INTERACTIVE CONTROL SYSTEM FOR AN HVAC SYSTEM

• US 20080048045A1
• Filed: 10/30/2007
• Published: 02/28/2008
• Est. Priority Date: 02/23/2005
• Status: Active Grant

• Current Assignee: Copeland Comfort Control LP (Emerson Electric Company)
• Original Assignee: Emerson Electric Company
• Inventors: Butler, William, Carey, Steven, Jayanth, Nagaraj, Pham, Hung
• Granted Patent: US 7,784,291 B2
• Time in Patent Office: Days
• US Class Current: 236/74R
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/42 of outdoor units
• CPC Class Codes: F24F 11/52 Indication arrangements, e.g. displays
• CPC Class Codes: F24F 11/54 using one central controller connected to several sub-controllers
• CPC Class Codes: F24F 11/58 using Internet communication
• CPC Class Codes: F24F 11/65 for selecting an operating mode
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 11/86 by controlling compressors within refrigeration or heat pump circuits
• CPC Class Codes: F24F 11/871 by controlling outdoor fans
• CPC Class Codes: F24F 2140/00 Control inputs relating to system states
• CPC Class Codes: F25B 2600/025 by controlling speed
• CPC Class Codes: F25B 2600/111 of condenser fans
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/2104 of an indoor room or compartment
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

An interactive system for controlling the operation of an HVAC system is provide that comprises a thermostat for initiating the operation of the HVAC system in either a full capacity mode of operation or at least one reduced capacity mode of operation, and a controller for an outside condenser unit having a condenser fan motor and a compressor motor, the controller being capable of operating the compressor in a full capacity mode and at least one reduced capacity mode. The system also comprises a controller for an indoor blower unit having a blower fan motor, the controller being capable of operating the blower fan motor in a full capacity mode an at least one reduced capacity mode. The system further includes a communication means for transmitting information between the outside condenser unit controller and at least the indoor blower controller, where the information relates to the operation of the indoor blower and the outdoor condenser unit. The indoor blower controller responsively controls the operation of the blower fan motor in a full capacity mode or a reduced capacity mode based on the information received from the outdoor unit controller, and the outdoor unit controller responsively controls the operation of the compressor in a full capacity mode or a reduced capacity mode based on the information received from the indoor blower controller.

Claims

1. An interactive system for controlling the operation of a cooling system having at least a thermostat, a controller for an indoor blower, and a controller for an outdoor condenser unit, the interactive system comprising:

an indoor blower including a blower motor, a line voltage sensor, and a motor current sensor;

a controller for the indoor blower motor, the blower motor controller being configured to monitor the sensed line voltage and blower motor current and establish baseline values for the line voltage and current of the indoor blower motor;

an outdoor condenser unit including a compressor, a compressor motor current sensor, and a compressor discharge pressure sensor;

a controller for the outdoor condenser unit, the outdoor condenser unit controller being configured to monitor the sensed compressor motor current and compressor discharge pressure and establish baseline values for the compressor motor current and compressor discharge pressure; and

a local network for enabling communication between the controller for the indoor blower motor, the controller for the outdoor condenser unit, and a thermostat.

2. The interactive system of claim 1 wherein controller for the indoor blower motor is configured to store the baseline values for the line voltage and current of the indoor blower motor in a memory included in the indoor blower controller.

3. The interactive system of claim 2 wherein controller for the indoor blower motor is configured to transmit the stored values for the baseline values for the line voltage and current of the indoor blower motor to the thermostat upon request.

4. The interactive system of claim 3 wherein the controller for the indoor blower motor is configured to determine from the sensed parameters whether a reduction in blower operation indicative of a dirty or clogged air filter condition has occurred, and to responsively communicate a signal via the network to the thermostat indicating the reduction in blower operation indicative of a dirty filter.

5. The interactive system of claim 1 wherein controller for the outdoor condenser unit is configured to store the baseline values for the compressor motor current and compressor discharge pressure in a memory included in the outdoor condenser unit.

6. The interactive system of claim 5 wherein controller for the indoor blower motor is configured to transmit the stored values for the baseline values for the line voltage and current of the indoor blower motor to the thermostat upon request.

7. The interactive system of claim 6 wherein the controller for the outdoor condenser unit is configured to determine from the sensed parameters whether a variation in the relationship between discharge pressure and compressor motor current is indicative of a degradation of compressor performance, and to responsively communicate a signal via the network to the thermostat indicating the degradation of compressor performance.

