Low charge cooler and natural cooling

Abstract

The present disclosure provides a system including a vapor compression assembly and a natural cooling assembly. The natural cooling assembly corresponds to a cooling fluid and includes an air-cooled heat exchanger, an additional heat exchanger, and a valve. The system also includes a controller configured to receive data indicative of an environmental condition, an operating condition, or both of the system. The controller is further configured to actuate the valve based on the data between: a first setting in which the cooling fluid is directed to the additional heat exchanger and blocked into a condenser of the vapor compression assembly; a second arrangement in which the cooling fluid is directed to the condenser and blocked into the additional heat exchanger; and a third arrangement in which a first portion of the cooling fluid is directed to the additional heat exchanger and a second portion of the cooling fluid is directed to the condenser.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 350,743, filed on June 9, 2022, entitled “LOW CHARGE CHILLER AND FREECOOLING,” which is hereby incorporated by reference in its entirety for all purposes. Background Art

[0003] This section is intended to introduce the reader to various aspects of the technology that may be related to various aspects of the present disclosure described below. It is believed that this discussion helps to provide the reader with background information to promote a better understanding of various aspects of the present disclosure. Therefore, it should be understood that these statements should be read in this light, rather than as an admission of the prior art.

[0004] The present application generally relates to heating, ventilation, air conditioning and / or refrigeration (HVAC&R) systems that employ a vapor compression assembly (or "chiller assembly") and a free cooling assembly.

[0005] Some HVAC&R systems (such as chillers) employ vapor compression assemblies. The vapor compression assembly utilizes a working fluid (e.g., a refrigerant) to change phase between vapor, liquid, and combinations thereof in response to different temperatures and pressures within components exposed to the vapor compression assembly. The vapor compression assembly may include an evaporator configured to place the working fluid in a heat exchange relationship with, for example, a conditioning or process fluid (e.g., water) such that the working fluid absorbs heat from the process fluid. The process fluid cooled by the working fluid may then be directed toward a conditioned environment (such as a data center) served by the HVAC&R system. The process fluid may be passed through downstream equipment (such as an air handler) to condition other fluids, such as air directed into the conditioned environment. A condenser of the vapor compression assembly may be employed to receive the working fluid and condense the working fluid into a liquid phase. A compressor of the vapor compression assembly may be employed to deflect the working fluid through the vapor compression assembly (e.g., by increasing the pressure of the working fluid).

[0006] In certain HVAC&R systems that employ a vapor compression assembly, a free cooling assembly may also be employed. For example, a cooling fluid (e.g., water, glycol, or a mixture thereof) associated with the free cooling assembly may be employed to cool various fluids associated with the HVAC&R system, such as a working fluid in a condenser of the vapor compression assembly. In addition, a cooling tower (or other cooling source) may also be employed in the free cooling assembly to reduce the temperature of the process fluid via ambient air. In this manner, the free cooling assembly may take advantage of relatively low ambient air temperatures for providing cooling and reducing the load on the vapor compression assembly.

[0007] In conventional systems, operation of the free cooling component may be activated during certain conditions, such as when the ambient air temperature is relatively low. When the ambient air temperature is relatively low, the HVAC&R system may be configured to operate with sufficient cooling capacity via the free cooling component without powering the compressor (e.g., by relying on thermosiphoning or natural convection to move the working fluid) and / or while reducing reliance on the compressor (or other components) of the vapor compression component. However, in conventional HVAC&R systems that utilize both vapor compression and free cooling components, technical limitations may require that reliance on the vapor compression component take precedence over reliance on the free cooling component. That is, in conventional HVAC&R systems, cooling may rely heavily on the vapor compression component, which requires a relatively large refrigerant charge in the vapor compression component and results in energy inefficiency of the HVAC&R system. Therefore, it is now recognized that there is a need for improvements in HVAC&R systems that employ vapor compression and free cooling components. Summary of the invention

[0008] The following describes an overview of certain embodiments disclosed herein. It should be understood that these aspects are presented only to provide the reader with a brief overview of these specific embodiments, and these aspects are not intended to limit the scope of the present disclosure. In fact, the present disclosure may cover various aspects that may not be described below.

[0009] In one embodiment, the HVAC&R system includes a vapor compression component and a free cooling component. The free cooling component corresponds to a cooling fluid (e.g., in an internal fluid cooling loop) and includes an air cooling heat exchanger, one or more additional heat exchangers, a fluid pump, and a valve. The HVAC&R system also includes at least one controller configured to receive data indicating an ambient condition, an operating condition, or both of the HVAC&R system. The at least one controller is also configured to actuate the valve between various settings based on the data. A first setting, in which the cooling fluid is directed to the additional heat exchanger and blocked from entering the condenser of the vapor compression component; a second setting, in which the cooling fluid is directed to the condenser and blocked from entering the additional heat exchanger; and a third setting, in which a first portion of the cooling fluid is directed to the additional heat exchanger and a second portion of the cooling fluid is directed to the condenser.

[0010] In another embodiment, a control component of a heating, ventilation, air conditioning, and / or refrigeration (HVAC&R) system includes a sensor configured to detect an ambient condition or an operating condition of the HVAC&R system. The at least one controller is configured to receive feedback from the sensor indicating the ambient condition or the operating condition. The at least one controller is also configured to actuate a valve of a free cooling component between various settings based on the feedback. The various settings include: a first setting in which a cooling fluid of the free cooling component is directed toward a heat exchanger of the free cooling component instead of a vapor compression component; a second setting in which the cooling fluid is directed toward the vapor compression component instead of the heat exchanger; and at least one third setting in which a first portion of the cooling fluid is directed toward the heat exchanger and a second portion of the cooling fluid is directed toward the vapor compression component.

[0011] In yet another embodiment, a method of operating a heating, ventilation, air conditioning and / or refrigeration (HVAC&R) system includes receiving, via at least one controller, first data indicating a first value of an ambient or operating condition of the HVAC&R system and controlling, via the at least one controller and based on the first data, a valve to a first setting in which a cooling fluid of a free cooling component is directed toward a heat exchanger of the free cooling component rather than a condenser of a vapor compression component. The method also includes receiving, via at least one controller, second data indicating a second value of the ambient or operating condition of the HVAC&R system, the second value being different from the first value and controlling, via the at least one controller and based on the second data, the valve to a second setting in which the cooling fluid is directed toward the condenser rather than the heat exchanger. The method also includes receiving, via the at least one controller, third data indicating a third value of the ambient or operating condition of the HVAC&R system, the third value being different from the first value and the second value and controlling, based on the third data, the valve to a third setting in which a first portion of the cooling fluid is directed toward the heat exchanger and a second portion of the cooling fluid is directed toward the condenser. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Various aspects of the present disclosure may be better understood after reading the following detailed description and referring to the drawings, in which:

[0013] Figure 1 is a schematic diagram of a heating, ventilation, air conditioning and / or refrigeration (HVAC&R) system according to one aspect of the present disclosure, the system employing a vapor compression component (or chiller component), a free cooling component, and control features configured to regulate reliance on the vapor compression component and the free cooling component;

[0014] Figure 2 According to one aspect of the present disclosure Figure 1 Schematic diagram of an HVAC&R system in which the ambient temperature is 85 degrees Fahrenheit and the operating load is 100% of the system design load capacity;

[0015] Figure 3 According to one aspect of the present disclosure Figure 1 Schematic diagram of an HVAC&R system in which the ambient temperature is 65 degrees Fahrenheit and the operating load is 100% of the system design load capacity;

[0016] Figure 4 According to one aspect of the present disclosure Figure 1 Schematic diagram of an HVAC&R system in which the ambient temperature is 60 degrees Fahrenheit and the operating load is 100% of the system design load capacity;

[0017] Figure 5 According to one aspect of the present disclosure Figure 1 A schematic diagram of an HVAC&R system in which the ambient temperature is 85 degrees Fahrenheit and the operating load is 50% of the system design load capacity;

[0018] Figure 6 According to one aspect of the present disclosure Figure 1 A schematic diagram of an HVAC&R system in which the ambient temperature is 65 degrees Fahrenheit and the operating load is 50% of the system design load capacity;

[0019] Figure 7 According to one aspect of the present disclosure Figure 1 A schematic diagram of an HVAC&R system in which the ambient temperature is 60 degrees Fahrenheit and the operating load is 50% of the system design load capacity;

[0020] Figure 8 The present invention is to illustrate the operation of one aspect of the present invention. Figure 1 a process flow diagram of a method for an HVAC&R system; and

[0021] Fig. 9 is a schematic diagram of a multi-temperature liquid hydronic cooling HVAC&R system according to one aspect of the present disclosure, the system employing a vapor compression component (or chiller component), a free cooling component, and control features configured to regulate dependence on the vapor compression component and the free cooling component. DETAILED DESCRIPTION

[0022] One or more specific embodiments will be described below. In order to provide a concise description of these embodiments, not all features of the actual implementation are described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, a large number of implementation-specific decisions must be made to achieve the developer's specific goals, such as complying with system-related and business-related constraints, which may vary from implementation to implementation. In addition, it should be understood that such development work may be complex and time-consuming, but will be a routine task of design, production and manufacturing for ordinary technicians who benefit from this disclosure.

