Abstract:
A heating, ventilation and air conditioning diagnostic system and associated method of use is disclosed. The system includes a controller for operating a heating, ventilation and air conditioning system, a plurality of sensors for monitoring various parameters associated with the operation of the heating, ventilation and air conditioning system that are in electronic communication with the controller, at least one input device that is in electronic communication with the controller, wherein the at least one input device is able to modify variables utilized by the controller to improve performance of the heating, ventilation and air conditioning system; and at least one output device that is in electronic communication with the controller. The variables can include non-safety timing values and text-based information. The system may include counters that can be read-only, reset to zero and overwritten through the plurality of input devices. Historical data can be recorded, reviewed and selectively analyzed.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This patent application claims priority to U.S. Provisional Patent Application Ser. No. 60/637,170 filed Dec. 17, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     A major problem associated with current heating, ventilation and air conditioning (“HVAC”) systems is that it is very difficult to customize non-safety timing values once a controller for an HVAC system is installed in the field for a particular application.  
         [0003]     Examples of such timing values include, but are not limited to, the temperature differential for water heater applications and air circulator blower delay times for furnace applications.  
         [0004]     Although the ability to ascertain real-time data from an HVAC system as well as view historical data, it is very difficult to quickly ascertain exactly when certain problems and defaults have occurred without going back through a tremendous amount of data. It is the timed pattern of problems and defaults that typically provide clues as to causation. By having a service technician forced to look at a tremendous amount of recorded historical data will prevent him or her from readily diagnosing malfunctions and problems.  
         [0005]     Another problem involving HVAC systems is the need for the service technician to obtain pertinent information to complete the task at hand without disturbing building owners or building operators. Also, there may be a need to perform research by the service technician to complete his or her job. Information of this nature can include the end user, the service company, the HVAC system manufacturer and information regarding a controller for the HVAC system.  
         [0006]     An example of a furnace diagnostic system having the above deficiencies is described in U.S. Pat. No. 6,658,372, which issued on Dec. 2, 2003, to Robertshaw Controls Company, incorporated herein by reference, and also U.S. Pat. No. 6,535,838, which issued on Mar. 18, 2003, to Robertshaw Controls Company, incorporated herein by reference.  
         [0007]     The present invention is directed to overcoming one or more of the problems set forth above.  
       SUMMARY OF INVENTION  
       [0008]     In one aspect of this invention, a heating, ventilation and air conditioning diagnostic system is disclosed. This system includes a controller for operating a heating, ventilation and air conditioning system, a plurality of sensors for monitoring various parameters associated with the operation of the heating, ventilation and air conditioning system that are in electronic communication with the controller, at least one input device that is in electronic communication with the controller, wherein the at least one input device is able to modify variables utilized by the controller to improve performance of the heating, ventilation and air conditioning system, and at least one output device that is in electronic communication with the controller.  
         [0009]     Another aspect of this invention is that a heating, ventilation and air conditioning diagnostic system is disclosed. The system includes a controller for operating a heating, ventilation and air conditioning system, a plurality of sensors for monitoring various parameters associated with the operation of the heating, ventilation and air conditioning system that are in electronic communication with the controller, wherein data from the plurality of sensors can be recorded in the controller, at least one input device that is in electronic communication with the controller, wherein the at least one input device is able to modify variables utilized by the controller to improve performance of the heating, ventilation and air conditioning system, and at least one output device that is in electronic communication with the controller.  
         [0010]     Yet another aspect of this invention is that a heating, ventilation and air conditioning diagnostic system is disclosed. The system includes a controller for operating a heating, ventilation and air conditioning system and the controller is in electronic communication with a plurality of counters, a plurality of sensors for monitoring various parameters associated with the operation of the heating, ventilation and air conditioning system that are in electronic communication with the controller, wherein data from the plurality of sensors can be recorded in the controller, at least one input device that is in electronic communication with the controller, wherein the at least one input device is able to modify variables utilized by the controller to improve performance of the heating, ventilation and air conditioning system, and at least one output device that is in electronic communication with the controller.  
