Patent Application
20250109879
This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
Heating, ventilation, and air conditioning (HVAC) systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature, humidity, and/or air quality, for occupants of the respective environments. HVAC systems may regulate environmental properties of environments via delivery of a conditioned air flow to the environment. For example, the HVAC system may generally include a fan or blower that is operable to direct an air flow across one or more heat exchange components of the HVAC system. As such, the blower may facilitate transfer of thermal energy between the heat exchange components and the air flow to generate the conditioned air flow for delivery to a suitable space within a building or other structure serviced by the HVAC system. The fan or blower may also drive flow of the conditioned air flow out of an HVAC unit and toward the space.
The fan or blower may be driven by a motor. Different types of motors are available for use with blowers of HVAC systems. Unfortunately, implementation of a particular type of motor typically involves utilization of a particular configuration and/or particular components of the HVAC system. Indeed, certain motors may be incompatible with certain HVAC system configurations and/or certain components. For example, an HVAC system may lack control components with which certain types of motors are configured to operate. In such cases, selecting an appropriate motor for an HVAC system application may be challenging and costly. Moreover, some HVAC systems may include control components configured for use with one type of motor, but the HVAC system may include another type of motor that does operate utilizing the control components. In some instances, HVAC systems may include a motor and control components that provide limited or restricted operation of the HVAC system.
A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.
The present disclosure relates to a control system of a blower of a heating, ventilation, and air conditioning (HVAC) system including a blower motor connector having a plurality of ports, where each port of the plurality of ports is configured to receive a respective control signal, and a blower motor controller electrically coupled to each port of the plurality of ports. The blower motor controller is configured to operate the blower at a plurality of air flow rates, and each air flow rate of the plurality of air flow rates corresponds to one of the respective control signals. The control system also includes a thermostat configured to concurrently transmit a first input signal and a second input signal indicative of a call for conditioning. The control system is configured to block transmission of the first input signal to a first port of the plurality of ports and configured to transmit the second input signal to a second port of the plurality of ports.
The present disclosure also relates to a heating, ventilation, and air conditioning (HVAC) system including a thermostat configured to transmit a fan input signal, a first stage cooling input signal, and a second stage cooling input signal, a blower configured to force a conditioned air flow through the HVAC system, and a blower motor configured to drive rotation of the blower, where the blower motor includes a blower motor controller and a motor connector, and the motor connector includes a first speed tap and a second speed tap. The blower motor controller is configured to operate the blower motor at a first speed in response to receipt of the first stage cooling input signal via the first speed tap and nonreceipt of the second stage cooling input signal via the second speed tap, operate the blower motor at a second speed, greater than the first speed, in response to receipt of the second stage cooling input signal via the second speed tap and nonreceipt of the first stage cooling input signal via the first speed tap, and operate the blower motor at a third speed, greater than the second speed, in response to concurrent receipt of the first stage cooling input signal via the first speed tap and the second stage cooling input signal via the second speed tap. The HVAC system further includes a compressor controller configured to control operation of a compressor of the HVAC system, where the compressor controller is configured to concurrently receive the first stage cooling input signal and the second stage cooling input signal transmitted via the thermostat, and the compressor controller is configured to selectively block transmission of the first stage cooling input signal to the first speed tap based on an operating stage of the compressor.
The present disclosure further relates to a heating, ventilation, and air conditioning (HVAC) system including an indoor unit having a blower and a blower motor, where the blower is configured to force a conditioned air flow through the indoor unit, the blower motor includes a motor controller and a motor connector, the motor connector includes a first port configured to receive a first signal and a second port configured to receive a second signal, the motor controller is configured to operate the blower motor at a first speed in response to receipt of the first signal and nonreceipt of the second signal and operate the blower motor at a second speed, greater than the first speed, in response to concurrent receipt of the first signal and the second signal. The HVAC system also includes a relay configured to concurrently receive the first signal and an additional signal via a thermostat, where the relay is configured to block transmission of the additional signal in response to receipt of the first signal and enable transmission of the first signal to the first port. The HVAC system further includes an outdoor unit having a compressor and an outdoor unit controller, where the outdoor unit controller is configured to control operation of the compressor, the outdoor unit controller is configured to concurrently receive the first signal and the second signal via the thermostat, and the outdoor unit controller is configured to transmit the first signal to the first port and transmit the second signal to the second port.
Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:
One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
As used herein, the terms “approximately,” “generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,” “slope,” “perpendicular,” “parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.
As briefly discussed above, a heating, ventilation, and air conditioning (HVAC) system may be used to thermally regulate a space within a building, home, or other suitable structure. For example, the HVAC system may include a vapor compression system that operates to transfer thermal energy between a working fluid, such as a refrigerant, and a fluid to be conditioned, such as air. The vapor compression system includes heat exchangers, such as a condenser and an evaporator, which are fluidly coupled to one another via one or more conduits of a working fluid loop or circuit. A compressor may be used to circulate the working fluid (e.g., refrigerant) through the conduits and other components of the working fluid circuit (e.g., the heat exchangers, an expansion device) and thereby enable the transfer of thermal energy between components of the working fluid circuit (e.g., between the condenser and the evaporator) and one or more thermal loads (e.g., an environmental air flow, a supply air flow).
In some applications, an HVAC system may be configured to operate based on a call for conditioning (e.g., call for cooling, call for heating) associated with a conditioned space. For example, the HVAC system may be configured to initiate operation to condition and provide a conditioned air flow to the conditioned space based on a deviation between a measured temperature of the conditioned space and a set point (e.g., desired) temperature of the conditioned space. Some HVAC systems may include a control system having a thermostat configured to receive a user input indicative of the set point temperature, and the thermostat may compare the set point temperature to the measured temperature of the conditioned space and/or other measured temperature indicative of the temperature of the conditioned space. For example, the measured temperature may be received from a sensor, such as a room temperature sensor or a return air sensor.
Based on a determination that the measured temperature deviates from the set point temperature, the control system (e.g., thermostat, control board) may output a signal (e.g., an electrical signal, an input signal) to initiate operation of the HVAC system. In some embodiments, the signal may be transmitted to one or more components of the HVAC system to initiate operation of the one or more components to enable generation and supply of a conditioned air flow to the conditioned space. For example, the signal may be transmitted toward a motor (e.g., blower motor) of a blower configured to direct an air flow across a heat exchanger (e.g., condenser, evaporator) of the vapor compression system. The motor may include a motor connector (e.g., tap connector, electrical connector, wire connector, harness connector) having ports (e.g., taps, input/output [I/O] ports) configured to receive and/or transmit electrical signals via wires connected to the motor connector. For example, a thermostat and/or a control board of the control system may transmit signals to the motor via the wires connected to the motor connector.
Unfortunately, existing thermostats and motor connectors provide limited operational settings for motors and/or blowers of HVAC systems. For example, many traditional thermostats may be configured to output a limited number and/or a limited type of signals, and traditional motor connectors may be configured to operate the blower at a limited number of operational settings (e.g., blower speeds) based on the signals output by traditional thermostats. As a result, efficient operation of HVAC systems utilizing existing thermostats and motor connectors may be restricted. Some HVAC systems may include a multi-stage (e.g., two-stage, three-stage) compressor but may nevertheless include a traditional thermostat and/or a traditional motor connector that curtails efficiency of the HVAC system having the multi-stage compressor.
