Patent Application
20250067461
The present subject matter relates generally to air conditioner units, and more particularly to a single bank resistance heater for a packaged terminal air conditioner units and a method for operating the same.
Air conditioner or conditioning units are conventionally utilized to adjust the temperature indoors, e.g., within structures such as dwellings and office buildings. Such units commonly include a closed refrigeration loop to heat or cool the indoor air. Typically, the indoor air is recirculated while being heated or cooled. A variety of sizes and configurations are available for such air conditioner units. For example, some units may have one portion installed within the indoors that is connected to another portion located outdoors, e.g., by tubing or conduit carrying refrigerant. These types of units are typically used for conditioning the air in larger spaces.
Another type of air conditioner unit, commonly referred to as single-package vertical units (SPVU) or package terminal air conditioners (PTAC), may be utilized to adjust the temperature in, for example, a single room or group of rooms of a structure. These units typically operate like split heat pump systems, except that the indoor and outdoor portions are defined by a bulkhead and all system components are housed within a single package that installed in a wall sleeve positioned within an opening of an exterior wall of a building.
When a conventional PTAC is operating in a cooling mode or a heating mode, a compressor circulates refrigerant within a sealed system, while indoor and outdoor fans urge flows of air across indoor and outdoor heat exchangers, respectively. In this manner, the indoor air may be cooled or heated, respectively. However, conventional PTACs may also include a heater assembly that is positioned within the indoor portion for providing supplemental heating to the flow of indoor air when the PTAC is operating in the heating mode.
Typically, manufacturers produce a variety of PTAC models to fit the needs of the indoor space, for example, the structure such as a dwelling or office building, that the PTAC may be utilized within. For example, a manufacturer may produce various PTAC models that each may have different amperage limitations and voltage supply conditions. This variety in PTAC models may lead to expensive harnesses for the electrical components of the PTAC, elaborate and time consuming test sequences, and costly assembly and maintenance of the PTAC.
Accordingly, an air conditioner unit that includes a single resistance bank heater and a heater controller operable for performing a heater control modulation algorithm would be useful. More specifically, a single resistance bank heater and a heater controller operable for controlling amperage levels of the single bank resistance heater would be particularly beneficial.
Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
In one exemplary embodiment, a method for operating an air conditioner unit is provided. The method may include a step of initiating a resistance heating cycle of the air conditioner unit. The method may further include a step of determining a plug personality of a plug of the air conditioner unit, wherein the plug personality is an amperage limit of the plug. The method may also include a step of determining a nominal voltage rating of the air conditioner unit. The method may further include a step of determining, based on the plug personality and the nominal voltage rating, a pulse width modulation rate percentage for a single bank resistance heater of the air conditioner unit. The method may also include a step of setting, within a memory of a heater controller, the determined pulse width modulation rate percentage for the single bank resistance heater.
In another exemplary embodiment, an air conditioner unit is provided. The air conditioner unit may include a plug for providing an electrical connection to the air conditioner unit. The air conditioner unit may also include a single bank resistance heater for selectively heating the flow of air. The air conditioner unit may further include a heater controller operable for: initiating a resistance heating cycle of the air conditioner unit; determining a plug personality of the plug, wherein the plug personality is an amperage limit of the plug; determining a nominal voltage rating of the air conditioner unit; determining, based on the plug personality and the nominal voltage rating, a pulse width modulation rate percentage for the single bank resistance heater; and setting, within the heater control board, the determined pulse width modulation rate percentage for the single bank resistance heater.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”).
The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a ten percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise, or counterclockwise, with the vertical direction V.
Referring now to
A housing 20 of the unit 10 may contain various other components of the unit 10. Housing 20 may include, for example, a rear grill 22 and a room front 24 which may be spaced apart along the transverse direction T by a wall sleeve 26. The rear grill 22 may be part of the outdoor portion 14, and the room front 24 may be part of the indoor portion 12. Components of the outdoor portion 14, such as an outdoor heat exchanger 30, an outdoor fan 32, and a compressor 34 may be housed within the wall sleeve 26. A fan shroud 36 may additionally enclose outdoor fan 32, as shown.