         [0011]     In yet another aspect of this invention, a method for utilizing a heating, ventilation and air conditioning diagnostic system is disclosed. The method includes utilizing a controller for operating a heating, ventilation and air conditioning system, monitoring various parameters from a plurality of sensors associated with an operation of the heating, ventilation and air conditioning system that are in electronic communication with the controller, providing electronic communication between at least one input device and the controller, providing electronic communication between at least one output device and the controller, and modifying variables utilized by the controller with the at least input device to improve performance of the heating, ventilation and air conditioning system.  
         [0012]     In another aspect of the present invention, a method for utilizing a heating, ventilation and air conditioning diagnostic system is disclosed. The method includes utilizing a controller for operating a heating, ventilation and air conditioning system that is in electronic communication with a plurality of counters, monitoring various parameters from a plurality of sensors associated with an operation of the heating, ventilation and air conditioning system that are in electronic communication with the controller, recording data from the plurality of sensors in the controller, providing electronic communication between at least one input device and the controller, providing electronic communication between at least one output device and the controller, and modifying variables utilized by the controller with the at least input device to improve performance of the heating, ventilation and air conditioning system.  
         [0013]     These are merely some of the innumerable aspects of the present invention and should not be deemed an all-inclusive listing of the innumerable aspects associated with the present invention. These and other aspects will become apparent to those skilled in the art in light of the following disclosure and accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0014]     For a better understanding of the present invention, reference may be made to the accompanying drawings in which:  
         [0015]      FIG. 1  is a block diagram of a diagnostic system for a heating, ventilation and air conditioning system (HVAC) in accordance with the present invention;  
         [0016]      FIG. 2  is a graphical user interface screen that illustrates various system inputs and outputs for a controller of the heating, ventilation and air conditioning system (HVAC) in accordance with the present invention; and  
         [0017]      FIG. 3  is a graphical user interface screen that visually illustrates a component, e.g., furnace, of the heating, ventilation and air conditioning system (HVAC) and associated inputs and outputs in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as to obscure the present invention.  
         [0019]     Referring now to  FIG. 1 , the present invention is directed to an electronic control system  10  for a heating, ventilation and air conditioning (“HVAC”) system. For the purposes of this patent application an HVAC system is broadly defined as system of heating, ventilation, evaporative cooling and/or air conditioning components, water heaters, as well as any combination thereof.  
         [0020]     The electronic control system  10  includes at least one component of an HVAC system, e.g., furnace, which is generally indicated by numeral  20 . A controller is generally indicated by numeral  30 . The controller  30  can include a single processor or a whole series of processors and any variant of a processor such as a computer or a programmable logic controller.  
         [0021]     The controller  30  is connected to at least one component  20 , e.g., plurality of components, through any form of electronic communication  100 . Also, the controller  30  can be an integral aspect of a particular component  20 , e.g., furnace. This can include a hardwired connection indicated by solid lines or wireless communication indicated by dotted lines. This can also include a computer network. Preferably, the computer network is local in nature such as a local area network (LAN). However, a wide area network (WAN) and other types of computer networks are possible.  
         [0022]     When using a LAN networking environment, the controller  30  is connected to the LAN through a network interface or adapter. When using a WAN networking environment, the controller  30  typically includes a modem or other means for establishing communications over the WAN, such as a global computer network e.g., the Internet. The WAN network permits communication to other points or systems with a more comprehensive computer network. The computer network is capable of communicating in a wide variety of methods including, but not limited to, point-to-point, star, mesh or star-mesh architecture. The protocols utilized can include, but are not limited to, proprietary, Internet, contention and polled protocols and their derivatives. Communication protocols can also include, but are not limited to, RS485 and RS232.  
