Patent Description:
Control panels for heating, ventilation, air conditioning, and refrigeration (HVACR) units typically include low-voltage components alongside high-voltage components. High-voltage components typically are very restrictive with respect to servicing, often requiring unit shutdown, servicers wearing protective equipment, and/or other significant steps to be safely serviced. Current control panels can provide high-voltage components in a region of the panel that can be protected by their own compartment having a separate door, but this is space-inefficient, particularly relative to the limited space in which control panels can be provided on some HVACR units.

<CIT> is directed to an outdoor unit of an air conditioner including a movable main panel, a compressor driving board including high voltage components, and a fan motor driving board on an intermediate plate.

<CIT> describes control boxes for HVAC units that provide a divider wall within an outer housing dividing said housing into high and low voltage sections, with wires passing through the divider.

<CIT> describes a watt-hour meter socket with isolated sub-enclosures for different voltages for use in electrical utility systems.

<CIT> describes a housing including multiple sealing surfaces for containing explosions within said housing.

This disclosure is directed to control panels for heating, ventilation, air conditioning, and refrigeration (HVACR) units, particularly control panels separating high and low-voltage controls, and HVACR units including such control panels.

Layered control panels according to the invention and defined in claim <NUM> can effectively separate low-voltage components from high-voltage components, while taking advantage of the layering to be space-efficient. Low-voltage components are provided on an outer layer so that they can be accessed readily, while high-voltage components are provided on an inner layer which is covered by the outer layer, restricting access to the high-voltage components. The layered design allows the same surface area to be used for each set of components, while the order of the layering facilitates servicing of low-voltage components while restricting access to high-voltage components. Further, this arrangement allows the HVACR unit to continue to be operated during servicing of the low-voltage components, facilitating diagnosis of some potential issues and streamlining troubleshooting processes.

According to the invention, a control panel for a heating, ventilation, air conditioning, and refrigeration (HVACR) unit includes a control panel housing having an open side, an inner layer disposed within the control panel housing, a plurality of high-voltage components disposed on the inner layer, an outer layer disposed closer to the open side of the control panel housing, and a plurality of low-voltage components disposed on the outer layer. The outer layer is configured to be movable between a closed position where the outer layer covers the plurality of high-voltage components with respect to the open side of the control panel housing and an open position where the plurality of high-voltage components are accessible through the open side of the control panel housing. All of the plurality of high-voltage components are disposed only on the inner layer. All of the plurality of low-voltage components are disposed only on the outer layer.

In an embodiment, the low-voltage components are safety extra-low voltage (SELV) components.

In an embodiment, the outer layer comprises a single piece. In an embodiment, the control panel further includes a hinge on a first side of the single piece of the outer layer, the hinge connecting the single piece of the outer layer to the control panel housing. In an embodiment, the control panel further includes a lock on a second side of the single piece of the outer layer, the second side opposite the first side.

In an embodiment, the outer layer comprises a plurality of pieces. In an embodiment, each of the plurality of pieces includes a hinge, the hinge connecting the piece to the control panel housing. In an embodiment, at least two of the plurality of pieces are configured to be locked to a housing support when the outer layer is in the closed position. In an embodiment, some of the plurality of low-voltage components are disposed on each of the plurality of pieces. In an embodiment, the low-voltage components are disposed on only one of the plurality of pieces.

In an embodiment, a heating, ventilation, air conditioning, and refrigeration (HVACR) unit includes a control panel disposed on an exterior surface of the HVACR unit. The control panel includes a control panel housing having an open side, an inner layer disposed within the control panel housing, a plurality of high-voltage components disposed on the inner layer, an outer layer disposed closer to the open side of the control panel housing, and a plurality of low-voltage components disposed on the outer layer. The outer layer is configured to be movable between a closed position where the outer layer covers the plurality of high-voltage components with respect to the open side of the control panel housing and an open position where the plurality of high-voltage components are accessible through the open side of the control panel housing. All of the plurality of high-voltage components are disposed only on the inner layer. All of the plurality of low-voltage components are disposed only on the outer layer.

This disclosure is directed to control panels for heating, ventilation, air conditioning, and refrigeration (HVACR) units, particularly control panels separating high and low-voltage controls.

<FIG> shows a perspective view of a control panel according to an embodiment, where the layer carrying low-voltage components is open. Control panel <NUM> includes control panel housing <NUM> having an open side <NUM>, an outer layer <NUM> including first outer layer portion <NUM>, and second outer layer portion <NUM>, a first hinge <NUM>, a second hinge <NUM>, low-voltage components <NUM>, inner layer <NUM>, and high-voltage components <NUM>. Housing support <NUM> is provided in the control panel housing <NUM>, between the inner layer <NUM> and the open side <NUM>, when the inner layer <NUM> is in a closed position.

