EP3671058A1 - Wärmepumpenabtauregler - Google Patents

Wärmepumpenabtauregler Download PDF

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Publication number
EP3671058A1
EP3671058A1 EP19217749.1A EP19217749A EP3671058A1 EP 3671058 A1 EP3671058 A1 EP 3671058A1 EP 19217749 A EP19217749 A EP 19217749A EP 3671058 A1 EP3671058 A1 EP 3671058A1
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EP
European Patent Office
Prior art keywords
defrost
heat pump
processing circuitry
controller
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19217749.1A
Other languages
English (en)
French (fr)
Other versions
EP3671058B1 (de
Inventor
Travis J. Read
Joseph Carlos Vargas
Derek WELLER
Peter M. Anderson
Donald C. KENNEDY
Paul Knauf
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Ademco Inc
Original Assignee
Ademco Inc
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Filing date
Publication date
Application filed by Ademco Inc filed Critical Ademco Inc
Publication of EP3671058A1 publication Critical patent/EP3671058A1/de
Application granted granted Critical
Publication of EP3671058B1 publication Critical patent/EP3671058B1/de
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B47/00—Arrangements for preventing or removing deposits or corrosion, not provided for in another subclass
    • F25B47/02—Defrosting cycles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/30—Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring
    • F24F11/41—Defrosting; Preventing freezing
    • F24F11/42—Defrosting; Preventing freezing of outdoor units
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/30—Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring
    • F24F11/41—Defrosting; Preventing freezing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/50—Control or safety arrangements characterised by user interfaces or communication
    • F24F11/52—Indication arrangements, e.g. displays
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/50—Control or safety arrangements characterised by user interfaces or communication
    • F24F11/61—Control or safety arrangements characterised by user interfaces or communication using timers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F2110/00—Control inputs relating to air properties
    • F24F2110/10—Temperature
    • F24F2110/12—Temperature of the outside air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F2140/00—Control inputs relating to system states
    • F24F2140/20—Heat-exchange fluid temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2600/00—Control issues
    • F25B2600/23—Time delays
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/11—Sensor to detect if defrost is necessary
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/21—Temperatures
    • F25B2700/2106—Temperatures of fresh outdoor air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B47/00—Arrangements for preventing or removing deposits or corrosion, not provided for in another subclass
    • F25B47/02—Defrosting cycles
    • F25B47/022—Defrosting cycles hot gas defrosting
    • F25B47/025—Defrosting cycles hot gas defrosting by reversing the cycle

Definitions

  • the disclosure relates to heat pump defrost controllers.
  • a heating, ventilation, and air conditioning (HVAC) system that includes a heat pump typically includes an indoor and an outdoor heat exchanger coil.
  • the heat exchanger coil may have a liquid, such as a refrigerant, running through piping, and when operating, the piping has air flowing over it. Because heat only flows from a high energy region to a low energy reason, a heat exchanger coil may extract energy from the air flowing through the coil if the coil is cooler than the surrounding air.
  • the heat pump In cooling mode, for example in summer in the northern hemisphere, the heat pump may be configured to cause the indoor coil to be cooler than indoor air passing through the indoor coil to remove heat from the air and cool the indoor space.
  • the heat pump may configure the outdoor heat exchanger coil to be cooler than the outdoor air passing through it to extract energy from the outdoor air, transfer it to the indoor coil, and heat the indoor space.
  • Ambient air contains moisture, which may condense on the cooler heat exchanger coil. If the heat exchanger coil is cold enough, this moisture may form ice. Ice build-up inhibits airflow through the coil. In heating mode, even at relatively warm outside air temperatures, ice may still form on the outside heat exchanger coil. The ice should be removed or the heat pump may fail to heat the indoor space.
  • the disclosure is directed to a universal heat pump defrost controller device that is configured to determine when and for how long to cause a heat pump to enter defrost mode to remove ice from the outdoor heat exchanger coil.
  • the defrost controller of this disclosure is configured to work with a variety of heat pumps which may implement a variety of defrost approaches.
  • An example of defrost approach may include a timing cycle, which puts the heat pump in defrost mode periodically for a set time.
  • Other examples of defrost approaches may include determining a temperature difference or a pressure difference between two or more areas of the heat pump and put the heat pump into defrost mode based on a temperature or pressure difference satisfying a predetermined threshold.
  • Other examples of defrost approaches may include some combination of temperature or pressure sensing along with periodic timing.
  • the universal heat pump defrost controller of this disclosure is includes an intuitive display and user input with which a user may install the defrost controller on a heat pump and configure the controller to efficiently control the defrost cycle for a specific heat pump under specific conditions.
