Heat pump motor optimization and sensor fault detection

• US 5,630,325 A
• Filed: 06/01/1995
• Issued: 05/20/1997
• 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:
  US08/456,960
• Time in Patent Office: 719 Days
• Field of Search: 62/222, 62/223, 62/210, 62/211, 62/204, 62/230
• US Class Current: 62/222
• 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 including a refrigerant compressor and an electrically controlled expansion valve, a system operating method comprising,

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

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

based on said comparing step;

(a) if the discharge temperature is above said predetermined temperature, using the discharge temperature to control the setting of said expansion valve, and

(b) if the discharge temperature is not above said predetermined temperature, setting said expansion valve to a predetermined setting.

2. The method of claim 1 wherein said alert condition represents a sensor fault condition.

3. The method of claim 1 wherein said alert condition represents a maximum load condition.

4. The method of claim 1 wherein said alert condition represents a low voltage condition.

5. The method of claim 3 or 4 wherein if the discharge temperature is above said predetermined temperature, said expansion valve is electrically controlled to increase refrigerant flow.

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

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

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

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

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

based on said comparing steps;

(a) if said outdoor air temperature is above said second predetermined temperature and if said discharge temperature is above said predetermined temperature, then controlling said expansion valve to increase refrigerant flow, and

(b) if said discharge temperature is not above said predetermined temperature,

setting said expansion valve to a predetermined setting.

7. The method of claim 6 wherein said alert condition represents a sensor fault condition.

8. The method of claim 6 wherein said alert condition represents a maximum load condition.

9. The method of claim 6 wherein said alert condition represents a low voltage condition.

10. The method of claim 8 or 9 wherein if the discharge temperature is above said predetermined temperature, said expansion valve is electrically controlled to increase refrigerant flow.

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

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

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

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

comparing the line voltage to a predetermined nominal voltage; and

based on said comparing steps;

(a) if said discharge temperature is above the said predetermined temperature and if said line voltage measurement is below said predetermined nominal voltage,

then controlling said expansion valve to increase refrigerant flow, and

(b) if said discharge temperature is not above said predetermined temperature,

setting said expansion valve to a predetermined setting.

12. The method of claim 11 wherein said alert condition represents a sensor fault condition.

13. The method of claim 11 wherein said alert condition represents a maximum load condition.

14. The method of claim 11 wherein said alert condition represents a low voltage condition.

15. The method of claim 13 or 14 wherein if the discharge temperature is above said predetermined temperature, said expansion valve is electrically controlled to increase refrigerant flow.