Chiller sound reduction control system and method

• US 20050223725A1
• Filed: 04/12/2005
• Published: 10/13/2005
• Est. Priority Date: 04/12/2004
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: York International Corporation (Johnson Controls International plc)
• Inventors: Graybill, Andrew John, Hill, Frank Highland IV, Casper, Ian Michael, Crane, Curtis Christian
• Granted Patent: US 7,743,617 B2
• Time in Patent Office: Days
• US Class Current: 62/183
• CPC Class Codes: F25B 2500/12 Sound
• CPC Class Codes: F25B 2600/021 Inverters therefor
• CPC Class Codes: F25B 2600/111 of condenser fans
• CPC Class Codes: F25B 2700/171 of the compressor
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems
• CPC Class Codes: F25B 49/027 Condenser control arrangements
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A noise control method is provided for a cooling system having at least one refrigerant circuit. The refrigerant circuit includes a compressor, a condenser, at least one condenser fan, and an evaporator. Noise control is only performed periodically in response to requirements for reduced operation at predetermined times. The request for reduced noise triggers the commencement of the noise control method. The noise control method involves reducing the operating speed of the compressor, as well as reducing the operating speed of at least one condenser fan, to within a predetermined range of allowable reduced operating speeds. The noise control method temporarily overrides the ability of the cooling system to fully respond to increased cooling or heating demands. When the noise control method is terminated, such as by the end of the stated period of time requiring reduced noise generation, the system is restored to normal operation, and remains fully responsive to cooling and heating demand until commencement of the next period of reduced noise requirements.

Claims

1. A method of providing sound control for a chiller system, the method comprising the steps of:

providing a chiller system comprising a control panel, a compressor, a condenser arrangement, at least one condenser fan, and an evaporator arrangement;

receiving a sound control signal at the control panel, the sound control signal being configured to initiate a reduced sound control mode of operation, the reduced sound control mode of operation comprising the steps of;

measuring an operating speed of the compressor;

controllably reducing the operating speed of the compressor in response to the measured operating speed of the compressor being greater than a maximum operating speed;

the maximum operating speed being directly related to the sound control signal;

determining an operating parameter of at least one condenser fan; and

controllably altering an operating configuration of the at least one condenser fan in response to the determined operating parameter of the at least one condenser fan being greater than a maximum operating parameter, the maximum operating parameter being directly related to the sound control signal.

2. The method of claim 1, wherein the at least one condenser fan comprises a plurality of condenser fans and the step of controllably altering the operating configuration of the at least one condenser fan is selected from the group consisting of:

disabling one or more condenser fans of the plurality of condenser fans, operating less than all condenser fans, operating one or more condenser fans of the plurality of condenser fans at a reduced fixed speed, and operating one or more condenser fans of the plurality of condenser fans at a reduced variable speed.

3. The method of claim 2, wherein said step of controllably altering the operating configuration of the at least one condenser fan includes selectively disabling one or more condenser fans of the plurality of condenser fans.

4. The method of claim 2, wherein said controllably altering the operating configuration of the at least one condenser fan includes adjusting the speed of one or more condenser fans of the plurality of condenser fans.

5. The method of claim 1 wherein said control panel including software executable for controlling the at least one compressor motor and at least one condenser fan interdependently, and for adjusting the speed of one or more condenser fans of the plurality of condenser fans, wherein the adjustable range of fan speed is nearly infinite.

6. The method of claim 1, further comprising manually initiating the sound control signal through a user interface

7. The method of claim 1, further comprising initiating the sound control signal through a control program

8. The method of claim 1 wherein the step of controllably reducing the operating speed of the compressor includes reducing an output frequency from a variable speed drive used to power a motor for the compressor.

9. The method of claim 1 wherein the step of controllably altering the operating configuration of the at least one condenser fan includes raising the condenser discharge pressure setting.

10. The method of providing sound control of a chiller system as set forth in claim 1, wherein the method also comprises monitoring cooling demand while the sound control signal is present, and limiting the system cooling capacity available to the system in response to capacity control commands, and overriding one or more system control algorithms when the system control algorithms call for operating the at least one compressor motor or the at least one condenser fan above the predetermined range of speeds of the at least one compressor motor or the parameters of the at least one condenser fan.

