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Low charge detection and diagnoses for non-critically charged refrigeration

system

Conference Paper · May 2017

DOI: 10.1109/EIT.2017.8053370

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Amro Quedan Fadi Alsaleem

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 280
Low charge detection and diagnoses for non-
critically charged refrigeration system
Amro Quedan
Architectural Engineering Department
University of Nebraska- Lincoln
Omaha, USA
aquedan@huskers.unl.edu
Mark Gariety
Emerson Climate Technology
Sidney, USA
Mark.Gariety@emerson.com
Abstract— In this paper, a new set of algorithms has been
developed to detect low charge fault for single compressor non-
critically charged refrigeration system for both frozen and
perishable goods. A mix of field units’ data and experimental data
were used to build the detection algorithms. Multiple detection
algorithms were devised based on the operation modes. The system
operates in multiple distinctive modes. Each mode has a defining
characteristic. The used data includes several healthy and
predefined low charge defected systems which gave us a prediction
of the loss of charge percentage in different operational modes.
This prediction provides us with a good knowledge of the system
performance and operation.
I. INTRODUCTION
According to a 2012 study conducted by the Food and
Agriculture Organization of the United Nations, about 30% of
the food produced in the world for human consumption every
year is lost or wasted. This study is based on weight. The
distribution and market have 12% share of total food loss and
waste [1]. The refrigeration system have a share in the supply
chain distribution stage and the malfunction in these systems.
The factors that caused the goods inside the refrigerated
systems to be lost or wasted have been classified as risk factors
[2]. These risk factors have been identified into three categories:
operational risk, hardware risk, and consignors risk. Two out of
eighteen risk factors are related to a malfunction in the
refrigeration unit itself. One of them is under the operational
risks and the other one is under the hardware risks. A principle
for risk strategies has been derived from these risk factors. These
principles for risk strategies have been divided into three
categories: risk prevention, risk reduction, and risk transfer. Risk
prevention implies the reduction of the loss possibility by
measuring before an accident occurs, risk reduction implies the
reduction in the effect after the loss occurrence by applying the
strategies before or after the accident, and risk transfer means
transferring the risk to others before the accident by insurance
contracts. The risk factors related to refrigeration unit
978-1-5090-4767-3/17/$31.00 ©2017 IEEE
Fadi Alsaleem
Architectural Engineering Department
University of Nebraska- Lincoln
Omaha, USA
Falsaleem2@unl.edu
Paul Fullenkamp
Emerson Climate Technology
Sidney, USA
Paul.Fullenkamp@emerson.com
malfunctions are mostly risk prevention and risk reduction. This
imply the importance to predict and warn these malfunction
before happening.
Little work has attempted to predict refrigerated system
malfunction. For example, in [3] a work has been done using a
monitoring system including data acquisition. All these systems
communicate with a microcomputer, which compares the
measured parameters that come from the refrigerated system and
compare them with a history stored in the microcomputer for the
same parameters. If any “out of limit” happened, an alert signal
goes to the system operator or other persons, indicating the
problem. The shortage of this method is that the predefined out
of limit conditions may vary depending on different
environmental and operation conditions and it is very hard to
find limits covering all operation mode.
A new technique for fault detection and isolation (FDI) was
developed by A. Jabbari, R. Jedermann, and W. Lang [4] using
a sensors networks in refrigerated system. It is claimed to detect
all types of faults and failures by these measurements systems.
Two artificial neural networks (ANN) were developed. Both of
them are based on predefined algorithms from the previous
measurement. The first one is based on comparing the
measurement with the approximation temperature. Based on the
output for the first ANN, the second ANN analyzes the expected
fault/ failure conditions and classify it. In this method, current
measurements were compared with previously trained patterns
for health systems. These patterns may not include all the system
behavior during a specific fault. In addition, they only capture
the operation conditions that the system went through. Finally,
in our recent work we have demonstrated the use of sensor data
fusion to detect low charge in residential HVAC systems [5].
From the aforementioned review, we identified that lack of
comprehensive fault detection and diagnostics for refrigerated
systems. In this paper, focus will be on non-critically charged
 281
refrigeration system and to develop a comprehensive fault
detection for low refrigerant. Non-critically charged, is a
terminology used to describe the, most common, refrigeration
