A RIDE-THROUGH METHOD AND SYSTEM FOR HVAC&R CHILLERS

• US 20070063668A1
• Filed: 06/07/2006
• Published: 03/22/2007
• Est. Priority Date: 09/02/2005
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Jadric, Ivan, Schnetzka, Harold
• Granted Patent: US 7,332,885 B2
• Time in Patent Office: Days
• US Class Current: 318/812
• CPC Class Codes: H02J 9/062 for AC powered loads
• CPC Class Codes: H02M 5/458 using semiconductor devices only

Abstract

A method of providing ride-through capability in a chiller/refrigeration system employs a variable speed drive with an active converter stage, a DC link stage and an inverter stage for providing variable frequency and voltage to power at least one motor. An induction motor is coupled to the output of the inverter stage for driving a compressor in the chiller/refrigeration system. The ride-through method comprises operating the active converter to regulate the DC link voltage of the DC link stage to a predetermined voltage level until the current through the active converter equals a predetermined current limit, then transferring regulation of the DC link to the inverter upon reaching the current limit of the converter. The compressor is unloaded, and the power flow through the inverter is reversed to maintain the voltage level of the DC link stage. Pre-rotation vanes, slide valve, or check valve are used to unload the compressor.

Claims

1. A method for controlling a variable speed drive to ride-through a voltage sag, comprising the steps of:

providing a motor and a compressor coupled to a mechanical load;

providing a variable speed drive to power the motor, the variable speed drive including an active converter stage and an inverter stage electrically coupled by a DC link stage;

monitoring a DC voltage of the DC link stage;

monitoring an input parameter of the active converter stage;

regulating the DC voltage of the DC link stage with the active converter in response to a change in the monitored DC link voltage;

in response to the DC voltage being less than a predetermined first threshold voltage, executing the steps of;

transferring the regulation of the DC voltage of the DC link stage to the inverter stage;

removing the mechanical load from the compressor; and

controlling the DC voltage of the DC link stage with the inverter stage by reversing power flow from the motor to the DC link stage.

2. The method of claim 1, wherein the step of removing the mechanical load from the compressor is implemented automatically by a check valve inserted in a refrigerant line of the compressor to prevent reverse refrigerant flow in response to a decrease in an operational speed of the compressor.

3. The method of claim 2, wherein the refrigerant line is a discharge line of the compressor.

4. The method of claim 2, wherein the refrigerant line is a suction line of the compressor.

5. The method of claim 1, wherein the compressor is a centrifugal compressor, and the step of removing the mechanical load from the compressor comprises operating a plurality of pre-rotation vanes to substantially eliminate the mechanical load of the compressor.

6. The method of claim 1, wherein the compressor is a screw compressor, and the step of removing the mechanical load from the compressor comprises operating a slide valve to substantially eliminate the mechanical load of the compressor.

7. The method of claim 1, further comprising the steps of:

monitoring an AC input voltage of an AC input power source; and

controlling the DC voltage of the DC link stage with the active converter stage in response to the monitored AC voltage being equal to or greater than a predetermined threshold voltage value.

8. A method for increasing voltage sag ride-through capability in a chiller system, comprising the steps of:

providing a motor and a compressor mechanically coupled together;

providing a variable speed drive to power the motor, the variable speed drive including an active converter stage and an inverter stage electrically coupled by a DC link stage;

monitoring a DC voltage of the DC link stage;

monitoring an input parameter of the active converter stage;

regulating the DC voltage of the DC link stage through the active converter stage;

regulating a motor speed through the inverter stage; and

in response to the DC voltage being less than a predetermined first threshold voltage, executing the steps of;

transferring the regulation of the DC voltage of the DC link stage to the inverter stage;

unloading the compressor;

disabling the active converter stage; and

controlling the DC voltage of the DC link stage with the inverter stage by reversing power flow from the motor to the DC link.

9. The method of claim 8, wherein the step of unloading the compressor is implemented by a check valve inserted in a refrigerant line of the compressor to prevent reverse refrigerant flow in response to a decrease in an operational speed of the compressor.

10. The method of claim 8, wherein the refrigerant line is a discharge line of the compressor.

11. The method of claim 8, wherein the refrigerant line is a suction line of the compressor.

12. The method of claim 8, wherein the compressor is a centrifugal compressor, and the step of unloading the compressor comprises varying the mechanical load of the compressor in response to a decrease in the DC link voltage by operating a plurality of pre-rotation vanes.

13. The method of claim 8, wherein the compressor is a screw compressor, and the step of unloading the compressor comprises varying the mechanical load of the compressor in response to a decrease in the DC link voltage by operating a slide valve.

14. The method of claim 8, further comprising the steps of:

monitoring an AC input voltage of an AC input power source; and

controlling the DC voltage of the DC link stage with the active converter stage in response to the monitored AC voltage being equal to or greater than a predetermined threshold voltage value.

19. The system of claim 14, wherein the compressor is a centrifugal compressor, and the unloading device is a plurality of pre-rotation vanes, the pre-rotation vanes having an actuator operable to substantially eliminate the mechanical load of the compressor.

20. The system of claim 14, wherein the compressor is a screw compressor and the unloading device is a slide valve, the slide valve operable to substantially eliminate the mechanical load of the compressor.

15. A chiller system comprising:

a compressor, a condenser, and an evaporator connected in a closed refrigerant loop;

an unloading device for unloading the compressor in response to a decrease in the operational speed of the compressor;

a motor connected to the compressor to power the compressor; and

a variable speed drive connected to the motor, the variable speed drive being configured to receive an input AC power at a fixed input AC voltage and a fixed input frequency and provide an output power at a variable voltage and variable frequency to the motor, the variable voltage having a maximum voltage greater in magnitude than the fixed input AC voltage and the variable frequency having a maximum frequency greater than the fixed input frequency, the variable speed drive comprising;

a converter stage connected to an AC power source providing the input AC power, the converter stage being configured to convert the input AC voltage to a DC voltage;

a DC link stage connected to the converter stage, the DC link stage being configured to filter the DC voltage and store energy from the converter stage;

an inverter stage connected to the DC link stage, the inverter stage being configured to convert the DC voltage from the DC link stage into the output power for the motor having the variable voltage and the variable frequency; and

a control panel to control operation of the variable speed drive, the control panel being configured to regulate the DC voltage of the DC link stage with the inverter stage in response to the DC voltage being less than a predetermined first threshold voltage;

wherein the control panel regulates the DC voltage of the DC link stage with the inverter stage by providing control signals to mechanically unload the compressor, and reverse power flow from the motor to the DC link stage to control the DC voltage of the DC link stage.

16. The system of claim 15, wherein the unloading device is a check valve, the check valve inserted in a refrigerant line of the compressor to prevent reverse refrigerant flow in response to a decrease in the operational speed of the compressor.

17. The system of claim 16, wherein the refrigerant line is a discharge line of the compressor.

18. The system of claim 16, wherein the refrigerant line is a suction line of the compressor.