Note: Descriptions are shown in the official language in which they were submitted.
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FAN OPERATION MANAGEMENT
TECHNICAL FIELD
[001] The present disclosure relates to fan operation management.
BACKGROUND
[002] At low ambient temperatures, fans that provide air to the condenser of
an air
conditioner may cycle on and off. Cycling the fans may cause mechanical wear
on the
fans and/or may cause instability due to changes in pressures in the air
conditioner and/or
portions thereof.
SUMMARY
[003] In various implementations, an air conditioner may include more than one
fan.
The fan(s) may include more than one setting, and the mass flow rate of the
air provided
by a fan may change based on the setting of the fan. The air conditioner may
alter the
setting of the fan(s) based on properties of the air conditioner. By
controlling the setting
of the fan(s), mechanical wear of the air conditioner may be reduced and/or
pressure
fluctuations in the air conditioner or portions thereof may be controlled. In
some
implementations, the setting of the fan(s) may maintain a pressure range in
the air
conditioner or portions thereof.
[004] In various implementations, an air conditioner system may include more
than one
compressor, one or more fans, a memory, and a processor. At least one of the
fans may
include one or more first fans, which include a high setting and one or more
lower
settings. The memory may store a fan management module and a processor of the
system
may execute the fan management module. The fan management module may receive a
request for operation of an air conditioner and determine a temperature
proximate at least
a portion of the air conditioner. The fan management module may determine
whether the
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determined temperature is less than a first predetermined low ambient
temperature. If the
determined temperature is less than the first predetermined low ambient
temperature, the
fan management module may allow restriction of the operation of at least one
of the fans.
If the determined temperature is less than the first predetermined low ambient
temperature, the fan management module may allow operation of at least one of
the first
fans.
[005] Implementations may include one or more of the following features. One
or more
lower settings of the first fans may include a first low setting, a second low
setting, and/or
a third low setting. The second low setting may be lower than the first low
setting (e.g.,
associated with a slower fan speed). The third low setting may be lower than
the second
low setting (e.g., associated with a slower fan speed). The fan management
module may
determine an operation of the compressors and determine whether the determined
temperature is less than a second predetermined low ambient temperature. The
second
predetermined low ambient temperature may be less than the first predetermined
low
ambient temperature. If the
determined temperature is less than the second
predetermined low ambient temperature and if the determined compressor
operation
includes a full load operation, the fan management module may allow operation
of at
least one first fan at the first low setting. If the determined temperature is
less than the
second predetermined low ambient temperature and if the determined compressor
operation comprises a part load operation, the fan management module may allow
operation of at least one first fan at the third low setting. If the
determined temperature is
less than the first predetermined low ambient temperature and the determined
temperature is not less than the second predetermined low ambient temperature
and the
determined compressor operation comprises a part load operation, the fan
management
module may allow operation of at least one first fan at the second low
setting. The fan
management module may allow operation of one of the first fans and restrict
operation of
the other fans, in some implementations. The fan management module may
determine an
operation of the compressors, and allow operation of at least one of the fans
at the high
setting if the determined compressor operation comprises a full load
operation. In some
implementations, the fan management module may determine an operation of the
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compressors, and allow operation of at least one of the fans at the second low
setting if
the determined compressor operation comprises a part load operation. In some
implementations, the fan management module may determine whether a compressor
operation comprises a part load operation, and allow operation of one or more
crankcase
heaters associated with one or more compressors in which operation is
restricted, if the
compressor operation comprises a part load operation. The fan management
module may
determine whether the determined temperature is less than a second
predetermined low
ambient temperature, which is less than the first predetermined low ambient
temperature.
If the determined temperature is less than the second predetermined low
temperature, the
fan management module may allow operation of one or more crankcase heaters
associated with one or more compressors of the air conditioner.
10061 In various implementations, a temperature may be determined proximate at
least a
portion of an air conditioner and a determination may be made whether the
determined
temperature is less than a first predetermined low ambient temperature. If the
determined
temperature is less than the first predetermined low ambient temperature,
operation of at
least one fan of the air conditioner may be restricted and operation of at
least one of the
fans of the air conditioner may be allowed.
10071 Implementations may include one or more of the following features. One
or more
fans of the air conditioner may include a high setting and at least one low
setting. A
determination may be made whether the determined temperature is less than a
second
predetermined low ambient temperature. If the determined temperature is less
than the
second predetermined low ambient temperature, then operation of at least one
of the fans
may be allowed at one of the low settings. In some implementations, an
operation of
compressors of the air conditioner may be determined, and a determination may
be made
whether the determined temperature is less than a second predetermined low
ambient
temperature. Operation of at least one of the fans may be allowed at the high
setting, if
the determined compressor operation includes a full load operation, and if the
determined
temperature is less than the first predetermined low ambient temperature and
not less than
the second predetermined low ambient temperature. In some implementations, an
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operation of compressors of the air conditioner may be determined. Operation
of at least
one of the fans of the air conditioner may be allowed at one of the low
settings, if the
determined compressor operation comprises a part load operation, and if the
determined
temperature is less than the first predetermined low ambient temperature. In
some
implementations, operation of one or more crankcase heaters associated with
one or more
of the compressors in which operation is restricted may be allowed, if the
determined
operation of the compressors comprises a part load operation, and if the
determined
temperature is less than the first predetermined low ambient temperature. A
determination may be made whether the determined temperature is less than a
second
predetermined low ambient temperature, which is less than the first
predetermined low
temperature. Operation of one or more crankcase heaters associated with one or
more of
the compressors of the air conditioner may be allowed, if the determined
temperature is
less than the second predetermined low ambient temperature. In some
implementations,
an operation of compressors of the air conditioner may be determined.
