U.S. patent application number 10/957067 was filed with the patent office on 2006-04-06 for modular header system.
This patent application is currently assigned to Hussmann Corporation. Invention is credited to Daniel Tamburrino.
Application Number | 20060070400 10/957067 |
Document ID | / |
Family ID | 36124214 |
Filed Date | 2006-04-06 |
United States Patent
Application |
20060070400 |
Kind Code |
A1 |
Tamburrino; Daniel |
April 6, 2006 |
Modular header system
Abstract
The present invention provides a header module adapted for use
with a retail store refrigeration system including a plurality of
refrigerated merchandisers. The header module includes a first
conduit defining at least a portion of a common suction header
adapted to carry low-pressure gaseous refrigerant received from the
plurality of refrigerated merchandisers and a second conduit
defining at least a portion of a common liquid header adapted to
carry compressed liquid refrigerant for discharge to the plurality
of refrigerated merchandisers. The first and second conduits are
integrally formed.
Inventors: |
Tamburrino; Daniel; (Dacula,
GA) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH, LLP
100 E WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Assignee: |
Hussmann Corporation
Bridgeton
MO
|
Family ID: |
36124214 |
Appl. No.: |
10/957067 |
Filed: |
October 1, 2004 |
Current U.S.
Class: |
62/504 ;
62/151 |
Current CPC
Class: |
F25B 41/22 20210101;
F25B 41/40 20210101; F25B 2500/18 20130101; F25B 47/022 20130101;
F25B 39/02 20130101; F25B 5/02 20130101; F25B 2400/22 20130101 |
Class at
Publication: |
062/504 ;
062/151 |
International
Class: |
F25B 49/00 20060101
F25B049/00; F25D 21/06 20060101 F25D021/06; F25B 39/02 20060101
F25B039/02 |
Claims
1. A header module adapted for use with a retail store
refrigeration system including a plurality of refrigerated
merchandisers, the header module comprising: a first conduit
defining at least a portion of a common suction header adapted to
carry low-pressure gaseous refrigerant received from the plurality
of refrigerated merchandisers; and a second conduit defining at
least a portion of a common liquid header adapted to carry
compressed liquid refrigerant for discharge to the plurality of
refrigerated merchandisers, wherein the first and second conduits
are integrally formed.
2. The header module of claim 1, further comprising: a first end
plate coupling the first conduit and second conduit; and a second
end plate coupling the first conduit and second conduit, the second
end plate positioned on the header module opposite the first end
plate.
3. The header module of claim 2, wherein the first and second end
plates are configured with grooves, and wherein the header module
includes a key configured to be selectively received within at
least one of the grooves of the first and second end plates.
4. The header module of claim 3, wherein the key is configured with
a dovetail shape.
5. The header module of claim 1, further comprising a suction inlet
passageway through the header module and in communication with the
first conduit.
6. The header module of claim 5, further comprising a suction
coupling positioned in the suction inlet passageway, wherein the
suction coupling is configured to receive a refrigeration line
carrying low-pressure gaseous refrigerant from at least one of the
plurality of refrigerated merchandisers.
7. The header module of claim 5, further comprising: a suction
valve positioned in the suction inlet passageway, the suction valve
being controllable to regulate flow of low-pressure gaseous
refrigerant through the suction inlet passageway; and a suction
isolation valve positioned in the suction inlet passageway to
selectively block flow of low-pressure gaseous refrigerant through
the suction inlet passageway.
8. The header module of claim 1, further comprising a liquid outlet
passageway through the header module and in communication with the
second conduit.
9. The header module of claim 8, further comprising a liquid
coupling positioned in the liquid outlet passageway, wherein the
liquid coupling is configured to receive a refrigeration line for
carrying compressed liquid refrigerant to at least one of the
plurality of refrigerated merchandisers.
10. The header module of claim 8, further comprising: a liquid
valve positioned in the liquid outlet passageway, the liquid valve
being controllable to regulate flow of compressed liquid
refrigerant through the liquid outlet passageway; and a liquid
isolation valve positioned in the liquid outlet passageway to
selectively block flow of compressed liquid refrigerant through the
liquid outlet passageway.
11. The header module of claim 1, further comprising: a third
conduit defining at least a portion of a common gas defrost header
adapted to carry superheated, compressed gaseous refrigerant for
selective discharge to the plurality of refrigerated merchandisers,
wherein the first, second, and third conduits are integrally
formed.
12. The header module of claim 11, further comprising a gas defrost
passageway through the header module and in communication with the
third conduit.