Accordingly, embodiments of the present disclosure include a control system configured to enable more adaptable operation of a blower of an HVAC system that includes a traditional thermostat configured to output a limited number and/or type of signals (e.g., calls for conditioning, input signals, control signals). In other words, even though the thermostat may be configured to transmit a limited number and/or types of signals, the control system is nevertheless configured to enable operation of the blower at a greater number of speeds than traditional systems. As a result, HVAC systems incorporating the present techniques may include a multi-stage and/or variable speed compressor (e.g., variable speed outdoor unit, variable speed condenser unit) and a blower of the HVAC system may be operated at a speed that is more closely aligned or tailored to a particular stage or speed of the compressor. Present embodiments therefore provide enhanced compatibility of traditional components (e.g., traditional, non-communicating thermostats) and more advanced components (e.g., multi-stage compressors), as well as improved efficiency of the HVAC system.
Turning now to the drawings,
In the illustrated embodiment, a building 10 is air conditioned by a system that includes an HVAC unit 12 with a reheat system in accordance with present embodiments. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit containing other equipment, such as a blower, integrated air handler, and/or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, such as the system shown in
The HVAC unit 12 is an air-cooled device that implements a vapor compression cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and/or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building with one vapor compression circuit configured to operate in different modes. In other embodiments, the HVAC unit 12 may include one or more vapor compression circuits for cooling an air stream and a furnace for heating the air stream.
A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and/or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.
As shown in the illustrated embodiment of
The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more vapor compression circuits. Tubes within the heat exchangers 28 and 30 may circulate a working fluid, such as R-410A, through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the working fluid undergoes phase changes and/or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and/or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the working fluid to ambient air, and the heat exchanger 30 may function as an evaporator where the working fluid absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may function as an evaporator and the heat exchanger 30 may function as a condenser. In further embodiments, the HVAC unit 12 may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of
The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and/or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the HVAC unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.
The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the working fluid before the working fluid enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and/or cooling. As may be appreciated, additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other things.
The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms. One or more of these components may be referred to herein separately or collectively as the control device 16. The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.
When the system shown in
The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat, or the set point plus a small amount, the residential heating and cooling system 50 may become operative to cool additional air for circulation through the residence 52. When the temperature reaches the set point, or the set point minus a small amount, the residential heating and cooling system 50 may stop the vapor compression cycle temporarily.
The residential heating and cooling system 50 may also operate as a heat pump. When operating as a heat pump, the roles of heat exchangers 60 and 62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58 will serve as an evaporator to evaporate working fluid and thereby cool air entering the outdoor unit 58 as the air passes over the outdoor heat exchanger 60. The indoor heat exchanger 62 will receive a stream of air blown over it and will heat the air by condensing the working fluid.
In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace 70 where it is mixed with air and combusted to form combustion products. The combustion products may pass through tubes or piping in a heat exchanger, separate from heat exchanger 62, such that air directed by the blower 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.
In some embodiments, the vapor compression system 72 may use one or more of a variable speed drive (VSDs) 92, a motor 94, the compressor 74, the condenser 76, the expansion valve or device 78, and/or the evaporator 80. The motor 94 may drive the compressor 74 and may be powered by the variable speed drive (VSD) 92. The VSD 92 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 94. In other embodiments, the motor 94 may be powered directly from an AC or direct current (DC) power source. In such embodiments, the vapor compression system 72 may not include the VSD 92. The motor 94 may include any type of electric motor that can be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated motor, or another suitable motor.
The compressor 74 compresses a working fluid vapor and delivers the vapor to the condenser 76 through a discharge passage. In some embodiments, the compressor 74 may be a centrifugal compressor. The working fluid vapor delivered by the compressor 74 to the condenser 76 may transfer heat to a fluid passing across the condenser 76, such as ambient or environmental air 96. The working fluid vapor may condense to a working fluid liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid working fluid from the condenser 76 may flow through the expansion device 78 to the evaporator 80.
The liquid working fluid delivered to the evaporator 80 may absorb heat from another air stream, such as a supply air stream 98 provided to the building 10 or the residence 52. For example, the supply air stream 98 may include ambient or environmental air, return air from a building, or a combination of the two. The liquid working fluid in the evaporator 80 may undergo a phase change from the liquid working fluid to a working fluid vapor. In this manner, the evaporator 80 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the working fluid. Thereafter, the vapor working fluid exits the evaporator 80 and returns to the compressor 74 by a suction line to complete the cycle.
In some embodiments, the vapor compression system 72 may further include a reheat coil. In the illustrated embodiment, the reheat coil is represented as part of the evaporator 80. The reheat coil is positioned downstream of the evaporator heat exchanger relative to the supply air stream 98 and may reheat the supply air stream 98 when the supply air stream 98 is overcooled to remove humidity from the supply air stream 98 before the supply air stream 98 is directed to the building 10 or the residence 52.
It should be appreciated that any of the features described herein may be incorporated with the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications. Furthermore, although the discussion below describes the present techniques as incorporated with HVAC systems configurated as a split system (e.g., residential heating and cooling system 50), it should be appreciated that the present techniques may be similarly incorporated in other HVAC system configurations, such as packaged units, rooftop units, air handlers, and so forth. Indeed, any suitable HVAC system having a blower motor configured to drive operation of the blower may incorporate one or more of the features described herein.
As noted above, HVAC systems typically include a fan or blower configured to force or drive an air flow through the HVAC system. Unfortunately, conventional HVAC systems are susceptible to various drawbacks, such as inefficient operation, increased energy consumption, and so forth. Accordingly, embodiments of the present disclosure are directed toward a control system for a blower that is configured to enable more efficient operation of the blower, despite the HVAC system including certain conventional components, such as a conventional (e.g., non-communicating) thermostat. To this end, the present techniques enable enhanced compatibility of conventional components (e.g., conventional thermostats) and more advanced or complex components (e.g., multi-stage compressors).
With the foregoing in mind,
As similarly discussed above, the HVAC system 100 is configured to generate and supply a conditioned air flow 104 to a conditioned space. To this end, the HVAC system 100 includes an indoor heat exchanger 106 (e.g., first heat exchanger, evaporator 80), which may be disposed along a working fluid circuit (e.g., vapor compression system 72) of the HVAC system 100. The indoor heat exchanger 106 is configured to transfer thermal energy between the conditioned air flow 104 and a working fluid directed through the indoor heat exchanger 106. The HVAC system 100 also includes a blower 108 (e.g., fan) configured to force a flow of air (e.g., supply air, return air, ambient air, any combination thereof) across the indoor heat exchanger 106 to generate and supply the conditioned air flow 104. In some embodiments, the HVAC system 100 may include a heat pump having the indoor heat exchanger 106, and the indoor heat exchanger 106 may therefore be configured to cool the conditioned air flow 104 in a cooling mode and heat the conditioned air flow 104 in a heating mode. In other embodiments, the HVAC system 100 may be configured as an air conditioner having a furnace 110. In such embodiments, the indoor heat exchanger 106 may operate to cool the conditioned air flow 104 in a cooling mode, and the furnace 110 may operate to heat the conditioned air flow 104 in a heating mode. The HVAC system 100 also includes a blower motor 112 (e.g., three-phase motor, brushless direct current motor) configured to drive operation (e.g., rotation) of the blower 108. Additional details of the blower motor 112 are described further below.
