Cold climate air-source heat pump

• US 7,266,959 B2
• Filed: 02/03/2005
• Issued: 09/11/2007
• Est. Priority Date: 02/03/2005
• Status: Expired due to Fees

• Current Assignee: Nyle Systems LLC
• Original Assignee: Nyle Special Products LLC
• Inventors: Lewis, Donald
• Primary Examiner(s): NORMAN, MARC E
• Application Number:
  US11/049,823
• Publication Number:
  US 20060168973A1
• Time in Patent Office: 950 Days
• Field of Search: 621/75, 622/10, 622/285, 622/29, 621/962, 622/03
• US Class Current: 62/175
• CPC Class Codes: F25B 1/10 with multi-stage compression with cascade operation F25B7/00
• CPC Class Codes: F25B 2400/0401 for the compressor
• CPC Class Codes: F25B 2600/2507 Flow-diverting valves
• 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 30/02 of the compression type

Abstract

An improved cold climate air-source heat pump comprising at least a primary compressor, a booster compressor, a first heat exchanger associated with an indoor environment and a second heat exchanger associated with an outdoor environment and with one heat exchanger acting as an evaporator and the other heat exchanger acting as a condenser, an expansion device, flow conduit means for circulating a refrigerant fluid in a closed loop, a first sensor means for sensing the temperature of the internal ambient air, a second sensor means for sensing the temperature of the external ambient air, a third sensor means for sensing the temperature of the refrigerant fluid flowing between the booster compressor and the primary compressor, a fourth sensor means for sensing the operative state of the primary compressor, a primary compressor operation control means responsive to inputs from the first sensor means, and a booster compressor operation control means responsive to inputs from the second, third, and fourth sensor means. The booster compressor operation control means is configured to initiate and shut down operation of the booster compressor based on inputs from the various sensor means, to ensure safe operation of the system and improved durability of the air-source heart pump.

Claims

1. An air-source heat pump comprising:

a primary compressor having a primary compressor inlet and a primary compressor outlet;

a booster compressor having a booster compressor inlet and a booster compressor outlet;

a first heat exchanger;

a second heat exchanger;

an expansion device;

a refrigerant fluid;

a flow conduit means connecting the first and second heat exchangers, the primary and booster compressors, and the expansion device for circulating the refrigerant fluid in a closed loop,

whereby the primary compressor outlet, the first heat exchanger, the expansion device, the second heat exchanger, the booster compressor inlet, the booster compressor outlet, and the primary compressor inlet are placed in respective serial fluid communication with one another to thereby circulate the refrigerant fluid, and

the flow conduit means is further connected to bypass the booster compressor and deliver refrigerant fluid from the second heat exchanger to the primary compressor when the booster compressor is inoperative, and with the flow conduit means connected to deliver refrigerant fluid from the second heat exchanger to the booster compressor and from the booster compressor to the primary compressor when operation of the booster compressor is initiated;

a first sensor means for sensing the temperature of internal ambient air;

a second sensor means for sensing the temperature of external ambient air;

a third sensor means for sensing the temperature of the refrigerant flowing between the booster compressor outlet and the primary compressor inlet;

a fourth sensor means for sensing the operation of the primary compressor;

a primary compressor operation control means responsive to inputs from the first sensor means, in connection with the primary compressor and in connection with the first sensor means,

wherein the primary compressor operation control means initiates operation of the primary compressor when the first sensor means indicates the temperature of the ambient air is below a first predetermined level, and

the primary compressor operation control means shuts down operation of the primary compressor when the first sensor means indicates the temperature of the ambient air has achieved a second predetermined level; and

a booster compressor operation control means responsive to inputs from the second, third, and fourth sensor means, in connection with the booster compressor and in connection with the second, third, and fourth sensor means,

wherein the booster compressor operation control means initiates operation of the booster compressor when the second sensor means indicates the temperature of the external ambient air is below a third predetermined level whereby operation of the primary compressor alone is not efficient,

the booster compressor operation control means shuts down operation of the booster compressor when the second sensor means indicates the temperature of the external ambient air has achieved a fourth predetermined level whereby the primary compressor may be efficiently operated alone,

the booster compressor operation control means shuts down operation of the booster compressor when the third sensor means indicates the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet exceeds a fifth predetermined level, and

the booster compressor operation control means shuts down operation of the booster compressor when the fourth sensor means indicates the primary compressor is inoperative.