13. The header module of claim 12, further comprising: a gas
defrost valve positioned in the gas defrost passageway, the gas
defrost valve being controllable to regulate flow of superheated,
compressed gaseous refrigerant through the gas defrost passageway;
and a gas defrost isolation valve positioned in the gas defrost
passageway to selectively block flow of superheated, compressed
gaseous refrigerant through the gas defrost passageway.
14. The header module of claim 12, further comprising a suction
inlet passageway through the header module and in communication
with an evaporator in one of the plurality of refrigerated
merchandisers, wherein the gas defrost passageway is selectively
fluidly connected with the suction inlet passageway to deliver
superheated, compressed gaseous refrigerant to the evaporator.
15. A modular header system adapted for use with a retail store
refrigeration system, the modular header system comprising: a first
header module including a first conduit defining at least a portion
of a common suction header adapted to carry low-pressure gaseous
refrigerant; and a second conduit defining at least a portion of a
common liquid header adapted to carry compressed liquid
refrigerant; wherein the first conduit and second conduit of the
first header module are integrally formed; and a second header
module including a first conduit defining at least a portion of the
common suction header; a second conduit defining at least a portion
of the common liquid header; wherein the first conduit and second
conduit of the second header module are integrally formed, and
wherein the second header module is coupled to the first header
module to fluidly couple the first conduits of the common suction
header and the second conduits of the common liquid header.
16. The modular header system of claim 15, wherein the first header
module includes a plate positioned toward respective ends of the
first conduit and second conduit of the first header module, and
wherein the second header module includes a plate positioned toward
respective ends of the first conduit and second conduit of the
second header module.
17. The modular header system of claim 16, wherein the first and
second plates are configured with grooves, wherein the modular
header system further comprises a key, and wherein the grooves are
configured to receive the key.
18. The modular header system of claim 17, wherein the key is
configured with a dovetail shape.
19. The modular header system of claim 15, further comprising a
suction inlet passageway through each of the first and second
header modules, the suction inlet passageways communicating with
the respective first conduits of the common suction header.
20. The modular header system of claim 19, further comprising a
suction coupling positioned in each suction inlet passageway,
wherein the suction couplings are each configured to receive a
refrigeration line carrying low-pressure gaseous refrigerant from a
respective refrigerated merchandiser.
21. The modular header system of claim 19, further comprising: a
suction valve positioned in each of the suction inlet passageways
of the first and second header modules, the suction valves being
controllable to regulate flow of low-pressure gaseous refrigerant
through the respective suction inlet passageways; and a suction
isolation valve positioned in each of the suction inlet passageways
to selectively block flow of low-pressure gaseous refrigerant
through the respective suction inlet passageways.
22. The modular header system of claim 15, further comprising a
liquid outlet passageway through each of the first and second
header modules, the liquid outlet passageways communicating with
the respective second conduits of the common liquid header.
23. The modular header system of claim 22, further comprising a
liquid coupling positioned in each liquid outlet passageway,
wherein the liquid couplings are each configured to receive a
refrigeration line carrying compressed liquid refrigerant to a
respective refrigerated merchandiser.
24. The modular header system of claim 22, further comprising: a
liquid valve positioned in each of the liquid outlet passageways of
the first and second header modules, the liquid valves being
controllable to regulate flow of compressed liquid refrigerant
through the respective liquid outlet passageways; and a liquid
isolation valve positioned in each of the liquid outlet passageways
to selectively block flow of compressed liquid refrigerant through
the respective liquid outlet passageways.
25. The modular header system of claim 15, wherein the first header
module includes a third conduit defining at least a portion of a
common gas defrost header adapted to carry superheated, compressed
gaseous refrigerant, wherein the first, second, and third conduits
of the first header module are integrally formed, wherein the
second header module includes a third conduit defining at least a
portion of the common gas defrost header, wherein the first
conduit, second conduit, and the third conduit of the second header
module are integrally formed, and wherein the second header module
is coupled to the first header module to fluidly couple the third
conduits of the common gas defrost header.
26. The modular header system of claim 25, further comprising a gas
defrost passageway through each of the first and second header
modules, the gas defrost passageways communicating with the
respective third conduits of the common gas defrost header.
27. The modular header system of claim 26, further comprising: a
gas defrost valve positioned in each of the gas defrost passageways
of the first and second header modules, the gas defrost valves
being controllable to regulate flow of superheated, compressed
gaseous refrigerant through the respective gas defrost passageways;
and a gas defrost isolation valve positioned in each of the gas
defrost passageways to selectively block flow of superheated,
compressed gaseous refrigerant through the respective gas defrost
passageways.
