Patent Publication Number: US-8117862-B2

Title: Device and method for recording air conditioning system information

Description:
BACKGROUND OF THE INVENTION 
     In the art of heating, ventilating and air conditioning (HVAC) equipment, there is an ever increasing utilization of electronic based or configured controls. The use of microprocessors for monitoring the status of an HVAC system and certain operating conditions, effecting control over operation of the HVAC system and for the storage of suitable system identification information has become increasingly common. However, one problem associated with the use of microprocessor based air conditioning system controls is the difficulty in obtaining accurate information concerning the operation and performance of the air conditioning equipment. Still further, control systems have been developed which have the capability to transmit information to remote locations via various types of data transmission equipment. However, human observation of operation of air conditioning equipment is, typically, a major source of information and known types of controls typically require external devices which must be connected to a microprocessor control board, for example, and require an interface and a computer to retrieve desired information. Such methods are cumbersome, expensive and difficult to implement. 
     Accordingly, with the increasing sophistication of air conditioning systems equipped with electronic controls, there has been a need to develop an information storage device which is removable from the control system processor so that information regarding, for example, the operation of air conditioning equipment may be analyzed and so that suitable control functions may be modified, as needed, by personnel servicing the air conditioning equipment. Moreover, there has also been a need to provide so-called generic controllers or control systems for air conditioning equipment which may be programmed or provided with operating parameters after completion of manufacture and even after installation of such equipment. It is to these ends that the present invention has been developed. 
     SUMMARY OF THE INVENTION 
     The present invention provides an information storage device or module for use in conjunction with HVAC equipment and a method of storing and retrieving information using or implementing such a device. 
     In accordance with one aspect of the present invention an information storage and retrieval device or module is provided which is operable to store a relatively large amount of information in a unit of compact physical size and which may be connected to a control system for a unit of HVAC equipment, hereinafter referred to as air conditioning equipment. By provision of a suitable port on the control system, such as on a circuit board of the control unit microprocessor, information may be automatically transferred to the device or transferred from the device or module. Accordingly, the device can be retrieved at a selected time and the information may be used, as needed, by servicing personnel. 
     Another aspect of the invention includes the provision of a device or module which may be releasably and operably connected to a control system for an air conditioning unit for retrieving information concerning the operating status and operating parameters of the unit and also for use in performing upgrades or modifications to the operating parameters of the control system. 
     Still further, the invention provides an information storage and retrieval device which may be utilized with air conditioning equipment wherein the control system for the air conditioning equipment, with respect to each particular unit or equipment, may be produced as a generic system and then “personalized” by using the device to input to the system controller such information as system model number, serial number, and specific data which can be utilized in operating the system. 
     The information storage device may be utilized to update existing so-called generic control systems from time to time in the field so that existing equipment has access to the latest processes and control features. The device or module may incorporate an EEPROM memory unit on a circuit board with a connector so that it can exchange data with a control board or microprocessor forming part of a control system for a particular unit of air conditioning equipment. Model specific data may be transferred to the control system and program files or upgrades to a basic program residing on the control system can be provided utilizing the so-called “personality module” or device of the present invention. Of course, control of information such as historical data including, for example, the number of operating cycles of the air conditioning equipment can be stored on the so-called personality module for future use and diagnostic work. 
     Still further, the device of the present invention can be utilized with respect to calibration data for parameters such as operating pressures and temperatures required for efficient, continuous and reduced hazard system operation. Such an arrangement allows the use of control system elements, such a thermistors or pressure transducers, in conjunction with air conditioning equipment instead of specialized switches having unique calibrations of temperature or pressure. Such an improvement simplifies the manufacturing process for air conditioning equipment and reduces the amount of information gathering, such as bar code scanning, of each of the components of the equipment at the point of manufacture. 
     In accordance with yet another aspect of the present invention, the aforementioned information storage personality module or device may contain information concerning the air flow characteristics for or calibration information of a particular type of air conditioning equipment on which it is installed and which may be specially programmed for laboratory use. Such devices may contain override data or instructional programming for nonstandard operating conditions, for example. Moreover, a so-called functional parts list may be carried on the information storage module or device as part of the information stored therein which would reduce the amount of documentation used in manufacturing, shipping and servicing a unit of air conditioning equipment, for example. 
     The aforementioned personality module or device may be of a particular shape which is easily recognizable and allows it to be inserted correctly in a matching connector part for connecting the device to the control system or control board of the equipment with which the device is to be used. The shape of the personality module or device is also such that the correct side to be connected to the control system can be detected by personnel manipulating and being able to feel the configuration of the device. The device may have features including a tether for maintaining it attached to the air conditioning equipment in which it is installed and matched, for example. 
