration system is a commercial refrigeration system.

39. A method as set forth in claim 38 wherein the case control module includes a processor and memory, and wherein the method further comprises storing the identification code in the memory during the manufacturing of the merchandiser, and wherein the obtaining and communicating acts occur at the commercial location of the commercial refrigerator system.

40. A method as set forth in claim 34 wherein the communicated operating parameter is selected from the group consisting of a defrost schedule, a discharge air temperature set point value, a defrost type, a number of defrosts per day, a discharge air temperature high limit value, a defrost termination temperature value, a time, and a date.

41. A method as set forth in claim 34 wherein the case control module further includes a communication address and wherein the method further comprises the act of, prior to communicating the identification code from the case control module to the system controller, communicating the communication address from the case control module to the system controller.

42. A method as set forth in claim 34 wherein the method further comprises, prior to communicating the identification code from the case control module to the system controller, storing information at the system controller for a plurality of merchandiser identification codes, the stored information including the information having a relation to the communicated identification code.

43. A method as set forth in claim 34 wherein the system controller includes a rack PLC, wherein the refrigeration system further includes an operator station, and wherein the method further comprises, prior to communicating the identification code from the case control module to the system controller, storing information at the operator station for a plurality of merchandiser identification codes, the stored information including the portion of the information having a relation to the communicated identification code, and wherein obtaining information at the system controller includes acquiring the information having a relation to the communicated identification code from the operator station.

44. A method of configuring a refrigeration system comprising

a compressor, condenser, valve, and evaporator in fluid communication,

a system controller operable to control one or more aspects of the refrigeration system, and

a valve control module coupled to the compressor and in communication with the system controller, the valve control module being operable to control the valve and including an identification code identifying the valve, the method comprising the acts of:

communicating the identification code from the valve control module to the system controller;

obtaining information at the system controller having a relation to the identification code; and

communicating at least a portion of the obtained information from the system controller to the valve control module, the communicated information including an operating parameter for the valve.

45. A method as set forth in claim 44 wherein the refrigeration system further comprises

a second valve, and

a second valve control module coupled to the second valve and in communication with the valve controller, the second valve control module being operable to control the second valve and including a second identification code identifying the second valve, the method comprising the acts of:

communicating the second identification code from the second valve control module to the system controller;

obtaining information at the system controller having a relation to the second valve code; and

communicating at least a portion of the obtained information having a relation to the second identification code from the system controller to the second valve control module, the communicated information including an operating parameter for the second valve.

46. A method as set forth in claim 45 wherein the refrigeration system further comprises a first suction group and a second suction group, and wherein the first suction group includes the first valve and the second suction group includes the second valve.

47. A method as set forth in claim 44 wherein the system controller includes a rack controller.

48. A method as set forth in claim 44 wherein the system controller includes an operator station.

49. A method as set forth in claim 44 wherein the refrigeration system is a commercial refrigeration system.

50. A method as set forth in claim 44 wherein the communicated operating parameter is a failsafe position for the valve.

51. A method as set forth in claim 44 wherein the valve control module further includes a communication address and wherein the method further comprises the act of, prior to communicating the identification code from the valve control module to the system controller, communicating the communication address from the valve control module to the system controller.

52. A method as set forth in claim 44 wherein the method further comprises, prior to communicating the identification code from the valve control module to the system controller, storing information at the system controller for a plurality of valve identification codes, the stored information including the information having a relation to the communicated identification code.

53. A method as set forth in claim 44 wherein the system controller includes a rack PLC, wherein the refrigeration system further includes an operator station, and wherein the method further comprises, prior to communicating the identification code from the valve control module to the system controller, storing information at the operator station for a plurality of valve identification codes, the stored information including the portion of the information having a relation to the communicated identification code, and wherein obtaining information at the system controller includes acquiring the information having a relation to the communicated identification code from the operator station.

54. A method of configuring a compressor control module connected to a compressor of a refrigeration system, the compressor control module including a processor, a memory, and at least one of a temperature sensor and a pressure sensor, the memory including an identification code for the compressor, the refrigeration system also including a system controller in communication with the compressor control module and operable to control the refrigeration system, the method including the acts of:

communicating the identification code from the compressor control module to the system controller; and

receiving an operating parameter for the compressor from the system controller after communicating the identification code to the system controller.

55. A method of configuring a refrigeration system comprising

a compressor, a condenser having a fan, a valve, and a refrigeration branch including an evaporator coil, all of which being in fluid communication,

a merchandiser adapted to be cooled by the evaporator coil,

a system controller operable to control one or more aspects of the refrigeration system,

a device controller coupled to the system controller and being associated with a device, the device controller and associated device being selected from the group consisting of

a compressor controller associated with the compressor and including a first identification code identifying the compressor,

a valve controller associated with the valve and including a second identification code identifying the valve,

a branch controller associated with the refrigeration branch and including a third identification code identifying the merchandiser

a fan controller associated with the fan, and

a case controller being associated with the merchandiser and including a fourth identification code identifying the merchandiser, the method comprising the acts of:

at the system controller,

polling for the device controller;

receiving the identification code for the device controller;

obtaining information about the device using the received identification code; and

configuring at least a portion of the refrigeration system including configuring the device.

56. A method as set forth in claim 55 wherein the third and fourth codes are the same.