Operation of one
or more crankcase heaters associated with one or more of the compressors in
which
operation is restricted may be allowed, if the determined temperature is less
than the first
predetermined low ambient temperature and the determined operation of the
compressors
comprises a part load operation.
1008] In various implementations, a temperature of a portion of an air
conditioner may
be determined and a predetermined low ambient temperature may be retrieved
from a
memory of a computer. A determination may be made whether the determined
temperature is less than the retrieved predetermined low ambient temperature.
If the
determined temperature is less than the predetermined low ambient temperature:
operation of at least one fan of the air conditioner may be restricted; and
operation of at
least one fan of the air conditioner may be allowed at a setting to maintain a
pressure of a
portion of the air conditioner in a predetermined pressure range.
[009] Implementations may include one or more of the following features. The
setting
to maintain the pressure of the portion of the air conditioner may be
determined based at
least partially on the determined temperature. The setting to maintain the
pressure of the
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portion of the air conditioner may be determined based at least partially on
the
determined temperature, a number of fans included in the air conditioner, a
number of
modes of operation of each fan of the air conditioner, and/or the
predetermined pressure
range. In some implementations, a determination may be made whether an
operation of
compressors of the air conditioner comprises a part load operation. Operation
of one or
more crankcase heaters associated with compressors in which operation is
restricted may
be allowed, if the operation of compressors comprises a part load operation
and if the
determined temperature is less than the retrieved predetermined low ambient
temperature.
[010] The details of one or more implementations are set forth in the
accompanying
drawings and the description below. Other features, objects, and advantages of
the
implementations will be apparent from the description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[011] For a more complete understanding of this disclosure and its features,
reference is
now made to the following description, taken in conjunction with the
accompanying
drawings, in which:
[012] Figure 1 illustrates an implementation of an example air conditioner.
[013] Figure 2 illustrates an implementation of an example process for
managing fan
operations.
[014] Figure 3 illustrates an implementation of an example process for
managing fan
operations.
[015] Figure 4 illustrates an implementation of an example process for
managing fan
operations.
[016] Like reference symbols in the various drawings indicate like elements.
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DETAILED DESCRIPTION
[017] In various implementations, an air conditioner may operate at a variety
of ambient
conditions. In some implementations, a user may request the delivery of cool
air during
low ambient temperatures (e.g., below approximately 65 degrees Fahrenheit,
below
approximately 62 degrees Fahrenheit, and/or from approximately 62 degrees
Fahrenheit
to approximately 45 degrees Fahrenheit). When the air conditioner operates in
response
to a request at low ambient temperatures, the air conditioner may cycle fans
on and off to
provide the appropriate cool air to a location, as requested by the user.
Cycling fans on
and off may increase the mechanical wear on the fan (e.g, when compared with
fan
operation in ambient temperatures above low ambient temperatures). In
some
implementations, operation of the air conditioner at low ambient temperatures
may cause
pressure fluctuations in the air conditioner or portions thereof, which may
cause less
stability (e.g., due to pressure fluctuations) in the air conditioner (e.g.,
when compared
with an air conditioner operating in ambient temperatures above low ambient
temperatures).
[018] In some implementations, the air conditioner may control the fan speed
during
operations at ambient temperatures that are in a low ambient temperature range
(e.g.,
below a first and/or a second predetermined ambient temperature and/or between
a first
predetermined ambient temperature and a second predetermined ambient
temperature).
For example, fan(s) may be restricted and/or allowed to operate. The air
conditioner may
determine an appropriate fan setting of the fans allowed to operate, when a
fan has more
than one fan setting. In some implementations, the air conditioner may control
crank
case heater operation during operations at ambient temperatures that are in a
low ambient
temperature range.
[019] Figure 1 illustrates an implementation of an example air conditioner
100. The air
conditioner may include components such as a condenser 110, compressor A 120,
compressor B 130, and evaporator 140. As illustrated, each compressor 120, 130
may
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include a crank case heater 125, 135. Lines (e.g., tubing) may couple various
components and allow refrigerant to flow in and/or out of various components
of the air
conditioner 100.
[020] Fans 160, 170 may cause air to flow through the condenser 110 and/or the
evaporator 140. The air conditioner 100 may include more than one fan to
provide air
flow to the condenser 110 and/or more than one fan to provide air flow to the
evaporator
140. As illustrated, the air conditioner 100 may include a first condenser fan
162, a
second condenser fan 164, and a third condenser fan 166 to provide air flow to
the
condenser 110 and a first evaporator fan 172, a second evaporator fan 174, and
a third
evaporator fan 176 to provide air flow to the evaporator 140.
[021] The condenser 110 may include an appropriate condenser. In some
implementations, the condenser 110 may be a microchannel condenser (e.g.,
condenser
with a channel size less than approximately 1 mm). Microchannel condensers may
be
sensitive to operating conditions during operation of the air conditioner
(e.g., when
compared with other condensers (e.g., condenser with tube size greater than 5
mm)). For
example, microchannel condensers may be sensitive to refrigerant charge (e.g.,
a level of
refrigerant in the system). When a microchannel condenser has a refrigerant
charge
greater than a maximum operating charge, the pressure in the microchannel
condenser
may become elevated due to the refrigerant capacity size difference between
the
microchannel condenser and the evaporator. In some implementations, a pressure
of the
condenser may be based at least partially on an operation of the fan(s) that
provide air to
the condenser (e.g., outdoor fans). The high pressures (e.g., pressures
greater than
approximately 615 psi, with a refrigerant that includes R-410A refrigerant)
may cause
mechanical failure, including prefailure events, such as excessive wear on
parts and/or
high-pressure switch activations. Thus, the air conditioner may control the
pressure in
the system to manage stability and/or inhibit mechanical failure of the air
conditioning
system. For example, by managing operation(s) of the fan(s) that provide air
to the
condenser, pressure in the system (e.g., the condenser) may be managed to
manage
stability and/or inhibit mechanical failure of the air conditioning system.