The HVAC system 100 also includes an outdoor heat exchanger 114, which may be disposed along the working fluid circuit of the HVAC system 100. The outdoor heat exchanger 114 may be configured to transfer thermal energy between an ambient air flow 116 and working fluid directed through the outdoor heat exchanger 114. To this end, the HVAC system 100 includes a fan 118 configured to force the ambient air flow 116 across the outdoor heat exchanger 114 and a motor 120 configured to drive operation of the fan 118. The HVAC system 100 further includes a compressor 122 (e.g., compressor system) configured to drive flow of the working fluid along the working fluid circuit and through components disposed along the working fluid circuit. It should be appreciated that the HVAC system 100 may include multiple compressors 122, in some embodiments. The compressor 122 may also be a multi-stage (e.g., two-stage, three-stage) compressor and/or a variable speed compressor configured to operate at multiple speeds, stages, and/or operating capacities. In other embodiments, the compressor 122 may be a single-stage compressor. Operation of the motor 120 and/or the compressor 122 may be controlled via an outdoor unit controller 124 (e.g., main controller, control system, compressor controller). In other embodiments, the motor 120 and/or the compressor 122 may be controlled by separate controllers (e.g., control systems), another common controller, a main system controller, another suitable control system, or any combination thereof. In any case, the outdoor unit controller 124 may be a component of the control system 102 and is configured to enable operation of the blower 108 and/or blower motor 112, in accordance with the present techniques. Additional details and operations of the outdoor unit controller 124 are described further below.
While the present embodiment illustrates the indoor heat exchanger 106, the furnace 110, the blower 108, and the blower motor 112 as components of (e.g., disposed within) an indoor unit 126 (e.g., air handler, air handling unit) and illustrates the outdoor heat exchanger 114, the fan 118, the motor 120, and the compressor 122 as components of (e.g., disposed within) an outdoor unit 128 to provide an embodiment of the residential heating and cooling system 50, it should be appreciated that other embodiments of the HVAC system 100 incorporating the techniques disclosed herein may be arranged in other configurations. For example, the components described above may be packaged in a common unit or housing (e.g., a single packaged unit) or may be packaged in another suitable arrangement.
As mentioned above, the blower motor 112 is configured to drive operation (e.g., rotation) of the blower 108. In some embodiments, the blower motor 112 may be an electronically commutated motor (ECM) (e.g., constant air flow motor, constant torque motor, constant speed motor), and the blower motor 112 may be configured to control operation of the blower 108 at variable speeds. As will be appreciated, the blower motor 112 may include components, such as a rotor (e.g., permanent magnet rotor, shaft) and stator, configured to drive rotation of the blower 108. The blower motor 112 also includes a blower motor controller 130 (e.g., circuitry, printed circuit board, control system, blower controller) configured to regulate operation of the blower motor 112. To this end, the blower motor controller 130 includes processing circuitry 132, such as a microprocessor, which may execute software for controlling the blower motor 112. The processing circuitry 132 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and/or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processing circuitry 132 may include one or more reduced instruction set (RISC) processors.
The blower controller 130 also includes a memory device 134 (e.g., a memory) that may store information, such as executable instructions, control software, look up tables, configuration data, etc. The memory device 134 may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device 134 may store a variety of information and may be used for various purposes. For example, the memory device 134 may store processor-executable instructions including firmware or software for the processing circuitry 132 to execute, such as instructions for controlling components of the blower motor 112 (e.g., to adjust a speed, torque, and/or air flow rate value of the blower motor 112). In some embodiments, the memory device 134 is a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processing circuitry 132 to execute. The memory device 134 may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The memory device 134 may store data, instructions, and any other suitable data. For example, the memory device 134 may include a database configured to store one or more reference values, operating parameter values, and/or any other suitable data to enable operation of the blower motor 112 in accordance with the presently disclosed techniques.
In some embodiments, the memory device 134 may include data correlating air flow rate values, torque values, speed values, and/or other suitable values with associated signals and/or combinations of signals (e.g., control signals, input signals) that may be received by the blower motor 112 (e.g., blower motor controller 130). As discussed further below, the blower motor 112 (e.g., blower motor controller 130) may include a motor connector 136 (e.g., tap connector, connector, pin connector, blower motor connector) configured to receive one or more signals (e.g., control signals, input signals) from one or more components of the control system 102. The motor connector 136 may be a component of the blower motor controller 130, the blower motor 112, or both. The motor connector 136 may be configured to receive one or more control signals (e.g., input signals) from the outdoor unit controller 124, and the blower motor controller 130 may be configured to determine (e.g., based on data stored on the memory device 134) a particular speed at which to operate the blower motor 112 and/or a particular air flow rate to be provided by the blower 108 based on the one or more control signals and/or input signals received via the motor connector 136. The motor connector 136 may also be configured to receive one or more inputs (e.g., control signals, input signals, voltages, etc.) via other components of the control system 102, as described further below.
In accordance with the present techniques, the outdoor unit controller 124 also includes processing circuitry 138 and a memory device 140, which may be similar to the processing circuitry 132 and the memory device 134 described above. That is, the processing circuitry 138 and/or the memory device 140 may include any of the components and/or characteristics of the processing circuitry 132 and the memory device 134 described above. The memory device 140 may be a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processing circuitry 138 to execute to enable operation of the control system 102 and/or the HVAC system 100 in accordance with the present techniques.
The control system 102 further includes a thermostat 142 configured to output one or more input signals 144 (e.g., thermostat signals, 24 volt [V] signals, calls for conditioning) to control (e.g., initiate, suspend) operation of the HVAC system 100. The thermostat 142 may be disposed within a conditioned space serviced by the HVAC system 100. The thermostat 142 is configured to receive a user input indicative of a set point operating parameter value (e.g., a set point temperature, a desired temperature, a set point humidity level) for the conditioned space. The thermostat 142 may also be communicatively coupled to one or more sensors 162 configured to detect an operating parameter value (e.g., measured operating parameter value) indicative of an operating parameter (e.g., temperature, humidity level) within the conditioned space. In some embodiments, one or more of the sensors 162 may be positioned within the conditioned space and be configured to detect an operating parameter value (e.g., air temperature, humidity level) within the conditioned space. In other embodiments, one or more of the sensors 162 may be positioned within ductwork or within the HVAC system 100 and be configured to detect an operating parameter value of return air received by the HVAC system 100 (e.g., the indoor unit 126) from the conditioned space.