[0023] When introducing elements of various embodiments of the present disclosure, the articles "a," "an," and "the" are intended to indicate that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements in addition to the listed elements. Additionally, it should be understood that references to "one embodiment" or "an embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that are further incorporated into the recited features.

[0024] Embodiments of the present disclosure relate to a heating, ventilation, air conditioning, and / or refrigeration (HVAC&R) system utilizing a vapor compression component and a free cooling component. The vapor compression component may be employed in the context of, for example, a chiller being utilized to cool a conditioning or process fluid during certain conditions. Generally speaking, an HVAC&R system is configured to cool a process fluid and route the process fluid toward a load. For example, a process fluid may be cooled by an HVAC&R system and directed to downstream equipment, such as an air handling unit (AHU). The AHU may cool an air flow via the process fluid and distribute the air flow to various spaces (e.g., rooms, data centers) conditioned by the HVAC&R system. Alternatively, in an immersion application, a process fluid may be employed to directly cool a load, such as equipment in a data center.

[0025] The vapor compression assembly may include a vapor compression circuit (referred to as a working fluid circuit in some cases of the present disclosure) that circulates a working fluid (e.g., a refrigerant) through an evaporator, a condenser, and a compressor. The compressor is operable to compress the working fluid (e.g., increase the pressure of the working fluid) under certain conditions, thereby deflecting the working fluid through the vapor compression circuit. An evaporator may be employed to cool a process fluid by absorbing heat from the process fluid into the working fluid under certain conditions. A condenser may be employed to remove heat from the working fluid under certain conditions, for example, via a cooling fluid of an internal fluid cooling circuit associated with a natural cooling assembly. In this way, when the cooling fluid of the internal fluid cooling loop is present at the condenser, the condenser may be considered to be a part of the internal fluid cooling loop.

[0026] The free cooling assembly may include an air-cooled heat exchanger disposed in an external environment, a valve, and a plate-frame heat exchanger that provides liquid-to-liquid cooling. For example, a plate-frame heat exchanger may be employed to cool a process fluid via a cooling fluid of the free cooling assembly under certain conditions. An air-cooled heat exchanger that may include a single fan (e.g., a single fan servicing a V-coil assembly) may be employed to reduce the temperature of the cooling fluid before the cooling fluid is directed toward the plate-frame heat exchanger and / or a condenser of the vapor compression assembly.

[0027] The valve (e.g., diverter valve) of the natural cooling assembly may be disposed in an internal fluid cooling circuit associated with the natural cooling assembly. In addition, the valve may be controlled to direct a portion of the cooling fluid to the condenser, the plate-frame heat exchanger, or each valve setting of both. For example, in certain conditions, the valve may be controlled to direct the cooling fluid to the condenser and block the cooling fluid to the valve setting of the plate-frame heat exchanger. In certain other conditions, the valve may be controlled to direct the cooling fluid to the plate-frame heat exchanger and block the cooling fluid to the valve setting of the condenser. In certain other conditions, the valve may be controlled to direct a portion of the cooling fluid to the plate-frame heat exchanger and direct an additional portion of the cooling fluid to the valve setting of the condenser. According to the present disclosure, the controller may receive an indication of an environmental condition (e.g., an ambient temperature, referred to as an ambient dry bulb temperature in certain cases of the present disclosure) and / or an operating condition (e.g., a return temperature or a target return temperature of a process fluid from a load, a supply temperature or a target supply temperature of a process fluid to a load, an operating load, etc.) of the HVAC&R system. Based on one or more of these inputs, the controller may actuate the valve to a preferred valve setting such that cooling fluid is directed toward the appropriate components of the HVAC&R system, as described above and in detail below.

[0028] It should be noted that there may be multiple valve arrangements of valves for directing a portion of the cooling fluid to the plate and frame heat exchanger and directing an additional portion of the cooling fluid to the condenser. Additionally or alternatively, there may be only one valve arrangement of valves for directing a portion of the cooling fluid to the plate and frame heat exchanger and directing an additional portion of the cooling fluid to the condenser, and the pump may be controlled to adjust the amount or flow of the portion and additional portion of the cooling fluid based on various conditions. In this way, the amount or flow of the portion of the cooling fluid directed to the plate and frame heat exchanger and the additional amount or additional flow of the additional portion of the cooling fluid directed to the condenser may be controlled to provide sufficient cooling to the cooling fluid (and subsequently the load) while minimizing reliance on the vapor compression assembly.

[0029] In addition to the above points, the setting of the compressor of the vapor compression system that operates to increase the pressure of the working fluid in the vapor compression circuit can be controlled by the controller to correspond to the valve setting, to correspond to the pump setting and / or by the controller based on the above-mentioned environmental and / or operating conditions. Still further to the above points, the fan of the air-cooled heat exchanger can be controlled to a setting to provide sufficient cooling to the cooling fluid of the free cooling component. Other control aspects are also possible and are described in detail with reference to the accompanying drawings.

[0030] By employing the above-described features, the HVAC&R system may be able to provide cooling to a conditioned space (such as a data center) via full reliance on the free cooling component and relatively low reliance on the vapor compression component, thereby providing sufficient cooling while improving energy efficiency and reducing the refrigerant charge of the vapor compression component relative to conventional embodiments. For example, for an HVAC&R system having a system design load capacity of 500 refrigeration tons, where the operating load is 100% of the system design load capacity, at least when the ambient temperature is approximately 60 degrees Fahrenheit or less, a supply temperature of the process fluid at 70 degrees Fahrenheit may be achieved via full reliance on the free cooling component (e.g., where the compressor of the vapor compression component is turned off). In addition, if the operating load is reduced, when the ambient temperature is significantly above 60 degrees Fahrenheit, a supply temperature of the process fluid at 70 degrees Fahrenheit may be achieved by full reliance on the free cooling component. For example, when the operating load is 50% of the system design load capacity, when the ambient temperature is approximately 65 degrees Fahrenheit or less, the HVAC&R system may be able to provide sufficient cooling as described above via full reliance on the free cooling component (e.g., where the compressor of the vapor compression component is turned off). Of course, at higher ambient temperatures, the HVAC&R system may rely heavily on free cooling components to provide process fluid at sufficient temperature for cooling the load.Other examples are provided with reference to the accompanying figures.

[0031] In general, the presently disclosed systems and methods enable greater reliance on free cooling and less reliance on vapor compression for cooling as compared to conventional embodiments. In doing so, the refrigerant charge required for the vapor compression components is reduced relative to conventional embodiments, and the energy efficiency of the HVAC&R system is improved relative to conventional embodiments. These and other features are described in detail below with reference to the accompanying drawings.

[0032] Figure 1is a schematic diagram of an embodiment of an HVAC&R system 10 that employs a vapor compression assembly 12 (or chiller assembly), a free cooling assembly 14, and control features configured to adjust reliance on the vapor compression assembly 12 and the free cooling assembly 14. Generally speaking, the vapor compression assembly 12 and the free cooling assembly 14 are configured to cool a process fluid 16 (e.g., water, glycol, a water-glycol mixture, a dielectric fluid in a liquid immersion application, etc.) corresponding to a process fluid loop 18, wherein the process fluid 16 is deflected through the process fluid loop 18 via a pump 19. As shown, the process fluid loop 18 can direct the process fluid 16 to a load 20 (e.g., a conditioned space and / or a data center) for cooling the load 20. Depending on the ambient conditions and / or operating conditions of the HVAC&R system 10, the reliance on the vapor compression assembly 12 and / or the reliance on the free cooling assembly 14 for cooling the process fluid 16 can be adjusted to ensure adequate cooling and reduce energy consumption of the HVAC&R system 10 relative to conventional embodiments. Reference is made below to Figure 1 These and other features are described in detail.