         [0023]     As an optional embodiment, additional processing capability  52  can be connected in electronic communication to the controller  30 . An illustrative, but nonlimiting example, of this type of additional processing capability  52  includes a daughter board. This electronic communication  100  can be in the form of either hard-wired, wireless-type communication and any variant thereof.  
         [0024]     Each component  20  preferably, but not necessarily, is in electronic communication  100  with a plurality of inputs  62 , e.g., sensors. There are input and/or output devices  50 ,  40  in electronic communication  100  with the electronic control system  10 . This can include an input and/or output device  50  that is connected via hardwired connections to the controller  30 . Optionally, the input and/or output device  40  that is connected via wireless communication to the controller  30 .  
         [0025]     Although a thermostat is preferred, the input and/or output devices  50 ,  40  can include virtually any type of electronic output device. Preferably, but not necessarily, the electronic output device includes an electronic display  102 , as shown in  FIG. 2 . Although a liquid crystal diode display is preferred for the electronic display  102 , a cathode ray tube, a plasma screen and virtually any other type of electronic display will suffice. The electronic display  102  can be hard wired, portable or in wireless connection with the controller  30  and any combination thereof.  
         [0026]     The input and/or output devices  50 ,  40  can also include an alarm to detect abnormal operating conditions or failures on part of the subsystems that can be visual or audible or both visual and audible. The alarm can be both local or over a computer network. If the alarm is over a computer network then nodes on the computer network will be able to visually or audibly indicate the alarm condition through controlled systems, subsystems and processes. Use of a wide area network, WAN, will permit safety and lower level alarm conditions to reach nodes that can provide an emergency response, monitoring services, owners, operators, repair and servicing organizations, and so forth. In premise nodes, such as that found on a local area network, LAN, the input and/or output devices  50 ,  40  can include, in addition to a thermostat, appliances, messaging terminals, personal computers, televisions, auxiliary smoke and fire monitors, and alarm mechanisms, and so forth.  
         [0027]     Moreover, the input and/or output devices  50 ,  40  can include any type of pushbutton entry system including, but not limited to, a keyboard, voice recognition, and so forth. This can include, but is not limited to, a television set interface, and a security alarm display. Specifically the wireless input and/or output devices  40  can include, but are not limited to global computer network enabled appliance, e.g., web appliance, telephone (wired or wireless), personal digital assistant (“PDA”), laptop computer, home control interface and a wide variety of devices that use Wireless Application Protocol (“WAP”). WAP is a secure specification that allows users to access information instantly via handheld wireless devices. Wireless communication can also include infra-red communications.  
         [0028]     Information from the plurality of inputs  62 , e.g., sensors, can be recorded as historical data in the controller  30  as well as accessed and viewed in real-time with the input and/or output device  50 ,  40 . Illustrative, but nonlimiting examples of this type of read-only data includes: status of a thermostat or a plurality of terminals for a thermostat and associated fuse status; a pressure switch input status; a high limit switch input status; a rollout switch input status; an inducer relay status; a gas valve relay status; a circulation blower relay status; a circulation blower heat relay status; a circulation blower cool relay status; an igniter triac status; a current mode for the controller  30 ; an igniter active line counts; and a time left auto-reset timer. A listing of these preferred inputs are listed below in Table 1. The access indication “R” means that the user through the input and/or output devices  50 ,  40  can only view the status of an input or output devices  50 ,  40  for the controller  30  and cannot change it.  
                           TABLE 1                                   Access   Inputs and Outputs for Controller 30                           R   Thermostat (Terminal W) Status           R   Thermostat (Terminal Y) Status           R   Thermostat (Terminal G) Status           R   Thermostat (Terminal R) Status and Fuse Status           R   Pressure Switch Input Status           R   High Limit Switch Input Status           R   Rollout Switch Input Status           R   Inducer Relay Status           R   Gas Valve Relay Status           R   Circulation Blower Relay Status           R   Circulation Blower Heat Relay Status           R   Circulation Blower Cool Relay Status           R   Igniter Triac Status           R   Current Mode of Controller 30           R   Igniter Active Line Counts           R   Time Left Auto-Reset Timer                      
 
         [0029]     An aspect of the present invention is information that can be stored in memory for the controller  30  and either accessed and in some instances accessed and modified through the input and/or output devices  50 ,  40 . Illustrative, but nonlimiting examples of read-only data of this type includes: controller  30  information, e.g., manufacturing identification of the controller  30 , model number of the controller  30 , serial number of the controller  30 , software revision of the controller  30 , and a date code for the controller  30 , e.g., date of origination for the controller  30 , and system manufacturing information for the controller  30 .  