In operation, the thermostat 142 may compare the set point operating parameter value (e.g., received via user input) and the measured operating parameter value detected by one or more of the sensors 162. Based on a determination that the measured operating parameter value deviates from the set point operating parameter value (e.g., by a threshold percentage, by a threshold amount), the thermostat 142 may output (e.g., transmit) one or more of the input signals 144 (e.g., an electrical signal, a 24V signal, call for conditioning signal, call for cooling signal, call for heating signal, call for dehumidification signal) indicative of a call for conditioning. In some embodiments, the thermostat 142 may be a conventional (e.g., non-communicating) thermostat, and the thermostat 142 may be configured to transmit a fan input signal (e.g., blower only signal, blower input signal, G call, G signal), a first stage signal (e.g., first stage cooling signal, Y1 call, Y1 signal, low cooling stage input signal), a second stage signal (e.g., second stage cooling signal, Y2 call, Y2 signal, high cooling stage input signal), and a heating signal (e.g., W call, W signal, heating input signal) as the one or more input signals 144. In accordance with the present techniques, the one or more input signals 144 may be transmitted toward the outdoor unit controller 124, and the outdoor unit controller 124 may process one or more of the input signals 144 to enable operation of the blower motor 112 (e.g., the blower 108) in accordance with the present techniques.
The thermostat 142 may include processing circuitry 146 and a memory device 148, which may be similar to the processing circuitry 132, 138 and the memory device 134, 140 described above. That is, the processing circuitry 146 and/or the memory device 148 may include any of the components and/or characteristics of the processing circuitry 132, 138 and the memory device 134, 140 described above. The memory device 148 may be a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processing circuitry 146 to execute. The memory device 148 may also be configured to store data, such as one or more set point operating parameter values, one or more HVAC system 100 operating schedules, machine-readable instructions for controlling transmission of one or more of the input signals 144, and so forth.
In some embodiments, the control system 102 may include a refrigerant detection system 150 (e.g., mitigation controller, refrigerant detection and mitigation system), and the refrigerant detection system 150 may be configured to receive the one or more input signals 144 from the thermostat 142. The refrigerant detection system 150 may include a controller 152, a relay 154 (e.g., switch), a dual in-line package (DIP) switch 156, or any combination thereof. In some embodiments, the controller 152 may be a control board (e.g., printed circuit board), and the relay 154 and/or the DIP switch 156 may be disposed on (e.g., integrated with) the control board. The refrigerant detection system 150 (e.g., controller 152) may be configured to transmit (e.g., pass through) one or more of the input signals 144 received from the thermostat 142 to the outdoor unit controller 124. In some embodiments, the relay 154 (e.g., switch, normally-closed switch) may be configured to filter one of the input signals 144 received from the thermostat 142 and to transmit another of the input signals 144 to the outdoor unit controller 124 and/or to the motor connector 136, as described further below. The refrigerant detection system 150 may be disposed within the indoor unit 126, integrated with the thermostat 142, incorporated with the HVAC system 100 as a separate component, or included with the HVAC system 100 in any other desirable arrangement.
Additionally or alternatively, the refrigerant detection system 150 (e.g., controller 152) may be configured to transmit one or more of the input signals 144 received from the thermostat 142 directly to the blower motor 112 (e.g., motor connector 136) as a control signal 158 (e.g., 24V signal). In some embodiments, the refrigerant detection system 150 may be configured to selectively transmit one or more of the input signals 144 to either the outdoor unit controller 124 or the motor connector 136 based on a type of one or more of the input signals 144 received by the refrigerant detection system 150 from the thermostat 142. The refrigerant detection system 150 may also be configured to selectively transmit one or more of the input signals 144 to either the outdoor unit controller 124 or the motor connector 136 based on data received from one or more of the sensors 162 (e.g., a refrigerant sensor, a working fluid sensor). For example, in response to receipt of data indicative of a refrigerant concentration (e.g., above a threshold value), the refrigerant detection system 150 (e.g., relay 154) may be configured to transmit the control signal 158 directly to the motor connector 136 to enable operation of the blower motor 112 at a speed (e.g., a low speed, a lower limit speed, a minimum speed, a ventilation speed) associated with refrigerant dilution and/or mitigation operation of the HVAC system 100.
One or more of the input signals 144 transmitted via the thermostat 142 may be passed through the refrigerant detection system 150, may be received by the outdoor unit controller 124, and may be processed by the outdoor unit controller 124. For example, the outdoor unit controller 124 (e.g., processing circuitry 138) may execute instructions (e.g., code) stored on the memory device 140 to determine one or more of the input signals 144 to transmit as one or more control signals 160 (e.g., 24V signals) from the outdoor unit controller 124 to the blower motor 112 (e.g., motor connector 136). In some embodiments, the outdoor unit controller 124 may determine the one or more control signals 160 (e.g., input signals 144) to transmit to the motor connector 136 based on a type of the one or more input signals 144 received from the refrigerant detection system 150 and/or based on one or more operating parameters of the HVAC system 100. The one or more operating parameters may include an operating stage (e.g., active operating stage, current operating stage) of the compressor 122, an operating stage of the furnace 110, another suitable operating parameter, or any combination thereof.
For example, the compressor 122 may be a two-stage compressor, and the outdoor unit controller 124 may be configured to transmit one or more of the input signals 144 as one or more control signals 160 to the motor connector 136 to enable operation of the blower motor 112 (e.g., blower 108) at a first speed (e.g., low air flow rate, first air flow rate) in response to first stage operation of the compressor 122 and to transmit one or more of the input signals 144 as one or more control signals 160 to the motor connector 136 to enable operation of the blower motor 112 (e.g., blower 108) at a second speed (e.g., high air flow rate, second air flow rate greater than the first air flow rate) in response to second stage operation of the compressor 122. In another embodiment, the compressor 122 may be a three-stage compressor, and the outdoor unit controller 124 may be configured to transmit one or more of the input signals 144 as one or more control signals 160 to the motor connector 136 to enable operation of the blower motor 112 (e.g., blower 108) at a first speed (e.g., low air flow rate, first air flow rate) in response to first stage operation of the compressor 122, to transmit one or more of the input signals 144 as one or more control signals 160 to the motor connector 136 to enable operation of the blower motor 112 (e.g., blower 108) at a second speed (e.g., medium air flow rate, second air flow rate greater than the first air flow rate) in response to second stage operation of the compressor 122, and to transmit one or more of the input signals 144 as one or more control signals 160 to the motor connector 136 to enable operation of the blower motor 112 (e.g., blower 108) at a third speed (e.g., high air flow rate, third air flow rate greater than the second air flow rate) in response to third stage operation of the compressor 122.
