Maintenance And Diagnostics For Refrigeration Systems

Abstract

A system includes a system controller for a refrigeration or HVAC system having a compressor rack with at least one compressor and a condensing unit with at least one condenser fan. The system includes a rack controller for the compressor rack. The rack controller is in communication with the system controller. The system includes a condensing unit controller for the condensing unit. The condensing unit controller is in communication with the system controller. The system controller receives component identification information identifying components of the compressor rack and the condensing unit, retrieves component information including at least one of component specification information, component capacity information, and component capability information, based on the component identification information, and performs setup operations based on the component information.

What is claimed is: 
     
         1 . A system comprising:
 a system controller for a refrigeration or HVAC system having a compressor rack with at least one compressor and a condensing unit with at least one condenser fan;   a rack controller for the compressor rack, the rack controller being in communication with the system controller; and   a condensing unit controller for the condensing unit, the condensing unit controller being in communication with the system controller;   wherein the system controller receives component identification information identifying components of the compressor rack and the condensing unit; retrieves component information including at least one of component specification information, component capacity information, and component capability information, based on the component identification information; and   
       performs setup operations based on the component information. 
     
     
         2 . The system of  claim 1  wherein the system controller transmits first data including one or more of the component identification information and the component information to a remote device, receives second data from the remote device for controlling one or more of the components of the compressor rack and the condensing unit based on the first data sent to the remote device, and controls the one or more of the components of the compressor rack and the condensing unit based on the second data received from the remote device. 
     
     
         3 . The system of  claim 1  wherein the system controller transmits one or more of the component identification information and the component information to a remote device for diagnosing one or more of the components of the compressor rack and the condensing unit and scheduling service for the one or more of the components of the compressor rack and the condensing unit from the remote device. 
     
     
         4 . A system comprising:
 a controller for a refrigeration or HVAC system having a compressor rack with at least one compressor,   wherein the controller comprises:   a monitoring module configured to monitor power consumption of a compressor in the compressor rack based on data received from a power meter associated with the compressor, a supply voltage for the compressor, or amperage of the compressor; and   a tracking module configured to diagnose health of the compressor based on the power consumption of the compressor.   
     
     
         5 . The system of  claim 4  wherein the monitoring module further comprises:
 a voltage determining module configured to determine the supply voltage for the compressor based on power supplied to the compressor rack and a number of compressors in the compressor rack; 
 a power factor module configured to adjust a power factor for the compressor based on the supply voltage and a voltage rating of the compressor; and 
 a power consumption module configured to determine the power consumption of the compressor based on the adjusted power factor, the supply voltage for the compressor, and the amperage of the compressor. 
 
     
     
         6 . The system of  claim 4  wherein the monitoring module further comprises:
 a power consumption module configured to estimate the power consumption of each compressor in the compressor rack based on the amperage of the compressor, a voltage rating of the compressor, and a power factor rating of the compressor; and 
 an error correction module configured to determine an error correction factor to apply to the estimated power consumption of each compressor such that a sum of power consumption values of each compressor and other loads of the refrigeration or HVAC system equals a measured aggregate power consumption of the compressor rack. 
 
     
     
         7 . A system comprising:
 a controller for a refrigeration or HVAC system having a compressor rack with at least one compressor,   wherein the controller comprises:   a discharge line temperature determining module configured to monitor in real time a plurality of operating parameters of a compressor in the compressor rack during operation of the compressor and to determine a minimum discharge line temperature based on the plurality of operating parameters; and   a compressor control module configured to shut down the compressor in response to a discharge line temperature of the compressor being less than or equal to the minimum discharge line temperature for a predetermined period of time and to restart the compressor using a bump start method.   
     
     
         8 . The system of  claim 7  wherein the minimum discharge line temperature represents a discharge line temperature corresponding to liquid refrigerant entering the compressor. 
     
     
         9 . The system of  claim 7  wherein the compressor control module configured to shut down the compressor further in response to a rate of change of the discharge line temperature being less than or equal to a predetermined threshold. 
     
     
         10 . The system of  claim 7  wherein the plurality of operating parameters of the compressor includes a discharge pressure, a suction pressure, and a return gas temperature of the compressor. 
     
     
         11 . The system of  claim 7  wherein the plurality of operating parameters of the compressor includes performance data of the compressor and properties of a refrigerant used in the compressor. 
     
     
         12 . The system of  claim 7  wherein the plurality of operating parameters of the compressor includes whether liquid injection is employed in the compressor. 
     
     
         13 . The system of  claim 7  wherein the discharge line temperature determining module configured to adjust the minimum discharge line temperature in real time based on the plurality of operating parameters. 
     
     
         14 . The system of  claim 7  wherein the controller:
 is located remotely from the refrigeration or HVAC system; 
 receives operational data from the compressor; and 
 provides the minimum discharge line temperature and shutdown and restart instructions to the compressor.