TECHNICAL FIELD
[0001] The present disclosure relates to an abnormality diagnostic system, an air conditioner,
and an air conditioning system.
BACKGROUND ART
[0002] As described in PATENT LITERATURE 1 and the like, there has been conventionally known
an air conditioner including a refrigerant circuit configured to execute vapor compression
refrigeration cycle operation by driving a compressor, and the air conditioner is
configured to cool or heat an indoor space. The air conditioner according to PATENT
LITERATURE 1 detects with use of sensors or estimates in accordance with a graph or
the like, operation data such as current and voltage of a compressor motor, evaporation
temperature, condensation temperature, evaporation pressure, and condensation pressure
of a refrigerant, estimates abnormality such as high or low pressure abnormality of
the compressor, abnormality on a degree of suction superheating, poor lubrication,
or liquid compression with use of a result of operation data, and enables execution
of operation avoiding the abnormality.
CITATION LIST
[PATENT LITERATURE]
SUMMARY OF THE INVENTION
[TECHNICAL PROBLEM]
[0004] The air conditioner according to PATENT LITERATURE 1 is not configured to specify
a cause of any abnormality actually occurred to disable continuous operation. It is
thus impossible to accurately find the cause of the abnormality even if a service
person or the like checks a state of the air conditioner after the abnormality occurs,
and it is difficult to promptly apply treatment.
[0005] It is an object of the present disclosure to provide an abnormality diagnostic system
configured to accurately specify a cause of abnormality, an air conditioner, and an
air conditioning system.
[SOLUTION TO PROBLEM]
[0006]
- (1) The present disclosure provides an abnormality diagnostic system including: a
processing unit configured to acquire operation data of an air conditioner and determine
occurrence of abnormality and occurrence of an abnormality symptom in the air conditioner;
a storage unit configured to store abnormality information including content of the
abnormality and information on occurred time of the abnormality, and symptom information
including content of the symptom and information on occurred time of the symptom;
and an output unit configured to output the abnormality information and the symptom
information stored in the storage unit.
According to the abnormality diagnostic system thus configured, the storage unit stores
the abnormality information including the information on the occurred time of the
abnormality, and the symptom information including the information on the occurred
time of the symptom, and the output unit outputs the abnormality information and the
symptom information. It is thus possible to chronologically check occurrence of the
abnormality and the symptom in accordance with the information thus outputted. It
is thus possible to check an abnormality symptom occurred before any abnormality occurred
to the air conditioner, and utilize the symptom information for abnormality cause
specification.
- (2) Preferably, the information on the occurred time corresponds to electrification
time of the air conditioner.
According to the above configuration, the storage unit stores the content of the abnormality
and the symptom as well as the electrification time of the air conditioner, to enable
chronologically checking occurrence of the abnormality and the symptom and determining
whether or not occurrence of the abnormality and the symptom have a cause due to a
life span in accordance with the electrification time.
- (3) Preferably, the information on the occurred time corresponds to operation time
of the air conditioner.
According to the above configuration, the content of the abnormality and the symptom
is stored along with the operation time of the air conditioner, to enable chronologically
checking occurrence of the abnormality and the symptom and determining whether or
not occurrence of the abnormality and the symptom have a cause due to wearing or deterioration
by operation of the air conditioner in accordance with the electrification time.
- (4) Preferably, the storage unit stores restart information including content of a
restart of the air conditioner to be executed before definition of the abnormality,
and information on occurred time of the restart, and the output unit outputs the abnormality
information, the symptom information, and the restart information stored in the storage
unit.
According to the above configuration, the symptom information as well as the restart
information can be used for specification of an abnormality cause.
- (5) Preferably, the processing unit causes a notification unit of the air conditioner
to notify of the content of the abnormality upon occurrence, and causes the notification
unit not to notify of the content of the symptom upon occurrence.
According to the above configuration, a use is not notified of occurrence of any abnormality
symptom so as to prevent the user from executing an unnecessary action (stopping air
conditioning or notifying a manager).
- (6) The present disclosure provides an air conditioner including the abnormality diagnostic
system according to any one of (1) to (5) described above.
The operation data acquired by the air conditioner itself thus configured can be directly
applied to diagnosis of abnormality and a symptom, and information thereon can be
kept in the air conditioner itself. When the air conditioner has any abnormality,
it is thus possible to promptly specify a cause of the abnormality with use of the
information on the symptom stored in the air conditioner. This also achieves reduction
in communication volume because there is no need to transmit the information on the
abnormality and the symptom externally (e.g. to a remote service center) for management
of these pieces of information.
- (7) The present disclosure provides an air conditioning system including: an air conditioner;
and a management device connected with the air conditioner via a local communication
network, in which the management device includes the abnormality diagnostic system
according to any one of (1) to (5) described above.
The above configuration enables the management device connected to the air conditioner
via the local communication network to diagnose as abnormality and a symptom and manage
abnormality information and symptom information. In the air conditioner installed
in a large facility such as a building, the management device can thus centralizedly
control the abnormality information and the symptom information. This also achieves
reduction in communication volume because there is no need to transmit the abnormality
information and the symptom information externally (e.g. to a remote service center)
for management of the abnormality information and the symptom information.
- (8) The present disclosure provides an air conditioning system including: an air conditioner;
a first management device connected to the air conditioner via a local communication
network; and a second management device connected to the first management device via
a wide area communication network, in which the air conditioner or the first management
device includes the abnormality diagnostic system according to any one of (1) to (5)
described above, and the abnormality diagnostic system includes a transmission unit
configured to transmit the abnormality information and the symptom information to
the second management device.
According to the above configuration, the abnormality information and the symptom
information can be transmitted to the second management device connected via the wide
area communication network, to enable management of the abnormality information and
the symptom information on the air conditioner at a place distant from a site equipped
with the air conditioner. Transmitted to the second management device is not the operation
data for diagnosis of abnormality and a symptom, but the abnormality information and
the symptom information as a diagnosis result, leading to reduction in volume of communication
to the second management device.
- (9) The present disclosure provides an air conditioning system including: an air conditioner;
and a management device connected to the air conditioner via a wide area communication
network, in which the management device includes the abnormality diagnostic system
according to any one of (1) to (5) described above, and the abnormality diagnostic
system includes a transmission unit configured to transmit the abnormality information
or the symptom information via the wide area communication network.