[0033] The vapor compression assembly 12 may include a vapor compression loop 22 (referred to as a working fluid loop in certain instances of the present disclosure) that routes a working fluid 24 (e.g., a refrigerant such as R-123, R-514A, R-1224yd, R-1233zd, R-134a, R-1234ze, R-1234yf, R-1311, R-32, R-410A, or others) through various components of the vapor compression assembly 12. For example, the vapor compression loop 22 may route the working fluid 24 through a compressor 28, a condenser 26, an expansion valve 32, and an evaporator 30 of the vapor compression assembly 12. The compressor 28 may be operable to deflect the working fluid 24 through the vapor compression loop 22 (e.g., by increasing the pressure of the working fluid 24) under certain conditions. The evaporator 30 may be operable to cool the process fluid 16 of the process fluid loop 18 under certain conditions. The expansion valve 32 is operable to reduce the pressure of the working fluid 22 between the condenser 26 and the evaporator 30. The condenser 26 is operable to remove heat from the working fluid 24 via liquid-to-liquid cooling in certain conditions, wherein the heat is transferred from the working fluid 24 to a cooling fluid 34 (e.g., water, ethylene glycol, a water-ethylene glycol mixture, etc.) corresponding to an internal fluid cooling loop 36 of the free cooling assembly 14. In this manner, when the cooling fluid 34 of the internal fluid cooling loop 36 is present at the condenser 26, the condenser 26 may be considered to be part of the internal fluid cooling loop 36.

[0034] As previously described, in certain environmental conditions and / or operating conditions of the HVAC&R system 10, the free cooling assembly 14 may be employed to reduce reliance on the vapor compression assembly 12 for cooling the process fluid 16 of the process fluid loop 18. For example, reliance on the compressor 28 of the vapor compression assembly 12 may be reduced while reliance on the free cooling assembly 14 is increased in response to certain conditions. In certain conditions, the compressor 28 may be completely disconnected or otherwise shut down, with the HVAC&R system 10 relying solely on the free cooling assembly 14 to provide cooling to the process fluid 16. Movement of the working fluid 24 through the vapor compression loop 22 may continue after the compressor 28 is disconnected or otherwise shut down via natural convection (e.g., via a thermosyphon). Additionally or alternatively, the HVAC&R system 10 may rely on both the free cooling assembly 14 and the vapor compression assembly 12 under certain conditions, with the compressor 28 being controlled to a relatively low setting, thereby improving energy efficiency while ensuring adequate cooling of the process fluid 16. Aspects of the free cooling assembly 14 and control of the HVAC&R system 10 to regulate reliance on the vapor compression assembly 12 and / or the free cooling assembly 14 are described in detail below.

[0035] In the illustrated embodiment, the free cooling assembly 14 includes an internal fluid cooling circuit 36 ​​configured to route the cooling fluid 34 through various components of the HVAC&R system 10, including the condenser 26 of the vapor compression assembly 12, an air-cooled heat exchanger 38 (e.g., having a fan 39) of the free cooling assembly 14, and a plate-frame heat exchanger 40 of the free cooling assembly 14. Typically, the air-cooled heat exchanger 38 is configured to cool the cooling fluid 34 (e.g., via the fan 39) before delivering the cooling fluid 34 to the condenser 26 of the vapor compression assembly 12 and / or the plate-frame heat exchanger 40 of the free cooling assembly 14. In some embodiments, the air-cooled heat exchanger 38 may include only one instance of the fan 39 configured to cool the cooling fluid 34 before delivering the cooling fluid 34 to the condenser 26 and / or the plate-frame heat exchanger 40.

[0036] When the cooling fluid 34 is present at the condenser 26, the cooling fluid 34 absorbs heat from the working fluid 24 corresponding to the vapor compression assembly 12, causing the working fluid 24 to condense before delivering the working fluid 24 to the expansion valve 32. When the cooling fluid 34 is present at the plate and frame heat exchanger 40, the cooling fluid 34 absorbs heat from the process fluid 16 corresponding to the process fluid loop 18. Aspects of the free cooling assembly 14 may be controlled to distribute some, none, or all of the cooling fluid 34 to the condenser 26 and to distribute some, none, or all of the cooling fluid 34 to the plate and frame heat exchanger 40, as described below.

[0037] The free cooling assembly 14 includes a valve 42 controlled to various settings to direct a portion of the cooling fluid 34 to the condenser 26 of the vapor compression assembly 12 and / or the plate frame heat exchanger 40 of the free cooling assembly 14. In addition, the free cooling assembly 14 includes a pump 44 configured to deflect the cooling fluid 34 through the internal fluid cooling 36. Depending on the ambient conditions and / or operating conditions of the HVAC&R system 10, the valve 42 can be controlled to a first valve setting in which the cooling fluid 34 is directed to the plate frame heat exchanger 40 and blocked from entering the condenser 26; a second valve setting in which the cooling fluid 34 is directed to the condenser 26 and isolated from the plate frame heat exchanger 40; or a third setting (or a third setting among a plurality of third settings) in which a portion of the cooling fluid 34 is directed to the plate frame heat exchanger 40 and another portion of the cooling fluid 34 is directed to the condenser 26.

[0038] A controller 46 of the HVAC&R system 10 may be employed to control the various components described above. In the illustrated embodiment, the controller 46 includes a processing circuit 48 and a memory circuit 50 having instructions stored thereon that, when executed by the processing circuit 48, cause the processing circuit 48 to perform various functions. It should be noted that, for the sake of brevity, only one example of the controller 46 is shown in the illustrated embodiment. However, it should be noted that multiple controllers (including dedicated processing and / or memory circuits) may be employed to implement the control features described in the present disclosure.

[0039] The controller 46 may receive one or more inputs indicative of various environmental conditions and / or operating conditions of the HVAC&R system 10. For example, the controller 46 may receive a first input from a first sensor 52 indicating an ambient temperature (e.g., proximate the air cooling heat exchanger 38). Additionally or alternatively, the controller 46 may receive a second input from a second sensor 54 indicating a supply temperature of the process fluid 16 directed to the load 20. Additionally or alternatively, the controller 46 may receive a third input from a third sensor 56 indicating a return temperature of the process fluid 16 returned from the load 20. In some embodiments, the controller 46 may employ a target supply temperature of the process fluid 16 directed to the load 20 and / or a target return temperature of the process fluid 16 returned from the load 20 (e.g., in addition to or in lieu of a detected temperature). Additionally or alternatively, the controller 46 may receive (or otherwise determine) a fourth input indicative of an operating load or cooling demand corresponding to the HVAC&R system 10 and / or the load 20. In practice, while the HVAC&R system 10 may include a system design load capacity, the cooling demand of the load 20 at certain operating intervals may correspond to an operating load that is less than the system design load capacity. The fourth input indicative of the operating load or cooling demand may be, for example, a percentage of the system design load capacity. The fourth input may be received from a sensor or other feedback device, which may be part of (or separate from) the one or more controllers 46. A control assembly according to the present disclosure may include one or more controllers 46, and in some embodiments, may include any combination of the first sensor 52, the second sensor 54, the third sensor 56, and / or other sensors or feedback devices.

[0040] In response to at least one of the above inputs (e.g., ambient temperature, supply temperature and / or target supply temperature of the process fluid 16, return temperature and / or target return temperature of the process fluid 16, operating load), the controller 46 can control various components of the HVAC&R system 10 to ensure adequate cooling of the load 20 while reducing energy consumption. Specifically, the controller 46 can control the valve 42 of the free cooling assembly 14 to direct some or all of the cooling fluid 34 to the condenser 26 of the vapor compression assembly 12 and to direct some or all of the cooling fluid 34 to the plate frame heat exchanger 40.

[0041] Other aspects of the HVAC&R system 10 may also be controlled to correspond to the valve setting of the valve 42 (or based on the above-described inputs). For example, the setting of the compressor 28 of the air-cooled heat exchanger 38 and / or the setting of the fan 39 may be controlled so as to provide sufficient cooling to the process fluid 16 while reducing the energy consumption of the HVAC&R system 10. In general, the presently disclosed systems and methods are configured to enable the HVAC&R system 10 to provide sufficient cooling to the process fluid 16 while relying heavily on the free cooling component 14, thereby improving the efficiency of the HVAC&R system 10 relative to conventional embodiments.

[0042] Figures 2 to 7 Various embodiments of HVAC&R systems 10 are shown in which the ambient temperature and operating load vary. Figures 2 to 7 As shown and described in detail below, the control is adjusted based at least in part on the ambient temperature and the operating load. Figures 2 to 4 In , the operating load is 100% of the system design load capacity (e.g., at ambient temperatures of 85 degrees Fahrenheit, 65 degrees Fahrenheit, and 60 degrees Fahrenheit, respectively). Figures 5 to 7 In the example, the operating load is 50% of the system design load capacity (e.g., at ambient temperatures of 85 degrees Fahrenheit, 65 degrees Fahrenheit, and 60 degrees Fahrenheit, respectively). In general, the lower the ambient temperature and / or operating load, the more the HVAC&R system 10 relies on the free cooling component 14 to save energy. Figures 2 to 7 Each figure in .

