KR20090015937A - Climate control system with automatic wiring detection - Google Patents

Abstract

A climate control system (10) includes an outdoor unit (14) and an indoor unit (12) having at least two fans (26,28). The fans (26,28) include control wiring (38,40) that is interchangeably connected to a control system (20), and feedback wiring (42,44) that is also interchangeably connected to the control system (20). The control system (20) is capable of automatically detecting the wiring configuration of the control wiring (38,40) and the feedback wiring (42,44). The climate control system (10) operates the fans (26,28) according to the detected wiring configuration to heat or cool an interior space.

Description

Indoor temperature control system with automatic wiring detection unit {CLIMATE CONTROL SYSTEM WITH AUTOMATIC WIRING DETECTION}

The present invention relates to a room temperature control system, and more particularly to a room temperature control system having an automatic wiring detection unit.

Room temperature control systems such as heat pumps are used to heat the interior space by transferring heat between the outside air and the inside air. As a result, the indoor temperature control system generally includes an indoor unit and an outdoor unit. The coolant flows between the indoor unit and the outdoor unit. In indoor and outdoor units, the refrigerant passes through coils that heat or cool the ambient air.

Heating and cooling of the interior space is achieved by adjusting the pressure of the refrigerant in the coil such that the refrigerant undergoes a phase change cycle of evaporation. To cool the indoor space, the indoor temperature control system uses a compressor to compress the refrigerant from low pressure gas to high pressure gas. This process makes the refrigerant hot. The hot refrigerant passes through the coil of the outdoor unit. The fan of the outdoor unit pressurizes the outside air across the coil, causing the coil to cool and the refrigerant to condense into a liquid state. The liquid refrigerant then passes through the expansion valve, where the refrigerant evaporates and is further cooled to become a low temperature low pressure gas. The cold refrigerant then passes through the coil of the indoor unit, where one or more fans force the air from the interior space to cross the cooling coil. The refrigerant absorbs some heat and thereby cools the air from the interior space. The cycle is repeated if necessary.

The same process is used to heat the interior space, except that the system is operated in reverse. In this case, the refrigerant is compressed and heated from low pressure gas to high pressure gas before entering the indoor unit. The heated refrigerant flows through the coil of the indoor unit, and the indoor air is pressurized across the coil to heat the air and cool the refrigerant. The refrigerant then passes through the expansion valve, where the refrigerant is evaporated and cooled to form a low temperature low pressure gas. The cold refrigerant then passes through the coil to an outdoor unit that is heated by external air. The cycle is repeated if necessary.

One or more fans may be used in the indoor unit to force air across the coil of the indoor unit and direct the heated or cooled air to a location in the interior space. Since multiple fans allow the indoor unit to distribute heated or cooled air in more directions within the interior space, it is advantageous for multiple fans to be in the indoor unit. However, having more than one fan introduces further complexity and additional costs of manufacturing and servicing the indoor unit. Accordingly, there is a need for an indoor temperature control system that reduces the cost and complexity of manufacturing and servicing indoor units with multiple fans.

The room temperature control system includes an automatic fan wiring detector that allows a plurality of fan motors to be interchangeably connected to the control unit of the room temperature control system. The fan motor includes a control wiring terminated at the control wiring connector and a feedback wiring terminated at the feedback wiring connector, respectively. The control unit includes a control board connector and a feedback board connector. The control wiring connector is interchangeably connected to the control board connector, and the feedback wiring connector is interchangeably connected to the feedback board connector. The control unit automatically detects the wiring shape and accordingly activates the fan to heat or cool the internal space.

1 is a perspective view of an indoor temperature control system including an indoor unit and an outdoor unit.

2 is a broken perspective view of the indoor unit.

3 is a wiring diagram showing a connection portion between a control board and a fan motor of an indoor unit.

4 is a schematic diagram of the control board and related components of the room temperature control system.

5 is a flowchart illustrating a method of automatically detecting a wiring shape of a fan motor.