Control panel housing <NUM> is a housing configured to contain one or more components such as controls, including low-voltage components <NUM> and high-voltage components <NUM>. Control panel housing <NUM> can protect its contents from an exterior environment and/or from unauthorized access. Control panel housing <NUM> can include one or more walls defining a perimeter of a shape and providing an open side <NUM>. The control panel housing <NUM> can be mounted on an HVACR unit, for example being provided on a wall of a cabinet of an HVACR unit such as a side wall of the cabinet.

Open side <NUM> is defined by the control panel housing <NUM>. Open side <NUM> of the control panel housing <NUM> can be sized and positioned in order to access to at least some of the contents of control panel housing <NUM>. The open side <NUM> can be sized and positioned to allow at least the portion of the contents of control panel housing <NUM> to be accessed for servicing, for example being sized to allow hands and tools of maintenance personnel to reach into the control panel housing <NUM>.

Outer layer <NUM> includes one or more panels. Outer layer <NUM> is configured to be movable between a closed position and an open position. In an embodiment, outer layer <NUM> is movable between the closed position and the open position by moving each of the one or more panels forming outer layer <NUM>. The one or more panels of the outer layer can each be rotatable about hinges to move between the closed and open positions. When outer layer <NUM> is in a closed position, outer layer <NUM> is in a space between the open side <NUM> and the inner layer <NUM>, such that the outer layer <NUM> can be accessed through the open side <NUM>, but outer layer <NUM> is positioned such that it obstructs access to inner layer <NUM>. Outer layer <NUM> has one or more low-voltage components <NUM> located on its surfaces. Low-voltage components <NUM> are located only on the outer layer <NUM> and are not included on inner layer <NUM>. In an embodiment, the low-voltage components <NUM> are provided on the outer layer <NUM> such that they can be accessed for operation or maintenance when the outer layer <NUM> is in the closed position. In an embodiment, the outer layer <NUM> is a continuous layer when in the closed position, including either one portion or multiple portions that connect to one another. In an embodiment, the outer layer <NUM> includes one or more portions, where at least some of the portions of outer layer <NUM> connect to the housing support <NUM> when outer layer <NUM> is in the closed position. In the embodiment shown in <FIG>, outer layer <NUM> includes first outer layer portion <NUM> and second outer layer portion <NUM>.

First outer layer portion <NUM> is one of the panels that forms a part of outer layer <NUM>. First outer layer portion <NUM> can be joined to the control panel housing <NUM> by way of first hinge <NUM>. First outer layer portion <NUM> can be any suitable material for a panel supporting low-voltage components <NUM>. First outer layer portion <NUM> can include at least some of the low-voltage components <NUM> included in control panel <NUM>. In an embodiment, first outer layer portion <NUM> includes one or more retention features <NUM> such that it can be secured to another part, such as second outer layer portion <NUM> or housing support <NUM>. In an embodiment, the first outer layer portion <NUM> can be secured to the housing support <NUM> when the first outer layer portion <NUM> is in the closed position for outer layer <NUM>.

Second outer layer portion <NUM> is another panel forming a part of outer layer <NUM>. Second outer layer portion <NUM> can be joined to the control panel housing <NUM> by way of second hinge <NUM>. Second outer layer portion <NUM> can be any suitable material for a panel supporting low-voltage components <NUM>. Second outer layer portion <NUM> can include at least some of the low-voltage components <NUM> included in control panel <NUM>. In an embodiment, second outer layer portion <NUM> includes one or more retention features <NUM> such that it can be secured to another part, such as first outer layer portion <NUM> or housing support <NUM>. In an embodiment, the second outer layer portion <NUM> can be secured to the housing support <NUM> when the second outer layer portion <NUM> is in the closed position for outer layer <NUM>.

Low-voltage components <NUM> are electronic components such as controls for the HVACR system. Low-voltage components <NUM> can be electronic components that can be safe to access, operate, or service without risk to personnel. In an embodiment, the low-voltage components <NUM> can be safe to access, operate, or service without requiring personnel to be equipped with personal protective equipment. Low-voltage components <NUM> can include, for example, any suitable separated or safety extra-low-voltage (SELV) components for the HVACR system including control panel <NUM>. The classification of low-voltage components <NUM> as SELV components can be performed according to any suitable standards for such status, such as defined installation standards. An example of such a standard is UL60335-<NUM>. All of the low-voltage components <NUM> included in control panel <NUM> are provided only on the outer layer <NUM> such that the low-voltage components <NUM> can be operated or serviced while the outer layer is in the closed position. Low-voltage components <NUM> are provided on any one or more portions of the outer layer <NUM>. In an embodiment, low-voltage components <NUM> are provided on each of the portions making up outer layer <NUM>. Non-limiting examples of low-voltage components include programmable logic controllers, communication modules, controller-to-harness interface circuits, extra low voltage distribution terminal blocks, and the like.