[0043] Figure 2 yes Figure 1 , wherein the ambient temperature is 85 degrees Fahrenheit and the operating load is 100% of the system design load capacity (e.g., as shown in FIG. 59 ). In addition, the supply temperature of the process fluid 16 to the load 20 is 70 degrees Fahrenheit, and the return temperature of the process fluid 16 from the load 20 is 100 degrees Fahrenheit. In the illustrated embodiment, the controller 46 of the HVAC&R system 10 controls the valve 42 of the free cooling assembly 14 to a valve setting such that the cooling fluid 34 is directed toward the condenser 26 of the vapor compression assembly 12 and is blocked from entering the plate frame heat exchanger 40 of the free cooling assembly 14. Thus, the HVAC&R system 10 relies on the vapor compression assembly 12 (e.g., wherein the compressor 28 is turned on and controlled to an adequate setting) for cooling the process fluid 16 via the evaporator 30, and does not rely on the plate frame heat exchanger 40. That is, no cooling fluid 34 is directed toward the plate frame heat exchanger 40.

[0044] Due to the relatively high ambient temperature (e.g., 85 degrees Fahrenheit) and operating load (e.g., 100% of the system design load capacity), the control shown relies on the vapor compression assembly 12 as shown. In fact, as shown in the illustrated embodiment, the valve 42 is controlled to a valve setting such that the cooling fluid 34 routed to the condenser 26 is approximately 93 degrees Fahrenheit and has a flow rate of approximately 600 gallons per minute (GPM), and such that no cooling fluid 34 is routed to the plate and frame heat exchanger 40.

[0045] In addition to adjusting the valve setting of valve 42 as described above, controller 46 may also adjust the pump setting of pump 44 associated with the internal fluid cooling circuit 36 ​​of the free cooling component 14, the compressor setting of compressor 28 associated with the vapor compression circuit 22 of the vapor compression component 12, the pump setting of pump 19 associated with the process fluid circuit 18, the fan setting of fan 39 of the air-cooled heat exchanger 38, or any combination thereof. Figure 2 Various performance and result data are shown, which are associated with the above conditions, including parameters associated with the compressor 28, condenser 26, evaporator 30, air cooling heat exchanger 38 (or its fan 39), plate frame heat exchanger 40, load 20, valve 42, pump 44, pump 19, temperature of various fluids, flow rate of various fluids, power consumption of various components, etc. In addition, as shown in box 60, the total chiller kW / Ton with the conditions and control characteristics shown is 0.690.

[0046] Figure 3 yes Figure 1 , wherein the ambient temperature is 65 degrees Fahrenheit and the operating load is 100% of the system design load capacity (e.g., as shown in FIG. 59 ). In addition, the supply temperature of the process fluid 16 to the load 20 is 70 degrees Fahrenheit, and the return temperature of the process fluid 16 from the load 20 is 100 degrees Fahrenheit. In the illustrated embodiment, the controller 46 of the HVAC&R system 10 controls the valve 42 of the free cooling assembly 14 to a valve setting such that a first portion of the cooling fluid 34 is directed toward the condenser 26 of the vapor compression assembly 12 (e.g., at a first flow rate) and a second portion of the free cooling fluid 34 is directed toward the plate frame heat exchanger 40 of the free cooling assembly 14 (e.g., at a second flow rate). Thus, the HVAC&R system 10 relies on the vapor compression assembly 12 for cooling the process fluid 16 via the evaporator 30 (e.g., wherein the compressor 28 is turned on and controlled to a sufficient setting) and relies on the free cooling assembly 14 for cooling the process fluid 16 via the plate frame heat exchanger 40.

[0047] Since the temperature is relatively moderate (e.g., 65 degrees Fahrenheit) and the operating load is high (e.g., 100% of the system design load capacity), the control shown relies on both the vapor compression assembly 12 as shown (e.g., where the compressor 28 is turned on and controlled to a sufficient setting) and the plate frame heat exchanger 40 of the free cooling assembly 14. As shown in the illustrated embodiment, the valve 42 is controlled to a valve setting such that the portion of the cooling fluid 34 routed to the condenser 26 is approximately 67 degrees Fahrenheit and has a flow rate of approximately 200 GPM, and such that the portion of the cooling fluid 34 routed to the plate frame heat exchanger 40 is approximately 67 degrees Fahrenheit and has a flow rate of approximately 400 GPM. Of course, if the ambient temperature rises from 65 degrees Fahrenheit, the valve 42 and / or pump 44 of the free cooling assembly 14 can be controlled such that the flow rate of the cooling fluid 34 directed toward the condenser 26 is greater than approximately 200 GPM and the flow rate of the cooling fluid 34 directed toward the plate frame heat exchanger 40 is less than approximately 400 GPM. Additionally, if the ambient temperature drops from 65 degrees Fahrenheit, the valve 42 and / or pump 44 of the free cooling assembly 14 may be controlled such that the flow rate of the cooling fluid 34 directed toward the condenser 26 is less than approximately 200 GPM and the flow rate of the cooling fluid 34 directed toward the plate and frame heat exchanger 40 is greater than approximately 400 GPM.

[0048] In addition to adjusting the valve setting of valve 42 as described above, controller 46 may also adjust the pump setting of pump 44 associated with the internal fluid cooling circuit 36 ​​of the free cooling component 14, the compressor setting of compressor 28 associated with the vapor compression circuit 22 of the vapor compression component 12, the pump setting of pump 19 associated with the process fluid circuit 18, the fan setting of fan 39 of the air-cooled heat exchanger 38, or any combination thereof. Figure 3 Various performance and result data are shown, which are associated with the above conditions, including parameters associated with the compressor 28, condenser 26, evaporator 30, air cooling heat exchanger 38 (or its fan 39), plate frame heat exchanger 40, load 20, valve 42, pump 44, pump 19, temperatures of various fluids, flows of various fluids, power consumption of various components, etc. In addition, as shown in box 60, the total chiller kW / Ton with the conditions and control characteristics shown is 0.089, which is substantially lower than Figure 2 The embodiment shown.

[0049] Figure 4 yes Figure 1Schematic diagram of an embodiment of the HVAC&R system 10 in FIG. 5 , wherein the ambient temperature is 60 degrees Fahrenheit and the operating load is 100% of the system design load capacity (e.g., as shown in FIG. 59 ). In addition, the supply temperature of the process fluid 16 to the load 20 is 70 degrees Fahrenheit, and the return temperature of the process fluid 16 from the load 20 is 100 degrees Fahrenheit. In the illustrated embodiment, the controller 46 of the HVAC&R system 10 controls the valve 42 of the internal fluid cooling loop 36 to a valve setting such that the cooling fluid 34 is blocked from entering the condenser 26 of the vapor compression assembly 12 and is directed toward the plate frame heat exchanger 40 of the free cooling assembly 14. Thus, the HVAC&R system 10 relies on the plate frame heat exchanger 40 of the free cooling assembly 14 to cool the process fluid 16 of the process fluid loop 18 and does not rely on the evaporator 30 of the vapor compression assembly 12 to cool the process fluid 16 of the process fluid loop 18. Although the operating load is high (eg, 100% of system design load capacity), due to the relatively low ambient temperature (eg, 60 degrees Fahrenheit), the illustrated control relies on the free cooling assembly 14 (rather than the vapor compression assembly 12) as shown.

[0050] In addition to adjusting the valve setting of valve 42 as described above, controller 46 may also adjust the pump setting of pump 44 associated with the internal fluid cooling circuit 36 ​​of the free cooling component 14, the compressor setting of compressor 28 associated with the vapor compression circuit 22 of the vapor compression component 12, the pump setting of pump 19 associated with the process fluid circuit 18, the fan setting of fan 39 of the air-cooled heat exchanger 38, or any combination thereof. Figure 4 Various performance and result data are shown, which are associated with the above conditions, including parameters associated with the compressor 28, condenser 26, evaporator 30, air cooling heat exchanger 38 (or its fan 39), plate frame heat exchanger 40, load 20, valve 42, pump 44, pump 19, temperature of various fluids, flow rate of various fluids, power consumption of various components, etc. In addition, as shown in box 60, the total chiller kW / Ton with the conditions and control characteristics shown is 0.030, which is substantially lower than Figure 2 and Figure 3 The embodiment shown.

