Abstract: A system includes a refrigerant compressor, an electric motor and configured to drive the refrigerant compressor, and a controller. The controller is configured to operate the compressor in a liquid clearing start mode where electrical current through the motor is prevented from exceeding a predetermined current limit for a period of time not to exceed a predetermined period of time, and is configured to operate the compressor in a run mode in response to determining the motor exceeds a predetermined speed threshold at or before expiration of the predetermined period of time, wherein the run mode does not prevent electrical current through the motor from exceeding said predetermined current limit.

Abstract: Temperature value determination of at least one variable frequency drive component is provided. In one form, a method includes providing a variable frequency drive that includes a first component in thermal communication with a second component in thermal communication with a switching device. A temperature value of the second component is determined using a temperature value of the first component, a power loss characteristic of the drive, and a first characteristic of heat transfer between the first and second components. The method further includes sensing a temperature value of the second component and determining a temperature value for the switching device using the power loss characteristic, a second characteristic of heat transfer between the second component and the switching device, and the greater of the sensed and determined temperature values of the second component. Further embodiments, forms, features, and aspects shall become apparent from the description and drawings.

Abstract: Operation of a variable frequency in a manner configured to avoid overheating is provided. In one form, a method includes providing a variable frequency drive that includes a switching device in thermal communication with a heat sink including a thermal mass. The method further includes operating the drive in a first mode before active cooling of the heat sink is established and a second mode following the first mode. Operation of the drive in the first mode includes operating the switching device in a first switching frequency mode, and the first switching frequency mode and the thermal mass of the heat sink are selected to provide a temperature of the switching device below a predetermined threshold before active cooling of the heat sink is established. Further embodiments, forms, features, and aspects shall become apparent from the description and drawings.

Abstract: A system includes a refrigerant circuit including a compressor, a condenser, an expander, an electric motor configured to drive the compressor, and a controller configured to control a motor drive to drive the electric motor. The controller is configured to first evaluate whether the compressor is idle based upon a control state of the controller being configured not to operate the motor drive to drive the motor, second, in response to an affirmative evaluation that the compressor is idle, evaluate a risk of undesired or un-commanded compressor rotation based upon a combination of two or more system conditions, each of the two or more system conditions indicating the risk of undesired or un-commanded compressor rotation, and third, in response to an affirmative evaluation of the risk of undesired or un-commanded compressor rotation, control the motor drive to oppose rotation of the compressor.

Abstract: An exemplary system includes a compressor, a condenser, an expander, and an evaporator fluidly coupled to form a vapor-compression circuit, and an electric motor configured to drive the compressor. An inverter having a plurality of switching elements is configured to provide an output voltage to the electric motor through operation of the switching elements. A waste heat recovery circuit is configured to transfer waste heat from the inverter to a load. A controller is configured provide switching commands to the switching elements of the inverter. The controller is further configured to sense a condition of the system, determine a heat production requirement based at least in part upon the system condition, and to vary the number of switching commands per unit time based at least in part upon the heat production requirement.

Abstract: Temperature value determination of at least one variable frequency drive component is provided. In one form, a method includes providing a variable frequency drive that includes a first component in thermal communication with a second component in thermal communication with a switching device. A temperature value of the second component is determined using a temperature value of the first component, a power loss characteristic of the drive, and a first characteristic of heat transfer between the first and second components. The method further includes sensing a temperature value of the second component and determining a temperature value for the switching device using the power loss characteristic, a second characteristic of heat transfer between the second component and the switching device, and the greater of the sensed and determined temperature values of the second component. Further embodiments, forms, features, and aspects shall become apparent from the description and drawings.

Abstract: Overvoltage protection apparatuses, systems and methods for variable frequency motor drives are disclosed. In an exemplary embodiment, a variable frequency motor drive system including a rectifier, a DC bus electrically coupled with the rectifier, and an inverter electrically coupled with the DC bus is provided. A protection device electrically coupled with the rectifier and configured to interrupt power supply to the system based upon fault conditions is provided. A controller is provided and configured to receive information indicative of a voltage of the DC bus, process the received information to model a condition of at least one component of the variable frequency motor drive, and control the protection device to interrupt power supply to the variable frequency motor drive if the modeled condition meets a fault criterion.

Abstract: Systems and methods are used to control operation of a rotary compressor of a refrigeration system to limit or prevent movement of rotors due to axial thrust loading resulting from rapid changes in speed of the rotors of the compressor. The operational profile of the motor is controlled to maintain acceleration torque and deceleration torque within predefined limits. The acceleration torque and deceleration torque are maintained within the predefined limits by controlling the speed of the motor, or by controlling the torque applied by the motor to the rotors during acceleration or deceleration.

Abstract: Temperature value determination of at least one variable frequency drive component is provided. In one form, a method includes providing a variable frequency drive that includes a first component in thermal communication with a second component in thermal communication with a switching device. A temperature value of the second component is determined using a temperature value of the first component, a power loss characteristic of the drive, and a first characteristic of heat transfer between the first and second components. The method further includes sensing a temperature value of the second component and determining a temperature value for the switching device using the power loss characteristic, a second characteristic of heat transfer between the second component and the switching device, and the greater of the sensed and determined temperature values of the second component. Further embodiments, forms, features, and aspects shall become apparent from the description and drawings.

Abstract: Techniques for motor magnet degradation controls and diagnostics are disclosed. An exemplary technique determines q-axis current, d-axis current, q-axis voltage, and/or d-axis voltage of a permanent magnet motor based upon sensed current and voltage information of the motor. This information is utilized to determine flux information. The flux information is utilized in evaluating collective state conditions of a plurality of motor magnets and evaluating localized state conditions of a subset of the plurality of motor magnets. The evaluations can be used to identify degradation or damage to one or more of the magnets which may occur as a result of elevated temperature conditions, physical degradation, or chemical degradation.