Inner layer <NUM> is a panel or support configured to support high-voltage components <NUM>. In an embodiment, inner layer <NUM> can be positioned within control panel housing <NUM> such that it is further from the open side <NUM> than the outer layer <NUM> at least when the outer layer <NUM> is in the closed position. Inner layer <NUM> can be positioned further from the open side <NUM> than an outermost portion of housing support <NUM> when a housing support <NUM> is included in control panel <NUM>. The inner layer <NUM> can be any suitable material for a panel supporting high-voltage components <NUM>. All high-voltage components <NUM> included in control panel <NUM> are located on inner layer <NUM>. No low-voltage components <NUM> are located on inner layer <NUM>.

In an embodiment, inner layer <NUM> can be opposite sides of some or all of the panels defining outer layer <NUM>, such as first outer layer portion <NUM> and second outer layer portion <NUM>. In this embodiment, inner layer <NUM> is provided inside the control panel housing <NUM> when the first outer layer <NUM> is in the closed position.

High-voltage components <NUM> are provided on inner layer <NUM>. The high-voltage components are electrical and electronic components such as controls of the HVACR system included in control panel <NUM>. The high-voltage components can be components that can pose risk to personnel accessing, operating, or servicing those components if energized during servicing. In an embodiment, the high-voltage components <NUM> can be the components that require lockout and/or tag-out procedures to be followed during servicing. The high-voltage components <NUM> can be components receiving power at voltages in excess of safe standards, such as components that do not comply with SELV standards. As described above, components can be identified as SELV using a suitable standard, such as standard UL60335-<NUM>. The high-voltage components <NUM> can be components requiring personal protective equipment to be worn when accessing, operating, or servicing those components. The high-voltage components <NUM> can be positioned on inner layer <NUM> such that they cannot be accessed through open side <NUM> when the outer layer <NUM> is in the closed position. The high-voltage components <NUM> can be positioned on inner layer <NUM> such that they can be accessed, operated, and/or serviced when outer layer <NUM> is not in the closed position, for example by being accessible through open side <NUM> when the outer layer <NUM> is in the open position. Non-limiting examples of high-voltage components include power distribution blocks, fuse blocks, contactors, circuit breakers, transformers, overload relays, and the like.

Housing support <NUM> can optionally be included within control panel housing <NUM>. Housing support <NUM> can be a structural feature such as a column, a horizontal bar, divider, or other suitable feature provided within control panel housing <NUM>. Housing support <NUM> can be configured to be contacted by portions of outer layer <NUM> when outer layer <NUM> is in the closed position. Housing support <NUM> can contribute to outer layer <NUM> obstructing access to high-voltage components <NUM> when the outer layer <NUM> is in the closed position.

Retention features <NUM> can be provided on outer layer <NUM> and/or the control panel housing <NUM> or optional housing support <NUM>. The retention features <NUM> are configured to allow outer layer <NUM> to be retained in the closed position. The retention features <NUM> can be any suitable structures for retaining the outer layer <NUM> such as flanges, slots, tabs, latches, snap-fit features, hooks, or any corresponding features. In an embodiment, retention features <NUM> can be provided, for example, on first outer layer portion <NUM>, second outer layer <NUM>, and housing support <NUM>. In this embodiment, the retention features <NUM> can be positioned and/or configured such that first outer layer portion <NUM> can be retained to housing support <NUM> at one position and second outer layer portion <NUM> can be retained to housing support <NUM> in another position. In another embodiment, retention features <NUM> can be configured to retain first outer layer portion <NUM> to second outer layer portion <NUM>. In another embodiment, retention features <NUM> can be configured to secure a single piece outer layer <NUM> to control panel housing <NUM>. In this embodiment, retention features <NUM> can be configured to secure the single piece outer layer <NUM> to the control panel housing <NUM> at an end of outer layer <NUM> opposite where a hinge connects the outer layer <NUM> to control panel <NUM>. In an embodiment, the retention features can include a hand- or tool-turnable screw and a threaded hole configured to accommodate the screw. In an embodiment, the opposing retention feature <NUM> contacted by the screw can be a detent formed in a surface of the control panel housing <NUM> or outer layer portion <NUM>, <NUM>, depending on where the screw is to be used for retention.

