Method and apparatus for monitoring a refrigeration-cycle system

• US 9,081,394 B2
• Filed: 03/15/2013
• Issued: 07/14/2015
• Est. Priority Date: 08/11/2004
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Kates, Lawrence
• Primary Examiner(s): Smith, Duane
• Assistant Examiner(s): PHAM, MINH CHAU THI
• Application Number:
  US13/835,742
• Publication Number:
  US 20140000291A1
• Time in Patent Office: 851 Days
• Field of Search: 554/00, 55D/IG.34, 95/1, 95/26, 952/77, 962/77, 964/17, 964/21, 96/26, 961/17, 964/14, 621/26, 621/29, 622/08, 116/112, 116/137.R, 116/276, 116/268, 116/271, 116/DIG.25, 116/DIG.42
• US Class Current: 1/1
• 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 11/32 Responding to malfunctions or emergencies
• CPC Class Codes: F24F 11/39 Monitoring filter performance
• CPC Class Codes: F24F 11/47 Responding to energy costs
• CPC Class Codes: F24F 11/56 Remote control
• CPC Class Codes: F24F 8/90 Cleaning of purification apparatus
• CPC Class Codes: F25B 2500/19 Calculation of parameters
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2700/02 Humidity
• CPC Class Codes: F25B 2700/133 through the condenser
• CPC Class Codes: F25B 2700/1351 of the cooled fluid upstream or downstream of the evaporator
• CPC Class Codes: F25B 2700/15 Power, e.g. by voltage or current
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/172 of the condenser fan
• CPC Class Codes: F25B 2700/1931 Discharge pressures
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/195 of the condenser
• 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 2700/21161 : of the fluid heated by the condenser
• CPC Class Codes: F25B 2700/21163 : of the refrigerant at the outlet of the condenser
• CPC Class Codes: F25B 2700/21172 : at the inlet
• CPC Class Codes: F25B 2700/21173 : at the outlet
• CPC Class Codes: F25B 2700/21174 : of the refrigerant at the inlet of the evaporator
• CPC Class Codes: F25B 2700/21175 : of the refrigerant at the outlet of the evaporator
• CPC Class Codes: F25B 49/00 : Arrangement or mounting of control or safety devices
• CPC Class Codes: F25B 49/005 : of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: F25D 2400/36 : Visual displays
• CPC Class Codes: G01K 13/00 : Thermometers specially adapted for specific purposes
• CPC Class Codes: G01K 2201/00 : Application of thermometers in air-conditioning systems
• CPC Class Codes: G01N 15/0826 : and measuring fluid flow rate, i.e. permeation rate or pressure change
• CPC Class Codes: G01N 2015/084 : Testing filters
• CPC Class Codes: G01N 2015/0846 : by use of radiation, e.g. transmitted or reflected light
• CPC Class Codes: G05B 15/02 : electric
• CPC Class Codes: G05D 23/1917 : using digital means
• CPC Class Codes: G05D 23/1928 : sensing the temperature of one space
• CPC Class Codes: G05D 23/1932 : to control the temperature of a plurality of spaces
• CPC Class Codes: Y10S 116/25 : Air filter condition indicator
• CPC Class Codes: Y10S 116/42 : Oil filter
• CPC Class Codes: Y10S 55/34 : Indicator and controllers

Abstract

A monitoring system for monitoring operation of a refrigerant-cycle system is disclosed. A condenser unit sensor measures an operating characteristic of a condenser unit, the condenser unit including a condenser and a compressor. An evaporator unit sensor measures an operating characteristic of an evaporator unit, the evaporator unit including an evaporator and a fan. An electrical sensor measures an electrical quantity indicative of power consumption of the refrigerant-cycle system. A processing system calculates an efficiency of the refrigerant-cycle system based on the power consumption of the refrigerant-cycle system, the operating characteristic of the condenser unit, and the operating characteristic of the evaporator unit.

Claims

1. A method of monitoring operation of a refrigerant-cycle system, the method comprising:

measuring an operating characteristic of a condenser unit using a condenser unit sensor, the condenser unit including a condenser and a compressor;

measuring an operating characteristic of an evaporator unit using an evaporator unit sensor, the evaporator unit including an evaporator and a fan, wherein the operating characteristic of the evaporator unit includes at least one of air pressure, air flow, and air temperature;

using an electrical sensor, measuring an electrical quantity indicative of power consumption of the refrigerant-cycle system; and

using a processing system, calculating an efficiency of the refrigerant-cycle system based on the power consumption of the refrigerant-cycle system, the operating characteristic of the condenser unit, and the operating characteristic of the evaporator unit.

2. The method of claim 1 further comprising:

calculating an amount of work done by the refrigerant-cycle system based on the operating characteristic of the condenser unit and the operating characteristic of the evaporator unit; and

calculating the efficiency of the refrigerant-cycle system based on the amount of work done by the refrigerant-cycle system and the power consumption of the refrigerant-cycle system.

3. The method of claim 1 further comprising transmitting the efficiency of the refrigerant-cycle system and an identification code of the refrigerant-cycle system to a remote monitoring system.

4. The method of claim 1 further comprising:

determining an expected efficiency of the refrigerant-cycle system based on an identification code of the refrigerant-cycle system; and

based on the efficiency of the refrigerant-cycle system and the expected efficiency of the refrigerant-cycle system, at least one of;

notifying an owner of the refrigerant-cycle system that the efficiency of the refrigerant-cycle system is low; and

notifying the owner of the refrigerant-cycle system to seek service.