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[022] Fans 160 may provide airflow to the condenser 110, and fans 170 may
provide
airflow to the evaporator 140. The fan(s) 160, 170 may include any appropriate
number
of fans, such as one, two, three, or four fans. A fan 160, 170 may be any
appropriate type
of fan, such as an axial fan. A fan 160, 170 may include more than one fan
setting. For
example, the fan may be a multi-speed fan and/or a variable speed fan. In some
implementations, a fan may include a high setting and one or more low
settings. The
settings may be associated with the speed at which the impeller of the fan
rotates. For
example, fan settings may include a high setting, a first low setting, and a
second low
setting. The second low setting may be associated with a lower fan speed than
the first
low setting. For example, a fan may allow operation at 800 RPM (rotations per
minute),
650 RPM, and/or 330 RPM. In some implementations, a fan may include a low
setting
and more than one high setting.
[023] The compressors 120, 130 of the air conditioner may include any
appropriate
arrangement of compressors (e.g., in separate circuits and/or in parallel
circuits). The
compressors 120, 130 may include a tandem compressor system. The tandem
compressor system may allow more than one compressor (e.g., compressor A 120
and
compressor B 130) to share discharge lines and suction lines.
[024] Compressor A 120 and/or compressor B 130 may include single stage and/or
multi-stage (e.g., more than one stage) compressors. Compressor A 120 and
compressor
B may be independently operable, in some implementations. For example,
compressor A
120 may be allowed to operate and compressor B may be restricted from
operation.
[025] Compressor A 120 and/or compressor B 130 may include crankcase heaters
125,
135. The crankcase heaters may include any appropriate crankcase heater. For
example,
the crankcase heater may be a variable wattage crankcase heater, an on/off
heater, and/or
a multi-stage heater. A crankcase heater may be disposed in a housing of the
compressor,
in some implementations. A crankcase heater may provide heat to a portion of a
compressor (e.g., the crankcase of a compressor). By delivering heat to the
crankcase of
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the compressor, the crankcase heater may inhibit refrigeration migration,
inhibit mixing
between the refrigerant and the crankcase oil, and/or inhibit condensation of
refrigerant in
the crankcase. For example, when a compressor has been turned off for a period
of time,
the temperature of the refrigerant in the compressor may be low and so the
crankcase
heater may be utilized to increase the temperature of the refrigerant in the
crankcase and
inhibit mixing with crankcase oil. In various implementations, the air
conditioner may
utilize the crankcase heater during operations at ambient temperatures in a
low ambient
temperature range (e.g., below approximately 65 degrees Fahrenheit, below
approximately 62 degrees Fahrenheit, and/or from approximately 62 degrees
Fahrenheit
to approximately 45 degrees Fahrenheit). In some implementations, the range of
temperatures included in a low ambient temperature range may be determined
based on
the components of the air conditioner, manufacturer(s), field technician(s),
user(s), and/or
any other appropriate entity.
[026] The air conditioner may include an expansion device 150, as illustrated.
The
expansion device may include any device that at least partially expands
refrigerant
passing through the device. For example, the expansion device 150 may include
a
thermal expansion valve, an orifice, an air conditioner capillary tube (e.g.,
a tube with a
smaller cross-sectional area than other lines in the system and/or a tube with
a diameter
of approximately 0.02 inches to approximately 0.09 inches) and/or an
electronic
expansion valve.
[027] A controller 180 (e.g., a computer) may be coupled (e.g., communicably,
such as
by wires or linked by Wi-Fi) to component(s) of the air conditioner 100 and
control
various operations of the component(s) and/or system. For example, the
controller 180
may include modules (e.g., instructions), such as an operation module and/or
management module, stored in a memory of the controller and executable by a
processor
of the controller, to perform various operations of the air conditioner 100.
The operation
module may control operations of the air conditioner 100, such as receiving
requests for
operation, determining whether to respond to requests for operation, operating
various
components (e.g, compressors, reversing valves, and/or expansion valves), etc.
The
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management module may control operation and/or restriction of operation of one
or more
components of the air conditioner 100, such as fan(s), crankcase heater(s),
compressor(s),
etc. For example, the management module may determine properties of the air
conditioner (e.g., temperature proximate a portion of the air conditioner such
as ambient
temperature and/or pressure of at least a portion of the air conditioner),
retrieve one or
more predetermined values for properties (e.g., predetermined low ambient
temperature(s)), determine settings for crankcase heater(s) and/or
compressor(s), allow
crankcase heater(s) and/or compressor(s) to operate, restrict crankcase heater
and/or
compressor operation(s), allow crankcase operation, and/or any other
appropriate
operation.
[028] The controller 180 may include a memory that stores the modules (e.g.,
instructions) and/or other data. For example, the memory may store
predetermined
property values (e.g., predetermined low ambient temperature value(s),
predetermined
low ambient temperature range(s), predetermined low compressor temperature(s),
predetermined operating pressure(s), and/or predetermined operating pressure
range(s));
associations between determined properties of the air conditioner and
compressor
operation(s) and/or crankcase heater operation(s); and/or other appropriate
data.
[029] Although Figure 1 illustrates an implementation of an air conditioner,
other
implementations may be utilized as appropriate. For example, the air
conditioner may
include and/or not include any components, as appropriate. The air conditioner
may not
include an expansion device. The air conditioner may include more than two
compressors (e.g., a tandem compressor with four compressors). The air
conditioner may
include one compressor. In some implementations, the expansion device may
include
more than one expansion device. The air conditioner may be a heat pump and may
include a reversing valve to allow cooling and heating operations. In
some
implementations, the air conditioner may include one or more fans (e.g., one
or more fans
associated with the evaporator and/or one or more fans associated with the
condenser).