Indoor portion 12 may include, for example, an indoor heat exchanger 40, a blower fan or indoor fan 42, and a heating unit 44. These components may, for example, be housed behind the room front 24. Additionally, a bulkhead 46 may generally support and/or house various other components or portions thereof of the indoor portion 12, such as indoor fan 42 and the heating unit 44. Bulkhead 46 may generally separate and define the indoor portion 12 and outdoor portion 14.
Outdoor and indoor heat exchangers 30, 40 may be components of a sealed system or refrigeration loop 48, which is shown schematically in
As is understood in the art, refrigeration loop 48 may be alternately operated as a refrigeration assembly (and thus perform a refrigeration cycle) or a heat pump (and thus perform a heat pump cycle). As shown in
According to an example embodiment, compressor 34 may be a variable speed compressor. In this regard, compressor 34 may be operated at various speeds depending on the current air conditioning needs of the room and the demand from refrigeration loop 48. For example, according to an exemplary embodiment, compressor 34 may be configured to operate at any speed between a minimum speed, e.g., 1500 revolutions per minute (RPM), to a maximum rated speed, e.g., 3500 RPM. Notably, use of variable speed compressor 34 enables efficient operation of refrigeration loop 48 (and thus air conditioner unit 10), minimizes unnecessary noise when compressor 34 does not need to operate at full speed, and ensures a comfortable environment within the room.
Specifically, according to an exemplary embodiment, compressor 34 may be an inverter compressor. In this regard, compressor 34 may include a power inverter, power electronic devices, rectifiers, or other control electronics suitable for converting an alternating current (AC) power input into a direct current (DC) power supply for the compressor. The inverter electronics may regulate the DC power output to any suitable DC voltage that corresponds to a specific operating speed of compressor. In this manner compressor 34 may be regulated to any suitable operating speed, e.g., from 0% to 100% of the full rated power and/or speed of the compressor. This may facilitate precise compressor operation at the desired operating power and speed, thus meeting system needs while maximizing efficiency and minimizing unnecessary system cycling, energy usage, and noise.
In exemplary embodiments as illustrated, expansion device 50 may be disposed in the outdoor portion 14 between the indoor heat exchanger 40 and the outdoor heat exchanger 30. According to the exemplary embodiment, expansion device 50 may be an electronic expansion valve (“EEV”) that enables controlled expansion of refrigerant, as is known in the art. According to alternative embodiments, expansion device 50 may be a capillary tube or another suitable expansion device configured for use in a thermodynamic cycle.
More specifically, according to exemplary embodiments, electronic expansion device 50 may be configured to precisely control the expansion of refrigerant to maintain, for example, a desired temperature differential of the refrigerant across the evaporator (i.e., the outdoor heat exchanger 30 in heat pump mode). In other words, electronic expansion device 50 throttles the flow of refrigerant based on the reaction of the temperature differential across the evaporator or the amount of superheat temperature differential, thereby ensuring that the refrigerant is in the gaseous state entering compressor 34.
In general, the terms “superheat,” “operating superheat,” or the like are generally intended to refer to the temperature increase of the refrigerant past the fully saturated vapor temperature in the evaporator. In this regard, for example, the superheat may be quantified in degrees Fahrenheit, e.g., such that 1° F. superheat means that the refrigerant exiting the evaporator is 1° F. higher than the saturated vapor temperature. It should be appreciated that the operating superheat may be measured and monitored by controller 64 in any suitable manner. For example, controller 64 may be operably coupled to a pressure sensor for measuring the refrigerant pressure exiting the evaporator, may convert that pressure to the saturated vapor temperature, and may subtract that temperature from the measured refrigerant temperature at the evaporator outlet to determine superheat.
According to exemplary embodiments, expansion device or electronic expansion valve 50 may be driven by a stepper motor or other drive mechanism to any desirable position between a fully closed position (e.g., when no refrigerant passes through EEV 50) to a fully open position (e.g., when there is little or no restriction through the EEV 50). For example, controller 64 may be operably coupled to EEV 50 and may regulate the position of the EEV 50 through a control signal to achieve a target superheat, a target restriction/expansion, etc.
More specifically, the control signal communicated from controller 64 may specify the number of control steps (or simply “steps”) and a corresponding direction (e.g., counterclockwise toward the closed position or clockwise toward the open position). Each EEV 50 may have a physical stroke span equal to the difference between the fully open position and the fully closed position. In addition, the EEV 50 may include a step range or range of control steps that correspond to the number adjustment steps it take for the EEV 50 to travel from the fully closed position to the fully open position.
