Monitoring system, monitoring method, and heating, ventilation, air conditioning and / or refrigeration (hvac&r) system

Abstract

The monitoring system is configured to monitor the environment within the enclosure of a heating, ventilation, air conditioning and / or cooling (HVAC&R) system. The monitoring system includes a sensor configured to acquire data representing environmental parameter values ​​within the enclosure. The monitoring system also includes a controller configured to receive data from the sensor, determine the occurrence of a thermal event within the enclosure based on the data, and instruct the circuit breaker of the HVAC&R system to switch to a fault configuration in response to the determination of the occurrence of a thermal event.

Description

Technology Field

[0001] This application claims the priority and benefit of U.S. Provisional Application No. 63 / 151,418, filed on February 19, 2021, with the title "SYSTEMS AND METHODS FOR MONITORING ELECTRICAL COMPONENTS OF A CHILLER SYSTEM," which is incorporated herein by reference in its entirety for all purposes. Background Technology

[0002] This section is intended to introduce to the reader various aspects of the technology that may be related to the various aspects of the present invention, as described below. It is believed that this discussion helps provide the reader with background information to facilitate a better understanding of the various aspects of the present invention. Accordingly, it should be understood that these contents should be read in this context, rather than as an acknowledgment of prior art.

[0003] Chiller systems used in commercial or industrial heating, ventilation, air conditioning and / or cooling (HVAC&R) systems generally include a compressor for circulating a working fluid (e.g., refrigerant) through a heat exchanger of the HVAC&R system. The heat exchanger facilitates the transfer of thermal energy between the working fluid and the space to be regulated, such as a room or zone within a building or other structure provided by the HVAC&R system. Typically, a chiller system includes one or more electrical components that facilitate the control and operation of the chiller system. For example, a chiller system may include a variable speed drive (VSD) that facilitates the adjustment of the operating speed of a motor (e.g., an electric motor) configured to drive the operation of the compressor. It may be desirable to monitor the operating conditions of the electrical components during the operation of the chiller system.

[0004] The present invention relates to a monitoring system configured to monitor the environment within an enclosure of a heating, ventilation, air conditioning and / or cooling (HVAC&R) system. The monitoring system includes a sensor configured to acquire data representing environmental parameter values ​​within the enclosure. The monitoring system also includes a controller configured to receive data from the sensor, determine the occurrence of a thermal event within the enclosure based on the data, and instruct a circuit breaker of the HVAC&R system to switch to a fault configuration in response to the determination of the occurrence of a thermal event.

[0005] The present invention also relates to a method comprising acquiring data representing environmental parameter values ​​within an enclosure of a heating, ventilation, air conditioning and / or cooling (HVAC&R) system through one or more sensors. The method further comprises the step of determining, through a controller, the occurrence of a thermal event within the enclosure based on the data. The method further comprises the step of instructing, through the controller, to switch to a fault configuration for a circuit breaker of the HVAC&R system in response to the determination of the occurrence of a thermal event.

[0006] The present invention also relates to a heating, ventilation, air conditioning and / or cooling (HVAC&R) system. The HVAC&R system includes a circuit breaker configured to send current from a power supply to an electrical component placed within the enclosure of the HVAC&R system. The HVAC&R system also includes a sensor configured to acquire data representing environmental parameters within the enclosure. The HVAC&R system also includes a controller configured to receive data from the sensor, determine the occurrence of a thermal event within the enclosure based on the data, and instruct the circuit breaker to switch to a fault configuration to interrupt the flow of current to the electrical component in response to the determination of the occurrence of the thermal event. Brief explanation of the drawing

[0007] Various embodiments of the present invention can be better understood by reading the following detailed description and referring to the drawings: FIG. 1 is a perspective view of one embodiment of a building in which a heating, ventilation, air conditioning and cooling (HVAC&R) system can be utilized in a commercial place according to an embodiment of the present invention; FIG. 2 is a perspective view of one embodiment of a vapor compression system according to an aspect of the present invention; FIG. 3 is a schematic diagram of one embodiment of the vapor compression system of FIG. 2 according to an embodiment of the present invention; FIG. 4 is a schematic diagram of one embodiment of the vapor compression system of FIG. 2 according to an embodiment of the present invention; FIG. 5 is a schematic diagram of one embodiment of a part of an HVAC&R system illustrating a monitoring system configured to monitor one or more components of an HVAC&R system according to an aspect of the present invention; FIG. 6 is a flowchart of one embodiment of a method for operating the monitoring system of FIG. 5 according to an embodiment of the present invention; and FIG. 7 is a partially exploded view of one embodiment of a sensor that may be included in the monitoring system of FIG. 5 according to an embodiment of the present invention. Specific details for implementing the invention

[0008] One or more specific embodiments of the present invention will be described below. These described embodiments are examples of the technology currently disclosed. Furthermore, as part of an effort to provide a concise description of these embodiments, not all features of actual implementations may be described in the specification. It should be understood that, as in any engineering technology or design plan, in the development of any such actual implementation, numerous implementation-specific decisions may be made to achieve the developer's specific objectives, such as compliance with system-related and business-related constraints that may vary from implementation to implementation. Moreover, it should be understood that while such development efforts may be complex and time-consuming, they will nevertheless be routine tasks of design, fabrication, and manufacturing for those skilled in the art who benefit from the present invention.