1 is a perspective view of an indoor temperature control system 10. The room temperature control system 10 includes an indoor unit 12, an outdoor unit 14, and a pipe 15. Room temperature control system 10 is a heat pump, chiller, air conditioner, or similar device capable of transferring heat between internal and external air to heat and / or cool the internal space. The indoor unit 12 comprises a control unit, a coil and a fan, which is described in more detail with reference to FIG. The external unit 14 includes a compressor, a coil and a fan. The refrigerant passes through the coils of the indoor and outdoor units and is compressed by a compressor. The refrigerant flows in the coils of the indoor unit 12 and the outdoor unit 14 and through the pipe 15 connecting between the indoor unit 12 and the outdoor unit 14.

2 is a broken perspective view of the indoor unit 12 for showing internal components. The indoor unit 12 includes a front panel 16, a case 18, a control box 20, a coil 22, a vertical flap 24, fans 26 and 28, fan motors 30 and 32, a frame. 34 and mounting panel 36. The front panel 16 is a panel that guides the flow of air to the indoor unit 12. The front panel 16 is pivotally connected to the lower front side of the case 18 so that the upper end of the front panel 16 is pivotally separated from the upper end of the case 18. The control box 20 includes a control circuit for the room temperature control system 10. The control box 20 is connected inside the lower part of the case 18, and a coil 22 is mounted on the control box 20 of the case 18 and the frame 34. The coil 22 includes a coolant that heats or cools the coil, thereby heating or cooling the air from the interior space as the coolant passes. The vertical flap 24 is mounted on the side of the indoor unit 12 and directs the flow of air from the indoor unit 12 to the outside. The fans 26, 28 are in the indoor unit 12 adjacent to the vertical flaps 24. The fans 26, 28 draw air to enter through the front and out through the sides of the indoor unit 12. The fan 26 is connected to the fan motor 30, and the fan 28 is connected to the fan motor 32. The fans 26, 28 and fan motors 30, 32 are supported by a frame 34 connected to the case 18. The fan motors 30, 32 each comprise two sets of wires comprising control wires 38, 40 and feedback wires 42, 44. Each wire 38, 40, 42, 44 is terminated in a connector connected to the control box 20. The mounting panel 36 forms a rear panel of the indoor unit 12 that can be mounted to a wall or other indoor structure.

3 is a wiring diagram showing a connection portion between the control board 50 and the fan motors 30 and 32. The control board 50 is a printed circuit board in the control box 20 (shown in FIG. 2). The control board 50 includes a microcontroller 52, fan drivers 54 and 56, control board connectors 58 and 60 and feedback board connectors 62 and 64. Fan motors 30, 32 are rotation sensors 66, 68, such as Hall-effect sensors, which detect the rotational speed of fan motors 30, 32 (eg, revolutions per minute or " RPM "). It includes. The fan motor 30 includes a control wiring 38 terminated at the control wiring connector 70 and a feedback wiring 42 terminated at the feedback wiring connector 72. The fan motor 32 includes a control wiring 40 terminated at the control wiring connector 74 and a feedback wiring 44 terminated at the feedback wiring connector 76.

The microcontroller 52 controls the operation of the fan motors 30, 32 (and associated fans 26, 28 shown in FIG. 2) via the fan drivers 54, 56. The fan motors 30 and 32 require more power to operate than are available directly from the microcontroller 52 and therefore the fan drivers 54 and 56 are provided to deliver the required power. Fan drivers 54 and 56 draw microcontroller 52 and other low voltage electronics from, for example, the high voltage alternating current ("AC") power used by fan motors 30 and 32 to deliver the required AC power. Optocouplers for isolation, and triacs and transistors or solid state relays. Fan drivers 54 and 56 are connected to respective board control connectors 58 and 60, respectively.

The microcontroller 52 receives feedback from the rotation sensors 66 and 68 informing the microcontroller 52 of the rotational speeds of the respective fan motors 30 and 32. The microcontroller 52 is connected to the microcontroller 52 through the feedback wirings 42 and 44, the feedback wiring connectors 72 and 76, and the feedback board connectors 62 and 64 by rotation sensors 66 and 68 of the fan motors 30 and 32. Feedback is provided. The rotation sensors 66 and 68 generate pulses representing the rotational speed, such as six pulses per revolution. The microcontroller 52 receives and calculates the number of pulses for a predetermined time to determine the current rotational speed of the fan motors 30 and 32.