Each “step” may refer to a predetermined rotation of the drive mechanism, e.g., such as a stepper motor, which may in turn move the EEV 50 a fixed linear distance toward the open or closed position (depending on the commanded step direction). For example, according to the exemplary embodiment, the EEV 50 may have a step range of 500 steps, with 0 steps corresponding to fully closed and 500 steps corresponding to fully open. However, it should be appreciated that according to alternative embodiments, any given electronic expansion valve may include a different number of control steps, and the absolute step adjustments described herein may be varied accordingly.
In addition, as used herein, the position of EEV 50 may be expressed as a percentage, e.g., where 0% corresponds to a fully closed position and 100% corresponds to a fully open position. According to exemplary embodiments, this percentage representation may also refer to the percentage of total control steps taken from the closed position, e.g., with 10% referring to 50 steps (e.g., 10% of the 500 total steps), 80% referring to 400 steps (e.g., 80% of 500 total steps), etc.
According to the illustrated exemplary embodiment, outdoor fan 32 is an axial fan and indoor fan 42 is a centrifugal fan. However, it should be appreciated that according to alternative embodiments, outdoor fan 32 and indoor fan 42 may be any suitable fan type. In addition, according to an exemplary embodiment, outdoor fan 32 and indoor fan 42 are variable speed fans, e.g., similar to variable speed compressor 34. For example, outdoor fan 32 and indoor fan 42 may rotate at different rotational speeds, thereby generating different air flow rates. It may be desirable to operate fans 32, 42 at less than their maximum rated speed to ensure safe and proper operation of refrigeration loop 48 at less than its maximum rated speed, e.g., to reduce noise when full speed operation is not needed. In addition, according to alternative embodiments, fans 32, 42 may be operated to urge make-up air into the room.
According to the illustrated embodiment, indoor fan 42 may operate as an evaporator fan in refrigeration loop 48 to encourage the flow of air through indoor heat exchanger 40. Accordingly, indoor fan 42 may be positioned downstream of indoor heat exchanger 40 along the flow direction of indoor air and downstream of heating unit 44. Alternatively, indoor fan 42 may be positioned upstream of indoor heat exchanger 40 along the flow direction of indoor air and may operate to push air through indoor heat exchanger 40.
The heating unit 44 may include a single bank resistance heater 60 that may be provided to produce heat. The single bank resistance heater 60 may include at least one heater coil or coil pass 62. For instance, as illustrated in
The operation of air conditioner unit 10 including compressor 34 (and thus refrigeration loop 48 generally) indoor fan 42, outdoor fan 32, heating unit 44, expansion device 50, and other components of refrigeration loop 48 may be controlled by a processing device such as a controller 64. Controller 64 may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner unit 10. Controller 64 may include a memory and one or more processing devices such as microprocessors, CPUs, or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of unit 10. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor.
Unit 10 may additionally include a control panel 66 and one or more user inputs 68, which may be included in control panel 66. The user inputs 68 may be in communication with the controller 64. A user of the unit 10 may interact with the user inputs 68 to operate the unit 10, and user commands may be transmitted between the user inputs 68 and controller 64 to facilitate operation of the unit 10 based on such user commands. A display 70 may additionally be provided in the control panel 66 and may be in communication with the controller 64. Display 70 may, for example, be a touchscreen or other text-readable display screen, or alternatively may simply be a light that can be activated and deactivated as required to provide an indication of, for example, an event or setting for the unit 10.
Referring briefly to
As shown in
In some cases, it may be desirable to treat or condition make-up air flowing through vent aperture 80 prior to blowing it into the room. For example, outdoor air which has a relatively high humidity level may require treating before passing into the room. In addition, if the outdoor air is cool, it may be desirable to heat the air before blowing it into the room. Therefore, according to an exemplary embodiment of the present subject matter, unit 10 may further include an auxiliary sealed system that is positioned over vent aperture 80 for conditioning make-up air. The auxiliary sealed system may be a miniature sealed system that acts similar to refrigeration loop 48, but conditions only the air flowing through vent aperture 80. According to alternative embodiments, such as that described herein, make-up air may be urged through vent aperture 80 without the assistance of an auxiliary sealed system. Instead, make-up air urged through vent aperture 80 may be conditioned at least in part by refrigeration loop 48, e.g., by passing through indoor heat exchanger 40. Additionally, the make-up air may be conditioned immediately upon entrance through vent aperture 80 or sequentially after combining with the air stream induced through indoor heat exchanger 40.
