Energy saving device for walk-in refrigerators and freezers

• US 6,397,612 B1
• Filed: 02/06/2001
• Issued: 06/04/2002
• Est. Priority Date: 02/06/2001
• Status: Expired due to Term

• Current Assignee: Energy Control Equipment
• Original Assignee: Energy Control Equipment
• Inventors: Kernkamp, John H., Kersten, Ed, Linder, E. E.
• Primary Examiner(s): Tanner, Harry B.
• Application Number:
  US09/778,612
• Time in Patent Office: 483 Days
• Field of Search: 621/86, 621/79, 621/80, 621/81, 621/83, 621/84, 236/DIG.9, 236/49.3, 236/35, 236/38, 165/299
• US Class Current: 62/186
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F25B 2600/112 of evaporator fans
• CPC Class Codes: F25B 2700/15 Power, e.g. by voltage or current
• CPC Class Codes: F25D 17/06 by forced circulation
• CPC Class Codes: F25D 29/00 Arrangement or mounting of control or safety devices
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

An energy saving apparatus for use with a heat exchange system having a cooled chamber, a compressor, a condenser, an evaporator, an evaporator fan, and refrigerant within refrigerant carrying lines has an evaporator fan controller for monitoring operational status of the system (cooling or non-cooling) and setting an energy saving operational speed for the evaporator fan based on the operational status of the system (cooling or non-cooling) and a current sensor coupled to the evaporator fan controller for detecting the operational status of the system (cooling or non-cooling). If the system is detected as cooling, the evaporator fan controller directs the evaporator fan to operate at a high speed and if the system is detected as not cooling (non-cooling), the evaporator fan controller decreases the operational speed of the evaporator fan to a low speed, thereby decreasing evaporator fan produced heat, resulting in an overall decreased energy requirement for the heat exchange system.

Claims

1. For use with a heat exchange system having a cooled chamber, a compressor, a condenser, an evaporator, an evaporator fan, and refrigerant within refrigerant carrying lines, an energy saving apparatus comprising:

a) evaporator fan control means for monitoring cooling/non-cooling status of the heat exchange system and setting an energy saving operational speed for the evaporator fan based on said cooling/non-cooling status and

b) current sensor means coupled to said evaporator fan control means for detecting said cooling/non-cooling status of the heat exchange system, whereby if the system is detected as cooling, said evaporator fan control means directs the evaporator fan to operate at a high speed and if said cooling/non-cooling status is detected as non-cooling, said evaporator fan control means decreases the operational speed of the evaporator fan to a low speed, thereby decreasing evaporator fan produced heat, resulting in an overall decreased energy requirement for the heat exchange system.

2. An apparatus according to claim 1, further comprising air flow monitor means coupled to said evaporator fan control means, whereby if air flow over the evaporator falls below a preset value said evaporator fan control means directs the evaporator fan to operate at said high speed.

3. An apparatus according to claim 1, further comprising fail-safe bypass relay means coupled to said evaporator fan control means, whereby if a power failure occurs to the energy saving apparatus the evaporator fan is directed to operate at said high speed.

4. An apparatus according to claim 1, wherein said current sensor means comprises a current sensor linked to the heat exchange system at a location where current flow reflects said cooling/non-cooling operational status of the system.

5. An apparatus according to claim 4, wherein said current sensor is linked to a solenoid that gates the refrigerant flow into the evaporator.

6. For use with a heat exchange system having a cooled chamber, a compressor outside said cooled chamber, a condenser outside the cooled chamber, an evaporator inside the cooled chamber, an evaporator fan inside the cooled chamber, and refrigerant within refrigerant carrying lines, an energy saving apparatus comprising:

a) an evaporator fan controller for monitoring cooling/non-cooling status of the heat exchange system and setting an energy saving operational speed for the evaporator fan based on said cooling/non-cooling status and

b) a current sensor coupled to said evaporator fan controller for detecting said cooling/non-cooling status of the heat exchange system, whereby if the system is detected as cooling, said evaporator fan controller directs the evaporator fan to operate at a high speed and if said cooling/non-cooling status is detected as non-cooling, said evaporator fan controller decreases the operational speed of the evaporator fan to a low speed, thereby decreasing evaporator fan produced heat, resulting in an overall decreased energy requirement for the heat exchange system.

