Diagnostics for a heating and cooling system

• US 5,623,834 A
• Filed: 05/03/1995
• Issued: 04/29/1997
• Est. Priority Date: 05/03/1995
• Status: Expired due to Term

• Current Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Original Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Inventors: Hickey, Mickey, Millet, Hank, Greschl, Gerald L., Herroon, Gregory P., Bahel, Vijay, Pham, Hung
• Primary Examiner(s): Tanner, Harry B.
• Application Number:
  US08/433,619
• Time in Patent Office: 727 Days
• Field of Search: 62/131, 62/126, 62/127, 62/129, 62/204, 62/205, 62/210, 62/211, 62/212, 62/222, 62/223, 62/224, 62/225
• US Class Current: 62/131
• CPC Class Codes: F25B 13/00 Compression machines, plants or systems, with reversible cycle defrosting cycles F25B47/02
• CPC Class Codes: F25B 2313/0293 related to the indoor fan, e.g. controlling speed
• CPC Class Codes: F25B 2313/0294 related to the outdoor fan, e.g. controlling speed
• CPC Class Codes: F25B 2313/0315 Temperature sensors near the outdoor heat exchanger
• CPC Class Codes: F25B 2600/2513 Expansion valves
• CPC Class Codes: F25B 2700/02 Humidity
• CPC Class Codes: F25B 2700/2104 of an indoor room or compartment
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 49/005 of safety devices F25B49/02 and F25B49/04 take precedence

Abstract

Compressor discharge temperature, ambient outdoor air temperature and thermal load are used as control parameters for controlling the expansion valve setting and indoor fan speed. Diagnostics monitor a feedback signal from the fan motor to detect fan over-speed and increased speed due to decreased air flow caused by a dirty indoor air filter. Discharge pressure of the compressor is monitored to detect a blocked outdoor fan. The difference between actual and optimum compressor discharge temperatures and suction pressure of the compressor are monitored to detect a stuck-closed expansion valve or low refrigerant charge. Compressor "short-cycling" is limited to prevent reduced reliability of the compressor. The difference between compressor discharge temperature and outdoor coil temperature is measured before and after startup to detect compressor failure.

Claims

1. A controller for a heat pump which operates in heating and cooling modes and is of the type having a compressor for discharging refrigerant through an expansion valve (EXV) into a heat exchanger, comprising:

a low pressure cutout means coupled to said compressor for electrically disconnecting said compressor when pressure on an inlet side of said compressor falls below a first parameter and for electrically reconnecting said compressor when said pressure rises above a second parameter; and

at least one control processor, coupled to said low pressure cutout means and said EXV, for providing a low pressure malfunction diagnostic that includes;

(a) a valve releasing system for attempting to free said EXV,

(b) a default setting system for operating said heat pump at default settings, and

(c) a counter incrementing system for incrementing a cycle counter,

wherein if said cycle counter is less than a first predetermined number and said low pressure cutout means disconnects said compressor, said at least one control processor executes systems (a)-(c), and if said cycle counter equals said first predetermined number, said at least one control processor declares a malfunction.

2. The controller for a heat pump of claim 1 wherein said valve releasing system attempts to free said EXV by

(a1) partially opening said EXV,

(a2) partially closing said EXV, and

(a3) repeating (a1) and (a2) a second predetermined number of times.

3. The controller for a heat pump of claim 1 wherein said default setting system

(b1) reverses a reversing valve,

(b2) sets said EXV at a first predetermined position,

(b3) sets said indoor fan speed to a first predetermined speed, and

(b4) sets said outdoor fan speed to a second predetermined speed.

4. The controller for a heat pump of claim 1 wherein said at least one control processor stops said heat pump if said cycle counter equals said predetermined number and said heat pump is operating in said cooling mode.

5. The controller for a heat pump of claim 1 wherein said at least one control processor initiates an emergency heating mode if said cycle counter equals said predetermined number and said heat pump is operating in said heating mode.

6. The controller for a heat pump of claim 1 wherein said malfunction declared by said control processor indicates at least one of a lost refrigerant charge malfunction and a stuck EXV malfunction.