For example, a fan may include a multi-speed fan (e.g., a two-stage fan, a
three-stage fan,
and/or a variable speed fan) capable of adjusting an amount of air (e.g.,
volumetric flow
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rate and/or mass flow rate). The fans 160 and/or the fans 170 may include a
different
number or the same number of fans. The fans 160 and/or the fans 170 may
include more
than three fans. In some implementations, the fans 160 and/or the fans 170 may
include
less than three fans. In some implementations, one or more of the compressors
may not
include a crankcase heater.
[030] In some implementations, a portion of the air conditioner 100 may be
disposed
outside a building (e.g., an "outdoor portion" on the ground proximate a
building and/or
on a roof of the building) and a portion of the air conditioner 100 may be
disposed inside
the building (e.g., an "indoor portion"). For example, the outdoor portion may
include
condenser 110 and fans 160 and the indoor portion may include evaporator 140
and fans
170. In some implementations, such as a rooftop unit, the condenser 110, fans
160,
compressor A 120, crankcase heater 125, compressor B 130, crankcase heater
135,
evaporator 140, fans 170, and the expansion device 150 may be disposed in the
outdoor
portion. The outdoor and/or indoor portion may be at least partially disposed
in
housing(s).
[031] During a cooling cycle of the air conditioner 100, cool air may be
provided by
blowing air (e.g., from fans 170) at least partially through evaporator 140.
The
evaporator 140 may evaporate liquid refrigerant in the evaporator. The
evaporator may
remove heat from the air to generate cool air, and the cool air may be
provided to a
location (e.g., via ducting). The gaseous refrigerant may exit the evaporator
140, then
may be compressed by compressor A 120 and compressor B 130, and delivered to a
condenser 110. The condenser 110 may condense the gaseous refrigerant by
blowing air
(e.g., from fans 160) at least partially through the condenser 110 to remove
heat from the
gaseous refrigerant.
[032] During air conditioner operation at ambient temperatures in a
predetermined low
ambient temperature range. To inhibit mechanical wear and/or pressure
fluctuations
(e.g., outside a predetermined operational pressure range), the air
conditioner may control
fan operations and/or crankcase heater operations.
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[033] Figure 2 illustrates an implementation of an example process 200 for
managing
fan operations. A request for operation of an air conditioner may be received
(operation
210). For example, a user may request that cool air be delivered to a
location. The user
may specify parameters (e.g., temperature setpoint and/or humidity setpoint)
in the
request. The controller (e.g., a module of the controller) of the air
conditioner may
receive the request.
[034] A determination may be made whether to allow operation of the air
conditioner
(operation 220). For example, the request may include parameter(s). The
controller
(e.g., a module of the controller) may determine whether to allow operation of
the air
conditioner based at least partially on the parameter(s) in the request. For
example, the
request may specify that a temperature at a location be maintained at
approximately 75
degrees Fahrenheit. The controller may determine that the location is already
at
approximately 75 degrees Fahrenheit and restrict operation of the air
conditioner. The
controller may determine that the location is above 75 degrees and allow
operation of the
air conditioner to provide cool air to the location. Thus, the temperature of
the location
may be reduced.
[035] A property of the air conditioner may be determined (operation 230). For
example, a temperature proximate at least a portion of the air conditioner
(e.g., ambient
temperature and/or temperature proximate an outdoor condenser) may be detei
mined.
The air conditioner may include sensors (e.g., disposed such that a property
at a
predetermined location may be measured) that are coupled to the controller
such that a
property can be determined by the controller (e.g., a module of the controller
that is
executed by a processor of the controller).
[036] Setting(s) of one or more fans of the air conditioner may be determined
based at
least partially on the deteiinined property and the determination of whether
to allow
operation of the air conditioner (operation 240). For example, settings for
fans that
provide airflow to the condenser and/or to an outdoor portion of the air
conditioner may
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be determined. The determined property may be compared to a retrieved property
value
(e.g., predetermined operational property value, predetermined low property
value, and/or
other appropriate values for comparisons) to determine (e.g., using a module
of the
controller) whether to alter a fan setting. In some implementations, a table
of
associations may be retrieved to facilitate a determination of the setting
that should be
allowed for a fan. For example, a table of associations may specify a fan
setting at a
determined property (e.g., temperature and/or pressure).
[037] Operation of the fan(s) may be allowed and/or restricted based at least
partially on
the determined setting(s) (operation 250). For example, the controller may
transmit
signal(s) to one or more of the fans to allow and/or restrict operation based
on the
determined settings. For example, if a fan setting is determined to be off,
then the
controller (e.g., a module of the controller that is stored in a memory of the
controller and
executed by a processor of the controller) may transmit a signal to a fan to
restrict
operation of the fan. If a fan setting is determined to be on and at a first
low setting, the
controller may transmit a signal to allow operation of the fan at the first
low setting.
[038] Process 200 may be implemented by various systems, such as system 100.
One or
more of the operations or portions thereof may be stored in a memory of the
system
and/or executed by a processor of the system (e.g., controller). In addition,
various
operations may be added, deleted, and/or modified. For example, more than one
property
of the air conditioner may be determined. Setting(s) of the fan(s) may be
determined
based at least partially on one or more of the determined properties. In some
implementations, a property of the air conditioner, such as pressure, may be
determined
(e.g., in addition to and/or instead of a temperature). In some
implementations, the
determined settings of the fans comprise settings for fans that provide
airflow to the
condenser and/or the outdoor portion of the air conditioner. In some
implementations,
the air conditioner may include at least one multi-speed fan, with a high
setting and one
or more lower settings. When an operation of a fan is restricted, a fan may be
restricted
from operating at the high setting and allowed to operate at a low setting
and/or be
restricted from operation (e.g., turned off).