  • a heat pump that does not defrost enough may limit air flow through the outdoor heat exchanger coil, reduce heat transfer efficiency and may cause stress on some heat pump components, such as the compressor.
  • a heat pump that defrosts more than is needed uses additional energy, such as electricity, which may reduce the overall efficiency of the HVAC system as part of an overall system to control the environment of one or more spaces within a building.
  • the universal heat pump defrost controller of this disclosure provides a defrost cycle control that is configurable to a particular heat pump approach, which may improve efficiency, equipment safety and reliability.
  • the disclosure is directed to a universal heat pump defrost controller device that is configured to determine when and for how long to cause a heat pump to enter defrost mode to remove ice from the outdoor heat exchanger coil.
  • the defrost controller of this disclosure is configured to work with a variety of heat pumps which may implement a variety of defrost approaches.
  • An example of a defrost approach may include a timing cycle, which puts the heat pump in defrost mode periodically for a set time.
  • Other examples of defrost approaches include determining a temperature difference or a pressure difference between two or more areas of the heat pump and put the heat pump into defrost mode based on a temperature or pressure difference satisfying a predetermined threshold.
  • Other examples of defrost approaches include some combination of temperature or pressure sensing along with periodic timing.
  • the universal heat pump defrost controller of this disclosure is includes an intuitive display and user input with which a user may install the defrost controller on a heat pump and configure the controller to efficiently control the defrost cycle.
  • the universal heat pump defrost controller of this disclosure provides a defrost cycle control that is configurable to a particular heat pump approach, which may improve efficiency, equipment safety and reliability.
  • the defrost controller on an existing heat pump installation may malfunction or fail.
  • a repair technician may either need to carry a large number and variety of replacement parts on the repair truck or delay a repair until the replacement model of defrost controller is delivered to the repair site.
  • a repair technician may instead carry a few universal defrost controllers that can be used on a variety of heat pump models. Installing a replacement defrost controller may require a significant amount of field configuration to work properly with the existing heat pump. In some examples, even replacing a defrost controller with the exact replacement part may require a significant amount of field configuration to account for changes in climate from default settings for the defrost controller.
  • Heat pump controllers, and heat pumps, from different manufacturers may operate at different temperatures, place their sensors in different locations, and have differing rates of frost accumulation. The large amount of variation may require in depth knowledge by the repair technician to properly configure the heat pump controller.
  • Some examples of existing heat pump controllers have no display and may either be non-configurable or offer very little configurability.
  • Some examples of universal defrost controllers, while capable of replacing many models, may be difficult to setup or require a great amount of heat pump appliance knowledge to configure properly.
  • a repair technician may also be referred to as an installer.
  • the universal heat pump defrost controller of this disclosure includes a controllable display on the defrost controller and may also include wireless connectivity to configure the controller via communication with a computing device.
  • the defrost controller of this disclosure includes a display for showing operating temperatures, which may show the installer normal/current operating temperatures of the appliance to help in troubleshooting and configuration.
  • the defrost controller of this disclosure may display key parameters, such as outdoor air temperature and outdoor coil temperature so the installer can easily see the operating conditions to help the installer troubleshoot a malfunctioning or poorly configured appliance.
  • FIG. 1 is a block diagram illustrating one example of a climate control system including a heat pump with a defrost controller according to one or more techniques of this disclosure.
  • Other examples of a climate control system using a heat pump may include more or fewer components than shown in FIG. 1 .
  • climate control system 100 is an example of a forced air system that may be used to control the temperature of an enclosed space, such as an office building, home, or other similar space.
  • Example climate control system 100 includes a forced air heating, ventilation and air conditioning (HVAC) system 102, HVAC controller 116, thermostat 118, heat pump 130 and defrost controller 120.
  • HVAC forced air heating, ventilation and air conditioning
  • HVAC system 102 is configured to draw return air 104 from one or more enclosed spaces, which may be indoor spaces. HVAC system 102 heats, cools or just circulates the air back to living spaces 106. HVAC system 102 includes a blower 112 mechanically connected to blower motor 114, heat exchanger 110, and one or more auxiliary heat exchangers 108. In this disclosure, for simplicity, the heated and cooled spaces will be referred to as living spaces.
  • Blower motor 104 drives blower 112 via a belt, or some other mechanical connection. Blower 112 forces air through heat exchanger 110, auxiliary heat exchanger 108 and to living spaces 106, which draws return air 104 from return air ducts in the living spaces.