[0009] When introducing elements of various embodiments of the present invention, the articles "one (a, an)" and "the" are intended to imply that there is one or more elements. The terms "comprising," "including," and "having" are inclusive and imply that additional elements may exist in addition to those listed. Furthermore, it should be understood that references to "one embodiment" or "one embodiment" of the present invention are not to be interpreted as excluding the existence of additional embodiments that also incorporate the cited features.

[0010] As briefly discussed above, heating, ventilation, air conditioning and / or cooling (HVAC&R) systems can be used to thermally regulate spaces within a building, house, or other suitable structure. For example, an HVAC&R system may include a vapor compression system (e.g., a chiller system) that transfers thermal energy between a heat transfer fluid, such as a refrigerant, and a fluid to be regulated, such as air, water, or brine. A vapor compression system may include a condenser and an evaporator that are fluidly coupled to each other through conduits. The compressor can be used to circulate the refrigerant through the conduits, thereby enabling the transfer of thermal energy between the heat transfer fluid and the fluid to be regulated through the condenser and / or evaporator. In many cases, the compressor can be driven by a motor (e.g., an electric motor) of the HVAC&R system.

[0011] Generally, an HVAC&R system includes electrical components (e.g., power components, control components, electromechanical components, etc.) configured to control the operation of various components of the chiller system, such as motors for compressors, fans, etc. For example, in some embodiments, the electrical components may include a variable speed drive (VSD) electrically coupled to the compressor motor and configured to control the operating speed of the motor. For example, the VSD can accelerate the motor from zero revolutions per minute (RPM) to a critical operating speed during the startup of the HVAC&R system. In some cases, the VSD can further adjust the magnitude of the operating speed and / or the critical operating speed during the operation of the HVAC&R system. In certain cases, it may be desirable to monitor the operating status or condition of the electrical components (e.g., VSD) during the operation of the HVAC&R system.

[0012] Accordingly, embodiments of the present invention relate to a monitoring system configured to monitor the operating state or condition of one or more electrical components of an HVAC&R system (e.g., a chiller system). The monitoring system may include one or more sensors placed within an enclosure of the HVAC&R system. The enclosure may be configured to accommodate at least some of the electrical components. The sensors are configured to monitor one or more environmental parameters within the enclosure, such as parameters corresponding to the quality and / or composition of the air contained or residing within the enclosure. The sensors may also generate and provide feedback indicating the environmental parameters. A controller of the monitoring system is electrically and / or communically coupled to the sensors and configured to receive feedback from the sensors. As discussed in detail herein, the controller is configured to determine and monitor the operating state or condition of one or more electrical components placed within the enclosure based on the feedback received from the sensors. Additionally, the controller may adjust the operation of the HVAC&R system based on the feedback received from the sensors (e.g., based on the operating state or condition of one or more electrical components).

[0013] Now, referring to the drawings, FIG. 1 is a perspective view of one embodiment of an environment for a heating, ventilation, air conditioning and / or cooling (HVAC&R) system (10) in a building (12) for a typical commercial place. The HVAC&R system (10) may include a vapor compression system (14) (e.g., a chiller system) that supplies a cooled liquid that can be used to cool the building (12). The HVAC&R system (10) may also include a boiler (16) that supplies a warm liquid for heating the building (12) and an air distribution system that circulates air into the building (12). The air distribution system may also include an air return duct (18), an air supply duct (20), and / or an air handler (22). In some embodiments, the air handler (22) may include a heat exchanger connected to the boiler (16) and the vapor compression system (14) by a conduit (24). The heat exchanger in the air handler (22) can receive heated liquid from the boiler (16) or cooled liquid from the steam compression system (14) depending on the operating mode of the HVAC&R system (10). Although the HVAC&R system (10) is illustrated as having separate air handlers on each floor of the building (12), in other embodiments, the HVAC&R system (10) may include other components that can be shared between or among the air handlers (22) and / or floors.

[0014] FIGS. 2 and FIGS. 3 are examples of a vapor compression system (14) that can be used in an HVAC&R system (10). The vapor compression system (14) can circulate a refrigerant through a circuit starting from a compressor (32). The circuit may also include a condenser (34), expansion valve(s) or device(s) (36), and a liquid cooler or evaporator (38). The vapor compression system (14) may further include a control panel (40) having an analog-to-digital (A / D) converter (42), a microprocessor (44), non-volatile memory (46) and / or an interface board (48).

[0015] Some examples of fluids that can be used as refrigerants in a vapor compression system (14) are hydrofluorocarbon (HFC) refrigerants, e.g., R-410A, R-407, R-134a, hydrofluoroolefin (HFO), “natural” refrigerants, e.g., ammonia (NH3), R-717, carbon dioxide (CO2), R-744, or hydrocarbon refrigerants, water vapor, or any other suitable refrigerant. In some embodiments, the vapor compression system (14) may be configured to efficiently utilize a refrigerant having a reference boiling point of about 19°C (66°F) at 1 atmosphere, which is also referred to as a low-pressure refrigerant when compared to an intermediate-pressure refrigerant such as R-134a. As used herein, “reference boiling point” may refer to a boiling point temperature measured at 1 atmosphere.