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[039] In some implementations, the temperature (e.g., ambient temperature)
proximate
at least a portion of the air conditioner may be determined. The controller
may select a
fan setting based on a received request for operation when the determined
temperature is
not in a predetermined low ambient temperature range (e.g., less than a
predetermined
low ambient temperature, such as 62 degrees Fahrenheit; and/or from
approximately 45
degrees Fahrenheit to approximately 62 degrees Fahrenheit). In some
implementations,
if the determined temperature is in a predetermined low ambient temperature
range (e.g.,
the determined temperature may be compared to a predetermined low ambient
temperature range retrieved from a memory of the controller), the controller
may
determine the fan setting based on a low ambient temperature protocol.
[040] In some implementations, the controller may retrieve a low ambient
temperature
protocol from a memory of the air conditioner. The low ambient temperature
protocol
may include formulas that relate determined temperatures, requests for
operation, and/or
fan speeds; association tables that relate determined temperatures, requests
for operation,
and/or fan speeds; and/or other appropriate ways to determine a fan speed
based at least
partially on determined temperature, determined pressure, and/or a request for
operation.
For example, a low ambient temperature protocol may determine fan speed based
on a
formula when a compressor operation comprises a full load, such as, but not
limited to
the following formula:
Fan speed = 0.000208328887205324 * (Determined Temperature)2
+ 0.000869569932420933* (Determined Temperature)
+ 0.29318046545814
[041] In some implementations, a low ambient temperature protocol may
determine fan
speed based on a formula when a compressor operation comprises a full load,
such as, but
not limited to the following formula:
Fan speed = 0.00021 * (Determined Temperature)2
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+ 0.00087 * (Determined Temperature) + 0.29
[042] In some implementations, a low ambient temperature protocol may
determine fan
speed based on a formula when a compressor operation comprises a part load,
such as,
but not limited to the following formula:
Fan speed = -0.0000499375955505381 * (Determined Temperature)2
+ 0.0127918634171138* (Determined Temperature)
+ 0.158510704636291
[043] In some implementations, a low ambient temperature protocol may
determine fan
speed based on a formula when a compressor operation comprises a part load,
such as,
but not limited to the following formula:
Fan speed = -0.00005 * (Determined Temperature)2
+ 0.013 * (Determined Temperature) + 0.16
[044] Utilization of the fan speed may maintain a pressure of the air
conditioner or
portion thereof in a predetermined pressure range. For example, the
predetermined
pressure range may be between the liquid line pressure switch setting and the
high-
pressure switch setting, in some implementations. In some implementations, the
predetermined pressure range may be based on steady state operational
pressures of the
air conditioner at temperatures above a predetermined low ambient temperature
range. In
some implementations, the predetermined pressure range may be based on
maintaining
compressor operation in a predetermined efficiency range (e.g., a middle
section of a
compressor efficiency map).
[045] In some implementations, the fan speed determined by the controller may
be
based at least partially on the request for operation. Based on the request
for operation,
the air conditioner may determine an operation of the compressors. For
example, the
compressor(s) may be operated at part load (e.g., one or more compressors may
be
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restricted and one or more compressors may be allowed to operate) or full load
(e.g., each
compressor of the air conditioner may be allowed to operate) based on the
request for
operation. The fan setting may be determined based at least partially on
whether the
compressor(s) of the air conditioner are operated at part load and/or full
load. The fan
may include one or more settings such as a high setting and one or more low
settings.
The high setting may be associated with a higher impeller speed than the low
settings.
The low settings may include a first low setting and a second low setting,
which is
associated with a lower impeller speed than the first low setting. When the
compressor
operation includes a full load operation and a determined temperature is less
than a
predetennined low ambient temperature, a fan may be allowed to operate at a
high
setting. When the compressor operation includes a part load operation and a
determined
temperature is less than a predetermined low ambient temperature, a fan may be
allowed
to operate at one of the low settings (e.g., a second low setting). In
some
implementations, if the detellnined temperature is less than a second
predetermined low
ambient temperature, which is less than the first predetermined low ambient
temperature,
and when the compressor operation includes a full load operation, a fan may be
allowed
to operate at a lower setting (e.g., a first low setting). In
some implementations, if the
determined temperature is less than a second predetermined low ambient
temperature and
when the compressor operation includes a part load operation, a fan may be
allowed to
operate at a lower setting (e.g., a third low setting, which is associated
with a lower
impeller speed than the second low setting).
[046] In some implementations, the low temperature protocol may include an
association table to facilitate determination (e.g., by a controller) of a fan
setting based on
temperature and/or compressor operation, such as but not limited to:
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[047] Table 1: example low temperature protocol association table
Compressor Determined Fan Speed of Fan
Temperature allowed to operate
Full Load Below first High Setting
predetermined low
ambient temperature
Full Load Below second First Low Setting
predetermined low
ambient temperature
Part Load Below first Second Low Setting
predetei mined low
ambient temperature
Part Load Below second Third Low Setting
predetermined low
ambient temperature
[048] Table 2: example low temperature protocol association table
Compressor Determined Fan Speed of Fan
Temperature allowed to operate
Full Load Below 62 degrees F > 650 RPM
Full Load Below 45 degrees F 650 RPM
Part Load Below 62 degrees F >330 RPM
Part Load Below 45 degrees F 330 RPM
[049] In some implementations, a crankcase heater operation may be managed
using the
low temperature protocol. The crankcase heater may be allowed to operate when
a
determined temperature (e.g., ambient temperature) is in a low ambient
temperature
range. For example, when a determined temperature is less than a first
predetermined
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ambient temperature and when compressor(s) are operated at part load, a
crankcase
heater associated with a compressor restricted from operation may be allowed
to operate.
