HVAC system leak detection

Patent metadata

Field	Value
Publication number	US-11898764-B2
Application number	US-202318153237-A
Country	US
Kind code	B2
Filing date	Jan 11, 2023
Priority date	Jun 18, 2021
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

An HVAC system includes a high-pressure subsystem and a low-pressure subsystem. After determining that refrigerant leak diagnostics should be performed, a controllable valve is closed between a condenser and compressor of the HVAC system. The compressor then operates until a predetermined input refrigerant pressure is reached. After the predetermined input refrigerant pressure is reached, operation of the compressor is stopped. After stopping operation of the compressor and waiting at least a predetermined wait time, the pressure in the low-pressure subsystem of the HVAC system is monitored. A rate of change of the pressure in the low-pressure subsystem is determined. If the rate of change is negative and a magnitude of the rate of change is greater than a threshold value, a leak location is determined to be in the low-pressure subsystem.

First claim

What is claimed is:

1. A heating, ventilation, and air conditioning (HVAC) system, the HVAC system comprising:
a high-pressure subsystem comprising:
a condenser operable to receive refrigerant and transfer heat from the refrigerant to a flow of outdoor air, thereby generating a cooled refrigerant; and
a controllable valve positioned in a refrigerant conduit connecting the condenser to an evaporator; and

a low-pressure subsystem comprising:
the evaporator operable to receive the cooled refrigerant and transfer heat from a flow of air to the cooled refrigerant;
a compressor operable to compress the refrigerant; and
a pressure sensor operable to measure a refrigerant pressure in the low-pressure subsystem; and

a controller communicatively coupled to the pressure sensor, and the controllable valve, wherein the controller comprises a processor configured to:
close the controllable valve;
cause the compressor to operate until a particular refrigerant pressure is reached;
after the particular refrigerant pressure is reached, stop operation of the compressor;
after stopping operation of the compressor and waiting at least a particular wait time, monitor the refrigerant pressure in the low-pressure subsystem of the HVAC system for a period of time;
determine a rate of change of the refrigerant pressure in the low-pressure subsystem for the period of time;
if the rate of change is negative and a magnitude of the rate of change is greater than a threshold value, determine that a leak location of the refrigerant is in the low-pressure subsystem of the HVAC system; and
if one or both of the rate of change is not negative and the magnitude of the rate of change is not greater than a threshold value, determine that the leak location of the refrigerant is in the high-pressure subsystem of the HVAC system.

2. The HVAC system of claim 1 , wherein the HVAC system further comprises:
a first sensor positioned and configured to measure a saturation temperature of the refrigerant in the evaporator; and
a second sensor positioned and configured to measure a superheated vapor temperature of the refrigerant in the evaporator; and
the controller is further configured to detect a possible leak of the refrigerant by:
determining a superheat value based on a difference between the saturation temperature and the superheated vapor temperature; and
determining that both the saturation temperature is less than a corresponding threshold value and the superheat value is greater than a corresponding threshold value.

3. The HVAC system of claim 1 , wherein the processor is further configured to:
determine a system diagnosis comprising the leak location; and
cause the system diagnosis to be provided to a service provider associated with the HVAC system.

4. The HVAC system of claim 1 , wherein the processor is further configured to:
determine a system diagnosis comprising the leak location; and
cause the system diagnosis to be displayed on a thermostat associated with the HVAC system.

5. The HVAC system of claim 1 , wherein the processor is further configured to cause display of a mode indication on a thermostat of the HVAC system indicating that the HVAC system is operating in a diagnostic mode.

6. The HVAC system of claim 1 , further comprising:
a blower operable, when functioning as intended, to provide the flow of air across the evaporator;
wherein the controller is further communicatively coupled to the blower and configured to:
determine a blower status indicating whether the blower is operating as intended; and
determine a system diagnosis comprising the leak location and the blower status.

7. The HVAC system of claim 1 , further comprising:
an air filter positioned and configured to filter the flow of air before the flow of air reaches the evaporator;
an air filter sensor operable to measure a change in air pressure across the air filter;
wherein the controller is further communicatively coupled to the filter sensor and configured to:
detect a blockage of the air filter based on the change in air pressure across the air filter; and
determine a system diagnosis comprising the leak location and an indication of the detected blockage of the air filter.

8. The HVAC system of claim 1 , wherein the HVAC system further comprises a check valve positioned proximate an output of the compressor and configured to prevent the refrigerant from flowing into the outlet of the compressor after operation of the compressor is stopped.

9. A method of operating a heating, ventilation, and air conditioning (HVAC) system, the method comprising:
closing a controllable valve of the HVAC system, wherein the controllable valve is positioned in a refrigerant conduit connecting a condenser to an evaporator;
causing a compressor of the HVAC system to operate until a particular refrigerant pressure is reached;
after the predetermined refrigerant pressure is reached, causing the compressor to stop operating;
after stopping operation of the compressor and waiting at least a particular wait time, monitoring a refrigerant pressure in a low-pressure subsystem of the HVAC system for a period of time;
determining a rate of change of the refrigerant pressure in the low-pressure subsystem for the period of time;
if the rate of change is negative and a magnitude of the rate of change is greater than a threshold value, determining that a leak location of the refrigerant is in the low-pressure subsystem of the HVAC system; and
if one or both of the rate of change is not negative and the magnitude of the rate of change is not greater than a threshold value, determining that the leak location of the refrigerant is in a high-pressure subsystem of the HVAC system.

10. The method of claim 9 , further comprising detecting a possible leak of refrigerant from the HVAC system by:
receiving a saturation temperature determined by a first sensor positioned and configured to measure the saturation temperature of the refrigerant in the evaporator;
receiving a superheated vapor temperature determined by a second sensor positioned and configured to measure the superheated vapor temperature of the refrigerant in the evaporator;
determining a superheat value based on a difference between the saturation temperature and the superheated vapor temperature; and
determining that both the saturation temperature is less than a corresponding threshold value and the superheat value is greater than a corresponding threshold value.

11. The method of claim 9 , further comprising:
determining a system diagnosis comprising the leak location; and
causing the system diagnosis to be provided to a service provider associated with the HVAC system.

12. The method of claim 9 , further comprising:
determining a system diagnosis comprising the leak location; and
causing the system diagnosis to be displayed on a thermostat associated with the HVAC system.

13. The method of claim 9 , further comprising causing display of a mode indication on a thermostat of the HVAC system indicating that the HVAC system is operating in a diagnostic mode.

14. The method of claim 9 , further comprising:
determining a blower status indicating whether a blower of the HVAC system is operating as intended; and
determining a system diagnosis comprising the leak location and the blower status.

15. The method of claim 9 , further comprising:
detecting a blockage of an air filter of the HVAC system based on a change in air pressure across the air filter; and
determining a system diagnosis comprising the leak location and an indication of the detected blockage of the air f

Assignees

• Lennox Ind Inc

Inventors

• Delgoshaei Payam
• Berg Eric

Classifications

• F24F11/36 Primary

  to leakage of heat-exchange fluid · CPC title

• F24F11/84

  using valves · CPC title

• F24F11/86

  by controlling compressors within refrigeration or heat pump circuits · CPC title

• F24F2140/12

  Heat-exchange fluid pressure · CPC title

• F24F2140/20

  Heat-exchange fluid temperature · CPC title