This invention relates generally to a system for analyzing a heating, ventilation, and air conditioning (“HVAC”) line set, and more particularly to an HVAC line set analyzer system for measuring the length of the tubing and number of sharp bends in the tubing forming the HVAC line set.
HVAC systems are common in homes, businesses and the like. The amount of refrigerant utilized for an HVAC system is affected by the length of the line set, wherein the longer the line set, the more refrigerant that will be required to add to the HVAC system in order for it function optimally. It is also understood in the industry that the sharp bends are treated as longer in length than the mere length of the bend due to the turbulence caused in the flow of refrigerant through the bends and this alters to total line set length calculation. This becomes an issue when a technician is hired to replace an existing HVAC system because much of the line set is located within walls of the building in which the HVAC system is installed.
Conventionally, in order to charge the HVAC system with refrigerant, the technician guesses as to the length and amount of sharp bends in the line set make that on an educated guess and charges the HVAC system with refrigerant. After the system runs for a period of time, the technician typically needs to return and check to see if more refrigerant needs to be added, thereby taking more time, increasing cost and lost profits when the technician could be working on installation or repair of another HVAC system. Furthermore, technicians are not typically able to account for other factors affecting the HVAC system and the amount of refrigerant needed, such as temperature, barometric pressure, elevation and forth. There does not exist a tool or system that can accurately measure the length of an HVAC line set that can account for the number of sharp bends in the line set, as well as account for external factors that may affect measurement or amount of refrigerant to add.
Accordingly, there is a need for an HVAC line set analyzer system for measuring the length of the tubing and number of sharp bends in the tubing forming the HVAC line set.
An embodiment includes an HVAC line set analyzer system comprising: a base unit configured to couple to an end of a tube of an HVAC line set, the base unit comprising: a base unit housing with a lid, wherein the lid is closable to seal components within the base unit housing, thereby controlling the internal environment of the base unit; an on-board computing device coupled within the base unit housing; a pressure chamber coupled within the base unit housing; a filter coupled to the base unit housing; a fan coupled within the base unit housing and in fluid communication with the filter; a base unit tube coupled within the base unit housing with a portion extending out of the base unit housing; a pressure chamber valve coupled to the base unit tube; a temperature sensor coupled to the base unit tube within the base unit housing; a connector hose coupled to the portion of the base unit tube extending outside of the base unit housing; a pressure transducer coupled to the on-board computing device and to the tubing; a differential pressure transducer coupled to the on-board computing device and to port accessing ambient air outside of the base unit housing; a compressor coupled to the base unit tube; an open/close valve coupled to an end of the base unit tube, the open/close valve configured to move between an open position opening the end of the base unit tube and a closed position closing the end of the base unit tube; a vent valve coupled to the open close valve, the vent valve configured to move between a sealed position sealing a vent hole formed in the base unit housing and an unsealed position unsealing the vent hole; an actuator coupled to the vent valve and the open/close valve; and a bleeder valve coupled to the base unit tube; and a remote unit configured to couple to an opposing end of the tube of the HVAC line set, the remote unit comprising: a remote unit housing with a lid, wherein the lid is closable to seal components within the remote unit housing, thereby controlling the internal environment of the remote unit; a computing device coupled within the remote unit housing; a wi-fi device coupled to the computing device; a remote unit tube coupled within the remote unit housing with a portion extending out of the remote unit housing; a temperature sensor coupled to the remote unit tube; a valve coupled to an end of the remote unit tube, the valve configured to move between an open position opening the end of the remote unit tube and a closed position closing the end of the remote unit tube; an actuator coupled to the valve and to the computing device; and a connector hose coupled to the portion of the remote unit tube extending outside of the remote unit housing.
Another embodiment includes a method of purging and equalizing temperature of an HVAC line set, the method comprising: coupling a base unit of an HVAC line set analyzer system to an end of tubing of an HVAC line set; coupling a remote unit of the HVAC line set analyzer system to an opposing end of the tubing of the HVAC line set, wherein an onboard computing unit of the base unit is in communication with a computing device of the remote unit; sending a command from the onboard computing device of the base unit to the computing device of the remote unit to open a valve operatively coupled to the opposing end of the tubing of the HVAC line set; the onboard computing device operating to open a pressure chamber valve in the base unit to equalize a pressure chamber of the base unit with ambient air pressure; the onboard computing device operating to close a vent valve of the base unit to seal a vent hole formed in a housing of the base unit and open an open/close valve of the base unit operatively coupled to the end of the tubing of the HVAC line set, thereby placing places the base unit and the remote unit in a condition where the only way air flow in the base unit can escape is through the tubing of the HVAC line set; purging the tubing of the HVAC line set in response to operating a fan of the base unit to flow air through the tubing of the HVAC line set; and continuing the purging of the tubing of the HVAC line set until a temperature sensor in the base unit and a temperature sensor in the remote unit are within a predetermined temperature range from each other.
