Air conditioner with multiple expansion devices

• US 10,139,143 B2
• Filed: 12/17/2013
• Issued: 11/27/2018
• Est. Priority Date: 12/17/2013
• Status: Active Grant

• Current Assignee: Lennox Industries Incorporated (Lennox International Incorporated)
• Original Assignee: Lennox Industries Incorporated (Lennox International Incorporated)
• Inventors: Havard, Jr., Harold Gene, Jewell, Terry, Qu, Yi
• Primary Examiner(s): Furdge, Larry
• Application Number:
  US14/109,697
• Publication Number:
  US 20150168041A1
• Time in Patent Office: 1,806 Days
• CPC Class Codes: F25B 2400/075 with parallel compressors
• CPC Class Codes: F25B 2600/2507 Flow-diverting valves
• CPC Class Codes: F25B 2600/2513 Expansion valves
• CPC Class Codes: F25B 2700/13 Mass flow of refrigerants
• CPC Class Codes: F25B 41/20 Disposition of valves, e.g. of on-off valves or flow control valves expansion valves F25B41/31
• CPC Class Codes: F25B 41/24 Arrangement of shut-off valves for disconnecting a part of the refrigerant cycle, e.g. an outdoor part
• CPC Class Codes: F25B 41/385 Dispositions with two or more expansion means arranged in parallel on a refrigerant line leading to the same evaporator
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems

Abstract

In various implementations, an air conditioner may include more than one expansion device. Refrigerant flow through the expansion device(s) may be controlled based at least partially on an operational property of the air conditioner.

Claims

1. An air conditioner comprising:

a condenser including an outlet;

one or more compressors, the one or more compressors comprising;

a low compressor setting; and

a first and a second high compressor settings, wherein a volumetric flow rate of refrigerant exiting the one or more compressors is greater at the first and second high compressor settings than at the low compressor setting;

a first expansion device fluidly coupled to the set of compressors such that the first expansion device permits fluid to exit the first expansion device at a first flow rate, wherein the first expansion device is an electronic expansion valve;

a second expansion device fluidly coupled to the one or more compressors such that the second expansion device permits fluid to exit the second expansion device at a second flow rate, wherein the first expansion device and the second expansion device are coupled in parallel;

a controller coupled to a plurality of components of the air conditioner, the controller comprising a memory storing an operation module and an expansion device management module each being executable by a processor, wherein the controller is operable to;

via the operation module, receive requests for operation and determine response to the requests for operation and operate the plurality of components of the air conditioner;

via the expansion device management module, allow operations of the air conditioner, comprising;

measure a flow rate in the air conditioner;

compare the measured flow rate to a plurality of flow rate ranges stored in a memory, the plurality of flow rate ranges associated with the low, first high, and second high compressor settings;

allow refrigerant from the outlet of the condenser to flow through the first expansion device if the measured flow rate is associated with the low compressor setting;

allow refrigerant from the outlet of the condenser to flow through the second expansion device if the measured flow rate is associated with the first high compressor setting; and

allow refrigerant from the outlet of the condenser to flow through the first and second expansion devices if the measured flow rate is associated with the second high compressor setting.

2. The air conditioner of claim 1, further comprising a reversing valve, and wherein the reversing valve comprises:

a first valve setting adapted to allow refrigerant flow through the first expansion device; and

a second valve setting adapted to allow refrigerant flow through the second expansion device.

3. The air conditioner of claim 1, further comprising:

a first valve adapted to regulate flow through the first expansion device; and

a second valve adapted to regulate flow through the second expansion device.

4. The air conditioner of claim 1, wherein the one or more compressors comprises a first compressor and a second compressor coupled in a tandem compressor assembly.

5. The air conditioner of claim 1, wherein the one or more compressors comprises a variable speed compressor, and wherein at least one of the first expansion device or the second expansion device comprises a thermal expansion device.

6. The air conditioner of claim 1, wherein at least one of the one or more of compressors comprises more than one stage of operation.

7. The air conditioner of claim 1, wherein the condenser comprises a microchannel condenser.

8. The air conditioner of claim 1, wherein:

the first expansion device comprises a first high speed orifice; and

the second expansion device comprises a second low speed orifice.

9. The air conditioner of claim 1 wherein at least one of the first expansion device or the second expansion device comprises a bleed thermal expansion device.