The motor connector 136 (e.g., tap connector, pin connector, wire connector, integrated connector, blower motor connector), which may be an integrated (e.g., formed in, secured to, fixedly attached) component of the blower motor 112, includes a plurality of ports 200 (e.g., taps, electrical connections, pins, input terminals). One or more of the plurality of ports 200 are electrically (e.g., communicatively) coupled to the blower motor controller 130 and are configured to receive wiring extending from refrigerant detection system 150 (e.g., relay 154), the thermostat 142, the outdoor unit controller 124, other components of the control system 102, or any combination thereof. Accordingly, the motor connector 136 is configured to transmit the input signals 144, the control signal 158 (e.g., one of the input signals 144 received and transmitted by the relay 154) received from the refrigerant detection system 150, and/or the control signals 160 (e.g., one or more of the input signals 144) received from the outdoor unit controller 124 to the blower motor 112 (e.g., blower motor controller 130) to enable operation of the blower 108 at a desired speed corresponding to operation of other components of the HVAC system 100, such as the compressor 122. It should be appreciated that input signals 144 transmitted as corresponding control signals 158, 160 may be substantially the same. Additionally, the blower motor 112 may receive power from a power source 214 via one or more of the ports 200 of the motor connector 136. Electromechanical components of the blower motor 112, such as a rotor and/or a stator, may be electrically coupled to the motor connector 136 and configured to receive the power (e.g., line voltage). As discussed in further detail below, the motor connector 136 provides connectivity (e.g., electrically connectivity, communicative coupling) of the blower motor 112 to the thermostat 142, the refrigerant detection system 150, and/or the outdoor unit controller 124 to enable operation of the blower motor 112 at an increased number of speed (e.g., air flow rate) settings based on conventional signals (e.g., input signals 144, 24 volt [V] signals) transmitted by the thermostat 142 (e.g., conventional thermostat, non-communicating thermostat).
In the illustrated embodiment, the plurality of ports 200 of the motor connector 136 is arranged in a first set 202 (e.g., first row, first connector, high voltage connector) of the ports 200 and a second set 204 (e.g., second row, second connector, low voltage connector) of the ports 200. The first set 202 of the ports 200 may include power supply pins (e.g., power connection pins, power circuit pins, electrical circuit pins) configured to provide power to the blower motor 112 from the power source 214 (e.g., transformer, utility power source). The power may be high voltage power (e.g., 120V, 208V, 230V, line voltage) supplied by the power source 214. For example, the first set 202 of the ports 200 may include a line voltage port 208 (e.g., line voltage pin) configured to receive power (e.g., a line voltage) from the power source 214. The first set 202 of the ports 200 may also include a neutral port 212 (e.g., neutral pin) configured to electrically couple and carry a return current to the power source 214 or to the earth (e.g., a ground point). Thus, the voltage of the line voltage port 208 may be defined relative to zero volts at the neutral port 212. The first set 202 of the ports 200 may further include a ground port 210 configured to electrically couple to a ground point (e.g., the earth) and a common port 206 configured to provide a connection to a common voltage (e.g., 24V, less than the line voltage).
The second set 204 of the ports 200 may include multiple speed taps 203 (e.g., speed ports, speed input terminals, ports 200). Each speed tap 203 of the second set 204 of the ports 200 may be configured to receive a respective wire configured to transmit a corresponding signal (e.g., input signal, control signal) to the speed tap 203. Each speed tap 203 of the second set 204 of the ports 200 may also correspond to a respective speed or air flow rate setting of the blower motor 112. In other words, the blower motor controller 130 (e.g., processing circuitry 132, memory device 134) may be programmed, coded, and/or configured to enable and/or cause operation of the blower motor 112 at a particular speed or air flow rate setting based on receipt of a respective signal (e.g., control signal, input signal) via one (e.g., a single one) of the speed taps 203 of the second set 204 of the ports 200. Each speed and/or air flow rate setting (e.g., value) may be associated with a respective rotational speed of the blower 108, a respective torque output of the blower motor 112 (e.g., a shaft of the blower motor 112), and/or a respective nominal air flow rate of the conditioned air flow 104.
For example, a first speed tap 216 (e.g., labeled “1” in
Additionally, in accordance with the present techniques, the blower motor controller 130 may be programmed, coded, and/or configured to enable and/or cause operation of the blower motor 112 at additional speeds or air flow rate settings based on receipt (e.g., concurrent receipt) of multiple signals (e.g., input signals, control signals) via multiple speed taps 203 of the second set 204 of the ports 200. In other words, the blower motor controller 130 (e.g., motor connector 136) may be configured to multiplex multiple received (e.g., concurrently received) signals (e.g., control signals, input signals) to enable operation of the blower motor 112 at additional speeds (e.g., in addition to the five speeds associated with the five speed taps 203 in the illustrated embodiment). For example, based on receipt (e.g., concurrent receipt) of respective signals via the first speed tap 216 and the second speed tap 218, the blower motor controller 130 may be configured to operate the blower motor 112 and/or the blower 108 at a sixth speed or air flow rate value different from the five speeds or air flow rate values associated with the individual speed taps 203. Similarly, based on receipt (e.g., concurrent receipt) of respective signals via the second speed tap 218 and the fourth speed tap 222, the blower motor controller 130 may be configured to operate the blower motor 112 and/or the blower 108 at a seventh speed or air flow rate value different from the sixth speed or air flow rate value and different from the five speeds or air flow rate values associated with the individual speed taps 203, and so forth. Accordingly, embodiments of the blower motor 112 having the motor connector 136 with five speed taps 203 may be configured to enable operation of the blower motor 112 at up to nine different speeds and/or air flow rate settings. Additional details of various signals received by the motor connector 136 and corresponding speeds and/or air flow rate settings are described below with reference to
As mentioned above, the present techniques include configuration of the control system 102 to enable operation of the blower motor 112 and the blower 108 at a greater number of speeds and/or air flow rate settings than a number of speed taps 203 included in the motor connector 136. The control system 102 is also configured to enable such functionality with the thermostat 142 having a conventional (e.g., non-communicating) configuration. That is, the thermostat 142 may be configured to transmit the input signals 144 (e.g., 24V signals; blower, fan, or G input signal; first cooling stage or Y1 input signal; second cooling stage or Y2 input signal; heating or W input signal) in a manner traditionally associated with conventional thermostats. Accordingly, the control system 102 enables enhanced compatibility (e.g., more efficient operation) of the thermostat 142 (e.g., conventional thermostat) with other components of the HVAC system 100 having more advanced functionality, such as the compressor 122 configured for multi-stage operation. To this end, one or more of the input signals 144 may be transmitted from the thermostat 142 to the outdoor unit controller 124 instead of directly to the blower motor 112 (e.g., motor connector 136). However, in some embodiments, one or more of the input signals 144 transmitted by the thermostat 142 may first be transmitted to the refrigerant detection system 150. Based on a type and/or a number of one or more of the input signals 144 received by the refrigerant detection system 150, the refrigerant detection system 150 may direct one or more of the input signals 144 directly to the motor connector 136 (e.g., as the control signal 158) and/or may direct one or more of the input signals 144 to the outdoor unit controller 124.
In the illustrated embodiment, the thermostat 142 (e.g., conventional thermostat) is configured to transmit four different input signals 144. Specifically, the thermostat 142 may transmit a fan input signal 226 (e.g., blower input signal, fan only input signal, G call, G input signal, fan only call, mitigation call), a first stage input signal 228 (e.g., low stage call, low stage cooling call, Y1 call, Y1 input signal, first stage cooling call, first stage cooling input signal), a second stage input signal 230 (e.g., high stage call, high stage cooling call, Y2 call, Y2 input signal, second stage cooling call, second stage cooling input signal), and a heating input signal 232 (e.g., heating call, W call, W input signal). The thermostat 142 may be configured to transmit each input signal 144 to the refrigerant detection system 150 via a respective wire electrically coupling the thermostat 142 to the refrigerant detection system 150.
