U.S. patent application number 14/798949 was filed with the patent office on 2017-01-19 for refrigerant charge and control method for heat pump systems.
The applicant listed for this patent is Nortek Global HVAC LLC. Invention is credited to Jie Chen, Aaron Richard Embry, Aaron D. Herzon.
Application Number | 20170016659 14/798949 |
Document ID | / |
Family ID | 56296650 |
Filed Date | 2017-01-19 |
United States Patent
Application |
20170016659 |
Kind Code |
A1 |
Chen; Jie ; et al. |
January 19, 2017 |
REFRIGERANT CHARGE AND CONTROL METHOD FOR HEAT PUMP SYSTEMS
Abstract
A heat pump system comprises a compressor, at least one
expansion valve, an accumulator for storing a volume of liquid
refrigerant therein, a liquid refrigerant indicator connected to
the accumulator to indicate an appropriate refrigerant charge in
cooling and heating modes, and a controller. The controller is
configured to determine a target compressor discharge pressure
based on measured outdoor air temperature and control the
compressor discharge pressure by modulating the position of the at
least one expansion valve, wherein the higher the target discharge
pressure target, the less liquid refrigerant is left in the
accumulator. The accumulator can be sized to always have capacity
to hold excess refrigerant during heating operations, and can
include a charge level indicator so as to allow proper charge of
the system in the field without additional tools.
Inventors: |
Chen; Jie; (Saint Charles,
MO) ; Herzon; Aaron D.; (Ballwin, MO) ; Embry;
Aaron Richard; (O'Fallon, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nortek Global HVAC LLC |
O'Fallon |
MO |
US |
|
|
Family ID: |
56296650 |
Appl. No.: |
14/798949 |
Filed: |
July 14, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25B 2700/2104 20130101;
F25B 2500/24 20130101; F25B 13/00 20130101; F25B 2700/04 20130101;
F25B 2600/2513 20130101; F25B 45/00 20130101; F25B 2500/19
20130101; F25B 2700/2106 20130101; F25B 49/02 20130101; F25B
2700/1931 20130101; F25B 2500/23 20130101; F25B 43/006
20130101 |
International
Class: |
F25B 45/00 20060101
F25B045/00; F25B 13/00 20060101 F25B013/00 |
Claims
1. A heat pump system comprising: a compressor; at least one
expansion valve; a liquid refrigerant indicator connected to the
accumulator to indicate an appropriate refrigerant charge in
cooling and heating modes; an accumulator continuously storing a
volume of liquid refrigerant therein; and a controller configured
to determine a target compressor discharge pressure based on
outdoor air temperature and control the compressor discharge
pressure by modulating the position of the at least one expansion
valve, wherein the higher the target discharge pressure target, the
less liquid refrigerant is left in the accumulator.
2. The heat pump system of claim 1, further comprising: an indoor
heat exchanger; and an outdoor heat exchanger in fluid
communication with indoor heat exchanger; wherein the at least one
expansion valve is arranged between and modulates the flow of the
refrigerant between the indoor heat exchanger and the outdoor heat
exchanger.
3. The heat pump system of claim 1, wherein modulating a position
of the at least one expansion valve comprises opening and/or
closing the at least one expansion valve causing an orifice size of
the valve to increase or decrease.
4. The heat pump system of claim 1, wherein the accumulator has an
element that is configured to indicate a desired amount for the
volume of liquid refrigerant within the accumulator.
5. The heat pump system of claim 4, wherein the element is
positioned such the volume of the liquid refrigerant when filled to
the desired amount comprises at least a charge difference volume
between a cooling mode of system operation and a heating mode of
system operation and a reserve volume to prevent the accumulator
from being dry or over flow.
6. The heat pump system of claim 5, wherein the element is
positioned to indicate the volume of the liquid refrigerant that is
appropriate regardless of a current mode of system operation and
regardless of a season in which refrigerant is contemplated to be
added to the system.
7. The heat pump system of claim 4, wherein the element comprises
two elements spaced from one another, each of the two elements
indicating the volume of liquid refrigerant in the accumulator that
is appropriate based upon both a current mode of system operation
and one season in which refrigerant is contemplated to be added to
the system.
8. The heat pump system of claim 1, wherein the volume of liquid
refrigerant in the accumulator comprises at least twice as much
refrigerant as a volume difference in refrigerant utilized by the
system between a cooling mode of system operation and a heating
mode of system operation.
9. The heat pump system of claim 1, wherein the controller is
further configured to determine an indoor air temperature and the
compressor discharge pressure is derived from the indoor air
temperature.
10. The heat pump system of claim 1, wherein in a heating mode of
system operation, an indoor air temperature is utilized in
controlling the compressor discharge pressure, and wherein in a
cooling mode of system operation, the outdoor air temperature is
utilized in controlling the compressor discharge pressure.
11. The heat pump system of claim 1, wherein the controller is
further configured to determine a potential for an overflowed
accumulator and increase a compressor discharge pressure target
which modulates the position of the at least one expansion valve to
a more closed position when the overflowed accumulator is
detected.
12. The heat pump system of claim 1, wherein the at least one
expansion valve comprises an assembly of two or more expansion
valves, each of the two or more expansion valves having an
associated check valve.
13. A method comprising: storing a volume of liquid refrigerant
continuously within an accumulator during operation of the heat
pump, the volume of liquid refrigerant comprising an appropriate
amount for both a heating mode and a cooling mode of operation of a
heat pump; determining an outdoor air temperature and a compressor
discharge pressure; and controlling the compressor discharge
pressure based upon the determined outdoor air temperature; wherein
the volume of the liquid refrigerant within the accumulator changes
based upon the discharge pressure.
14. The method of claim 13, further comprising: increasing a
compressor discharge pressure target to modulate the position of
the at least one expansion valve to prevent a overflowed
accumulator; and issuing one of a warning or turning off the heat
pump system if the target discharge pressure reaches a
predetermined high limit to prevent compressor damage.
15. The method of claim 13, further comprising indicating a desired
amount for the volume of liquid refrigerant within the
accumulator.
16. The method of claim 15, wherein the indicating is independent
of a current mode of heat pump operation and a season in which
refrigerant is contemplated to be added to the heat pump.
17. The method of claim 15, wherein the indicating is dependent
upon both a current mode of heat pump operation and a season in
which refrigerant is contemplated to be added to the heat pump.
18. The method of claim 13, further comprising determining an
indoor air temperature and deriving the compressor discharge
pressure from the indoor air temperature.
19. The method of claim 13 further comprising: controlling the
compressor discharge pressure based upon an indoor air temperature
in a heating mode of heat pump operation; and controlling the
compressor discharge pressure based upon the determined outdoor air
temperature in a cooling mode of heat pump operation.
20. An accumulator comprising: a housing configured to house a
continuous volume of liquid refrigerant during both a heating mode
and a cooling mode of operation of a heat pump; and an element that
is configured to indicate a desired amount for the volume of the
liquid refrigerant within the accumulator.
21. The accumulator of claim 20, wherein the element is positioned
such the volume of the liquid refrigerant when filled to the
desired amount comprises at least a liquid refrigerant charge
difference volume between a cooling mode of heat pump operation and
a heating mode of heat pump operation and a reserve volume to
prevent the accumulator from being dry or overflow.
