US20130139529A1 - Fan Speed Control For Air-Cooled Condenser In Precision Cooling - Google Patents
Fan Speed Control For Air-Cooled Condenser In Precision Cooling Download PDFInfo
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- US20130139529A1 US20130139529A1 US13/490,820 US201213490820A US2013139529A1 US 20130139529 A1 US20130139529 A1 US 20130139529A1 US 201213490820 A US201213490820 A US 201213490820A US 2013139529 A1 US2013139529 A1 US 2013139529A1
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- Prior art keywords
- refrigerant
- temperature
- controller
- sensed
- speed
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D17/00—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces
- F25D17/04—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection
- F25D17/06—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection by forced circulation
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B49/00—Arrangement or mounting of control or safety devices
- F25B49/02—Arrangement or mounting of control or safety devices for compression type machines, plants or systems
- F25B49/027—Condenser control arrangements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2600/00—Control issues
- F25B2600/11—Fan speed control
- F25B2600/111—Fan speed control of condenser fans
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/21—Temperatures
- F25B2700/2106—Temperatures of fresh outdoor air
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
- Y02B30/70—Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating
Definitions
- the present disclosure relates to fan speed control for an air-cooled condenser.
- Cooling systems such as the type that utilize a vapor compression cycle, can include a compressor, a condenser, an expansion device, and an evaporator.
- the compressor is operable to condense a working fluid or refrigerant from a suction pressure to a discharge pressure, which is supplied to a condenser.
- heat is removed from the refrigerant while the refrigerant is at an elevated pressure.
- the refrigerant flows from the condenser through an expansion device wherein the pressure is reduced. From there, the refrigerant flows through an evaporator wherein heat is added and the temperature of the refrigerant is increased.
- the refrigerant flows from the evaporator to the compressor and the process begins again.
- the condenser may be an air-cooled condenser wherein a fan can be utilized to supply a flow of air over the condenser to facilitate the removal of heat from the refrigerant flowing therethrough.
- the current control methodology involves maintaining the condensing pressure (the pressure of the refrigerant at/in the condenser) at a fixed and elevated value to allow for proper function of an expansion valve.
- the fixed condensing pressure is a minimum condensing pressure.
- the condensing pressure can be maintained at or above approximately 220 PSIG when R407C is utilized as a refrigerant, by way of non-limiting example.
- the condensing pressure can be maintained at or above the fixed elevated value by adjusting the operation of the condenser. For example, the speed of the fan that supplies the airflow through the condenser can be adjusted to maintain the fixed elevated condensing pressure with a variable frequency drive or a fan speed control.
- the condensing pressure can also be maintained at or above the fixed elevated value by adjusting inlet valves, head pressure control valves, or other means to reduce the effectiveness of the air-cooled condenser.
- the present teachings provide for an air conditioner system including a condenser fan, an ambient temperature sensor, a refrigerant pressure sensor, and a controller.
- the ambient temperature sensor is to sense ambient temperature at the system.
- the refrigerant pressure sensor is to sense pressure of a refrigerant of the system.
- the target refrigerant pressure module is to identify an optimum pressure of the refrigerant in the system.
- the controller is to generate an output representing a speed of the condenser fan operable to maintain the pressure of the refrigerant at about the optimum pressure as the ambient temperature of the system changes.
- the present teachings also provide for an air conditioner system including a compressor, a condenser fan, an ambient temperature sensor, a refrigerant temperature sensor, a target refrigerant temperature module, and a controller.
- the ambient temperature sensor is to sense ambient temperature at the system.
- the refrigerant temperature sensor is to sense temperature of a refrigerant of the system.
- the target refrigerant temperature module is to identify an optimum temperature of the refrigerant in the system.
- the controller is to generate an output representing a speed of the condenser fan operable to maintain the temperature of the refrigerant at about the optimum temperature.
- the present teachings further provide for a method for controlling a condensing fan of an air conditioner system with a controller.
- the method includes determining whether a compressor of the air conditioner system is on or off.
- the method further includes operating the condenser fan of the air conditioner system at a first speed corresponding to a sensed ambient temperature for a predetermined time period when the compressor is on.
