Interactive control system for an HVAC system

• US 7,748,225 B2
• Filed: 11/16/2007
• Issued: 07/06/2010
• 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 P., Carey, Steven L., Jayanth, Nagaraj, Pham, Hung
• Primary Examiner(s): Norman; Marc E
• Application Number:
  US11/941,673
• Publication Number:
  US 20080066479A1
• Time in Patent Office: 963 Days
• Field of Search: 622/281, 622/285, 622/30, 621/81, 621/83, 621/49, 700/276, 236/51
• US Class Current: 62/181
• 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. A controller for an outside condenser unit of an air conditioner including a compressor configured to operate in a full capacity mode and at least one reduced capacity mode, the controller comprising:

an input connection connected to a Y2 line and configured to receive a signal requesting high capacity cooling operation from a thermostat via the Y2 line connected to the input connection;

a peer-to-peer network connection configured to receive information from at least an indoor blower controller and send information to at least an indoor blower controller;

a processor for controlling the operation of a condenser fan and a compressor in a full capacity mode of operation and in at least one reduced capacity mode of operation, wherein the processor is configured to control the operation of the condenser fan and the compressor in a full capacity mode of operation in response to a signal requesting low stage cooling operation from a thermostat via a Y2 line; and

a sensor for sensing the current in the compressor motor, which sensor is in communication with the processor;

wherein the processor responsively switches the operation of the compressor to a reduced capacity mode of operation that is inconsistent with said thermostat signal requesting high capacity cooling operation when the current sensed in the compressor motor remains above a predetermined level for at least a predetermined time, and responsively communicates a high capacity fault via the network such that the indoor blower controller responsively controls the blower motor at a reduced speed corresponding to the reduced capacity of the compressor, whereby the controller for the outside condenser unit provides a limp-along mode of cooling operation.

2. The controller of claim 1, wherein the processor is configured to switch the operation of the compressor to a reduced capacity mode of operation by actuating a solenoid to operate the compressor at a reduced capacity.

3. The controller of claim 1 further comprising a sensor for sensing the compressor discharge temperature wherein the processor responsively switches the operation of the compressor to a reduced capacity mode of operation when the discharge temperature exceeds a predetermined temperature value.

4. A controller for an outside condenser unit of an air conditioner including a compressor configured to operate in a full capacity mode and at least one reduced capacity mode, the controller comprising:

an input connection to a Y2 line configured to receive a signal requesting high capacity cooling operation from a thermostat via the Y2 line in connection with the input connection;

a network connection to a two-wire peer-to-peer network in connection with an indoor blower controller, such that the controller for the outside condenser unit is configured to receive information from and send information to an indoor blower controller;

a processor for controlling the operation of a condenser fan and a compressor in a full capacity mode of operation in response to a signal requesting high capacity cooling operation from a thermostat via a Y2 line, wherein the processor is configured to respond, to information received via the network connection indicating that the indoor blower motor is at a reduced blower speed, by switching the operation of the compressor to a reduced capacity mode of operation that is inconsistent with the signal requesting high capacity cooling operation from the thermostat via the Y2 line, whereby the controller for the outside condenser unit provides a limp-along mode of cooling operation.

5. The controller of claim 4, wherein the processor is configured to switch the operation of the compressor to a reduced capacity mode of operation by actuating a solenoid to operate the compressor at a reduced capacity.

6. A controller for an outside condenser unit of an air conditioner capable of operating in a full capacity mode and at least one reduced capacity mode, the controller comprising:

an input connection connected to a Y1 line and configured to receive a signal requesting low stage cooling operation from a thermostat via the Y1 line connected to the input connection;

a network connection to a two-wire peer-to-peer network in connection with an indoor blower controller, such that the controller for the outside condenser unit is configured to receive information from at least an indoor blower controller and send information to at least an indoor blower controller;

a processor for controlling the operation of a condenser fan and a compressor in a full capacity mode of operation and in at least one reduced capacity mode of operation, wherein the processor is configured to control the operation of the condenser fan and the compressor in a full capacity mode of operation in response to a signal requesting low stage cooling operation from a thermostat via a Y1 line, wherein the processor is configured to sense that reduced capacity compressor operation is not functioning and to respond by switching the operation of the compressor to a full capacity mode of operation that is inconsistent with the signal requesting low stage cooling operation from the thermostat via the Y1 line, whereby the controller for the outside condenser unit provides a limp-along mode of cooling operation.

7. The controller of claim 6 further comprising an outside temperature sensor, wherein the controller for an outside condenser unit controls the speed of the condenser fan motor at a reduced speed based on the sensed ambient temperature.