22. The heat pump system of claim 20, wherein the element is
positioned to indicate the volume of the liquid refrigerant that is
appropriate regardless of a current mode of system operation and
regardless of a season in which refrigerant is contemplated to be
added to the system.
23. The heat pump system of claim 20, wherein the element comprises
two elements spaced from one another, each of the two elements
indicating the volume of liquid refrigerant in the accumulator that
is appropriate based upon both a current mode of system operation
and one season in which refrigerant is contemplated to be added to
the system.
Description
COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains
material that is subject to copyright protection. The copyright
owner has no objection to the facsimile reproduction by anyone of
the patent document or the patent disclosure, as it appears in the
Patent and Trademark Office patent files or records, but otherwise
reserves all copyright rights whatsoever. The following notice
applies to the software and data as described below and in the
drawings that form a part of this document: Copyright 2015, Nordyne
LLC. All Rights Reserved.
TECHNICAL FIELD
[0002] This document pertains generally, but not by way of
limitation, to heat pump systems utilizing accumulators, and, more
particularly, this documents relates to refrigerant charge control
in heat pump systems.
BACKGROUND
[0003] Some conventional heat pump systems can perform heating and
cooling of an indoor space by utilizing an indoor heat exchanger
and an outdoor heat exchanger in conjunction with an accumulator.
For example, in order to perform cooling, the indoor heat exchanger
operates as an evaporator and the outdoor heat exchanger operates
as a condenser. In conjunction with an expansion device, the
outdoor condenser is used to lower the temperature of the
refrigerant that is subsequently used to cool air of the indoor
space. The refrigerant is heated with warm indoor air of the indoor
area within the evaporator and then drawn into a compressor for
circulating back to the condenser. Placement of the condenser
outdoors allows heat from the refrigerant to be discharged to
outdoor air. To perform heating, the system operates in
reverse.
[0004] Due to thermodynamic differences in performing heating and
cooling, different refrigerant charge is required during cooling
and heating season for the system to operate at optimum
performances. Additional refrigerant charge differentials can arise
due to the use of different sized heat exchangers. For example, the
indoor heat exchanger is typically smaller in internal volume due
to size constraints imposed by the conditioned space. These factors
result in the system optimally operating at mainly two different
optimum refrigerant charges for heating and cooling. Further, small
refrigerant charge differential can arise as indoor and outdoor
temperatures change within the cooling or heating season. Thus, for
a heat pump to operate at optimum performance, it is desirable to
have multiple different refrigerant charges as the conditions
change. Refrigerant charge can not only affect the performances
such as cooling/heating capacities or energy efficiencies, it can
also affect the heat pump operation. For example, if the
refrigerant charge is added to the system in the winter, the system
may malfunction in the summer.
[0005] Refrigerant charge can be a difficulty for heat pump
installers, especially in the residential air source heat pump
market. In the summer, one of the conventional methods is to
measure the outdoor ambient temperature, and add refrigerant to the
system until certain system parameters fall within the required
range. This kind of methods requires a field installer to carry
sensors and lookup tables. In other systems, additional
instrumentation can be built into the system or provided to the
installer as a tool that will assist in determining the charge
level. During the winter time, charging refrigerant becomes more
difficult. In many cases, the installer has to come back to check
the refrigerant charge at the beginning of the cooling season to
prevent refrigerant charge related issues.
[0006] Reversible heat pump systems often include an accumulator
that is positioned on the low pressure side of the compressor. The
accumulator is useful in preventing ingestion of liquid refrigerant
into the compressor. Liquid refrigerant can cause damage if drawn
into the moving components of the compressor. Accumulators are not
typically used on cooling only heat pump systems.
[0007] Additionally, in order to maintain the proper charge level
of refrigerant in the system, charge compensators can be used on
the high pressure outdoor condenser side. For example, a typical
charge compensator can comprise a tube inside of a shield or
reservoir. During heating operation, flow of cold refrigerant
through the tube causes liquid refrigerant to accumulate in the
reservoir. During cooling operation, hot refrigerant in the tube
causes liquid refrigerant in the reservoir to boil off into vapor.
One such system is described in U.S. Pat. No. 5,136,855 to
Lenarduzzi. By adding a charge compensator, the refrigerant charge
can be more balanced. However, proper charge of the system in the
field is still not resolved. A proper charge in the winter does not
guarantee a proper charge in the summer. Other charge control
devices are described in U.S. Patent Application Pub. No.
2008/0127667 to Buckley et al., U.S. Pat. No. 8,578,731 to Jin,
U.S. Pat. No. 6,227,003 to Smolinsky, and U.S. Pat. No. 5,937,670
to Derryberry.
OVERVIEW
[0008] Systems and methods of the present disclosure address the
above-mentioned issues by providing a refrigerant charge method for
heat pump systems. The presently disclosed systems and methods also
provide a system control method to allow a heat pump system to
operate at optimum refrigerant charge as indoor temperature,
outdoor temperature, or operating modes change.
[0009] The present inventors have recognized, among other things,
that a problem to be solved in heat pump systems can include
accommodating excess refrigerant during heating mode operation as
compared to cooling mode operation. In an example, the present
subject matter can provide a solution to this problem, such as by
using an expansion device with a controllable orifice size that can
be widened to allow more liquid refrigerant to be stored in an
accumulator or that can be narrowed to boil off liquid refrigerant
in the accumulator.
[0010] The present inventors have recognized, among other things,
that a problem to be solved in heat pump systems can include
accommodating differences in refrigerant charge requirement during
summer and winter operation. In an example, the present subject
matter can provide a solution to this problem, such as by using an
accumulator as a refrigerant storage device and charge level
indicator. The accumulator has one or more fill level indicators
positioned so as to indicate the proper charge level in the summer
as well as in the winter. In another example, the present subject
matter provides a control method to optimize the heat pump
performance while allowing the excess refrigerant to be stored in
the accumulator without overfilling the accumulator, and to prevent
the accumulator from running dry during cooling operations.
[0011] A heat pump system comprises a compressor, at least one
expansion valve, an accumulator for storing a volume of liquid
refrigerant therein, a liquid refrigerant indicator connected to
the accumulator to indicate an appropriate refrigerant charge in
cooling and heating modes, and a controller. The controller is
configured to determine a target compressor discharge pressure
based on measured outdoor air temperature and control the
compressor discharge pressure by modulating the position of the at
least one expansion valve, wherein the higher the target discharge
pressure target, the less liquid refrigerant is left in the
accumulator. The accumulator can be sized to always have capacity
to hold excess refrigerant during heating operations, and can
include a charge level indicator so as to allow proper charge of
the system in the field without additional tools.
[0012] This overview is intended to provide an overview of subject
matter of the present patent application. It is not intended to
provide an exclusive or exhaustive explanation of the present
subject matter. The detailed description is included to provide
further information about the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings, which are not necessarily drawn to scale,
like numerals may describe similar components in different views.
Like numerals having different letter suffixes may represent
different instances of similar components. The drawings illustrate
generally, by way of example, but not by way of limitation, various
embodiments discussed in the present document.