Referring now to
According to the illustrated embodiment, auxiliary fan 102 is an axial fan positioned at an inlet of fan duct 104, e.g., upstream from vent aperture 80. However, it should be appreciated that any other suitable number, type, and configuration of fan or blower could be used to urge a flow of makeup air according to alternative embodiments. In addition, auxiliary fan 102 may be positioned in any other suitable location within air conditioner unit 10 and auxiliary fan 102 may be positioned at any other suitable location within or in fluid communication with fan duct 104. The embodiments described herein are only exemplary and are not intended to limit the scope of the present subject matter.
Referring now to
As illustrated, room front 24 of unit 10 generally defines an intake vent 110 and a discharge vent 112 for use in circulating a flow of air (indicated by arrows 114) throughout a room. In this regard, indoor fan 42 is generally configured for drawing in air 114 through intake vent 110 and urging the flow of air through indoor heat exchanger 40 before discharging the air 114 out of discharge vent 112. According to the illustrated embodiment, intake vent 110 is positioned proximate a bottom of unit 10 and discharge vent 112 is positioned proximate a top of unit 10. However, it should be appreciated that according to alternative embodiments, intake vent 110 and discharge vent 112 may have any other suitable size, shape, position, or configuration.
During a cooling cycle, refrigeration loop 48 is generally configured for urging cold refrigerant through indoor heat exchanger 40 in order to lower the temperature of the flow of air 114 before discharging it back into the room. Specifically, during a cooling operation, controller 64 may be provided with a target temperature, e.g., as set by a user for the desired room temperature. In general, components of refrigeration loop 48, outdoor fan 32, indoor fan 42, and other components of unit 10 operate to continuously cool the flow of air.
In order to facilitate operation of refrigeration loop 48 and other components of unit 10, unit 10 may include a variety of sensors for detecting conditions internal and external to the unit 10. These conditions can be fed to controller 64 which may make decisions regarding operation of unit 10 to rectify undesirable conditions or to otherwise condition the flow of air 114 into the room. For example, as best illustrated in
As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensor 120 may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. In addition, temperature sensor 120 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that unit 10 may include any other suitable number, type, and position of temperature, and/or other sensors according to alternative embodiments.
As used herein, the terms “humidity sensor” or the equivalent may be intended to refer to any suitable type of humidity measuring system or device positioned at any suitable location for measuring the desired humidity. Thus, for example, humidity sensor 122 may refer to any suitable type of humidity sensor, such as capacitive digital sensors, resistive sensors, and thermal conductivity humidity sensors. In addition, humidity sensor 122 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the humidity being measured. Although exemplary positioning of humidity sensors is described herein, it should be appreciated that unit 10 may include any other suitable number, type, and position of humidity sensors according to alternative embodiments.
Referring now to
In some embodiments, the heater control assembly 200 may include a thermal cutoff switch 202, a first temperature sensor 204, and a second temperature sensor 206 that each may be mounted to a bracket 208 extended from the bulkhead 46. As illustrated in
In some embodiments, the thermal cutoff switch 202 may be mounted adjacent to the single bank resistance heater 60. In addition, the thermal cutoff switch 202 may be electrically coupled to the single bank resistance heater 60, for instance, the thermal cutoff switch 202 may be connected in series with the single bank resistance heater 60 such that the thermal cutoff switch 202 may cut off power to the single bank resistance heater 60 when a predetermined temperature threshold, for example, a maximum allowable temperature of the ambient air surrounding the heating unit 44, may be met. For example, the thermal cutoff switch 202 may be provided to cut off power to the single bank resistance heater 60 to protect the single bank resistance heater 60 from overheating, for example, when the single bank resistance heater 60 may operate without the flow of air 114 passing over them, for instance, during a blockage condition of the air conditioner unit 10.
