Methods and systems for preventing premature compressor failure from improper operation

A method for detecting and correcting an improper operation of a compressor of a refrigerant circuit, the method comprising:

• starting the compressor by a compressor drive module;
• running the compressor for a predetermined period of time upon starting the compressor;
• obtaining a computed torque profile of the compressor, the computed torque profile tracking a torque on the compressor over the predetermined period of time;
• comparing the computed torque profile with a previously stored torque profile to determine whether the compressor is operating in an improper direction;
• correcting operation of the compressor when it is determined that the compressor is operating in the improper direction, wherein correcting operation of the compressor includes:
• stopping the compressor by the compressor drive module,
• reversing an operation direction of the compressor by the compressor drive module, and
• re-staring the compressor in the reversed operation direction;
• and
• operating the compressor when it is determined that the compressor is operating properly.

A system for detecting and correcting an improper operation of a compressor, the system comprising:

• the compressor that compresses refrigerant directed through a refrigerant circuit;
• a compressor drive module that drives the compressor;
• a main controller that controls operation of the compressor drive module;
• and
• at least one sensor that is configured to sense at least one operational parameter of the system,
• wherein the compressor drive module is configured to start the compressor;
• upon starting the compressor, the main controller is configured to detect whether the compressor is operating in an improper direction by comparing a first measured sensor profile of a refrigerant circuit parameter and a previously stored start-up sensor profile,
• the first measured sensor profile tracking sensed values of the parameter over a first predetermined period of time;
• the compressor drive module is configured to stabilize the compressor after the main controller comparing the first measured sensor profile and the previously stored start-up sensor profile;
• after the compressor is stabilized, the main controller is configured to confirm whether the compressor is operating in the improper direction, the confirmation includes:
• the main controller is configured to conduct a torque profile comparison to determine whether the compressor is operating in the improper direction, and
• when the main controller determines that the compressor is operating properly, the main controller is configured to conduct a sensor profile comparison to determine a sensor mismatch;
• the main controller is configured to correct operation of the compressor, via the compressor drive module, when it is confirmed that the compressor is operating in the improper direction;
• and
• the main controller is configured to operate the compressor, via the compressor drive module, when it is detected that the compressor is operating properly.