[0014] FIG. 1 is a schematic diagram of a heat pump system having a
refrigerant expansion device configured to control charge level in
an accumulator.
[0015] FIG. 2A is a schematic flow chart of the heat pump system of
FIG. 1 showing the system operating in a cooling mode with a
discharge pressure below a target level.
[0016] FIG. 2B is a schematic flow chart of the heat pump system of
FIG. 1 showing the system operating in a heating mode with a
discharge pressure above a target level.
[0017] FIG. 3 is a schematic diagram of a bi-directional electronic
expansion valve assembly suitable for use as the refrigerant
expansion device of FIG. 1.
[0018] FIG. 4 is a schematic diagram showing an accumulator having
a charge level indicator window in an intermediate charge
position.
[0019] FIG. 5 is a schematic diagram showing an accumulator having
charge level indicator windows in summer and winter charge
positions.
[0020] FIG. 6 is a schematic diagram showing a heat pump system
incorporating a heat exchanger for heating water and a level sensor
in the accumulator.
[0021] FIG. 7 is a flow chart diagramming steps for controlling
discharge pressure and refrigerant volume in the heat pump systems
of FIGS. 1-6.
[0022] FIGS. 8A and 8B show the target discharge pressure as a
function of outdoor and indoor air temperature in cooling and
heating season.
[0023] FIG. 9 shows the target discharge pressure as a function of
outdoor air temperature in cooling and heating season.
DETAILED DESCRIPTION
[0024] FIG. 1 is a schematic of heat pump system 10 having
reversing valve 12, first temperature sensor 14A, second
temperature sensor 14B, compressor 16, accumulator 18, outdoor heat
exchanger 20, expansion device 22 and indoor heat exchanger 24,
which are connected in series through refrigerant lines 25A-25G to
form a vapor-compression circuit for conditioning indoor air
A.sub.I of space 26.
[0025] System 10 is connected to a digital control system, which
includes controller 28, outdoor fan 30 and indoor fan 32. Based
upon factors such as outdoor air temperature T.sub.1 and indoor air
temperature T.sub.2 sensed by sensors 14A and 14B, respectively,
measured discharge pressure P.sub.D and target discharge pressure
P.sub.T, which can be determined by temperatures T.sub.1 and
T.sub.2, controller 28 operates fans 30 and 32, compressor 16,
valve 12 and expansion device 22 to provide conditioned air to
space 26.
[0026] System 10 may also include, although not shown, other valves
that can be used for various purposes such as service valves used
to control draining of fluid from system 10, check valves
configured to prevent back flow of fluid through system 10, or
level sensors for determining the amount of fluid in the
accumulator 18. System 10 may also include other components, such
as a drier that operates to remove moisture from the refrigerant,
or a water heater heat exchanger, as is discussed with reference to
FIG. 6. Any suitable refrigerant as is known in the industry, such
as R-410A refrigerant, may be used with system 10.
[0027] System 10 is configured as a split system in which indoor
heat exchanger 24 is positioned within space 26, and outdoor heat
exchanger 20, accumulator 18, compressor 16 and expansion device 22
are positioned outside space 26. In some embodiments, compressor
16, accumulator 18 and expansion device 22 can be located within
space 26 individually or in combination. In other embodiments, all
components of system 10 can be located outside of space 26, such as
in rooftop system applications. Space 26 comprises a building, home
or any other enclosed space in which conditioned air is desired to
be provided. Outdoor heat exchanger 20 and indoor heat exchanger 24
are able to operate as both condensers and evaporators, and system
10 is operable to provide conditioned air to space 26 that is
either heated or cooled. As such, valve 12 operates as a reversing
valve, as is known in the industry, to allow refrigerant from
compressor 16 through the vapor-compression circuit in forward and
reverse directions.
[0028] Indoor heat exchanger 24 can be sized to have a smaller
refrigerant capacity than outdoor heat exchanger 20, typically due
to constraints within space 26. Additionally, because of differing
mass flow characteristics in the vapor-compression cycle between
heating and cooling, less refrigerant volume may be required during
the heating mode as compared to the cooling mode. As such, it can
be desirable to store excess refrigerant during heating operations
of system 10 for later use during cooling operations. Accumulator
18 stores liquid refrigerant while system 10 operates in a heating
mode, thereby preventing liquid refrigerant from reaching
compressor 16. Flooding of compressor 16 with liquid refrigerant
can be harmful to the operation of compressor 16. The refrigerant
can be reintroduced into the vapor-compression cycle during cooling
mode operation.
[0029] The common use of an accumulator in a heat pump system is to
prevent liquid refrigerant to enter the compressor. During
compressor run time, the common practice is to constantly maintain
certain level of superheat at the evaporator outlet. This can be
accomplished by using a properly sized orifice, using a thermal
expansion valve, or using an electric expansion valve as the
expansion device. Using these methods result in a dry accumulator
(an accumulator without any liquid refrigerant). In view of the
foregoing differences between operating in the heating mode, which
is typically conducted in the winter, and operating in the cooling
mode, which is typically conducted in the summer, difficulties can
arise in maintaining system 10 charged with refrigerant at the
proper active charge level. Here, the active charge is defined as
the weight of all refrigerant in the heat pump system except for
the liquid refrigerant stored in the accumulator. Additionally,
even the slightest leak of, for example, several ounces of
refrigerant, can cause system 10 to operate inefficiently. Thus,
the refrigerant charge is desired to be checked and adjusted
periodically to account for seasonal temperature changes and leaks.
Adding a charge compensator may solve the seasonal charge issue by
either storing a full tank of liquid refrigerant or no liquid
refrigerant at all. However, this will only partially resolve the
seasonal refrigerant charge issue. The system 10 disclosed herein,
utilizes accumulator 18 that is sized to allow system 10 to operate
with a liquid refrigerant charge in heating and cooling modes, in
winter and summer, with initial charge level L.sub.A that
accommodates all operating modes and conditions so that accumulator
18 will not run dry or overflow.
[0030] Expansion device 22 and accumulator 18 of the present
disclosure alleviate differences in operation during summer and
winter, i.e. differences in refrigerant charge requirements while
operating in cooling and heating modes. In particular, expansion
device 22 can be adjusted, e.g. the diameter O.sub.D of orifice 34
can be altered, in order to control the flow rate of liquid
refrigerant leaving the condenser. Expansion device 22 can be
opened, e.g. orifice 34 can be increased in size, to allow more
refrigerant to enter the evaporator and thereby be stored in the
accumulator. Alternatively, expansion device 22 can be closed, e.g.
orifice 34 can be reduced in size, to allow less refrigerant to
pass through the evaporator and enter accumulator 18 to boil off
liquid refrigerant stored therein. This process causes the active
refrigerant charge in system 10 to change. The more expansion
device 22 is closed, the less liquid refrigerant is stored in
accumulator 18. The refrigerant that leaves accumulator 18 becomes
a part of the active charge in system 10 and causes the discharge
pressure to increase. Therefore, controlling discharge pressure
P.sub.D by opening or closing expansion device 22 is an effective
method to adjust active refrigerant charge in system 10. Further,
discharge pressure P.sub.D of system 10 is directly related to
condensing temperature of system 10.
