Heat pump motor optimization and sensor fault detection

• US 5,440,895 A
• Filed: 01/24/1994
• Issued: 08/15/1995
• Est. Priority Date: 01/24/1994
• Status: Expired due to Term

• Current Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Original Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Inventors: Caillat, Jean-Luc M., Bahel, Vijay, Pham, Hung, Warner, Wayne R., Hickey, Mickey, Millet, Hank, Herroon, Gregory P.
• Primary Examiner(s): Tanner, Harry B.
• Application Number:
  US08/186,010
• Time in Patent Office: 568 Days
• Field of Search: 62/211, 62/223, 62/210, 62/222, 62/230, 62/204
• US Class Current: 62/223
• 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 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/41 Defrosting; Preventing freezing
• CPC Class Codes: F24F 11/42 of outdoor units
• CPC Class Codes: F24F 11/52 Indication arrangements, e.g. displays
• CPC Class Codes: F24F 2110/00 Control inputs relating to air properties
• CPC Class Codes: F25B 2700/15 Power, e.g. by voltage or current
• CPC Class Codes: F25B 41/35 by rotary motors, e.g. by stepping motors
• CPC Class Codes: F25B 49/005 of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

The microprocessor-based HVAC control system detects sensor faults by comparing thermistor readings with predetermined extreme values, indicative of sensor fault. The system automatically selects the appropriate combination of automatic/preset modes of operating key system components such as the expansion valve, the demand defrost system and the indoor fan speed control system. With a view towards minimizing any negative impact on system performance and reliability in the event of sensor malfunction.

Claims

1. In a heat pump system powered by an electrical line, including a refrigerant compressor and an electrically controlled expansion valve, a system operating method comprising,

obtaining an outdoor air temperature by measuring a property indicative of the outdoor air temperature;

obtaining a line voltage by measuring a property indicative of line voltage;

comparing the outdoor air temperature with a predetermined temperature indicative of an alert condition;

comparing the line voltage to a predetermined value indicative of a low voltage condition, and

based on said comparing steps;

if the outdoor air temperature is above said predetermined temperature and if the line voltage is below said predetermined value, then automatically increasing the setting of said expansion valve to increase the flow of refrigerant in said heat pump system.

2. The system of claim 1 wherein said heat pump system includes an outdoor unit and wherein said outdoor air temperature is obtained by measuring the ambient air temperature at said outdoor unit.

3. The system of claim 1 wherein said outdoor air temperature is obtained by measuring the discharge temperature of refrigerant discharging from said compressor and using said discharge temperature as an indication of outdoor air temperature.

4. In a heat pump system including a refrigerant compressor and an electrically controlled expansion valve, a system operating method comprising:

obtaining an outdoor air temperature by measuring a property indicative of the outdoor air temperature;

obtaining a discharge temperature by measuring a property indicative of the temperature of refrigerant discharged from the compressor;

comparing the outdoor air temperature with a first predetermined temperature indicative of an alert condition;

comparing the discharge temperature to a second predetermined temperature indicative of an alert condition; and

based on said comparing steps;

if the outdoor air temperature is above said first predetermined temperature and if the discharge temperature is above said second predetermined temperature then automatically increasing the setting of said expansion valve to increase the flow of refrigerant in said heat pump system.

5. The system of claim 4 wherein said heat pump system includes an outdoor unit and wherein said outdoor air temperature is obtained by measuring the ambient air temperature at said outdoor unit.

6. In a heat pump system including a refrigerant compressor powered by electric current and an electrically controlled expansion valve, a system operating method comprising,

obtaining an outdoor air temperature by measuring a property indicative of the outdoor air temperature;

obtaining a current signal by measuring a property indicative of the current powering said compressor;

comparing the outdoor air temperature with a predetermined temperature indicative of an alert condition;

comparing the current signal to a predetermined value indicative of an alert condition, and

based on said comparing steps;

if the outdoor air temperature is above said predetermined temperature and if the current signal is above said predetermined value, then automatically increasing the setting of said expansion valve to increase the flow of refrigerant in said heat pump system.

7. The system of claim 6 wherein said heat pump system includes an outdoor unit and wherein said outdoor air temperature is obtained by measuring the ambient air temperature at said outdoor unit.

8. The system of claim 6 wherein said outdoor air temperature is obtained by measuring the discharge temperature of refrigerant discharging from said compressor and using said discharge temperature as an indication of outdoor air temperature.