     Those skilled in the art will further appreciate the advantages and superior features of the invention upon reading the detailed description which follows in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of a typical control system for a unit of air conditioning equipment and illustrating the information storage and transfer module or device of the invention; 
         FIG. 2  is a detail view showing the device of the invention connected to a processor for transferring information therebetween; 
         FIG. 3  is a table of typical items of information storable in the device of the invention; 
         FIG. 4  is an end view of a preferred embodiment of the device of the invention; and 
         FIG. 5  is a side elevation of the device. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     In the description which follows like elements are marked throughout the specification and drawing with the same reference numerals, respectively. Certain elements and/or features may be shown in schematic form in the interest of clarity and conciseness. 
     Referring to  FIG. 1 , there is illustrated an air conditioning apparatus, generally designated by the numeral  10 , shown in schematic form. Apparatus  10  may take various forms but, in the embodiment illustrated, is shown to include a cabinet  12  having an air inlet or return air opening  14  and an air discharge opening  16  connected by suitable ducting to a suitable enclosed space  18 . Air returns from space  18  to the cabinet  12  via a path  20 . Air conditioning apparatus  10  includes a motor driven blower or fan  22  connected to an electric drive motor  24  which may include its own control unit  26 , as illustrated. Motor driven blower  22  is disposed within cabinet  12 , typically in a flow path wherein air entering the cabinet may flow over a cooling coil type heat exchanger  28 , then through blower  22  to a heat exchanger  30  which may comprise a combustion furnace, for example. Yet another type of air heating means may be disposed in cabinet  12  including an electric resistance grid type heater  32 , as indicated in  FIG. 1 . In applications of air conditioning apparatus  10  which includes a combustion furnace, there is typically an electrically operated gas flow control valve  34  and pressure and temperature sensors  36  and  38  associated with furnace  30  for monitoring the combustion process and operating parameters of the combustion furnace. Additional temperature sensors associated with the apparatus  10  may include a return air temperature sensor  40 , an apparatus discharge temperature sensor  42 , a temperature sensor  44  within the space  18  and, possibly, a humidity sensor  46  for sensing the humidity within the space  18 . Sensors  44  and  46  are connected to a thermostat  48 , as indicated. 
     A preferred control system for the apparatus  10 , indicated generally by numeral  50 , includes a microprocessor  52  and additional control elements to be described. Microprocessor  52  is operably connected to the thermostat  48  via signal conductors, including conductors  54 ,  56 ,  58 ,  60  and  62  which, respectively, may provide signals to the microprocessor including a first stage call for heat, a second stage call for heat, a first cooling stage call, a continuous fan operating mode signal, and possibly, a heat pump operating signal. The apparatus  10  illustrated, typically includes a vapor compression compressor and condenser unit, not shown, operably connected to the evaporator or cooling coil  28  and possibly configured for either air cooling operation only or heat pump operation. Those skilled in the art will recognize that, in a typical air conditioning apparatus, multiple sources of heat may or may not be available. However, for convenience in describing the invention in this application the apparatus  10  has been shown to include at least one source of cooling effect, namely, the heat exchanger  28 , and single or multiple sources of heating which could include the heat exchanger  28 , includes the combustion furnace  30  and could include the electric heater  32 . Alternatively, multiple stages of electric heating could be incorporated in the apparatus  10  in place of the combustion furnace  30 . 
     Accordingly, for the particular configuration of the apparatus  10 , as illustrated, the control system  50  typically includes a motor control relay  64 ,  FIG. 1 , operable to receive a signal from the microprocessor  52  by way of a conductor  66  and wherein a feedback signal from the relay  64  may be input to the microprocessor via a conductor  68 . Still further, the electric heating element  32  may include a control relay  70  and an interlock relay  72  operable to receive signals from the microprocessor  52  by way of conductor means  71  and  73 , respectively, with relay status feedback signals input to the microprocessor via conductors  74  and  75 , respectively. Temperature sensors  40  and  42  provide input signals to the microprocessor  52  by way of conductor means  41  and  43 , respectively. Combustion furnace control valve  34  receives a control signal via conductor means  35  output by controller or microprocessor  52  and provides a status feedback signal via conductor means  37 . Sensors  36  and  38  provide signals to the controller  52  via conductor means  36   a  and  38   a , respectively. 
     As further shown in  FIG. 1 , controller or microprocessor  52  may include an interface  80  having a visual display  80   a  and human operable input means including a keypad or touch screen  80   b  for altering the operating characteristics of the controller  52  or for reading information therefrom. However, an advantage of the apparatus  10 , including its control system  50 , is the provision of an information storage and retrieval device in accordance with the invention, generally designated by the numeral  82 . Device  82  may be characterized as a so-called personality module and may be operably connected to the controller  52  through suitable connector means  84   a ,  84   b  to transfer information between the controller  52  and the device  82 . In this regard the device  82  may include its own processor  85  and one or more memory units  86  and  88 , for example. Processor  85  may also be operable to communicate information to and from memory means  86 ,  88  through an optical communications link  89 , for example. Accordingly, the device or module  82  may be releasably connected to the controller  52  to alter certain operating parameters of the controller, record information as to the current operating status of the apparatus  10  and its control system  50 , record historic operating data, and provide a technician with a list of the manufacturer&#39;s part numbers for components of the apparatus  10  and its control system  50 , for example. 
