Abstract: A method of operating an electric motor is disclosed. The method includes: determining a d-axis resistance of an electric motor and a Q-axis resistance of the electric motor as a function of a bulk current; determining a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current; generating an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor; generating an estimated angle of the electric motor based on the estimated flux of the electric motor; and, based on the estimated angle of the electric motor, controlling switching of an inverter that powers the electric motor.

Abstract: A compressor may include a scroll member, a hub, a discharge valve and a bypass valve. An end plate of the scroll member includes a recess, a discharge passage in communication with the recess, and a bypass passage in communication with the recess and disposed radially outward relative to the discharge passage. The hub may be received in the recess and may include a central opening in communication with the discharge passage and the bypass passage. The discharge valve may be disposed between the hub and the end plate and may control fluid flow through the discharge passage. The bypass valve may be disposed between the hub and the end plate and may be movable between a first position restricting fluid flow through the bypass passage and a second position allowing fluid to flow through the bypass passage, around the discharge valve and through the central opening.

Abstract: A compressor may include a shell, first and second scrolls, a seal assembly, a modulation control chamber, and a modulation control valve. The first scroll may include a first end plate having a biasing passage extending therethrough. The seal assembly may isolate a discharge pressure region from a suction pressure region. The seal assembly and the first scroll may define an axial biasing chamber therebetween that communicates with the axial biasing chamber and a first pocket between the first and second scrolls. The modulation control chamber may be fluidly coupled with the biasing chamber by a first passage. The modulation control valve may be fluidly coupled with the modulation control chamber by a second passage and movable between a first position allowing communication between the second passage and the suction pressure region and a second position restricting communication between the second passage and the suction pressure region.

Abstract: A compressor is provided and may include a first scroll member having an end plate and a spiral wrap extending from the end plate. The end plate may include a first modulation port and a second modulation port each in fluid communication with a compression pocket formed by the spiral wrap. A first modulation valve ring may be movable relative to the end plate between a first position blocking the first modulation port and a second position spaced apart from the first modulation port. A second modulation valve ring may movable relative to the end plate between a first position blocking the second modulation port and a second position spaced apart from the second modulation port. The second modulation ring may be located radially inward from the first modulation valve ring.

Abstract: A monitoring system for a heating, ventilation, or air conditioning (HVAC) system of a residential or commercial building includes an evaporator unit device and four temperature sensors. The evaporator unit device includes an electrical sensor that measures current supplied to a circulator blower of the HVAC system. The measured current from the first electrical sensor is used to diagnose a problem with the circulator blower. The first temperature sensor that measures a temperature of refrigerant flowing between a condenser of the HVAC system and an expansion valve of the HVAC system. The second temperature sensor measures a temperature of refrigerant flowing between an evaporator and a compressor. The third temperature sensor measures a temperature of air flowing away from the evaporator. The fourth temperature sensor measures a temperature of air flowing toward the evaporator. The evaporator unit device transmits sensor data to a remote monitoring service over a data network.

Abstract: A compressor is provided and may include a shell having an inner surface and an outer surface and a bearing housing disposed within the shell and having an engagement surface opposing the inner surface. The engagement surface may include a first channel formed substantially perpendicular to a longitudinal axis of the shell and a second channel formed substantially parallel to the longitudinal axis of the shell and in communication with the first channel. The first channel and the second channel may receive a deformed portion of the shell therein to fix a position of the bearing housing relative to the shell.

Abstract: An indication system is provided and includes evaluation, messaging, and display modules and a display. The evaluation module generates a message based on a parameter of a compressor or a drive. The messaging module: generates a message based on the parameter; generates a string of glyphs based on the message; selects a predetermined number of glyphs in the string of glyphs; generates column data for the selected glyphs; and generates packets including the column data. The display module generates output signals based on the packets. The display includes an array of LEDs, does not include a transistor, and illuminates the LEDs based on the output signals. The display module is configured to generate the output signals to illuminate one or more of the LEDS in a column-by-column format, such that power is only provided to one column of the array of LEDs at any moment in time.

Abstract: Scroll members for scroll compressors made from one or more near-net shaped powder metal processes, either wholly or partially fabricated together from sections. In certain variations, the involute scroll portion of the scroll member has a modified terminal end region. The terminal end region may include an as-sintered coupling feature comprising a tip component that forms a contact surface for contacting an opposing scroll member during compressor operation. The tip component can be a tip seal or a tip cap received by the as-sintered coupling feature. The tip cap may be sinter-bonded or otherwise coupled to the terminal end region. In other variations, a terminal end region may comprise a second material including a tribological material that forms a contact surface. Methods of making such scroll members for scroll compressors are also provided.

Abstract: A crankcase heating control system for a heat pump system includes a data receiving module and a power control module. The data receiving module is configured to receive: data indicative of a temperature of a compressor of the heat pump system; and data indicative of an ambient temperature. The power control module is configured to: selectively apply power to a heater of a crankcase of the compressor; and disable the heater when all of: a period since the compressor was last turned is greater than a predetermined period; the ambient temperature is less than a predetermined temperature; and the temperature of the compressor is less than the predetermined temperature.

Abstract: A system includes a compressor driven by a motor. A condenser receives working fluid from the compressor. An evaporator is in fluid communication with the condenser and the compressor. A first sensor produces a first signal indicative of one of current and power drawn by the motor. A second sensor produces a second signal indicative of a discharge line temperature. A processing circuitry processes the first signal and the second signal to determine a freeze time. The processing circuitry processes the freeze time, the current signal, and the discharge line temperature signal to determine a working fluid charge level.