10. A method comprising:

allowing operation of an air conditioner, wherein the air conditioner comprises;

compressor settings comprising a low compressor setting and a first and a second high compressor settings, wherein a volumetric flow rate of refrigerant exiting one or more compressors of the air conditioner is greater at the first high compressor setting than at the low compressor setting, and greater at the second high compressor setting than at the first high compressor setting; and

a first expansion device fluidly coupled to the one or more compressors; and

a second expansion device fluidly coupled to the one or more compressors and coupled in parallel with the first expansion device;

via an operation module operable in a controller, receiving requests for operation and determining response to the requests for operation and operating a plurality of components of the air conditioner;

via an expansion device management module operable in a controller coupled to the plurality of components of the air conditioner, allowing operations of the air conditioner, comprising;

measuring a flow rate in the air conditioner;

comparing the measured flow rate to a plurality of flow rate ranges stored in a memory, the plurality of flow rate ranges associated with the low, first high, and second high compressor settings;

allowing refrigerant from an outlet of a condenser of the air conditioner to flow through the first expansion device if the measured flow rate is associated with the low compressor setting;

allowing refrigerant from the outlet of the condenser to flow through the second expansion device if the measured flow rate is associated with the first high compressor setting; and

allowing refrigerant from the outlet of the condenser to flow through the first and second expansion devices if the measured flow rate is associated with the second high compressor setting.

11. The method of claim 10, wherein determining a compressor setting comprises determining a compressor setting based at least partially on a volumetric flow rate of a refrigerant proximate an outlet of at least one of the one or more compressors of the air conditioner.

12. The method of claim 10, wherein determining a compressor setting comprises:

determining a third volumetric flow rate of refrigerant exiting at least a portion of the one or more compressors;

comparing the determined third volumetric flow rate to a predetermined low flow rate; and

identifying the compressor setting as the low compressor setting if the determined third volumetric flow rate is less than the predetermined low flow rate.

13. The method of claim 10, wherein determining a compressor setting comprises:

determining a third volumetric flow rate of refrigerant exiting at least a portion of the one or more compressors;

comparing the determined third volumetric flow rate to a predetermined high flow rate; and

identifying the compressor setting as one of the high compressor settings if the determined third volumetric flow rate is greater than the predetermined high flow rate.

14. An air conditioner comprising:

a microchannel condenser;

a first expansion device;

a second expansion device wherein the first expansion device and the second expansion device are coupled in parallel;

at least one valve managing refrigerant flow to at least one of the first expansion device or the second expansion device;

one or more compressors fluidly coupled to the first and second expansion devices;

one or more sensors adapted to measure one or more third volumetric flow rates exiting at least a portion of the one or more compressors;

a memory storing one or more predetermined flow rates; and

and a controller adapted to;

via an operation module operable in the controller, receive requests for operation and determine response to the requests for operation and operate a plurality of components;

via an expansion device management module operable in the controller coupled to the plurality of components of the air conditioner, allow operations of the air conditioner, comprising;

measure a flow rate in the air conditioner;

compare the measured flow rate to a plurality of flow rate ranges stored in the memory, the plurality of flow rate ranges associated with a low, first high, and second high compressor settings;

allow refrigerant from an outlet of a condenser of the air conditioner to flow through the first expansion device if the measured flow rate is associated with the low compressor setting;

allow refrigerant from the outlet of the condenser to flow through the second expansion device if the measured flow rate is associated with the first high compressor setting; and

allow refrigerant from the outlet of the condenser to flow through the first and second expansion devices if the measured flow rate is associated with the second high compressor setting.

15. The air conditioner of claim 14, wherein at least one of the valves comprises a reversing valve, and wherein the reversing valve comprises:

a first valve setting adapted to allow refrigerant flow through the first expansion device; and

a second valve setting adapted to allow refrigerant flow through the second expansion device.

16. The air conditioner of claim 14, wherein the at least one valve comprises a first valve adapted to regulate flow through the first expansion device and a second valve adapted to regulate flow through the second expansion device.

17. The air conditioner of claim 14, wherein the one or more compressors comprises a first compressor and a second compressor coupled in a tandem assembly.

18. The air conditioner of claim 14, wherein at least one of the one or more compressors comprises more than one stage of operation.

19. The air conditioner of claim 14, wherein at least one of the predetermined flow rates comprises a predetermined high flow rate greater than the first predetermined flow rate;

and wherein the controller is further adapted to;

retrieve the predetermined high flow rate from the memory of the air conditioner; and

allow refrigerant from an outlet of the condenser to flow through the first expansion device and the second expansion device if at least one of the determined third volumetric flow rates is greater than the predetermined high flow rate.