[0031] In the case of cooling, outdoor heat exchanger 20 is the
condenser. Controlling discharge pressure P.sub.D to maintain an
appropriate amount of temperature difference between the condensing
temperature and the outdoor air temperature can effectively achieve
optimum performance. Here, the optimum performance is defined as an
appropriate compromise between cooling or heating capacity and the
energy efficiency determined by for a particular system.
[0032] In the case of heating, indoor heat exchanger 24 is the
condenser, controlling discharge pressure P.sub.D to maintain an
appropriate amount of temperature difference between the condensing
temperature and indoor air temperature can effectively achieve
optimum performance. However, in case the measured indoor air
temperature is not available to controller 28, the outdoor
temperature can be used to determine the discharge pressure target
P.sub.T.
[0033] FIG. 2A is a schematic flow chart of heat pump system 10 of
FIG. 1 showing the system operating in a cooling mode with
discharge pressure P.sub.D-Low below target pressure P.sub.T. In
the depicted embodiment of FIG. 2A, system 10 operates as an air
conditioning system to provide cooled air to space 26 such that the
vapor-compression circuit acts as a cooling circuit. The cooling
circuit comprises compressor 16, reversing valve 12, outdoor heat
exchanger 20 acting as a condenser, expansion device 22, Indoor
heat exchanger 24 acting as an evaporator, accumulator 18 and
refrigerant lines 25A-25G. The cooling circuit provides cooling to
indoor air A.sub.I of space 26.
[0034] As a result of system 10 operating at P.sub.D-Low in the
cooling mode, liquid refrigerant level in accumulator 18 is at
L.sub.Pos, which is above the correct charge level L.sub.A. Such a
condition may arise due to ambient air temperature changes, e.g. a
sudden temperature spike, or switching from a heating operation
mode. To reach target discharge pressure P.sub.T, controller 28
closes expansion device 22. This action causes some liquid
refrigerant in the accumulator to boil off and brings the liquid
level back to L.sub.A.
[0035] While system 10 is operating in a cooling mode to provide
cooled indoor air A.sub.I to space 26, compressor 16 compresses a
refrigerant to a high pressure and to a high temperature above that
of ambient outdoor air A.sub.O such that the refrigerant is
comprised substantially of superheated vapor.
[0036] The refrigerant is discharged from compressor 16 into line
25A where valve 12 operates to supply the refrigerant to outdoor
heat exchanger 20 through line 25B while controller 28 activates
fan 30 to blow relatively cooler outdoor air A.sub.O across outdoor
heat exchanger 20. The refrigerant dumps heat to outdoor air
A.sub.O within outdoor heat exchanger 20 as outdoor air A.sub.O
passes over heat exchange circuits of outdoor heat exchanger 20.
The refrigerant cools and condenses to a subcooled liquid having a
lower temperature than before while still at a high pressure.
[0037] From outdoor heat exchanger 20, the refrigerant is passed
through line 25C and expansion device 22, which rapidly lowers the
pressure and rapidly lowers the temperature of the refrigerant to
below that of indoor air A.sub.I such that the refrigerant converts
to a two-phase state of liquid and vapor in an expansion process.
Under pressure from compressor 16, the cold refrigerant continues
to flow into indoor heat exchanger 24 through line 25D where
controller 28 activates fan 32 to blow relatively warmer indoor air
A.sub.I across indoor heat exchanger (evaporator) 24. Indoor air
A.sub.I dumps heat to the refrigerant within indoor heat exchanger
24 as indoor air A.sub.I passes over heat exchange circuits of
indoor heat exchanger 24, thereby cooling space 26. The refrigerant
evaporates and absorbs heat from the relatively warmer indoor air
A.sub.I such that the refrigerant is vaporized to a primary
saturated vapor. The warm vapor is then drawn into accumulator 18
through line 25E, valve 12 and line 25F. The common practice is to
allow slightly superheated refrigerant to enter the accumulator.
For example, the superheat at the inlet of accumulator 18 can be
about 3.degree. F. to about 15.degree. F. (.about.-16.1.degree.
C.--9.4.degree. C.). In order to realize the above mentioned
benefits, the proposed control method will under certain conditions
allow some liquid refrigerant to enter accumulator 18. One function
of accumulator 18 is to only allow refrigerant vapor to enter
compressor 16 as long as accumulator 18 is itself not full of
liquid refrigerant.
[0038] Finally, the vaporized refrigerant is drawn into compressor
16 through line 25G where it is compressed and heated into a high
temperature, high pressure vapor such that the cycle can be
repeated. Controller 28 monitors the temperature inputs utilizing
temperature sensors 14A (outdoor air temperature) to maintain
discharge pressure P.sub.D at target pressure P.sub.T.
[0039] As mentioned, system 10 may be operating with too little
active charge such that too much liquid refrigerant is stored in
accumulator 18, indicated by charge level L.sub.Pos. In order to
bring the liquid refrigerant level down to level L.sub.A, orifice
34 of expansion device 22 can be reduced in size by controller 28.
The reduction of the diameter O.sub.D of orifice 34 allows less hot
liquid refrigerant to be fed to expansion device 22 by outdoor heat
exchanger 20 (acting as a condenser). In indoor heat exchanger 24
(acting as an evaporator) all of the liquid refrigerant is
evaporated. In accumulator 18, some of the stored liquid
refrigerant is also evaporated. Thus the active charge increases
causing the discharge P.sub.D increase. Controller 28 continues
this process by determining P.sub.D and comparing it to P.sub.T
until discharge pressure P.sub.D reaches target pressure P.sub.T,
as described below with reference to FIG. 7.
[0040] Controller 28 actively controls operation of the cooling
circuit and the operation of expansion device 22 to control the
discharge pressure P.sub.D by controlling valve 12 and orifice 34
using feedback from temperature sensors 14A and 14B. In particular,
controller 28 can operate control algorithms (e.g. the method of
FIG. 7) based on a comparison of measured discharge pressure
P.sub.D and target pressure P.sub.T (calculated based on sensed
temperatures T.sub.1 or T.sub.2), the .DELTA.P. Target pressure
P.sub.T can be determined based on experimentation, testing or
calculation given a particular configuration of system 10. For
example, a series of tests with different discharge pressure under
the same outdoor air temperature can be done in cooling mode to
find out at which discharge pressure P.sub.D the performance of
system 10 is optimized. Then, use that discharge pressure P.sub.D
as the target discharge pressure P.sub.T under the tested outdoor
air temperature. Further, a series of such tests can be done with
different outdoor air temperatures. This ensures that system 10
performs at optimum performances under any summer outdoor air
temperatures. The same series of tests can be done in heating mode
operation except that the indoor air temperature is preferred to
replace outdoor air temperature. As mentioned early in this
document, the outdoor air temperature can also be used in heating
mode if the indoor air temperature is absent. FIGS. 8A, 8B and 9
Show the relationships between the target discharge pressure and
the outdoor and indoor air temperatures. In one embodiment, system
10 is provided with only outdoor air temperature sensor 14A, from
which target discharge pressure P.sub.T can be determined using
temperature T.sub.1. In another embodiment, system 10 is provided
with both outdoor air temperature sensor 14A and indoor air
temperature sensor 14B, in which case target discharge pressure
P.sub.T can be determined using indoor temperature sensor 14B or
temperature T.sub.2, which provides a more accurate indication of
target discharge pressure P.sub.T in the heating mode. In both
embodiments, system 10 is provided with a pressure sensor in line
25A to directly sense discharge pressure P.sub.D.