- the method also includes operating the condenser fan at a second speed after expiration of the predetermined time period, the second speed determined by the controller based on the sensed ambient temperature and an error between a sensed refrigerant pressure and a target refrigerant pressure.
- the second speed is sufficient to move the sensed refrigerant pressure to the target refrigerant pressure.
- the present teachings also provide for a method for controlling a condensing fan of an air conditioner system with a controller.
- the method includes stopping the condensing fan when sensed refrigerant temperature is less than a first predetermined refrigerant temperature.
- the method also includes operating the condensing fan at a first speed predetermined to correspond to sensed ambient temperature when sensed refrigerant temperature is greater than or equal to the first predetermined refrigerant temperature and less than a second predetermined refrigerant temperature.
- the method further includes operating the condensing fan at a second speed predetermined to correspond to sensed ambient temperature and based on error between sensed refrigerant temperature and a target refrigerant temperature when sensed refrigerant temperature is greater than or equal to the second predetermined refrigerant temperature and less than a third predetermined refrigerant temperature, the second speed sufficient to move sensed refrigerant temperature to the target refrigerant temperature.
- the method still further includes operating the condensing fan at a third speed based on error between sensed refrigerant temperature and the target refrigerant temperature when sensed refrigerant temperature is greater than or equal to a third predetermined refrigerant temperature that is greater than the second predetermined refrigerant temperature, the third speed sufficient to move sensed refrigerant temperature to the target refrigerant temperature.
- FIG. 1 is a block diagram that illustrates a cooling system according to the present teachings
- FIG. 2 is a functional block diagram that illustrates a control system of the cooling system of FIG. 1 ;
- FIG. 3 is a flow chart of a control method for a condensing fan of the cooling system
- FIG. 4 is a functional block diagram that illustrates another control system of the cooling system of FIG. 1 ;
- FIG. 5 is a flow chart of another control method for the condensing fan of the cooling system.
- FIG. 6 is a flow chart that provides additional detail regarding the control method of FIG. 5 .
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- the cooling system 10 includes an air-cooled condenser 12 , an expansion device 14 , an evaporator 16 , and a compressor 18 .
- the compressor 18 is operable to condense a refrigerant or working fluid from a suction pressure to a discharge pressure.
- the refrigerant exits compressor 18 and flows through condenser 12 , expansion device 14 , and evaporator 16 , and then returns to compressor 18 .
- heat Q 1 is removed from the refrigerant by an airflow flowing across condenser 12 .
- the airflow is provided by a fan 20 powered by a motor 22 .
- the pressure of the refrigerant is reduced as the refrigerant passes across expansion device 14 .
- heat Q 2 is transferred to the refrigerant flowing therethrough.
- the cooling system 10 further includes various sensors or other devices for monitoring the system 10 .
- pressure sensor 24 senses condensing pressure of the refrigerant in the cooling system 10 .
- Ambient temperature sensor 26 senses ambient temperature of the airflow supplied to the condenser 12 by the fan 20 .
- Refrigerant temperature sensor 28 senses temperature of the refrigerant.
- the cooling system 10 is generally controlled by a controller 30 .
- the controller 30 is configured to receive various inputs, such as from the compressor 18 , the pressure sensor 24 , the ambient temperature sensor 26 , the refrigerant temperature sensor 28 , and the motor 22 representing a speed of the motor 22 and the fan 20 , as further described herein.
- the controller 30 can also receive a user input 32 , which is indicative of a desired operational mode for the cooling system 10 .
- the controller 30 is further configured to generate various outputs, such as to the motor 22 of the condenser fan 20 .
- the controller 30 includes various modules.
- module refers to an application-specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality.
- ASIC application-specific integrated circuit
- processor shared, dedicated, or group
- memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality.
- an exemplary control system of the cooling system 10 is generally illustrated at reference numeral 50 .
- the controller 30 is illustrated as having a first controller configuration 30 A (referred to herein as controller 30 A).
- the controller 30 A includes a proportional-integral-derivative controller (PID) module 52 , a first function module 54 , and a second function module 56 .
- Switch 58 selects an output from the controller 30 A, as further described herein.
- PID proportional-integral-derivative controller
- the controller 30 A can be a single module operable to perform the described functionality, a plurality of integrated modules, as shown, that can perform the described functionality, a combination of integrated and individual modules that can perform the described functionality, and/or one or more individual modules that can perform the described functionality.