28. The modular header system of claim 26, further comprising a
suction inlet passageway through each of the first and second
header modules, the respective suction inlet passageways
communicating with an evaporator in a refrigerated merchandiser,
wherein the gas defrost passageways are selectively fluidly
connected with the respective suction inlet passageways of the
first and second header modules to deliver superheated, compressed
gaseous refrigerant to the respective evaporators.
29. The modular header system of claim 25, wherein one of the first
and second header modules is coupled to a suction inlet of a
compressor via a first refrigeration line, wherein the one of the
first and second header modules is coupled to an outlet of a liquid
receiver via a second refrigeration line, and wherein the one of
the first and second header modules is coupled to a discharge
outlet of the compressor via a third refrigeration line.
30. The modular header system of claim 25, further comprising a
valve positioned downstream of a discharge outlet of a compressor
and upstream of the common liquid header defined by the first and
second header modules, wherein the valve selectively causes a
pressure differential between the common liquid header and the
common gas defrost header defined by the first and second header
modules.
31. A method of assembling a retail store refrigeration system
including a plurality of refrigerated merchandisers, the method
comprising: providing a first header module including a first
conduit defining at least a portion of a common suction header
adapted to carry low-pressure gaseous refrigerant received from the
plurality of refrigerated merchandisers; a second conduit defining
at least a portion of a common liquid header adapted to carry
compressed liquid refrigerant for discharge to the plurality of
refrigerated merchandisers, the first conduit and second conduit of
the first header module being integrally formed; providing a second
header module including a first conduit defining at least a portion
of the common suction header; a second conduit defining at least a
portion of the common liquid header; the first conduit and the
second conduit of the second header module being integrally formed;
interconnecting the second header module with the first header
module; and fluidly coupling the first conduits of the common
suction header and the second conduits of the common liquid
header.
32. The method of claim 31, wherein providing a first header module
includes providing a first header module having a third conduit
defining at least a portion of a common gas defrost header adapted
to carry superheated, compressed gaseous refrigerant for selective
discharge to the plurality of refrigerated merchandisers, the first
conduit, second conduit, and the third conduit of the first header
module being integrally formed, wherein providing a second header
module includes providing a second header module having a third
conduit defining at least a portion of the common gas defrost
header, the first conduit, second conduit, and the third conduit of
the second header module being integrally formed, wherein fluidly
coupling includes fluidly coupling the third conduits of the common
gas defrost header.
33. The method of claim 32, wherein interconnecting the second
header module with the first header module includes engaging a key
with grooves located on the first and second header modules.
34. The method of claim 32, further comprising controlling a
suction valve positioned in a suction inlet passageway in at least
one of the first and second header modules to regulate flow of
low-pressure gaseous refrigerant through the suction inlet
passageway of the at least one of the first and second header
modules.
35. The method of claim 34, further comprising: controlling the
suction valve to block flow of low-pressure gaseous refrigerant
through the suction inlet passageway of at least one of the first
and second header modules; and controlling a gas defrost valve
positioned in a gas defrost passageway in the at least one of the
first and second header modules to regulate flow of superheated,
compressed gaseous refrigerant through the gas defrost passageway
and through the suction inlet passageway of the at least one of the
first and second header modules.
36. The method of claim 32, further comprising controlling a liquid
valve positioned in a liquid outlet passageway in at least one of
the first and second header modules to regulate flow of compressed
liquid refrigerant through the liquid outlet passageway of the at
least one of the first and second header modules.
37. The method of claim 32, further comprising: coupling one of the
first and second header modules to a suction inlet of a compressor
via a first refrigeration line; coupling the one of the first and
second header modules to an outlet of a liquid receiver via a
second refrigeration line; and coupling the one of the first and
second header modules to a discharge outlet of the compressor via a
third refrigeration line.
38. The method of claim 32, further comprising: mounting a suction
coupling in a suction inlet passageway in at least one of the first
and second header modules; securing a refrigeration line to the
suction coupling; and fluidly connecting the refrigeration line to
an outlet of an evaporator in one of the plurality of refrigerated
merchandisers.
39. The method of claim 38, wherein securing the refrigeration line
to the suction coupling includes brazing the refrigeration line to
the suction coupling.
40. The method of claim 32, further comprising: mounting a liquid
coupling in a liquid outlet passageway in at least one of the first
and second header modules; securing a refrigeration line to the
liquid coupling; and fluidly connecting the refrigeration line to
an inlet of an evaporator in one of the plurality of refrigerated
merchandisers.