In this regard, the thermal cutoff switch 202 may be provided to avoid or prevent unsafe operating conditions of the air conditioner unit 10 by breaking an electrical connection to the single bank resistance heater 60 when the predetermined temperature threshold is met or exceeded. For example, in some embodiments the thermal cutoff switch 202 may contain a low melting point alloy that may melt and break the electrical current to the single bank resistance heater 60 when the predetermined temperature threshold is met or exceeded. As another example, in some embodiments, the thermal cutoff switch 202 may include a bimetallic strip that may bend and break the electrical connection to the single bank resistance heater 60 when the predetermined threshold is met or exceeded.
In some embodiments, the thermal cutoff switch 202 may be a one shot thermal cutoff switch 202 that may permanently break the electrical connection to the single bank resistance heater 60 when the thermal cutoff switch 202 is tripped. Particularly, when the one shot thermal cutoff switch 202 is tripped it may not be reenergized or reused until the air conditioner unit 10 is repaired, for example, until the blockage of air flow 114 is cleared, and the thermal cutoff switch 202 is replaced.
Replacement of the thermal cutoff switch 202 may be costly and time consuming. Accordingly, embodiments of the present disclosure provide the first temperature sensor 204 and the second temperature sensor 206 of the heater control assembly 200. For instance, as illustrated in
Particularly, in some embodiments, the first temperature sensor 204 may be positioned downstream of the indoor heat exchanger 40 and upstream of the thermal cutoff switch 202. In addition, the first temperature sensor 204 may be positioned proximate the front 210 of the single bank resistance heater 60, wherein “positioned proximate the front” may refer to the first temperature sensor 204 being positioned closer to the front 210 of the single bank resistance heater 60 than the back 212 of the single bank resistance heater 60 approximately along or approximately parallel to the transverse direction T. Further, the first temperature sensor 204 may be positioned above the single bank resistance heater 60 approximately along or approximately parallel to the vertical direction V.
In some embodiments, for instance, as illustrated in
In some embodiments, a controller, for example, the controller 64 or a heater controller 65 (described in more detail below), may be operably coupled to the single bank resistance heater 60, the first temperature sensor 204, and the second temperature sensor 206. Prior to operation of the air conditioner unit 10, the controller may be provided with the predetermined temperature threshold. In some embodiments, the predetermined temperature threshold may be a temperature set by regulations, for example, government regulations, and may correspond to the temperature at which the thermal cutoff switch 202 may be tripped.
During operation of the air conditioner unit 10, a first temperature reading of the flow of air 114 upstream, and more specifically, immediately upstream, of the thermal cutoff switch 202 may be obtained by the first temperature sensor 204 and a second temperature reading of the flow of air 114 downstream, and more specifically, immediately downstream, of the thermal cutoff switch 202 may be obtained by the second temperature sensor 206.
The first temperature reading, the second temperature reading, or a combination thereof, may be fed to the controller, wherein the controller may be configured to adjust or throttle an amperage and/or wattage power output to the single bank resistance heater 60 by adjusting the voltage to regulate an electrical current to the single bank resistance heater 60. In this regard, the ambient temperature of the heating unit 44, and more particularly, the ambient temperature surrounding the thermal cutoff switch 202 may be maintained below the predetermined temperature threshold.
Moreover, if it is detected that there is sudden change in the conditions of the air conditioner unit 10 that may potentially damage the heating unit 44 or cause an unsafe heating condition, for instance, if it is detected that there is a blocking condition, the controller may throttle the amperage and/or wattage power output to the single bank resistance heater 60 or the controller may execute a rapid shutdown of the single bank resistance heater 60.
Referring now to
The operation of the single bank resistance heater 60 may be controlled by a processing device such as the heater controller 65. Heater controller 65 may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner unit 10. Heater controller 65 may include a memory and one or more processing devices such as microprocessors, CPUs, or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of unit 10. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor.