[0016] In some embodiments, the vapor compression system (14) may use one or more of a variable speed drive (VSD) (52), a motor (50), a compressor (32), a condenser (34), an expansion valve or device (36), and / or an evaporator (38). The motor (50) may drive the compressor (32) and may be powered by the variable speed drive (VSD) (52). The VSD (52) receives AC power from an alternating current (AC) power source having a specific fixed line-to-line voltage and fixed line frequency and provides power to the motor (50) having a variable voltage and frequency. In other embodiments, the motor (50) may be powered directly by an AC or direct current (DC) power source. The motor (50) may include any type of electric motor that can be powered by the VSD or directly by an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or other suitable motor.

[0017] The compressor (32) compresses the refrigerant vapor and delivers the vapor to the condenser (34) through the discharge passage. In some embodiments, the compressor (32) may be a centrifugal compressor. The refrigerant vapor delivered to the condenser (34) by the compressor (32) may transfer heat to the cooling fluid (e.g., water or air) of the condenser (34). As a result of the heat transfer with the cooling fluid, the refrigerant vapor may condense into liquid refrigerant within the condenser (34). The liquid refrigerant from the condenser (34) may flow to the evaporator (38) through the expansion device (36). In the exemplary embodiment of FIG. 3, the condenser (34) is water-cooled and includes a tube bundle (54) connected to a cooling tower (56) that supplies cooling fluid to the condenser (34).

[0018] The liquid refrigerant delivered to the evaporator (38) may or may not be the same cooling fluid used in the condenser (34) and may absorb heat from another cooling fluid. The liquid refrigerant in the evaporator (38) may undergo a phase change from liquid refrigerant to refrigerant vapor. As illustrated in the exemplary embodiment of FIG. 3, the evaporator (38) may include a tube bundle (58) having a supply line (60S) and a return line (60R) connected to a cooling load (62). The cooling fluid of the evaporator (38) (e.g., water, ethylene glycol, calcium chloride brine, sodium chloride brine, or other suitable fluid) enters the evaporator (38) through the return line (60R) and exits the evaporator (38) through the supply line (60S). The evaporator (38) can lower the temperature of the cooling fluid in the tube bundle (58) through heat transfer with the refrigerant. The tube bundle (58) in the evaporator (38) may include multiple tubes and / or multiple tube bundles. In any case, the vapor refrigerant exits the evaporator (38) and returns to the compressor (32) via the suction line to complete the cycle.

[0019] FIG. 4 is a schematic diagram of a vapor compression system (14) in which an intermediate circuit (64) is integrated between a condenser (34) and an expansion device (36). The intermediate circuit (64) may have an inlet line (68) that is fluidly connected directly to the condenser (34). In another embodiment, the inlet line (68) may be fluidly connected indirectly to the condenser (34). As illustrated in the exemplary embodiment of FIG. 4, the inlet line (68) includes a first expansion device (66) located upstream of an intermediate vessel (70). In some embodiments, the intermediate vessel (70) may be a flash tank (e.g., a flash intercooler). In other embodiments, the intermediate vessel (70) may be composed of a heat exchanger or a "surface economizer." In the exemplary embodiment of FIG. 4, the intermediate vessel (70) is used as a flash tank, and the first expansion device (66) is configured to lower (e.g., expand) the pressure of the liquid refrigerant received from the condenser (34). During the expansion process, some of the liquid may evaporate, and thus the intermediate vessel (70) can be used to separate the vapor from the liquid received from the first expansion device (66).

[0020] Additionally, the intermediate vessel (70) can provide greater expansion of the liquid refrigerant due to the pressure drop experienced when the liquid refrigerant enters the intermediate vessel (70) (e.g., due to the rapid increase in volume experienced when entering the intermediate vessel (70)). The vapor from the intermediate vessel (70) can be drawn by the compressor (32) into the suction line (74) of the compressor (32). In another embodiment, the vapor from the intermediate vessel can be drawn into the intermediate stage of the compressor (32) (e.g., not the suction stage). The liquid collected in the intermediate vessel (70) may be at a lower enthalpy than the liquid refrigerant exiting the condenser (34) due to the expansion device (66) and / or expansion in the intermediate vessel (70). The liquid from the intermediate vessel (70) then flows from line (72) through the second expansion device (36) to the evaporator (38).