systems that losing a small amount of charge, should not have
severe impact on the system performance.
The refrigeration system studied in this work is used for
cooling goods and is typically operated at 400 volts, 32 AMP, 3-
phase, 60Hz power with the maximum electrical load of 18kVA.
During the pull-down mode, the system under investigation
consume on average 12-15 kWh electricity and 2.25kWh during
the normal operation, and average 2.8875kWh per hour
depending on the goods and temperatures. The average
operating hours is 3000 hours/year [6]. Considering that the
average electricity commercial retail price of June 2016 was
10.58cents/kWh. The yearly operating cost for the system
studied is $917. This cost can be easily amplified if the unit kept
running while experiencing a fault such as losing charge.
The organization of this paper is as follows. In section 2, we
introduce non-critically charged refrigeration system. In section
3, we described the experimental set-up and the field units’ data
that were used in this study. Section 4, detailed the algorithms
we have built to detect low refrigerant fault.
II. REFRIGERATION SYSTEM OPERATION MODES
A. General description
In this paper, all the algorithms were developed using non-
critically charged refrigeration systems. These units are all-
electric, single-piece refrigeration units with bottom air supply.
The units are designed to cool and heat goods and run using
digital compressor. The digital compressor modulates the
system capacity (MODPCT) from 10% to 100%. Similar
compressor modulation can be also achieved by using a variable
speed compressor. The refrigerated system usually contains
sensors to measure the following ambient temperature,
compressor temperature, condenser coil temperature, set point
temperature, evaporator coil temperature, supply air
temperature, return air temperature and compressor speed
percentage. Typical average system may have only very basic
sensors, generic sensors, such as supply air temperature, set
point temperature, return air temperature, compressor
temperature and the ambient temperature. In this work, we show
the development for a low refrigerant detection algorithm based
on using the advanced unit sensors. In a separate work, we will
discuss the use of the generic sensors.
B. The refrigerated unit operation modes.
The refrigerated unit has multiple operation modes
depending on the set point temperature and inside and outside
thermal loading effect. Next, we describe these modes of
operation with more details.
B.1 Medium set point temperatures (perishable goods).
For medium set point temperatures (~>35F), the
compressor usually runs from 10% to 100% of its full
capacity. The compressor modulation changes to respond to
the system internal heating load effect and environmental
conditions. The medium temperature mode of operation
requires temperature measurement to be sampled at decent
sampling rates as the system’s response varies quickly with
time (transient response). In this mode, a relationship can be
defined between the compressor running speed and the system
temperature. Figure (1) shows, as an example, the system
operation at different medium set point temperature and
different internal loading conditions. In this figure, the internal
load due to adding fresh goods was simulated by running a
space heater at different heating settings. The compressor may
work in full load mode, in which the compressor keeps
running at 100% to reach the predefined set point. In this case,
the compressor may stay in this mode for a while due to a high
thermal load difficult environmental conditions. In this
operation mode, the high sampling rate is not required.
B.2 Low temperature set point temperatures (freezing goods).
During an operation of the compressor where the set point
is low, below freezing, the compressor will work in On-Off
mode. In this mode, the compressor operation will be defined
depending on the relation between the ON period and the
compressor off time (Duty cycle) where the compressor will
be running at 100% during the ON period and 0% during the
off period.
Samples in minutes
Figure (1): Compressor capacity percentage (MODPCT) at different medium
set point temperature and different loading conditions. The lower set point, the
higher compressor capacity percentage. Also at the same set-point, a higher
compressor capacity is needed as the internal thermal load increases.
C. Experimental Setup.
All the experimental data had been extracted from
refrigerated units. Two different sets of experimental data
have been used. The first set was from field units where the
data have been logged each hour. The second set of data was
lab experimental units where the data have been logged each
second and then an average had been taken for each minute.
We used 18 different field units. The amount of data for
these units vary from two months to five years. The sampling
rate for these data was each hour which means that we have as
much as 17520 data point for an average system. Figure (2)
shows data time line for different field units. The used
experimental data consist of 35 different experiments with
different set points, different ambient temperature, and
different compressor mode percentage. Figure (3) illustrates
 282