5. The method of claim 1 further comprising:

determining an expected efficiency of the refrigerant-cycle system based on an identification code of the refrigerant-cycle system; and

determining a relative efficiency of the refrigerant-cycle system based on the expected efficiency and the efficiency of the refrigerant-cycle system.

6. The method of claim 5 further comprising, in response to the relative efficiency of the refrigerant-cycle system being less than a predetermined value, notifying an owner of the refrigerant-cycle system of at least one of (i) that the efficiency of the refrigerant-cycle system is low and (ii) to seek service.

7. The method of claim 5 further comprising selectively adjusting operation of the refrigerant-cycle system in response to the relative efficiency of the refrigerant-cycle system being less than a predetermined value for at least a predetermined period.

8. The method of claim 5 further comprising transmitting an instruction to a thermostat to increase a setpoint temperature in response to the relative efficiency of the refrigerant-cycle system being less than a predetermined value for a predetermined period, wherein the thermostat controls operation of the condenser unit and the evaporator unit based on the setpoint temperature.

9. The method of claim 5 further comprising determining, based on the identification code of the refrigerant-cycle system, whether to adjust operation of the refrigerant-cycle system.

10. The method of claim 1 wherein the operating characteristic of the evaporator unit includes an air pressure difference across the evaporator, and wherein the method further comprises

measuring a first temperature of air at a point prior to flowing through the evaporator using a first temperature sensor;

and

measuring a second temperature of air at a point prior after flowing through the evaporator using a second temperature sensor, wherein the calculating the efficiency is further based on the first temperature and the second temperature.

11. A monitoring system for monitoring operation of a refrigerant-cycle system, the monitoring system comprising:

a condenser unit sensor measuring an operating characteristic of a condenser unit, the condenser unit including a condenser and a compressor;

an evaporator unit sensor measuring an operating characteristic of an evaporator unit, the evaporator unit including an evaporator and a fan, wherein the evaporator unit sensor is at least one of an air pressure sensor, an air flow sensor, and an air temperature sensor;

an electrical sensor measuring an electrical quantity indicative of power consumption of the refrigerant-cycle system; and

a processing system that calculates an efficiency of the refrigerant-cycle system based on the power consumption of the refrigerant-cycle system, the operating characteristic of the condenser unit, and the operating characteristic of the evaporator unit.

12. The monitoring system of claim 11 wherein the processing system:

calculates an amount of work done by the refrigerant-cycle system based on the operating characteristic of the condenser unit and the operating characteristic of the evaporator unit; and

calculates the efficiency of the refrigerant-cycle system based on the amount of work done by the refrigerant-cycle system and the power consumption of the refrigerant-cycle system.

13. The monitoring system of claim 11 further comprising a remote monitoring system, wherein the processing system transmits the efficiency of the refrigerant-cycle system and an identification code of the refrigerant-cycle system to the remote monitoring system.

14. The monitoring system of claim 11 further comprising a remote monitoring system that:

determines an expected efficiency of the refrigerant-cycle system based on an identification code of the refrigerant-cycle system; and

based on the efficiency of the refrigerant-cycle system and the expected efficiency of the refrigerant-cycle system, at least one of;

notifies an owner of the refrigerant-cycle system that the efficiency of the refrigerant-cycle system is low;

notifies the owner of the refrigerant-cycle system to seek service; and

selectively adjusts operation of the refrigerant-cycle system.

15. The monitoring system of claim 11 further comprising a remote monitoring system that:

determines an expected efficiency of the refrigerant-cycle system based on an identification code of the refrigerant-cycle system; and

determines a relative efficiency of the refrigerant-cycle system based on the expected efficiency and the efficiency of the refrigerant-cycle system.

16. The monitoring system of claim 15 wherein, in response to the relative efficiency of the refrigerant-cycle system being less than a predetermined value, the remote monitoring system notifies an owner of the refrigerant-cycle system of at least one of (i) that the efficiency of the refrigerant-cycle system is low and (ii) to seek service.

17. The monitoring system of claim 15 wherein the remote monitoring system selectively adjusts operation of the refrigerant-cycle system in response to the relative efficiency of the refrigerant-cycle system being less than a predetermined value for at least a predetermined period.

18. The monitoring system of claim 15 wherein:

the remote monitoring system transmits an instruction to a thermostat to increase a setpoint temperature in response to the relative efficiency of the refrigerant-cycle system being less than a predetermined value for a predetermined period, and

the thermostat controls operation of the condenser unit and the evaporator unit based on the setpoint temperature.

19. The monitoring system of claim 15 wherein the remote monitoring system determines, based on the identification code of the refrigerant-cycle system, whether to adjust operation of the refrigerant-cycle system.

20. The monitoring system of claim 11 further comprising:

a first temperature sensor measuring a first temperature of air at a point prior to flowing through the evaporator; and

a second temperature sensor measuring a second temperature of air at a point after flowing through the evaporator,

wherein the processing system calculates the efficiency also based on the first temperature and the second temperature,

wherein the evaporator unit sensor includes a differential pressure sensor, and

wherein the operating characteristic of the evaporator unit includes an air pressure difference across the evaporator.