Medium voltage power controller

• US 8,590,329 B2
• Filed: 06/07/2012
• Issued: 11/26/2013
• Est. Priority Date: 12/22/2004
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Norbeck, Dean K., Hansen, John C.
• Primary Examiner(s): Ali, Mohammad M
• Application Number:
  US13/491,120
• Publication Number:
  US 20120240614A1
• Time in Patent Office: 537 Days
• Field of Search: 622/281, 622/591, 622/98, 624/78, 624/98, 310/94, 310/98, 415/17, 415/19
• US Class Current: 62/228.1
• CPC Class Codes: F25B 2600/0253 with variable speed
• CPC Class Codes: F25B 49/025 Motor control arrangements
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02P 1/28 by progressive increase of voltage applied to primary circuit of motor
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A medium voltage power controller box is mounted on a chiller unit with the other components of the chiller system. The power controller box can be positioned on the chiller system unit to permit the power controller box to be close coupled to the motor, and specifically to the main motor lead exit hub without the need for any power conduit connections between the power controller box and the motor. In addition, the power controller box also does not require any control interface and receives controls from a control panel. A short conduit connection between the control panel and the power controller box is used to provide the necessary connections between the control panel and the power controller box.

Claims

1. A system comprising:

a compressor, a condenser and an evaporator in fluid communication;

the compressor, condenser and evaporator being mounted as a structure;

a motor connected to the compressor to drive the compressor, the motor being mounted on the structure, the motor being powered by a voltage greater than 600 volts; and

an enclosure comprising all components used in starting and operating the motor at variable speeds, the enclosure and components being configured for operation at voltages greater than 600 volts, the enclosure being mounted on the structure near the motor to permit electrical connections between the enclosure and the motor.

2. The system of claim 1 further comprising a cooling system to cool the components in the enclosure, the cooling system using at least one of air cooling, refrigerant cooling, liquid cooling or other cooling devices.

3. The system of claim 1 wherein the components of the enclosure comprise at least one of a power controller device, solid state starter device, variable speed drive, a main disconnect switch or a logic module.

4. The system of claim 3 wherein the power controller device comprises at least one switch selected from the group consisting of a silicon controlled rectifier, a gate turn off device, a field effect transistor, and an insulated gate bipolar transistor.

5. The system of claim 4 wherein the switches of the power controller device are electrically insulated from each other with at least one of potting material, oil, thermal dielectric fluid, vacuum, or inert pressurized gas.

6. The system of claim 3 wherein the power controller device is configured to provide a soft start or variable speed capability to the motor.

7. The system of claim 3 wherein the logic module receives control instructions from a control panel for the components in the enclosure.

8. The system of claim 3 wherein the main disconnect switch comprises a manually operated switch.

9. The system of claim 8 wherein the components comprise an electrical switch connected between the main disconnect switch and the solid state starter device or variable speed drive.

10. The system of claim 9 wherein the components comprise a bypass connection, the bypass connection being connected in parallel with the solid state starter device or variable speed drive between the electrical switch and the motor to bypass the solid state starter device or variable speed drive after the motor is started.

11. The system of claim 10 wherein the bypass connection comprises a second electrical switch.

12. The system of claim 1 further comprising a control panel, the control panel being operable to control operation of the components in the enclosure.

13. The system of claim 1 further comprising a control panel, the control panel being operable to provide control commands to the components in the enclosure.

14. The system of claim 1 wherein the enclosure and the motor are mounted on one component of the structure.

15. The system of claim 1 wherein the motor is mounted within the enclosure.

16. A system comprising:

a compressor, a condenser and an evaporator in fluid communication, the compressor, condenser and evaporator being mounted to form an integral unit;

a motor connected to the compressor to drive the compressor, the motor being mounted on the unit, the motor being powered by a voltage greater than 600 volts and less than 25,000 volts;

a control panel being mounted on the unit;

at least one box used in starting and operating the motor at a fixed speed or variable speed, the at least one box being mounted on the unit near the motor, the at least one box comprising;

a power controller positioned in the at least one box, the power controller comprising at least one silicon controlled rectifier, gate turn off device, field effect transistor, or insulated gate bipolar transistor, the power controller being electrically connected to the motor, the power controller being configured for operation at voltages in a range between 600 volts and 25,000 volts;

a disconnect switch being electrically connectable to a power source supplying a voltage greater than 600 volts and less than 25,000 volts;

a first electrical switch connected between the disconnect switch and the power controller, the first electrical switch being operable to be opened and closed in response to control instructions received from the control panel, the first electrical switch being configured for operation at voltages in a range between 600 volts and 25,000 volts; and

a second electrical switch being connected in parallel with the power controller between the first electrical switch and the motor to bypass the power controller after the motor is started, the second electrical switch being configured for operation at voltages in a range between 600 volts and 25,000 volts; and

wherein the at least one box is mounted on the unit to permit electrical connections between the at least one box and the motor without a separate power conduit connection between the at least one box and the motor.

17. The system of claim 16 wherein the at least one box comprises two or more boxes, each box of the two or more boxes housing at least one component, a first box of the two or more boxes being mounted on the unit to permit an electrical connection between the first box of the two or more boxes and the motor without using an electrical conduit connection, and a second box of the two or more boxes being mounted near the first box.

18. The system of claim 16 wherein the at least one box further comprises a module, the module being configured to receive control instructions from the control panel and provide control instructions to the first electrical switch, the second electrical switch and the at least one silicon controlled rectifier, gate turn off device, or insulated gate bipolar transistor.

19. The system of claim 16 wherein the at least one box and the motor are mounted on one component of the unit.

20. A system comprising:

a compressor, a condenser and an evaporator being integrally mounted as a unit;

a motor connected to the compressor to drive the compressor, the motor being mounted on the unit;

a control panel being mounted on the unit; and

a variable speed drive controlled by the control panel, the variable speed drive being configured to provide voltages to the motor in a range between 600 volts and 25,000 volts to operate the motor at variable speeds, the variable speed drive being mounted on the unit near the motor; and

wherein the variable speed drive is mounted on the unit to permit electrical connections between the variable speed drive and the motor without a power conduit connection between the variable speed drive and the motor.

21. The system of claim 20 wherein the control panel is configured to control power sections of the variable speed drive.

22. The system of claim 20 further comprising a main disconnect switch connected between the variable speed drive and a medium voltage electrical service, the main disconnect switch being mounted separate from the unit.

23. The system of claim 20 further comprising two or more boxes mounted on the unit, the two or more boxes each housing one or more components of the variable speed drive.

24. The system of claim 23 wherein at least one box of the two or more boxes is mounted on the unit to permit an electrical connection between the at least one box and the motor without using an electrical conduit connection.