Air filter monitor for HVAC units

• US 6,448,896 B1
• Filed: 08/24/2001
• Issued: 09/10/2002
• Est. Priority Date: 08/24/2001
• Status: Expired due to Term

• Current Assignee: Carrier Corporation (Carrier Global Corporation)
• Original Assignee: Carrier Corporation (Carrier Global Corporation)
• Inventors: DeWolf, Thomas L., Inman, Brian D., Bankus, Roger S., Dolan, Robert P.
• Primary Examiner(s): TRIEU, VAN THANH
• Application Number:
  US09/935,946
• Time in Patent Office: 382 Days
• Field of Search: 340/577, 340/580, 340/584, 340/606, 340/607, 340/609, 340/610, 340/611, 236/49.3, 236/DIG.9, 622/04, 622/24, 622/283, 318/812, 318/814
• US Class Current: 340/607
• CPC Class Codes: B01D 2273/30 Means for generating a circulation of a fluid in a filtration system, e.g. using a pump or a fan
• CPC Class Codes: B01D 46/0086 Filter condition indicators
• CPC Class Codes: B01D 46/44 controlling filtration
• 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 11/39 Monitoring filter performance
• CPC Class Codes: F24F 11/49 ensuring correct operation, e.g. by trial operation or configuration checks
• CPC Class Codes: F24F 11/52 Indication arrangements, e.g. displays
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 13/28 Arrangement or mounting of filters
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

An electronic system for monitoring the condition of the filter in an HVAC unit includes a controller which issues at least one command to a circuit for the motor of the fan producing airflow through the filter. The command to the driver circuit is associated with a desired run speed for the fan. The controller is operative to compute the speed of the fan following issuance of the command to the motor drive circuit. This computed speed is compared to a predetermined fan speed that would normally occur when the filter is dirty. The electronic system is operative to generate a warning in the event that the computed fan speed does not compare favorably with the predetermined fan speed.

Claims

1. A unit for conditioning air having an air filter located in an air flow path and a fan for causing air to flow through the filter;

wherein said unit includes a system for detecting whether the air filter needs to be replaced based upon a reading of the speed of the fan, said system comprising;

a sensor for detecting movement of the fan;

a device for entering an indication of desired speed for the fan;

a motor control connected to the motor for the fan; and

a processor operative to note the entered indication of desired speed for the fan and to thereafter select a command for the motor control based upon the entered indication of desired speed so as to cause the motor to rotate the fan at the desired speed when the air filter located in the air flow path is clean, said processor being responsive to the output of said sensor for computing the speed of the fan, said processor being furthemore operative to compare the computed speed with a predetermined speed of the fan associated with the entered indication of desired speed for the fan, the predetermined speed being indicative of a dirty filter located in the air flow path when the motor control is commanded to rotate the fan at the desired speed, said processor being furthermore operative to generate a signal indicating when a dirty filter has been detected as a result of comparing the computed speed with the predetermined speed.

2. The unit for conditioning air of claim 1 wherein said system for detecting whether the filter needs to be replaced further comprises:

a display for receiving the output signal from said processor so as to display an indication that the filter needs to be replaced.

3. The unit for conditioning air of claim 1 wherein the predetermined speed of the fan indicative of a dirty filter is selected by said processor based upon an association with the entered indication of speed for the fan.

4. The unit for conditioning air of claim 3 wherein the predetermined speed of the fan indicative of a dirty filter is selected from a table of stored predetermined speeds indicative of a dirty filter for associated entries of entered indications of speed for the fan.

5. The unit for conditioning air of claim 1 wherein the predetermined speed of the fan indicative of a dirty filter is a predetermined amount above the speed of the fan that would occur if a clean filter were installed in the unit.

6. The unit for conditioning air of claim 1 wherein said processor is operative to detect when a new filter is installed in the unit, said processor being thereafter operative to issue at least one command that causes the fan to be rotated at the desired speed associated with the entered indication of desired speed for the fan, said processor being furthermore operative to compute the speed of the fan from detected rotations of the fan provided by said sensor, said processor being thereafter operative to compute a speed indicative of a dirty filter using the computed speed based upon detected rotations of the fan provided by said sensor.

7. The unit for conditioning air of claim 6 wherein the computation of speed indicative of a dirty filter comprises adding a predetermined speed differential to the speed computed by detecting rotations of the fan.

8. A process for detecting whether a filter needs to be replaced within an air conditioning unit wherein air is caused to flow through a filter by a rotating fan said process comprising the steps of:

noting that an indication as to a preferred fan speed has been selected;

generating a command to a control for a motor which rotates the fan in response to the noted indication as to a preferred fan speed having been selected; and

selecting a predetermined fan speed of the fan indicating when the filter needs to be replaced based upon the noted indication as to a preferred fan speed;

detecting the speed of the rotating fan;

comparing the detected speed of the fan with the selected predetermined speed of the fan indicating when the filer needs to be replaced; and

generating an indication that the filter needs to be replaced when the detected speed does not favorably compare with the selected predetermined speed of the fan indicating the filter needs to be replaced.

9. The process of claim 8 wherein the selected predetermined speed of the fan is a predetermined amount greater than the speed of the fan produced by the motor rotating the fan in response to the noted indication as to preferred fan speed when a clean filter has been installed in the air conditioning unit.

10. The process of claim 8 wherein said step of comparing the detected speed of the fan with the selected predetermined speed of the fan occurring when the fan needs to be replaced comprises the step of:

deciding whether the detected speed is greater than the selected predetermined speed of the fan occurring when the filter needs to be replaced.

11. The process of claim 8 wherein said step of selecting a predetermined fan speed of the fan indicating when the filter needs to be replaced comprises the step of:

accessing a table of predetermined fan speeds associated with indication as to preferred fan speeds; and

selecting the predetermined fan speed associated with the indication as to a preferred fan speed that has been selected.

12. The process of claim 8 further comprising the steps of:

noting when a filter has been replaced;

issuing at least one command to a motor control for a motor which rotates the fan;

detecting the speed of the rotating fan;

computing a fan speed indicating when the filter needs to be replaced using the detected speed of the fan resulting from issuing at least one command to the motor control; and

storing the computed fan speed indicating when the filter needs to be replaced for use as the predetermined fan speed in said step of comparing detected speed of the fan with a predetermined speed.

13. The process of claim 8 further comprising the steps of:

noting when a filter has been replaced;

issuing a plurality of commands to a motor control for a motor which rotates the fan;

detecting the speed at which the fan rotates for each issued command to the motor control;

computing speeds of the fan indicating when the filter needs to be replaced for each level of fan speed which may be selected; and

storing the computed speed of the fan indicating when the filter needs to be replaced in association with a corresponding level of fan speed which may be selected.