Yet another embodiment includes a method of measuring a length of an HVAC line set, the method comprising: coupling a base unit of an HVAC line set analyzer system to an end of tubing of an HVAC line set; coupling a remote unit of the HVAC line set analyzer system to an opposing end of the tubing of the HVAC line set, wherein an onboard computing unit of the base unit is in communication with a computing device of the remote unit; sending a command from the onboard computing device of the base unit to the computing device of the remote unit to close a valve operatively coupled to the opposing end of the tubing of the HVAC line set; the onboard computing device operating to open a vent valve of the base unit to unseal a vent hole formed in a housing of the base unit and close an open/close valve of the base unit operatively coupled to the end of the tubing of the HVAC line set; the onboard computing device operating to close a pressure chamber valve in the base unit, thereby cutting off a pressure chamber of the base unit from the rest of the HVAC line set analyzer system; operating a compressor of the base unit operatively coupled to the tubing of the HVAC line set to pressurize the HVAC line set analyzer system and the tubing of the HVAC line set to a preset pressure as measured by a pressure transducer of the base unit; opening the pressure chamber valve to add the pressure chamber to a volume of the tubing of the HVAC line set being measured; measuring a pressure drop caused by adding the pressure chamber to the volume of the tubing of the HVAC line set being measured; operating the onboard computing device to calculate a volume of an unknown length of the tubing of the HVAC line set in response to calculating the pressure drop and the known volume of the pressure chamber; and operating the onboard computing device to convert the volume of the tubing of the HVAC line set to a length of the HVAC line set.
Another embodiment includes a method of measuring a number of sharp bends of an HVAC line set, the method comprising: coupling a base unit of an HVAC line set analyzer system to an end of tubing of an HVAC line set; coupling a remote unit of the HVAC line set analyzer system to an opposing end of the tubing of the HVAC line set, wherein an onboard computing unit of the base unit is in communication with a computing device of the remote unit; the onboard computing device operating to open a bleeder valve to release pressure in the line set until a predetermined pressure level is reached and then closing the bleeder valve; sending a command from the onboard computing device of the base unit to the computing device of the remote unit to open the valve; the onboard computing device operating to close the vent valve of the base unit to seal the vent hole formed in the housing of the base unit and open the open/close valve of the base unit operatively coupled to the end of the tubing of the HVAC line set, thereby placing places the base unit and the remote unit in a condition where the only way air flow in the base unit can escape is through the tubing of the HVAC line set; operating a fan coupled to the housing of the base unit at a calibrated speed; measuring a static pressure in the housing of the base unit with a differential pressure transducer of the base unit; operating the onboard computing device, compare the measured static pressure with a look up table of the expected static pressure for a given length of tubing that is stored in a memory of the onboard computing device of the base unit and calculate a difference of pressure; and analyzing the difference of pressure by the on-board computing device to determine a number of sharp bends in the tubing of the HVAC line set. The method of measuring a number of sharp bends may further include calculating, by the onboard computing device, an equivalent tubing length associated with the number of sharp bends in the tubing of the HVAC line set and add the equivalent tubing length to a measurement of the length of the in the tubing of the HVAC line set to determine a total length of tubing of the HVAC line set.
The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings.
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
As discussed above, embodiments of the present invention relate to an HVAC line set analyzer system for measuring the length of the tubing and number of sharp bends in the tubing forming the HVAC line set.
Referring to
Referring specifically to
The open close valve 25 is coupled to a base unit tube 29, wherein tube 29 includes a junction 18. The junction 18 is used to couple the tube 29 to the compressor 24 on one side of the junction 18 and to the pressure chamber 11 on the other side with the pressure chamber valve 15 and a manifold 14 coupled along the line between the pressure chamber 11 and the junction 18. The pressure transducer 21 may be coupled to a junction 19 along the line between the compressor 24 and the junction 18. The differential pressure transducer 22 may be coupled to ambient pressure through a nozzle 55 in the lid 31 as shown or in the housing 30.
The base unit 10 may further include a bleeder valve 50 with a bleeder nozzle 51. The bleeder valve 50 may be coupled to the junction 19. The bleeder valve 50 operates to release pressure in the tube 29 and line set 48 when moving from a pressurized condition to an open condition. The bleeder valve 50 is opened prior to opening the open/close valve 25 and pressurized air flows out of bleeder nozzle 51. This allows the pressure in the tube 29 and line set 48 to reduce until a predetermined pressure level prior to opening to avoid damage and other negative effects to the base unit 10 caused by opening the open/close valve 25 with the tube 29 and line set 48 pressurized.