41. The method of claim 40, wherein securing the refrigeration line
to the liquid coupling includes brazing the refrigeration line to
the liquid coupling.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to a refrigeration system,
and more particularly to a refrigeration system comprising one or
more refrigerated merchandisers or refrigerated display cases.
BACKGROUND OF THE INVENTION
[0002] Retail store refrigeration systems typically comprise a
plurality of refrigerated merchandisers to store refrigerated
products in a retail area. Each refrigerated merchandiser typically
includes one or more evaporators to cool the airflow circulating
through the merchandiser. However, the other components of the
refrigeration system, such as one or more compressors and
condensers, are typically located in an area of the retail store
separate from the retail area. To transport compressed liquid
refrigerant from the outlet of the condenser to the plurality of
merchandisers in the retail area, a complete header system is
typically constructed from copper tubing and conventional valves
for each merchandiser. Such a complete header system is sufficient
to transport refrigerant to and from the evaporator in the
merchandiser during both a refrigeration cycle and a defrost
cycle.
[0003] Each complete header system typically includes a suction
header, which allows multiple suction lines from the merchandiser
lineups to be distributed to the suction inlet of multiple
compressors serving that suction group. A complete header system
also typically includes a liquid header, which provides a common
compressed liquid refrigerant from the condenser outlet, to be
distributed among multiple branch liquid lines serving the
merchandiser lineups. A complete header system further includes a
gas defrost header which allows superheated refrigerant from the
compressor to flow through the merchandiser's evaporators during a
defrost cycle. The suction header, liquid header, and the gas
defrost header are typically custom-made for each retail store
refrigeration system using skilled labor. Sections of copper tubing
are brazed together to form the headers, sometimes on-site in the
retail store.
SUMMARY OF THE INVENTION
[0004] The present invention provides, in one aspect, a header
module adapted for use with a retail store refrigeration system
including a plurality of refrigerated merchandisers. The header
module includes a first conduit defining at least a portion of a
common suction header adapted to carry low-pressure gaseous
refrigerant received from the plurality of refrigerated
merchandisers and a second conduit defining at least a portion of a
common liquid header adapted to carry compressed liquid refrigerant
for discharge to the plurality of refrigerated merchandisers. The
first and second conduits are integrally formed. In some
embodiments, an integrally-formed third conduit defines at least a
portion of a common gas defrost header and is adapted to carry
superheated, compressed gaseous refrigerant for selective discharge
to the plurality of refrigerated merchandisers.
[0005] The present invention provides, in another aspect, a modular
header system adapted for use with a retail store refrigeration
system. The modular header system includes a first header module
having a first conduit defining at least a portion of a common
suction header adapted to carry low-pressure gaseous refrigerant
and a second conduit defining at least a portion of a common liquid
header adapted to carry compressed liquid refrigerant. The first
conduit and second conduit of the first header module are
integrally formed. The modular header system also includes a second
header module having a first conduit defining at least a portion of
the common suction header and a second conduit defining at least a
portion of the common liquid header. The first conduit and second
conduit of the second header module are integrally formed. The
second header module is coupled to the first header module to
fluidly couple the first conduits of the common suction header and
the second conduits of the common liquid header.
[0006] The present invention provides, in yet another aspect, a
method of assembling a retail store refrigeration system including
a plurality of refrigerated merchandisers. The method includes
providing first and second header modules, interconnecting the
second header module with the first header module, and fluidly
coupling the first conduits of the common suction header and the
second conduits of the common liquid header.
[0007] Other features of the invention will become apparent to
those skilled in the art upon review of the following detailed
description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a header module of the
present invention.
[0009] FIG. 2 is a reverse perspective view of the header module of
FIG. 1.
[0010] FIG. 3 is a cross-sectional view through section line 3-3 of
the header module of FIG. 1.
[0011] FIG. 4 is a schematic illustrating the header module of FIG.
1 incorporated into a retail store refrigeration system.
[0012] Before any features of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangements
of the components set forth in the following description or
illustrated in the drawings. The invention is capable of other
embodiments and of being practiced or being carried out in various
ways. Also, it is understood that the phraseology and terminology
used herein is for the purpose of description and should not be
regarded as limiting. The use of "including", "having", and
"comprising" and variations thereof herein is meant to encompass
the items listed thereafter and equivalents thereof as well as
additional items. The use of letters to identify elements of a
method or process is simply for identification and is not meant to
indicate that the elements should be performed in a particular
order.
