Method and apparatus for monitoring a condenser unit in a refrigerant-cycle system

• US 20060032247A1
• Filed: 05/17/2005
• Published: 02/16/2006
• Est. Priority Date: 08/11/2004
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Lawrence Kates
• Inventors: Kates, Lawrence
• Granted Patent: US 7,114,343 B2
• Time in Patent Office: Days
• US Class Current: 62/129
• 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 11/32 Responding to malfunctions or emergencies
• CPC Class Codes: F24F 11/39 Monitoring filter performance
• CPC Class Codes: F24F 11/47 Responding to energy costs
• CPC Class Codes: F24F 11/56 Remote control
• CPC Class Codes: F24F 8/90 Cleaning of purification apparatus
• CPC Class Codes: F25B 2500/19 Calculation of parameters
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2700/02 Humidity
• CPC Class Codes: F25B 2700/133 through the condenser
• CPC Class Codes: F25B 2700/1351 of the cooled fluid upstream or downstream of the evaporator
• CPC Class Codes: F25B 2700/15 Power, e.g. by voltage or current
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/172 of the condenser fan
• CPC Class Codes: F25B 2700/1931 Discharge pressures
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/195 of the condenser
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• 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 2700/21161 : of the fluid heated by the condenser
• CPC Class Codes: F25B 2700/21163 : of the refrigerant at the outlet of the condenser
• CPC Class Codes: F25B 2700/21172 : at the inlet
• CPC Class Codes: F25B 2700/21173 : at the outlet
• CPC Class Codes: F25B 2700/21174 : of the refrigerant at the inlet of the evaporator
• CPC Class Codes: F25B 2700/21175 : of the refrigerant at the outlet of the evaporator
• CPC Class Codes: F25B 49/00 : Arrangement or mounting of control or safety devices
• CPC Class Codes: F25B 49/005 : of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: F25D 2400/36 : Visual displays
• CPC Class Codes: G01K 13/00 : Thermometers specially adapted for specific purposes
• CPC Class Codes: G01K 2201/00 : Application of thermometers in air-conditioning systems
• CPC Class Codes: G01N 15/0826 : and measuring fluid flow rate, i.e. permeation rate or pressure change
• CPC Class Codes: G01N 2015/084 : Testing filters
• CPC Class Codes: G01N 2015/0846 : by use of radiation, e.g. transmitted or reflected light
• CPC Class Codes: G05B 15/02 : electric
• CPC Class Codes: G05D 23/1917 : using digital means
• CPC Class Codes: G05D 23/1928 : sensing the temperature of one space
• CPC Class Codes: G05D 23/1932 : to control the temperature of a plurality of spaces
• CPC Class Codes: Y10S 116/25 : Air filter condition indicator
• CPC Class Codes: Y10S 116/42 : Oil filter
• CPC Class Codes: Y10S 55/34 : Indicator and controllers

Abstract

A real-time monitoring system that monitors various aspects of the operation of a refrigerant-cycle system is described. In one embodiment, the system includes a processor that measures power provided to the refrigerant-cycle system and that gathers data from one or more sensors and uses the sensor data to calculate a figure of merit related to the efficiency of the system. In one embodiment, the sensors include one or more of the following sensors: a suction line temperature sensor, a suction line pressure sensor, a suction line flow sensor, a hot gas line temperature sensor, a hot gas line pressure sensor, a hot gas line flow sensor, a liquid line temperature sensor, a liquid line pressure sensor, a liquid line flow sensor. In one embodiment, the sensors include one or more of an evaporator air temperature input sensor, an evaporator air temperature output sensor, an evaporator air flow sensor, an evaporator air humidity sensor, and a differential pressure sensor. In one embodiment, the sensors include one or more of a condenser air temperature input sensor, a condenser air temperature output sensor, and a condenser air flow sensor, an evaporator air humidity sensor. In one embodiment, the sensors include one or more of an ambient air sensor and an ambient humidity sensor.

Claims

1. A monitoring system for monitoring a condenser unit in a refrigerant-cycle system, comprising:

a first temperature sensor configured to measure input refrigerant temperature to a condenser unit;

a second temperature sensor configured to measure output refrigerant temperature from said condenser unit;

one or more ambient sensors configured to measure one or more ambient conditions;

an electrical sensor to sense power provided to sense electrical power provided to a compressor of said condenser unit; and

a processing system configured to calculate a performance criteria of said condenser using at least a portion of the data from said first temperature sensor, said second temperature sensor, said ambient sensors, and said electrical sensor.