The base unit 10 may further comprise a barometric sensor 58. The barometric sensor 58 is coupled to the on-board computing device 23. The barometric sensor 58 may be a sensitive barometric pressure device. The barometric pressure variations that are present in real-life settings that this system 100 will operate may result in reducing accuracy should the system operate with a fixed air pressure standard, such as, 14.7 psi. in order to account for barometric variations, the barometric sensor 58 is incorporated to supply a starting pressure to the on-board computing device 23 that is real time accurate instead of a theoretical pressure. This results in greater accuracy of the calculations performed by the system 100
Further still, the base unit 10 includes a control knob 90, a display 91 and a power switch 92. The control knob 90 and the display 91 are coupled to the power source 53 and the on-board computing device 23. The display 91 provides visual indicator of the process the system 100 is performing and the control knob 90 allows for inputting the process to perform by the system 100. The power switch 92 operates to turn on power for all components of the base unit 10.
Referring additionally to
The remote unit 40 comprises a housing 41 with a lid 42, wherein the lid 42 may be closed and sealed, thereby controlling the internal environment of the remote unit 40. The components of the remote unit 40 may be coupled within or on an outside of the housing 41, wherein the components of the remote unit 40 are coupled within the housing 41 unless expressly indicated that the component may be coupled on the outside of the housing 41. The remote unit 40 comprises a temperature sensor 38; a valve 43; an actuator 44; a computing device 45 that is wi-fi enabled and coupled to remote unit antenna 57, the computing device 45 coupled to the actuator 43; a power unit 46; and a connector hose 34 coupled outside of the housing 41.
The base unit 10 and the remote unit 40 of the system 10 operate to obtain the measurements of the length of the tubing 48 of an HVAC line set and the number of sharp bends in the line set. Accordingly, operation of the system 10 may include the following description of connecting the system to an HVAC line set; purging and equalizing temperature; measuring length of tubing; and measuring a number of sharp bends.
Connecting the HVAC Line Set Analyzer System
The base unit 10 is connected to an end of the tubing 48 to be measured by coupling connector hose 17 to a base unit tube 29 with a clamp 32 on one end and to the end of tubing 48 with a clamp 33 on the other end. The base unit 10 is coupled to the end of the tubing 48 located within the home or building, such as in a space wherein the air handler is located, like, without limitation, an attic of a home.
The remote unit 40 is connected in similar manner by connector hose 34 coupled to remote unit tube 47 with a clamp 36 on one end and to the end of tubing 48 with a clamp 35. The remote unit 40 is coupled to the far end of the tubing 48 to be measured, located at the end of the tubing outside of the home or building. The remote unit 40 is controlled through the computing device 45.
Once connected, the electrical power to the base unit 10 and the remote unit 40 may be turned on which will activate the fan 13 and the on-board computing device 23. The fan 13 draws air into the housing 30 through filter 12, and the fan 13 typically remains on throughout the operation of the base unit 10. The fan 13 serves multiple purposes as will be explained later. The fan 13 may be a high flow, high static pressure fan, with speed control.
Purging and Equalizing Temperature
An operator may operate the system 10 to purge and equalize temperature, wherein operation of a purge and equalizing temperature sequence includes the following. A command will be sent from the base unit 10 to the remote unit 40 to open the valve 43. This is done by computing device 45 receiving the signal sent from the on-board computing device 23 in a signal with a command to open the valve 43. The computing device 45 sends a signal to the actuator 44 that operates to move the valve 43 to an open position and maintain the valve 43 in the open position. This valve 43 was designed to open so that it produces no turbulence or static back pressure to air flowing out of it.
Next the base unit 10 shall momentarily open pressure chamber valve 15 to equalize the pressure chamber 11 with ambient air pressure. The actuator 26 of the base unit 10 will operate to close vent valve 28 and open the open/close valve 25. The vent valve 28 operates to seal a vent hole 20 formed in the housing 30 of the base unit. The open/close valve 25 in an open position opens an end of the tubing 29. This places the base unit 10 and the remote unit 40 in a condition where the only way air flow from the fan can escape is through the tubing 48 to be measured. This purging operation will continue until the temperature sensor 16 in the base unit 10 and the temperature sensor 38 in the remote unit 40 give nearly equal readings. This operation purges the tubing 48 of any contaminants such as refrigerant, moisture, or nitrogen, while also equalizing the temperature. The on-board computing device 23 will then recognize when the temperatures are within a predetermined temperature range from each other and alert the operator to end the purging and equalizing step and proceed to the next step of measuring a length of the tubing 48.
It is important to note that the temperature sensors 16 and 38 have a secondary function that includes helping refine the length measurement of the line set that is described below, since pressure varies with temperature. The system operates to purge and equalize temperature in the HVAC line set to avoid changes happening during the measurement step that follows. Additionally, the system 100 may use the final temperature to calibrate the measurement.
