Adaptive control for a refrigeration system using pulse width modulated duty cycle scroll compressor

Abstract

A diagnostic system includes a controller adapted for coupling to a compressor or electronic stepper regulator valve. The controller produces a variable duty cycle control signal to adjust the capacity of the compressor or valve position of the electronic stepper regulator valve as a function of demand for cooling. The diagnostic system further includes a diagnostic module coupled to the controller for monitoring and comparing the duty cycle with at least one predetermined fault value indicative of a system fault condition and an alert module responsive to the diagnostic module for issuing an alert signal when the duty cycle bears a predetermined relationship to the fault value.

1. A diagnostic system for an electronic stepper regulator valve, comprising:
 a controller adapted for coupling to an electronic stepper regulator valve, said controller producing a variable duty cycle control signal for adjusting a valve position of said electronic stepper regulator valve, in which said duty cycle is a function of demand for cooling;    a diagnostic module coupled to said controller for monitoring and comparing said duty cycle with at least one predetermined fault value indicative of a fault condition; and    an alert module responsive to said diagnostic module for issuing an alert signal when said duty cycle bears a predetermined relationship to said fault value.    
     
     
       2. The diagnostic  A control system of  claim 1 , wherein said diagnostic module monitors and compares at least one of the following conditions  comprising:
 a controller operable to produce a variable duty cycle control signal for controlling a cooling system device in which said duty cycle is a function of demand for cooling; and  
   a diagnostic module associated with said controller and operable to compare said duty cycle with a predetermined value indicative of a system condition and issue a signal when said duty cycle bears a predetermined relationship to a fault value;   
 wherein said diagnostic module monitors at least one of the following conditions: saida valve position of saidan electronic stepper regulator;    an error value percentage indicative of the percentage of sampled error within an accepted offset range for a defined period of time;    a moving average of said valve position for a defined period of time;    a steady state loading percentage set equal to said moving average of said valve position for a defined period of time when said error value percentage is less than fifty percent;    a discharge cooling fluid temperature;    an evaporator coil inlet temperature;    an evaporator coil exit temperature;    a moving average of a difference between said discharge cooling fluid temperature and said evaporator coil inlet temperature;    a moving average of a difference between said evaporator coil exit temperature and said evaporator coil inlet temperature to approximate a superheat value; and    a length of time said evaporator coil exit temperature is less than said evaporator coil inlet temperature during a predefined period of time.    
 
     
     
       3. The diagnostic  control system of claim  1    15 , wherein said diagnostic  module monitors a percentage of sampled error over a defined period of time. 
     
     
       4. The diagnostic  control system of  claim 3 , wherein said predetermined fault  value is an accepted offset range. 
     
     
       5. The diagnostic  control system of  claim 4 , wherein said diagnostic  module determines an error value percentage indicative of said percentage of sampled error within said accepted offset range for said defined period of time. 
     
     
       6. The diagnostic system of  claim 5 , wherein said diagnostic module determines an error value percentage indicative of said percentage of sampled error within said accepted offset range for said defined period of time. 
     
     
       7. The diagnostic  control system of claim  6    27 , wherein said alert module issues an alert signal when said  a valve position of said electronic stepper regulator valve is approximately zero percent for approximately ninety percent of said defined period of time and said error value percentage is less than one hundred percent, said alert signal indicating said electronic stepper regulator valve is over-sized. 
     
     
       8. The diagnostic  control system of claim  6    27 , wherein said diagnostic module further monitors and compares a superheat value indicative of evaporator superheat. 
     
     
       9. The diagnostic  control system of  claim 8 , wherein said alert module issues an alert signal when said valve position of said electronic stepper regulator valve is approximately one hundred percent for approximately ninety percent of said defined period of time, said error value percentage is approximately zero percent, and said superheat value is approximately greater than 5° F., said alert signal indicating said electronic stepper regulator valve is undersized. 
     
     
       10. The diagnostic  control system of  claim 8 , wherein said diagnostic module further monitors and compares an evaporator coil inlet temperature value indicative of evaporator coil inlet temperature. 
     
     
       11. The diagnostic  control system of  claim 10 , wherein said alert module issues an alert signal when said error value percentage is approximately zero percent, said valve position of said electronic stepper regulator valve is approximately zero percent for approximately one hundred percent of said defined period of time, said evaporator coil inlet temperature value is less than approximately 32° F., and said superheat value is approximately greater than 5° F., said alert signal indicating said electronic stepper regulator valve is stuck open. 
     