BRIEF DESCRIPTION OF DRAWINGS
[0007]
FIG. 1 is a configuration diagram of an air conditioning system according to an embodiment
of the present disclosure.
FIG. 2 is a schematic refrigerant circuit diagram of an air conditioner.
FIG. 3 is a configuration diagram of an outdoor control unit.
FIG. 4 is a chart exemplifying content of abnormality information, retry information,
and symptom information stored in a storage unit.
FIG. 5 is a chart of exemplary abnormality symptom sensing.
FIG. 6A is a chart exemplifying content of abnormality information displayed on a
display unit.
FIG. 6B is a chart exemplifying content of retry information displayed on the display
unit.
FIG. 6C is a chart exemplifying content of symptom information displayed on the display
unit.
FIG. 7 is a flowchart depicting a procedure of diagnosing as a sensing gap of a temperature
sensor.
FIG. 8 is a flowchart depicting a procedure of diagnosing as a sensing gap of a pressure
sensor.
DETAILED DESCRIPTION
[0008] Embodiments of an air conditioning system will be described in detail hereinafter
with reference to the accompanying drawings.
[0009] FIG. 1 is a configuration diagram of an air conditioning system according to an embodiment
of the present disclosure.
[0010] As depicted in FIG. 1, the air conditioning system includes an air conditioner 11,
a centralized management device 50, and a management server 62. The air conditioner
11 adjusts, to predetermined target temperature, air temperature in an indoor space
as an air conditioning target space. The air conditioner 11 according to the present
embodiment is configured to cool and heat the indoor space.
[0011] The air conditioner 11 includes an indoor unit 21 and an outdoor unit 22. The air
conditioner 11 is of a multiple type and exemplarily includes a plurality of indoor
units 21 connected parallelly to the outdoor unit 22. The air conditioner 11 may alternatively
include a single outdoor unit 22 and a single indoor unit 21.
[0012] FIG. 2 is a schematic refrigerant circuit diagram of an air conditioner.
[0013] As depicted in FIG. 2, the air conditioner 11 includes a refrigerant circuit 23.
The refrigerant circuit 23 is configured to circulate a refrigerant between each of
the indoor units 21 and the outdoor unit 22. The refrigerant circuit 23 includes a
compressor 30, an oil separator 31, a four-way switching valve 32, an outdoor heat
exchanger (heat source heat exchanger) 33, an outdoor expansion valve 34, a subcooler
35, a liquid shutoff valve 36, an indoor expansion valve 24, an indoor heat exchanger
(utilization heat exchanger) 25, a gas shutoff valve 37, an accumulator 38, refrigerant
pipes 40L and 40G connecting these components, and the like.
[0014] The indoor unit 21 includes the indoor expansion valve 24 and the indoor heat exchanger
25 constituting the refrigerant circuit 23. The indoor expansion valve 24 is constituted
by a motor valve configured to adjust a refrigerant flow rate. The indoor heat exchanger
25 is of a cross-fin tube type or a microchannel type, and is used for heat exchange
with indoor air.
[0015] The indoor unit 21 further includes an indoor fan 26 and an indoor temperature sensor
27. The indoor fan 26 is configured to bring indoor air into the indoor unit 21, cause
heat exchange with the brought in air in the indoor heat exchanger 25, and cause the
air to blow indoors. The indoor fan 26 includes a motor having a number of operating
revolutions adjustable in accordance with inverter control. The indoor temperature
sensor 27 detects indoor temperature.
[0016] The outdoor unit 22 includes the compressor 30, the oil separator 31, the four-way
switching valve 32, the outdoor heat exchanger 33, the outdoor expansion valve 34,
the subcooler 35, the liquid shutoff valve 36, the gas shutoff valve 37, and the accumulator
38, which constitute the refrigerant circuit 23.
[0017] The compressor 30 sucks a low-pressure gas refrigerant and discharges a highpressure
gas refrigerant. The compressor 30 includes a motor having a number of operating revolutions
adjustable in accordance with inverter control. The compressor 30 is of a variable
capacity type (performance variable type) having capacity (performance) variable in
accordance with inverter control of the motor. The compressor 30 may alternatively
be of a constant capacity type. There may alternatively be provided a plurality of
compressors 30. In this case, the compressors may include both the compressor 30 of
the variable capacity type and the compressor 30 of the constant capacity type.
[0018] The oil separator 31 is configured to separate refrigerating machine oil contained
in a refrigerant discharged from the compressor 30. The refrigerating machine oil
separated in the oil separator 31 is returned to the compressor 30 via an oil return
tube 41. The oil return tube 41 is provided with an on-off valve 42. The on-off valve
42 is configured as an electromagnetic valve. When the on-off valve 42 is opened,
the refrigerating machine oil in the oil separator 31 passes the oil return tube 41
and is sucked into the compressor 30 along with the refrigerant flowing in a suction
pipe 44.
[0019] The four-way switching valve 32 reverses a refrigerant flow in the refrigerant pipe,
and switchingly supplies one of the outdoor heat exchanger 33 and the indoor heat
exchanger 25 with the refrigerant discharged from the compressor 30. The air conditioner
11 can thus switchingly execute cooling operation and heating operation.
[0020] The outdoor heat exchanger 33 is of a cross-fin tube type, a microchannel type, or
the like, and causes heat exchange with the refrigerant with use of air as a heat
source to condense or evaporate the refrigerant.
[0021] The outdoor expansion valve 34 is constituted by a motor valve configured to adjust
a refrigerant flow rate or the like.
[0022] The subcooler 35 subcools a refrigerant condensed in the outdoor heat exchanger 33.
The subcooler 35 includes a first heat transfer tube 35a and a second heat transfer
tube 35b. The first heat transfer tube 35a has a first end connected to a refrigerant
pipe extending to the outdoor expansion valve 34. The first heat transfer tube 35a
has a second end connected to a refrigerant pipe extending to the liquid shutoff valve
36. The second heat transfer tube 35b has a first end connected to a branching tube
35c branching from a refrigerant pipe disposed between the first heat transfer tube
35a and the outdoor expansion valve 34. The branching tube 35c is provided with an
expansion valve 43. The second heat transfer tube 35b has a second end connected to
the suction pipe 44 provided to return the refrigerant to the compressor 30.