The thermostat 142 is configured to transmit one or more of the input signals 144 based on a desired operation of the HVAC system 100. The thermostat 142 may also determine the desired operation of the HVAC system 100 based on any suitable parameter or metric. For example, in response to a determination that a detected temperature of a conditioned space is greater than a set point temperature by a first threshold amount, the thermostat 142 may determine that first stage cooling operation of the HVAC system 100 is desired and may therefore transmit the first stage input signal 228 to the refrigerant detection system 150. Similarly, in response to a determination that the detected temperature of the conditioned space is greater than the set point temperature by a second threshold amount, greater than the first threshold amount, the thermostat 142 may determine that second stage cooling operation of the HVAC system 100 is desired and may therefore transmit the second stage input signal 230 to the refrigerant detection system 150. In response to a determination that the detected temperature of the conditioned space is less than the set point temperature (e.g., by a threshold amount), the thermostat 142 may determine that heating operation of the HVAC system 100 is desired and may therefore transmit the heating input signal 232 to the refrigerant detection system 150.
The following discussion describes operation of the control system 102 implemented with the HVAC system 100 configured as a single-stage or two-stage system. For example, the compressor 122 may be configured to operate in a single stage or to operate in a first stage (e.g., low stage) and in a second stage (e.g., high stage). In response to a determination that cooling operation and/or first stage cooling operation of the HVAC system 100 is desired, the thermostat 142 may transmit the first stage input signal 228 to the refrigerant detection system 150. It will be appreciated that the thermostat 142 (e.g., conventional thermostat) may be configured (e.g., a default configuration, existing control logic) to also transmit (e.g., concurrently transmit) the fan input signal 226 with the first stage input signal 228. However, eventual transmission of the fan input signal 226 and the first stage input signal 228 to the motor connector 136 would cause energization of two speed taps 203 and thereby result in multiplexing of the fan input signal 226 and the first stage input signal 228, which may not enable operation of the blower motor 112 (e.g., blower 108) at a desired speed and/or air flow rate.
Accordingly, in response to receipt of the first stage input signal 228, the refrigerant detection system 150 may be configured to cut (e.g., filter) or block transmission of the fan input signal 226 to the outdoor unit controller 124 and/or the motor connector 136. To this end, the refrigerant detection system 150 may include the relay 154 (e.g., signal filter, switch) configured to block (e.g., filter, cut) the fan input signal 226. For example, the relay 154 may be a normally-closed switch and may be electrically coupled to the thermostat 142, such that the normally-closed switch is configured to concurrently receive the fan input signal 226 and the first stage input signal 228. In a closed configuration (e.g., normally-closed configuration), the relay 154 (e.g., normally-closed switch) enables transmission of the fan input signal 226 from the refrigerant detection system 150 directly to the first speed tap 216 of the motor connector 136. When the fan input signal 226 alone (e.g., without the first stage input signal 228) is transmitted to the refrigerant detection system 150 (e.g., relay 154, normally-closed switch), the normally-closed switch may direct the fan input signal 226 from the refrigerant detection system 150 directly to the first speed tap 216 as a fan control signal 234 (e.g., 24V signal, blower control signal) to energize the first speed tap 216 and enable operation of the blower motor 112 at a particular speed (e.g., predetermined speed, first speed, lower limit speed, mitigation speed, ventilation speed) corresponding to energization of the first speed tap 216 alone (e.g., without energization of other speed taps 203). In some instances, the fan input signal 226 alone (e.g., without other input signals 144) may be transmitted to the refrigerant detection system 150 in response to a detected concentration of refrigerant (e.g., greater than a corresponding threshold) within the indoor unit 126 and/or within the conditioned air flow 104. Additionally or alternatively, the fan input signal 226 alone (e.g., without other input signals 144) may be transmitted to the refrigerant detection system 150 in response to a call for ventilation.
On the other hand, when the fan input signal 226 in transmitted to the refrigerant detection system 150 along with (e.g., concurrently with) the first stage input signal 228 (e.g., indicative of a call for cooling operation and/or first stage cooling operation), receipt of the first stage input signal 228 by the normally-closed switch may cause the normally-closed switch (e.g., relay 154) to transition to an open configuration. In the open configuration, the normally-closed switch may block transmission of the fan input signal 226 and/or the fan control signal 234 to the first speed tap 216. The first stage input signal 228 may also be transmitted (e.g., passed through) from the refrigerant detection system 150 to the outdoor unit controller 124 in the open configuration of the normally-closed switch. The outdoor unit controller 124 may then transmit the first stage input signal 228 to the second speed tap 218 as a first stage control signal 236 (e.g., via a corresponding wire electrically coupling the outdoor unit controller 124 and the second speed tap 218), thereby energizing the second speed tap 218 alone (e.g., without energization of other speed taps 203) and enabling operation of the blower motor 112 at a speed and/or air flow rate value (e.g., low speed air flow, first air flow rate) corresponding to energization of the second speed tap 218 alone. In other words, in response to receipt of the first stage input signal 228 (e.g., first stage control signal 236) via the second speed tap 218 and nonreceipt of other input signals 144 (e.g., control signals 160) at other speed taps 203, the blower motor controller 130 may operate the blower motor 112 at a speed and/or air flow rate value (e.g., stored in the memory device 134) corresponding to energization of the second speed tap 218 alone. In some embodiments, the first stage control signal 236 may be the same or substantially the same as the first stage input signal 228 (e.g., 24V signal).
In some embodiments, the refrigerant detection system 150 may include other components configured to filter or block transmission of the fan input signal 226 when the fan input signal 226 accompanies (e.g., is concurrently received with) the first stage input signal 228. For example, the controller 152 of the refrigerant detection system 150 may be programmed and/or configured to filter, cut, and/or block transmission of the fan input signal 226 in response to concurrent receipt of the first stage input signal 228 with the fan input signal 226, thereby enabling transmission of the first stage input signal 228 to the outdoor unit controller 124, transmission of the first stage control signal 236 (e.g., first stage input signal 228) from the outdoor unit controller 124 to the motor connector 136, and energization of the second speed tap 218 in the manner described above.