During the manufacturing process of the room temperature control system 10, the fan motors 30, 32 are connected to the control board 50. In particular, the control wiring connectors 70 and 74 are connected to the control board connectors 58 and 60, and the feedback wiring connectors 72 and 76 are connected to the feedback board connectors 62 and 64.

To save time and reduce the likelihood of error, control wiring connectors 70 and 74 may be interchangeably connected with control board connectors 58 and 60. Similarly, feedback wiring connectors 72 and 76 may be interchangeably connected with feedback board connectors 62 and 64.

For example, during installation of the fan motor 30, both the control wiring connector 70 and the feedback connector 72 are connected to the control board 50. To do so, the control wiring connector 70 can be inserted into either the control board connector 58 or the control board connector 60. Similarly, feedback connector 72 may be inserted into either feedback board connector 62 or feedback board connector 64. As long as only one wiring connector is inserted into one board connector, the installation of the fan motor 32 is actually the same.

In one embodiment, the control wiring connectors 70, 74 are shaped and / or dimensioned differently than the feedback wiring connectors 72, 76, so that the corresponding control board connectors 58, 60 and the feedback board connector 62, respectively. , 64). In this embodiment, it is impossible for the installer to accidentally insert the feedback wiring into the control board connector or insert the control wiring into the feedback board connector.

After all the connectors are installed and the room temperature control system 10 is turned on, the microcontroller 52 automatically detects the wiring shape of the fan motors 30, 32 relative to the control board 50. A method of automatically detecting the wiring shape is described in more detail with reference to FIG.

One of the advantages realized with interchangeable connectors is that the fan motors 30, 32 can be identical. This reduces inventory costs because only a single part number needs to be kept in stock and reduces the complexity of the manufacturing process because it makes the fan motors indistinguishable. An alternative method is to have a non-circular connector that is shaped or dimensioned so that the connector fits only in the proper position on the circuit board 50. However, this alternative, which remains in stock and requires two distinct part numbers, increases the cost and complexity since the fan motor 30 has a different control wiring connector and feedback wiring connector than the fan motor 32. Let's do it. In addition, other board connectors (both control and feedback connectors) are also kept in stock and must be distinguished from each other. This problem is solved by providing a replaceable connector.

The same advantages apply not only during the manufacturing process of the room temperature control system 10, but also during repair. If the fan motor is broken or requires other repairs, the repairer does not have to distinguish between multiple types of fan motors since the fan motors are interchangeable. In addition, the repairer does not have to spend time understanding the board connection is appropriate since any available board connection can be used as long as the wiring connector is fitted to the boat connector.

4 is a schematic diagram of the control board 50 and associated components of the room temperature control system 10. The control board 50 includes a microcontroller 52 and fan drivers 54 and 56. The room temperature control system 10 also includes a power input 80, a line filter 82, a power supply 84, a power supply 86, a driver chip 88, switches and relays 90, and communication circuits 92. ), A stepper motor 93, a temperature sensor 94, a current transformer 96, and an interface circuit 98.

AC power is supplied to the room temperature control system 10 via a fused power input 80 and then filtered by a line filter 82. Power is switched to an appropriate level by the power supplies 84,86. The power supply 84 supplies 14 V and 16 V power to the high voltage device, and the power supply 86 supplies low voltage power to the microcontroller 52 and other digital components.

The microcontroller 52 is a digital processing circuit capable of operating software or firmware algorithms to control the operation of the room temperature control system 10. The microcontroller 52 includes a random access memory (RAM) 100 and a read only memory (ROM) 102 and is coupled to an electrically erasable and programmable read only memory (EEPROM) 104. The control algorithm is stored in a ROM 102 executed by the microcontroller 52 to properly operate the room temperature control system 10. The wiring shape data is stored in the RAM 100 after the wiring shape algorithm is successfully completed. The wiring shape algorithm is described in more detail with reference to FIG. Additional shape data regarding the specific functionality and performance of the room temperature control system 10 is stored in the EEPROM 104 which is readable by the microcontroller 52.