2. The air-source heat pump of claim 1 wherein

one of the first and second heat exchange means is an evaporator;

and

the other of the first and second heat exchange means is a condenser.

3. The air-source heat pump of claim 1 further comprising

a reversing valve, in fluid communication through the flow conduit means with the primary compressor outlet, said reversing valve capable of being movably positioned between a first position and a second position, to control the direction of flow of the refrigerant fluid through in the flow conduit means,

wherein when the reversing valve is positioned in the first position refrigerant fluid is directed from the primary compressor outlet to one of the heat exchangers, and

when the reversing valve is positioned in the second position refrigerant fluid is directed from the primary compressor outlet to the other of the heat exchangers.

4. The air-source heat pump of claim 1 wherein the refrigerant fluid is R410A.

5. The air-source heat pump of claim 1 wherein the expansion device is a thermal expansion valve.

6. The air-source heat pump of claim 1 wherein the first sensor means comprises an electronic temperature sensing device.

7. The air-source heat pump of claim 1 wherein the second sensor means comprises an electronic temperature sensing device.

8. The air-source heat pump of claim 1 wherein the third sensor means comprises an electronic temperature sensing device.

9. The air-source heat pump of claim 1 wherein the fourth sensor means comprises a current transformer,

with the fourth sensor means generating an input to the booster compressor operation control means indicating the primary compressor is operative when current flowing to the primary compressor falls within a predetermined range, and

the fourth sensor means generating an input to the booster compressor operation control means indicating the primary compressor is inoperative when current flowing to the primary compressor falls outside the predetermined range.

10. The air-source heat pump of claim 1 wherein the fourth sensor means comprises a centrifugal switch, said centrifugal switch being in connection with a motor of the primary compressor and configured to close when the motor is turning and to open when the motor is not turning,

with the fourth sensor means generating an input to the booster compressor operation control means indicating the primary compressor is operative when the centrifugal switch is closed, and

the fourth sensor means generating an input to the booster compressor operation control means indicating the primary compressor is inoperative when the centrifugal switch is opened.

11. The air-source heat pump of claim 1 wherein the fourth sensor means comprises a flow switch, said flow switch located in the primary compressor outlet and configured to close when the flow of the refrigerant fluid from the primary compressor outlet falls within a predetermined range and to open when the flow of the refrigerant fluid from the primary compressor outlet falls outside the predetermined range,

with the fourth sensor means generating an input to the booster compressor operation control means indicating the primary compressor is operative when the flow switch is closed, and

the fourth sensor means generating an input to the booster compressor operation control means indicating the primary compressor is inoperative when the flow switch is opened.

12. The air-source heat pump of claim 1 wherein the booster compressor operation control means comprises a logic controller,

whereby the logic controller evaluates inputs from the second, third, and fourth sensor means to determine when operation of the booster compressor should be initiated and when operation of the booster compressor should be shut down,

with the booster compressor operation control means configured to initiate operation of the booster compressor when the second sensor means indicates the temperature of the external ambient air is below a third predetermined level, the third sensor means indicates the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet does not exceed a fifth predetermined level, and the fourth sensor means indicates the primary compressor is operative, and

the booster compressor operation control means configured to shut down operation of the booster compressor when the second sensor means indicates the temperature of the external ambient air exceeds a fourth predetermined level and/or the third sensor means indicates the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet exceeds a fifth predetermined level and/or the fourth sensor means indicates the primary compressor is inoperative.