[0023] The subcooler 35 causes heat exchange between the refrigerant flowing from the compressor
30, passing the outdoor heat exchanger 33 and the expansion valve 34, and flowing
in the first heat transfer tube 35a, and the refrigerant decompressed by the expansion
valve 43 and flowing in the second heat transfer tube 35b, and subcools the refrigerant
flowing in the first heat transfer tube 35a. The refrigerant flowing in the second
heat transfer tube 35b passes the suction pipe 44, and is sucked into the compressor
30 via the accumulator 38.
[0024] The accumulator 38 temporarily reserves a low-pressure refrigerant to be sucked into
the compressor 30, for separation between a gas refrigerant and a liquid refrigerant.
The accumulator 38 is provided on the suction pipe 44. The accumulator 38 is connected
with a first end of an oil return tube 45. The oil return tube 45 has a second end
connected to the suction pipe 44. The oil return tube 45 is provided to return the
refrigerating machine oil from the accumulator 38 to the compressor 30. The oil return
tube 45 is provided with an on-off valve 46. The on-off valve 46 is configured as
an electromagnetic valve. When the on-off valve 46 is opened, the refrigerating machine
oil in the accumulator 38 passes the oil return tube 45 and is sucked into the compressor
30 along with the refrigerant flowing in the suction pipe 44.
[0025] The liquid shutoff valve 36 is a manually operated on-off valve. The gas shutoff
valve 37 is also a manually operated on-off valve. The liquid shutoff valve 36 and
the gas shutoff valve 37 are closed to block refrigerant flows in the refrigerant
pipes 40L and 40G, and are opened to allow the refrigerant flows in the refrigerant
pipes 40L and 40G.
[0026] The outdoor unit 22 further includes an outdoor fan 39, pressure sensors 51 and 52,
temperature sensors 53 to 59, a current sensor 60, and the like. The outdoor fan 39
includes a motor having a number of operating revolutions adjustable in accordance
with inverter control. The outdoor fan 39 is configured to bring outdoor air into
the outdoor unit 22, cause heat exchange with the brought in air in the outdoor heat
exchanger 33, and cause the air to blow out of the outdoor unit 22.
[0027] The pressure sensors 51 and 52 include a suction pressure sensor 51 and a discharge
pressure sensor 52. The suction pressure sensor 51 detects pressure of a refrigerant
sucked into the compressor 30. The discharge pressure sensor 52 detects pressure of
a refrigerant discharged from the compressor 30.
[0028] The temperature sensors 53 to 59 include refrigerant temperature sensors 53 to 57
configured to detect refrigerant temperature, an outdoor air temperature sensor 58
configured to detect outdoor air temperature, and a temperature sensor 59 configured
to detect surface temperature of the compressor 30. The refrigerant temperature sensor
53 detects temperature of a refrigerant sucked into the compressor 30. The refrigerant
temperature sensor 54 detects temperature of a refrigerant discharged from the compressor
30. The refrigerant temperature sensor 55 detects temperature of a refrigerant on
a liquid side of the outdoor heat exchanger 33. The refrigerant temperature sensor
56 detects temperature of a refrigerant provided between the subcooler 35 and the
liquid shutoff valve 36. The refrigerant temperature sensor 57 detects temperature
of a refrigerant flowing out of the second heat transfer tube 35b of the subcooler
35.
[0029] Detection values of the suction pressure sensor 51, the discharge pressure sensor
52, and the refrigerant temperature sensors 53 and 54 are used to obtain evaporation
temperature and condensation temperature of a refrigerant and a degree of superheating
of the refrigerant in the outdoor heat exchanger 33 and the indoor heat exchanger
25. The number of revolutions of the compressor 30, opening degrees of the outdoor
expansion valve 34 and the indoor expansion valve 24, and the like are controlled
to adjust these values.
[0030] When the air conditioner 11 thus configured executes cooling operation, the four-way
switching valve 32 is kept in a state indicated by solid lines in FIG. 1. The compressor
30 discharges a gas refrigerant having high temperature and high pressure, which flows
into the outdoor heat exchanger 33 via the four-way switching valve 32, and exchanges
heat with outdoor air due to functioning of the outdoor fan 39 to be condensed and
liquefied. The refrigerant thus liquefied passes the outdoor expansion valve 34 in
a fully opened state and the subcooler 35, and flows into the indoor unit 21. The
refrigerant in the indoor unit 21 is decompressed to have predetermined low pressure
at the indoor expansion valve 24, and further exchanges heat with indoor air in the
indoor heat exchanger 25 to be evaporated. The indoor fan 26 causes the indoor air
cooled due to evaporation of the refrigerant to blow indoors so as to cool the indoor
space. The refrigerant evaporated in the indoor heat exchanger 25 returns to the outdoor
unit 22 via the gas refrigerant pipe 40G, and is sucked into the compressor 30 by
way of the four-way switching valve 32. Also during defrosting operation of removing
frost adhering to the outdoor heat exchanger 33, the air conditioner 11 behaves similarly
to behavior during cooling operation.
[0031] When the air conditioner 11 executes heating operation, the four-way switching valve
32 is kept in a state indicated by broken lines in FIG. 1. The compressor 30 discharges
the gas refrigerant having high temperature and high pressure, which flows into the
indoor heat exchanger 25 of the indoor unit 21 via the four-way switching valve 32.
In the indoor heat exchanger 25, the refrigerant exchanges heat with indoor air to
be condensed and liquefied. The indoor fan 26 causes the indoor air heated due to
condensation of the refrigerant to blow indoors so as to heat the indoor space. The
refrigerant liquefied in the indoor heat exchanger 25 returns to the outdoor unit
22 via the liquid refrigerant pipe 40L, is decompressed to have predetermined low
pressure at the outdoor expansion valve 34, and further exchanges heat with outdoor
air in the outdoor heat exchanger 33 to be evaporated. The refrigerant evaporated
and gasified in the outdoor heat exchanger 33 passes the four-way switching valve
32 to be sucked into the compressor 30.
[0032] The indoor unit 21 further includes an indoor control unit 29 and a remote controller
29A. The indoor control unit 29 is constituted by a microcomputer including a calculation
unit such as a CPU and a storage unit such as a RAM or a ROM. The indoor control unit
29 may include an integrated circuit such as an FPGA or an ASIC. The indoor unit 21
includes sensors having detection values to be transmitted to the indoor control unit
29. The indoor control unit 29 controls behavior of the indoor expansion valve 24
and the indoor fan 26 in accordance with the detection values of the indoor temperature
sensor 27 and the like.