In embodiments of the HVAC system 100 configured as a two-stage system, the thermostat 142 may also be configured to transmit the second stage input signal 230 in response to a determination (e.g., via the thermostat 142) that second stage cooling operation of the HVAC system 100 is desired. As will be appreciated, the thermostat 142 (e.g., conventional thermostat) may be configured (e.g., a default configuration) to also transmit (e.g., concurrently transmit) the first stage input signal 228 with the second stage input signal 230 in response to a determination that second stage cooling operation is desired. In accordance with some embodiments, the refrigerant detection system 150 may be configured to pass both the first stage input signal 228 and the second stage input signal 230 through to the outdoor unit controller 124. In response, according to the illustrated embodiment, the outdoor unit controller 124 is configured to transmit the first stage input signal 228 as the first stage control signal 236 to the second speed tap 218 and to transmit (e.g., concurrently transmit) the second stage input signal 230 as a second stage control signal 238 to the fourth speed tap 222 (e.g., via respective wires electrically coupling the outdoor unit controller 124 to the second speed tap 218 and the fourth speed tap 222). Thus, the second speed tap 218 and the fourth speed tap 222 may be concurrently energized, thereby resulting in multiplexing of the first stage control signal 236 and the second stage control signal 238. The blower motor controller 130 may therefore operate the blower motor 112 at a speed and/or air flow rate value (e.g., high speed air flow, stored in the memory device 134) corresponding to energization (e.g., concurrent energization) of the second speed tap 218 and the fourth speed tap 222.
In response to a determination that heating operation of the HVAC system 100 is desired, the thermostat 142 may be configured to transmit the heating input signal 232 to the refrigerant detection system 150. It will be appreciated that the thermostat 142 (e.g., conventional thermostat) may be configured (e.g., programmed) to also transmit (e.g., concurrently transmit) the fan input signal 226 with the heating input signal 232 in response to the determination that heating operation is desired. In embodiments of the refrigerant detection system 150 having the relay 154 configured as a normally-closed switch, the normally-closed switch may remain in the closed configuration and may therefore transmit the fan input signal 226 as the fan control signal 234 directly to the first speed tap 216 to energize the first speed tap 216. The refrigerant detection system 150 may be configured to pass the heating input signal 232 through to the outdoor unit controller 124, and in response the outdoor unit controller 124 is configured to transmit a heating control signal 240 (e.g., heating input signal 232) to the fifth speed tap 224 (e.g., via a corresponding wire electrically coupling the outdoor unit controller 124 to the fifth speed tap 224). Thus, the first speed tap 216 and the fifth speed tap 224 may be concurrently energized, thereby resulting in multiplexing of the fan control signal 234 and the heating control signal 240. The blower motor controller 130 may therefore operate the blower motor 112 at a speed and/or air flow rate value (e.g., upper limit air flow speed, maximum air flow speed, stored in the memory device 134) corresponding to concurrent energization of the first speed tap 216 and the fifth speed tap 224.
It should be noted that, while the third speed tap 220 is not electrically coupled to the outdoor unit controller 124 in the embodiment of
The present techniques may also be utilized with embodiments of the HVAC system 100 configured as a three-stage system. For example, the compressor 122 may be configured to operate in a first stage (e.g., low stage), in a second stage (e.g., medium stage, a greater operating capacity than the first stage), and in a third stage (e.g., high stage, a greater operating capacity than the second stage). To enable more efficient operation of the HVAC system 100 at each of the three stages of operation, the control system 102 is configured to cause operation of the blower motor 112 and the blower 108 at multiple speeds and/or air flow rate values that are more tailored to the different stages of operation of the HVAC system 100. In other words, the control system 102 is configured to enable operation of the blower motor 112 and the blower 108 at a particular, respective speed and/or air flow rate value corresponding to each of the three operating stages of the HVAC system 100 (e.g., compressor 122).
In response to a determination that first stage cooling operation of the HVAC system 100 is desired, the thermostat 142 may transmit the first stage input signal 228 to the refrigerant detection system 150. As discussed above, the thermostat 142 may also be configured to transmit (e.g., concurrently transmit) the fan input signal 226 with the first stage input signal 228 based on a determination that first stage cooling operation is desired. However, the refrigerant detection system 150 (e.g., relay 154, normally-closed switch, controller 152) may operate to block transmission of the fan input signal 226 and/or fan control signal 234 to the first speed tap 216 (e.g., in response to concurrent receipt of the first stage input signal 228 with the fan input signal 226) and may transmit the first stage input signal 228 (e.g., pass through) from the refrigerant detection system 150 to the outdoor unit controller 124. The outdoor unit controller 124 may then transmit the first stage input signal 228 to the second speed tap 218 as the first stage control signal 236, thereby energizing the second speed tap 218 alone (e.g., nonreceipt of other input signals 144 and/or control signals 158, 160 via other speed taps 203) and enabling operation of the blower motor 112 at a speed and/or air flow rate value (e.g., low speed air flow) corresponding to energization of the second speed tap 218 alone (e.g., without energization of other speed taps 203).
In response to a determination that higher stage (e.g., second stage, third stage) cooling operation of the HVAC system 100 is desired, the thermostat 142 may transmit the second stage input signal 230 to the refrigerant detection system 150. As similarly discussed above, the thermostat 142 may also be configured (e.g., a default configuration) to transmit (e.g., concurrently transmit) the first stage input signal 228 with the second stage input signal 230. In accordance with some embodiments, the refrigerant detection system 150 may be configured to pass both the first stage input signal 228 and the second stage input signal 230 through to the outdoor unit controller 124. In embodiments of the HVAC system 100 configured for three-stage operation, the outdoor unit controller 124 may be configured to selectively transmit one or both of the first stage input signal 228 and the second stage input signal 230 to the motor connector 136. For example, the outdoor unit controller 124 may be configured to determine whether to transmit the second stage input signal 230 as the second stage control signal 238 to the fourth speed tap 222 (e.g., without also transmitting the first stage input signal 228 as the first stage control signal 236 to the second speed tap 218) or to transmit (e.g., concurrently transmit) both the first stage control signal 236 (e.g., first stage input signal 228) and the second stage control signal 238 (e.g., second stage input signal 230) to the motor connector 136.
The outdoor unit controller 124 may be configured to determine whether to transmit the second stage control signal 238 alone or to transmit the first stage control signal 236 and the second stage control signal 238 concurrently based on any suitable parameter or metric. For example, the outdoor unit controller 124 may be configured to receive data indicative of an operating parameter, such as working fluid (e.g., refrigerant) temperature and/or pressure (e.g., subcooling, superheat), fan 118 speed, motor 120 speed, indoor heat exchanger 106 temperature and/or pressure, outdoor heat exchanger 114 temperature and/or pressure, a temperature differential between a set point temperature and a temperature of the conditioned air flow 104, and/or any other suitable operating parameter, from one or more of the sensors 162.