         [0030]     Illustrative, but nonlimiting examples of this type of data that can be read as well as modified includes: dealer information for the component  20 , e.g., furnace. Nonlimiting examples of this type of information includes name of a dealer, phone number of a dealer, installation date for the component  20 , e.g., furnace, and service dates for the component  20 , e.g., furnace, and customer information, e.g., customer&#39;s name, address and zip code.  
         [0031]     A listing of this data is provided below in Table 2. The access indication “R” means that the user through the input and/or output devices  50 ,  40  can only view the value and cannot change it. Access indication “W” indicates that the user through the input and/or output devices  50 ,  40  can alter the value to any desired value.  
                       TABLE 2                       Access   Command   Purpose                   R, W   Customer   Name, Address and Zip Code           Information       R   Controller   Manufacturing           Information   Identification, Model               Number, Serial Number,               Software Revision,               and Date Code       R, W   Dealer Information   Name, Phone Number,               Installation and               Service Date       R   System   System Manufacturing Information           Manufacturing           Information                  
 
         [0032]     Another aspect of this Invention is that information from the plurality of inputs  62 , e.g., sensors, can be tallied or summed through counting-type electronic devices, e.g., counters.  
         [0033]     Illustrative, but nonlimiting examples of this type of summed or tallied read-only data includes: a total number of heating cycles from flame detected to the flame not being present; a current mode of the controller  30 ; a total number of cooling cycles from when cooling is detected to when cooling is no longer present (such as found by detecting electrical power to the compressor from a specific terminal on the thermostat); and a current time stamp for the electronic control system  10 .  
         [0034]     Illustrative, but nonlimiting examples of this type of summed or tallied data that can be read as well as the counter, timer or event tally reset to zero (0) includes: a total number of the heating cycles since the counter or tally is cleared; a total number of the cooling cycles since the counter or tally is cleared; a number of pressure switch openings after a flame is sensed since the counter or tally is cleared; a number of high limit switch openings since the counter or tally is cleared; a number of rollout switch openings since the counter or tally is cleared; a number of internal resets since the counter or tally is cleared; an average time for a heating cycle; an average time for a cooling cycle; an average number of reset commands since the system has been cleared; and a failure history with a previous predetermined number, e.g.,  20 , of failures indicated with a time stamp.  
         [0035]     Illustrative, but nonlimiting examples of this type of summed or tallied data that can be read as well as set to a desired value by the user, includes: at least one timing delay for turning the heat on; at least one timing delay for turning the heat off; at least one timing delay for turning the cooling on; and at least one timing delay for turning the cooling off.  
         [0036]     A listing of this timer data is provided below in Table 3. The access indication “R” means that the user through the input and/or output devices  50 ,  40  can only view the value and cannot change it. Access indication “W” indicates that the user through the input and/or output devices  50 ,  40  can alter the value to any desired value. The access indication “Z” means that the user through the input and/or output devices  50 ,  40  can reset the counter, timer or event tally to zero (0).  