[0033] The remote controller 29A is used to input commands to start and stop operation for
the air conditioner 11, input operating modes such as cooling operation and heating
operation, input indoor set temperature, and the like. The remote controller 29A includes
a display unit 29A1 (see FIG. 3) configured to display setting content and the like.
The display unit 29A1 functions also as a notification unit configured to notify a
user of abnormality occurrence, as to be described later.
[0034] The outdoor unit 22 further includes an outdoor control unit 70. The outdoor control
unit 70 is constituted by a microcomputer including a calculation unit such as a CPU
and a storage unit such as a RAM or a ROM. The outdoor control unit 70 may include
an integrated circuit such as an FPGA or an ASIC. The outdoor unit 22 includes the
various sensors 51 to 60 having detection values to be transmitted to the outdoor
control unit 70. The outdoor control unit 70 controls behavior of the compressor 30,
the outdoor fan 39, the expansion valves 34 and 43, and the like in accordance with
the detection values of the various sensors 51 to 60. As to be described later, the
outdoor control unit 70 constitutes an abnormality diagnostic system configured to
diagnose whether or not the air conditioner 11 has abnormality.
[0035] The indoor control unit 29, the outdoor control unit 70, and the centralized management
device 50 are connected via a local communication network such as a local area network
(LAN). Specifically, the indoor control unit 29 and the outdoor control unit 70 are
mutually communicably connected via a transmission line. The indoor control unit 29
and the outdoor control unit 70 are mutually communicably connected to the centralized
management device 50 via transmission lines.
[0036] The centralized management device 50 includes a control unit 50a like a microcomputer
including a calculation unit such as a CPU and a storage unit such as a ROM or a RAM.
The control unit 50a may include an integrated circuit such as an FPGA or an ASIC.
The centralized management device 50 is installed in a control center of a building
or the like. The centralized management device 50 manages the outdoor unit 22 and
the indoor unit 21. Specifically, the centralized management device 50 causes the
control unit 50a to monitor working situations of the outdoor unit 22 and the indoor
unit 21, set air conditioning temperature, control to operate and stop, and the like.
[0037] The management server 62 is provided at a remote location from the building equipped
with the air conditioner 11. The management server 62 is exemplarily constituted by
a personal computer including a control unit 62a having a calculation unit such as
a CPU and a storage unit such as a ROM or a RAM. The control unit 62a may include
an integrated circuit such as an FPGA or an ASIC. The centralized management device
50 and the management server 62 are communicably connected via a wide area communication
network 63 such as the Internet.
[0038] The air conditioning system according to the present embodiment may alternatively
exclude the centralized management device 50 and the management server 62.
[Abnormality diagnostic system]
[0039] The outdoor control unit 70 constitutes the abnormality diagnostic system configured
to sense occurrence of "abnormality", sense occurrence of an "abnormality symptom"
(hereinafter, also simply called a "symptom") in the air conditioner 11. The outdoor
control unit 70 acquires, as operation data, the detection values of the various sensors
51 to 60, control data of the compressor 30, the outdoor fan 39, the expansion valves
34 and 43, and the like. In accordance with the operation data thus acquired, the
outdoor control unit 70 controls behavior of various instruments such as the compressor
30, and senses abnormality and symptoms of the air conditioner 11.
[0040] Examples of the instruments as targets of sensing occurrence of abnormality and symptoms
include the compressor 30, the outdoor fan 39, the expansion valves 34 and 43, the
temperature sensors 53 to 59, and the pressure sensors 51 and 52. The outdoor control
unit 70 stops the air conditioner 11 upon sensing of occurrence of "abnormality" of
the air conditioner 11. The outdoor control unit 70 continuously operates the air
conditioner 11 upon sensing of occurrence of an "abnormality symptom" of the air conditioner
11.
[0041] The outdoor control unit 70 executes retry operation of temporarily stopping the
air conditioner 11 when predetermined abnormality occurs and operating again (restarting)
after elapse of predetermined time. If abnormality occurs even when retry operation
is executed a predetermined number of times, the outdoor control unit 70 defines the
abnormality as formal "abnormality".
[0042] A conventional and publicly known method can be applied to abnormality sensing. For
example, the compressor 30 can be determined as abnormal when current flowing in the
motor has a value larger than a predetermined threshold, when the suction pressure
sensor 51 and the discharge pressure sensor 52 have detection values larger or smaller
than a predetermined threshold, when the detection values of the pressure sensors
51 and 52 have a difference smaller than a predetermined threshold, or the like.
[0043] A method described in FIG. 5 or the like can be applied to sensing of an abnormality
symptom. Details of FIG. 5 will be described later.
[0044] FIG. 3 is a configuration diagram of an outdoor control unit.
[0045] The outdoor control unit 70 includes a processing unit 71, a storage unit 72, a display
unit 73, and an output unit 74. The processing unit 71 is constituted by a calculation
device such as a CPU, and processes behavior control of the compressor 30 as described
above as well as abnormality diagnosis.
[0046] Upon sensing occurrence of "abnormality", "retry operation", and an "abnormality
symptom", the processing unit 71 processes to store, in the storage unit 72, information
thereon, namely, "abnormality information", "retry information (restart information)",
and "symptom information". The processing unit 71 processes to cause the display unit
73 to display the "abnormality information", the "retry information", and the "symptom
information" stored in the storage unit 72. The processing unit 71 further processes
to cause the display unit 29A1 of the remote controller 29A to display the "abnormality
information" among the types of information stored in the storage unit 72. Note that
the processing unit 71 processes to cause the display unit 29A1 to display not the
"symptom information" or the "retry information" but only the "abnormality information".
[0047] The storage unit 72 stores detection data of the various sensors in the air conditioner
11, and control data of the compressor 30 and the like. When the processing unit 71
senses occurrence of "abnormality", "retry operation", and a "symptom", the storage
unit 72 stores "abnormality information", "retry information", and "symptom information"
thereof.
[0048] The "abnormality information" includes abnormality content and information on occurred
time thereof. The "symptom information" includes symptom content and information on
occurred time thereof. The "retry information" includes abnormality content as a cause
of retry operation, and information on occurred time thereof.