2. The monitoring system of claim 1, wherein said processing system is configured to calculate efficiency.

3. The monitoring system of claim 1, wherein said processing system is configured to calculate energy costs due to inefficient operation of said condenser unit.

4. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to refrigerant undercharge.

5. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to refrigerant overcharge.

6. The monitoring system of claim 1, further comprising an airflow sensor for a fan provided to said condenser unit.

7. The monitoring system of claim 1, further comprising a temperature sensor configured to measure output air temperature of a condenser coil in said condenser unit.

8. The monitoring system of claim 1, further comprising one or more pressure sensors configured to measure a refrigerant pressure differential across said compressor.

9. The monitoring system of claim 1, further comprising at least one humidity sensor.

10. The monitoring system of claim 1, further comprising one or more electrical sensors to measure electrical power provided to a fan motor of said condenser unit.

11. The monitoring system of claim 1, further comprising a refrigerant flow sensor.

12. The monitoring system of claim 1, wherein said processing system is configured to provide data for plots of energy usage and costs.

13. The monitoring system of claim 1, wherein said processing system is configured to provide data related to operation of said condenser to a remote monitoring center.

14. The monitoring system of claim 1, wherein said processing system is configured to provide data related to operation of said condenser system to a remote monitoring center using powerline networking.

15. The monitoring system of claim 1, wherein said processing system is configured to provide data related to operation of said condenser to a remote monitoring center using broadband over powerline networking.

16. The monitoring system of claim 1, further comprising a temperature sensor to measure a temperature of refrigerant provided to said compressor.

17. The monitoring system of claim 1, further comprising a temperature sensor to measure a temperature of refrigerant output from said compressor.

18. The monitoring system of claim 1, further comprising a temperature sensor to measure a temperature of refrigerant output from a condenser coil.

19. The monitoring system of claim 1, wherein said monitoring system is configured with data regarding a maximum expected efficiency for said condenser unit under various ambient temperatures.

20. The monitoring system of claim 1, wherein said monitoring system is configured with data regarding a type of refrigerant used in said condenser unit.

21. The monitoring system of claim 1, further comprising a pressure sensor configured to measure a pressure of the refrigerant in a refrigerant line provided to said compressor.

22. The monitoring system of claim 1, further comprising a pressure sensor to measure refrigerant pressure in an output line of said condenser unit.

23. The monitoring system of claim 1, further comprising at least one refrigerant contaminant sensor.

24. The monitoring system of claim 1, further comprising an ambient humidity sensor.

25. A monitoring system for monitoring a condenser unit in a refrigerant-cycle system, comprising:

means for measuring one or more inputs to said condenser;

means for measuring one or more outputs from said condenser;

programmed data parameters related to operation of said condenser; and

a processing system configured to calculate one or more performance criteria of said condenser using at least a portion of the data from said means for measuring one or more inputs, said means for measuring one or more outputs, and said programmed data parameters, said processing system configured to provide a performance history of said performance criteria and to calculate an operational efficiency of said condenser using in part said performance criteria.

26. The monitoring system of claim 25, wherein said data parameters comprise a type of refrigerant.

27. The monitoring system of claim 25, wherein said data parameters comprise a property of a refrigerant.

28. The monitoring system of claim 25, wherein said data parameters comprise one or more calibration values.

29. The monitoring system of claim 25, further comprising a pressure sensor to measure refrigerant pressure.

30. The monitoring system of claim 25, wherein said data parameters comprise one or more calibration values obtained from said condenser during a calibration process.

31. The monitoring system of claim 25, wherein said data parameters comprise one or more physical properties of said condenser.

32. The monitoring system of claim 25, wherein said data parameters comprise one or more dimensional properties of said condenser.

33. The monitoring system of claim 25, wherein said one or more inputs comprise input air temperature.

34. The monitoring system of claim 25, wherein said one or more inputs comprise input refrigerant temperature.

35. The monitoring system of claim 25, wherein said one or more inputs comprise electrical power provided to a condenser fan.

36. The monitoring system of claim 25, wherein said one or more inputs comprise electrical power provided to a compressor.

37. The monitoring system of claim 25, wherein said one or more outputs comprise output refrigerant pressure.

38. The monitoring system of claim 25, wherein said one or more outputs comprise output refrigerant temperature.

39. The monitoring system of claim 25, wherein said one or more outputs comprise refrigerant flow.