[0041] Controller 28 may also operate system 10 in a heating mode
(or simply may operate to increase the amount of liquid stored in
accumulator 18 regardless of heating or cooling), as is discussed
with reference to FIG. 2B.
[0042] FIG. 2B is a schematic flow chart of the heat pump system of
FIG. 1 showing system 10 operating in a heating mode with discharge
pressure P.sub.D-High above target pressure P.sub.T. In the
depicted embodiment of FIG. 2B, system 10 operates as an heat pump
system to provide heated air to space 26 such that the
vapor-compression circuit acts as a heating circuit. The heating
circuit comprises compressor 16, reversing valve 12, outdoor heat
exchanger 20 acting as an evaporator, expansion device 22, indoor
heat exchanger 24 acting as a condenser, accumulator 18 and
refrigerant lines 25A-25G. The heating circuit provides heating to
indoor air A.sub.I of space 26.
[0043] As a result of system 10 operating at P.sub.D-High in the
heating mode, liquid refrigerant level in accumulator 18 is at
L.sub.Neg, which is below correct charge level L.sub.B. Such a
condition may arise due to ambient air temperature changes, e.g. a
sudden temperature drop, or switching from a cooling operation
mode. To reach the target discharge pressure P.sub.T, controller 28
opens expansion device 22. This action results in additional liquid
refrigerant to remain in the accumulator and brings the liquid
level back to level L.sub.B.
[0044] While system 10 is operating in a heating mode to provide
heated indoor air A.sub.I to space 26, compressor 16 compresses a
refrigerant to a high pressure and to a high temperature above that
of ambient indoor air A.sub.I such that the refrigerant is
comprised substantially of superheated vapor.
[0045] The superheated refrigerant is discharged from compressor 16
into line 25A where reversing valve 12 operates to supply the
refrigerant to indoor heat exchanger 24 through line 25E while
controller 28 activates fan 32 to blow relatively cooler indoor air
A.sub.I across indoor heat exchanger 24. Indoor air A.sub.I draws
heat from the refrigerant within indoor heat exchanger 24 as indoor
air A.sub.I passes over heat exchange circuits of indoor heat
exchanger 24, thereby heating space 26. The refrigerant cools and
condenses to a subcooled liquid having a lower temperature than
before while still at a high pressure.
[0046] From indoor heat exchanger 24, the refrigerant is passed
through line 25D and expansion device 22, which lowers the pressure
and the temperature of the refrigerant to below that of outdoor air
A.sub.O such that the refrigerant converts to a two-phase state of
liquid and vapor in an expansion process. Under pressure from
compressor 16, the cold refrigerant continues to flow into outdoor
heat exchanger 20 through line 25C where controller 28 activates
fan 30 to blow relatively warmer outdoor air A.sub.O across outdoor
heat exchanger (evaporator) 20. The refrigerant draws heat from
outdoor air A.sub.O within outdoor heat exchanger 20 as outdoor air
A.sub.O passes over heat exchange circuits of outdoor heat
exchanger 20. The refrigerant evaporates and absorbs heat from the
relatively warmer outdoor air A.sub.O such that the refrigerant is
vaporized to a saturated vapor. The vapor is then drawn into
accumulator 18 through line 25B, valve 12 and line 25F. The common
practice is to allow slightly superheated refrigerant to enter the
accumulator. For example, the superheat at the inlet of accumulator
18 can be about 3.degree. F. to about 15.degree. F.
(.about.-16.1.degree. C.--9.4.degree. C.). In order to realize the
above mentioned benefits, the proposed control method will under
certain conditions allow some liquid refrigerant to enter
accumulator 18.
[0047] Finally, the vaporized refrigerant is drawn into compressor
16 through line 25G where it is compressed and heated into a high
temperature, high pressure vapor such that the cycle can be
repeated. Controller 28 monitors the temperature inputs utilizing
temperature sensors 14A (outdoor air temperature) or 14B (indoor
air temperature) to maintain the discharge temperature P.sub.D at
target pressure P.sub.T.
[0048] As mentioned, system 10 may be operating with too much
active charge such that too little liquid refrigerant is stored in
accumulator 18, indicated by P.sub.D being high than P.sub.T. In
order to bring P.sub.D down to match P.sub.T, orifice 34 of
expansion device 22 can be enlarged by controller 28. Enlargement
of the diameter O.sub.D of orifice 34 allows some additional liquid
refrigerant to enter accumulator 18 to increase liquid refrigerant
level to L.sub.B. Controller 28 continues this process by
determining P.sub.D and comparing it to P.sub.T until the discharge
pressure reaches target pressure P.sub.T, as described below with
reference to FIG. 7.
[0049] The liquid refrigerant levels such as L.sub.A and L.sub.B in
the accumulator 18 are artificial levels. In fact, after the
initial refrigerant charge, the liquid level in accumulator varies
between summer and winter. It even varies when outdoor or indoor
air temperature changes in the same cooling or heating operation.
This is because, as the indoor, outdoor, or operating mode changes,
the optimum active change for system 10 changes. The proposed
control method allows system 10 to have optimum performance at all
conditions by controlling the discharge pressure to test verified
target pressure.
[0050] In view of the foregoing, system 10, using expansion device
22, can convert between operating in heating and cooling modes and
controller 28 will automatically control expansion device 22 to
maintain discharger pressure P.sub.D at target pressure P.sub.T or
within an acceptable range, so that heating and cooling may occur
at optimal levels, which may be determined on an individual basis
for the particular arrangement of system 10. As a result, the
active charge level of the liquid refrigerant increases or
decreases causing the weight of liquid refrigerant within
accumulator 18 to increase or decrease.
[0051] Expansion device 22 can comprise a single integrated
electronic unit wherein the size (e.g. diameter O.sub.D) of orifice
34 (FIG. 1) is actively controlled, as shown in FIGS. 2A and 2B,
and flow is reversible through the device. However, expansion
device 22 may also comprise an assembly of several components, as
shown in FIG. 3.
[0052] FIG. 3 is a schematic diagram of bi-directional electronic
expansion valve (BEEV) 36 suitable for use as expansion device 22
in system 10 of FIGS. 1-2B. Device 36 can also be any kind of
expansion valve with a variable orifice. BEEV 36 comprises first
expansion device 38A, first check valve 40A, second expansion
device 38B and second check valve 40B. Expansion devices 38A and
38B may not be reversible and have orifices 41A and 41B,
respectively, which can restrict flow through the respective valve.
Likewise, check valves 40A and 40B comprise valves that permit flow
in only one direction without much restriction. Expansion devices
38A and 38B and check valves 40A and 40B are arranged to have
opposite flow directions.