  • Heat exchanger 110 is an indoor heat exchanger connected via plumbing to an outdoor heat exchanger in heat pump 130. In cooling mode, heat exchanger 110 transfers energy from the air to liquid refrigerant in the coils of heat exchanger 110, thereby cooling the air sent to living spaces 106. In heating mode, heat exchanger 110 transfers energy from outside air passed through the outdoor heat exchanger coil in heat pump 130 (not shown in FIG. 1 ), thereby heating the air sent to living spaces 106.
  • Auxiliary heat exchanger 108 is used to heat the air sent to living spaces 106 when heat pump 130 does not provide adequate heat, such as during a defrost cycle, or if the outside air temperature (OAT) is too cold for heat pump 130 to function.
  • Examples of auxiliary heat exchanger 108 may include an electric heating unit, such as a resistance heater, a heat exchanger connected to a gas or other type of furnace.
  • HVAC controller 116 receives a signal from thermostat 118 and sends a signal to defrost controller 120 as well as control signals to HVAC system 102.
  • thermostat 118 may directly connect to HVAC system 102 and defrost controller 120.
  • Thermostat 118 may send a call for heat or call for cold to HVAC controller 116, which may in turn send signals to heat pump 130 and HV AC system 102 to circulate cold or warm air to living spaces 106.
  • HVAC controller may also send and receive signals from defrost controller 120 to control the defrost cycle of heat pump 130.
  • Defrost controller 120 is configured to operate with a variety of different heat pumps 130 operating in a variety of different climates.
  • defrost controller 120 may include one or more circuit boards, a display, input controls and a wireless communication interface.
  • the one or more circuit boards may include a number of electrical connection terminals used to connect control or sensing signals between the components of heat pump 130 and defrost controller 120.
  • Defrost controller 120 may also have connection terminals to communicate with HVAC controller 116 and/or directly with thermostat 118.
  • Defrost controller 120 may also include one or more mounting tabs to mechanically secure defrost controller 120 to heat pump 130.
  • Defrost controller 120 may include one or more processors to execute the functions of the defrost controller.
  • Examples of the one or more processors in defrost controller 120 may include any one or more of a microcontroller (MCU), e.g. a computer on a single integrated circuit containing a processor core, memory, and programmable input/output peripherals, a microprocessor ( ⁇ P), e.g. a central processing unit (CPU) on a single integrated circuit (IC), a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a system on chip (SoC) or equivalent discrete or integrated logic circuitry.
  • a processor may be integrated circuitry, i.e., integrated processing circuitry, and that the integrated processing circuitry may be realized as fixed hardware processing circuitry, programmable processing circuitry and/or a combination of both fixed and programmable processing circuitry.
  • defrost controller 120 may initiate defrost in heat pump 130 based on defrost controller 120 operating in timing mode or demand mode.
  • a first timer may measure an accumulated run time on the compressor, such as thirty, forty-five, ninety minutes or other configurable time interval.
  • the defrost controller initiates a defrost mode for a set length of time.
  • the interval may be configured based on the model and type of heat pump as well as the location of the heat pump. For example, in dry, arid climate, the interval may be set longer than the interval in more humid regions.
  • the installer may configure the time interval, the defrost mode run time and other timing using the display on defrost controller 120, or via a wireless or wired connection to a computing device.
  • Demand mode may be based on a pressure difference or a temperature difference.
  • a pressure difference system may consider that that ice on the coil may result in an increase in the pressure differential across the outdoor heat exchanger coil.
  • a defrost controller operating in pressure demand mode may compare the pressure on both sides (input and output) of the outdoor coil. When the difference between the two pressures reaches a preset level, defrost controller 120 may initiate a defrost.
  • defrost controller 120 may measure the temperature of the piping in the outdoor heat exchanger coil of heat pump 130 as well as the outside air temperature. As ice builds up on the coil, the refrigerant may not absorb as much heat from the outdoor air and the coil gets colder. In other words, as ice accumulates, this ⁇ T may increases because the coil temperature drops. Processing circuitry of defrost controller 120 may initiate a defrost when the temperature sensors indicate a preset ⁇ T limit has been satisfied.
  • defrost controller 120 determines when to initiate a defrost based on the configured temperature set point and other factors.
  • processing circuitry within defrost controller 120 may include instructions to automatically detect when heat pump 130 is in heating vs cooling mode. For example, by sensing the temperature of the heat pump coil, defrost controller 120 may determine if heat pump 130 is heating or cooling based on the temperature rise of the outdoor coil. An outdoor coil rising in temperature may indicate cooling mode. An outdoor coil dropping in temperature may indicate heating mode.
  • Defrost functionality may be automatically enabled when coil temperature is detected in the applicable range.
