Variable speed drive for a chiller system

• US 7,208,891 B2
• Filed: 05/06/2005
• Issued: 04/24/2007
• Est. Priority Date: 05/06/2005
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: York International Corporation (Johnson Controls International plc)
• Inventors: Jadric, Ivan, Schnetzka, Harold Robert
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): McCloud; Renata
• Application Number:
  US11/123,685
• Publication Number:
  US 20060250107A1
• Time in Patent Office: 718 Days
• Field of Search: None
• US Class Current: 318/12
• CPC Class Codes: B60H 1/00428 electric
• CPC Class Codes: H02P 2201/09 Boost converter, i.e. DC-DC step up converter increasing the voltage between the supply and the inverter driving the motor general aspects of plural converters in cascade H02M
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: Y02T 10/88 Optimized components or subsystems, e.g. lighting, actively controlled glasses

Abstract

A variable speed drive with a boost converter is provided for a chiller system driven by an induction motor. The boost converter can be a diode or thyristor rectifier followed by a boost DC/DC converter or a three-phase pulse width modulated boost converter. The boost converter provides a boosted voltage to the DC link, which results in a boosted voltage being applied to the induction motor by the inverter of the variable speed drive.

Claims

1. A drive system for a compressor of a chiller system, the drive system comprising:

a variable speed drive, the variable speed drive being configured to receive an input AC voltage at a fixed AC input voltage and provide an output AC power at a variable voltage and variable frequency, the variable speed drive comprising;

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

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

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

a motor connected to the inverter stage and powered by the output AC power from the inverter stage, the motor being connectable to a compressor of the chiller system to power the compressor;

wherein the converter stage comprises a three-phase pulse width modulated boost rectifier having insulated gate bipolar transistors and is configured to maintain a boosted DC voltage greater than the input AC voltage when the input AC voltage falls below the fixed AC input voltage.

2. The drive system of claim 1 wherein the boosted DC voltage is a DC voltage greater than 1.3 times the root-mean-squared value of the fixed AC input voltage.

3. The drive system of claim 1 wherein the motor has a voltage rating greater than the fixed input AC voltage.

4. The drive system of claim 1 wherein the converter stage is configured to control a current waveform drawn from the AC power source to have a substantially sinusoidal shape and to be substantially in phase with the fixed input AC voltage.

5. The drive system of claim 1 wherein the converter stage is configured to provide the boosted DC voltage to the DC link substantially independent of the fixed input AC voltage, thereby permitting the variable speed drive to operate during a reduction in the fixed input AC voltage for a predetermined time.

6. The drive system of claim 1 wherein the inverter stage is configured to have a DC current of reduced magnitude in response to the boosted DC voltage being present at the DC link, thereby reducing inverter losses in the variable speed drive.

7. The drive system of claim 1 wherein the motor is configured to have a motor current having a RMS value of reduced magnitude in response to the variable voltage being greater than the fixed input AC voltage, thereby reducing motor losses in the motor.

8. The drive system of claim 1, wherein the motor is an induction motor.

9. A chiller system comprising:

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

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 boosted DC voltage, the boosted DC voltage being greater than the fixed input AC voltage;

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

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

wherein the converter stage comprises a three-phase pulse width modulated boost rectifier having insulated gate bipolar transistors.

10. The chiller system of claim 9 wherein the boosted DC voltage is a DC voltage greater than 1.3 times the root-mean-squared value of the fixed AC input voltage.

11. The chiller system of claim 9 wherein the motor has a voltage rating greater than the fixed input AC voltage.

12. The chiller system of claim 9 wherein the converter stage is configured to control a current waveform drawn from the AC power source to have a substantially sinusoidal shape and to be substantially in phase with the fixed input AC voltage.

13. The chiller system of claim 9 wherein the converter stage is configured to provide the boosted DC voltage to the DC link substantially independent of the fixed input AC voltage, thereby permitting the variable speed drive to operate during a reduction in the fixed input AC voltage for a predetermined time.

14. The chiller system of claim 9 wherein the motor is configured to have a motor current having a RMS value of reduced magnitude in response to the variable voltage being greater in magnitude than the fixed input AC voltage, thereby reducing motor losses in the motor.

15. The chiller system of claim 9 wherein the inverter stage is configured to have a DC current of reduced magnitude in response to the boosted DC voltage being present at the DC link, thereby reducing inverter losses in the variable speed drive.

16. The chiller system of claim 9 wherein the motor is an induction motor.