In some embodiments, the algorithm 300 may include a process function 302 of starting a resistance heating cycle of the air conditioner unit 10, and more particularly, the single bank resistance heater 60. In some embodiments, the air conditioner unit may be connected to a power supply, for instance, an electrical outlet, via an electrical plug, such as a plug 71 illustrated in
In some embodiments, after the process function 302, the plug personality of the electrical plug may be determined. In some embodiments, the electrical plug may be connected to a controller of the air conditioner unit, for instance the heater controller 65 of the air conditioner unit 10. The plug personality may be determined by the controller “reading” the maximum amount of current that may be drawn by the electrical plug. Specifically, in some embodiments, for the controller to “read” the plug personality of the electrical plug, a number of decisions based on the amount of current that may be drawn by the electrical plug, for example, when the electrical plug is connected to a power supply such as an electrical outlet, are made.
For instance, after the process function 302, the algorithm 300 may execute a decision function 304 of determining if the plug personality of the electrical plug may be twenty Amps (20 A). In this regard, the controller, for example, the heater controller 65, may read, for instance, determine, the maximum amount of current that the electrical plug may draw. In some embodiments, it may be determined at the decision function 304 that the plug personality of the electrical plug is twenty Amps (20 A). In such embodiments, in response to it being determined that the plug personality is twenty Amps (20 A), the algorithm 300 may include a process function 306 wherein a first value may be set to two thirds (e.g., ⅔).
Alternatively, in some embodiments, it may be determined at the decision function 304 that the plug personality of the electrical plug is not twenty Amps (20 A). In such embodiments, in response to it being determined that the plug personality is not twenty Amps (20 A), the algorithm 300 may include a decision function 308 of determining if the plug personality of the electrical plug may be thirty Amps (30 A). As described above, the plug personality may be determined by a controller of the air conditioner unit reading the maximum amount of current that the electrical plug may draw.
In some embodiments, it may be determined at process function 306 that the plug personality of the electrical plug is thirty Amps (30 A). In such embodiments, in response to it being determined that the plug personality is thirty Amps (30 A), the algorithm 300 may include a process function 310 wherein the first value may be set to one (e.g., 1). Alternatively, in some embodiments, it may be determined at the decision function 304 that the plug personality of the electrical plug is not thirty Amps (30 A). In such embodiments, in response to it being determined that the plug personality is not thirty Amps (30 A), the algorithm 300 may include a process function 312 wherein it may be determined that the plug personality of the electrical plug may be fifteen Amps (15 A) and wherein the first value may be set to one half (e.g., ½).
In some embodiments, the algorithm 300 may include a decision function 314 of determining a nominal voltage rating of the air conditioner unit. In some embodiments, the nominal voltage rating of the air conditioner unit may be determined to be any suitable nominal voltage rating of an air conditioner unit. For instance, as illustrated in
In some embodiments, it may be determined at decision function 314 that the nominal voltage rating of the air conditioner unit is two hundred and thirty Volts (230V). In such embodiments, in response to the nominal voltage rating being determined to be two hundred and thirty Volts (230V), for instance, at decision function 314, a process function 316 may be executed, wherein a second value is set to three fourths (e.g., ¾). Furthermore, in some embodiments, it may be determined that the nominal voltage rating of the air conditioner unit is two hundred and sixty five Volts (265V). In such embodiments, in response to the nominal voltage rating being determined to be two hundred and sixty five Volts (265V), for instance, at decision function 314, a process function 318 may be executed, wherein a second value is set to one (e.g., 1).
In response to the plug personality being determined, for instance, at decision function 304 or at decision function 308, and the nominal voltage rating being determined, for instance, at decision function 314, the algorithm 300 may execute a process function 322 wherein a pulse width modulation rate percentage is determined. As an example, the pulse width modulation rate percentage may be calculated with the following at process function 320.
Pulse Width Modulation Rate Percentage=K1*K2*100
In some embodiments, the pulse width modulation rate percentage may be fed, for example, sent to via a signal, to the controller of the air conditioner unit at process function 324. For instance, the pulse width modulation rate percentage may be fed to a main controller of the air conditioner unit, for instance the controller 64 of the air conditioner unit 10. Moreover, in some embodiments, the main controller may feed, for example, send a signal to, a daughter controller, for instance, the heater controller 65 of the air conditioner unit 10, that may include the pulse width modulation rate percentage. In this regard, a process function 326 may be executed wherein the single bank resistance heater, for example, the single bank resistance heater 60, may be controlled by the daughter controller, for example, the heater controller 65. For instance, as the pulse width modulation rate percentage is based off of the plug personality and the nominal voltage rating, a pulse rate of the daughter controller may be configured to avoid tripping of a circuit breaker that it may be connected, particularly, in low voltage and low amperage models of the air conditioner unit.