     Device  82  may be disconnected from controller  52  and connected to a processor  90 ,  FIG. 2 , which may or may not be connected to a communications network  92  for communicating information to and from the device or module  82 , as needed. The memory requirements of device  82  may be satisfied by a non volatile memory, such as a 16K bit EEPROM, which may be a type M24C16 available from ST Microelectronics, or a Microchip Technologies type 24LC16B, for example. The connector  84  may be a type available from JST as their part no. S4B-JL-F-E, or equivalent. 
     As mentioned previously, the module or device  82  may be programmed at the manufacturing location of the apparatus  10  to store information concerning the specific model of the apparatus. Examples of data stored in the memories  86 ,  88  are the apparatus model and serial number, air flow data, and a list of specific part numbers for replaceable parts that are specific to the particular apparatus with which the module  82  is associated. The information stored in the module or device  82  that is necessary for operation of the apparatus  10  is transferred into one or more memories  52   a  and/or  52   b ,  FIG. 1 , of the controller or processor  52 . 
     Accordingly, data necessary for operation of the apparatus  10  and its control system  50 , when transferred into the memories  52   a  and/or  52   b , allows normal operation of the apparatus in the event the module  82  is removed or becomes unreadable. Normally, at power-up of the control system  50 , the controller or processor  52  compares locally stored memory data in the memory  52   a  and/or  52   b  with the data stored in the memory  86  and/or  88 . The system  50  may be programmed to accept valid data from device  82  which would supersede any locally stored data in the controller  52 .  FIG. 3  illustrates, for example, a table of typical types of data stored in the module or device  82  for a particular type of motor  24  used in the apparatus  10 , such a motor including, for example, one of a PSC motor (permanent split capacitor), a CTM motor (constant torque motor), and a serial communicating variable speed motor (VS). 
     Referring now to  FIGS. 4 and 5 , there is illustrated a preferred physical embodiment of the device or module  82  which includes a generally rectangular box-like housing  100  having a boss  102  at one end,  FIG. 5 , with an opening  104  formed therein for attaching a tether or the like, not shown, to the module. Connector  84   a  projects in a longitudinal direction from one side  100   a  of housing  100  and is aligned generally with one end  100   b  of housing  100  to facilitate connecting the module or device  82  to the connector part  84   b  of controller  52  or to a corresponding connector part associated with the processor  90 ,  FIGS. 1 and 2 . Suitable indicia may be applied to the housing  100  via a label  103 , as indicated in  FIG. 5 . The physical dimensions of the module  82  are not remarkable and the module or device  82  may be easily handheld and transported. For example, the overall length of the housing  100  may be on the order of about 1.8 inches, including the boss  104 , the overall height may be on the order of 1.0 inch, and the thickness of the housing may be less than 0.50 inches. 
     Accordingly, the module or device  82  enables the obtaining of accurate information about the operation and performance of HVAC equipment, such as the apparatus  10  and the module may be easily connected to and disconnected from the control system  50  via the connector  84   a ,  84   b . Moreover, data or information may also be transferred via a LITE PORT connector, such as connector  89 ,  FIG. 1 , if desired. Once the module or device  82  is connected to the controller  52 , for example, information in the controller memories  52   a  and/or  52   b  may be automatically stored in the module and information in the module may be transferred to the controller  52 , such information being of the types described hereinbefore. Still further, the control system  50  may be upgraded as to its performance parameters by putting such information in the module  82  via a processor, such as the processor  90  and once the controller  52  detected a connection to the module  82  the upgrade information would be transferred to the control system  50 . 
     Moreover, as mentioned previously, equipment or apparatus model specific data may be transferred to the controller  52 , upon energization of the controller  52  and upon energization of the apparatus  10  and its control system  50 . Accordingly, generic control components, such as the controller  52 , may be provided when the equipment or apparatus  10  is manufactured and prepared for placement in service. 
     Still further, the apparatus  10  may be provided with sensors, such as the sensors  36  and  38 , rather than pressure responsive or temperature responsive switches, and operating parameters for a particular apparatus  10  may be placed in the memory of module  82  and then transferred to the controller  52  for a particular model of apparatus  10  whereby the calibration of pressure and temperature conditions required for continuous operation can be stored on the module and transferred to the controller on a model by model basis. In this way also, the module  82  may be programmed for laboratory usage in selecting nonstandard airflow parameters and control override capabilities. As mentioned previously, a parts list for each apparatus  10 , including descriptions for various replacement parts, may be programmed into the module  82  to reduce the amount of paper documents used in shipping documentation or literature associated with each apparatus. 
     Those skilled in the art will recognize that the fabrication and operation of the apparatus  10 , its control system  50  and the module or device  82  may be carried out based on the description herein and information available to and known to those skilled in the art. Although a preferred embodiment of the invention has been described in detail those skilled in the art will also recognize that various substitutions and modifications may be made to the specific embodiment described without departing from the scope and spirit of the appended claims.