Additionally or alternatively, the outdoor unit controller 124 may be configured to determine whether to transmit the second stage control signal 238 alone to the motor connector 136 or to transmit the first stage control signal 236 and the second stage control signal 238 concurrently to the motor connector 136 based on an operating stage (e.g., active operating stage, operating speed) of the compressor 122. For example, in response to a determination the compressor 122 is operating in a second stage (e.g., medium stage, within a first range of speeds, stored on the memory device 140, less than the third stage, greater than the first stage), the outdoor unit controller 124 may transmit the second stage control signal 238 alone to the fourth speed tap 222. In other words, based on operation of the compressor 122 in the second stage, the outdoor unit controller 124 may filter the first stage input signal 228 received from the refrigerant detection system 150 and may block transmission of the first stage control signal 236 (e.g., first stage input signal 228) to the second speed tap 218 (e.g., via a signal filter, relay, switch, programming, code). Thus, the fourth speed tap 222 alone may be energized, without energization (e.g., nonreceipt of other input signals 144 and/or control signals 158, 160) of other speed taps 203, thereby causing operation of the blower motor 112 at a speed and/or air flow rate value (e.g., medium speed air flow, greater than low speed air flow; second air flow rate, greater than first air flow rate) corresponding to energization of the fourth speed tap 222 alone (e.g., without energization of other speed taps 203 via other input signals 144 and/or control signals 158, 160). In response to a determination the compressor 122 is operating in a third stage (e.g., high stage, within a second range of speeds, greater than the first range of speeds, stored on the memory device 140), the outdoor unit controller 124 may transmit the first stage control signal 236 (e.g., first stage input signal 228) to the second speed tap 218 and to concurrently transmit the second stage control signal 238 (e.g., second stage input signal 230) to the fourth speed tap 222. Thus, the second speed tap 218 and the fourth speed tap 222 may be concurrently energized, thereby resulting in multiplexing of the first stage control signal 236 and the second stage control signal 238. The blower motor controller 130 may therefore operate the blower motor 112 at a speed and/or air flow rate value (e.g., high speed air flow, greater than medium speed air flow; third air flow rate, greater than second air flow rate) corresponding to energization of the second speed tap 218 and the fourth speed tap 222 during third stage operation of the HVAC system 100. In a heating mode, the control system 102 incorporated with embodiments of the HVAC system 100 configured for three-stage operation may function in a manner similar to that described above with regard to embodiments of the HVAC system 100 configured for single-stage or two-stage operation. For example, in the heating mode, the control system 102 may operate to cause energization of the first speed tap 216 and the fifth speed tap 224, thereby causing multiplexing of the first speed tap 216 and the fifth speed tap 224 and corresponding operation of the blower motor 112 and blower 108 at the speed and/or air flow rate value (e.g., upper limit air flow rate or speed, maximum air flow rate or speed) associated with energization of both the first speed tap 216 and the fifth speed tap 224.
In the manners described above, operation of the HVAC system 100 having certain components with more advanced and/or adaptable operations (e.g., multi-stage compressor, variable speed compressor, compressor 122) and certain components with more limited capabilities (e.g., thermostat 142, conventional thermostat) is enabled. In particular, operation of the blower motor 112 and the blower 108 may be enabled via conventional thermostat signals (e.g., input signals 144) while also being more narrowly tailored to (e.g., compatible and/or efficient with) multi-stage operation of other components of the HVAC system 100, such as the compressor 122.
As mentioned above, embodiments of the motor connector 136 having five speed taps 203 may be electrically coupled (e.g., wired) to the outdoor unit controller 124 in different configurations to enable operation of the blower motor 112 and blower 108 at different desired speeds and/or air flow rate values. The blower motor controller 130 may be programmed (e.g., via data stored in the memory device 134) to associate a respective speed and/or air flow rate value at which to operate the blower motor 112 and/or blower 108 with individual energization of each speed tap 203 (e.g., without energization of other speed taps 203), as well as to associate a respective speed and/or air flow rate value at which to operate the blower motor 112 and/or blower 108 with multiplexing (e.g., concurrent energization) of different combinations of the speed taps 203. The outdoor unit controller 124 may be electrically coupled (e.g., via respective wires) to transmit the first stage control signal 236 (e.g., first stage input signal 228) to a first selected speed tap 203 and to transmit the second stage control signal 238 (e.g., second stage input signal 230) to another selected speed tap 203. Different speed taps 203 may be selected and electrically coupled to the outdoor unit controller 124 via wires corresponding to the input signals 144 and/or control signals 158, 160 described herein to achieve different speeds and/or air flow rates values during operation of the blower motor 112 and blower 108 in different operating modes of the HVAC system 100.
With the foregoing in mind,
While energization of each speed tap 203 individually enables operation of the blower motor 112 and blower 108 at a respective, different speed and/or air flow rate value (e.g., stored in the memory device 134), energization of different combinations of two speed taps 203 may cause multiplexing via the motor connector 136 to enable operation of the blower motor 112 and blower 108 at additional speeds and/or air flow rate values (e.g., stored in the memory device 134). For example, electrical coupling (e.g., wiring) between the outdoor unit controller 124 and the motor connector 136 to enable transmission of the first stage control signal 236 (e.g., first stage input signal 228) to the second speed tap 218 and transmission of the second stage control signal 238 (e.g., second stage input signal 230) to the first speed tap 216 enables operation of the blower motor 112 and/or the blower 108 at a sixth speed and/or air flow rate value (e.g., labeled as “6” in
The method 300 may begin at block 302, whereby multiple input signals (e.g., input signals 144) are received from the thermostat 142 of the control system 102. For example, the multiple input signals may be received by the outdoor unit controller 124 of the control system 102. The multiple input signals may be received directly from the thermostat 142 or may be received from the thermostat 142 via the refrigerant detection system 150 configured to pass the multiple input signals through to the outdoor unit controller 124. The multiple input signals may include, for example, the first stage input signal 228 and the second stage input signal 230. At block 304, a blower speed (e.g., desired blower speed, target blower speed) is determined based on one or more operating parameters of the compressor 122. The one or more operating parameters may include an operating speed, stage, or capacity of the compressor 122, a working fluid pressure and/or temperature (e.g., discharge temperature/pressure, suction temperature/pressure), a current draw, a power consumption level, another suitable operating parameter, or any combination thereof. Upon the determination of the blower speed (e.g., desired blower speed), the method 300 may proceed to block 304, whereby a particular input signal or multiple input signals may be selectively transmitted to the blower motor 112 (e.g., motor connector 136) based on the determined blower speed. For example, based on the determined blower speed (e.g., medium air flow rate), the outdoor unit controller 124 may transmit the second stage control signal 238 to the motor connector 136 and may filter and/or block transmission of the first stage control signal 236 to energize one speed tap 203 of the motor connector 136 and enable operation of the blower motor 112 and the blower 108 at the speed and/or air flow rate value corresponding to the speed tap 203 energized via the second stage control signal 238 (e.g., without multiplexing, nonreceipt of other input signals 144 and/or control signals 158, 160 via other speed taps 203). Additionally or alternatively, based on the determined blower speed (e.g., high air flow rate), the outdoor unit controller 124 may transmit both the first stage control signal 236 and the second stage control signal 238 to the motor connector 136 to energize two speed taps 203 of the motor connector 136, thereby multiplexing the two speed taps 203 (e.g., first stage control signal 236 and second stage control signal 238) and enable operation of the blower motor 112 and the blower 108 at the speed and/or air flow rate value corresponding to the two multiplexed speed taps 203 concurrently energized via the first stage control signal 236 and the second stage control signal 238.
While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, such as temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth, without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.
Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.
The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).
This application claims priority from and the benefit of U.S. Provisional Application No. 63/541,734, entitled “CONTROL SYSTEM FOR HVAC BLOWER,” filed Sep. 29, 2023, which is herein incorporated by reference in its entirety for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63541734 | Sep 2023 | US |