[0051] Figure 5 yes Figure 1Schematic diagram of an embodiment of the HVAC&R system 10 in FIG. 5 , wherein the ambient temperature is 85 degrees Fahrenheit and the operating load is 50% of the system design load capacity (e.g., as shown in FIG. 59 ). In addition, the supply temperature of the process fluid 16 to the load 20 is 70 degrees Fahrenheit, and the return temperature of the process fluid 16 from the load 20 is 100 degrees Fahrenheit. In the illustrated embodiment, the controller 46 of the HVAC&R system 10 controls the valve 42 of the free cooling assembly 14 to a valve setting such that a portion of the cooling fluid 34 is directed toward the condenser 26 of the vapor compression assembly 12 (e.g., at a first flow rate) and a second portion of the free cooling fluid 34 is directed toward the plate frame heat exchanger 40 of the free cooling assembly 14 (e.g., at a second flow rate). Thus, the HVAC&R system 10 relies on the vapor compression assembly 12 for cooling the process fluid 16 via the evaporator 30 (e.g., wherein the compressor 28 is turned on and controlled to a sufficient setting) and the HVAC&R system 10 relies on the heat exchanger 40 of the plate frame free cooling assembly 14 for cooling the process fluid 16.

[0052] Although the ambient temperature is relatively high (e.g., 85 degrees Fahrenheit), due to the relatively low operating load (e.g., 50% of the system design load capacity), the control shown relies on both the vapor compression assembly 12 as shown (e.g., where the compressor 28 is turned on and controlled to a sufficient setting) and the plate frame heat exchanger 40 of the free cooling assembly 14. As shown in the illustrated embodiment, the valve 42 is controlled to a valve setting such that the portion of the cooling fluid 34 routed to the condenser 26 is approximately 89 degrees Fahrenheit and has a flow rate of approximately 137 GPM, and such that the portion of the cooling fluid 34 routed to the plate frame heat exchanger 40 is approximately 89 degrees Fahrenheit and has a flow rate of approximately 163 GPM. Of course, if the ambient temperature rises from 85 degrees Fahrenheit, the valve 42 and / or pump 44 of the free cooling assembly 14 can be controlled such that the flow rate of the cooling fluid 34 directed toward the condenser 26 is greater than approximately 137 GPM and the flow rate of the cooling fluid 34 directed toward the plate frame heat exchanger 40 is less than approximately 163 GPM. Additionally, if the ambient temperature drops from 85 degrees Fahrenheit, the valve 42 and / or pump 44 of the free cooling assembly 14 may be controlled such that the flow rate of the cooling fluid 34 directed toward the condenser 26 is less than approximately 137 GPM and the flow rate of the cooling fluid 34 directed toward the plate and frame heat exchanger 40 is greater than approximately 163 GPM. Similar adjustments may be made based on changes in operating load.

[0053] In addition to adjusting the valve setting of valve 42 as described above, controller 46 may also adjust the pump setting of pump 44 associated with the internal fluid cooling circuit 36 ​​of the free cooling component 14, the compressor setting of compressor 28 associated with the vapor compression circuit 22 of the vapor compression component 12, the pump setting of pump 19 associated with the process fluid circuit 18, the fan setting of fan 39 of the air-cooled heat exchanger 38, or any combination thereof. Figure 5 Various performance and result data are shown, which are associated with the above conditions, including parameters associated with the compressor 28, condenser 26, evaporator 30, air cooling heat exchanger 38 (or its fan 39), plate frame heat exchanger 40, load 20, valve 42, pump 44, pump 19, temperature of various fluids, flow rate of various fluids, power consumption of various components, etc. In addition, as shown in box 60, the total chiller kW / Ton with the conditions and control characteristics shown is 0.380, which is substantially lower than Figure 2 In fact, although Figure 2 and Figure 5 The ambient temperature is 85 degrees Fahrenheit, but Figure 5 The operating load in Figure 2 In operating loads in the range, it is possible to rely at least partially on the free cooling assembly 14, thereby reducing the total cooler kW / Ton.

[0054] Figure 6 yes Figure 1 Schematic diagram of an embodiment of the HVAC&R system 10 in FIG. 5 , wherein the ambient temperature is 65 degrees Fahrenheit and the operating load is 50% of the system design load capacity (e.g., as shown in FIG. 59 ). In addition, the supply temperature of the process fluid 16 to the load 20 is 70 degrees Fahrenheit, and the return temperature of the process fluid 16 from the load 20 is 100 degrees Fahrenheit. In the illustrated embodiment, the controller 46 of the HVAC&R system 10 controls the valve 42 of the free cooling assembly 14 to a valve setting such that the cooling fluid 34 is directed toward the plate frame heat exchanger 40 of the free cooling assembly 14 and is blocked from entering the condenser 26 of the vapor compression assembly 12. Thus, the HVAC&R system 10 relies on the plate frame heat exchanger 40 of the free cooling assembly 14 for cooling the process fluid 16 of the process fluid loop 18 and does not rely on the evaporator 30 of the vapor compression assembly 12 for cooling the process fluid 16 of the process fluid loop 18. Because the ambient temperature is relatively moderate (e.g., 65 degrees Fahrenheit) and the operating load is relatively low (e.g., 50% of the system design load capacity), the control shown relies on the free cooling assembly 14 as shown (rather than the vapor compression assembly 12, which may include the compressor 28 being disconnected or otherwise shut down).

[0055] In addition to adjusting the valve setting of valve 42 as described above, controller 46 may also adjust the pump setting of pump 44 associated with the internal fluid cooling circuit 36 ​​of the free cooling component 14, the compressor setting of compressor 28 associated with the vapor compression circuit 22 of the vapor compression component 12, the pump setting of pump 19 associated with the process fluid circuit 18, the fan setting of fan 39 of the air-cooled heat exchanger 38, or any combination thereof. Figure 6 Various performance and result data are shown, which are associated with the above conditions, including parameters associated with the compressor 28, condenser 26, evaporator 30, air cooling heat exchanger 38 (or its fan 39), plate frame heat exchanger 40, load 20, valve 42, pump 44, pump 19, temperature of various fluids, flow rate of various fluids, power consumption of various components, etc. In addition, as shown in box 60, the total chiller kW / Ton with the conditions and control characteristics shown is 0.008, which is substantially lower than Figure 2 and Figure 5 kW / Ton in.

[0056] Figure 7 yes Figure 1 Schematic diagram of an embodiment of the HVAC&R system 10 in which the ambient temperature is 60 degrees Fahrenheit and the operating load is 50% of the system design load capacity (e.g., as shown in Figure 59). In addition, the supply temperature of the process fluid 16 to the load 20 is 70 degrees Fahrenheit, and the return temperature of the process fluid 16 from the load 20 is 100 degrees Fahrenheit. Figure 6 Similar to the above, Figure 7 In the illustrated embodiment, the controller 46 of the HVAC&R system 10 controls the valve 42 of the internal fluid cooling loop 36 to a valve setting such that the cooling fluid 34 is directed toward the plate frame heat exchanger 40 of the free cooling assembly 14 and is blocked from entering the condenser 26 of the vapor compression assembly 12. Thus, the HVAC&R system 10 relies on the plate frame heat exchanger 40 of the free cooling assembly 14 for cooling the process fluid 16 of the process fluid loop 18 and does not rely on the evaporator 30 of the vapor compression assembly 12 for cooling the process fluid 16 of the process fluid loop 18. Due to the relatively low ambient temperature (e.g., 60 degrees Fahrenheit) and operating load (e.g., 50% of the system design load capacity), the illustrated control relies on the free cooling assembly 14 as shown (rather than the vapor compression assembly 12, which includes the compressor 28 that is disconnected or otherwise shut down).

[0057] In addition to adjusting the valve setting of valve 42 as described above, controller 46 may also adjust the pump setting of pump 44 associated with the internal fluid cooling circuit 36 ​​of the free cooling component 14, the compressor setting of compressor 28 associated with the vapor compression circuit 22 of the vapor compression component 12, the pump setting of pump 19 associated with the process fluid circuit 18, the fan setting of fan 39 of the air-cooled heat exchanger 38, or any combination thereof. Figure 7 Various performance and result data are shown, which are associated with the above conditions, including parameters associated with the compressor 28, condenser 26, evaporator 30, air cooling heat exchanger 38 (or its fan 39), plate frame heat exchanger 40, load 20, valve 42, pump 44, pump 19, temperatures of various fluids, flows of various fluids, power consumption of various components, etc. In addition, as shown in box 60, the total chiller kW / Ton with the conditions and control characteristics shown is 0.005.