13. The air-source heat pump of claim 12 wherein the booster compressor operation control means further comprises a first timing means,

whereby the first timing means is activated upon the booster compressor operation control means shutting down operation of the booster compressor as a result of the third sensor means indicating the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet exceeds a fifth predetermined level,

and thereafter the logic controller evaluates the first timing means and evaluates inputs from the second, third, and fourth sensor means, to determine when operation of the booster compressor should be re-initiated,

with the booster compressor operation control means re-initiating operation of the booster compressor when inputs received by the booster compressor operation control means from the second, third, and fourth sensor means are determined by the logic controller to indicate proper conditions for operation of the booster compressor and a predetermined period of time has elapsed as determined by the first timing means.

14. The air-source heat pump of claim 1 wherein

the first heat exchanger is a condenser located in the flow conduit means downstream of the primary compressor and upstream of the expansion device;

and

the second heat exchanger is an evaporator located in the flow conduit means downstream of the expansion device and upstream of the booster compressor.

15. The air-source heat pump of claim 14 further comprising a defrosting means sufficient to eliminate ice buildup from the second heat exchanger.

16. The air-source heat pump of claim 15 further comprising

a fifth sensor means for sensing operation of the defrosting means, with the fifth sensor means in connection with the booster compressor operation control means and the booster compressor operation control means responsive to inputs from the fifth sensor means;

and

the booster compressor operation control means comprises a defrost timing means;

whereby the booster compressor operation control means shuts down operation of the booster compressor and activates the defrost timing means upon receiving an input from the fifth sensor means indicating the defrosting means had completed a defrosting cycle, and

the booster compressor operation control means re-initiates operation of the booster compressor when a first predetermined period of time has elapsed as determined by the defrost timing means.

17. The air-source heat pump of claim 16 wherein the booster compressor operation control means further comprises a logic controller,

whereby the logic controller evaluates inputs from the second, third, fourth, and fifth sensor means and the defrost timing means to determine when operation of the booster compressor should be initiated and when operation of the booster compressor should be shut down,

with the booster compressor operation control means configured to initiate operation of the booster compressor when the second sensor means indicates the temperature of the external ambient air is below a third predetermined level, the third sensor means indicates the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet does not exceed a fifth predetermined level, the fourth sensor means indicates the primary compressor is operative, and the defrost timing means indicates more than the first predetermined period of time has elapsed since the defrosting means last completed a defrosting cycle, and

the booster compressor operation control means configured to shut down operation of the booster compressor when the second sensor means indicates the temperature of the external ambient air has achieved a fourth predetermined level and/or the third sensor means indicates the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet exceeds a fifth predetermined level and/or the fourth sensor means indicates the primary compressor is inoperative and/or the fifth sensor means indicates the defrosting means has completed a defrosting cycle and the first predetermined period of time as determined by the defrost timing means has not yet elapsed.

18. The air-source heat pump of claim 17 wherein the booster compressor operation control means further comprises a second timing means,

whereby the second timing means is activated upon the booster compressor operation control means shutting down operation of the booster compressor as a result of the third sensor means indicating the temperature of the refrigerant fluid flowing between the booster compressor outlet and the primary compressor inlet exceeds a fifth predetermined level,

and thereafter the logic controller evaluates the second timing means and evaluates inputs from the second, third, fourth, and fifth sensor means and the defrost timing means, to determine when operation of the booster compressor should be re-initiated,

with the booster compressor operation control means re-initiating operation of the booster compressor when inputs received by the booster compressor operation control means from the second, third, fourth, and fifth sensor means and from the defrost timing means are determined by the logic controller to indicate proper conditions for operation of the booster compressor, and a second predetermined period of time has elapsed as determined by the second timing means.

19. The air-source heat pump of claim 15 further comprising

a reversing valve, in fluid communication through the flow conduit means with the primary compressor outlet, said reversing valve capable of being movably positioned between a first position and a second position, to control the direction of flow of the refrigerant fluid through in the flow conduit means,

wherein when the reversing valve is positioned in the first position refrigerant fluid is directed from the primary compressor outlet to the first heat exchanger,

and when the reversing valve is positioned in the second position refrigerant fluid is directed from the primary compressor outlet to the second heat exchanger.