  • an installer may configure defrost controller 120 the reversing valve system type for the particular heat pump 130.
  • heat pump 130 may energize the reversing valve when in cooling mode (O) or may energize the reversing valve when in heating mode (B).
  • a minimum defrost interval timer may disable the temperature or pressure imitated defrost until a minimum interval from the previous defrost cycle has expired.
  • a fail-safe timer may be incorporated to limit the maximum length of a defrost cycle. This timer may be used as a backup in case the coil sensor fails and does not terminate defrost.
  • FIG. 2 is a conceptual diagram illustrating an example front view of a heat pump defrost controller according to one or more techniques of this disclosure.
  • Defrost controller 200 is an example of defrost controller 120 described above in relation to FIG. 1 and includes the same characteristics and functions.
  • Defrost controller 200 is configured with a square form factor, in which the vertical dimensions 232 are approximately equal to the horizontal dimensions 230. Also, the size of defrost controller 200 is small, when compared to other examples of defrost controllers. Defrost controller 200 is intended as a replacement for original equipment manufacturer (OEM) defrost controllers or other universal controllers. Other components and various wires and cable assemblies. it can be very difficult to find room to install any new devices or kits in an existing heat pump, such as heat pump 130 described above in relation to FIG. 1 . Because the space available on most heat pumps is limited, the small relative size and square form factor of defrost controller 200 provide advantages over other types of defrost controllers.
  • OEM original equipment manufacturer
  • Defrost controller 200 may be installed in a heat pump with limited space and in either a horizontal or vertical rotation to be compatible with a wide variety of heat pumps.
  • Defrost controller 200 includes menu display 202 and setting display 204, indicator lights 206, controls 208, 210 and 212, circuit board 222 on which are mounted temperature sensor connectors 216 and 218, other connectors 214 and relay 220.
  • circuit board 222 may also include processing circuitry 223, shown as a dashed line image.
  • the connectors on circuit board 222 are arranged to be all together and below control and indicator panel 234 of defrost controller 200.
  • Control and indicator panel 234 may also be referred to as user interface 234.
  • the connectors on circuit board 222 such as other connectors 214 may be spade connectors or other type of quick connect electrical connectors. Having all the connectors, each connector with a clear label, in one location below control and indicator panel 234, may provide advantages over other examples of defrost controllers that have difficult to read labels, and may have wiring connections coming from different locations and out of different directions from the circuit board.
  • the arrangement of the electrical connectors of defrost controller 200 may simplify installation and thereby reduce installation time, minimize confusion, rework and troubleshooting.
  • connections 214 may include connections to power the reversing valve or to power the auxiliary heat or some portion of the auxiliary heat while the heat pump is in defrost.
  • Defrost controller 200 may be configured to automatically turn on auxiliary heat when in defrost, or rely on the thermostat to call for auxiliary heat as needed.
  • LPS (or LPC) (2 terminals) High pressure cutout/switch- these terminals must be shorted for compressor operation.
  • AUX Output to auxiliary/emergency heat -energized during a defrost cycle or when requested by W input.
  • CONT (2 terminals) Output to compressor contactor-energized by Y request.
  • the CONT terminal may also be labeled as a COMPR terminal.
  • REV or RV (2 terminals) Output to reversing valve. Energized by 0 input and as required by a defrost cycle.
  • Air temperature sensor connector 218 may receive the OAT from a temperature probe (not shown in FIG. 2 ).
  • Coil temperature sensor connection 216 may receive the temperature of the outdoor heat exchanger coil (not shown in FIG. 2 ).
  • Processing circuitry of defrost controller 200 (not shown in FIG. 2 ) may use the temperature information to execute the temperature demand mode functions described above in relation to FIG. 1 .
  • connecting one or more temperature sensors may automatically configure defrost controller 200 to perform certain functions.
  • processing circuitry of defrost controller 200 may implement the most sophisticated defrost algorithm as determined by the sensors connected to it. In the example of both sensors (air and coil temperatures) are in place, the processing circuitry may implement temperature demand defrost mode.
  • the processing circuitry may implement a hybrid timed mode in which a period of time while the coil is below some threshold temperature may be used as the defrost trigger.
  • defrost controller 200 may defrost after 30 minutes of runtime below 35degF is detected.
  • Defrost controller 200 may be configured to automatically switch between operating modes. For example. In the event that the air temperature sensor fails, defrost controller 200 may be configured to automatically switch from temperature demand mode to timed mode. The air temperature sensor may fail for example, if the sensor becomes disconnected or damaged, such as because of weather. Processing circuitry within defrost controller 200 may detect the status of the air temperature sensor, or some other sensor, e.g. that the sensor is malfunctioning or providing signals that indicate a malfunction. Similarly, the processing circuitry may detect that a sensor has been disconnected or is in some other inactive status.