[0021] With reference to the foregoing, FIG. 5 is a schematic diagram of one embodiment of an HVAC&R system (10) and illustrates a monitoring system (100) configured to monitor the operating conditions or status of one or more electrical components (102) of the HVAC&R system (10) in general. For example, one or more components (102) may include a VSD (52) and / or components of the VSD (52). For clarity, as used herein, "electrical components (102)" may refer to and / or include digital components (e.g., microprocessors, application-specific integrated circuits (ASICs), field programmable gate arrays (FPGAs)), analog components (e.g., wires, resistors, capacitors, inductors, diodes, transistors), electromechanical components (e.g., solenoids, actuators), power components (e.g., power supplies, inverters, power buses, etc.) and / or other components that utilize and / or operate with current. In the illustrated embodiment, the HVAC&R system (10) includes a circuit breaker (104) configured to receive power from a power supply (106). As a non-limiting example, the power supply (106) may provide three-phase, fixed-voltage, and fixed-frequency alternating current (AC) power to the circuit breaker (104) from an AC power grid, a distribution system, or other source. The circuit breaker (104) is configured to distribute the power received from the power supply (106) to the electrical components (102) of the HVAC&R system (10). In some embodiments, the circuit breaker (104) may supply power to a monitoring system (100). In other embodiments, the monitoring system (100) may receive power from a separate power source (e.g., a battery).

[0022] In any case, the circuit breaker (104) may monitor the magnitude of the current flow from the power supply (106) to the electrical component (102) through the circuit breaker (104) (e.g., across the contacts of the circuit breaker (104). The circuit breaker (104) is configured to enable or stop the current flow across the circuit breaker (104) based on the magnitude of the current flow. For example, in response to the magnitude of the current flow across the circuit breaker (104) exceeding a threshold or remaining above the threshold for a predetermined time interval, the circuit breaker (104) may electrically disconnect the power supply (106) from the electrical component (102) (e.g., by opening the contacts of the circuit breaker (104)) to block the current flow from the power supply (106) to the electrical component (102). That is, the circuit breaker (104) can be switched to an open circuit configuration to electrically isolate the power supply (106) from all electrical components (102) or a subset of electrical components (102). In practice, it should be understood that in some embodiments, the circuit breaker (104) may include a plurality of individual circuit breakers configured to selectively enable or block the flow of current from the power supply (106) to the corresponding electrical components (102) of the HVAC&R system (10).

[0023] In some embodiments, in an open circuit configuration of the circuit breaker (104), the circuit breaker (104) may be configured to block the flow of current (107) to the electrical component (102) (e.g., from the power supply (106)) while still allowing the flow of current (108) to the monitoring system (100) (e.g., from the power supply (106)). As discussed below, in a fault configuration of the circuit breaker (104) (e.g., a type of open circuit configuration of the circuit breaker (104)), the circuit breaker (104) may block the flow of current (e.g., from the power supply (106)) to both the electrical component (102) and the monitoring system (100).

[0024] In the illustrated embodiment, the monitoring system (100) includes a controller (110) (e.g., a printed circuit board [PCB], an automation controller, or a programmable logic controller [PLC]) configured to receive power from a circuit breaker (104). In particular, the controller (110) may be electrically coupled to a power converter (112) configured to receive AC power (e.g., current) from the circuit breaker (104) and output direct current (DC) power (e.g., current) to the controller (110). As a non-limiting example, the power converter (112) may receive 120-volt AC power from the circuit breaker (104) and output 24-volt DC power to the controller (110). In some embodiments, a fuse (114) may be electrically coupled between the circuit breaker (104) and the power converter (112).

[0025] In certain embodiments, part or all of the electrical component (102) and / or the monitoring system (100), or part thereof, may be placed within the enclosure (120) (e.g., electronic enclosure, housing) of the HVAC&R system (10). The controller (110) may be electrically and / or telecommunicationally coupled to one or more sensors (122) of the monitoring system (100). As described in detail herein, the sensors (122) are configured to monitor one or more environmental parameters within the interior (124) of the enclosure (120) and to provide feedback to the controller (110) indicating the environmental parameters. As used herein, "environmental parameters" may include, for example, the concentration (e.g., parts per million [ppm]) of a compound (e.g., organic compound, inorganic compound) that may be dispersed in the air within the enclosure (120). As a non-limiting example, such a compound may include carbon monoxide. Additionally or alternatively, "environmental parameters" may include the concentration of particulate matter (e.g., carbon particles) that may be suspended in the air within the enclosure (120). The sensors (122) may include a first group of sensors (130) or a subset (e.g., one or more of the sensors (122)) and a second group of sensors (132) or a subset (e.g., one or more of the sensors (122)) that facilitate the detection and monitoring of environmental parameters within the enclosure (120) via the controller (110) as discussed below. It should be understood that individual sensors (122) of the first group of sensors (130) and / or the second group of sensors (132) may be placed at various appropriate locations within the enclosure (120). For example, the sensors (130, 132) may be located adjacent to a specific electrical component (102) that requires monitoring. The controller (110) can generally utilize feedback received from the sensor (122) to evaluate the operating conditions or status of the electrical component (102) and / or the HVAC&R system (10).

[0026] For example, in some embodiments, certain electrical components (102) may experience performance degradation over time. In fact, the useful or designed life of some electrical components (102) may expire, and it may be desirable to perform maintenance and / or replacement of such electrical components (102) to maintain the desired operation of the HVAC&R system (10). In some cases, performance degradation of the electrical components (102) and / or other variables (e.g., environmental factors such as power quality, humidity, etc.) may cause the electrical components (102) to experience a thermal event during the operation of the HVAC&R system (10). As used herein, a thermal event may indicate an operating condition or state of the electrical component (102) in which the temperature of the electrical component (102) exceeds the expected operating temperature range of the electrical component (102) (e.g., overheating of the electrical component (102)). In this way, during a thermal event, the operating state of the electric component (102) may deviate from the expected operating state of the electric component (102) (for example, the temperature of the electric component (102) may rise above the expected operating temperature of the electric component (102)).