The microcontroller 52 also includes various input and output ports through which the microcontroller 52 can interact with other components within the room temperature control system 10. The microcontroller 52 uses the driver chip 88 to operate and control the switch and relay 90, the communication circuit 92, and the stepper motor 93. The driver chip 88 can handle high current demands of relays, communication circuits, and motors as directed by the microcontroller 52. Switches and relays 90 are used to control various components, including compressors, reversing valves (which switch between heating and cooling of the interior space), outdoor fans, indoor air quality features such as air filters, and condensate pumps. The communication circuit 92 is also used to communicate with the components of the outdoor unit 14. The stepper motor 93 is controlled by the microcontroller 52 via the driver chip 88. The stepper motor 93 may, for example, position the front panel, the vertical flaps, and the louvers (not shown) used to further control the direction of airflow coming in or out of the room temperature control system 10. It works to adjust.

As described above, the microcontroller 52 controls the operation of the fan motors 30, 32 via the fan drivers 54, 56, and the rotation sensors 66, 68 associated with the fan motors 30, 32. Receive feedback from. Rotation sensors 66 and 68 are, for example, hall effect sensors.

The microcontroller 52 receives inputs from the temperature sensor 94 and the current transformer 96. The temperature sensor 94 provides temperature readings from various locations of the indoor temperature control system 10, such as air temperature entering the indoor unit 12, refrigerant / coil temperature, and any other predetermined temperature measurement. The current transformer 96 provides an indication to the microcontroller 52 when the defrost circulation of the outdoor unit 14 can be completed. Defrost circulation is used to remove ice made from the coils of the outdoor unit 14.

Microcontroller 52 generally interacts with various components defined as interface circuit 98. The interface circuit 98 provides various methods of communication between a person (such as a user, manufacturer, repairer, etc.) and the room temperature control system 10. The interface circuit 98 includes a buzzer 106, a state light emitting diode (LED) 108, a programming interface 110, a building management system input 112, and a display board 114. The buzzer 106 is used to generate an audible sound by the microcontroller 52 to alert a person when something has changed (such as when a user requests a change in operating mode) or when attention is required.

Microcontroller 52 uses status LED 108 to provide a visual signal to communicate with a person. For example, status LED 108 flashes periodically to indicate that it is functioning properly. Status LED 108 will also blink to provide a diagnostic code in case of malfunction.

The programming interface 110 provides input and output ports for programming the microcontroller 52 and the EEPROM 104 with predetermined configuration, programming algorithms, or for communicating any other predetermined data, such as diagnostic devices. .

The building management system input 112 provides an input to the microcontroller 52 to request an operation mode adjustment. For example, if the room temperature control system 10 operates in a hotel, the front desk may use the building management system to turn off the room temperature control system 10 in case the room is not used or a fire occurs.

The display board 114 is connected to the microcontroller 52 and includes an infrared receiver 116, a manual override switch 118, a light emitting diode (LED) 120, and a display shape jumper 122. Infrared receiver 116 accepts input from infrared remote control 124. The input directs the microcontroller 52 a predetermined operating mode or configuration. The manual override switch 118 allows the user to manually change the operating mode, such as turning the room temperature control system on and off without a remote control. The LED 120 provides a visual indication of the status of the control unit 20, such as indicating whether the room temperature control system 10 is turned on and displaying a diagnostic code in case of malfunction. Display shape jumper 122 provides an input to microcontroller 60 that indicates whether various display board models are currently connected.

FIG. 5 is a flow diagram illustrating a method 140 for automatically detecting the wiring shape of the fan motors 30, 32 and thus automatically adjusting the wiring shape setting of the room temperature control system 10. The method is stored as executable code in ROM 102 and executed by microcontroller 52.