[0058] It should be noted that in Figure 6 and Figure 7 , valve 42 is controlled (eg, via controller 46) to a setting that blocks cooling fluid 34 from condenser 26 of vapor compression assembly 12 and directs cooling fluid 24 to plate and frame heat exchanger 40 of free cooling assembly 14. Figure 6 and Figure 7 The flow of the cooling fluid 34 has this corresponding relationship, but Figure 7 The total cooler kW / Ton is lower than Figure 6 Total cooler kW / Ton. Figure 7 The total cooler kW / Ton is lower than Figure 6 is based on lower ambient temperatures (e.g. Figure 7 The middle is 60 degrees, Figure 6 65 degrees in the example) and corresponding control of other features of the HVAC&R system 10. In fact, because the ambient temperature is reduced, other components of the HVAC&R system 10 can be operated in a manner that reduces energy consumption, such as the fan 39 of the air cooling heat exchanger 38. For example, Figure 6 The fan 39 of the air cooling heat exchanger 38 in the Figure 7 The fan 39 of the air-cooled heat exchanger 38 in FIG. 1 is operated at 0.7 kW. In this manner, the fan 39 may be a variable speed fan, for example, which is controlled to a setting based on a desired or target amount of cooling of the cooling fluid 34 by the fan 39 .

[0059] In general, relative to conventional embodiments, the HVAC&R system 10 according to the present disclosure is configured to rely more on the free cooling component 14 than the steam compression component 12, regardless of whether the HVAC&R system 10 is operated to rely solely on the steam compression component 12 for cooling the process fluid 16, rely solely on the free cooling component 14 for cooling the process fluid 16, or rely on both the steam compression component 12 and the free cooling component 14 for cooling the process fluid 16.

[0060] Figure 8 It shows the operation Figure 1 1 is a process flow diagram of an embodiment of a method 100 for an HVAC&R system of FIG. 1. In the illustrated embodiment, the method 100 includes deflecting a process fluid (block 102) through a process fluid loop via a pump such that the process fluid is routed through an evaporator of a vapor compression assembly, a load, and a heat exchanger of a plate frame free cooling assembly. Depending on ambient conditions, operating conditions of the HVAC&R system, and / or certain corresponding control features, the working fluid of the vapor compression assembly, the cooling fluid of the free cooling assembly, or both may be employed to cool the process fluid. For example, the evaporator of the vapor compression assembly may be employed to cool the process fluid via the working fluid of the vapor compression assembly in certain conditions. Additionally or alternatively, a plate frame heat exchanger may be employed to cool the process fluid via the cooling fluid of the free cooling assembly in certain conditions.

[0061] The method 100 also includes detecting (block 104) an ambient temperature via a sensor (e.g., a temperature sensor). The sensor may be disposed adjacent to, for example, an air-cooled heat exchanger of a free cooling assembly. As will be appreciated in light of the following description, the ambient temperature detected by the sensor may be used to determine various control features associated with the HVAC&R system, such as control features for flowing a cooling fluid of the free cooling assembly to a condenser plate-frame heat exchanger of a vapor compression assembly (e.g., for removing heat from a working fluid of the vapor compression assembly), a plate-frame heat exchanger of the free cooling assembly (e.g., for cooling a process fluid), or both.

[0062] The method 100 also includes controlling (box 106) valve settings of valves of the free cooling component via a controller and based at least on ambient temperature and an operating load (or cooling demand) associated with the load to control the flow of cooling fluid of the free cooling component to one or more of a condenser of the vapor compression component, a plate and frame heat exchanger of the free cooling component, or both. Figures 2 to 7Various control features associated with various ambient temperatures and / or operating loads are shown and described in detail above. In general, when the ambient temperature and / or operating load are relatively low, the system relies more heavily (or entirely) on the free cooling component than the vapor compression component. The valve setting of the valve may also depend at least in part on the supply temperature (or target supply temperature) of the process fluid to the load and / or the return temperature (or target return temperature) of the process fluid from the load.

[0063] The method 100 also includes controlling (block 108) other aspects of the HVAC&R system via the controller. For example, the control of other aspects of the HVAC&R system may depend, at least in part, on the above-mentioned environmental conditions and / or operating conditions of the HVAC&R system. Additionally or alternatively, the control of other aspects of the HVAC&R system may depend on the valve settings of the valves. Aspects of the HVAC&R system that may be controlled based on the above-mentioned data may include compressor settings of the compressor, pump settings of the pumps corresponding to the free cooling components, pump settings of the pumps corresponding to the process fluid loops, fan settings of the air-cooled heat exchangers of the free cooling components, and / or other aspects of the HVAC&R system. For example, when the system relies solely on the free cooling components to cool the process fluid, the compressor may be disconnected, shut down, or otherwise controlled to a reduced setting. Additionally or alternatively, when the system's reliance on the vapor compression components for cooling the process fluid is relatively low, the setting of the compressor may be reduced. In addition, when the ambient temperature and / or operating load are relatively low, the fan setting of the fan of the air-cooled heat exchanger may be reduced. Based on these controls, control of the valve settings of the valves, and other aspects of the presently disclosed HVAC&R system, adequate cooling of the process fluid (and subsequent loads) can be provided while reducing energy consumption and reducing the refrigerant charge in the vapor compression assembly relative to conventional embodiments.

[0064] Figures 1 to 7 The features shown in and described above are examples of HVAC&R systems that employ a vapor compression component and a free cooling component, wherein the free cooling component is preferentially used to save energy and reduce the refrigerant charge in the vapor compression component. Figures 1 to 7 The assembly shown in and described in detail above can achieve energy savings and reduce refrigerant charge relative to conventional embodiments. Figures 1 to 7 The corresponding descriptions are merely exemplary, and other components intended to achieve the above technical effects and / or further improve energy saving and reduce refrigerant charge are also possible.

[0065] For example, Fig. 9is a schematic diagram of an embodiment of a multi-temperature liquid hydronic cooling HVAC&R system 210 that employs a vapor compression component 212 (or chiller component), a free cooling component 214, and control features configured to regulate dependence on the vapor compression component 212 and the free cooling component 214.

[0066] In general, the vapor compression assembly 212 and the free cooling assembly 214 are configured to cool a process fluid 216 (e.g., water, glycol, a water-glycol mixture, a dielectric fluid in a liquid immersion application, etc.) corresponding to a process fluid loop 218, wherein the process fluid 216 is deflected through the process fluid loop 218 via one or more pumps 219a, 219b. As shown, the process fluid loop 218 can direct the process fluid 216 to one or more loads 220a, 220b. In the illustrated embodiment, the load 220a is a high temperature load and the load 220b is a low temperature load. Depending on the ambient conditions and / or operating conditions of the HVAC&R system 210, the reliance on the vapor compression assembly 212 and / or the reliance on the free cooling assembly 214 for cooling the process fluid 216 can be adjusted to ensure adequate cooling and reduce the energy consumption of the HVAC&R system 210 relative to conventional embodiments.

[0067] The vapor compression assembly 212 may include a vapor compression loop 222 (referred to as a working fluid loop in certain instances of the present disclosure) that routes a working fluid 224 (e.g., a refrigerant such as R-123, R-514A, R-1224yd, R-1233zd, R-134a, R-1234ze, R-1234yf, R-1311, R-32, R-410A, or others) through various components of the vapor compression assembly 212. For example, the vapor compression loop 222 may route the working fluid 224 through a compressor 228, a condenser 226, an expansion valve 232, and an evaporator 230 of the vapor compression assembly 212. The compressor 228 may be operable to bias the working fluid 224 through the vapor compression loop 222 (e.g., by increasing the pressure of the working fluid 224) under certain conditions. The evaporator 230 is operable to cool the process fluid 216 of the process fluid loop 218 under certain conditions. The expansion valve 232 is operable to reduce the pressure of the working fluid 224 between the condenser 226 and the evaporator 230. The condenser 226 is operable to remove heat from the working fluid 224 via liquid-to-liquid cooling under certain conditions, wherein the heat is transferred from the working fluid 224 to a cooling fluid 234 (e.g., water, ethylene glycol, a water-ethylene glycol mixture, etc.) of an internal fluid cooling loop 236 corresponding to the free cooling component 214. In this way, when the cooling fluid 234 of the internal fluid cooling loop 236 is present at the condenser 226, the condenser 226 can be considered to be part of the internal fluid cooling loop 236.

[0068] In the illustrated embodiment, the vapor compression assembly 212 includes features configured to divert the flow path of some or all of the working fluid 224 under certain conditions. For example, a valve 237 may be controlled (e.g., via a controller 246) based on certain environmental and / or operating conditions to cause the refrigerant 224 to flow through a heat exchanger 235 that corresponds to a heat recovery path 241 that employs a heat recovery fluid 243 (e.g., water, glycol, or a water-glycol mixture). In this manner, the heat recovery fluid 243 may extract heat from the working fluid 224 at the heat exchanger 235. The heat exchanger 235 may be a plate-and-frame heat exchanger of a brazed heat exchanger.