Abstract: A controller is configured to generate control signals to control a variable frequency drive coupled with a load. A simulator receives the control signals and processes the control signals. The simulator simulates a variable frequency drive and a load by generating feedback signals based on a model and the control signals. The controller receives the feedback signals from the simulator.

Abstract: Unique apparatuses, methods, and systems of opposing, limiting, and/or preventing undesired or un-commanded compressor rotation are disclosed. One exemplary embodiment is an HVACR system comprising a variable frequency drive configured to drive an electric motor to rotate a screw compressor or scroll compressor. A controller is configured to monitor various aspects of the system and to control the drive. When a condition indicative of potential undesired or un-commanded compressor rotation is identified, the controller commands the variable frequency drive to control the motor to limit and preferably prevent compressor rotation. One technique comprises shorting switches of the drive to a DC bus rail to allow back EMF induced current in the motor windings to be dissipated through winding resistance thus providing a damping force. Another technique comprises controlling the inverter to insert a DC current into the motor to cause the motor to align to and hold a particular position.

Abstract: Techniques for motor magnet degradation controls and diagnostics are disclosed. An exemplary technique determines q-axis current, d-axis current, q-axis voltage, and/or d-axis voltage of a permanent magnet motor based upon sensed current and voltage information of the motor. This information is utilized to determine flux information. The flux information is utilized in evaluating collective state conditions of a plurality of motor magnets and evaluating localized state conditions of a subset of the plurality of motor magnets. The evaluations can be used to identify degradation or damage to one or more of the magnets which may occur as a result of elevated temperature conditions, physical degradation, or chemical degradation.

Abstract: Systems and methods are used to control operation of a rotary compressor of a refrigeration system to limit or prevent movement of rotors due to axial thrust loading resulting from rapid changes in speed of the rotors of the compressor. The operational profile of the motor is controlled to maintain acceleration torque and deceleration torque within predefined limits. The acceleration torque and deceleration torque are maintained within the predefined limits by controlling the speed of the motor, or by controlling the torque applied by the motor to the rotors during acceleration or deceleration.

Abstract: Diagnostic and/or control methods, systems and apparatuses for variable frequency drives are disclosed. The variable frequency drive may be controlled by a controller that may conduct one or more tests or evaluations. The tests or evaluations may include determining whether a switching device in the variable frequency drive is open-circuited, short-circuited, or operating normally. The tests may include determining whether current provided at an inverter output of the variable frequency drive is within a predetermined range. An exemplary embodiment evaluates the drive for a short circuit condition, an open circuit condition, and a sensor error or failure condition, controls operation of the drive based upon these one or more evaluations, may abort operation of the drive based upon one or more evaluations, and may set a fault code indicative of the type of error encountered.

Abstract: Variable frequency drive active harmonic mitigation controls and diagnostics are disclosed. Exemplary controls and diagnostics include operating a variable frequency drive including converting an AC input line voltage to a DC voltage, generating a motor drive signal using the DC voltage, and driving an electric motor with the motor drive signal. A harmonic mitigation signal is provided to the drive configured to at least partially mitigate harmonics during the operation of the drive. The harmonic mitigation signal is inhibited based upon presence of an error condition associated with the drive input. The inhibiting is terminated based upon the absence of the error condition. A diagnostic fault condition based upon a number of occurrences of the error condition.

Abstract: Techniques for motor magnet degradation controls and diagnostics are disclosed. An exemplary technique determines q-axis current, d-axis current, q-axis voltage, and/or d-axis voltage of a permanent magnet motor based upon sensed current and voltage information of the motor. This information is utilized to determine flux information. The flux information is utilized in evaluating collective state conditions of a plurality of motor magnets and evaluating localized state conditions of a subset of the plurality of motor magnets. The evaluations can be used to identify degradation or damage to one or more of the magnets which may occur as a result of elevated temperature conditions, physical degradation, or chemical degradation.

Abstract: Systems and methods are used to control operation of a rotary compressor of a refrigeration system to limit or prevent movement of rotors due to axial thrust loading resulting from rapid changes in speed of the rotors of the compressor. The operational profile of the motor is controlled to maintain acceleration torque and deceleration torque within predefined limits. The acceleration torque and deceleration torque are maintained within the predefined limits by controlling the speed of the motor, or by controlling the torque applied by the motor to the rotors during acceleration or deceleration.

Abstract: Apparatuses, methods, and systems offering enhanced robustness, efficiency and rated voltage operability for refrigerant compressor drives are disclosed. An exemplary embodiment is a method of operating a variable frequency drive. The method includes operating the drive over a first operating range to provide at least a desired operating speed and minimize d-axis current, operating the drive over a second operating range including injecting d-axis current to provide at least the desired operating speed, operating the drive over a third operating range at a de-rated speed less than the desired operating speed. In the first operating range the drive input voltage is greater than a first value. In the second operating range the drive input voltage is lower than the first value and greater than a second value. In the third operating range the drive input voltage is lower than the second value.

Abstract: Embodiments of a HVAC electrical system power supply packaging system within an ultimate enclosure are provided. The HVAC electrical system power supply packaging system provides serviceability, safety, manufacturability, and system management failure diagnostic reporting enhancements over conventional packaging systems while conforming to agency safety requirements. The embodiments disclosed herein also reduce equipment and service costs for HVAC electrical system power supply components provided within the HVAC electrical system power supply packaging system by reducing delays in servicing these components. Thus, customer uptime of the HVAC system can be increased.