Abstract: Low voltage electrical power is supplied to a diagnostic control device in a sealed compressor. Electrical power is tapped from a high voltage power line and transformed to low voltage power that in turn operates the diagnostic control device. The diagnostic control device and the electric voltage transforming system are housed within the sealed compressor shell, thus eliminating the need for additional openings in the compressor shell. Other low voltage devices can be powered in this way.

Abstract: Several transmission embodiments selectively communicate rotary drive to an orbiting scroll to achieve capacity modulation. In these embodiments, when the motor is driven in a first direction, the orbiting scroll is driven at a rate which is equal to the motor speed. However, if the motor is driven in a reverse direction, the orbit rate of the orbiting scroll is reduced. The transmission ensures that the orbiting scroll member itself is driven in the proper forward direction regardless of whether the motor is being driven in forward or reverse.

Abstract: Several transmission embodiments selectively communicate rotary drive to an orbiting scroll to achieve capacity modulation. In these embodiments, when the motor is driven in a first direction, the orbiting scroll is driven at a rate which is equal to the motor speed. However, if the motor is driven in a reverse direction, the orbit rate of the orbiting scroll is reduced. The transmission ensures that the orbiting scroll member itself is driven in the proper forward direction regardless of whether the motor is being driven in forward or reverse.

Abstract: A number of improvements increase the flow of lubricant within a scroll compressor. A centrifugal oil separator is mounted on the discharge port to remove oil from the refrigerant. The oil is returned through a leak path such that the oil can easily return back to a suction pressure chamber. The leak path is preferably upstream of a check valve. Thus, at shutdown, the leak path will not allow upstream components to also equalize in pressure with the suction pressure chamber of the compressor. Further, a number of embodiments include ways of resisting flow of refrigerant through the leak path, while still allowing oil flow. A number of valve elements are described which perform this function. Alternatively, labyrinth flow paths, or positioning of the return paths such that it will be closed when the compressor is shut down are disclosed.

Abstract: Low voltage electrical power is supplied to a diagnostic control device in a sealed compressor. Electrical power is tapped from a high voltage power line and transformed to low voltage power that in turn operates the diagnostic control device. The diagnostic control device and the electric voltage transforming system are housed within the sealed compressor shell, thus eliminating the need for additional openings in the compressor shell. Other low voltage devices can be powered in this way.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: A system includes a motor mounted within a housing and a compressor pump unit. A single-phase PSC motor includes a switch assembly which selectively connects primary or alternate windings. During normal load operation, when maximum efficiency is desired, the switch is placed in one position, then during high load operation, when maximum torque output is needed at maximum a load point, the switch is placed in the closed position. In effect, the number of main winding turns is decreased and the motor is strengthened. As the auxiliary capacitors are also now connected in parallel, the net effect is an increase in the total auxiliary capacitance, which also serves to strengthen the motor. Another embodiment provides a switch for a three-phase WYE connected motor. In yet another embodiment, a three phase delta connected motor switch is provided.

Abstract: Low voltage electrical power is supplied to a diagnostic control device in a sealed compressor. Electrical power is tapped from a high voltage power line and transformed to low voltage power that in turn operates the diagnostic control device. The diagnostic control device and the electric voltage transforming system are housed within the sealed compressor shell, thus eliminating the need for additional openings in the compressor shell. Other low voltage devices can be powered in this way.

Abstract: Several transmission embodiments selectively communicate rotary drive to an orbiting scroll to achieve capacity modulation. In these embodiments, when the motor is driven in a first direction, the orbiting scroll is driven at a rate which is equal to the motor speed. However, if the motor is driven in a reverse direction, the orbit rate of the orbiting scroll is reduced. The transmission ensures that the orbiting scroll member itself is driven in the proper forward direction regardless of whether the motor is being driven in forward or reverse.

Abstract: An improved method of aligning the bearing components within a scroll compressor includes the step of mounting the crankcase to be an interference fit within the center shell, and having a surface abutting a true upper surface of the shell. This ensures that the axis of the bearing in the crankcase is idealized and centered on the center axis of the center shell. At the same time, the lower bearing is mounted on the lower end cap, and is also cut to be concentric with a force fit outer surface of the end cap. This ensures the lower bearing is also centered on the inner periphery of the center shell. Once it is ensured the center shell is true, then it is also thus ensured the upper and lower bearings are aligned on a common axis. An improved lower bearing structure with a reverse taper is also disclosed.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: A variable size is provided for a discharge port in a scroll compressor. The variable size is movable dependent on conditions within the scroll compressor to achieve a desired pressure ratio based upon operational conditions in the compressor or an associated refrigerant cycle. In one embodiment a plunger moves axially to increase or decrease the size of a discharge port. In a second embodiment, the plunger rotates about an axis and has a groove that is selectively aligned with the port to increase or decrease the effective size of the port.