  • Relay 220 may control a fan or blower used to move outside air through the outside heat exchanger (not shown in FIG. 2 ).
  • a fan may be installed on top of a heat pump, such as heat pump 130 depicted in FIG. 1 . The fan may pull outside air through the coils of the outside heat exchanger and out through the top of the heat pump.
  • processing circuitry in defrost controller 200 may cause relay 220 to shut off the fan during a defrost.
  • circuit board layout of defrost controller 200 may be configured to allow for a variety of configurations while maintaining a reduced cost when compared to other examples of defrost controllers.
  • Circuit board 222 may include the main functions of defrost controller 200, such as the processor, display driver, and connections.
  • a second circuit board (not shown in FIG. 2 ) may be stacked on top of circuit board 222 and include other optional functions.
  • the second circuit board may include a wireless function in some examples, a wired communication connection in other examples, a variety of options for indicator lights 206 and so on. In this manner, defrost controller 200 may be manufactured with the same main circuit board used in all variations, and one or more different second circuit boards that include additional options, which may reduce the cost of manufacturing.
  • Menu display 202 and setting display 204 are seven-segment light emitting diode (LED) displays. In other examples, other types of displays may be used, including a liquid crystal display (LCD), or other types of displays.
  • Menu display 202 and setting display 204 are the same type of off-the-shelf display, which provides an advantage over other types of displays. Using an off-the-shelf display may reduce costs by not using a customized display. Also, using the same type of display for both menu display 202 and setting display 204 may reduce manufacturing cost by reducing the number and types of components that need to stocked in a production facility. Having two discrete displays with separation 203 between them may make the overall user interface easier to follow and less confusing. The separation may, for example, be plastic or some other color or material that contrasts with the color and material of menu display 202 and setting display 204. In one example implementation, menu display 202 displays a menu item, and setting display 204 displays the setting for that menu item.
  • Indicator lights 206 may include one or more indicators that provide information to an installer.
  • indicator lights 206 include a system light, a wireless light and a fault light.
  • indicator lights 206 may include more or fewer lights and have different functions than those depicted in FIG. 2 .
  • a defrost controller without a wireless capability may not include the wireless indicator light.
  • a green indicator in the system light may indicate proper system power and operation.
  • a red indicator light in the fault light may indicate a system fault.
  • the installer may use controls 208, 210 and 212 as well as menu display 202 and setting display 204 to review and troubleshoot a fault indication or other diagnostic information.
  • an installer may communicate with defrost controller 200 via a wireless connection to a computing device.
  • defrost controller 200 may include an optical indicator 205.
  • optical indicator 205 may include a QR code, barcode or similar optical indicator.
  • an installer may initiate a wireless connection with defrost controller 200 by reading optical indicator 205 using, for example a mobile computing device.
  • Optical indicator 205 may provide connection and identification information for defrost controller 200 to a software product executing on the mobile computing device.
  • both menu display 202 and setting display 204 may depict either numbers or characters.
  • menu display 202 may depict the category or mode and setting display 204 may depict the value or setting of the category or mode.
  • menu display 202 and setting display 204 may be combined to display a set of characters or numbers.
  • An installer may configure defrost controller to operate with a particular heat pump by selecting a category in menu display 202 by changing the value in menu display 202 with the controls, such as up button 208, down button 210 and select button 212.
  • the installer may read the value of the selected category in setting display 204.
  • the installer may further change the value of the selected category by pressing up button 208, down button 210 and select button 212 as appropriate.
  • pressing combinations of buttons, or pressing and holding one or more buttons for a selected period of time may perform other functions. For example, pressing an holding the select button for a period of time may reset a category value to a default value.
  • processing circuitry in defrost controller 200 receives input from up button 208, down button 210 and select button 212 and causes menu display 202 and setting display 204 to depict the appropriate value.
  • categories that may be found in the table below. Table 2 - Example Categories of Settings Category Description Value 1 Defrost Enable Temperature. Temperature in degrees Coil temperature where defrost functionality is active. 2 Termination Temperature. Temperature in degrees Coil temperature where defrost is terminated.
  • menu display 202 and setting display 204 may be configured to blink, with blinking indicating which of the two is active.
  • active means which of menu display 202 and setting display 204 corresponds to the parameter being changed, such as whether a category or menu level is being changed (e.g., menu display 202) or a value/setting for the category or menu level (e.g., setting display 204) is being changed.