[0027] In a specific embodiment, the presence of certain compounds and / or particulates in the air within the enclosure (120) may indicate the potential occurrence and / or actual occurrence of a thermal event. That is, environmental parameters within the enclosure (120) may change before and / or during a thermal event. Accordingly, the sensor (122) is configured to detect the presence of one or more compounds and / or particulates in the air that may indicate a potential or actual thermal event. The controller (110) may therefore detect the occurrence or potential occurrence of a thermal event within the enclosure (120) in response to feedback from one or more sensors (122) indicating a current (e.g., real-time) and / or detected environmental parameters within the enclosure (120).

[0028] For example, in some embodiments, carbon monoxide may be present inside (124) of the enclosure (120) before or during a thermal event. A first sensor group (130) may include a carbon monoxide sensor configured to detect the concentration of carbon monoxide inside (124). Thus, based on feedback from the first sensor group (130), the controller (110) may monitor the carbon monoxide concentration inside the enclosure (120) continuously or intermittently (e.g., during the operation of the HVAC&R system (10)). In some embodiments, the controller (110) may determine the occurrence of a thermal event in response to feedback from any one of the first sensor group (130) indicating that the carbon monoxide concentration inside (124) exceeds a threshold (e.g., by a target value or tolerance) at a specific point in time or for a predetermined time interval (e.g., 5 seconds). Additionally or alternatively, the controller (110) may determine the potential or actual occurrence of a thermal event in response to feedback from a subset (e.g., two or more) of the first sensor group (130) indicating that the carbon monoxide concentration inside (124) exceeds a threshold at a specific point in time or for a predetermined time interval. For this purpose, the controller (110) may detect the potential or actual occurrence of a thermal event without utilizing temperature feedback from one or more temperature sensors configured to monitor, for example, the operating temperature inside the enclosure (120) (e.g., of one or more electrical components (102)).

[0029] In certain embodiments, the controller (110) may detect the potential or actual occurrence of a thermal event based on feedback from a second sensor group (132) in addition to, or instead of, feedback that may be received by the controller (110) from a first sensor group (130). For example, in some embodiments, particulate matter (e.g., carbon particles) may be present inside (124) of the enclosure (120) before, at the start, and / or during the thermal event. The second sensor group (132) may include an optical sensor (e.g., a photoelectric detector) configured to detect the concentration of particulate matter (e.g., carbon particles) that may be suspended in the air inside (124). Thus, based on the feedback received from the second sensor group (132), the controller (110) may continuously or intermittently monitor the concentration of particulate matter suspended in the air inside the enclosure (120) (e.g., during the operation of the HVAC&R system (10). In some embodiments, the controller (110) may determine the potential occurrence or actuality of a thermal event in response to feedback from any sensor of the second sensor group (132) indicating that the concentration of particulate matter suspended in the air inside (124) exceeds a threshold value (e.g., by a target value or tolerance) at a specific point in time or during a predetermined time interval (e.g., 5 seconds). Additionally, or alternatively, the controller (110) may determine the potential occurrence or actuality of a thermal event in response to feedback from a subset (e.g., two or more) of the second sensor group (132) indicating that the concentration of particulate matter suspended in the air inside (124) exceeds a threshold value at a specific point in time or during a predetermined time interval.For this purpose, the controller (110) can detect the potential occurrence or actual presence of a thermal event within the enclosure (120) without utilizing temperature feedback from one or more temperature sensors configured to monitor, for example, the operating temperature within the enclosure (120) (e.g., of the electrical component (102)).

[0030] In some embodiments, in response to the detection of a potential occurrence or actual occurrence of a thermal event within the enclosure (120), the controller (110) may send a command to a shunt trip (140) of a circuit breaker (104) to execute a interruption of the flow of power (e.g., current) from the power supply (106) to the electrical component (102) or to the monitoring system (100). The shunt trip (140) enables adjustment of the circuit breaker (104) based on an input signal from the controller (110) (e.g., instead of based on the magnitude of the current flowing through the circuit breaker (104) at a specific point in time). For example, the shunt trip (140) may be configured to operate the circuit breaker (104) (e.g., in response to receiving a control signal from the controller (110)) to switch the circuit breaker (104) to a fault configuration (e.g., a type of open circuit configuration), whereby the circuit breaker (104) can electrically disconnect the power supply (106) from the electrical component (102) and / or the monitoring system (100). In this way, in the fault configuration, the circuit breaker (104) can block the flow of current (146) (e.g., both currents (107 and 108)) from the power supply (106) to the electrical component (102) and the monitoring system (100). For this purpose, based on feedback from any one or a combination of sensors (122), the shunt trip (140) may cause the controller (110) to execute the interruption of current flow from the circuit breaker (104) to the electrical component (102) as well as to the components of the monitoring system (100) (e.g., sensors (122), controller (110)). By disabling the flow of current from the power supply (106) to the electrical component (102), the controller (110) may suppress the progression and / or expansion of a thermal event and allow the electrical component (102) to cool to a temperature substantially equal to or lower than the expected operating temperature of the electrical component (102).

