An HVAC system generally includes a closed loop refrigeration system with at least one evaporator, at least one condenser and at least one compressor. As the refrigerant travels through the evaporator, it absorbs heat from a heat transfer fluid to be cooled and changes from a liquid to a vapor phase. After exiting the evaporator, the refrigerant proceeds to a compressor, then a condenser, then an expansion valve, and back to the evaporator, repeating the refrigeration cycle. The fluid to be cooled (e.g. air) passes through the evaporator in a separate fluid channel and is cooled by the evaporation of the refrigerant. The cooled fluid can then be sent to a distribution system for cooling the spaces to be conditioned, or it can be used for other refrigeration purposes.
One type of air conditioner system is a split system where there is an indoor unit or heat exchanger, which is generally the evaporator, and an outdoor unit or heat exchanger, which is generally the condenser. Often, the outdoor unit is placed outdoors and is subject to outdoor ambient conditions, particularly temperature. When the outdoor ambient temperature falls, the amount of heat being removed from the refrigerant in the condenser increases. The increased heat removal in the condenser can result in a decrease in the refrigerant pressure at the suction line to the compressor, commonly referred to as head pressure. The decrease in head pressure results in a lowering of the temperature of the refrigerant at the evaporator. When the temperature of the refrigerant at the evaporator becomes too low, icing of the system can occur. Icing is a condition when the temperature at the exterior of the evaporator is sufficiently low to freeze water present in the atmosphere. The ice formed by the water frozen on the surface reduces the available heat transfer surface and eventually prevents the proper operation of the HVAC system by inhibiting heat transfer and/or damaging system components.
Some attempts to address the problem of icing have utilized the control of system pressure. In one approach, a variable speed condenser fan or a plurality of condenser fans having independent controls are used to control airflow over the condenser coil. As the amount of air passing over the coil decreases, the amount of heat transfer taking place at the coil decreases. Therefore, the temperature of the refrigerant in the condenser and the pressure of the system increase to allow the indoor coil to cool the air without icing problems. The use of the variable speed condenser fan or a plurality of condenser fans having independent controls has the drawback that it is expensive and requires complicated wiring and controls.
An alternate approach for the problem of low system pressure or icing is a parallel set of condensers in the refrigerant cycle, as described in U.S. Pat. No. 3,631,686. The parallel set of refrigerant condensers allows for two modes of operation. One mode of operation allows refrigerant to flow from only one of the refrigerant condensers. During this mode of operation, the condenser that does not permit the flow of refrigerant fills with liquid refrigerant. Because of this flooding, there is a reduction in the effective surface area of the condenser. The reduced surface area thereby reduces the ability of the condenser to remove heat from the refrigerant. Therefore, the temperature of the refrigerant in the condenser and the head pressure of the system increase allowing the indoor coil to cool the air without icing. The use of parallel refrigerant condensers has the drawback that it requires an additional condenser coil and additional piping, thereby increasing the space and cost required for installation. Another drawback associated with refrigerant flooding of the condenser coil is the resultant decrease in system capacity. Refrigerant normally available in a properly operating system is trapped in the condenser coil and not available to the compressor, thereby decreasing system capacity.
An additional alternate approach for the problem of low system pressure is the use of a valve that controls the discharge or flow of liquid refrigerant from the condenser to a receiver vessel downstream of the condenser to maintain control of the amount of condensing surface exposed to the outside temperature, as described in U.S. Pat. No. 2,874,550. The discharge of refrigerant from the condenser is controlled by a pressure-response valve that mechanically opens to allow the flow of liquid refrigerant from the condenser to the receiver vessel reducing the level of liquid inside the condenser, thereby lowering the system pressure. Alternatively, the valve is closed to stop the flow until the level of refrigerant rises in the condenser in an amount that reduces the effective cooling surface of the condenser. The reduced surface area thereby reduces the ability of the condenser to remove heat from the refrigerant, thereby raising the pressure of the system. The use of a pressure-response valve and a vessel downstream of the condenser to maintain control of the amount of condensing surface has the drawback that it includes a specially designed valve and additional piping, thereby increasing the required space and cost. As discussed above, another one of the drawbacks with refrigerant flooding the condenser coil is decreased system capacity. Refrigerant normally available in a properly operating system is trapped in the condenser coil and not available to the compressor, thereby decreasing system capacity.
An additional alternate approach for the problem of low system pressure is the use of a refrigerant bypass around the condenser, as described in U.S. Pat. No. 3,060,699 and U.S. Reissued Pat. No. Re. 27,522. If the temperature and pressure of the refrigerant in the condenser are sufficiently high, a valve will close on a condenser bypass and the flow of refrigerant will be directed to the condenser. If the temperature and pressure of the condenser are not sufficiently high, the valve will open on a condenser bypass and at least some of the flow of refrigerant will be directed away from the condenser. The result of the bypass is an increase in pressure through the pipe leading to the evaporator downstream of the compressor. The use of a bypass has the drawback that it includes a specially designed valve and additional piping, thereby increasing the required space and cost.
What is needed is a method and system for controlling the system refrigerant pressure without the drawbacks discussed above.