Cost-effective remote monitoring, diagnostic and system health prediction system and method for vapor compression and heat pump units based on compressor discharge line temperature sampling

• US 9,168,315 B1
• Filed: 09/07/2011
• Issued: 10/27/2015
• Est. Priority Date: 09/07/2011
• Status: Active Grant

• Current Assignee: Mainstream Engineering Coporation
• Original Assignee: Mainstream Engineering Coporation
• Inventors: Scaringe, Robert P., Roth, Robert Paul, Lambert, Daniel L., Thomas, Erik P., Carff, Chad L.
• Primary Examiner(s): Bradford, Jonathan
• Application Number:
  US13/226,520
• Time in Patent Office: 1,511 Days
• Field of Search: 621/25, 621/26, 621/27, 621/29, 621/49, 622/92, 236/51
• US Class Current: 1/1
• CPC Class Codes: A61K 48/00 Medicinal preparations containing genetic material which is inserted into cells of the living body to treat genetic diseases; Gene therapy
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/36 to leakage of heat-exchange fluid
• CPC Class Codes: F24F 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/58 using Internet communication
• CPC Class Codes: F24F 11/62 characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
• CPC Class Codes: F24F 11/63 Electronic processing
• CPC Class Codes: F24F 2140/00 Control inputs relating to system states
• CPC Class Codes: F25B 2345/003 Control issues for charging or collecting refrigerant to or from a cycle
• CPC Class Codes: F25B 2500/07 Exceeding a certain pressure value in a refrigeration component or cycle
• CPC Class Codes: F25B 2500/08 Exceeding a certain temperature value in a refrigeration component or cycle
• CPC Class Codes: F25B 2500/222 Detecting refrigerant leaks
• CPC Class Codes: F25B 2500/24 Low amount of refrigerant in the system
• CPC Class Codes: F25B 2600/05 Refrigerant levels
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2600/19 Refrigerant outlet condenser temperature
• CPC Class Codes: F25B 2700/04 Refrigerant level
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/2102 at the outlet of the gas cooler
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21151 : at the suction side of the compressor
• CPC Class Codes: F25B 2700/21152 : at the discharge side of the compressor
• CPC Class Codes: F25B 2700/2116 : of a condenser
• CPC Class Codes: F25B 2700/21162 : of the refrigerant at the inlet of the condenser
• CPC Class Codes: F25B 2700/21163 : of the refrigerant at the outlet of the condenser
• CPC Class Codes: F25B 49/005 : of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: F25B 49/02 : for compression type machines, plants or systems
• CPC Class Codes: F25B 49/022 : Compressor control arrangements
• CPC Class Codes: F25B 49/027 : Condenser control arrangements
• CPC Class Codes: G06N 5/04 : Inference or reasoning models
• CPC Class Codes: G08B 21/187 : Machine fault alarms

Abstract

A diagnostic monitoring system and method is employed for one or more vapor compression systems such as air conditioners and heat pumps having a compressor, an indoor air handler fan coil and an outdoor condensor. Temperature, voltage and current sensors are provided at the outdoor condensor to determine that at least one vapor compression system is operating properly. Data obtained from the sensors is wirelessly transmitted to a receiving-device for use by the systems'"'"' custodian or repair service provider and includes information concerning an occurrence of periods when one or more of the vapor compression systems are operating at an abnormal state.

Claims

1. A monitoring system for at least one vapor-compression system having an outdoor section comprised of a compressor and a condenser, wherein the monitoring system comprises at least one sensor associated with only the outdoor section so that a processed output of the sensor is able by itself to predict low refrigerant charge based on a predicted sensor value determined by comparison of one of a previously obtained measured performance curve, a table of values and an equation, each as a function of outdoor ambient air temperature obtained during normal operation of the vapor-compression system in relation to a measured sensor value.

2. The monitoring system of claim 1, wherein the predicted sensor value is the temperature of a compressor discharge when the measured compressor discharge temperature deviates from the corresponding predicted temperature by a predetermined amount.

3. The monitoring system of claim 2, wherein the predetermined amount is at least 25 degrees F. above the predicted temperature.