8. The interactive system of claim 1 wherein the thermostat is configured to include a learning mode for initiating operation periods of the compressor and blower during the day and night, to thereby speed the process of obtaining baseline parameter information for the compressor motor and blower motor.

9. The interactive system of claim 1 wherein the thermostat is capable of receiving signals through the network from a remote location, requesting the thermostat to transmit specific parameter information, where in response to receiving said request signals the thermostat is configured to prompt the outdoor condenser unit controller, the indoor blower controller, or both, to transmit stored baseline values for the specific parameters.

10. The interactive system of claim 9, wherein the remote location is that of an outside monitoring service provider in communication with the network.

11. The interactive system of claim 1, wherein the thermostat is configured to monitor at least one temperature sensor within the space being conditioned by the cooling system, the thermostat being configured to determine from the sensed temperature the rate of temperature change within the space for establishing a baseline rate of temperature change, and to thereafter determine when a subsequent rate of temperature change has decreased below the baseline rate of temperature change by a predetermined level that is indicative of a possible low refrigerant charge condition.

12. An interactive system for controlling the operation of an air conditioning system, the interactive system comprising:

a blower motor for operating an indoor blower associated with an air conditioning system;

a compressor motor for operating a compressor of an outdoor condenser unit associated with an air conditioning system;

a thermostat configured to send a first signal requesting operation of the indoor blower and to send a second signal requesting operation of the outdoor compressor to an indoor blower controller and an outdoor unit controller, respectively;

an indoor blower controller that receives the first thermostat signal requesting operation of the indoor blower and responsively establishes operation of the blower motor, the indoor blower controller being configured to detect a malfunction of the blower motor, where upon detection of a malfunction of the blower motor the indoor blower controller communicates a signal indicating the blower motor malfunction to an outdoor unit controller;

an outdoor unit controller that receives the second thermostat signal requesting operation of the outdoor compressor and responsively establishes operation of the compressor motor, wherein when the outdoor unit controller simultaneously receives a thermostat signal requesting operation of the outdoor compressor and a signal from the indoor blower controller indicating a blower motor malfunction, the outdoor unit controller responsively discontinues operation of the compressor motor, regardless of whether the thermostat signal is requesting operation of the outdoor compressor.

13. The interactive system of claim 12, wherein the first thermostat signal and the second thermostat signal are 24 volt signals.

14. The interactive system of claim 13 where the outdoor unit controller discontinues operation of the compressor motor until the signal from the indoor blower controller indicating a blower motor malfunction is discontinued.

15. The interactive system of claim 14 wherein the blower motor malfunction is an over-temperature condition of either the blower motor, or an inverter driver circuit of the blower motor.

16. An interactive system for controlling the operation of an air conditioning system, the interactive system comprising:

a blower motor for operating an indoor blower associated with an air conditioning system;

a compressor motor for operating a compressor of an outdoor condenser unit associated with an air conditioning system;

a thermostat configured to send a first signal requesting operation of the indoor blower and to send a second signal requesting operation of the outdoor compressor to an indoor blower controller and an outdoor unit controller, respectively;

an outdoor unit controller that receives the second thermostat signal requesting operation of the outdoor compressor and responsively establishes operation of the compressor motor, the outdoor unit controller being configured to detect a compressor motor failure, where upon detection of a compressor motor failure the outdoor unit controller communicates a signal indicating the compressor motor failure to an indoor blower controller;

an indoor blower controller that receives the first thermostat signal requesting operation of the indoor blower and responsively establishes operation of the blower motor, wherein when the indoor blower controller simultaneously receives a thermostat signal requesting operation of the indoor blower and a signal from the outdoor unit controller indicating a compressor motor failure, the indoor blower controller responsively discontinues operation of the blower motor, regardless of whether the thermostat signal is requesting operation of the indoor blower.

17. The interactive system of claim 16, wherein the first thermostat signal and the second thermostat signal are 24 volt signals.

18. The interactive system of claim 17 where the outdoor unit controller discontinues operation of the compressor motor until the signal from the indoor blower controller indicating a blower motor malfunction is discontinued.

19. The interactive system of claim 17 wherein the compressor motor failure is caused by an open motor winding circuit.

20. The interactive system of claim 17 wherein the compressor motor failure is caused by a locked-rotor current condition.