DETAILED DESCRIPTION
[0013] FIGS. 1 and 4 illustrate a header module 10 adapted to
fluidly connect one or more evaporators 14 in a refrigerated
merchandiser 18 with other components in a retail store
refrigeration system, such as one or more compressors 22 and
condensers 26. In such a retail store refrigeration system, the
refrigerated merchandiser 18 is located in a retail area, while the
compressors 22 and condensers 26 can be located in an area of the
retail store separate from the retail area. For example, the
compressors 22 may be located in a machine room separate from the
retail area, and the condensers 26 may be positioned on a rooftop
of the retail store.
[0014] As shown in FIG. 1, the header module 10 includes a
pre-assembled unit or body 30, made from plastic, metal, or other
material, that incorporates a suction valve system in communication
with a suction conduit 38, a liquid delivery valve system in
communication with a liquid conduit 46, and a gas defrost valve
system in communication with a gas defrost conduit 54. The suction
conduit 38, liquid conduit 46, and the gas defrost conduit 54 are
integrally formed with the body 30 and each other. A plurality of
header modules 10 may be interconnected, such that the plurality of
suction conduits 38, liquid conduits 46, and gas defrost conduits
54 form a common suction header 58, a common liquid header 62, and
a common gas defrost header 66, respectively, of a desired length
(see FIG. 4). In some embodiments, header modules 10 only include
two of the three common headers 58, 62, 66. For example, the header
modules 10 can include only common suction and liquid headers 58,
62.
[0015] With reference to FIG. 1, the plurality of interconnected
header modules 10 may provide a separate valve system for each
respective refrigerated merchandiser 18 in the retail store. The
header modules 10 are interconnected by mating end plates 70 that
are fastened together by inter-engaging keys 74 and keyways 78. In
the illustrated construction of the header module 10, the keys 74
and keyways 78 are configured in a dove-tail shape. Alternatively,
typical fasteners such as bolts or clamps may be used to
interconnect the header modules 10. On each header module 10,
O-rings 82 may be positioned at one or both ends of the suction
conduit 38, liquid conduit 46, and the gas defrost conduit 54 to
seal against an adjacent suction conduit 38, liquid conduit 46, and
gas defrost conduit 54 of adjacent header modules 10.
[0016] With reference to FIGS. 3 and 4, the suction valve system is
in fluid communication between the evaporators 14 and the
compressor 22. The suction valve system includes a suction coupling
86 positioned within a bore 90 of the body 30, a controllable
suction valve 94 positioned within a bore 98 of the body 30, and a
suction isolation valve 102 positioned within a bore 106 of the
body 30. The bores 90, 98 are in fluid communication with one
another via a connecting passage 92, while the bores 98, 106 are in
fluid communication with one another via another connecting passage
104. The bore 106 is in fluid communication with the suction
conduit 38 via yet another connecting passage 108. As such, a
combination of the bores 90, 98, 106 and connecting passages 92,
104, 108 generally define a suction inlet passageway. In operation,
when the suction isolation valve 102 is open, the suction valve 94
may be automatically or manually controlled to regulate the amount
of low-pressure, gaseous refrigerant that is received from the
remote evaporators 14 through the suction coupling 86 and
discharged to the suction header 58.
[0017] The suction valve 94 may, in one construction of the header
module 10, be a suction-stop EPR valve controlled by a solenoid
(not shown) to either open the suction-stop EPR valve to regulate
the flow across the suction-stop EPR valve or close the
suction-stop EPR valve. In addition, the suction valve 94 may be,
in another construction of the header module 10, a non-suction stop
EPR valve that is either manually opened to regulate the flow
across the non-suction stop EPR valve or closed. Alternatively, the
suction valve 94 may be replaced by a suction-stop solenoid that
may be selectively opened to allow unregulated flow therethrough.
The controllable suction valve 94 may be a cartridge-type valve.
Such a cartridge-type valve is available from the Parker Hannifin
Corporation. Alternatively, the suction valve 94 may be an
electronically controlled valve, such as a screw-operated valve
actuated by a servo-motor.
[0018] The suction isolation valve 102 may be utilized during
servicing of the corresponding refrigerated merchandiser 18 to, for
example, isolate the refrigerated merchandiser 18 from the rest of
the refrigerated merchandisers 18 in the retail store refrigeration
system. In other words, when the suction isolation valve 102 is
closed, the flow of low-pressure gaseous refrigerant through the
suction inlet passageway is blocked. This may be desirable when
repairing or replacing the evaporator(s) 14 in the refrigerated
merchandiser 18, or when repairing or replacing the controllable
suction valve 94. The suction isolation valve 102 may be, for
example, a quarter-turn ball valve that may be manually opened and
closed. Such a quarter-turn ball valve is also available from the
Parker Hannifin Corporation.