When a determined temperature is less than a first predetermined ambient
temperature
and when compressor(s) are operated at full load, a crankcase heater may be
restricted
from operation. In some implementations, when a determined temperature is less
than a
second predetermined ambient temperature (e.g., less than approximately 45
degrees
Fahrenheit), operation of a crankcase heater may be allowed in each of the
crankcase
heaters (e.g., while the compressor is allowed to operate and/or restricted
from
operation).
[050] In some implementations, when the compressor(s) are operated at part
load, the
crankcase heater may be allowed to operate when at least one fan of the air
conditioner is
restricted. The crankcase heater may be restricted from operating when more
than one
fan of the air conditioner is allowed to operate.
[051] Figure 3 illustrates an implementation of an example process 300 for
managing
fan operations. A request for operation of an air conditioner may be received
(operation
310). For example, a user may transmit a request via a thermostat for
operation of an air
conditioner. The controller (e.g, a module of the controller) may receive the
request.
The request may include parameters, such as a setpoint temperature.
[052] A temperature proximate the air conditioner or portions thereof may be
determined (operation 320). For example, a temperature proximate an outdoor
condenser
may be determined. The determined temperature may be approximately equal to
the
ambient temperature. In some implementations, such as a rooftop air
conditioner, a
temperature proximate a housing of the air conditioner may be determined. A
sensor
(e.g., thermocouple) of the air conditioner may be coupled to the controller
to allow the
controller to determine a temperature proximate a portion of the air
conditioner, such as
the ambient temperature.
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[053] One or more predetermined low ambient temperatures may be retrieved
(operation 330). For example, a memory of a controller may store one or more
predetermined low ambient temperatures. In some implementations, predetermined
low
ambient temperatures may include a first predetermined low ambient temperature
and a
second predetermined low ambient temperature, which is lower in temperature
than the
first predetermined low ambient temperature. For example, the first
predetermined low
ambient temperature may be approximately 65 degrees Fahrenheit, approximately
62
degrees Fahrenheit, and/or approximately 60 degrees Fahrenheit. A
second
predetermined low ambient temperature may be approximately 48 degrees
Fahrenheit,
approximately 45 degrees Fahrenheit, and/or approximately 43 degrees
Fahrenheit, for
example.
[054] The determined temperature may be compared to one or more of the
retrieved
predetermined low ambient temperatures (operation 340). For example, the
controller
may deteimine if the determined temperature is lower than the predetermined
low
ambient temperature(s). In some implementations, the controller may determine
if the
deteimined temperature is between two of the retrieved predetermined low
ambient
temperatures.
[055] Setting(s) of one or more of the fans of the air conditioner may be
determined at
least partially based on the comparison (operation 350). For example, if a
determined
temperature is greater than the predetermined low ambient temperature(s), then
the
controller may determine a setting of a fan based at least partially on the
received request
for operation. If a determined temperature is less than at least one of the
predetermined
low ambient temperatures, then a controller may utilize a low ambient
temperature
protocol to determine a setting of fan(s) of the air conditioner. The
low ambient
temperature protocol may include determining setting(s) for fan(s), by, for
example,
allowing the controller to retrieve a formula and/or a table of associations
to determine a
fan speed based at least partially on an ambient temperature. The fans for
which settings
may be determined may include the fans proximate a location in which the
determined
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temperature is measured, the fans disposed in an outdoor portion of the air
conditioner,
and/or the fans that provide airflow to the condenser, in some
implementations.
[056] Operation of the fan(s) may be allowed and/or restricted based on the
determined
setting(s) (operation 360). For example, the setting(s) of the fan may include
turning the
fan off and/or allowing fan operation at a speed (e.g., according to the
setting). If the
setting of the fan includes turning the fan off, then operation of the fan may
be restricted.
If a setting of the fan includes operation of a fan at a low speed, for
example, then
operation of the fan may be allowed at the low speed. In some implementations,
one fan
may be allowed to operate while other fans are restricted from operating. In
some
implementations, all the fans of the air conditioner may be operated or
restricted.
[057] Process 300 may be implemented by various systems, such as system 100.
One or
more of the operations or portions thereof may be stored in a memory of the
system
and/or executed by a processor of the system (e.g., controller). In addition,
various
operations may be added, deleted, and/or modified. In some implementations,
process
300 may be performed in combination with other processes such as process 200.
For
example, more than one temperature proximate the air conditioner may be
determined.
The determined temperature(s) may be compared to the retrieved low ambient
temperature(s). In some implementations, predetermined low temperature
range(s) may
be retrieved (e.g., from a memory of the controller) and utilized in a
comparison of the
determined temperature to the retrieved low ambient temperature(s) (e.g.,
temperature
ranges).
[058] In some implementations, an air conditioner may include more than one
fan. One
or more of the fans may include a high setting and one or more low settings
(e.g., a first
low setting and a second low setting, which is associated with a slower
impeller speed
than the first low setting). The settings may be associated with impeller fan
speeds.
When a setting of the fan is determined (e.g., by the controller), a high
setting, one of the
low settings, and/or an off setting may be selected. For example, when a
determined
temperature is less than a first predetermined low ambient temperature, then a
controller
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(e.g., a module of a controller) may allow a first low setting for one of the
fans and
restrict operation of the other fans. If the determined temperature is less
than a second
predetermined low ambient temperature (e.g, less than the first predetermined
low
ambient temperature), then the controller may allow a second low setting for
one of the
fans and restrict operation of the other fans.