[0031] In some embodiments, the monitoring system (100) includes an indicator (150) (e.g., flip-dot memory device, visual indicator, etc.) configured to provide an indication (e.g., visual indication) of whether the controller (110) has activated the shunt trip (140) in response to the detection of a thermal event. That is, the indicator (150) may provide an indication of whether the controller (110) has executed a interruption of current flow from the power supply (106) to the electrical component (102) and the monitoring system (100) based on feedback from the sensor (122).

[0032] For example, in some embodiments, the indicator (150) may include an electromagnet (152), a plate (154) (e.g., a disk), and a spring (156). The electromagnet (152) may be configured to generate sufficient magnetic force to maintain the plate (154) in a first orientation (e.g., face-up orientation) through the current supplied to the electromagnet (152) from the circuit breaker (104). In response to the interruption of current to the electromagnet (152) (e.g., when the controller (110) switches the circuit breaker (104) to a fault configuration in response to the detection of a thermal event), the reduction or loss of magnetic force generated by the electromagnet (152) allows the spring (156) to switch the plate (154) from the first orientation to a second orientation (e.g., face-down orientation). As a result, an operator (e.g., a service technician) inspecting the HVAC&R system (10) can determine whether a thermal event has occurred by inspecting the indicator (150). For example, the operator can determine that no thermal event has occurred based on observation of the plate (154) of the indicator (150) in the first orientation. Conversely, the operator can determine that a thermal event has occurred based on observation of the plate (154) of the indicator (150) in the second orientation.

[0033] As discussed above, the indicator (150) may switch the plate (154) from the first orientation to the second orientation in response to the interruption of power or current to the monitoring system (100), as may occur when the controller (110) activates the shunt trip (140) to switch the circuit breaker (104) to the fault configuration. However, the indicator (150) may not switch the plate (154) from the first orientation to the second orientation in response only to the interruption of power or current to the electrical component (102). For example, the indicator (150) may not switch the plate (154) from the first orientation to the second orientation in response to the circuit breaker (104) interrupting the current flow to the electrical component (102) due to the current flow through the circuit breaker (104) exceeding a threshold value. In such an environment, the circuit breaker (104) (e.g., in an open circuit configuration) can nevertheless maintain the supply of power (e.g., current flow) to the monitoring system (100) (e.g., controller (110)). The indicator (150) may be coupled to the controller (110) and / or other suitable components of the monitoring system (100). In other embodiments, the monitoring system (100) may include any other suitable device configured to warn the operator of the occurrence of a thermal event in addition to or instead of the indicator (150). In additional embodiments, the controller (110) may be configured to send an indication (e.g., a warning message, a warning command) to another electronic device outside the monitoring system (100) upon detection of a thermal event. The controller (110) may send the indication before the operation of the shunt trip (140), simultaneously with the operation of the shunt trip (140), or in response to the operation of the shunt trip (140).

[0034] In some embodiments, the controller (110) includes a processor (160), such as a microprocessor, capable of running software to control components of the HVAC&R system (10) and / or components of the monitoring system (100). The processor (160) may include a plurality of microprocessors, one or more "general-purpose" microprocessors, one or more special-purpose microprocessors and / or one or more specific-purpose integrated circuits (ASICs), or a combination thereof. For example, the processor (160) may include one or more reduced instruction set (RISC) processors. The controller (110) may also include a memory device (162) (e.g., memory, memory storage, etc.) capable of storing information such as instructions, control software, lookup tables, configuration data, etc. The memory device (162) may include volatile memory such as random access memory (RAM) and / or non-volatile memory such as read-only memory (ROM). The memory device (162) may store various information and may be used for various purposes. For example, the memory device (162) may store processor-executable instructions, including firmware or software to be executed by the processor (160), such as instructions for controlling components of the HVAC&R system (10) and / or monitoring system (100). In some embodiments, the memory device (162) is a type of non-transient machine-readable medium capable of storing machine-readable instructions to be executed by the processor (160). The memory device (162) may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium or a combination thereof. The memory device (162) may store data, instructions, and any other suitable data.

[0035] FIG. 6 is a flowchart of one embodiment of a method (170) for operating a monitoring system (100) according to the technology described herein. It should be noted that the steps of the method (170) discussed below may be performed in any suitable order and are not limited to the order shown in the exemplary embodiment of FIG. 6. It should also be noted that additional steps of the method (170) may be performed in certain embodiments and specific steps of the method (170) may be omitted. It should also be understood that specific steps of the method (170) may be performed simultaneously with other steps. The method (170) may be executed by the processor (160) of the controller (110) (e.g., through the execution of processor-executable instructions stored in the memory device (162)) and / or by other suitable processing circuits of the HVAC&R system (10) and / or the monitoring system (100).