[0069] As previously described, in certain environmental conditions and / or operating conditions of the HVAC&R system 210, the free cooling component 214 may be employed to reduce reliance on the vapor compression component 212 for cooling the process fluid 216 of the process fluid loop 218. For example, reliance on the compressor 228 of the vapor compression component 212 may be reduced while reliance on the free cooling component 214 is increased in response to certain conditions. In certain conditions, the compressor 228 may be completely disconnected or otherwise shut down, with the HVAC&R system 210 relying solely on the free cooling component 214 to provide cooling to the process fluid 216. Movement of the working fluid 224 through the vapor compression loop 222 may continue after the compressor 228 is disconnected or otherwise shut down via natural convection (e.g., via a thermosyphon). Additionally or alternatively, the HVAC&R system 210 may rely on both the free cooling component 214 and the vapor compression component 212 under certain conditions, with the compressor 228 being controlled to a relatively low setting, thereby improving energy efficiency while ensuring adequate cooling of the process fluid 216. Aspects of the control of the free cooling component 214 and the HVAC&R system 210 to adjust the reliance on the vapor compression component 212 and / or the free cooling component 214 are described in detail below.

[0070] In the illustrated embodiment, the free cooling assembly 214 includes an internal fluid cooling circuit 236 configured to route the cooling fluid 234 through various components of the HVAC&R system 210, including the condenser 226 of the vapor compression assembly 212, an air-cooled heat exchanger 238 (e.g., having a fan 239) of the free cooling assembly 214, and a plate-frame heat exchanger 240 of the free cooling assembly 214. Typically, the air-cooled heat exchanger 238 is configured to cool the cooling fluid 234 (e.g., via the fan 239) before delivering the cooling fluid 234 to the condenser 226 of the vapor compression assembly 226 and / or the plate-frame heat exchanger 240 of the free cooling assembly 214. In some embodiments, the air-cooled heat exchanger 238 may include only one instance of the fan 239 configured to cool the cooling fluid 234 before delivering the cooling fluid 234 to the condenser 226 and / or the plate-frame heat exchanger 240.

[0071] When the cooling fluid 234 is present at the condenser 226, the cooling fluid 234 absorbs heat from the working fluid 224 corresponding to the vapor compression assembly 212, causing the working fluid 224 to the condenser before delivering the working fluid 224 to the expansion valve 232. When the cooling fluid 234 is present at the plate and frame heat exchanger 240, the cooling fluid 234 absorbs heat from the process fluid 216 corresponding to the process fluid loop 218. Aspects of the free cooling assembly 214 can be controlled to distribute some, none, or all of the cooling fluid 234 to the condenser 226 and some, none, or all of the cooling fluid 234 to the plate and frame heat exchanger 240, as described below.

[0072] The free cooling assembly 214 includes a valve 242 controlled to various settings to direct a portion of the cooling fluid 234 to the condenser 226 of the vapor compression assembly 212 and / or the plate frame heat exchanger 240 of the free cooling assembly 214. In addition, the free cooling assembly 214 includes a pump 244 configured to deflect the cooling fluid 234 through the internal fluid cooling loop 236. Depending on the ambient conditions and / or operating conditions of the HVAC&R system 210, the valve 242 can be controlled to a first valve setting in which the cooling fluid 234 is directed to the plate frame heat exchanger 240 and blocked from entering the condenser 226; a second valve setting in which the cooling fluid 234 is directed to the condenser 226 and isolated from the plate frame heat exchanger 240; or a third setting (or a third setting among a plurality of third settings) in which a portion of the cooling fluid 234 is directed to the plate frame heat exchanger 240 and another portion of the cooling fluid 234 is directed to the condenser 226.

[0073] A controller 246 of the HVAC&R system 210, including processing circuitry 248 and memory circuitry 250, may be employed to control the various components described above. For example, the controller 246 may receive one or more inputs indicative of various environmental conditions and / or operating conditions of the HVAC&R system 210. In practice, the controller 246 may receive a first input from a first sensor 252 indicative of an ambient temperature (e.g., proximate the air cooling heat exchanger 238). Additionally or alternatively, the controller 246 may receive a second input from a second sensor 254a, 254b indicative of a supply temperature of the process fluid 216 directed to the loads 220a, 220b. Additionally or alternatively, the controller 246 may receive a third input from a third sensor 256a, 256b indicative of a return temperature of the process fluid 216 returned from the loads 220a, 220b. In some embodiments, the controller 246 may employ a target supply temperature for the process fluid 216 directed to the loads 220a, 220b and / or a target return temperature for the process fluid 216 returned from the loads 220a, 220b (e.g., in addition to or in lieu of the detected temperature). Additionally or alternatively, the controller 246 may receive (or otherwise determine) a fourth input indicative of an operational load corresponding to the HVAC&R system 210 and / or the loads 220a, 220b.

[0074] In response to at least one of the above inputs (e.g., ambient temperature, supply temperature and / or target supply temperature of the process fluid 216, return temperature and / or target return temperature of the process fluid 216, operating load), the controller 246 can control various components of the HVAC&R system 210 to ensure sufficient cooling of the loads 220a, 220b while reducing energy consumption. Specifically, the controller 246 can control the valve 242 of the free cooling component 214 to direct some or all of the cooling fluid 234 to the condenser 226 of the vapor compression component 212 and direct some or all of the cooling fluid 234 to the plate frame heat exchanger 240.

[0075] Other aspects of the HVAC&R system 210 may also be controlled to correspond to the valve setting of the valve 242 (or based on the above-described inputs). For example, the setting of the compressor 228 of the air cooling heat exchanger 238 and / or the setting of the fan 239 may be controlled so as to provide sufficient cooling to the process fluid 216 while reducing the energy consumption of the HVAC&R system 210. In general, the presently disclosed systems and methods are configured to enable the HVAC&R system 210 to provide sufficient cooling to the process fluid 216 while relying heavily on the free cooling component 214, thereby improving the efficiency of the HVAC&R system 210 relative to conventional embodiments.

[0076] As previously described, the HVAC&R system 210 includes a heat recovery path 241 configured to flow a heat recovery fluid 243 to the heat exchanger 235. The heat recovery fluid 243 may also be provided to an additional heat exchanger 260 upstream of the heat exchanger 235. The additional heat exchanger 260 may be employed to receive a portion of the process fluid 216 (e.g., to cool the process fluid 216).

[0077] As described above, the HVAC&R system 210 employs a working fluid 224, a cooling fluid 234, a process fluid 216, and a heat recovery fluid 243. In the illustrated embodiment, the HVAC&R system may employ a fifth fluid loop 262 that flows a fifth fluid 264 (e.g., water, glycol, a water-glycol mixture) for additional cooling purposes. The fifth fluid loop 262 may flow the fifth fluid 264 through a cooling tower 266 and a wet economizer heat exchanger 267. A pump 268 may be employed to deflect the fifth fluid 264 through the fifth fluid loop 262. At the wet economizer heat exchanger 267, the fifth fluid 264 may extract heat from the process fluid 216. Additionally, the cooling tower 266 may include a fan 269 that is controlled (e.g., by the controller 246) to various fan settings based on the wet-bulb temperature detected by the sensor 271, the required cooling capacity, and / or the availability of water, such that the cooling tower 266 (e.g., the fan 269 of the cooling tower 266) provides sufficient cooling to the fifth fluid 264. In some embodiments, the pump setting of the pump 268 may also be controlled based on the wet-bulb temperature detected by the sensor 271 and / or other environmental conditions and / or operating conditions of the HVAC&R system 210.

[0078] Fig. 9 The process fluid loop 218 in the embodiment of the present invention also includes a series of diverter valves 270a, 270b, 270c, 270d, 270e that are controlled to various settings to cause the process fluid 216 to flow through various paths of the process fluid loop 218 in various ways. In addition, the process fluid loop 218 includes a series of bypass valves 272a, 272b, 272c for opening and closing various paths in the process fluid loop 218. The controller 246 can control the diverter valves 270a, 270b, 270c, 270d, 270e and the bypass valves 272a, 272b, 272c, 272d (e.g., based on ambient conditions, operating conditions of the HVAC&R system, etc.) to control the flow of the process fluid 216 through the various components of the HVAC&R system 210 described in detail above. Examples of multi-temperature liquid circulation cooling HVAC&R systems with flow control features can be found in PCT / US22 / 19819, entitled “Multi-Level Thermal Management System and Method,” filed on March 20, 2022, which is incorporated herein by reference in its entirety.

