Compressor diagnostics for a modular outdoor refrigeration system

Abstract

A refrigeration system includes a compressor, one or more sensors, and a controller. The one or more sensors are operable to sense data associated with the operation of the refrigeration system. The controller is operable to receive the data associated with the operation of the refrigeration system from the one or more sensors, determine an ideal output value of the compressor based at least on data associated with the operation of the refrigeration system, and determine, based at least on the data associated with the operation of the refrigeration system and the ideal output variable, that the performance of the compressor is abnormal.

1 . A refrigeration system comprising:
 a compressor;   one or more sensors operable to sense a suction pressure, a suction temperature, a discharge pressure, and an actual current associated with the compressor;   a controller operable to:
 receive the suction pressure, the suction temperature, the discharge pressure, and the actual current sensed by the one or more sensors; 
 calculate a range of values representing an ideal current for the compressor, the range of values determined based on the suction pressure, the suction temperature, and the discharge pressure sensed by the one or more sensors; and 
 trigger an alarm in response to a determination that the actual current sensed by the one or more sensors is outside the calculated range of values representing the ideal current. 
   
     
     
         2 . A refrigeration system comprising:
 a compressor;   one or more sensors operable to sense data associated with the operation of the refrigeration system;   a controller operable to:
 receive the data associated with the operation of the refrigeration system from the one or more sensors; 
 determine an ideal output variable of the compressor based at least on the data associated with the operation of the refrigeration system; 
 determine, based at least on the data associated with the operation of the refrigeration system and the ideal output variable, that the performance of the compressor is abnormal. 
   
     
     
         3 . The refrigeration system of  claim 2 , wherein the controller is further operable to report when the performance of the compressor is abnormal. 
     
     
         4 . The refrigeration system of  claim 2 , wherein the ideal output variable is one of:
 mass flow;   power;   current; or   capacity.   
     
     
         5 . The refrigeration system of  claim 2 , wherein the sensors are operable to sense:
 suction temperature of the compressor;   suction pressure of the compressor;   discharge pressure of the compressor; and   actual current of the compressor.   
     
     
         6 . The refrigeration system of  claim 2 , wherein:
 to determine the ideal output variable of the compressor, the controller is operable to calculate a range of values associated with the ideal output variable; and   to determine that the performance of the compressor is abnormal, the controller is operable to determine that a value associated with the operational data is outside the range of values associated with the ideal output value.   
     
     
         7 . The refrigeration system of  claim 2 , wherein the controller is operable to:
 determine a reserve measurement based on a value associated with the ideal output variable and a value associated with the operational data;   report when the reserve measurement is less than a specified value.   
     
     
         8 . The refrigeration system of  claim 7 , wherein the reserve measurement corresponds to a reserve capacity, the ideal output variable corresponds to a maximum capacity of the refrigeration system, and the value associated with the operational data corresponds to an actual capacity of the refrigeration system. 
     
     
         9 . A method for a refrigeration system, comprising:
 receiving data associated with the operation of the refrigeration system;   determining an ideal output variable of a compressor based at least on the data associated with the operation of the refrigeration system;   determining, based at least on the data associated with the operation of the refrigeration system and the ideal output variable, that the performance of the compressor is abnormal.   
     
     
         10 . The method of  claim 9 , further comprising:
 reporting when the performance of the compressor is abnormal.   
     
     
         11 . The method of  claim 9 , wherein the ideal output variable is one of:
 mass flow;   power;   current; or   capacity.   
     
     
         12 . The method of  claim 9 , wherein the data associated with the operation of the refrigeration system is received from sensors, the sensors operable to sense:
 suction temperature of the compressor;   suction pressure of the compressor;   discharge pressure of the compressor; and   actual current of the compressor.   
     
     
         13 . The method of  claim 9 , wherein determining a reserve measurement comprises:
 calculating a range of values associated with the ideal output variable; and   determining that a value associated with the operational data is outside the range of values associated with the ideal output variable.   
     
     
         14 . The method of  claim 9 , further comprising:
 determining a reserve measurement based on a value associated with the ideal output variable and a value associated with the operational data; and   reporting when the reserve measurement is less than a specified value.   
     
     
         15 . The method of  claim 14 , wherein the reserve measurement corresponds to a reserve capacity, the ideal output variable corresponds to a maximum capacity of the refrigeration system, and the value associated with the operational data corresponds to an actual capacity of the refrigeration system. 
     
     
         16 . A controller for a refrigeration system, the controller comprising one or more processors and logic encoded in non-transitory computer readable memory, the logic, when executed by the one or more processors, operable to:
 receive data associated with the operation of the refrigeration system from one or more sensors;   determine an ideal output variable of a compressor based at least on the data associated with the operation of the refrigeration system;   determine, based at least on the data associated with the operation of the refrigeration system and the ideal output variable, that the performance of the compressor is abnormal; and   report when the performance of the compressor is abnormal.   
     
     
         17 . The controller of  claim 16 , wherein the ideal output variable is one of:
 mass flow;   power;   current; or   capacity.   
     
     
         18 . The controller of  claim 16 , wherein the one or more sensors are operable to sense:
 suction temperature of the compressor;   suction pressure of the compressor;   discharge pressure of the compressor; and   actual current.   
     
     
         19 . The controller of  claim 16 , further operable to:
 determine the ideal output variable of the compressor by calculating a range of values associated with the ideal output variable; and   determine that the performance of the compressor is abnormal by determining that a value associated with the operational data is outside the range of values associated with the ideal output variable.   
     
     
         20 . The controller of  claim 19 , further operable to:
 determine a reserve measurement based on a value associated with the ideal output variable and a value associated with the operational data; and   report when the reserve measurement is less than a specified value.