Abstract: A system includes a sensor and a controller for a refrigeration or HVAC system having a compressor. The sensor senses a temperature of the compressor during operation of the compressor. The controller is configured to determine a rate of change of the temperature relative to time and to perform one or more procedures to protect the compressor based on the rate of change of the temperature. The one or more procedures to protect the compressor include shutting down the compressor, throttling a pressure regulator valve of an evaporator associated with the compressor, adjusting an expansion valve associated with the evaporator, reducing speed of the compressor, and partially or wholly unloading the compressor.

Abstract: A compressor is provided and may include a shell, a motor assembly, a driveshaft, a pump housing, and a pumping mechanism. The motor assembly may be disposed within the shell. The driveshaft may be drivingly engaged with the motor assembly. The pump housing may be rotatably supported by the driveshaft for rotation relative to the shell. The pumping mechanism may be disposed within the pump housing and rotating with or orbiting about the driveshaft.

Abstract: A method of operating a refrigeration system that receives power from an electrical grid includes selectively operating at least one component of the refrigeration system in a first state. The method includes selectively detecting a fault event of the electrical grid in response to a concurrent (i) increase in amount of current drawn by the component and (ii) decrease in voltage of power received by the component. The method includes, in response to detecting the fault event, switching the component from the first state to a second state. The component consumes less power in the second state than in the first state. The method includes determining a first delay period. The method includes identifying a conclusion of the fault event. The method includes, in response to the conclusion of the fault event, waiting for the first delay period before switching the component back to the first state.

Abstract: A compressor may include a crankcase, a crankshaft, a piston, a discharge valve and a suction plenum. The crankcase defines a discharge plenum receiving working fluid at a first pressure. The crankshaft is disposed within the discharge plenum. The piston is drivingly connected to the crankshaft and reciprocatingly received in a cylinder. The piston and cylinder cooperate to define a compression chamber therebetween. The discharge valve may control fluid flow through a discharge passage between the compression chamber and the discharge plenum. The suction plenum may receive working fluid at a second pressure that is less than the first pressure. The suction plenum may provide working fluid at the second pressure to the compression chamber.

Abstract: A circuit for driving a motor of a compressor includes a microcontroller, which includes an op-amp, a comparator, a first serial interface, and a first dedicated pin. The op-amp amplifies a value indicating current in a power factor correction converter, which includes a power switch. The comparator asserts a comparison signal in response to the amplified value exceeding a reference value. The comparison signal is output on the first dedicated pin. A programmable logic device (PLD) includes a second serial interface in communication with the first serial interface and a second dedicated pin. The comparison signal is received on the second dedicated pin and the PLD receives control messages from the microcontroller via the second serial interface. The PLD sets a value in an off-time register based on a control message from the microcontroller. The PLD controls the power switch according to the comparison signal and the off-time register.

Abstract: A compressor including a shell including an opening; an electrical terminal engaging said opening and including a fence at least partially surrounding a plurality of first electrically conductive members; a plug including a plurality of second electrically conductive members in electrical communication with said first electrically conductive members, the plug including a threaded coupling unitary therewith; a plurality of wires extending from said second electrically conductive members through the threaded coupling; a conduit adapter including a first threaded surface for engagement with the threaded coupling, and a second threaded surface; and a threaded conduit engaging the second threaded surface to allow the plurality of wires to extend from the plug body, through the conduit adapter, and into the threaded conduit.

Abstract: A compressor may include a shell, a compression mechanism, a driveshaft, a motor assembly, and a stator support member. The compression mechanism is disposed within the shell. The driveshaft drivingly is engaged with the compression mechanism. The motor assembly may be disposed within the shell and is drivingly engaged with the driveshaft. The motor assembly includes a rotor and a stator. The stator is fixed relative to the shell. The rotor may include an axially extending portion and a radially extending portion. The axially extending portion may be disposed radially outward relative to the stator. The radially extending portion may engage the driveshaft and may be disposed axially between the stator and the compression mechanism. The stator support member may be fixed relative to the shell and the stator. The stator support member may extend longitudinally through at least a portion of the stator.

Abstract: A compressor according to the principles of the present disclosure includes a shell, a compression mechanism, a driveshaft, a drive bearing cavity, and a drive bearing. The compression mechanism is disposed within the shell and includes an orbiting scroll member and a non-orbiting scroll member. The orbiting scroll member includes a baseplate and a tubular portion extending axially from the baseplate. The driveshaft is drivingly engaged with the orbiting scroll member. The drive bearing cavity is disposed between an outer radial surface of the driveshaft and an inner radial surface of the tubular portion of the orbiting scroll member. The baseplate of the orbiting scroll member defines a first discharge passage in fluid communication with the drive bearing cavity. The drive bearing is disposed in the drive bearing cavity and is disposed about the driveshaft adjacent to the first end of the driveshaft.

Abstract: A control system for a refrigeration system motor includes an angle determination module that generates an output rotor angle indicating a desired angle of a rotor of the motor. A control module controls the motor based on the output rotor angle. An estimator module determines an estimated rotor angle. A transition module generates a transition signal in response to convergence of the estimator module. Upon startup, the angle determination module generates the output rotor angle based on a first rotor angle. Upon generation of the transition signal, the angle determination module generates the output rotor angle based on the first rotor angle and the estimated rotor angle. After generation of the transition signal, the angle determination module reduces a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

Abstract: A charge-verification tool is used with a charge-verification system to diagnose and remedy a charge condition. The charge-verification tool includes a device having a controller configured to communicate with a system controller in the charge-verification system and a display configured to display measurements and instructions to an installer. The device is a user interface and is configured to provide communication between the installer and the system controller in the charge-verification system. The controller prompts the installer to input charge-verification system information including refrigeration line length and diameter. The controller receives a subcooling temperature calculated by the system controller and determines whether the subcooling temperature is between a threshold and a target subcooling temperature.