[0053] First expansion device 38A and first check valve 40A can be
placed in space 26 proximate indoor heat exchanger 24 (e.g. in line
25D), while second expansion device 38B and second check valve 40B
can be placed outdoors proximate outdoor heat exchanger 20 (e.g. in
line 25C). Thus, in a cooling mode, refrigerant flow F.sub.C passes
through second check valve 40B and first expansion device 38A, and
in a heating mode, refrigerant flow F.sub.H passes through first
check valve 40A and second expansion device 38B.
[0054] Orifices 41A and 41B have variable diameters that can be
actively controlled similarly as is described with reference to
orifice 34 in FIGS. 2A and 2B, above.
[0055] FIG. 4 is a schematic diagram showing accumulator 18 having
charge level indicator window 42A in an intermediate charge
position 3 on housing 44. Housing 44 is connected to refrigerant
lines 25F and 25G, as described with reference to FIGS. 1-2B.
Housing 44 comprises any suitable accumulator design for storing
pressurized refrigerant that may be in liquid and vapor form and
allowing only vapor refrigerant to exit. Indicator window 42A
comprises any suitable material that is sufficiently transparent to
view liquid refrigerant. The indicator window can also be a liquid
refrigerant level detector capable of provide an electronic signal
such as voltage or current when the refrigerant liquid-vapor
interface is near level 3 in FIG. 4.
[0056] Indicator window 42A is positioned at level 3 shown in FIG.
4. Refrigerant can be added to system 10 in summer or winter so
that liquid refrigerant is at the level of window 42A at position
3. In summer during cooling, if system 10 is charged to level 3,
liquid refrigerant will rise to level 4 in winter during heating.
Thus, extra volume V.sub.2 will be provided between level 4 and
level 5 to provide a buffer so that compressor 16 is not fed liquid
refrigerant. In winter during heating, if system 10 is charged to
level 3, liquid refrigerant will fall to level 2 in the summer
during cooling. Thus, extra volume V.sub.2 will be provided between
level 2 and level 1 to prevent accumulator 18 from running dry. As
such, volume V.sub.1 comprises the range of liquid refrigerant in
which system 10 is configured to operate between winter and summer
(heating and cooling) operations. Accumulator 18 permits volume
V.sub.1 to reside in two different bandwidths opposite level 3,
depending on when the refrigerant level was topped off, with two
different reserve volumes V.sub.2 residing at opposite ends of the
two volumes V.sub.2 within accumulator 18.
[0057] FIG. 5 is a schematic diagram showing accumulator 18 having
charge level indicator windows 42B and 42C in summer and winter
charge positions 4 and 2 on housing 44. Accumulator 18 of FIG. 5
operates in the same way as described with respect to FIG. 4,
except indicator windows 42B and 42C are located at levels 2 and 4.
Indicator windows 42B and 42C can also be a liquid refrigerant
detector capable of provide an electronic signal such as voltage or
current when the refrigerant liquid-vapor interface is near level 2
or 4 in FIG. 5.
[0058] The above mentioned accumulator design can be used to help
heat pump installer to determine appropriate refrigerant charge
after the system is newly installed, during maintenance or system
repair. As has been discussed, normally, cooling mode operation
requires more active charge than heating mode operation. During
cooling operation in the summer, refrigerant can be filled to level
2 so that in the winter refrigerant level will not rise above level
4. During heating operation in the winter, refrigerant can be
filled to level 4 so that in the summer refrigerant will not drop
below level 2.
[0059] Heating mode operation requires more active charge than the
cooling mode. During cooling operation in the summer, refrigerant
can be filled to level 4 so that in the winter refrigerant level
will not drop below level 2. During heating operation in the
winter, refrigerant can be filled to level 2 so that in the summer
refrigerant will not rise above level 4.
[0060] In another embodiment, charge level indicator windows 42B
and 42C can be replaced with a single, oblong window spanning the
length of the accumulator from window 42B to 42C, for example. The
ends of the window are positioned at or near levels 2 and 4 to
allow for charge readings at the desired levels. In other
embodiments, charge level indicator windows 42A-42C can be replaced
with other elements that provide an indication of the liquid level,
such as a float or hash marks and the like. In yet another
embodiment, the two indicators 42B and 42C can be replaced by a
refrigerant lever detector with continuous liquid level detection
capability and with an electric signal output to indicate the
liquid level in accumulator 18.
[0061] As another example of applying the current invention, FIG. 6
is a schematic diagram showing a heat pump system 10A incorporating
heat exchanger 46 for heating water. Water heat exchanger 46
comprises a means for heating water stored at a location separate
from system 10A.
[0062] Water heat exchanger 46 is positioned in series with outdoor
heat exchanger 20 and a three way valve 47 on the high pressure
side of compressor 16. Water heat exchanger 46 can, therefore, act
as a desuperheater or a condenser. Operation of water heat
exchanger 46 is discussed below in brief and is discussed in
greater detail in U.S. Patent Application Pub. No. 2014/0245770 to
Chen et al., which is hereby incorporated by reference in its
entirety for all purposes.
[0063] System 10A has three major heat exchangers indoor, outdoor,
and water heat exchangers. By changing the position of the
reversing valve 12 and the three way valve 47, different
combination of the heat exchanges can be used. In certain cases,
all three heat exchanger can be used. In other cases, only two heat
exchangers are used. When there is an unused heat exchanger, the
amount of refrigerant in a particular heat exchanger is not certain
without a proper refrigerant management. The above mentioned patent
provided a method to drive the refrigerant out of the unused heat
exchanger before the system starts a new mode of operation. During
the new mode of operation, certain valves such as 34A, 34B, or SV
can be opened or closed to manage the amount of refrigerant in the
unused heat exchange. As an example application of the current
invention, system 10A can still use the same method mentioned in
the above patent to drive the refrigerant out of the unused heat
exchange before a new mode operation starts. However, to manage the
refrigerant in the active system during new mode of operation, the
method proposed in the current invention can be used. The target
discharge pressure P.sub.T can be used to control the discharge
pressure P.sub.D. Accumulator 18 can be used to store liquid
refrigerant allowing the active refrigerant change to be optimized.
In the case of using the water heat exchanger as a condenser, the
target discharge pressure can be determined based on water heat
exchanger water inlet temperature. As described earlier in this
document, the condensing temperature of the water heat exchanger
can be optimized based on a series of tests. When the water heat
exchanger is used as a desuperheater, the outdoor or indoor air
temperature can be used to determine the target discharge pressure
P.sub.T in cooling or heating mode operation.
[0064] FIG. 7 is a flow chart diagramming the steps for controlling
discharge pressure and active refrigerant charge in heat pump
system 10 of FIGS. 1-6. During operation to cool or heat space 26,
heat pump system 10 controls diameter O.sub.D of orifice 34 of
expansion device 22 based on whether compressor discharge pressure
P.sub.D satisfies the predetermined target discharge pressure
P.sub.T.
[0065] At step 100, discharge pressure P.sub.D, outdoor temperature
T.sub.1 and/or indoor temperature T.sub.2 are measured such as by
using temperature sensor 14A and/or 14B. According to other
examples, temperature T.sub.1 and/or T.sub.2 can be calculated by
measuring other physical properties such as electric resistance or
electric current which are indirectly related to the temperature.