[059] In some implementations, the controller may determine whether to allow
operation of a crankcase heater. A determination of whether to allow operation
of a
crankcase heater may be based on the determined temperature. In some
implementations,
a determination of whether to allow operation of the crankcase heater may be
based at
least partially on the load of the compressor(s) and/or the setting of the
fan. For example,
when the compressor(s) operate at a part load, the crankcase heater may be
allowed to
operate when at least one of the fans is restricted from operation. A
crankcase heater
may be restricted from operating when more than one fan is and/or all of the
fans are
allowed to operate, in some implementations. In some implementations, when a
determined temperature is less than a first predetermined low ambient
temperature and
when the compressor(s) operate at part load, the crankcase heater associated
with
compressor(s) restricted from operating may be allowed to operate. When a
determined
temperature is less than a first predetermined low ambient temperature (e.g.,
less than the
first low ambient temperature) and when the compressor(s) operate at full
load, the
crankcase heater may be restricted from operating. When a determined
temperature is
less than a second predetermined low ambient temperature (e.g., less than the
first low
ambient temperature) and when the compressor(s) operate at part load, the
crankcase
heater associated with compressor(s) restricted from operating may be allowed
to operate.
In some implementations, operation of crankcase heaters associated with
compressors
allowed to operate, may be allowed, for example when a determined temperature
is less
than the second predetermined low ambient temperature.
[060] In some implementations, each compressor may include a crankcase heater.
When a controller determines whether to allow operation of a crankcase heater,
the
controller may allow each crankcase heater to have the same operation (e.g.,
on or off)
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PATENT
and/or different operations. For example, when compressors are allowed to
operate at
part load, the crankcase heater on the compressor that is restricted from
operation may be
allowed to operate. When compressors are allowed to operate at part load and
all of the
fans are allowed to operate, the crankcase heaters may be restricted from
operation.
[061] Figure 4 illustrates an implementation of an example process 400 for
managing
fan operations. A request for operation of an air conditioner may be received
(operation
410). For example, a user may transmit a request for operation of an air
conditioner (e.g.,
to provide cool air to a location). The request may be received by a module,
which is
stored in a memory of the controller and executed by the processor of the
controller.
[062] A temperature proximate a portion of the air conditioner may be
determined
(operation 420). For example, the air conditioner may include one or more
sensors to
determine temperature. The sensors may transmit a measurement to the
controller and a
temperature may be determined. The temperature may be measured at one or more
portions of the air conditioner and utilized and/or aggregated.
[063] One or more predetermined low ambient temperatures nay be retrieved
(operation
430). The predetermined low ambient temperature(s) may be stored in a memory
of the
air conditioner (e.g, controller). The predetermined low ambient
temperature(s) may
include a value or range of values.
[064] The determined temperature may be compared to one or more of the
retrieved
predetermined low ambient temperatures (operation 440). For example, the
controller
may determine if the determined temperature has a value less than and/or
greater than one
or more of the retrieved predetermined low ambient temperature(s). For
example, the
controller (e.g., a module executed by the processor of the controller) may
determine if
the determined temperature is less than a predetermined low ambient
temperature.
[065] If the determined temperature is less than at least one of the
predetermined low
ambient temperatures, operation of at least one of the fans may be restricted
and
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operation of at least one of the fans may be allowed, where the setting of the
fan
maintains a pressure of a portion of the air conditioner in a predetermined
pressure range
(operation 450). For example, a predetermined operational pressure range may
be
retrieved from a memory of the controller. The predetermined operational
pressure range
may include values that are less than the pressure at which a high-pressure
switch of the
air conditioner is triggered and/or greater than the liquid refrigerant
pressure in the air
conditioner. For example, the predetermined operational pressure range may be
greater
than approximately 30 psi and/or less than approximately 650 psi. Settings of
fans
allowed to operate may be determined by the controller to allow a pressure of
a portion of
the air conditioner to be maintained in the predetermined operational pressure
range. For
example, a formula may be retrieved that allows a fan setting to be determined
based on
determined temperature(s).
[066] Process 400 may be implemented by various systems, such as system 100.
One or
more of the operations or portions thereof may be stored in a memory of the
system
and/or executed by a processor of the system (e.g., controller). In addition,
various
operations may be added, deleted, and/or modified. In some implementations,
process
400 may be performed in combination with other processes such as process 200
and/or
process 300. For example, more than one pressure of a portion of the air
conditioner may
be determined. The determined pressures may be compared to one or more of the
retrieved predetermined pressure(s). In
some implementations, if the determined
pressure is within a predetermined operational pressure range, then setting(s)
of the fan(s)
may be determined based at least partially on the received request for
operation. If the
determined pressure is not within a predetermined operational pressure range,
then
setting(s) of the fan(s) may be based at least partially on a low ambient
temperature
protocol. Operation of the fan(s) may be allowed and/or restricted based at
least partially
on the determined setting(s). For example, the controller may transmit signals
to the fans
based on the determined settings and fan operations may be allowed and/or
restricted.
[067] In some implementations, operation of a crankcase heater and/or one or
more
portions of a low ambient temperature protocol may be utilized to maintain a
pressure of
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at least a portion of the air conditioner in a predetermined pressure range.
For example,
when a pressure is greater than a retrieved predetermined pressure and a
determination is
made to allow an ambient temperature protocol, a crankcase heater may be
allowed to
operate and/or may be restricted from operation. For example, a determination
of
whether to allow a crankcase heater operation may be based at least partially
on a setting
of the compressor (e.g, full load and/or partial load) and/or setting(s) of
fan(s).
[068] In some implementations, the setting(s) of the fans may be determined at
least
partially based on the determined temperature and/or the determined pressure.
For
example, the determined temperature may be compared to predetermined
temperature(s)
retrieved from a memory of the air conditioner and/or determined pressure may
be
compared to predeteimined pressure(s) retrieved from a memory of the air
conditioner.
The comparisons may be utilized to determine settings of the fans. A
determination of
whether to determine settings of the fans based on a low ambient temperature
protocol
may be based at least partially on the comparisons. For example, if the
determined
temperature is less than a predetermined low ambient temperature range and/or
the
determined pressure is outside a predetermined operational pressure range,
then a low
temperature protocol may be utilized to determine settings of the fans.