[0019] With reference to FIGS. 3 and 4, the liquid delivery valve
system is in fluid communication between the liquid header 62 and
the evaporator(s) 14 in the refrigerated merchandisers 18. The
liquid delivery valve system includes a liquid coupling 110
positioned within a bore 114 of the body 30, a controllable liquid
valve 118 positioned within a bore 122 of the body 30, and a liquid
isolation valve 126 positioned within a bore 130 of the body 30.
The bores 114, 122 are in fluid communication with one another via
a connecting passage 116, while the bores 122, 130 are in fluid
communication with one another via another connecting passage 124.
The bore 130 is in fluid communication with the liquid conduit 46
via yet another connecting passage 132. As such, a combination of
the bores 114, 122, 130 and connecting passages 116, 124, 132
generally define a liquid outlet passageway. In operation, when the
liquid isolation valve 126 is open, the liquid valve 118 may be
automatically or manually controlled to regulate the amount of
compressed liquid refrigerant that is allowed to flow to the remote
evaporators 14 through the liquid coupling 110 from the liquid
header 62.
[0020] Like the suction valve 94, the liquid valve 118 may be a
liquid-stop valve controlled by a solenoid (not shown), a
non-liquid stop valve that is manually adjusted, a liquid-stop
solenoid, a cartridge-type valve, or an electronically controlled
valve, such as a screw-operated valve actuated by a
servo-motor.
[0021] Like the suction isolation valve 102, the liquid isolation
valve 126 may be utilized during servicing of the corresponding
refrigerated merchandiser 18. The liquid isolation valve 126 may
also be, for example, a quarter-turn ball valve that may be
manually opened and closed.
[0022] With continued reference to FIGS. 3 and 4, the gas defrost
valve system is in fluid communication between the outlet of the
compressor 22 and the remote evaporators 14 through the suction
coupling 86. In some embodiments, the gas defrost valve system is
in fluid communication with the outlet of the compressor 22 while
in other embodiments the gas defrost valve system is in fluid
communication with a receiver RC downstream of the condensers CN.
Also, in other embodiments, the gas within the common gas defrost
header 66 can be used as a high pressure source to operate certain
pilot valves (such as a high pressure source to modulate the piston
of a electronic pressure regulating valve).
[0023] The gas defrost valve system includes a controllable gas
defrost valve 134 positioned within a bore 138 of the body 30, and
a gas defrost isolation valve 142 positioned within a bore 146 of
the body 30. The bores 90, 138 are in fluid communication with one
another via a connecting passage 140, while the bores 138, 146 are
in fluid communication with one another via another connecting
passage 148. The bore 146 is in fluid communication with the gas
defrost conduit 54 via yet another connecting passage 152. As such,
a combination of the bores 90, 138, 146 and connecting passages
140, 148, 152 generally define a gas defrost passageway. In
operation, when the gas defrost isolation valve 142 is open, the
gas defrost valve 134 may be automatically or manually controlled
to regulate the amount of superheated, compressed gaseous
refrigerant that is discharged to the remote evaporators 14 through
the suction coupling 86 from the outlet of the compressor 22.
[0024] Like the suction valve 94 and the liquid valve 118, the gas
defrost valve 134 may be a vapor-stop valve controlled by a
solenoid (not shown), a non-vapor stop valve that is manually
adjusted, a vapor-stop solenoid, a cartridge-type valve, or an
electronically controlled valve, such as a screw-operated valve
actuated by a servo-motor.
[0025] Like the suction isolation valve 102 and the liquid
isolation valve 126, the gas defrost isolation valve 142 may be
utilized during servicing of the corresponding refrigerated
merchandiser 18. The gas defrost isolation valve 142 may also be,
for example, a quarter-turn ball valve that may be manually opened
and closed.
[0026] The valves 94, 102, 118, 126, 134, 142 and the couplings 86,
110 are joined to the body 30 by fastening mating flanges 150
together. Alternatively, other fastening structure may be utilized
to secure the valves 94, 118, 134 and the couplings 86, 110 to the
body 30, such as threaded fittings and/or quick-release
fittings.
[0027] With reference to FIG. 4, a schematic illustrating a retail
store refrigeration system incorporating the header module 10 of
the present invention is shown. For illustrative purposes only,
FIG. 4 shows only two header modules 10. However, it should be
understood that any number of header modules 10 may be
interconnected in the retail store refrigeration system. In
addition, a controller (not shown) may be electrically connected to
one or more of the header modules 10 to control operation of one or
more of the suction valve 94, liquid valve 118, and the gas defrost
valve 134.
