Medium voltage power controller

• US 8,820,105 B2
• Filed: 11/22/2013
• Issued: 09/02/2014
• 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:
  US14/088,003
• Publication Number:
  US 20140075982A1
• Time in Patent Office: 284 Days
• Field of Search: 622/281, 622/591, 624/98, 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 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 variable speed drive, the variable speed drive being operable to provide a variable current and variable voltage to the motor to operate the motor at variable speeds, the variable speed drive comprising;

a first enclosure mounted on the unit near the motor;

a second enclosure mounted next to the unit;

an inverter electrically connected to the motor, the inverter being mounted in the first enclosure; and

a disconnect switch connected to a supply voltage for the variable speed drive, the disconnect switch being mounted in the second enclosure.

2. The system of claim 1 wherein the second enclosure is mounted on one of a floor, a wall or a mounting structure separate from the unit.

3. The system of claim 1 wherein the first enclosure is mounted on the unit to permit electrical connections between the inverter and the motor without a separate power conduit connection between the first enclosure and the motor.

4. The system of claim 1 wherein the variable speed drive further comprises:

a contactor, the contactor being mounted in one of the first enclosure or the second enclosure;

a transformer, the transformer being mounted in one of the first enclosure or the second enclosure;

a rectifier, the rectifier being mounted in one of the first enclosure or the second enclosure; and

a bus filter, the bus filter being mounted in one of the first enclosure or the second enclosure.

5. The system of claim 4 wherein the contactor is mounted in the second enclosure, the transformer is mounted in the second enclosure, the rectifier is mounted in the second enclosure, and the bus filter is mounted in the second enclosure.

6. The system of claim 4 wherein the contactor is mounted in the first enclosure, the transformer is mounted in the first enclosure, the rectifier is mounted in the second enclosure, and the bus filter is mounted in the second enclosure.

7. The system of claim 4 wherein the contactor is mounted in the first enclosure, the transformer is mounted in first enclosure, the rectifier is mounted in the first enclosure, and the bus filter is mounted in the second enclosure.

8. The system of claim 4 wherein the contactor is mounted in the first enclosure, the transformer is mounted in the first enclosure, the rectifier is mounted in the first enclosure, and the bus filter is mounted in the first enclosure.

9. The system of claim 4 wherein the variable speed drive further comprises:

input terminals and fuses mounted in the second enclosure; and

output terminals and an output filter mounted in the first enclosure.

10. The system of claim 4 wherein the bus filter comprises a filter capacitor.

11. The system of claim 4 wherein the rectifier comprises at least one of a diode or an insulated gate bipolar transistor.

12. 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;

a control panel being mounted on the structure;

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 comprising;

at least one box mounted on the structure;

a rectifier, a DC link and an inverter mounted in the at least one box; and

the rectifier comprising an electrical switching arrangement, the electrical switching arrangement having a plurality of switches being opened and closed to convert AC power to DC power.

13. The system of claim 12 wherein the plurality of switches of the electrical switching arrangement comprises a plurality of silicon controlled rectifiers, gate turn off devices, field effect transistors, or insulated gate bipolar transistors.

14. The system of claim 12 wherein the at least one box is mounted on at least one of a shell of the evaporator or a shell of the condenser.

15. The system of claim 12 wherein the at least one box is mounted on the structure 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.

16. The system of claim 12 wherein the plurality of switches of the electrical switching arrangement are electrically insulated from each other with at least one of potting material, oil, thermal dielectric fluid, vacuum, or inert pressurized gas.

17. The system of claim 12 wherein the control panel is configured to control the rectifier and the inverter of the variable speed drive.

18. The system of claim 12 further comprising a main disconnect switch connected between the variable speed drive and a medium voltage electrical service.

19. The system of claim 12 wherein the at least one box comprises two boxes, the rectifier being mounted in a first box of the two boxes and the inverter being mounted in a second box of the two boxes, the second box being mounted on the structure near the motor to avoid using electrical conduit to connect the second box and the motor.

20. The system of claim 12 wherein the variable speed drive further comprises a module mounted in the at least one box, the module being configured to receive control instructions from the control panel and provide control instructions to the plurality of switches of the electrical switching arrangement.