Abstract: A compressor diagnostic system incorporates a control which receives a plurality of data streams about various operational features of the compressor. As an example, both temperature and pressure of the suction and discharge refrigerant are taken and sent to the control. Moreover, information with regard to the power being supplied to the motor is taken and stored. All of this information is utilized at a control which compares the information to expected values and determines a fault based upon the evaluation. Moreover, in another feature of this invention, much of this data is stored, and maintained at the compressor. In the event of a compressor failure, this stored information will provide a maintenance worker with a good indication of why the compressor failed.

Abstract: A two-stage reciprocating compressor is provided. The compressor includes a block with a single cylinder and associated single compression chamber and single piston. The compressor further includes a crankshaft. The crankshaft has an eccentric crankpin that is operatively connected to the piston. A reversible motor is provided to rotate the crankshaft in a forward direction and in a reverse direction. An eccentric cam is rotatably mounted on the eccentric crankpin. The eccentric cam is held stationary with respect to the crankpin when the crankshaft is rotating in the forward direction. When rotating in the forward direction, the crankshaft drives the piston at a full stroke between a bottom position and a top dead center position. The eccentric cam rotates with respect to the crankpin when the crankshaft is rotating in the reverse direction. When rotating in the reverse direction, the crankshaft drives the piston at a reduced stroke between an intermediate position and the top dead center position.

Abstract: An improved method of aligning the bearing components within a scroll compressor includes the step of mounting the crankcase to be an interference fit within the center shell, and having a surface abutting a true upper surface of the shell. This ensures that the axis of the bearing in the crankcase is idealized and centered on the center axis of the center shell. At the same time, the lower bearing is mounted on the lower end cap, and is also cut to be concentric with a force fit outer surface of the end cap. This ensures the lower bearing is also centered on the inner periphery of the center shell. Once it is ensured the center shell is true, then it is also thus ensured the upper and lower bearings are aligned on a common axis. An improved lower bearing structure with a reverse taper is also disclosed.

Abstract: A system includes a motor mounted within a housing and a compressor pump unit. A single-phase PSC motor includes a switch assembly which selectively connects primary or alternate windings. During normal load operation, when maximum efficiency is desired, the switch is placed in one position, then during high load operation, when maximum torque output is needed at maximum a load point, the switch is placed in the closed position. In effect, the number of main winding turns is decreased and the motor is strengthened. As the auxiliary capacitors are also now connected in parallel, the net effect is an increase in the total auxiliary capacitance, which also serves to strengthen the motor. Another embodiment provides a switch for a three-phase WYE connected motor. In yet another embodiment, a three phase delta connected motor switch is provided.

Abstract: An unloader valve for a scroll compressor to selectively communicate suction and discharge is positioned outwardly of the compressor housing. In this way, the unloader valve is ideally positioned to address several system failures. As an example, loss or charge, reverse running, fan failure, etc. are all addressed in an efficient and quick manner. The unloader valve may be the normal unloader valve controlled by a system control which also selectively controls capacity. The unloader valve control is modified such that it is also operable to open the unloader valve when a system failure is detected.

Abstract: An improved scroll compressor having an axially movable non-orbiting scroll eliminates the need for a separator plate. With the elimination of the separator plate, a back pressure chamber is provided to resist the discharge pressure which will be directed against a rear face of the non-orbiting scroll. In other embodiments, a seal on the rear of the non-orbiting scroll contacts the inner periphery of the end cap. Various ways of increasing the discharge pressure volume, or eliminating undesirable noise are also disclosed. Further, several ways of connecting the end cap to the center shell are also disclosed.

Abstract: A scroll compressor is provided that has greater control over the compressed volume by having a plurality of sequentially spaced unloader valves and associated holes. By providing the plurality of valves, a control achieves greater variation over the final compressed volume. The present invention is most preferably utilized in the type of scroll compressor having a hybrid wrap geometry to provide an increased volume of refrigerant adjacent the suction area of the compressor.

Abstract: A compressor diagnostic system incorporates a control which receives a plurality of data streams about various operational features of the compressor. As an example, both temperature and pressure of the suction and discharge refrigerant are taken and sent to the control. Moreover, information with regard to the power being supplied to the motor is taken and stored. All of this information is utilized at a control which compares the information to expected values and determines a fault based upon the evaluation. Moreover, in another feature of this invention, much of this data is stored, and maintained at the compressor. In the event of a compressor failure, this stored information will provide a maintenance worker with a good indication of why the compressor failed.