[0028] A first header module H1 is shown in fluid communication
with a first refrigerated merchandiser M1. Although not shown in
FIG. 4, an adapter plate including a suction header coupling, a
liquid header coupling, and a gas defrost header coupling is
coupled to the first header module H1. The adapter plate includes
keyways configured to receive the dovetail-shaped keys 74 engaged
with the first header module H1. The O-rings 82 (see FIG. 1) on the
first header module H1 respectively seal the suction header
coupling to the suction header 58, the liquid header coupling to
the liquid header 62, and the gas defrost header coupling to the
gas defrost header 66.
[0029] Respective refrigeration lines R1, R2, R3 may be fluidly
connected to the couplings to transport refrigerant to the first
header module H1 or away from the first header module H1. Such
refrigeration lines R1, R2, R3 may be formed from copper tubing
that is inserted into the couplings and brazed to the couplings.
Alternatively, the couplings may include quick-release structure to
fluidly connect with the refrigeration lines R1, R2, R3, or the
couplings may include structure requiring hand tools to fluidly
connect with the refrigeration lines R1, R2, R3.
[0030] With continued reference to FIG. 4, a second header module
H2 is shown in fluid communication with a second refrigerated
merchandiser M2. The second header module H2 may directly
interconnect with the first header module H1 by inter-engaging the
keys 74, or, alternatively, additional header modules 10 may be
positioned between the first and second header modules H1, H2 to
fluidly communicate with additional refrigerated merchandisers
18.
[0031] If the second header module H2 is to be the last module 10
in a line or system of interconnected modules 10, an end plate 154
may be utilized to close or cap the ends of the respective headers
58, 62, 66. Although the end plate 154 is shown schematically in
FIG. 4, the end plate 154 may include dovetail-shaped keyways to
inter-engage the dovetail-shaped keyways 78 of the second header
module H2 via keys 74. The end plate 154 may also include O-rings
to seal the respective headers 58, 62, 66 to the end plate 154.
[0032] Other components in the retail store refrigeration system
are also shown in FIG. 4. The suction inlet of a compressor C is
fluidly connected to the suction header coupling via the
refrigeration line R1. Alternatively, more than one compressor 22
may be utilized in either a parallel or series arrangement. For
example, two or three header modules 10 may be utilized for each
compressor 22 in the refrigeration system. From the discharge
outlet of the compressor C, another refrigeration line R4 fluidly
connects the compressor C with the inlet of a condenser CN to
discharge compressed gaseous refrigerant to the condenser CN.
Alternatively, more than one condenser CN may be utilized in either
a parallel or series arrangement. In addition, the refrigeration
line R2 is fluidly connected to the outlet of the compressor C and
the gas defrost header coupling to transport heated, compressed
gaseous refrigerant to the gas defrost header 66. In the
illustrated schematic, the refrigeration line R2 taps into or
fluidly connects with refrigeration line R4 to communication with
the outlet of the compressor C. Alternatively, the compressor C may
incorporate a second discharge outlet (not shown) to directly
connect to the refrigeration line R2.
[0033] From the outlet of the condenser CN, compressed liquid
refrigerant is discharged for accumulation in a receiver RC. From
the receiver RC, the compressed liquid refrigerant flows through a
defrost differential valve DDV before being transported to the
liquid header 62 via the refrigeration line R3. Alternatively, the
defrost differential valve DDV may be positioned upstream of the
condenser CN and downstream of where the refrigerant line R2 taps
into or fluidly connects with the refrigerant line R4. The defrost
differential valve DDV is operable to cause a relatively small
pressure drop across the valve DDV and is discussed in more detail
below.
[0034] The first refrigerated merchandiser M1 is shown operating in
a normal refrigeration mode, whereby compressed liquid refrigerant
is transported to the merchandiser M1, and low-pressure gaseous
refrigerant is transported from the merchandiser M1. More
particularly, in the first header module H1 (see FIG. 3), the
liquid isolation valve 126 is opened and the liquid valve 118 is
controlled to allow a metered amount of compressed liquid
refrigerant to exit the first header module H1 via the liquid
coupling 110.
[0035] From the liquid coupling 110, as shown in FIG. 4, the
compressed liquid refrigerant is transported to the first
refrigerated merchandiser M1 via a refrigeration line R5. The
refrigeration line R5 may also be formed from copper tubing that is
inserted into the liquid coupling 110 and brazed to the coupling
110. In the illustrated construction, an expansion valve 158 is
shown positioned in the first refrigerated merchandiser M1 and in
fluid communication with the refrigeration line R5 and a first
evaporator EV1. Alternatively, more than one evaporator 14 may be
utilized in a parallel or series arrangement in the first
refrigerated merchandiser M1.
