Heater interlock control for air conditioning system

• US 9,228,757 B2
• Filed: 04/11/2014
• Issued: 01/05/2016
• Est. Priority Date: 03/27/2007
• Status: Active Grant

• Current Assignee: Trane International Inc. (Trane Technologies plc)
• Original Assignee: Trane International Inc. (Trane Technologies plc)
• Inventors: Helt, Robert Wayne
• Primary Examiner(s): Tompkins, Alissa
• Assistant Examiner(s): DECKER, PHILLIP
• Application Number:
  US14/251,223
• Publication Number:
  US 20140219642A1
• Time in Patent Office: 634 Days
• US Class Current: 1/1
• CPC Class Codes: F24D 19/1087 system using a heat pump
• CPC Class Codes: F24H 3/002 using electric energy supply

Abstract

A method is provided for controlling operation of electrical heating elements in a heating, ventilating, and air conditioning (HVAC) system in accordance with fan operating conditions, the method comprising the steps of: monitoring speeds at which a fan motor is operating; communicating status signals indicative of fan motor operating speeds; and upon receiving a status signal indicating the fan motor is operating at a speed exceeding a predetermined maximum speed, communicating a control signal instructing a heater interlock to interrupt power supplied to at least one electrical heating element.

Claims

1. A method for operating an air conditioning apparatus, said apparatus including a cabinet, an air blower including an electric blower motor for propelling air from an air inlet to an air outlet of said cabinet, and at least one electric heating element disposed in an air flowstream propelled by said blower through said cabinet, said apparatus further comprising a first temperature sensor for sensing the temperature of an enclosed space being supplied with conditioned air by said apparatus and a control system including a system controller operably connected to said first temperature sensor and to a second temperature sensor for sensing the temperature of air being discharged from said apparatus, said control system further including a heater interlock operable to prevent energization of said heating element and at least one heater relay in communication with said heater interlock, said method including the steps of:

receiving by the system controller a status signal indicating the electric blower motor is operatively running above or below a maximum or a minimum speed, respectively;

communicating by the system controller a shutoff signal instructing the heater interlock to prevent electrical power from being supplied to the at least one electrical heating element in response to the system controller receiving the status signal indicating the electric blower motor is operatively running above or below the maximum or the minimum speed, respectively;

receiving by the system controller a status signal indicating at least one of (1) the air discharge temperature measured by the second temperature sensor exceeds a predetermined value and (2) a rate of change in the air discharge temperature measured by the second temperature sensor exceeds a predetermined value; and

communicating by the system controller a shutoff signal instructing one of the heater interlock and the at least one heater relay to prevent electrical power from being supplied to the at least one electrical heating element in response to the system controller receiving the status signal indicating at least one of (1) the air discharge temperature exceeds the predetermined value and (2) the rate of change in the air discharge temperature exceeds the predetermined value.

2. The method set forth in claim 1 including the step of:

causing said heater interlock to prevent energization of said heating element if said blower motor is not rotating.

3. The method set forth in claim 1 including the step of:

monitoring a status of said heater relay and causing said heater interlock to prevent energization of said electrical heating element if the status of said relay is not one commanded by said system controller.

4. The method set forth in claim 1 including the step of:

causing said heater interlock to prevent energization of said heating element if said blower motor is not rotating in a direction commanded by said system controller.

5. The method set forth in claim 1 including the step of:

causing said heater interlock to prevent energization of said heating element if said blower motor is not producing a torque commanded by said system controller.

6. The method set forth in claim 1 including the step of:

causing said heater interlock to prevent energization of said heating element if a motor control relay is not in a condition commanded by said system controller.

7. The method set forth in claim 1 including the step of:

continuously monitoring the operating speed of the motor.

8. The method set forth in claim 7 including the step of:

receiving a status signal indicative of an airflow blockage through the cabinet; and

communicating by the system controller a shutoff signal instructing the heater interlock to prevent electrical power from being supplied to at least one electrical heating element selected from the plurality of electrical heating elements.

9. The method set forth in claim 1 including the step of:

detecting a controller malfunction and de-energizing the motor; and

automatically preventing by the heater interlock electrical power from being supplied to the at least one electrical heating element.

10. The method set forth in claim 1 including the step of:

receiving by the system controller a signal for a combined mode of operation; and

communicating by the system controller at least one control signal for effectuating the combined mode of operation, wherein the combined mode of operation includes continuous operation of the motor, energization of the at least one electrical heating element, and operation of the heat exchanger to reject heat.

11. The method set forth in claim 1 including the step of:

receiving by the system controller a fault signal indicating said heater interlock is operating in a faulty condition; and

communicating by the system controller a command signal instructing said motor controller to operate said electric blower motor at a predetermined maximum speed.

12. A method for controlling operation of electrical heating elements in a heating, ventilating, and air conditioning (HVAC) system in accordance with fan operating conditions, the method comprising the steps of:

providing an HVAC system comprising an air conditioning apparatus including a cabinet, a fan including a motor for propelling air from an air inlet in the cabinet to an air outlet, a heat exchanger disposed within the cabinet between the air inlet and the fan, a plurality of electrical heating elements disposed in an airflow propelled by the fan through the cabinet, a thermostat for sensing temperature of an enclosed space being supplied with air conditioned by the HVAC system, a heater interlock operatively connected to the plurality of electrical heating elements and operable to control electrical power supplied thereto, one or more relays in communication with the plurality of electrical heating elements and the heater interlock, and a system controller operable to communicate signals for controlling operation of the HVAC system, wherein the signals being based on status signals indicative of operating conditions associated with one or more components of the HVAC system;

receiving by the system controller a status signal indicating the motor is operatively running above or below a maximum or a minimum speed, respectively;

communicating by the system controller a shutoff signal instructing the heater interlock to prevent electrical power from being supplied to at least one electrical heating element selected from the plurality of electrical heating elements in response to the system controller receiving the status signal indicating the electric blower motor is operatively running above or below the maximum or the minimum speed, respectively;

receiving a status signal indicating one of the one or more relay contacts is improperly open or closed; and

communicating by the system controller a command signal to operate the motor at a maximum heat speed in response to receiving the status signal indicating one of the one or more relay contacts is improperly open or closed.

13. The method set forth in claim 12 including the step of:

causing said heater interlock to prevent energization of said heating element if said blower motor is not rotating.

14. The method set forth in claim 12 including the step of:

continuously monitoring the operating speed of the motor.

15. The method set forth in claim 14 including the step of:

receiving a status signal indicative of an airflow blockage through the cabinet; and

communicating by the system controller a shutoff signal instructing the heater interlock to prevent electrical power from being supplied to at least one electrical heating element selected from the plurality of electrical heating elements.

16. The method set forth in claim 12 including the step of:

receiving by the system controller a fault signal indicating said heater interlock is operating in a faulty condition; and

communicating by the system controller a command signal instructing said motor controller to operate said electric blower motor at a predetermined maximum speed.

17. The method set forth in claim 12 including the step of:

causing said heater interlock to prevent energization of said heating element if said blower motor is not rotating in a direction commanded by said system controller.

18. The method set forth in claim 12 including the step of:

causing said heater interlock to prevent energization of said heating element if a motor control relay is not in a condition commanded by said system controller.