[0036] The method (170) includes operating a monitoring system (100) to detect the potential occurrence or actual presence of a thermal event within the enclosure (120) as indicated by block (172). An exemplary embodiment of the method (170) also includes monitoring feedback (e.g., data) from a first sensor group (130) and a second sensor group (132) as indicated by blocks (174 and 176), respectively. As indicated by block (178), the controller (110) can determine, for example, whether feedback from a sensor of the first sensor group (130) indicates that the carbon monoxide concentration within the enclosure (120) exceeds a first threshold. As shown by block (180), the controller (110) can determine, for example, whether feedback from the sensor of the second sensor group (132) indicates that the concentration of particulate matter suspended in the air inside the enclosure (120) exceeds a second threshold.

[0037] In response to a determination that none of the sensors (122) of the first sensor group (130) provide feedback indicating that the concentration of carbon monoxide in the enclosure (120) exceeds a first threshold, and none of the sensors (122) of the second sensor group (132) provide feedback indicating that the concentration of particulate matter suspended in the air in the enclosure (120) exceeds a second threshold, the controller (110) can return to block (172) of the method (170). In response to a determination that at least one sensor (122) of the first sensor group (130) provides feedback indicating that the concentration of carbon monoxide in the enclosure (120) exceeds a first threshold and / or at least one sensor (122) of the second sensor group (132) indicates that the concentration of particulate matter suspended in the air within the enclosure (120) exceeds a second threshold, as shown in block (182), the controller (110) may activate a shunt trip (140) according to the aforementioned technique to switch the circuit breaker (104) to a fault configuration. In another embodiment, it should be understood that the controller (110) may control the shunt trip (140) and / or detect a thermal event based on feedback from other suitable sensors in addition to or instead of the feedback provided by the first and second sensor groups (130, 132).

[0038] FIG. 7 is a partial exploded view of one embodiment of a sensor (122) referred herein as a sensor (190) (e.g., a sensor assembly or module). The sensor (190) may include or may include one of the sensors (122) of a first sensor group (130) and / or one of the sensors (122) of a second sensor group (132). In practice, in some embodiments, the sensor (190) may accommodate one or more first sensor groups (130) and one or more second sensor groups (132) within the housing (192) of the sensor (190). In other embodiments, each sensor (122) of the first sensor group (130) and each sensor (122) of the second sensor group (132) may be placed within separate housings (192).

[0039] In some embodiments, the sensor (190) may include one or more magnets (194) (e.g., permanent magnets) that are coupled to or recessed into the surface of the housing (192) (e.g., base surface (196), base portion). The magnets (194) facilitate magnetic coupling (e.g., removable coupling, removable attachment) of the sensor (190) to a desired panel or other structural component of the enclosure (120) (e.g., a metal panel forming at least part of the enclosure (120). In this way, the magnets (194) facilitate the installation of the sensor (190) at various locations on or inside the enclosure (120) without involving modification (e.g., physical alteration) of the enclosure (120). That is, to attach the sensor (190) to a specific part of the enclosure (120), a service technician can magnetically engage the magnet (194) with a metal component (e.g., panel, beam, strut) of the enclosure (120) to hold the sensor (190) at a desired location within the enclosure (120) (e.g., adjacent to one or more of the electrical components (102)). In practice, it should be understood that the monitoring system (100) may be a retro-fit kit configured to be installed within an enclosure (e.g., the enclosure (120)) of an existing embodiment of the HVAC&R system (10) that previously did not include the monitoring system (100).

[0040] As described above, embodiments of the present invention may provide one or more technical effects useful for detecting the occurrence of a thermal event within an enclosure of an HVAC&R system that may include one or more electrical components. Specifically, the present embodiment includes a monitoring system having one or more sensors configured to monitor environmental parameters within an enclosure configured to accommodate an electrical component. The monitoring system may facilitate the detection of a thermal event within the enclosure based on the monitored environmental parameters without using a dedicated temperature sensor. Additionally, the monitoring system may interrupt the supply of current to the electrical component to suppress the occurrence or amplification of the thermal event. The technical effects and technical problems described herein are merely examples and are not limited thereto. It should be noted that the embodiments described herein may have other technical effects and may solve other technical problems.

[0041] It is important to note that the configuration and arrangement of the monitoring system as illustrated in the various exemplary embodiments are merely exemplary. Although only a few embodiments have been described in detail in the present invention, those skilled in the art reviewing the present invention will readily understand that many modifications (e.g., changes in the size, dimensions, structure, shape and proportions of various elements, values ​​of parameters, mounting arrangements, use of materials, colors, orientations, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter cited in the claims. For example, elements illustrated as being integrally formed may be composed of a number of parts or elements, the positions of the elements may be reversed or otherwise changed, and the nature or number of individual elements or positions may be changed or altered. Accordingly, all such modifications are intended to be included within the scope of the present invention. The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover equivalent structures as well as the structures and structural equivalents described herein as performing the cited function. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of exemplary embodiments without departing from the scope of the invention.

[0042] The claimed technology presented and referred to herein is referenced and applied to concrete examples and material objects of a substantial nature that clearly improve the current art, and as such, is not abstract, intangible, or purely theoretical. Furthermore, where the claims appended to the end of this specification include one or more components designated as “means for [performing] a function” or “steps for [performing] a function”, such components are intended to be interpreted in accordance with 35 USC 112(f). However, in the case of claims including components designated in a different manner, such components are not intended to be interpreted in accordance with 35 USC § 112(f).