[0036] During normal refrigeration mode of the first refrigerated
merchandiser M1, low-pressure gaseous refrigerant exits the first
evaporator EV1 and is routed back to the first header module H1 via
another refrigeration line R6. The refrigeration line R6 is fluidly
connected to the suction coupling 86, such that the low-pressure
gaseous refrigerant is transported to the suction header 58 through
the open suction valve 94 and the open suction isolation valve 102.
The refrigeration line R6 may also be formed from copper tubing
that is inserted into the suction coupling 86 and brazed to the
coupling 86. From the suction header 58, the low-pressure gaseous
refrigerant may be drawn into the suction inlet of the compressor C
to repeat the refrigeration cycle.
[0037] Alternatively, the low-pressure gaseous refrigerant may be
drawn into the suction inlet of the compressor C, pressurized by
the compressor C, and discharged from the compressor C for use in a
defrost cycle. The second refrigerated merchandiser M2 is shown
operating in a defrost mode, whereby heated, compressed gaseous
refrigerant is transported to the merchandiser M2, and cooled,
compressed substantially liquid refrigerant is transported back to
the second header module H2 from the merchandiser M2. More
particularly, in the second header module H2 (see FIG. 3), one or
both of the suction isolation valve 102 and the suction valve 94
may close to prevent refrigerant flow into the common suction
header 58. The gas defrost isolation valve 142 may then open, and
the gas defrost valve 142 may control the amount of heated,
compressed gaseous refrigerant that flows out of the gas defrost
header 66 to exit the second header module H2 via the suction
coupling 86.
[0038] From the suction coupling 86 of the second header module H2,
as shown in FIG. 4, the heated, compressed gaseous refrigerant is
transported from the suction coupling 86 to a second evaporator EV2
via another refrigeration line R7. The heated, compressed gaseous
refrigerant may be at least partially condensed while flowing
through the second evaporator EV2, as a result of the heat transfer
from the refrigerant to the second evaporator EV2 to melt
accumulated frost on the evaporator EV2. Subsequently, the cooled,
compressed liquid refrigerant exiting the second evaporator EV2 is
transported back to the second header module H2 via another
refrigeration line R8, which is fluidly connected to the liquid
coupling 110 of the second header module H2.
[0039] With reference to FIG. 3, upon re-entering the second header
module H2, the cooled, compressed liquid refrigerant may flow past
the open liquid valve 118, past the open liquid isolation valve
126, and into the liquid header 62 to mix with compressed liquid
refrigerant discharged from the receiver RC. Thus, the cooled,
compressed liquid refrigerant that was used in a defrost cycle in
the second refrigerated merchandiser M2 may, for example, flow
through the liquid header 62 and be used in a normal refrigeration
cycle in the first refrigerated merchandiser M1.
[0040] As such, one or more header modules 10 in a plurality of
interconnected header modules 10 may be configured, at any given
time, in a defrost mode while other header modules 10 are
configured in a normal refrigeration mode. The previously-mentioned
defrost differential valve DDV permits this to occur. With
reference to FIG. 4, when at least one header module 10 in a
plurality of interconnected header modules 10 switches from a
normal refrigeration mode to a defrost mode, the defrost
differential valve DDV is actuated to cause a relatively small drop
in pressure of the compressed liquid refrigerant across the valve
DDV. This, in effect, creates a relatively small difference in
pressure between the gas defrost header 66 and the liquid header
62. Such a difference in pressure is sufficient to cause the
heated, compressed gaseous refrigerant in the gas defrost header 66
to flow through a particular refrigerated merchandiser 18 in a
defrost mode (e.g., the second refrigerated merchandiser M2) and
return to the liquid header 62 as a cooled, compressed
substantially liquid refrigerant. The defrost differential valve
DDV may, for example, be configured to drop the pressure of the
compressed liquid refrigerant flowing through the valve DDV
approximately 15-30 psi.
[0041] The header modules 10 may be prefabricated, such that they
may be interconnected or assembled to form a complete header system
in a relatively small amount of time. In addition, the method of
assembling or interconnecting the header modules 10 (e.g., by using
the dovetail-shaped keys 74 and keyways 78) decreases the labor
associated with assembling the complete header system since the
skilled labor typically required to braze together complicated
sections of copper tubing is substantially decreased.
* * * * *