- the controller 30 A as illustrated and described is merely exemplary in nature and is not intended to limit the scope of the present disclosure.
- the controller 30 A is described as including the PID module 52 , any suitable control module can be included.
- the controller 30 A generates a condenser fan speed output to the motor 22 based on a variety of different inputs.
- the compressor 18 provides an input to the controller 30 A representing on/off status of the compressor.
- the refrigerant pressure sensor 24 provides an input representing observed refrigerant pressure.
- the ambient temperature sensor 26 provides an input representing observed ambient temperature.
- a target pressure (or setpoint) of the refrigerant is input to the controller 30 A from module 34 .
- the target pressure is a predetermined, optimum pressure based on efficiency and optimization calculations for the entire cooling system 10 .
- the controller 30 A maintains the refrigerant at the target pressure even as ambient temperature detected by the ambient temperature sensor 26 changes by controlling the speed of the condenser fan 20 and the motor 22 .
- the system 50 determines at block 104 whether the compressor 18 is on or off based on the compressor on/off status input received by the controller 30 A from the compressor 18 . If the compressor is not on, then the controller proceeds to block 106 and stops the condenser fan 20 after 30 seconds of operation at a suitable speed. The controller 30 A then ends operation at block 108 . In various embodiments, control returns to block 104 to monitor the on/off status of the compressor 18 .
- the controller 30 A proceeds to block 110 and first sets the switch 58 such that output of the controller 30 A is generated by the second function module 56 .
- the second function module 56 generates an initial speed for the motor 22 , and thus an initial speed for the fan 20 as well, based on ambient temperature sensed by the ambient temperature sensor 26 .
- the initial speed generated at block 110 provides the controller 30 A with a fast initial response that will set the speed of the condenser fan 20 high enough to prevent the sensed refrigerant pressure from exceeding the target refrigerant pressure, thus preventing a pressure “overshoot.”
- the controller 30 A moves to block 112 and sets the switch 58 such that output of the controller 30 A is generated by the PID module 52 .
- the PID module 52 generates an output based on two inputs.
- the first input is generated by the first function module 54 and includes gains and parameters for the PID module 52 based on the ambient temperature observed by the ambient temperature sensor 26 .
- the second input is the error between refrigerant pressure sensed by the refrigerant pressure sensor 24 and the target refrigerant pressure or setpoint generated at module 34 .
- the output of the PID module 52 represents a speed for the motor 22 , and thus a speed for the condenser fan 20 sufficient to bring the refrigerant pressure sensed by the refrigerant pressure sensor 24 to, or nearly to, the target refrigerant pressure of module 34 .
- bumpless transfer is provided between the selected output of controller 30 A and the PID module 52 , as illustrated in FIG. 2 .
- the PID module 52 will generate an output updated to maintain the refrigerant pressure sensed by the refrigerant pressure sensor 24 at, or approximate to, the target refrigerant pressure generated by module 34 , while also taking into account changes in ambient temperature sensed by the ambient temperature sensor 26 .
- the controller 30 A can end operation at block 114 in response to, for example, user input 32 .
- controller 30 B another exemplary control system of the cooling system 10 is generally illustrated at reference numeral 150 .
- the controller 30 is illustrated as having a second controller configuration 30 B (referred to herein as controller 30 B).
- the controller 30 B includes the PID module 52 , the first function module 54 , and the second function module 56 .
- the control system 150 further includes a third function module 60 , a first switch 62 , a second switch 64 , and a zero fan speed detector 66 .
- the controller 30 B can be in place of or in addition to the controller 30 A, as a backup for example, to control the speed of the condenser fan 20 based on the temperature of the refrigerant as sensed by the refrigeration temperature sensor 28 .
- the controller 30 B can be a single module operable to perform the described functionality, a plurality of integrated modules, as shown, that can perform the described functionality, a combination of integrated and individual modules that can perform the described functionality, and/or one or more individual modules that can perform the described functionality.
- the controller 30 B as illustrated and described is merely exemplary in nature and is not intended to limit the scope of the present disclosure.
- the controller 30 B is described as including the PID module 52 , any suitable control module can be included.