                           TABLE 3                                   Access   Property Name                           R   Total Number of Heating Cycles               (Flame Detected To Not Flame Present)           R   Total Number of Cooling Cycles               (Power to Terminal Y Detected To               Power Applied to Terminal Y Not               Present)           R, Z   Total Number of Heating Cycles Since               Cleared           R, Z   Total Number of Cooling Cycles Since               Cleared           R   Current Mode of the Controller 30           R, Z   Number of Pressure Switch Openings               After a Flame is Sensed           R, Z   Number of High Limit Switch Openings           R, Z   Number of Rollout Switch Openings           R, Z   Number of Internal Resets           R, Z   Average Time for a Heating Cycle           R, Z   Average Time for a Cooling Cycle           R, Z   Number of Reset Commands Since the               System Has Been Cleared           R, W   Heat On Delay Timing           R, W   Heat Off Delay Timing (Number 1)           R, W   Heat Off Delay Timing (Number 2)           R, W   Heat Off Delay Timing (Number 3)           R, W   Heat Off Delay Timing (Number 4)           R, W   Cool On Delay Timing           R, W   Cool Off Delay Timing (Number 1)           R, W   Cool Off Delay Timing (Number 2)           R   Current System Time Stamp           R, Z   Failure History - Previous               Predetermined Number of Errors With               Time Stamp                      
 
         [0037]     Referring now to  FIG. 2 , the electronic display  102  can provide a graphical user interface screen  104  that provides a significant amount of visual information for the user. In an illustrative, but nonlimiting example, a graphical user interface screen  104  for a furnace system is depicted. There are click-on tabs for the graphical user interface screen  104  for the user to access other portions of the software with examples being a file function  108 , a configure function  110 , a data function  112  and a help function  114 .  
         [0038]     There is a listing of running counters indicated by numeral  120 . Illustrative, but nonlimiting examples of these counters include: a total number of heating cycles from flame detected to the flame not being present  122 ; a total number of cooling cycles from when cooling is detected to when cooling is no longer present (such as found by detecting electrical power to the compressor from a specific terminal on the thermostat)  124 ; a total number of the heating cycles since the counter or tally is cleared  126 ; a total number of the cooling cycles since the counter or tally is cleared  128 ; a number of pressure switch openings after a flame is sensed since the counter or tally is cleared  130 ; a number of high limit switch openings since the counter or tally is cleared  132 ; a number of rollout switch openings since the counter or tally is cleared  134 ; a number of internal resets since the counter or tally is cleared  136 ; an average time for a heating cycle  138 ; an average time for a cooling cycle  140 ; an average number of external reset commands since the system has been cleared  142 ; an number of time the ignition retried  144  and the number of ignition recycles  146 . There is verbiage indicating whether the counters are to be displayed on the graphical user interface screen  160  and an associated visual indicator  161 .  
         [0039]     There is a display for inputs indicated by numeral  162 . Illustrative, but nonlimiting examples of these inputs include: an indication that a pressure switch is activated  164 ; an indication that a rollout switch is activated  166 ; an indication that a high limit switch is activated  168 ; an indication of power being applied to a particular terminal, e.g., “R”, for a thermostat  172 ; an indication of power being applied to a particular terminal, e.g., “G”, for a thermostat  174 ; an indication of power being applied to a particular terminal, e.g., “Y”, for a thermostat  176 ; and an indication of power being applied to a particular terminal, e.g., “W”, for a thermostat  178 . There is also a graphical indication of a series of delay timers being on or off as indicated by numeral  180 .  
         [0040]     There is a display for outputs indicated by numeral  182 . Illustrative, but nonlimiting examples of these outputs include: a circulation blower for heating being operational  184 ; a circulation blower for cooling being operational  186 ; a circulation blower being operational at a low level  188 ; an indication that a gas valve is operational  190 ; an indication that an inducer is operational  192 ; and an indication of an igniter state  194 .  
         [0041]     There is a display for general information indicated by numeral  200 . Illustrative, but nonlimiting examples of this type of information includes: a control mode  201 , e.g., monitor a burner; igniter line counts  202 , e.g.,  40 ; and reset time remaining 204, e.g., zero.  