At 102, the target discharge pressure P.sub.T is determined based
on T.sub.1 or T.sub.2 as shown in FIGS. 8A and 8B or FIG. 9. At
104, .DELTA.P, the difference between P.sub.D and P.sub.T, is
computed. If the .DELTA.P is greater than a constant .DELTA.P1,
step 106A is executed to increase the O.sub.D of orifice 34 of
expansion device 22. Here .DELTA.P1 can be a constant value which
specifies the tolerance of the discharge pressure controller. If
the .DELTA.P is less than a constant minus .DELTA.P1, step 106B is
executed to decrease the O.sub.D of orifice 34 of expansion device
22. Otherwise, O.sub.D is unchanged. The process repeats itself
after a time delay as shown in step 108. FIG. 7 is one of the
method which can be used to control the discharge pressure P.sub.D
based on a predetermine target discharge pressure P.sub.T. Other
methods such as PID control can also be used to control the
discharge pressure.
[0066] In cooling mode, discharge pressure P.sub.D is determined
using outdoor temperature T.sub.1. As outdoor temperature T.sub.1
increases, the target discharge temperature (as used in determining
target pressure P.sub.T) increases (within a predetermined
range).
[0067] In heating mode, there are two options for determining
discharge pressure P.sub.D. In Option 1, discharge pressure P.sub.D
is determined using indoor temperature sensor 14B and temperature
T.sub.2. As indoor temperature T.sub.2 increases, the target
discharge temperature (as used in determining target pressure
P.sub.T) increases (within a predetermined range). In Option 2,
discharge pressure P.sub.D is determined using outdoor temperature
sensor 14A and temperature T.sub.1. As outdoor temperature T.sub.1
increases, the target discharge temperature (as used in determining
target pressure P.sub.T) increases (within a predetermined range).
The advantage of Option 1 is better energy efficiency optimization
over the indoor temperature range. The advantage of Option 2 is
using fewer sensors, as indoor temperature sensors are typically
optional features in heat pump systems, depending on the intended
use.
[0068] Controller 28 can be configured to execute the method of
FIG. 7 and actively control discharge pressure P.sub.D. Controller
28 can include circuitry, memory and user input devices. Controller
28 can be connected in electronic communication with temperature
sensors 14A and 14B, valve 12, expansion device 22, and compressor
16. Controller can also be connected to liquid refrigerant level
sensor(s) to determine whether the heat pump system 10 is properly
charged with refrigerant. Controller 28 can also include other
components commonly found in electronic controllers, such as
analog-to-digital converters that may convert analog input from the
sensors to digital signals useable by circuitry, clocks, signal
conditioners, signal filters, voltage regulators, current controls,
modulating circuitry, input ports, output ports and the like.
Controller 28 can also include appropriate input ports for
receiving sensor inputs and user inputs. For example, a user of
system 10 (FIG. 1) may input desired target pressure P.sub.T, and
an acceptable range encompassing target pressure P.sub.T, into the
memory of controller 28. The memory may comprise non-volatile
random access memory (NVRM), read only memory, physical memory,
optical memory or the like. Controller 28 may comprise any suitable
computing device such as an analog circuit, or a digital circuit,
such as a microprocessor, a microcontroller, an
application-specific integrated circuit (ASIC) or a digital signal
processor (DSP).
[0069] As another example of applying the current invention, the
system 10 may include a feature to provide a refrigerant charge
level indication. In this case, the accumulator 18 is equipped with
an electronic refrigerant level indicator 48, as indicated
schematically in FIG. 1. Indicator 48 is able to detect two liquid
refrigerant levels. These two levels are at the maximum and minimum
required charge level. When the controller 28 senses the liquid
refrigerant at the maximum level, it may increase the target
discharge pressure normally calculated using FIGS. 8A and 8B or
FIG. 9. As a results, the active refrigerant charge increases
preventing the liquid refrigerant from entering the compressor. The
controller 28 may also send an electric signal indicating that the
system 10 is over charged. In case the target discharge pressure
reaches an unacceptable level, the controller may shut down the
system 10 which may include compressor, fan, blower, and other
components. When the controller 28 senses the liquid refrigerant at
the minimum level it may send an electric signal indicating that
the system 10 is under charged.
[0070] System 10 includes several benefits over conventional
systems, some of which are discussed below.
[0071] The correct refrigerant charge of system 10 can be simply
determined using windows 42A-42C. No tools are required.
[0072] Since conventional systems can only have one active charge,
the performance can only be optimized at one outdoor temperature.
System 10 can adjust active charge at various indoor and outdoor
temperatures, the system performance can be optimized at various
conditions.
[0073] The performance of system 10 is less sensitive to small
refrigerant leaks than conventional systems since the refrigerant
in accumulator 18 will make up the lost refrigerant in the active
system.
[0074] System 10 does not require refrigerant checks in the
opposite season in which it is installed.
[0075] System 10 will have less likelihood of shutting down due to
high discharge pressure issues over conventional systems because of
the self-correcting advantages of accumulator 18 and expansion
device 22 when controlled by controller 28.
Various Notes & Examples
[0076] In Example 1, a heat pump system comprises: a compressor, at
least one expansion valve, an accumulator continuously storing a
volume of liquid refrigerant therein, a liquid refrigerant
indicator connected to the accumulator to indicate an appropriate
refrigerant charge in cooling and heating modes, and a controller
configured to determine a target compressor discharge pressure
based on outdoor air temperature and control the compressor
discharge pressure by modulating the position of the at least one
expansion valve, wherein the higher the target discharge pressure
target, the less liquid refrigerant is left in the accumulator.
[0077] Example 2 can include, or can optionally be combined with
the subject matter of one or any combination of Example 1, to
optionally include an indoor heat exchanger, and an outdoor heat
exchanger in fluid communication with indoor heat exchanger,
wherein the at least one expansion valve is arranged between and
modulates the flow of the refrigerant between the indoor heat
exchanger and the outdoor heat exchanger.
[0078] Example 3 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1 and 2,
to optionally include modulating a position of the at least one
expansion valve comprises opening and/or closing the at least one
expansion valve causing an orifice size of the valve to increase or
decrease.
[0079] Example 4 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-3, to
optionally include an accumulator having an element that is
configured to indicate a desired amount for the volume of liquid
refrigerant within the accumulator.
[0080] Example 5 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-4, to
optionally include an element that is positioned such the volume of
the liquid refrigerant when filled to the desired amount comprises
at least a charge difference volume between a cooling mode of
system operation and a heating mode of system operation and a
reserve volume to prevent the accumulator from being dry or over
flow.
[0081] Example 6 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-5, to
optionally include an element that is positioned to indicate the
volume of the liquid refrigerant that is appropriate regardless of
a current mode of system operation and regardless of a season in
which refrigerant is contemplated to be added to the system.
[0082] Example 7 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-6, to
optionally include an element comprising two elements spaced from
one another, each of the two elements indicating the volume of
liquid refrigerant in the accumulator that is appropriate based
upon both a current mode of system operation and one season in
which refrigerant is contemplated to be added to the system.
[0083] Example 8 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-7, to
optionally include a volume of liquid refrigerant in the
accumulator that comprises at least twice as much refrigerant as a
volume difference in refrigerant utilized by the system between a
cooling mode of system operation and a heating mode of system
operation.