  • An installer may, for example, push the up/down buttons to choose which category they want to change (the left menu display 202 numbers will blink), and then press select to enter that menu level.
  • the menu number on menu display 202 stops blinking and the setting icon (setting display 202) starts blinking.
  • the installer can then press the up/down arrows to adjust the setting (i.e. 30, 60, 90 minute timer, etc) for that menu item.
  • the value for the menu item will be shown on setting display 202.
  • the installer can lock in the setting and go back to the main menu.
  • the installer can press and hold select to complete setup.
  • Defrost controller 200 may be configured to display the coil and air temperatures on the onboard display(s). It is also conceivable that the temperatures may be transmitted wirelessly through Bluetooth or WiFi for example, to be displayed or analyzed on a remote device. It is also conceivable that additional parameters be displayed such as refrigerant temperature delta across the coil, air temperature delta across the coil, refrigerant pressure, etc. Displaying temperatures helps the installer troubleshoot a malfunctioning or poorly configured appliance. Since the two key parameters (outdoor temperature and coil temperature) are displayed, the installer can easily see the operating conditions.
  • FIG. 3 is a conceptual diagram illustrating an example isometric view of a heat pump defrost controller with break-away tabs according to one or more techniques of this disclosure.
  • Defrost controller 300 is an example of defrost controller 130 and defrost controller 200 described above in relation to FIGS. 1 and 2 respectively and includes the same functions and characteristics.
  • Defrost controller 300 includes control and indicator panel 334, relay 320, other connectors 314, and mounting tabs 240 and 242A and 242B.
  • Control and indicator panel 334 includes menu display 302, setting display 304, and controls 308 as described above in relation to FIG. 2 .
  • the example of control and indicator panel 334 only includes two indicator lights 306, a system light and a fault light. Control and indicator panel 334 may also be referred to as user interface 334.
  • defrost controller 300 is intended as a replacement for an OEM defrost controllers or another universal controller. Because the space available on most heat pumps is limited, the small relative size and square form factor of defrost controller 300 may provide advantages over other types of defrost controllers. Additionally, it may be desirable for the installer to only use two mounting tabs to attach defrost controller 300 to a heat pump, such as heat pump 130 described above in relation to FIG. 1 . Mounting tabs 242A and 242B as well as mounting tab 240 and a fourth mounting tab not visible in FIG. 3 , but shown in FIG. 2 , may be removed to fit in the tight space available on the heat pump. Defrost controller 200 may be mounted either horizontally or rotated to be mounted vertically.
  • Each mounting tab e.g. 240, 242A, 242B includes a thinned or weak region 245 to make it easier to remove one or more of the mounting tabs.
  • region 245 may be scored or reduced in material thickness such as by a V-shaped or other shaped groove.
  • a mounting tab that may interfere with installation may be broken off cleanly, in a manner that does not damage the housing 305 of the device, such as by using pliers or hands to bend the mounting tab.
  • defrost controller 300 may be securely mounted in a variety of heat pumps to withstand vibration that may be caused by the heat pump compressor, fan or other components, yet be compatible with the limited space available inside a heat pump.
  • defrost controller 300 represents an example of a defrost controller that can include four mounting tabs connected to the housing 305. At the time of install, an installer may be able to easily remove any of the four mounting tabs in order to achieve a better placement or fit when mounting the defrost controller inside a heat pump.
  • FIGS. 4A - 4D are a schematic wiring diagrams of a heat pump defrost controller according to one or more techniques of this disclosure.
  • Defrost controllers 400A - 400D are examples of defrost controller 130 and defrost controller 200 described above in relation to FIGS. 1 and 2 respectively and includes the same functions and characteristics.
  • the connection terminals depicted in FIG. 4A - 4D are similar to those described above in relation to FIG. 2 and Table 1.
  • FIG. 4A is a schematic wiring diagram of a heat pump defrost controller installed in a heat pump with no low pressure switch.
  • the high pressure switch (HPC) connections on defrost controller 400A connect to the high pressure switch on the heat pump.
  • the low pressure switch (LPC) connections are shorted.
  • FIG. 4B is a schematic wiring diagram of a heat pump defrost controller installed in a heat pump the pressure switches in series with the contactor.
  • the compressor connection (COMPR) connects to the series connected high pressure switch, low pressure switch and contactor on the heat pump.
  • the high pressure switch (HPC) connections are shorted to each other and the ow pressure switch (LPC) connections are shorted to each other.
  • the example of FIG. 4B also has no connection to the defrost control.
  • FIG. 4C is a schematic wiring diagram of a heat pump defrost controller installed in a heat pump with pressure switches connected to the defrost control.