     
       12. The diagnostic  control system of  claim 10 , wherein said error value percentage is approximately zero percent, said valve position of said electronic stepper regulator valve is approximately one hundred percent for approximately one hundred percent of said defined period of time, said evaporator coil inlet temperature value is approximately greater than 32° F., and said superheat value is approximately greater than 5° F., said alert signal indicating said electronic stepper regulator valve is stuck closed. 
     
     
       13. The diagnostic  control system of  claim 10 , wherein said diagnostic module further monitors and compares an evaporator coil exit temperature value indicative of evaporator coil exit temperature. 
     
     
       14. The diagnostic  control system of  claim 13 , wherein said alert module issues an alert signal when said valve position of said electronic stepper regulator valve is approximately one hundred percent for approximately one hundred percent of said defined period of time, said error value percentage is approximately zero, said superheat value is approximately less than 5° F., said evaporator coil inlet temperature value is approximately less than 25° F., and said evaporator coil exit temperature value is less than said evaporator coil inlet temperature value for greater than fifty percent of said defined period of time, said alert signal indicating that air flow to an evaporator is blocked or evaporator fans are not operating properly. 
     
     
       15. The control system of  claim 2 , wherein said cooling system device is selected from a group comprising: an expansion device, a fan, a compressor, and a refrigerant control device. 
     
     
       16. The control system of  claim 15 , wherein said expansion device is at least one of an orifice, thermal expansion valve, and electronic expansion valve. 
     
     
       17. The control system of  claim 15 , wherein said refrigerant control device is an evaporator stepper regulator. 
     
     
       18. The control system of  claim 15 , wherein said fan is a variable speed fan. 
     
     
       19. The control system of  claim 15 , wherein said fan is a condenser fan. 
     
     
       20. The control system of  claim 19 , wherein said condenser fan is a variable speed fan. 
     
     
       21. The control system of  claim 2 , wherein said module includes said diagnostic module and an alert module. 
     
     
       22. The control system of  claim 21 , wherein said alert module issues said signal. 
     
     
       23. The control system of  claim 2 , wherein said signal is an alert signal. 
     
     
       24. A control system comprising:
   a controller operable to produce a variable duty cycle control signal for controlling an electronic stepper regulator valve in which said duty cycle is a function of demand for cooling; and        a module associated with said controller and operable to compare said duty cycle with a predetermined value indicative of a system condition and issue a signal when said duty cycle bears a predetermined relationship to said fault value.     
     
     
       25. The control system of  claim 5 , wherein said module includes a diagnostic module and an alert module, said diagnostic module comparing said duty cycle with said predetermined value, and said alert module issuing said signal, said predetermined value being said fault value and said signal being an alert signal. 
     
     
       26. The control system of  claim 24 , wherein said module includes a diagnostic module and an alert module. 
     
     
       27. The control system of  claim 26 , wherein said diagnostic module compares said duty cycle with said predetermined value. 
     
     
       28. The control system of  claim 26 , wherein said alert module issues said signal. 
     
     
       29. The control system of  claim 24 , wherein said signal is an alert signal. 
     
     
       30. The control system of  claim 24 , further comprising an expansion device controlled by said variable duty cycle. 
     
     
       31. The control system of  claim 24 , further comprising a fan controlled by said variable duty cycle. 
     
     
       32. The control system of  claim 24 , wherein said controller is operable to control a fan based on said duty cycle. 
     
     
       33. The control system of  claim 32 , further comprising an expansion device controlled by said variable duty cycle. 
     
     
       34. The control system of  claim 32 , wherein said fan is a variable speed fan. 
     
     
       35. The control system of  claim 34 , wherein said fan is a condenser fan. 
     
     
       36. The control system of  claim 24 , wherein said controller is operable to control a compressor based on said duty cycle. 
     
     
       37. The control system of  claim 36 , further comprising an expansion device controlled by said variable duty cycle. 
     
     
       38. The control system of  claim 36 , further comprising a variable speed fan controlled by said controller. 
     
     
       39. The control system of  claim 38 , wherein said controller controls said fan based on a current operating duty cycle of said compressor.