Claims

Claim 1 A monitoring system configured to monitor the environment within an enclosure of a heating, ventilation, air conditioning and / or cooling (HVAC&R) system, comprising: a sensor configured to acquire data representing environmental parameter values ​​within the enclosure; and a controller, wherein the controller: receives the data from the sensor; determines the occurrence of a thermal event within the enclosure based on the data; and instructs a circuit breaker of the HVAC&R system to switch to a fault configuration in response to the determination of the occurrence of the thermal event. Claim 2 A monitoring system according to claim 1, wherein the data includes the concentration of carbon monoxide within the enclosure. Claim 3 A monitoring system according to claim 1, wherein the data includes the concentration of particulate matter suspended in the air within the enclosure. Claim 4 A monitoring system according to claim 1, comprising a circuit breaker, wherein the circuit breaker is configured to monitor the magnitude of a current sent to an electrical component of the HVAC&R system through the circuit breaker, and wherein the circuit breaker is configured to switch to an open circuit configuration that interrupts the flow of current to the electrical component in response to the magnitude of the current exceeding a threshold value. Claim 5 A monitoring system according to claim 4, wherein, in the open circuit configuration, the circuit breaker is configured to send current from the power supply to the controller. Claim 6 A monitoring system according to claim 5, wherein, in the fault configuration, the circuit breaker is configured to interrupt the current flow from the power supply to the controller and interrupt the current flow to the electrical component. Claim 7 A monitoring system according to claim 6, comprising an indicator configured to provide a visual indication of the occurrence of the thermal event in response to the interruption of the current flow to the controller. Claim 8 A monitoring system according to claim 1, wherein the controller is configured to determine the occurrence of the thermal event in response to a determination that the data from the sensor indicates that the environmental parameter value exceeds a threshold value. Claim 9 A monitoring system according to claim 1, wherein the controller is configured to determine the occurrence of the thermal event in response to a determination that the data from the sensor indicates that the value of the environment parameter exceeds a threshold value during a predetermined time interval. Claim 10 A monitoring system according to claim 1, wherein the controller is configured to transmit a warning message to an electronic device in response to the determination of the occurrence of the thermal event. Claim 11 A monitoring system according to claim 1, wherein the sensor comprises: a housing; and a magnet coupled to the housing, the magnet being configured to allow the sensor to be detachably mounted to the enclosure. Claim 12 A monitoring method comprising: acquiring data representing environmental parameter values ​​within an enclosure of a heating, ventilation, air conditioning and / or cooling (HVAC&R) system through one or more sensors; determining, through a controller, the occurrence of a thermal event within the enclosure based on said data; and, through the controller, instructing a circuit breaker of the HVAC&R system to switch to a fault configuration in response to said determination of the occurrence of said thermal event. Claim 13 A monitoring method according to claim 12, wherein the step of determining the occurrence of the heat event comprises determining the occurrence of the heat event through the controller based on the environmental parameter value exceeding a threshold value at a specific point in time or based on the environmental parameter value exceeding a threshold value during a predetermined time interval. Claim 14 A monitoring method according to claim 12, wherein the step of instructing the circuit breaker to switch to the fault configuration includes, through the controller, the step of causing the circuit breaker to interrupt the flow of current from the power supply to the electrical component disposed within the enclosure. Claim 15 A monitoring method according to claim 12, wherein the step of acquiring data comprises monitoring, through one or more sensors, a first concentration of carbon monoxide in the enclosure, a second concentration of particulate matter suspended in the air in the enclosure, or both. Claim 16 A heating, ventilation, air conditioning and / or cooling (HVAC&R) system comprising: a circuit breaker configured to send current from a power supply to an electrical component disposed within an enclosure of said HVAC&R system; a sensor configured to acquire data representing environmental parameters within said enclosure; and a controller, wherein the controller: receives said data from said sensor; determines the occurrence of a thermal event within said enclosure based on said data; and, in response to the determination of said occurrence of the thermal event, instructs said circuit breaker to switch to a fault configuration to interrupt the flow of said current to said electrical component. Claim 17 An HVAC&R system according to claim 16, wherein the circuit breaker is configured to switch to an open circuit configuration to interrupt the flow of the current to the electrical component in response to the magnitude of the current exceeding a threshold value. Claim 18 An HVAC&R system according to claim 17, wherein the circuit breaker is configured to send current from the power supply to the controller in the open circuit configuration and to block the flow of current from the power supply to the controller in the fault configuration. Claim 19 An HVAC&R system according to claim 18, comprising an indicator configured to provide a visual indication of the occurrence of the thermal event in response to the interruption of the flow of the current to the controller. Claim 20 An HVAC&R system according to claim 16, comprising an additional sensor configured to acquire additional data indicating the environmental parameter within the enclosure, wherein the controller comprises: the data from the sensor indicating that the value of the environmental parameter exceeds a threshold; and the additional data from the additional sensor indicating that the value of the environmental parameter exceeds the threshold, configured to determine the occurrence of the thermal event.

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