[0079] In general, the presently disclosed systems and methods are configured to provide adequate cooling to one or more loads associated with an HVAC&R system while improving energy efficiency over conventional embodiments, reducing refrigerant charge for vapor compression over conventional embodiments, etc.

[0080] Although only certain features of the present embodiment are shown and described herein, many modifications and changes will be made by those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit of the present disclosure. In addition, it should be understood that certain elements of the disclosed embodiments may be combined or exchanged with each other.

[0081] The technology presented and claimed herein is referenced and applied to substantial objects and specific examples of a practical nature that improve the art in a demonstrable manner and are therefore not abstract, intangible, or purely theoretical. In addition, if any claim appended to the end of this specification contains one or more elements expressed as "means for [performing] [the function] ..." or "steps for [performing] [the function] ...", it is expected that such elements will be interpreted in accordance with 35 U.S.C. 112(f). However, for any claim containing elements specified in any other manner, it is intended that such elements will not be interpreted in accordance with 35 U.S.C. 112(f).

Claims

1. A heating, ventilation, air conditioning and / or refrigeration (HVAC&R) system comprising: Vapor compression components; A free cooling assembly, which corresponds to the cooling fluid and includes an air-cooled heat exchanger, an additional heat exchanger, a pump and a valve; as well as At least one controller configured to: receiving data indicative of an ambient condition, an operating condition, or both of the HVAC&R system; and Actuating the valve based on the data between: a first arrangement in which the cooling fluid is directed to the additional heat exchanger and blocked from entering the condenser of the vapor compression assembly; a second arrangement in which the cooling fluid is directed to the condenser and blocked from entering the additional heat exchanger; as well as A third arrangement in which a first portion of the cooling fluid is directed to the additional heat exchanger and a second portion of the cooling fluid is directed to the condenser.

2. The HVAC&R system of claim 1, comprising a process fluid loop configured to direct a process fluid through an evaporator of the vapor compression assembly, a load, and the additional heat exchanger.

3. The HVAC&R system of claim 1 , comprising a sensor configured to detect an ambient temperature corresponding to the ambient condition, wherein the at least one controller is configured to receive the data indicative of the ambient temperature corresponding to the ambient condition from the sensor.

4. The HVAC&R system of claim 1, wherein the at least one controller is configured to control a fan setting of a fan of the air-cooled heat exchanger based on the data.

5. The HVAC&R system of claim 1, wherein the at least one controller is configured to control a compressor setting of a compressor of the vapor compression assembly based on the data.

6. The HVAC&R system of claim 1, wherein the at least one controller is configured to control a pump setting of the pump based on the data and the pump is configured to deflect the cooling fluid through the free cooling component.

7. The HVAC&R system of claim 1, wherein the additional heat exchanger comprises a plate and frame heat exchanger.

8. The HVAC&R system of claim 1 , wherein the at least one controller is configured to receive an input indicative of an operating load or cooling demand corresponding to a load of the HVAC&R system, and the input corresponds to the data indicative of the operating condition of the HVAC&R system.

9. The HVAC&R system of claim 1 , wherein the at least one controller is configured to receive one or more inputs indicative of a return temperature of the cooling fluid from a load corresponding to the HVAC&R system, a supply temperature of the cooling fluid to the load, or both, and the one or more inputs correspond to the data indicative of the operating condition of the HVAC&R system.

10. The HVAC&R system of claim 1 , wherein the at least one controller is configured to receive one or more inputs indicative of a target return temperature of the cooling fluid from a load corresponding to the HVAC&R system, a target supply temperature of the cooling fluid to the load, or both, and the one or more inputs correspond to the data indicative of the operating condition of the HVAC&R system.

11. The HVAC&R system of claim 1 , comprising a heat recovery path, the heat recovery path comprising: a first heat recovery heat exchanger configured to receive the cooling fluid and the heat recovery fluid; as well as A second heat recovery heat exchanger is disposed downstream of the first heat recovery heat exchanger on the heat recovery path and is configured to receive the heat recovery fluid and the working fluid of the vapor compression assembly.

12. The HVAC&R system of claim 1, comprising: an additional cooling circuit corresponding to an additional cooling fluid; as well as A wet economizer heat exchanger is configured to receive the process fluid and the additional cooling fluid.

13. The HVAC&R system of claim 12, wherein: the supplemental cooling circuit comprising a cooling tower and a pump configured to deflect the supplemental cooling fluid between the wet economizer heat exchanger and the cooling tower; and The at least one controller is configured to control a fan setting of a fan of the cooling tower based on at least one of a required cooling capacity or water availability.

14. The HVAC&R system of claim 1, comprising: a process fluid circuit configured to direct a process fluid through the evaporator of the vapor compression assembly, the additional heat exchanger, a high temperature load, and a low temperature load; as well as a plurality of valves disposed in the process fluid circuit; as well as A controller is configured to actuate the plurality of valves to control one or more flows of the process fluid to the high temperature load and the low temperature load.

15. The HVAC&R system of claim 14, wherein the controller is configured to actuate the plurality of valves based on the data.

16. A control assembly for a heating, ventilation, air conditioning and / or refrigeration (HVAC&R) system, the control assembly comprising: a sensor configured to detect an ambient condition or an operating condition of the HVAC&R system; as well as At least one controller configured to: receiving feedback from the sensor indicative of the environmental condition or operating condition; actuating a valve of a free cooling assembly between a plurality of settings based on the feedback, the plurality of settings comprising: A first setting, in which the cooling fluid of the free cooling component is directed toward a heat exchanger of the free cooling component rather than a vapor compression component; a second setting, in which the cooling fluid is directed toward the vapor compression component rather than the heat exchanger; and at least one third setting, in which a first portion of the cooling fluid is directed toward the heat exchanger and a second portion of the cooling fluid is directed toward the vapor compression component.

17. The control assembly of claim 16, wherein the at least one controller is configured to control a fan setting of a fan of an air cooling heat exchanger of the free cooling assembly based on the feedback, wherein the air cooling heat exchanger is separate from the heat exchanger.

18. The control assembly of claim 16, wherein the at least one controller is configured to control a compressor setting of a compressor of the vapor compression assembly based on the feedback.

19. The control assembly of claim 16, wherein the at least one controller is configured to control a pump setting of a pump of the free cooling assembly based on the feedback, wherein the pump is configured to deflect the cooling fluid through the free cooling assembly.

20. The control assembly of claim 16, wherein the at least one controller is configured to actuate the valve between the plurality of settings based on additional feedback separate from the feedback and indicative of an operating load or cooling requirement.

21. The control assembly of claim 16, wherein the at least one controller is configured to control a plurality of valves corresponding to a process fluid loop based on the feedback, the process fluid loop being configured to direct a process fluid through an evaporator of the vapor compression assembly, the heat exchanger of the free cooling assembly, and a load.

22. A method of operating a heating, ventilation, air conditioning and / or refrigeration (HVAC&R) system, the method comprising: receiving, via at least one controller, first data indicative of a first value of an ambient condition or an operating condition of the HVAC&R system; controlling, via the at least one controller and based on the first data, a valve to a first setting in which a cooling fluid of a free cooling assembly is directed toward a heat exchanger of the free cooling assembly instead of a condenser of a vapor compression assembly; receiving, via at least one controller, second data indicative of a second value of the environmental condition or operating condition of the HVAC&R system, the second value being different than the first value; controlling, via the at least one controller and based on the second data, the valve to a second setting in which the cooling fluid is directed toward the condenser instead of the heat exchanger; receiving, via the at least one controller, third data indicative of a third value of the environmental or operating condition of the HVAC&R system, the third value being different than the first value and the second value; as well as The valve is controlled via the at least one controller and based on the third data to a third setting in which a first portion of the cooling fluid is directed towards the heat exchanger and a second portion of the cooling fluid is directed towards the condenser.

23. The method according to claim 22, comprising: sinking heat from a working fluid of the vapor compression assembly to the cooling fluid when the cooling fluid is present at the condenser; as well as When the cooling fluid is present at the heat exchanger, heat is sunk from the process fluid of the process fluid loop to the cooling fluid.

24. The method of claim 23, comprising directing a process fluid of a process fluid loop between a load and an evaporator of the vapor compression assembly, the heat exchanger of the free cooling assembly, or both.

25. The method of claim 22, comprising cooling the cooling fluid via an air-cooled heat exchanger of the free cooling assembly.

26. The method of claim 25, comprising controlling, via the at least one controller, a fan setting of a fan of the air cooling heat exchanger based on a first value at a first time point, a second value at a second time point different from the first time point, and a third value at a third time point different from the first time point and the second time point.

27. The method of claim 22, comprising controlling the valve via the at least one controller based on an operating load or cooling demand of the HVAC&R system.

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