[0049] FIG. 4 is a chart exemplifying content of abnormality information, retry information,
and symptom information stored in a storage unit.
[0050] As depicted in FIG. 4, the storage unit 72 stores an abnormality state (abnormality,
retry operation, or a symptom), abnormality content, accumulated electrification time
(also simply called "electrification time") upon abnormality occurrence, and accumulated
compressor operation time upon abnormality occurrence, which are associated with one
another. The accumulated compressor operation time corresponds to operation time while
the air conditioner 11 is actually conditioning air. FIG. 4 describes "abnormality",
"symptoms", and "retry operation" are listed from the bottom in accordance with the
order of occurrence. The storage unit 72 is configured to store latest information
and information on past n events. The value n can be exemplarily 83, in which case
the storage unit 72 can store information on 84 events in total.
[0051] FIG. 6A to FIG. 6C are charts each exemplifying content of abnormality information,
retry information, and symptom information displayed on a display unit of the outdoor
control unit.
[0052] The display unit 73 displays "abnormality information", "retry information", and
"symptom information" stored in the storage unit 72. The display unit 73 adopts digital
display with seven segments or the like, and displays abnormality information, retry
information, and symptom information in a coded manner with use of numbers, alphabets,
and the like. The display unit 73 according to the present embodiment displays, as
abnormality information, retry information, and symptom information, abnormality content,
retry operation content, and symptom content, respectively, in the coded manner.
[0053] The display unit 73 displays abnormality information, retry information, and symptom
information on each of three events, namely, "latest", "past 1", and "past 2". Accordingly,
a service person in charge of its recovery checks the display unit 73 when the air
conditioner 11 stops due to abnormality, so as to find content of actually occurred
abnormality as well as information on retry operation and a symptom recently occurred
to utilize retry information and symptom information for determination of a cause
of the occurred abnormality. However, the display unit 73 simply individually displays
three pieces of each type of abnormality information, retry information, and symptom
information. It is thus difficult to understand mutual relationships thereof. The
outdoor control unit 70 according to the present embodiment is thus configured to
output in a form enabling understanding of the mutual relationships of these pieces
of information.
[0054] As depicted in FIG. 3, the output unit 74 of the outdoor control unit 70 outputs
abnormality information, retry information, and symptom information stored in the
storage unit 72 to an external instrument exemplified by a terminal 100 (hereinafter,
also referred to as "service terminal") such as a PC or a smartphone carried by the
service person. The output unit 74 is provided on a control board or the like constituting
the outdoor control unit 70, and is constituted by an output interface or the like
wiredly connected with the service terminal 100. The output unit 74 may alternatively
a communication device configured to wirelessly output abnormality information and
the like.
[0055] As described earlier, abnormality information, retry information, and symptom information
stored in the storage unit 72 each include electrification time and operation time
of the air conditioner 11 at a timepoint of occurrence thereof, and the output unit
74 externally outputs the abnormality information, the retry information, and the
symptom information each including information on occurred time thereof. It is thus
possible to chronologically check the abnormality information, the retry information,
and the symptom information having been outputted as indicated in FIG. 4 or the like.
The service person can accordingly find, on the basis of the information thus outputted,
what kind of retry operation has been executed or what kind of a symptom has occurred
before abnormality occurrence. The service person can thus easily estimate the cause
of the occurred abnormality in accordance with the retry information and the symptom
information, to appropriately and promptly execute recovery (repair or replacement
of a component) from the abnormality.
[0056] Abnormality information, retry information, and symptom information include electrification
time and operation time of the air conditioner 11 as information on occurred time.
The electrification time enables determination of whether or not a cause of occurred
abnormality, retry operation, or a symptom is relevant to wearing or deterioration
due to operation of the air conditioner 11. Similarly, the electrification time enables
determination of whether or not the cause of occurred abnormality, retry operation,
or a symptom is relevant to a life span. The output unit 74 may alternatively be configured
to output, to the display unit 73 of the outdoor control unit 70, abnormality information,
retry information, and symptom information in a form enabling chronological checking
of these pieces of information.
[Exemplary abnormality symptom]
[0057] FIG. 5 is a chart exemplifying content of abnormality information, retry information,
and symptom information stored in the storage unit.
[0058] FIG. 5 exemplifies components constituting the air conditioner 11, content of abnormality
symptoms possibly occurring to the components, and methods of sensing the content,
which are associated with one another. For example, "current value", "damp", and "superheating"
exemplify content of abnormality symptoms possibly occurring to the compressor 30.
[0059] The "current value" means sensing a state where a value of current flowing in the
motor of the compressor 30 is larger than a predetermined value. The current value
in this case adopts a moving average from current time to before a predetermined period,
for sensing of long-term abnormality in current value. The "damp" means sensing a
damp sate (having a degree of superheating less than a predetermined value) of the
refrigerant discharged from the compressor 30. The "superheating" means sensing a
superheating sate (having a degree of superheating equal to or more than the predetermined
value) of the refrigerant discharged from the compressor 30. Upon sensing any one
of these states, the outdoor control unit 70 diagnoses the compressor 30 as having
an "abnormality symptom". However, the air conditioner 11 continuously operates because
the air conditioner 11 does not have readily trouble in operation even upon sensing
of any one of these states.
[0060] FIG. 5 exemplifies "leak" as content of an abnormality symptom possibly occurring
to the expansion valve 34. This means that the refrigerant temperature sensor disposed
downstream of the expansion valve 34 senses a refrigerant damp state. Upon sensing
of this state, the outdoor control unit 70 diagnoses the expansion valve 34 as having
an "abnormality symptom".
[0061] FIG. 5 exemplifies "imperfectly thawed frost" as content of an abnormality symptom
possibly occurring to the outdoor heat exchanger 33. This means that the air conditioner
11 executing defrosting operation does not satisfy a predetermined completion condition
a number of times exceeding a predetermined number. Upon sensing of this state, the
outdoor control unit 70 diagnoses the outdoor heat exchanger 33 as having an "abnormality
symptom". However, the air conditioner 11 continuously operates because the air conditioner
11 does not have readily trouble in operation even upon sensing of any one of these
states.
[0062] FIG. 5 exemplifies a "sensing gap" as an abnormality symptom of any of the temperature
sensors 53 to 59. This means sensing divergence in detection value between a temperature
sensor as a diagnosis target and a different temperature sensor. Upon detection of
this state, the outdoor control unit 70 diagnoses the temperature sensor as having
an "abnormality symptom".