the different experiments parameters and their operational

conditions.

Two different set points with the same ambient temperature

at different compressor mode percentages are being shown in
Figure (4)(a)(b) to illustrate the operation of the system at
different internal conditions (simulated by running heater at
different heating capacity).

Samples in minutes
Figure (4) (b): Experimental unit behavior at 77˚C set point and 77˚C ambient
temperature.

All these units have the same algorithms to work depending on

the operational loads and the operational set points. The
operational loads have been classified in two modes, full load
and partial load. The set points have been classified in two
Figure (2): Field unit data time line. ranges the first one is above freezing point and the second one
is below freezing point.
120
(-40)(100)

100 (-20)(77)
III. ALGORITHMS
(-20)(100)
A. Modeling Software
Loading percentage %

80 (0)(77)
(0)(100)

60 (30)(77)
(30)(100)
The huge amount of data from different field and
40 (40)(77)
experimental units are used to explore the operation and the
(40)(100) performance of the refrigerated units during normal operation
20 (57)(77) and under fault so we will be able to detect or even diagnose
(57)(100)
malfunctions while occurring. There are many methods that can
0
0 2 4 6 8 10 12 14
(77)(77)
be used for modeling scientific data; some of these methods use
fixed-form parametric models that are derived from expert
Figure (3): experimental unit’s data conditions, y-axis is the variation in the
knowledge and others use numerical models based on machine
internal loading conditions simulated by a space heater and x-axis is a label to learning models such as neural network. Others, use a greedy
describe a test performed under a specific outdoor and set-point temperature. monomial search to explore restricted model spaces. The goal
for all these methods is to find natural relations where they exist,
where the analytical form has a minimal restriction. ‘Eureqa’, a
hybrid of all above approaches, is a software that uses
symbolically precise conserved relations explained by
unconstrained analytical expression and keep the data in their
scientific knowledge [7].