[069] Although a specific controller has been described in Figure I, the
controller may
be any appropriate computer or other programmable logic device. The controller
may
include a processor that executes instructions (e.g., modules) and manipulates
data to
perform operations of the controller. Processor may include a programmable
logic
device, a microprocessor, or any other appropriate device for manipulating
information in
a logical manner and memory may include any appropriate form(s) of volatile
and/or
nonvolatile memory, such as RAM and/or Flash memory.
[070] In addition, various software may be stored on the memory. For example,
instructions (e.g., operating systems and/or other types of software), an
operation module
and/or a fan management module may be stored on the memory. The operation
module
may operate the air conditioner and/or components thereof during normal
operations
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(e.g., operations in which the system operates based at least partially on
user requests for
operation). The fan management module may perform one or more of the
operations in
processes 200, 300, 400, portions thereof, and/or combinations thereof. For
example, the
fan management module may determine properties; retrieve predetermined
property
values and/or ranges of values; compare values; determine fan settings and/or
crankcase
heater settings; determine whether to allow low ambient temperature protocols;
determine
whether to retrieve a table of associations and/or foimulas; and/or other
operations.
[071] In some implementations, modules may be combined, such as into a single
module or multiple modules. Operation modules and/or fan management modules
may
be distinct modules. In an implementation, operation modules and/or fan
management
modules may include various modules and/or sub-modules.
[072] A communication interface may allow the controller to communicate with
components of the heat pump, other repositories, and/or other computer
systems. The
communication interface may transmit data from the controller and/or receive
data from
other components, other repositories, and/or other computer systems via
network
protocols (e.g., TCP/IP, Bluetooth, and/or Wi-Fi) and/or a bus (e.g., serial,
parallel, USB,
and/or FireWire). Operations of the heat pump stored in the memory may be
updated
and/or altered through the communication via network protocols (e.g, remotely
through a
firmware update and/or by a device directly coupled to the controller).
[073] The controller may include a presentation interface to present data to a
user, such
as though a monitor and speakers. The presentation interface may facilitate
receipt of
requests for operation from users.
[074] A client (e.g, control panel in field or building) may allow a user to
access the
controller and/or instructions stored on the controller. The client may be a
computer
system such as a personal computer, a laptop, a personal digital assistant, a
smart phone,
or any computer system appropriate for communicating with the controller. For
example,
a technician may utilize a client, such as a tablet computer, to access the
controller. As
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another example, a user may utilize a client, such as a smart phone, to access
the
controller and request operations.
[0751 Although Figure 1 provides one example of controller that may be used
with the
disclosure, controller can be implemented through computers such as servers,
as well as a
server pool. For example, controller may include a general-purpose personal
computer
(PC) a Macintosh, a workstation, a UNIX-based computer, a server computer, or
any
other suitable device. In
some implementations, a controller may include a
programmable logic device. For example, the controller may be mounted to a
wall of a
location in which air conditioning may be provided. According to one
implementation,
controller may include a web server. Controller may be adapted to execute any
operating
system including UNIX, Linux, Windows, or any other suitable operating system.
Controller may include software and/or hardware in any combination suitable to
provide
access to data and/or translate data to an appropriate compatible foimat.
10761 Various implementations of the systems and techniques described herein
can be
realized in digital electronic circuitry, integrated circuitry, specially
designed ASICs
(application specific integrated circuits), computer hardware, firmware,
software, and/or
combinations thereof These various implementations can include implementations
in
one or more computer programs that are executable and/or interpretable on a
programmable system, including at least one programmable processor, which may
be
special or general purpose, coupled to receive data and instructions from, and
to transmit
data and instructions to, a storage system, at least one input device, and at
least one
output device.
10771 These computer programs (also known as programs, software, software
applications or code) include machine instructions for a programmable
processor, and can
be implemented in a high-level procedural and/or object-oriented programming
language,
and/or in assembly/machine language. As used herein, the Willi "machine-
readable
medium" refers to any computer program product, apparatus and/or device (e.g.,
magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used
to
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provide machine instructions and/or data to a programmable processor,
including a
machine-readable medium that receives machine instructions as a machine-
readable
signal. The term "machine-readable signal" refers to any signal used to
provide machine
instructions and/or data to a programmable processor. The machine-readable
signal(s)
may be non-transitory waves and/or non-transitory signals.
[078] Although users have been described as a human, a user may be a person, a
group
of people, a person or persons interacting with one or more computers, and/or
a computer
system.
[079] It is to be understood the implementations are not limited to particular
systems or
processes described which may, of course, vary. It is also to be understood
that the
terminology used herein is for the purpose of describing particular
implementations only,
and is not intended to be limiting. As used in this specification, the
singular forms "a",
"an" and "the" include plural referents unless the content clearly indicates
otherwise.
Thus, for example, reference to "a setting" includes a combination of two or
more
settings and reference to "a fan" includes different types and/or combinations
of fans.
[080] Although the present disclosure has been described in detail, it should
be
understood that various changes, substitutions and alterations may be made
herein
without departing from the spirit and scope of the disclosure as defined by
the appended
claims. Moreover, the scope of the present application is not intended to be
limited to the
particular embodiments of the process, machine, manufacture, composition of
matter,
means, methods and steps described in the specification. As one of ordinary
skill in the
art will readily appreciate from the disclosure, processes, machines,
manufacture,
compositions of matter, means, methods, or steps, presently existing or later
to be
developed that perfoim substantially the same function or achieve
substantially the same
result as the corresponding embodiments described herein may be utilized
according to
the present disclosure. Accordingly, the appended claims are intended to
include within
their scope such processes, machines, manufacture, compositions of matter,
means,
methods, or steps.
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