- the controller 30 B generates a condenser fan speed output to the motor 22 based on a variety of different inputs.
- the compressor 18 provides an input to the controller 30 B at the first switch 62 representing on/off status of the compressor.
- the ambient temperature sensor 26 provides an input representing sensed ambient temperature to the first and second function modules 54 and 56 .
- the refrigerant temperature sensor 28 provides an input representing sensed refrigerant temperature to the third function module 60 .
- a target refrigerant temperature (or setpoint) of the refrigerant is input to the controller 30 B from module 36 .
- the error between the sensed refrigerant temperature and the target refrigerant temperature is input to the PID module 52 .
- the target refrigerant temperature (or set point) is a predetermined temperature based on efficiency and optimization calculations for the entire cooling system 10 .
- the controller 30 B maintains the refrigerant at the target temperature even as ambient temperature and various other environmental conditions change by controlling the speed of the condenser fan 20 and the motor 22 .
- the controller 30 B determines whether the compressor 18 is on or not. If the compressor 18 is not on, then the controller 30 B proceeds to block 206 and stops the condenser fan 20 after a predetermined time of operation, such as about 30 seconds for example, at a predetermined speed.
- the predetermined speed can be any suitable speed, such as a speed sufficient to provide standard operation. If the controller 30 B determines that the compressor is on, then the controller 30 B proceeds to block 208 . Otherwise, the controller 30 B can end operation at block 224 or return to block 204 . In various embodiments, control returns to monitor whether the compressor 18 is on or off.
- the controller 30 B reads the input from the refrigerant temperature sensor 28 and accesses the third function module 60 to determine whether the refrigerant temperature is greater than or equal to 15° C. for example, or another suitable preset temperature. If the refrigerant temperature is not greater than or equal to 15° C., then the controller 30 B proceeds to block 210 and generates an output stopping the motor 22 and the condenser fan 20 . If the refrigerant temperature is greater than or equal to 15° C., then the controller 30 B proceeds to block 212 . Otherwise, the controller 30 B can end operation at block 224 or return to block 204 . In various embodiments, control returns to monitor whether the compressor 18 is on or off.
- the controller 30 B reads the input from the refrigerant temperature sensor 28 and accesses the third function module 60 to determine whether the refrigerant temperature is greater than or equal to 25° C. for example, or another suitable preset temperature. If the refrigerant temperature is not greater than or equal to 25° C., then the controller 30 B proceeds to block 214 .
- the controller 30 B accesses the second function module 56 , which includes an ambient temperature table with preset speeds for the condenser fan 20 based on ambient temperature. The controller 30 B uses the second function module 56 to generate an output to the motor 22 to run the condenser fan 20 at a preset speed proscribed by the ambient temperature table based on ambient temperature sensed by the ambient temperature sensor 26 .
- the controller 30 B proceeds to block 216 . Otherwise, the controller 30 B can end operation at block 224 or return to block 204 . In various embodiments, control returns to monitor whether the compressor 18 is on or off.
- the controller 30 B reads the input from the refrigerant temperature sensor 28 and accesses the third function module 60 to determine whether the refrigerant temperature is greater than or equal to 35° C. for example, or another suitable preset temperature. If the refrigerant temperature is not greater than or equal to 35° C., then the controller 30 B proceeds to block 218 . At block 218 , generates a fan speed output to the motor 22 that interpolates fan speed based on control by the PID module 52 and fan speed proscribed by the ambient temperature table of the second function module 56 . If the refrigerant temperature is greater than or equal to 35° C., then the controller 30 B proceeds to block 220 . Otherwise, the controller 30 B can end operation at block 224 or return to block 204 . In various embodiments, control returns to monitor whether the compressor 18 is on or off.
- the controller 30 B uses PID module 52 to generate a fan speed output to the motor 22 .
- block 220 uses the PID module 52 to control speed of the condenser fan 20 will be described in detail.
- the controller 30 B proceeds to block 230 and accesses the first function module 54 to load PID gain constants from the ambient temperature table of the second function module 56 and perform gain scheduling for the PID module 52 .
- the controller 30 B determines whether the speed of the condenser fan 20 based upon the output fan speed detector 66 . If the speed is zero, then the controller proceeds to block 234 .