The symbolic regression is an evolutionary computation

method based that looks into space for a mathematical
expression while minimizing different error metrics. This
method looks for both the parameters and the equation form
simultaneously. A random combination of several function and
mathematical operations is used to form the initial expression.
By probabilistically varying previous equations’ sub expressions
and recombining previous equations a new equation formed.
Then the algorithm keeps the better equations and gets rid of the
unpromising solutions. Finally, the algorithm returns a set of
Samples in minutes equations after they reach a desired level of accuracy [8].
Figure (4) (a): Experimental unit behavior at 30˚C set point and 77˚C ambient
temperature.
 283
B. Low charge effect at different compressor operation modes
B.1 Medium set point temperatures
During medium set point temperatures, as discussed before,
the compressor speed varies between 0% to 100% (full speed).
As the unit loses its charge while running at an operating speed
that is less than the full speed, we expect the compressor speed
to increase to compensate for the capacity drop. Hence, a
function that predicts the normal compressor speed at a given
condition can be used to warn this up-normal speed increase.
On the other hand, if the compressor is running at full speed
mode during the loss of charge event, then the detection can be
done by using a function that detects the temperature changes
in the system where the cooling unit will not be able to satisfy
the required conditions.
B.2 Low temperature set point temperatures
In this operation mode, the compressor will work in a duty
cycle concept. For the event of loss of charge while the
compressor is running with a duty cycle less than 100%, the
increase in the duty cycle percentage can be used to warn the
loss of charge. On the other hand, for the event of loss of
charge while the compressor is running at 100% duty cycle, the
low charge detection can be done using an algorithm that detect
the change in the refrigerant temperatures. In this case, the
cooling unit will not be able to achieve the required operating
temperatures.
Figure (5) shows the used algorithm depending on the set
point temperature and the compressor operation mode.
Figure (5). The used algorithms for low charge detection depending on set
point and compressor operation mode.
C. Medium set point temperature algorithms
As shown in Figure (5), the algorithms for detecting the low
charge for medium temperature application are classified into
two algorithms: temperatures based algorithm for full load
operation and compressor speed based algorithm for partial
operation. For both algorithms, the Eureqa software [7] was
used to model the system behavior under normal and fault
condition. Data from healthy and under fault field and lab units
running at different loading conditions were used in this
learning. As an example, Figure (6) shows the actual and
predicted loss of charge using the medium temperature full
load algorithm.
As discussed before, to detect low charge fault at partial
load condition the deviation of compressor speed from what is
expected to be normal is the key. Hence, an algorithm has been
developed to predict the normal compressor running speed
during different conditions. Figure (7) shows a comparison
between the actual compressor running speed percentage for a
normal system and the predicted using the developed
algorithm. Any deviation from this normal expected
compressor speed should indicate a loss of charge fault.
A new logic has been developed to merge the above two
algorithms for medium temperature application. As shown in
Figure (8), the new logic will take the maximum value of the
two algorithms, regardless of the compressor speed, and report
the obtained value as the expected value for the loss of charge
percentage. This simple logic has the advantage of reducing the
complexity of detecting low charge shown in Figure (5).
Figure (9) shows the comparison between applying the merged
algorithm and the actual charge value percentage for new test
data that were not used to train the algorithm model. This new
data includes experiment tests with different set points and
ambient conditions, and tests in which the system was allowed
to run at different reduced charge level for extended time, to
simulate a real loss of charge in the field. Despite all these
differences, between the test data and the data used to build the
algorithm model, the figure shows decent agreement.
Samples in hours (field units) Samples in minutes
Figure (6): Comparison between the actual and predicted charge percentage in
some units, full load algorithm.
Samples in minutes
Figure (7): The actual and predicted compressor speed percentage for the
medium temperature partial load algorithm.
 284
Figure (8): Low charge detection algorithm depending on the set point
only.
Samples in minutes
Figure (9): The merged low charge detection algorithm results. The brown
plot is the predicted loss of charge and gray plot is the actual loss of charge
percentages for new data that was not used in developing the algorithm model.
D. Low set point temperatures algorithms
From Figure (5), the algorithms for detecting low charge for
low temperature application was classified into two algorithms;
temperatures-based algorithm for the full load mode
compressor duty cycle-based algorithm for partial load mode.
The development and results of these algorithms will be
discussed in separate work.
IV. CONCLUSIONS
The malfunction of refrigeration systems is responsible for
12% share of total food loss and waste. We need a good
knowledge of these systems performance and operation to
predicted low charge fault. A new set of algorithms has been
developed to provide us with this knowledge. These algorithms
have been classified depending on the unit operational modes.
Each operation mode has its’ own characteristics. This set of
algorithms has been developed using several healthy and
predefined low charge systems. The predefined low charge
systems helped us to predict the loss of charge percentage in
different operational modes.
APPENDIX A. TERMONOLOGY AND ASSUMPTIONS
A. Loss of charge percentage
The loss of charge percentage is normalized to the
final/maximum removed charge value. For example, during a
low charge test, if the maximum charge removal was 7lb and at
a given charge removal step, there was only 3.5lb out, then the
current loss of charge percentage at that step is 100*(7-
3.5)/7=50%.
B. Algorithms and sampling rate
Most of the algorithms were built based on the lab test data
where data of high sampling rate were collected. Initial testing
on the limited, uncontrolled, field units shows at least these
algorithms didn’t flag the low charge fault. We believe that
having more controlled extended low charge real field test data
(with the 1- hour sampling rate) should be used to verify and
tune the algorithms (if needed) to trigger a low charge fault.
C. Duty cycle
In determining the duty cycle for the freezing mode, the data
is converted to a binary code; 1 if the compressor is at full load,
and zero otherwise. Then a decoding script will convert these
binary numbers to duty cycle percentage. For example, if the
compressor status was encoded to the following during a period
of time: 0001111000000. Duty cycle of 40% (i.e. we start
counting from the first one until that last zero (total period),
where the number of ones is the (ON period).
REFERENCES
[1] Lipinski, B., et al. "Reducing food loss and waste." World
Resources Institute Working Paper, June (2013).
[2] Tseng, W., et al. "Risk analysis of cargos damages for aquatic
products of refrigerated containers: shipping operators’
perspective in Taiwan." Information Management and Business
Review 4.2 (2012): 86-94.
[3] Wallace, G., et al. "System & method for monitoring &
diagnosing faults in environmentally controlled containers, such
system and method being especially adapted for remote computer
controlled monitoring of numerous transportable containers over
existing on-site power wiring." U.S. Patent No. 4,234,926. 18
Nov. 1980.
[4] Jabbari, Al, Jedermann, R., and Lang. W., "Application of
computational intelligence for sensor fault detection and
isolation." World academy of science, engineering and
technology 33 (2007): 265-270.
[5] Alsaleem, F., and Quedan, A., Low Refrigerant Algorithm
Detection for Cooling Systems Relying on Trending and Data
Analysis, International High Performance Buildings Conference,
Purdue University, 2016.
[6] Electric Refrigerated Container Racks: Technical Analysis
Report, EPRI report, 2010.
[7] http://www.nutonian.com/products/eureqa/
[8] Schmidt, M., and Hod L., "Distilling free-form natural laws
from experimental data." science 324, no. 5923 (2009): 81-
88.
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