The method 140 begins when the room temperature control system 10 is turned on (step 142). System 10 first determines whether a feedback input (input to microcontroller 52 associated with connectors 62 and 64) has already been assigned to the fan (step 144). If so, the room temperature control system 10 continues normal operation (step 146). If not assigned, the room temperature control system 10 then continues the automatic detection of the wiring shape. In this step (step 144), the microcontroller operates to bypass wiring detection if the room temperature control system 10 has not been disconnected from the power source 80 since the last time that wiring detection was successfully completed. Because of the possibility that a person can reshape the wiring while the power is off, the wiring shape is rechecked at any time when the room temperature control system 10 is disconnected from the power source 80. However, if the room temperature control system 10 remains plugged into the power source 80 and returns immediately after turning off only the power supply, it does not have to be rechecked because the wiring is supposed to be repaired or service not performed.

If the microcontroller 52 determines that the feedback input has not already been assigned to the fan (step 144), the microcontroller 52 turns on the first fan connected to the connector 58 (step 148). For the purposes of the discussion below, the fan connected to the connector 58 is referred to as the first fan (fan 1), and the fan connected to the connector 60 is referred to as the second fan (fan 2). The feedback provided by the rotation sensors 66, 68 via the connectors 62, 64 is also referred to as first and second feedback inputs (input 1 and input 2).

When the first fan is turned on, the fan is set at a relatively high speed, such as 1,050 revolutions per minute (RPM) (step 148). During this time, the second fan remains off. Microcontroller 52 then checks for feedback (if any) at the first input and the second input (step 150). Even if only one fan is on, it is possible for both inputs to have feedback indicating that both fans are rotating. For this reason, airflow from one fan can cause the other fan to rotate. However, the rotation of the second fan will be less than that of the first fan. The microcontroller 52 compares the second input with the first input to determine which one is larger (step 150). In one embodiment, microcontroller 52 checks to see that the input is at least 500 RPM greater than the other.

If the first input is greater than the second input, microcontroller 52 then assigns the first input to the first fan and stores the result in RAM 100 (step 152). If the second input is greater than the first input, microcontroller 60 then assigns a second input to the first fan (step 154). If either input is not greater than the other, an error such as a first fan not connected, a rotation sensor not connected, or a malfunction in these components of the room temperature control system 10 has occurred. It is displayed. As a result, microcontroller 52 turns off fan 1 (step 155), turns on fan diagnostics (step 156), and stops detecting additional wiring shapes.

When in fan diagnostic mode 156, room temperature control system 10 will not operate to heat or cool the room space. Instead, the user is informed that the error has occurred through one or more methods, such as buzzer 106, status LED 108 and / or LED 120 of display board 114. In one embodiment, the LEDs 118 and 120 blink a diagnostic code indicating to the user that there is a problem with the fan motor wiring. The room temperature control system 10 remains in the fan diagnostics mode until the room temperature control system 10 is turned off and back on (step 156), in which case the microcontroller repeats the method 140 starting at step 142. .

If the assignment of the input to the first fan was successful (step 152 or step 154), the first fan is turned off (step 158) and the second fan is turned on (step 160). The microcontroller 52 receives an indication of each fan speed from the first and second inputs and determines which input is greater (step 162). In one embodiment, microcontroller 52 determines which input is at least 500 RPM greater than the other input. If the first input is greater than the second input, microcontroller 52 assigns the first input to the second fan (step 166) and stores the result in RAM 100. If the second input is greater than the first input, the microcontroller 52 assigns a second input to the second fan (step 168) and stores the result in the RAM 100. If either input is not greater than the other input, an error occurs and microcontroller 52 turns off fan 2 (step 167) and turns on the fan diagnostics (step 156).

If the input was successfully assigned to the second fan, then the second fan is turned off (step 168). The microcontroller 52 then performs a final check to ensure that fan wiring detection is successful. Microcontroller 52 first verifies that both inputs have been assigned to the fan (step 170). In other words, the first input must be assigned to the first fan or the second fan and the second input must be assigned to the first fan or the second fan. Otherwise, an error then occurs and microcontroller 52 turns on the fan diagnostics (step 156).