         [0042]     There is a display representing an indication of furnace flame strength indicated by numeral  222 . There is a graphical representation of a meter indicated by numeral  224 . There is also verbiage that indicates that a weak flame is below a certain predetermined value, e.g.,  226 .  
         [0043]     There is a display for communication settings indicated by numeral  150 . This includes a visual display as to whether the screen update feature  152  is indicated as being on or off  154 . There is a visual indication  156  that indicates whether a controller  30  is in electronic communication  100  with an input and/or output devices  50 ,  40 .  
         [0044]     Also present on the graphical user interface screen  104  is a device for reviewing historical data from the electronic control system  10  that is generally indicated by numeral  205 . This includes a graphical interface pushbutton for a fast rewind of the historical data  206 , a graphical interface pushbutton to stop playing the historical data  208 , a graphical interface pushbutton to play the historical data  210 , a graphical interface pushbutton to pause recording the historical data  216  and a graphical interface pushbutton for recording of the historical data  218 . There is also a visual indicator for the specific function that is currently activated  212 , e.g., stop, rewind, play, pause, fast forward or record. There is a graphical user interface pushbutton  220  to seek a particular hour of recorded historical data. There is also a multiplier function  214  to speed or slow down the recording and playback of historical data from the electronic control system  10  by a predetermined factor.  
         [0045]     Information from the plurality of inputs  62 , e.g., sensors, viewed in real-time with the input and/or output devices  50 ,  40 , shown in  FIG. 1 , is preferably, but not necessarily, displayed with a graphical user interface screen  160  that replicates at least one component  20 , e.g., furnace, and at least one of the plurality of inputs  62 , e.g., sensors in  FIG. 3 . This graphical user interface screen  160  is generally indicated by numeral  300 . There is a visual indicator  304  providing connection status between the controller  30  and an input and/or output devices  40 ,  50 . There is a visual indicator  306  signifying if a pressure switch is open or closed. Also, there is a visual indicator  308  signifying if a high limit switch is open or closed. Furthermore, there is a visual indicator  310  signifying if a rollout switch is open or closed.  
         [0046]     There is also a graphical representation of at least one component  20 , e.g., furnace, indicated by numeral  302 . Components of an illustrative furnace may include a first air circulator blower  312 , an air duct  314 , a gas valve  316 , igniters  318  and a second air circulator blower  322 . There is an icon for obtaining system information  324  and an icon for saving data  336 . There is also a graphical representation of a control circuitry  320  for the at least one component  20 , e.g., furnace.  
         [0047]     In addition, there is the previous system for reviewing historical data from the electronic control system  10  (as shown in  FIG. 1 ) that is generally indicated by numeral  205 . This includes a graphical interface pushbutton for a fast rewind of the historical data  206 , a graphical interface pushbutton to stop playing the historical data  208 , a graphical interface pushbutton to play the historical data  210 , a graphical interface pushbutton to pause recording the historical data  216  and a graphical interface pushbutton for recording of the historical data  218 . There is also a visual indicator for the specific function that is currently activated  212 , e.g., stop, rewind, play, pause, fast forward or record. There is also a multiplier function  214  to speed or slow down the recording and playback of historical data from the electronic control system  10  by a predetermined factor, e.g., 64.  
         [0048]     In addition in  FIG. 3 , there is a visual representation  332  of an input and/or output devices  50 ,  40 . An illustrative, but nonlimiting, example of an input and/or output devices  50 ,  40  includes a digital thermostat  332 . There is a visual indicator  330  signifying whether heating is operational, a visual indicator  328  signifying whether cooling is operational and a visual indicator  326  signifying whether a fan is operational. Also, there is a visual indicator  334  indicating whether electrical power has been applied to the input and/or output devices  50 ,  40 , e.g., digital thermostat  332 .  
         [0049]     The preferred embodiment of the present invention and the method of using the same has been described in the foregoing specification with considerable detail, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention performed by others skilled in the art to which the invention pertains will be considered infringements of this invention when those modified forms fall within the claimed scope of this invention.