4. The monitoring system of claim 1, wherein the predicted sensor value is determined by way of a best-fit polynomial form of equation.

5. The monitoring system of claim 1, wherein data concerning predicted low refrigerant charge is wirelessly transmitted to at least one of the system'"'"'s custodian and a repair service provider.

6. The monitoring system of claim 2, wherein the temperature of the compressor discharge is measured on the external surface of the compressor discharge tubing.

7. The monitoring system of claim 1, wherein the predicted sensor value is the temperature of a condenser discharge when the measured compressor discharge deviates from the corresponding predicted temperature by a predetermined amount.

8. The monitoring system of claim 7, wherein the temperature of the condenser discharge is measured on the external surface of the condenser discharge tubing.

9. The monitoring system of claim 1, wherein the predicted sensor value is the temperature of the compressor inlet when the measured compressor inlet temperature deviates from the corresponding predicted temperature by a predetermined amount.

10. The monitoring system of claim 9, wherein the temperature of the compressor inlet is measured on the external surface of the compressor inlet tubing.

11. The monitoring system of claim 1, wherein the comparison is performed at a comparable ambient air temperature.

12. The monitoring system of claim 1, wherein the predicted sensor value is the temperature of refrigerant entering the compressor when the measured refrigerant temperature at an inlet of the compressor deviates from the corresponding predicted temperature by a predetermined amount.

13. The monitoring system of claim 12, wherein the temperature of the refrigerant entering the compressor is measured on an external surface of compressor inlet tubing.

14. The monitoring system of claim 12, wherein the predetermined amount is at least 25 degrees F. above the predicted temperature.

15. A monitoring system for at least one vapor-compression system having an outdoor section comprised of a compressor and a condenser, wherein the monitoring system comprises at least two sensors associated with only the outdoor section so that processed outputs of the two sensors are able by themselves to predict diminished condenser air flow based on predicted sensor values of outdoor condenser refrigerant outlet temperature and a compressor discharge refrigerant temperature determined by comparison of previously obtained measured performance curve, a table of values and an equation, each as a function of outdoor ambient air temperature obtained during normal operation of the vapor-compression system in relation to the measured condenser outlet temperature and compressor discharge temperature to determine if the system is operating with undesirably reduced condenser airflow.

16. The monitoring system of claim 15, wherein the predicted sensor value is the temperature of both an outdoor condenser liquid refrigerant outlet tube external surface temperature and a compressor discharge tube external surface temperature to determine if the system is operating with undesirably reduced condenser airflow.

17. The monitoring system of claim 15, wherein the system is configured to determine that the condenser airflow has been undesirably reduced when the currently measured condenser liquid refrigerant outlet temperature is the temperature of the external surface of the outlet tubing and this temperature is higher than the predicted temperature at normal operation by at least a predetermined condenser liquid line offset amount and the measured compressor discharge temperature is the external surface temperature of the compressor discharge tube outlet tube and this temperature is within a predetermined acceptable range of the predicted temperature at normal operation and the predicted normal compressor discharge tube external surface temperature, and the predicted normal condenser liquid refrigerant outlet temperatures being evaluated in relation to outdoor ambient temperature.

18. The monitoring system of claim 17, wherein the condenser temperature offset amount is approximately 6 degrees F. and the compressor discharge temperature range is approximately 15 degrees F. within the predicted condenser discharge temperature at normal operation.

19. The monitoring system of claim 18, wherein a measured current draw at least a predetermined current offset amount above a predicted current draw is used to confirm the undesirably reduced condenser air flow.

20. The monitoring system of claim 19, wherein the predetermined current offset amount is at least 0.3 amperes.

21. The monitoring system of claim 16, wherein data concerning an occurrence of periods when the at least one vapor compression system is operating with undesirably reduced condenser airflow is transmitted via the Internet to at least one of the system'"'"'s custodian and a repair service provider.

22. The monitoring system of claim 16, wherein a measured current draw of one of the compressor and the total current draw of the outdoor components is used to confirm the undesirably reduced condenser air flow.