  • the high pressure switch (HPC) connections on defrost controller 400C connect to the high pressure switch on the heat pump.
  • the low pressure switch (LPC) connections on defrost controller 400C connect to the low pressure switch on the heat pump.
  • FIG. 4D is a schematic wiring diagram of a heat pump defrost controller installed in a heat pump with a simple timer circuit.
  • the Y connector of defrost controller 400D connects to the series connected high pressure switch, low pressure switch and contactor on the heat pump.
  • the high pressure switch (HPC) connections are shorted to each other and the low pressure switch (LPC) connections are shorted to each other.
  • the reversing delay and the short cycle delay described above in relation to FIG. 2 may be configured for a very short or to zero delay.
  • the high pressure switch (HPC) connections on defrost controller 400C may connect to the high pressure switch on the heat pump.
  • the low pressure switch (LPC) connections on defrost controller 400C may connect to the low pressure switch on the heat pump.
  • the coil sensor may be used to determine whether the reversing valve is set for heating mode or cooling mode.
  • FIG. 5A is a conceptual diagram illustrating an example coil temperature sensor. may connect to coil temperature sensor connection 216, described above in relation to FIG. 2 .
  • Coil temperature sensor 500 includes a temperature sensor at clip 502A and a connection 504, configured to mate with coil temperature sensor connection 216 depicted in FIG. 2 .
  • processing circuitry within a defrost controller may receive a signal from coil temperature sensor 500 indicating the coil temperature to the processing circuitry.
  • the processing circuitry may use the signal in determining the temperature difference between the coil and the outside air temperature to initiate a defrost cycle.
  • processing circuitry within the defrost controller may include instructions to automatically detect when heat pump is in heating or in cooling mode. For example, by sensing the temperature of the heat pump coil, the defrost controller may determine if heat pump is heating or cooling based on the temperature rise of the outdoor coil. An outdoor coil dropping in temperature may indicate heating mode. Defrost functionality may be automatically enabled when coil temperature is detected in the applicable range.
  • FIG. 5B is a conceptual diagram illustrating an example coil temperature sensor connected to a heat exchanger coil.
  • Coil sensor clip 502B is an example of coil sensor clip 502A described above in relation to FIG. 5A .
  • the location of coil sensor clip 502B on outside heat exchanger coil 506 may affect the configuration and the operation of a defrost controller of this disclosure.
  • and installer may place the sensor on the coil where the OEM sensor thermostat was located.
  • the original settings for proper adjustment of the termination and enable temperatures on the defrost controller may be used if coil sensor clip 502B is placed in the same location as the OEM sensor.
  • the installer may utilize the configuration features of the defrost controller of this disclosure to ensure proper operation of the temperature sensing.
  • the location of the OEM sensor may be inaccessible or difficult to access.
  • An installer may place the new coil sensor clip 502B on the coil loop nearest the expansion valve where refrigerant is entering the outside heat exchanger coil during the heating mode. This location may give the largest temperature difference between the air temperature and the coil temperature.
  • the installer may utilize the configuration features of the defrost controller of this disclosure to configure the defrost controller for the new sensing setup.
  • FIG. 6 is a conceptual diagram illustrating an example air temperature sensor according to one or more techniques of this disclosure.
  • Air temperature sensor 600 may be used to initiate a defrost cycle when a defrost controller of this disclosure is in the demand temperature mode.
  • Air temperature sensor 600 may include sensor 604 and connection 602. Connection 602 may be configured to mate with air temperature sensor connector 218 described above in relation to FIG. 2 .
  • Processing circuitry in the defrost controller may receive a signal from air temperature sensor connector 218 and determine the OAT based on the signal.
  • the processing circuitry may initiate a defrost cycle based on a temperature difference between the OAT and the outside coil temperature satisfying a threshold.
  • Use of the air sensor may be desirable because the defrost controller may reduce the number of unnecessary defrosts that are common among defrost timers and therefore improve efficiency of the heat pump.
  • FIG. 7 is a conceptual diagram illustrating an example display sequence shown by a defrost controller according to one or more techniques of this disclosure.
  • the menu display and setting display may cycle through the examples depicted in FIG. 7 .
  • the menu display and setting display may cycle through normal operating screens showing the current mode and the values of the two temperature sensors.
  • the menu display and setting display of FIG. 7 are examples of menu display 202 and setting display 204 described above in relation to FIG. 2 .
  • Mode screen 700 shows that the defrost controller is indicating the heat pump is in OFF mode.
  • Other examples of current mode of operation may include heat, cool, delay and other similar modes.