7. An apparatus according to claim 6, further comprising an air flow monitor coupled to said evaporator fan controller, whereby if air flow over the evaporator falls below a preset value said evaporator fan controller directs the evaporator fan to operate at said high speed.

8. An apparatus according to claim 6, further comprising a fail-safe bypass relay means coupled to said evaporator fan controller, whereby if a power failure occurs to the energy saving apparatus the evaporator fan is directed to operate at said high speed.

9. An apparatus according to claim 6, wherein said current sensor is linked to the heat exchange system at a location where current flow reflects said cooling/non-cooling operational status of the system.

10. An apparatus according to claim 6, wherein said current sensor comprises a current sensor coil coupled to a solenoid that gates the refrigerant flow into the evaporator, wherein said current sensor coil detects electrical current within said solenoid reflective of said cooling/non-cooling operational status of the system.

11. A method for saving energy by adapting a heat exchange system with a fan controller apparatus, wherein said heat exchange system has a cooled chamber, a compressor, a condenser, an evaporator, an evaporator fan, and refrigerant within refrigerant carrying lines, comprising the steps:

a) coupling into the heat exchange system an evaporator fan control means for monitoring cooling/non-cooling status of the heat exchange system and setting an energy saving operational speed for the evaporator fan based on said cooling/non-cooling status and

b) including a current sensor means coupled to said evaporator fan control means for detecting said cooling/non-cooling status of the heat exchange system, whereby if the system is detected as cooling, said evaporator fan control means directs the evaporator fan to operate at a high speed and if the system is detected as non-cooling, said evaporator fan control means decreases the operational speed of the evaporator fan to a low speed, thereby decreasing evaporator fan produced heat, resulting in an overall decreased energy requirement for the heat exchange system.

12. A method for saving energy according to claim 11, further comprising the step of adapting the heat exchange system with an air flow monitor means coupled to said evaporator fan control means, whereby if air flow over the evaporator falls below a preset value said evaporator fan control means directs the evaporator fan to operate at said high speed.

13. A method for saving energy according to claim 11, further comprising the step of adapting the heat exchange system with a fail-safe bypass relay means coupled to said evaporator fan control means, whereby if a power failure occurs to the energy saving apparatus the evaporator fan is directed to operate at said high speed.

14. A method according to claim 11, wherein said current sensor means comprises a current sensor linked to the heat exchange system at a location where current flow reflects said cooling/non-cooling operational status of the system.

15. A method for saving energy according to claim 14, wherein said current sensor is linked to a solenoid that gates the refrigerant flow into the evaporator.

16. A method for saving energy by retrofitting an existing heat exchange system with a fan controller apparatus, wherein said heat exchange system has a cooled chamber, a compressor, a condenser, an evaporator, an evaporator fan, and refrigerant within refrigerant carrying lines, comprising the steps:

a) coupling into the heat exchange system an evaporator fan controller for monitoring cooling/non-cooling status of the heat exchange system and setting an energy saving operational speed for the evaporator fan based on said cooling/non-cooling status and

b) including a current sensor means coupled to said evaporator fan controller for detecting said cooling/non-cooling status of the heat exchange system, whereby if the system is detected as cooling, said evaporator fan controller directs the evaporator fan to operate at a high speed and if the system is detected as non-cooling, said evaporator fan controller decreases the operational speed of the evaporator fan to a low speed, thereby decreasing evaporator fan produced heat, resulting in an overall decreased energy requirement for the heat exchange system.

17. A method for saving energy according to claim 16, further comprising the step of adapting the existing heat exchange system with an air flow monitor means coupled to said evaporator fan controller, whereby if air flow over the evaporator falls below a preset value said evaporator fan controller directs the evaporator fan to operate at said high speed.

18. A method for saving energy according to claim 16, further comprising the step of adapting the existing heat exchange system with a fail-safe bypass relay means coupled to said evaporator fan controller, whereby if a power failure occurs to the energy saving apparatus the evaporator fan is directed to operate at said high speed.

19. A method according to claim 16, wherein said current sensor means comprises a current sensor linked to the heat exchange system at a location where current flow reflects said cooling/non-cooling operational status of the system.

20. A method for saving energy according to claim 16, wherein said current sensor means comprises a current sensor linked to a solenoid that gates the refrigerant flow into the evaporator.