If both inputs are assigned to a fan, microcontroller 52 then verifies that both inputs are not assigned to the same fan (step 172). In other words, both the first and second inputs must not be assigned to the first fan, and neither must be assigned to the second fan. If so, an error occurs and the microcontroller 52 turns on the fan diagnostics (step 156). Once each input is properly assigned to a particular fan, fan wiring detection is successful and the room temperature control system 10 continues normal operation (step 146).

Although the present invention has been described with reference to preferred embodiments, it will be apparent to those skilled in the art that modifications may be made in form and detail within the spirit and scope of the invention.

Claims (20)

Room temperature control system, An indoor unit for adjusting a temperature of indoor air having a first fan and a second fan each having a control wiring; An outdoor unit for transferring heat to outdoor air, A control system for controlling the operation of the indoor unit and the outdoor unit, The control system includes a first board connector and a second board connector interchangeably connected to the control wiring of the first fan motor and the control wiring of the second fan motor, respectively, and a fan controller connected to each board connector, wherein the first fan and the first fan are connected to each other. 2. A room temperature control system comprising a fan controller for controlling the operation of the fan and automatically detecting the wiring shape of the control wirings of the first and second fan motors. The method of claim 1, wherein the fan controller, Microcontroller, A first fan driver connected to the fan wiring of the first fan and the microcontroller, And a second fan driver coupled to the fan wiring of the second fan and the microcontroller. The room temperature control system of claim 1, wherein the control wiring further comprises a feedback wiring. The room temperature control system of claim 3, wherein each fan further comprises a rotation sensor connected to each feedback wire. The room temperature control system of claim 1, wherein the fan further comprises feedback wiring. 6. The control system of claim 5, wherein the control system further comprises a first feedback board connector and a second feedback board connector, each feedback board connector connected to a fan controller and connected to the feedback wiring of the first fan and the feedback wiring of the second fan. Interchangeably connected, wherein the fan controller is configured to automatically detect the wiring shape of the feedback wirings of the first and second fans. Fan control system, A first fan and a second fan, A first fan motor and a second fan motor each having control wiring terminated to a wiring connector, respectively; A fan motor controller for automatically detecting wiring shapes of the first and second fan motors, A first board connector and a second board connector connected to the fan motor controller, The wiring connector is interchangeably connected to the first board connector and the second board connector. The method of claim 7, wherein the fan motor controller, Microcontroller, A first fan driver connected to the microcontroller, And a second fan driver coupled to the microcontroller. 8. The fan control system of claim 7, wherein the fan motor further comprises a motor rotation sensor. The fan control system of claim 9, wherein the rotation sensor comprises a Hall-effect sensor. The method of claim 8, wherein each fan driver, An optocoupler for isolating the fan motor from the microcontroller, Means for connecting to an optocoupler for delivering power to the fan motor. The fan control system of claim 11, wherein the means for delivering power is selected from the group consisting of triacs, transistors, and relays. 8. The fan control system of Claim 7, wherein the control wiring comprises a feedback wiring. 8. The fan control system of Claim 7, wherein each fan motor further comprises a first feedback wiring terminated with a feedback wiring connector. 8. The apparatus of claim 7, further comprising a first feedback board connector and a second feedback board connector, each feedback board connector being connected to a fan motor controller, wherein the feedback wiring of each fan motor is connected to the first feedback board connector and the first feedback board connector. 2 Fan control system interchangeably connected to feedback board connectors. It is a method of automatically detecting the wiring shape of multiple fan motors having respective rotation sensors, Iii. Turning on the first fan motor, Ii. Detecting rotation of the fan motor with one of the rotation sensors; Iii. Placing the rotation sensor of step ii in the first fan motor; Iii. Turning off the first motor, Iii. Repeating steps (v) through (v) for each fan motor. 17. The method of claim 16, i. Identifying each rotation sensor associated with a particular fan motor. The method of claim 17, wherein step ⅵ is Identifying each rotation sensor assigned to the fan motor, And determining that no two rotation sensors are assigned to the same fan motor. 19. The method of claim 18, further comprising initiating a fan diagnostic mode if any step fails. 17. The method of claim 16, further comprising operating the fan in accordance with the detected wiring shape when all steps are successful.

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