[0063] FIG. 5 exemplifies a "sensing gap" as an abnormality symptom of the pressure sensor
51 or 52. This means sensing divergence between saturation temperature corresponding
to pressure (calculated value) obtained from the detection value of the pressure sensor
51 or 52 as a diagnosis target, and the detection value of a different temperature
sensor. Upon sensing of this state, the outdoor control unit 70 diagnoses the pressure
sensor 51 or 52 as having an "abnormality symptom".
[0064] Operation of the air conditioner 11 does not readily have trouble even upon such
sensing of symptom occurrence. Accordingly, the outdoor control unit 70 does not stop
but continues operation of the air conditioner 11. Among the abnormality symptoms
indicated in FIG. 5, the "current value" of the compressor 30, the "leak" of the expansion
valve, the "imperfectly thawed frost" of the heat exchanger 33, the "sensing gap"
of any of the temperature sensors 53 to 59, and the "sensing gap" of the pressure
sensor 51 or 52 are sensed in accordance with a method different from the method of
sensing abnormality occurrence, in order for detection of slight abnormality that
does not need to stop the air conditioner 11.
(Specific processing of symptom sensing)
[0065] Among the "abnormality symptoms" described above, the "sensing gap" of any of the
temperature sensors 53 to 59 and the pressure sensors 51 and 52 will be described
in detail.
[0066] Each of the various sensors included in the air conditioner 11 may gradually have
a "sensing gap" of having a detection value different from a normal value. If such
a "sensing gap" increases, the air conditioner 11 may not be appropriately controlled
and have trouble in operation. The air conditioner 11 according to the present embodiment
will thus have diagnosis that there is an abnormality symptom if any of the temperature
sensors 53 to 59 and the pressure sensors 51 and 52 has a "sensing gap".
[0067] Diagnosis as having a "sensing gap" of any of the temperature sensors 53 to 59 and
the pressure sensors 51 and 52 is executed while the air conditioner 11 stops operation.
The outdoor control unit 70 compares the detection value of each of the temperature
sensors 53 to 59 and the calculated value obtained from the detection value of each
of the pressure sensors 51 and 52 with a predetermined reference value. If there is
large divergence from the reference value continuously for at least predetermined
time, the outdoor control unit 70 diagnoses the sensor as having a "sensing gap".
[0068] While the air conditioner 11 is stopped, the detection values of the temperature
sensors 53 to 59 included in the air conditioner 11 will gradually converge to outdoor
air temperature. The saturation temperature corresponding to pressure obtained from
the detection value of each of the pressure sensors 51 and 52 included in the air
conditioner 11 will converge to outdoor air temperature. According to the present
embodiment, the outdoor control unit 70 diagnoses as to a "sensing gap" by setting
a value corresponding to outdoor air temperature as the "reference value", and comparing
the reference value with the detection values of the temperature sensors 53 to 59
and the saturation temperature corresponding to pressure (calculated value) obtained
from the detection value of each of the pressure sensors 51 and 52.
[0069] FIG. 7 is a flowchart depicting a procedure of diagnosing as a sensing gap of a temperature
sensor.
[0070] Description is made hereinafter to a procedure of diagnosing any of the temperature
sensors 53 to 59 as having a "sensing gap" with reference to the flowchart.
[0071] In step S1, the outdoor control unit 70 determines whether or not the air conditioner
11 is stopped. The outdoor control unit 70 proceeds with processing to step S2 if
determination in step S1 is positive (Yes).
[0072] In step S2, the outdoor control unit 70 acquires detection values of the temperature
sensors 53 to 59. Subsequently in step S3, the outdoor control unit 70 calculates
a reference value with use of the detection values of the plurality of temperature
sensors 53 to 59. The present embodiment sets the reference value as a median of some
of the detection values among the detection values of the plurality of temperature
sensors 53 to 59. The median is adopted as the reference value because outdoor air
temperature can be improved in reproducibility by decreasing possibility of being
affected by any unusually high value or any low value included in the detection values
of the plurality of temperature sensors.
[0073] The reference value is obtained by preferably using three or more temperature sensors.
When the reference value is obtained by using an even number of temperature sensors,
the reference value can be set as an average of two values close to the median. The
temperature sensors 54 and 59 according to the present embodiment are not used for
calculation of the reference value because the temperature sensors 54 and 59 are disposed
around the compressor 30 and are likely to be affected by heat of the compressor 30.
[0074] In step S4, the outdoor control unit 70 determines whether or not a difference between
the detection value of each of the temperature sensors 53 to 58 and the reference
value exceeds a predetermined threshold. If determination in step S4 is positive (Yes),
the outdoor control unit 70 determines in step S5 whether or not predetermined time
has elapsed after a stop of the air conditioner 11. Examples of the predetermined
time include eight hours. If determination in step S5 is positive (Yes), the outdoor
control unit 70 diagnoses a corresponding one of the temperature sensors 53 to 59
as having a "sensing gap", stores as abnormality symptom information in the storage
unit 72, and ends processing.
[0075] If the determination in step S4 is negative (No), the outdoor control unit 70 proceeds
with processing to step S8, diagnoses the temperature sensors 53 to 59 as having no
"sensing gap", and ends processing.
[0076] The predetermined threshold referred to in step S4 can be set in accordance with
a type of the temperature sensor as a diagnosis target. For example, the compressor
30 is heated by a crankcase heater while the air conditioner 11 is stopped. The temperature
sensors 54 and 59 disposed around the compressor 30 are thus higher in detection value
than the remaining temperature sensors 53 and 55 to 58. These temperature sensors
54 and 59 are accordingly provided with a highly set threshold.
[0077] Time for diagnosis as a "sensing gap" is set to as long as eight hours because there
needs certain time until detection values of temperature sensors converge to ambient
temperature (outdoor air temperature). However, the time should not be particularly
limited.
[0078] FIG. 8 is a flowchart depicting a procedure of diagnosing as a sensing gap of a pressure
sensor.
[0079] Description is made hereinafter to a procedure of diagnosing the pressure sensor
51 or 52 as having "sensing gap" with reference to the flowchart.