Measuring Length of Tubing
An operator may operate the system 10 to measure the length of the tubing 48, wherein operation of a measure the length of the tubing sequence includes the following.
The base unit 10 operates the on-board computing device 23 and the barometric sensor 58 to obtain a real time actual starting pressure accounting for any barometric variations. A command will then be sent from the base unit 10 to the remote unit 40 to close the valve 43. This is done by computing device 45 receiving the signal from the on-board computing device 23 with the command to close the valve 43. The computing device 45 sends a signal to the actuator 44 that operates to move the valve 43 to a closed position and maintain the valve 43 in the closed position. In response to a command from the on-board computing device 23, the actuator 26 of the base unit 10 will operate to open vent valve 28 and close the open/close valve 25. The pressure chamber valve 15 is moved to a closed position, thereby cutting off the pressure compartment 11 from the rest of the system 10. The compressor 24 will pressurize the system 10 and the tubing 48 to a preset pressure as measured by pressure transducer 21. The base unit 10 will then operate to open the pressure chamber valve 15. This will add the pressure chamber 11 to the volume being measured. By opening the pressure chamber valve 15 to open the pressure chamber 11 to volume being measured, a pressure drop is caused. The on-board computing device 23 will use this pressure difference to calculate the volume of the unknown length tubing 48, since the pressure chamber 11 shall be a precisely known volume. The volume measurement will then be converted into length by the on-board computer 23. The tubing 48 is conventionally a ⅞ inch HVAC tubing known to be precisely 0.785 inches inside diameter, thereby utilizing a math conversion to calculate the length of the tubing 48 from the pressure. It will be understood that the fan 13 is constantly running during operation of the base unit 10 and performs a dual function of flowing air into the line set 48 when it is open and cooling the electrical components within the housing 30 of the base unit 10.
Measuring a Number of Sharp Bends
An operator may operate the system 10 to measure the number of sharp bends or 90-degree bends of the tubing 48, wherein operation of a measure the number of sharp bends sequence includes the following.
The on-board computing device 23 will then send a command to the bleeder valve 50 to open and bleed off pressure from the tube 19 and the line set 48, wherein pressurized air flows through the bleeder valve 50 and out of the bleeder nozzle 51 until the pressure transducer 21 measures the pressure within the tube 19 and line set 48 at a predetermined pressure level. Once the predetermined pressure level is met, a command will be sent from the base unit 10 to the remote unit 40 to open the valve 43. This is done by computing device 45 receiving the signal from the on-board computing device 23 with the command to open the valve 43. The computing device 45 then sends a signal to the actuator 44 that operates to move the valve 43 to an open position and maintain the valve 43 in the open position. In response to a command from the on-board computing device 23, the actuator 26 of the base unit 10 will operate to close vent valve 28 and open the open/close valve 25. The fan 13 is set and operates at a calibrated speed. The static pressure in the housing of the base unit 10 shall be measured by the differential pressure transducer 22. The on-board computing device 23 may have stored in and accessible form memory of the on-board computing device 23 a look up table of the expected static pressure for a given length of tubing. Long radius bends make very little change in this pressure, but sharp zero radius bends known as (brazed 90s) generate turbulence, thereby providing a significant step up in static pressure. The on-board computing device 23 can then estimate with a high degree accuracy how many sharp bends are in the unknown length of tubing based on the step up in the static pressure. The on-board computing device 23 may then perform a simple calculation of an equivalent length tubing associated with the number of sharp bends of tubing and add that length to the measurement of the length of the tubing 48 for a total length tubing for purposes of adding refrigerant to the HVAC system.
The fan 13 operates constantly during of operation of the HVAC line set analyzer system 100. In some embodiments, referring to
With no shroud, issues arise with the high flow, high static pressure fan 13. It is only high static pressure up to where the restriction causes the blades to stall and then the pressure collapses in the system 10. At high restriction the air stops passing through the fan and spins in a ball above the fan 13. The centrifugal force of the spinning air actually pulls air away from the fan, creating a slight vacuum where there needs to be positive pressure for the system 10 to operate correctly.
With the shroud, the conical section 82 works with the stepped cone section centrifugal force causes rings of spinning air to progress toward the fan creating positive pressure. The stepped cone section 84 operates to maintain a positive pressure and thereby eliminating blade stall and the maximum static pressure is increased by up to 30%. The shroud 80 has been tested, and as shown in
The embodiments and examples set forth herein were presented in order to best explain the present invention and its practical application and to thereby enable those of ordinary skill in the art to make and use the invention. However, those of ordinary skill in the art will recognize that the foregoing description and examples have been presented for the purposes of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the teachings above without departing from the spirit and scope of the forthcoming claims.
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