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 9,435,576 B1
• Filed: 03/10/2016
• Issued: 09/06/2016
• Est. Priority Date: 09/07/2011
• Status: Active Grant

• Current Assignee: Mainstream Engineering Coporation
• Original Assignee: Mainstream Engineering Coporation
• Inventors: Roth, Robert Paul, Thomas, Erik P., Scaringe, Robert P., Lambert, Daniel, Carff, Chad L.
• Primary Examiner(s): Bradford, Jonathan
• Application Number:
  US15/066,299
• Time in Patent Office: 180 Days
• 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 method of detecting that a complete loss of condenser air flow has occurred in at least one vapor compression or heat pump unit having a compressor and a condenser, comprising monitoring one of existing compressor high current safety shut-off and high condenser saturation temperature, and, when the unit shuts off at least three times resulting from consecutive short cycles, checking a condenser liquid line temperature to determine if the liquid line temperature is at least 40 degrees Fahrenheit above a previously recorded baseline condenser liquid line temperature.

2. The method of claim 1, wherein an occurrence of periods when the unit is operating with a loss of condenser air flow is transmitted to at least one of the unit'"'"'s owner and a repair service provider.

3. The method of claim 1 wherein the step of monitoring is effected by monitoring one of the temperature and corresponding saturation pressure via a high pressure shut-off.

4. The method of claim 1, wherein the three consecutive short cycles can occur within a 5-minute period.