- the controller 30 B determines an initial speed of the fan 20 based on the gain scheduling performed at block 230 . If at block 232 the controller 30 B determines that the fan speed is not zero, then the controller 30 B bypasses block 234 .
- the controller 30 B records current speed of the fan 20 for bumpless transfer.
- the controller 30 B reads both the sensed refrigerant temperature based on the input received from the refrigerant temperature sensor 28 , and the target refrigerant temperature (setpoint) from the module 36 .
- the difference or error between the sensed refrigerant temperature and the target refrigerant temperature is input to the PID module 52 .
- the PID module 52 calculates an output at block 240 .
- This output represents a speed of the motor 22 , and thus the fan 20 , sufficient to bring the refrigerant temperature sensed by the sensor 28 to the target refrigerant temperature provided by module 36 .
- the controller 30 B can end operation at block 224 ( FIG. 5 ) or return to block 204 . In various embodiments, control returns to monitor whether the compressor 18 is on or off.
- the control system 150 maintains the refrigerant temperature at the target refrigerant temperature.
- This hybrid control can utilize low-cost temperature sensors, such as thermistors that vary resistance with temperature, instead of pressure sensors at the condenser outlet to control the condenser fan speed, and can be used independently or as backup when the pressure sensor 24 fails.
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Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12192667.9A EP2597389A3 (en) | 2011-11-14 | 2012-11-14 | Fan speed control for air-cooled condenser in precision cooling |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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CN201110359448.9A CN103105023B (zh) | 2011-11-14 | 2011-11-14 | 用于气冷式冷凝器在精确制冷时的风扇速度控制 |
CN2011103594489 | 2011-11-14 |
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US20130139529A1 true US20130139529A1 (en) | 2013-06-06 |
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US13/490,820 Abandoned US20130139529A1 (en) | 2011-11-14 | 2012-06-07 | Fan Speed Control For Air-Cooled Condenser In Precision Cooling |
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US9297567B2 (en) | 2009-01-30 | 2016-03-29 | National Refrigeration & Air Conditioning Canada Corp. | Condenser assembly with a fan controller and a method of operating same |
US20160178245A1 (en) * | 2014-12-23 | 2016-06-23 | Lg Electronics Inc. | Refrigerator |
CN105805924A (zh) * | 2016-05-11 | 2016-07-27 | 江苏海事职业技术学院 | 一种具有良好冷凝效果的空调机 |
WO2016138382A1 (en) * | 2015-02-27 | 2016-09-01 | Carrier Corporation | Refrigeration system condenser fan control |
US20160342181A1 (en) * | 2015-05-21 | 2016-11-24 | Dell Products, Lp | System and Method for Adjusting Cooling Fan Control Settings Based on Identification of a Module |
US20170129311A1 (en) * | 2015-11-06 | 2017-05-11 | Ford Global Technologies, Llc | Air conditioning system and method of controlling the same |
US9835360B2 (en) | 2009-09-30 | 2017-12-05 | Thermo Fisher Scientific (Asheville) Llc | Refrigeration system having a variable speed compressor |
US9989289B2 (en) | 2013-02-12 | 2018-06-05 | National Refrigeration & Air Conditioning Corp. | Condenser unit |
US10653042B2 (en) * | 2016-11-11 | 2020-05-12 | Stulz Air Technology Systems, Inc. | Dual mass cooling precision system |
US10712033B2 (en) | 2018-02-27 | 2020-07-14 | Johnson Controls Technology Company | Control of HVAC unit based on sensor status |
US11181291B2 (en) * | 2016-11-01 | 2021-11-23 | Ecoer Inc. | DC varaiable speed compressor control method and control system |
DE102014109331B4 (de) | 2013-07-04 | 2022-01-05 | Smc Corporation | Konstanttemperaturflüssigkeitszirkuliervorrichtung und Betriebsverfahren hierfür |
US11364769B2 (en) | 2019-12-17 | 2022-06-21 | Ford Global Technologies, Llc | Vehicle cabin thermal management system and control methods |
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EP3411642B9 (en) * | 2016-02-03 | 2023-05-24 | Danfoss A/S | A method for controlling a fan of a vapour compression system in accordance with a variable temperature setpoint |
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