  • Outdoor air temperature screen 702 displays the sensed OAT, for example as sensed by air temperature sensor 600 described above in relation to FIG. 6 .
  • the menu screen displays the character A, indicating air temperature and the setting display indicates 56 degrees. Temperature displays may be in Fahrenheit or in Celsius, depending on the configuration of the temperature display setting.
  • Coil temperature screen 704 displays the sensed outside heat exchanger coil temperature, for example as sensed by coil temperature sensor 500 described above in relation to FIGS. 5A and 5B .
  • the menu screen displays the character C, indicating coil temperature and the setting display indicates 47 degrees.
  • FIG. 8 is a conceptual diagram illustrating example displays that may be shown on the menu and setting display of the defrost controller according to one or more techniques of this disclosure.
  • the displays of FIG. 8 are examples of the display function described above in relation to FIG. 2 and Table 2.
  • a defrost controller may be placed in TEST mode (802), which may be used for a variety of functions, including to verify the function of the compressor, fan, and reversing valve and similar tests.
  • TEST mode 802
  • an installer may verify or set the termination temperature (804), which is indicated by the category 2, and the value of 90 degrees.
  • the category may shift to the left-most position in the menu display, and the remaining digits shown in both the menu display and settings display.
  • a termination temperature of 103 degrees may be displayed as shown by 806.
  • the defrost controller display may use two-digit hexadecimal numbering to indicate the value or the category. As shown by 808, the termination temperature is shown in hexadecimal 67, which is equivalent to decimal 103 degrees.
  • the seven-segment displays may indicate any fault codes, fault history, and similar indications.
  • FIG. 9 shows an example setup processing using dual displays in accordance with the techniques of this disclosure.
  • the example of FIG. 9 is another example of the display function described above in relation to FIG. 8 .
  • Controls may include a button (910) for entry, selection etc. one or more buttons (906) for changing selected values, indicators for OK (902), alert or caution (904) and error (908).
  • the user interface may also display a dual set of digits.
  • the left pair of digits (912) may represent the current setting being configured.
  • the right pair of digits (914) may represent the options for that setting.
  • the digit pair that is blinking e.g. 916, 918) may indicate where the current focus is.
  • the button (910) to the right of the digits may be also configured to toggle the focus, e.g. between the left and the right set of digits.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Human Computer Interaction (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Fuzzy Systems (AREA)
  • Mathematical Physics (AREA)
  • Signal Processing (AREA)
  • Air Conditioning Control Device (AREA)
  • Defrosting Systems (AREA)
EP19217749.1A 2018-12-18 2019-12-18 Wärmepumpen-abtauregelungsvorrichtung und -verfahren Active EP3671058B1 (de)

Applications Claiming Priority (2)

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US201862781551P 2018-12-18 2018-12-18
US16/717,815 US20200191458A1 (en) 2018-12-18 2019-12-17 Universal heat pump defrost controller

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EP3671058B1 EP3671058B1 (de) 2024-05-08

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US11054164B2 (en) * 2017-06-30 2021-07-06 Robert Bosch Llc Environmental control unit including maintenance prediction
US11137727B2 (en) * 2019-04-04 2021-10-05 Swivel-Link, LLC Validation device for testing a machinery safety system
CN112524747A (zh) * 2020-12-08 2021-03-19 海信（广东）空调有限公司 空调器的除霜控制方法、空调器的室内机及空调遥控器

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US20060232907A1 (en) * 2005-04-14 2006-10-19 Ranco Incorporated Of Delaware Wide input voltage range relay drive circuit for universal defrost timer
US20150184921A1 (en) * 2013-12-26 2015-07-02 Emerson Electric Co. Heat pump controller with user-selectable defrost modes and reversing valve energizing modes
US20150211779A1 (en) * 2014-01-30 2015-07-30 Trane International Inc. System and Method of Protecting an HVAC System

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Publication number Priority date Publication date Assignee Title
JPS60142138A (ja) * 1983-12-27 1985-07-27 ハネウエル・インコーポレーテツド ヒートポンプ装置の除霜制御装置
US20060232907A1 (en) * 2005-04-14 2006-10-19 Ranco Incorporated Of Delaware Wide input voltage range relay drive circuit for universal defrost timer
US20150184921A1 (en) * 2013-12-26 2015-07-02 Emerson Electric Co. Heat pump controller with user-selectable defrost modes and reversing valve energizing modes
US20150211779A1 (en) * 2014-01-30 2015-07-30 Trane International Inc. System and Method of Protecting an HVAC System

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EP3671058B1 (de) 2024-05-08

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