<FIG> shows a front view of the control panel <NUM> shown in <FIG>, when the outer layer carrying low-voltage components is closed. As can be seen in the view shown in <FIG>, each of first outer layer portion <NUM> and second outer layer portion <NUM> are rotated about first and second hinges <NUM>, <NUM> such that they extend inwards from control panel housing <NUM> towards housing support <NUM>. Each of first outer layer portion <NUM> and second outer layer portion <NUM> are locked to housing support <NUM> by their respective retention features <NUM>. Thus, the low-voltage components <NUM> are accessible through the open side <NUM> of control panel housing <NUM>, while outer layer <NUM> is positioned between the open side <NUM> of control panel housing <NUM> and the inner layer <NUM>. The high-voltage components <NUM> are inaccessible from open side <NUM> when the outer layer <NUM> is in the closed position shown in <FIG>.

The closed position shown in <FIG> can be a standard position for the outer layer <NUM> during normal operations and servicing of the control panel <NUM>. Since only low-voltage components <NUM> are accessible in the closed position shown in <FIG>, those components can be serviced or otherwise manipulated without requiring shutdown of the HVACR unit including control panel <NUM> or personnel donning electrical personal protective equipment. The retention features <NUM> retain the outer layer <NUM> in the position where it obstructs access to the high-voltage components <NUM>. When retention features <NUM> are disengaged, the first portion <NUM> and second portion <NUM> of outer layer <NUM> can each be moved to place the control panel <NUM> into the open position shown in <FIG>.

<FIG> shows a front view of the control panel <NUM> shown in <FIG>, when the outer layer <NUM> carrying low-voltage components is open. The open position shown in <FIG> can be achieved by releasing any retention features <NUM> and moving outer layer <NUM>, for example by rotating first portion <NUM> about first hinge <NUM> and rotating second portion <NUM> about second hinge <NUM>. In the open position, the inner layer <NUM> and the high-voltage components <NUM> can be accessed through the open side <NUM> of control panel housing <NUM>. In an embodiment the housing support <NUM> can still be located between a portion of open side <NUM> and the inner layer <NUM>. In an embodiment, the high-voltage components <NUM> can be disposed on inner layer <NUM> such that access to the high-voltage components <NUM> is not obstructed by housing support <NUM>. In an embodiment, the open position of <FIG> can be taken following lockout and/or tag-out procedures for the servicing of high-voltage components <NUM>.

<FIG> shows a heating, ventilation, air conditioning, and refrigeration (HVACR) system including a control panel according to an embodiment. HVACR system <NUM> includes cabinet <NUM> having side walls <NUM>, and a control panel <NUM> provided on a surface of one of the side walls <NUM>. Cabinet <NUM> is a structure containing at least some components of the HVACR system <NUM>, such as, as non-limiting examples, air handling blowers, outdoor coils, compressors, or any other suitable HVACR system component. Side walls <NUM> define the exterior of the cabinet <NUM>. The control panel <NUM> is provided on one of the side walls <NUM>. Control panel <NUM> contains one or more electronic components used to control and/or operate HVACR system <NUM>. The control panel <NUM> can be the control panel of <FIG> or <FIG> and <FIG> as described above. In an embodiment, control panel <NUM> is mounted recessed into the side wall <NUM> such that when it is in the closed position, the outer layer is recessed or flush with respect to side wall <NUM>. In an embodiment, control panel <NUM> projects outwards from side wall <NUM>. Control panel <NUM> can further include one or more doors <NUM>. The doors <NUM> can cover an open side of a control panel housing of the control panel <NUM>. When closed, doors <NUM> can obstruct access to an outer layer including low-voltage components of control panel <NUM>, such as outer layer <NUM> of control panel <NUM> as described above and shown in <FIG>. In an embodiment, doors <NUM> form part of one of side walls <NUM>. In an embodiment, doors <NUM> can be flush with side wall <NUM> that control panel <NUM> is mounted in.

Claim 1:
A control panel (<NUM>, <NUM>) for a heating, ventilation, air conditioning, and refrigeration (HVACR) unit (<NUM>), comprising:
a control panel housing (<NUM>) having an open side (<NUM>);
an inner layer (<NUM>) disposed within the control panel housing (<NUM>);
a plurality of high-voltage components (<NUM>) disposed on the inner layer (<NUM>);
an outer layer (<NUM>) disposed closer to the open side (<NUM>) of the control panel housing (<NUM>) than the inner layer (<NUM>);
a plurality of low-voltage components (<NUM>) disposed on the outer layer (<NUM>);
characterized in that:
the outer layer (<NUM>) is configured to be movable between:
a closed position where the outer layer (<NUM>) covers the plurality of high-voltage components (<NUM>) with respect to the open side (<NUM>) of the control panel housing (<NUM>), and
an open position where the plurality of high-voltage components (<NUM>) are accessible through the open side (<NUM>) of the control panel housing (<NUM>), and
all high-voltage components (<NUM>) included in the control panel are disposed only on the inner layer (<NUM>); and
all low-voltage components (<NUM>) included in the control panel are disposed only on the outer layer (<NUM>).