Compressor diagnostic and protection system
View Patent ↗A system includes a compressor, processing circuitry, a first sensor detecting high-side data indicative of an operating condition of a high-pressure side of the refrigeration circuit, and a second sensor detecting low-side data indicative of an operating condition of a low-pressure side of the refrigeration circuit. The processing circuitry receives the high-side data and the low-side data from the first and second sensors and processes at least one of the high-side data and low-side data to select an operating mode for the compressor. The operating modes include a normal mode, a reduced-capacity mode, and a shutdown mode.
1. A system comprising:
a compressor operable in a refrigeration circuit, said compressor having a shell and a motor disposed within said shell;
a first sensor detecting high-side data indicative of an operating condition of a high-pressure side of said refrigeration circuit;
a second sensor detecting low-side data indicative of an operating condition of a low-pressure side of said refrigeration circuit; and
processing circuitry receiving said high-side data and said low-side data from said first and second sensors and comparing a rate of change of at least one of said high-side data and said low-side data to identify a fault.
2. The system of claim 1 , wherein said processing circuitry compares said rate of change during a start-up phase, a quasi-steady state phase, and a steady-state phase of said compressor.
3. The system of claim 2 , wherein said processing circuitry identifies said fault based on said comparison and said phase of said compressor.
4. The system of claim 1 , wherein said first sensor is selected from the group comprising: a current sensor, a pressure sensor, and a temperature sensor.
5. The system of claim 4 , wherein said pressure sensor is a discharge pressure sensor.
6. The system of claim 4 , wherein said temperature sensor is a condenser temperature sensor.
7. The system of claim 4 , further comprising a voltage sensor, said voltage sensor in combination with said current sensor and operable to detect compressor and motor electrical component failures.
8. The system of claim 1 , wherein said second sensor is selected from the group comprising a suction pressure sensor and a temperature sensor.
9. The system of claim 8 , wherein said temperature sensor is a suction line temperature sensor disposed proximate to a suction port of said compressor.
10. The system of claim 8 , wherein said temperature sensor is a discharge line temperature sensor disposed proximate to a discharge port of said compressor.
11. The system of claim 10 , wherein said discharge line temperature sensor is disposed within said shell of said compressor.
12. The system of claim 10 , wherein said discharge line temperature sensor is disposed external from said shell of said compressor.
13. The system of claim 1 , further comprising an ambient temperature sensor in communication with said processing circuitry.
14. The system of claim 13 , wherein said ambient temperature sensor is mounted on said processing circuitry.
15. The system of claim 1 , further comprising a power interruption device operable to selectively restrict power to said motor to provide system protection in response to a signal from said processing circuitry.
16. The system of claim 1 , further comprising a diagnostics system in communication with said processing circuitry to log and store operating conditions of said compressor.
17. The system of claim 1 , wherein said compressor includes a plurality of light emitting devices operable to indicate said fault detected by said first sensor or said second sensor.
18. The system of claim 17 , wherein said plurality of light emitting devices includes different colored lights to distinguish among a high-side fault condition, a low-side fault condition, and a normal operating condition.
19. A controller for a compressor in a refrigeration circuit, said controller comprising:
a sensor detecting high-side data indicative of an operating condition of a high-pressure side of the refrigeration circuit; and
processing circuitry receiving said high-side data during installation of the compressor and generating a baseline signature of high-side data versus time for the compressor, said processing circuitry comparing said high-side data over time to said baseline signature to determine a fault condition.
20. The controller of claim 19 , wherein said processing circuitry compares said high-side data during a start-up phase, a quasi-steady state phase, and a steady-state phase of the compressor.
21. The controller of claim 20 , wherein said processing circuitry identifies said fault condition based on said comparison and said phase of said compressor.
22. The controller of claim 19 , wherein said sensor is selected from the group comprising: a current sensor, a pressure sensor, and a temperature sensor.
23. The controller of claim 22 , wherein said pressure sensor is a discharge pressure sensor.
24. The controller of claim 22 , wherein said temperature sensor is a condenser temperature sensor.
25. The controller of claim 22 , further comprising a voltage sensor, said voltage sensor in combination with said current sensor and operable to detect compressor and motor electrical component failures.
26. The controller of claim 19 , further comprising an ambient temperature sensor in communication with said processing circuitry.
27. The controller of claim 19 , further comprising a power interruption device operable to limit compressor duty cycle when said processing circuitry identifies said fault condition.
28. The controller of claim 19 , further comprising a diagnostics system in communication with said processing circuitry to log and store operating conditions of said compressor.
29. The controller of claim 19 , wherein said compressor includes a plurality of light emitting devices operable to indicate said fault condition detected by said first sensor or said second sensor.
30. The controller of claim 29 , wherein said plurality of light emitting devices includes different colored lights to distinguish among a high-side fault condition, a low-side fault condition, and a normal operating condition.
31. The controller of claim 19 , wherein said processing circuitry includes selecting an operating mode based on said fault condition.
32. The controller of claim 31 , wherein said operating modes include a normal mode, a reduced capacity mode, and a shutdown mode.
33. A controller for a compressor in a refrigeration circuit said controller comprising:
a sensor detecting low-side data indicative of an operating condition of a low-pressure side of the refrigeration circuit; and
processing circuitry receiving said low-side operating data and determining a fault condition based on said low-side operating data and an elapsed time following start-up of the compressor.
34. The controller of claim 33 , wherein said sensor is selected from the group comprising a suction pressure sensor and a temperature sensor.
35. The controller of claim 34 , wherein said temperature sensor is a suction line temperature sensor disposed proximate to a suction port of the compressor.
36. The controller of claim 34 , wherein said temperature sensor is a discharge line temperature sensor disposed proximate to a discharge port of the compressor.
37. The controller of claim 36 , wherein said discharge line temperature sensor is disposed within a shell of the compressor.
38. The controller of claim 36 , wherein said discharge line temperature sensor is disposed external from a shell of the compressor.
39. The controller of claim 33 , wherein said processing circuitry selects an operating mode for the compressor based on said fault condition.
40. The controller of claim 39 , wherein said operating modes include a normal mode, a reduced capacity mode, and a shutdown mode.