[0080] In step S11, the outdoor control unit 70 determines whether or not the air conditioner
11 is stopped. The outdoor control unit 70 proceeds with processing to step S12 if
the determination in step S1 is positive (Yes).
[0081] In step S12, the outdoor control unit 70 acquires detection values of the pressure
sensors 51 and 52 and the temperature sensors 53 to 59. Subsequently in step S13,
the outdoor control unit 70 calculates a reference value with use of a plurality of
detection values among the detection values of the plurality of temperature sensors
53 to 59. The present embodiment sets the reference value as a median of a plurality
of detection values. The median is adopted as the reference value because outdoor
air temperature can be improved in reproducibility by decreasing opportunity of being
affected by any unusually high or low value included in the detection values of the
plurality of temperature sensors.
[0082] The reference value is obtained by preferably using three or more temperature sensors.
When the reference value is obtained by using an even number of temperature sensors,
the reference value can be set as an average of two values close to a center. Preferably,
the temperature sensors 54 and 59 are not used for calculation of the reference value
because the temperature sensors 54 and 59 are disposed around the compressor 30 and
are likely to be affected by heat of the compressor 30.
[0083] In step S14, the outdoor control unit 70 calculates saturation temperature corresponding
to pressure of the refrigerant with use of the detection value of each of the pressure
sensors 51 and 52. In step S15, the outdoor control unit 70 determines whether or
not a difference between the saturation temperature corresponding to pressure obtained
from the detection value of each of the pressure sensors 51 and 52 and the reference
value exceeds a predetermined threshold. If determination in step S15 is positive,
the outdoor control unit 70 determines in step S16 whether or not predetermined time
has elapsed after a stop of the air conditioner 11. Examples of the predetermined
time include eight hours. If determination in step S16 is positive (Yes), the outdoor
control unit 70 diagnoses the pressure sensor 51 or 52 as having a "sensing gap" (step
S17), stores as abnormality symptom information in the storage unit 72 (step S18),
and ends processing.
[0084] If determination in step S15 is negative (No), the outdoor control unit 70 proceeds
with processing to step S19, diagnoses the pressure sensor 51 or 52 as having no "sensing
gap", and ends processing.
[Other embodiments]
[0085] According to the present embodiment, the reference value calculated in each of step
S3 in FIG. 7 and step S13 in FIG. 8 should not be limited to the median of the detection
values of the plurality of temperature sensors, but may alternatively be an average.
In this case, the average is more preferably calculated with use of the plurality
of detection values excluding the maximum value and the minimum value.
[0086] In the flowchart in each of FIG. 7 and FIG. 8, the detection values of each of the
temperature sensors that are not diagnosis targets may be used for calculation of
the reference value. The air conditioner 11 includes the temperature sensor 58 configured
to detect outdoor air temperature, and the detection value of the temperature sensor
58 can alternatively be adopted as the reference value. If the temperature sensor
58 itself has a "sensing gap" in this case, it is impossible to detect a sensing gap
of each of the remaining temperature sensors 53 to 57 and 59. It is thus more preferred
to set the reference value with use of the median or the average of the detection
values of the plurality of temperature sensors.
[0087] When any of the temperature sensors 53 to 59 and the pressure sensors 51 and 52 is
diagnosed as having a "sensing gap", the processing unit 71 in the outdoor control
unit 70 may obtain a correction factor in accordance with a difference between the
detection value of the temperature sensor or the calculated value (saturation temperature
corresponding to pressure) obtained from the detection value of the pressure sensor
and the reference value, and control operation of the air conditioner 11 with use
of the correction factor.
[0088] The processing unit 71 in the outdoor control unit 70 may transmit an abnormality
diagnosis result to the centralized management device 50 that may manage abnormality
information, retry information, and symptom information. The processing unit 71 in
the outdoor control unit 70 may alternatively transmit the abnormality diagnosis result
to the management server 62 that may manage the abnormality diagnosis result. Transmitting
not operation data of the air conditioner 11 but only the abnormality diagnosis result
achieves inhibition of increase in communication volume. In the case where the management
server 62 manages the abnormality diagnosis result, in order to resolve inconvenience
that the outdoor control unit 70 cannot refer to abnormality information, retry information,
and symptom information, the management server 62 is more preferred to include a transmission
unit configured to transmit abnormality information, retry information, and symptom
information to the service terminal 100, the centralized management device 50, or
the like via the wide area communication network 63.
[0089] The air conditioner 11 according to the above embodiment includes the abnormality
diagnostic system (the outdoor control unit 70). Alternatively, the centralized management
device 50 may include the abnormality diagnostic system. In this case, operation data
of the air conditioner 11 is transmitted from the air conditioner 11 to the centralized
management device 50, and the control unit 50a in the centralized management device
50 executes abnormality diagnosis. However, operation data is transmitted from the
air conditioner 11 to the centralized management device 50 only at predetermined time
intervals and there is thus limitation in volume of the operation data that can be
used for abnormality diagnosis. It is therefore more preferred to provide the abnormality
diagnostic system in the air conditioner 11 in terms of more accurate abnormality
diagnosis.
[0090] Similarly, the management server 62 may alternatively be provided with the abnormality
diagnostic system. In this case, operation data of the air conditioner 11 is transmitted
from the centralized management device 50 or the air conditioner 11 to the management
server 62, and the control unit 62a in the management server 62 executes abnormality
diagnosis. This needs transmission of large volume of operation data of the air conditioner
11 to the management server 62 via the wide area communication network 63, leading
to excessive increase in communication cost. Accordingly, the abnormality diagnostic
system is more preferably provided in the air conditioner 11 or the centralized management
device 50.
[0091] In the case where the management server 62 manages the abnormality diagnosis result,
in order to resolve inconvenience that the outdoor control unit 70 and the centralized
management device 50 cannot refer to abnormality information, retry information, and
symptom information, the management server 62 is more preferred to include a transmission
unit configured to transmit abnormality information, retry information, and symptom
information to the service terminal 100, the centralized management device 50, or
the like via the wide area communication network 63.
[0092] According to the above embodiment, the processing unit 71, the storage unit 72, and
the output unit 74 constituting the abnormality diagnostic system are included in
one device (the outdoor control unit 70 of the air conditioner 11, the control unit
50a of the centralized management device 50, or the control unit 62a of the management
server 62). These units may alternatively be included in different instruments, such
as different control units (computers), and these different control units may cooperate
with each other to constitute the abnormality diagnostic system.