Referring now to
In some embodiments, the method 400 may include a step 410 of initiating a resistance heating cycle of the air conditioner unit. For instance, at step 410 the process of generating heat using a single bank resistance heater, for example, the single bank resistance heater 60 of the air conditioner unit 10, may be initiated. In some embodiments, the step 410 of initiation the resisting heating cycle may include ensuring the air conditioner unit, and more particularly the single bank resistance heater of the air conditioner unit, is connected to a power supply, for example, an electrical outlet. For instance, this may include a user of the air conditioner unit connecting a plug of the air conditioner unit, for example, the plug 71 of air conditioner unit 10, into a power supply, for example, an electrical outlet. Furthermore, the resistance heating cycle of the air conditioner unit may be initiated such that a flow of current may flow through the single bank resistance heater.
The method 400 may also include a step 420 of determining a plug personality of a plug of the air conditioner unit. In some embodiments, the plug personality of the air conditioner unit may be an amperage limit, for example, a maximum amount of current that may be drawn, of the plug of the air conditioner unit. In some embodiments, it may be determined that the plug personality, for instance, the amperage limit, is fifteen Amps, twenty Amps, or thirty Amps.
In addition, in some embodiments, the determined plug personality, for example, as determined at step 420, may correspond to a first value. In some embodiments, in response to the plug personality being determined to be 15 A the first value may be set to ½. Additionally, in some embodiments, in response to the plug personality being determined to be 20 A the first value may be set to ⅔. Further, in some embodiments, in response to the plug personality being determined to be 30 A the first value may be set to 1.
Further, the method 400 may include a step 430 of determining a nominal voltage rating of the air conditioner unit, for instance, as described in more detail above with respect to the algorithm 300. In some embodiments, the determined nominal voltage rating corresponds to a second value, wherein the nominal voltage rating is determined to be 230V or 265V. In some embodiments, in response to the nominal voltage rating being determined to be 230V the second value may be set to ¾. In some embodiments, in response to the nominal voltage rating being determined to be 265V the second value may be set to 1.
The method 400 may also include a step 440 of determining, based on the plug personality and the nominal voltage rating, a pulse width modulation rate percentage for a single bank resistance heater of the air conditioner unit. For instance, the pulse width modulation rate may be determined by the equation described above, e.g., with reference to process function 320 of the algorithm 300. In response, to the pulse width modulation rate being determined, for instance, at step 440, the method 400 may further include a step 450 of setting, within a memory of the controller, for example, heater controller 65 of the air conditioner unit 10, the determined pulse width modulation rate percentage for the single bank resistance heater, wherein the determined pulse width modulation rate percentage is based on the first value and the second value. Additionally, in some embodiments, in response to the step 450, the method 400 may include a step of providing a voltage to the single bank resistance heater, for example, the single bank resistance heater 60, wherein the voltage controlled by the pulse width modulation rate percentage, for instance, as determined at step 440. In some embodiments, the pulse width modulation rate percentage may correspond to the maximum amount of power that may be provided to the single bank resistance heater.
Embodiments of the present subject matter may advantageously provide a large amperage single bank resistance heater, for instance, the exemplary single bank resistance heater 60, with a heater controller, for instance the exemplary heater controller 65, for modulating an air conditioner unit such as a packaged terminal air conditioner (PTAC) unit. The large amperage single bank heater may advantageously function as a universal, or common resistance heater that may be utilized in various air conditioner units with a variety of different amperages, for example, 15 A, 20 A, and 30 A, as well as a variety of different nominal voltage ratings, for example, 230V and 265V nominal voltage ratings.
The single bank resistance heater may advantageously eliminate the need to manufacture various models of air conditioner units based on the heater amperage. The heater controller and the utilized methods and algorithms may advantageously set the maximum current draw as well as compensate for voltage variations based on a plug personality of the plug and a nominal voltage rating. In this regard, the air conditioner unit may avoid tripping breakers. Additionally, in some embodiments, feedback, for instance, feedback such as temperature readings from the first temperature sensor and the second temperature sensor may also be used to control, maintain, or throttle amperage levels of the single bank resistance heater.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