11. A method of providing sound control in a chiller system, wherein the chiller system including a compressor, a condenser arrangement, at least one condenser fan, and an evaporator arrangement;

the method comprising the steps of;

determining whether a sound control signal is received by a control panel;

assigning a maximum operating speed for a motor powering the compressor responsive to said sound control signal;

assigning a maximum operating parameter for the at least one condenser fan responsive to said sound control signal;

determining whether the compressor and the at least one condenser fan are operating within corresponding permissible ranges, wherein the corresponding permissible range for the compressor has an upper limit and at least one condenser fan corresponding to maximum operating speed or maximum operating parameter;

adjusting at least one of a) the speed of the compressor motor or b) the operating parameter of the at least one condenser fan responsive to the determination that the compressor or the at least one condenser fan are operating outside the corresponding permissible range; and

wherein the step of adjusting operates to reduce the sound generated by the chiller system.

12. The method as set forth in claim 11, wherein also comprising the step of transmitting the sound control signal to a variable speed drive wherein said variable speed drive being configured to permit interdependent control of

a) speed of the at least one compressor motor;

and

b) operating parameter of the at least one condenser fan.

13. The method as set forth in claim 11, and further comprising the step of controlling the number of operating condenser fans in response to the adjusted operating parameter, wherein said at least one condenser fan comprises a plurality of fans.

14. The method as set forth in claim 11, wherein said at least one condenser fan comprises a plurality of fans being selected from the group comprising fixed speed, variable speed, or combination thereof;

and further comprising the step of controlling the speed of operating condenser fans in response to the adjusted operating parameter.

15. The method as set forth in claim 11, wherein also comprising the step of operating the at least one compressor motor at a reduced speed while operating the at least one condenser fan or fans at a speed greater than the permissible speed setting associated with the sound control signal for an initial period until the chiller system parameters become stabilized for operation of the chiller system at the reduced operating speed of the at least one compressor;

and reducing the speed after reaching a stable operating range of the chiller system, compatible with the speed of the at least one compressor motor.

16. A chiller system including a control panel, a compressor, a condenser arrangement, at least one condenser fan, and an evaporator arrangement;

means for receiving a sound control signal at the control panel, the sound control signal being configured to initiate a reduced sound control mode of operation;

means for measuring an operating speed of the compressor;

means for controllably reducing the operating speed of the compressor in response to the measured operating speed of the compressor being greater than a maximum operating speed;

the maximum operating speed being directly related to the sound control signal;

means for measuring an operating parameter of at least one condenser fan; and

means for controllably altering an operating configuration of the at least one condenser fan responsive to the sound control signal.

17. The chiller system of claim 16 wherein the at least one condenser fan comprises a plurality of condenser fans, the plurality of condenser fans being configured from one of the group consisting of:

a) one or more condenser fans of the plurality of condenser fans is disabled, b) less than all condenser fans of the plurality of fans are operable, c) one or more condenser fans of the plurality of condenser fans operate at a reduced fixed speed; and

d) one or more condenser fans of the plurality of condenser fans operate at a reduced variable speed.

18. The system of claim 16, wherein said at least one condenser fan is selected from the group consisting of:

single speed fan, multiple speed fan, and variable speed fan.

19. The chiller system as set forth in claim 16, wherein means for controllably altering the operating configuration of the at least one condenser fan includes means for selectively disabling the at least one condenser fan.

20. The chiller system as set forth in claim 16, wherein means for controllably altering the operating configuration of the at least one condenser fan includes means for adjusting the speed of one or more condenser fans of the plurality of condenser fans.

21. The chiller system as set forth in claim 16, wherein said control panel including software executable for controlling the at least one compressor and at least one condenser fan interdependently, and for adjusting the speed of one or more condenser fans of the plurality of condenser fans, wherein the adjustable range of fan speed is nearly infinite.

22. The chiller system as set forth in claim 16, wherein means for controllably reducing the operating speed of the compressor includes means for reducing an output frequency from a variable speed drive used to power a motor for the compressor.

23. The method of claim 16, wherein means for controllably altering the operating configuration of the at least one condenser fan includes means for raising the condenser discharge pressure setting.

24. The chiller system as set forth in claim 16, wherein the means for controllably reducing the operating speed of the compressor comprises a common VSD configured to permit interdependent control of

a) speed of the at least one compressor motor;

and

b) operating parameter of the at least one condenser fan.