[0084] Example 9 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-8, to
optionally include a controller that is further configured to
determine an indoor air temperature and the compressor discharge
pressure is derived from the indoor air temperature.
[0085] Example 10 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-9, to
optionally include a heating mode of system operation, an indoor
air temperature is utilized in controlling the compressor discharge
pressure, and wherein in a cooling mode of system operation, the
outdoor air temperature is utilized in controlling the compressor
discharge pressure.
[0086] Example 11 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-10, to
optionally include a controller that is further configured to
determine a potential for an overflowed accumulator and increase a
compressor discharge pressure target which modulates the position
of the at least one expansion valve to a more closed position when
the overflowed accumulator is detected.
[0087] Example 12 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 1-11, to
optionally include at least one expansion valve comprising an
assembly of two or more expansion valves, each of the two or more
expansion valves having an associated check valve.
[0088] In Example 13, a method comprises: storing a volume of
liquid refrigerant continuously within an accumulator during
operation of the heat pump, the volume of liquid refrigerant
comprising an appropriate amount for both a heating mode and a
cooling mode of operation of a heat pump; determining an outdoor
air temperature and a compressor discharge pressure; and
controlling the compressor discharge pressure based upon the
determined outdoor air temperature; wherein the volume of the
liquid refrigerant within the accumulator changes based upon the
discharge pressure.
[0089] Example 14 can include, or can optionally be combined with
the subject matter of one or any combination of Example 13, to
optionally include increasing a compressor discharge pressure
target to modulate the position of the at least one expansion valve
to prevent a overflowed accumulator; and issuing one of a warning
or turning off the heat pump system if the target discharge
pressure reaches a predetermined high limit to prevent compressor
damage.
[0090] Example 15 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 13 and 14,
to optionally include indicating a desired amount for the volume of
liquid refrigerant within the accumulator.
[0091] Example 16 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 13-15, to
optionally include indicating that is independent of a current mode
of heat pump operation and a season in which refrigerant is
contemplated to be added to the heat pump.
[0092] Example 17 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 13-16, to
optionally include indicating that is dependent upon both a current
mode of heat pump operation and a season in which refrigerant is
contemplated to be added to the heat pump.
[0093] Example 18 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 13-17, to
optionally include determining an indoor air temperature and
deriving the compressor discharge pressure from the indoor air
temperature.
[0094] Example 19 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 13-18, to
optionally include controlling the compressor discharge pressure
based upon an indoor air temperature in a heating mode of heat pump
operation; and controlling the compressor discharge pressure based
upon the determined outdoor air temperature in a cooling mode of
heat pump operation.
[0095] In Example 20, an accumulator comprises: a housing
configured to house a continuous volume of liquid refrigerant
during both a heating mode and a cooling mode of operation of a
heat pump; and an element that is configured to indicate a desired
amount for the volume of the liquid refrigerant within the
accumulator.
[0096] Example 21 can include, or can optionally be combined with
the subject matter of one or any combination of Example 20, to
optionally include an element that is positioned such the volume of
the liquid refrigerant when filled to the desired amount comprises
at least a liquid refrigerant charge difference volume between a
cooling mode of heat pump operation and a heating mode of heat pump
operation and a reserve volume to prevent the accumulator from
being dry or overflow.
[0097] Example 22 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 20 and 21,
to optionally include and element that is positioned to indicate
the volume of the liquid refrigerant that is appropriate regardless
of a current mode of system operation and regardless of a season in
which refrigerant is contemplated to be added to the system.
[0098] Example 23 can include, or can optionally be combined with
the subject matter of one or any combination of Examples 20-22, to
optionally include an element that comprises two elements spaced
from one another, each of the two elements indicating the volume of
liquid refrigerant in the accumulator that is appropriate based
upon both a current mode of system operation and one season in
which refrigerant is contemplated to be added to the system.
[0099] Each of these non-limiting examples can stand on its own, or
can be combined in any permutation or combination with any one or
more of the other examples.
[0100] The above detailed description includes references to the
accompanying drawings, which form a part of the detailed
description. The drawings show, by way of illustration, specific
embodiments in which the present subject matter can be practiced.
These embodiments are also referred to herein as "examples." Such
examples can include elements in addition to those shown or
described. However, the present inventors also contemplate examples
in which only those elements shown or described are provided.
Moreover, the present inventors also contemplate examples using any
combination or permutation of those elements shown or described (or
one or more aspects thereof), either with respect to a particular
example (or one or more aspects thereof), or with respect to other
examples (or one or more aspects thereof) shown or described
herein.
[0101] In the event of inconsistent usages between this document
and any documents so incorporated by reference, the usage in this
document controls.
[0102] In this document, the terms "a" or "an" are used, as is
common in patent documents, to include one or more than one,
independent of any other instances or usages of "at least one" or
"one or more." In this document, the term "or" is used to refer to
a nonexclusive or, such that "A or B" includes "A but not B," "B
but not A," and "A and B," unless otherwise indicated. In this
document, the terms "including" and "in which" are used as the
plain-English equivalents of the respective terms "comprising" and
"wherein." Also, in the following claims, the terms "including" and
"comprising" are open-ended, that is, a system, device, article,
composition, formulation, or process that includes elements in
addition to those listed after such a term in a claim are still
deemed to fall within the scope of that claim. Moreover, in the
following claims, the terms "first," "second," and "third," etc.
are used merely as labels, and are not intended to impose numerical
requirements on their objects.
[0103] Method examples described herein can be machine or
computer-implemented at least in part. Some examples can include a
computer-readable medium or machine-readable medium encoded with
instructions operable to configure an electronic device to perform
methods as described in the above examples. An implementation of
such methods can include code, such as microcode, assembly language
code, a higher-level language code, or the like. Such code can
include computer readable instructions for performing various
methods. The code may form portions of computer program products.
Further, in an example, the code can be tangibly stored on one or
more volatile, non-transitory, or non-volatile tangible
computer-readable media, such as during execution or at other
times. Examples of these tangible computer-readable media can
include, but are not limited to, hard disks, removable magnetic
disks, removable optical disks (e.g., compact disks and digital
video disks), magnetic cassettes, memory cards or sticks, random
access memories (RAMs), read only memories (ROMs), and the
like.
[0104] The above description is intended to be illustrative, and
not restrictive. For example, the above-described examples (or one
or more aspects thereof) may be used in combination with each
other. Other embodiments can be used, such as by one of ordinary
skill in the art upon reviewing the above description. The Abstract
is provided to comply with 37 C.F.R. .sctn.1.72(b), to allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. Also, in the
above Detailed Description, various features may be grouped
together to streamline the disclosure. This should not be
interpreted as intending that an unclaimed disclosed feature is
essential to any claim. Rather, inventive subject matter may lie in
less than all features of a particular disclosed embodiment. Thus,
the following claims are hereby incorporated into the Detailed
Description as examples or embodiments, with each claim standing on
its own as a separate embodiment, and it is contemplated that such
embodiments can be combined with each other in various combinations
or permutations. The scope of the present subject matter should be
determined with reference to the appended claims, along with the
full scope of equivalents to which such claims are entitled.
* * * * *