[0093] According to the above embodiment, the plurality of temperature sensors 53 to 59
and the plurality of pressure sensors 51 and 52 are diagnosis targets of a "sensing
gap". Alternatively, at least one of these sensors has only to be the diagnosis target
of the sensing gap.
[Functional effects of embodiments]
[0094]
- (1) The above embodiment provides the abnormality diagnostic system including: the
processing unit 71 configured to acquire operation data of the air conditioner 11
and determine occurrence of abnormality and occurrence of an abnormality symptom in
the air conditioner 11; the storage unit 72 configured to store abnormality information
including content of the abnormality and information on occurred time of the abnormality,
and symptom information including content of the symptom and information on occurred
time of the symptom; and the output unit 74 configured to output the abnormality information
and the symptom information stored in the storage unit 72. In this manner, the storage
unit stores the abnormality information including the information on the occurred
time of the abnormality, and the symptom information including the information on
the occurred time of the symptom, and the output unit outputs the abnormality information
and the symptom information. It is thus possible to chronologically check occurrence
of the abnormality and the symptom in accordance with the information thus outputted.
It is accordingly possible to check an abnormality symptom occurred before any abnormality
occurred to the air conditioner 11, and utilize the symptom information for abnormality
cause specification.
- (2) The storage unit 72 according to the above embodiment stores the electrification
time of the air conditioner 11. In other words, the information on the occurred time
in the abnormality information and the symptom information corresponds to the electrification
time of the air conditioner 11. In this manner, the storage unit 72 stores the content
of the abnormality and the content of the symptom as well as the electrification time
of the air conditioner 11, to enable chronologically checking occurrence of the abnormality
and the symptom and determining whether or not occurrence of the abnormality and the
symptom have a cause due to a life span in accordance with the electrification time.
- (3) The storage unit 72 according to the above embodiment stores the operation time
of the compressor 30 in the air conditioner 11. In other words, the information on
the occurred time in the abnormality information and the symptom information can correspond
to the operation time of the air conditioner 11. In this manner, the content of the
abnormality and the symptom is stored along with the operation time of the air conditioner
11, to enable chronologically checking occurrence of the abnormality and the symptom
and determining whether or not occurrence of the abnormality and the symptom have
a cause due to wearing or deterioration by operation of the air conditioner 11 in
accordance with the electrification time.
- (4) According to the above embodiment, the storage unit 72 stores the restart information
(retry information) including the content of a restart and the information on the
occurred time of the restart of the air conditioner 11 to be executed before definition
of the abnormality, and the output unit 74 outputs the abnormality information, the
symptom information, and the retry information stored in the storage unit 72. Accordingly,
the symptom information as well as the retry information can be used for specification
of an abnormality cause.
- (5) According to the above embodiment, the processing unit (71) causes the notification
unit of the air conditioner (11) to notify of the content of the abnormality upon
occurrence, and causes the notification unit not to notify of the content of the symptom
upon occurrence. Accordingly, a use is not notified of occurrence of any abnormality
symptom so as to prevent the user from executing an unnecessary action (stopping air
conditioning or notifying a manager).
- (6) The abnormality diagnostic system according to the above embodiment is provided
in the air conditioner 11. The operation data acquired by the air conditioner 11 itself
can thus be directly applied to diagnosis of abnormality and a symptom, and information
thereon can be kept in the air conditioner 11 itself. When the air conditioner 11
has any abnormality, it is thus possible to promptly specify a cause of the abnormality
with use of the symptom information stored in the air conditioner 11. This also achieves
reduction in communication volume because there is no need to transmit the abnormality
information and the symptom information externally (e.g. to the management server
62 at a remote service center) for management of these pieces of information.
- (7) According to the other embodiment described above, the abnormality diagnostic
system is provided in the centralized management device (management device) 50 connected
with the air conditioner 11 via the local communication network. In this case, the
above configuration enables the centralized management device 50 connected via the
local communication network to diagnose as abnormality and a symptom and manage information
thereon. In the air conditioner 11 installed in a large facility such as a building,
the centralized management device 50 can thus centralizedly control the information
on abnormality and a symptom. This also achieves reduction in communication volume
because there is no need to transmit the abnormality information and the symptom information
externally (e.g. to the remote service center provided with the management server
62) for management of these pieces of information.
- (8) According to the other embodiment described above, the abnormality diagnostic
system is provided in the air conditioner 11 or the centralized management device
(first management device) 50, and includes the transmission unit configured to transmit
the information on abnormality and a symptom to a management server (second management
device) 55. The abnormality information and the symptom information can thus be transmitted
to the management server 62 connected via the wide area communication network, to
enable management of the abnormality information and the symptom information on the
air conditioner 11 at a place distant from a site equipped with the air conditioner
11. Transmitted to the management server 62 is not the operation data for diagnosis
of abnormality and a symptom, but the abnormality information and the symptom information
as the diagnosis result, leading to reduction in volume of communication to the management
server 62.
- (9) According to the other embodiment described above, the abnormality diagnostic
system is provided in the management server (management device) 55, and the management
server 62 includes the transmission unit configured to transmit the abnormality information
or the symptom information via the wide area communication network. The abnormality
information or the symptom information managed in the management server 62 can thus
be transmitted to a terminal of a service person at a cite equipped with the air conditioner
11, the centralized management device, or the like.
[0095] The present disclosure should not be limited to the above exemplification, but is
intended to include any modification recited in the claims within meanings and a scope
equivalent to those of the claims.
REFERENCE SIGNS LIST
[0096]
- 11
- air conditioner
- 29A1
- display unit (notification unit) of remote controller
- 50
- centralized management device (first management device)
- 50a
- control unit (abnormality diagnostic system)
- 51
- pressure sensor
- 52
- pressure sensor
- 53
- temperature sensor
- 54
- temperature sensor
- 55
- temperature sensor
- 56
- temperature sensor
- 57
- temperature sensor
- 58
- temperature sensor (ambient temperature sensor)
- 59
- temperature sensor
- 62
- management server
- 62a
- control unit (abnormality diagnostic system)
- 63
- wide area communication network
- 70
- outdoor control unit (abnormality diagnostic system)
- 71
- processing unit
- 72
- storage unit
- 73
- display unit
- 74
- output unit